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RELATED APPLICATION
[0001] This application is a continuation in part of pending application Ser. No. 10/770735 entitled “Apparatus and Method for the Repair and Stabilization of Underground Pipes” filed Feb. 3, 2004, and pending application Ser. No. 10/182,889 entitled “Apparatus, Methods, and Liners for Repairing Conduits” and filed Feb. 2, 2001.
BACKGROUND OF INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an “insitu” method to repair underground pipes and conduits to reduce or eliminate ground water infiltration while stabilizing the proximate ground formation surrounding the pipes.
[0004] 2. Background of the Invention
[0005] The Clean Water Act has mandated that ground water infiltration into our sewer systems be substantially reduced or eliminated. Many methods of repair have been devised over the last thirty years. Some of those repair methods include slip lining, pipe bursting, cured in place pipe lining (CIPP), fold and form thermoplastic lining, spot repairs, as well as the traditional dig and removal/replacement of pipelines.
[0006] It is a known fact that the federal interstate highway system has met and in certain cases exceeded its design life by controlling or reducing incidents of pavement collapse, seftling and irregular surfaces. This has been achieved with the development of techniques for the injection of grouts or placement of epoxy patches. In addition, the concrete repair industry has developed and refined the utilization of expandable structural closed cell foams to raise, level and stabilize concrete slabs, foundations, pavements and buildings.
[0007] The “insitu lining” repair of pipes has been the most effective alternative to pipe “dig and replacement” for many year. Occasionally an existing annular space or void adjacent to the outside surface of the pipe or conduit has been injected with gelatinous grout materials to eliminate water infiltration into the pipe. This repair has been only temporary since the gelatinous material is not dimensionally stabile and often requires later replacement. The grout is not capable of stabilizing the ground around the pipe even if the entire annular space is filled with the gelatinous grout. The lack of stability and support can result in additional stress on the pipe structure, with eventual degradation of the pipe and resulting water infiltration.
[0008] Injection of expanding closed cell foams has seldom been used to repair pipes. Where the closed cell foams have been used to level or reinforce pipe sections, there has been migration of the foam into the pipe/conduit joint that, if left in place, can cause an occlusion or blockage. When this migration into the IS interior diameter of the pipe does occur, a cutting or grinding device must be inserted as a subsequent step to remove the excess foam.
[0009] Another issue is the typical foams being used today are polyurethane's which often contain isocyanate, a groundwater contaminant. Some research has been conducted to determine if the closed cell foam chemistry could be used with grout packers. The blowing agents in the foam, however, create a near immediate reaction that will not allow the annular space to be filled with the foam.
[0010] There are hybrid polyester/urethanes expandable closed cell foams that could be used and avoid isocyanate. However, these alternate foam formulations have not been well suited to curing in the ambient underground soil conditions.
[0011] Another method for repair of pipes has been to excavate a damaged pipe section and wrap the outer pipe wall with a high tensile strength material having an elasticity maintaining the band in contact with the pipe. See for example U.S. Pat. No. 4,700,752 of Norman C. Fawley. Another method has been to repair or reinforce a pipe section by wrapping the outer pipe wall with a composite material having a multiplicity of high tensile strength filaments encapsulated in a resin matrix. The wrapping material is manufactured in a coiled structure and installed by deflecting portions of the material into an uncoiled configuration and then wrapping those portions of the material around the pipe. The material may be applied with an adhesive coating on the pipe surface and between each coil layer. See for example Fawley, U.S. Pat. Nos. 5,683,529 and 5,677,046.
[0012] The measure of physical properties of materials relevant to the present invention include ASTM D1621 Compressive Strength, ASTM D790 Flexural Strength, ASTM D1622 Density, ASTM C 273 Shear Strength, ASTM D 2126 Dimensional Stability, ASTM D696 Coefficient of expansion, ASTM D 543 Chemical Resistance, and ASTM D 2842 Water Absorption.
SUMMARY OF INVENTION
[0013] Insitu pipe repair methods have been developed utilizing techniques for heat assisted cured in place pipe lining (“CIPP”) utilizing epoxy repair materials. This technology has allowed the use of styrene free thermosetting or thermoplastic resins in an impregnated (“prepreg”) composite repair material that is cured with an expandable and heatable bladder. Thermoset resins are curable resins that can be introduced or impregnated into a fibrous repair material. The curing of the resin results in a change of phase of the resin from a liquid to a solid. As a solid, the repair material continues to have the fiber structure. This technology has been adapted for use in the repair or sealing of pipes or conduits, including sewer mains and lateral lines, (“pipes) and the junctions or interfaces of multiple pipelines.
[0014] This invention teaches the use of this technology in combination with the injection of chemical reactants creating expanding closed cell foam (“foaming liquids”) for stabilization of the surrounding ground proximate to the underground pipes. The heat assisted CIPP mechanisms and techniques for interior pipe repair thereby allow the use of more environmentally friendly foaming liquids than feasible in ambient conditions to stabilize the ground surrounding the pipe. The inflated bladder can provide a heat source for curing of the resin of the prepreg repair materials, closed cell foaming liquid resin and limiting resin redistribution, and a supporting mechanism for maintaining the pipe diameter and to prevent infiltration of the foam or foaming liquid into the pipe interior.
[0015] The invention also teaches use of the expandable bladder alone within the inside diameter of the pipe in combination with the injection of foaming liquids proximate to the exterior of the pipe surface. The invention also teaches use of an expandable and heatable bladder within the inside pipe diameter to assist in the cure of the injected foaming liquids.
[0016] The present invention provides for an improved method of stabilizing the adjacent underground soils or formation around the pipe, minimizing ground water infiltration into the pipe, while repairing the host pipe/conduit or connection.
[0017] The invention also minimizes exfiltration of sewerage from the pipe. Such exfiltration is a problem particularly when the pipe system is fully charged during a rainfall event.
[0018] This invention also teaches the use of an elastically coilable and radially Is outward expandable material to support and repair pipes. The teaching of this invention includes use for the internal repair of the pipe wall. This may be used in conjunction with other embodiments of the invention such as soil compaction and stabilization using closed cell foam and resin cured pipe wall repair materials.
[0019] The invention also teaches use of a exterior tensioned support exerting a radially compressive force that may be used in conjunction with the interior support, an interior inflated bladder, or alone as a heat source combination with heat responsive repair materials.
[0020] Other benefits of the invention will also become apparent to those skilled in the art and such advantages and benefits are included within the scope of this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate preferred embodiments of the invention. These drawings, together with the general description of the invention given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the invention.
[0022] [0022]FIG. 1 illustrates a typical sewer pipe and lateral connection.
[0023] [0023]FIG. 2 illustrates typical defects necessitating repair of a sewer pipe and sewer pipe connection.
[0024] [0024]FIG. 2A represents a cross sectional view of a defective pipe.
[0025] [0025]FIG. 3A illustrates the prior art use of foaming liquids.
[0026] [0026]FIGS. 4A and 4B illustrate the use of the inflatable bladder in combination with injection of foaming liquid.
[0027] [0027]FIG. 5 illustrates the pipe repair equipment utilized with simultaneous repair of the pipe interior and ground stabilization.
[0028] [0028]FIGS. 5A and 5C further illustrate the pipe repair equipment.
[0029] [0029]FIG. 6C illustrates a detail of the woven repair material for a pipe interface repair.
[0030] [0030]FIG. 9 illustrates a woven repair material utilized in one embodiment of the invention.
[0031] [0031]FIGS. 10, 10A and 10 B are cross sectional views of a hybrid woven repair material.
[0032] [0032]FIGS. 11A and 11B are additional cross sectional views of other hybrid fiber woven repair material.
[0033] [0033]FIG. 12 is an illustration of the braided repair material.
[0034] [0034]FIG. 12A is an illustration of a rochelle knit.
[0035] [0035]FIG. 13 is an illustration of the helically wound repair material.
[0036] [0036]FIG. 14 is an illustration of multiply aligned pipe segments.
[0037] [0037]FIG. 14A is an illustration of misaligned pipe segments.
[0038] [0038]FIGS. 15 and 15A illustrate the realignment of pipe segments utilizing the invention.
[0039] [0039]FIGS. 16 and 16A further illustrate the realignment of pipe segments utilizing the invention.
[0040] [0040]FIGS. 17A through 17G provide a cross sectional view of the operation of one embodiment of the invention.
[0041] [0041]FIGS. 18A through 18C illustrate cross sectional views of the tensioned support.
[0042] [0042]FIG. 18D illustrates a prior art method.
[0043] [0043]FIG. 19 illustrates the relationship of the pipe surface to the resin impregnated tensioned support with electrically conductive fibers for heating.
[0044] [0044]FIGS. 20A and 20B illustrate the combined application of internal and external tensioned supports.
DETAILED DESCRIPTION OF THE INVENTION
[0045] The above general description and the following detailed description are merely illustrative of the subject invention and additional modes, advantages and particulars of this invention will be readily suggested to those skilled in the art without departing from the spirit and scope of the invention. The teaching of this invention will be understood to be applicable for both the repair or support of sewer pipe connecting interface, as well as for linear and non linear pipelines.
[0046] [0046]FIG. 1 illustrates typical underground sewer pipe configuration that can be the object of repair by the method and apparatus of this invention. The pipes comprise a lateral line 500 typically emerging from a single building or home (not shown). The lateral line is installed for gravity drainage 640 into a collector sewer or sewer main pipe 200 through a connection or connecting interface 400 . Sewerage is gravity conveyed 650 through the diameter 300 of the sewer pipe 200 . The lateral pipe and the main sewer pipe each has a longitudinal axis 350 . However, over time, the orientation of the individual pipe segments may change from the original longitudinal axis, creating a “non linear” pipe. (Reference is made to FIGS. 14 and 14A.) Non linear pipe can also, of course, include curved pipe.
[0047] The lateral pipeline and the main sewer pipe are typically comprised of separate segments jointed by a male-female type connecting end flange. The female flange component 210 and corresponding male component 211 are illustrated in FIG. 2. It will be appreciated that the sewer pipe system is buried within the ground 100 beneath the ground surface 105 . The system can be accessed through various ports such as manholes (not shown).
[0048] [0048]FIG. 2 is a cross sectional schematic of the sewer pipe 200 along the longitudinal axis 350 . The direction of the gravity flow of sewerage is shown by vector arrow 650 . The male 211 -female 210 coupling of the separate sewer pipe sections is also illustrated.
[0049] [0049]FIG. 2 illustrates a common problem experienced with sewer pipe systems. Due do a variety of causes, including the aging of the pipe material, ground shifts or settlement, etc., ground water 175 migrates into the sewer pipes 200 . This can cause the exfiltration of sewerage into the surrounding soil or ground water, particularly when the sewer lines are heavily charged, such as during a significant rain event. Alternatively, the infiltration of ground water can burden the sewerage treatment system thereby increasing treatment costs or causing inadequate treatment. (In addition to the obvious environmental damages that may result from inadequate sewer treatment, the inadequate treatment may result in fines and other damages being imposed by regulatory agencies.)
[0050] The infiltration of ground water often carries particles of the adjacent soil 100 into the sewer system, which can over time result in voids 150 being created surrounding the pipe 200 . The creation of voids or increased interstitial spaces results in groundwater collecting proximate to the pipe. This groundwater can then pass, i.e., infiltrate, into the sewer pipe wall 250 through the cracks 240 or holes 255 . It can also pass through defects, such as gaps, in the junctions of each pipe segment 210 211 .
[0051] [0051]FIG. 2A is a schematic illustration across the longitudinal axis 350 of a section of the damaged sewer pipe 200 beneath the ground surface 105 and adjacent void 150 in surrounding soil 100 . Also illustrated are the pipe diameter 300 and cracks 240 and voids 255 through the thickness 251 of the pipe wall 250 . The several vector arrows 175 illustrate the flow of ground water from the soil 100 into the void 150 surrounding the pipe 200 and through the cracks 240 and holes 255 within the sewer pipe wall 250 . It will be appreciated that the voids intended to be remedied by the subject invention need not be of the large size depicted in these illustrations. Further, it will be appreciated that the subject invention is not limited to repair holes or cracks in pipes, but can be used to seal connections (or “couplings”) between pipe segments, or between pipe lines, e.g., a sewer collection pipe and one or more lateral pipes convey waste (“sewerage”) from individual residences, etc.
[0052] Use of close cell expandable foams have been used to fill subsurface voids in soils, including use to mechanically raise objects supported by the soil. This has been used in foundation leveling, etc., as taught by U.S. Pat. Nos. 4,567,708, 6,521,673 and 6,634,831. However, this technology has important limitations for use in filing voids surrounding sewer pipes or sealing/repairing pipe defects. One disadvantage is the infiltration of the closed cell foam into the interior pipe diameter (through which sewerage is intended to flow), thereby creating an occlusion that must be mechanically removed to prevent blockage of the sewage flow. In addition, the expansive pressure of the closed cell foam (useful in filling or compacting the soil particles or interstitial voids within the soil or between the underground soil and the structure, e.g., sewer pipe or lateral collector, to minimize water collection/infiltration), may also further damage the pipe wall.
[0053] [0053]FIG. 3A is a schematic illustration across the longitudinal axis 350 wherein closed cell foam 600 is injected from the ground surface 105 through the injection mechanism 650 into the void 150 within the ground 100 adjacent to damaged sewer pipe wall 250 . The foam equipment combines static head mixers 650 with a strong insertion device attached to pumps (not shown) located at the ground surface 105 . The cross section view illustrates the closed cell foam filling the void 150 and infiltrating into the diameter 300 of the sewer pipe 200 through the holes 255 and cracks 240 within the pipe wall 250 . The infiltrating foam is shown to create obstructions 337 338 339 within the pipe diameter 300 . It will be appreciated that the foam may not fill the entire void 150 , perhaps due to the presence of entrapped ground water (not shown), thereby allowing for the continued collection of ground water proximate to the repaired pipe. The migration of foam into the pipe can ultimately block the pipe diameter 300 unless a cufter/grinder unit (not shown) is inserted into the pipe and the occlusion is removed. It will be appreciated that it is desirable to avoid this time consuming and expensive step.
[0054] One embodiment of the apparatus and methods taught in this specification is the advantageous use of techniques for installing a thermally responsive pipe repair material (thermoset or thermoplastic impregnated liner) within the interior diameter of a sewer pipe in combination with injection of expanding closed cell foam proximate to the outer diameter of the sewer pipe. The repair material for the interior pipe diameter may be of a variety of structures, including a structure being defined as an arrangement of fibers such that the repair material has similar dimensions as the pipe diameter or pipe interface to be repaired or sealed. The arrangement of fibers further allows the repair material to be flexible and seamless. FIG. 9 illustrates an example of a woven structure 410 having a longitudinal axis 350 . In the illustration, fibers 118 119 intersecting at a variable angle 125 . It will be appreciated that the composition of fibers and fiber architecture can be varied, as shown in the cross sectional illustrations along the axis AA in FIGS. 10, 10A, 11 A and 11 B discussed later. In a preferred embodiment utilizing the repair material, the material includes a resin having a viscosity. An additive may be provided to alter the resin viscosity. It will be appreciated that it may be advantageous to increase resin viscosity to retard resin redistribution within the fiber repair material or fiber liner prior to and during the installation process.
[0055] A flexible and inflatable bladder is inserted within the pipe diameter. The bladder serves as a mold to press and hold the repair material to the interior surface of the pipe during the repair process. The inflated bladder, which, in an alternate embodiment of the invention, can be used without the resin impregnated repair material or liner, also minimize the migration of the chemical reactant or resulting foam injected into the underground soils proximate to the pipe. The migration of chemical reactants or foam can result in occlusion or obstruction of the pipe diameter. This would obviously hinder the flow of sewerage through the pipe.
[0056] The fibrous construction of the repair material, or the components of the inflatable bladder, can include conductive fibers, e.g., carbon fibers, that can be connected to an electrical power source. These conductive fibers, when powered with electric current, may provide electrically resistive or impedance heating (termed herein as “resistive heating”) directly through or immediately proximate to the thermosetting resin contained in the repair material. The combined and concurrent pressing of the resin impregnated fibers to the inner pipe wall surface with the heating of the thermosetting resin allows an improved repair and support. The addition of heat, in contrast to ambient conditions, allows more rapid curing. Further, this allows the bladder to remain in place as a mold pressing the repair material for a greater portion of the cure and minimizes the degradation of the repair by resin redistribution. It will be appreciated that the use of the expanding and heatable bladder also minimizes the formation of “annulae” between the interior pipe wall surface and the liner.
[0057] Further, heat from the bladder or repair material is also available to radiate through the thickness of the pipe wall to facilitate to the cure of the foaming liquid exterior to the pipe wall. Curing of the foam creates a phase change in the foam to a closed cell solid. The closed cell foamed solid can compact the underground proximate to the pipe, decrease voids or interstitial space containing infiltrating ground water, as well as support and seal the pipe and pipe junctions.
[0058] The availability of the proximate heat source also allows use of alternate foaming agents, particularly agents not containing isocyanates. It will be appreciated that isocyanates are considered to be a source of environmental contamination. These alternate reactants include hybrid polyurethane or polyester/polyurethane blend resin, and epoxy resins combined with diluents, catalysts, blowing agents and surfactants, an acrylimide, and cementitous slurry.
[0059] [0059]FIG. 4A is a schematic cross sectional illustration along the longitudinal axis 350 illustrating an embodiment of the method and apparatus of the invention by placing a flexible and inflatable heating bladder 450 inside the pipe diameter 300 . The bladder is placed in the area of the pipe having holes 255 or cracks 240 in the pipe wall 250 . In this manner, the inflated bladder can provide support to the damaged pipe and facilitate maintaining the pipe diameter 300 during the repair process. The bladder may have resistively heatable sub-components to facilitate the curing of the chemical reactant injected proximate to the exterior pipe wall surface 254 .
[0060] [0060]FIG. 4B is a schematic illustration across the longitudinal axis 350 of the pipe after inflation of the bladder 450 . The bladder, if used as a heat source, may assist in the curing of the closed cell foam. It will restrain the injectible chemical reactant and resulting foam 600 from permeating the pipe through coupling connectors ( 211 210 of FIG. 2) or cracks 240 or holes 255 in the pipe wall 250 . The migration of foam is illustrated in FIG. 3A by the multiple vector arrows. The liner 410 (not shown) may be placed over the bladder for reinforcement or to minimize binding of the bladder to the cured foam.
[0061] An embodiment of the invention includes the use of resistive energy as a source of heat for curing the injected chemical reactant, as well as to block the migration into the pipe diameter. This heat curing can be accomplished in combination with the placement of a resin impregnated (“prepreg”) repair material within the pipe diameter. As mentioned above, the repair material or the flexible bladder may contain electrically conductive fibers. Alternatively, the fiber can be a combination of electrically conductive fibers and non-conductive fibers, which include polyester, glass, aramid, and quartz fibers, and thermoplastic fibers such as, but not limited to polypropylene, nylon and polyethylene.
[0062] The repair process is illustrated in FIGS. 4A, 4B and FIGS. 17 A-G where one skilled in the respective arts observes that there are similarities in both systems, which require 50 K.W. generators and 150 CFM compressors and various cables and hoses. The present invention demonstrates the synergies between the two systems, which eliminates boiler trucks, and on site mixing and impregnation of repair material.
[0063] An alternative embodiment that can be used alone or in conjunction with the bladder is inserting an elastically coilable and radially expandable material. This can be of differing materials, including metal. Important features will be the elasticity, high strength and shape memory, thereby allowing the material to be wound into a tighter coil with a more compact diameter or shorter radius and expansively returning to its original shape. Upon release of the winding energy, the material relaxes and returns to its original coil diameter. This relaxed diameter will be greater than the internal pipe diameter, thereby causing a relative uniform radial outward pressure force.
[0064] It will be appreciated that the mechanism will maintain an open annulus within the pipe thereby allowing the continued passage of fluids through the pipe. Of course this can permit the relaxed coil to remain in place during the curing process, and thereafter without interruption of service.
[0065] This invention addresses the cause and repair of connection offsets or misalignment of pipes and conduits. The misalignment of an originally installed linear pipe may result from faulty bedding surrounding the pipe, which is not tested as it is in pressure pipe/conduit situations, and ultimately can crack or offset the joints after the pipeline is back-filled. Another cause of misalignment is the result of the movement of ground water as already discussed. While some may contend this method is redundant and more costly, one skilled in the art will easily recognize the efficiencies and safety elements of the present invention
[0066] This embodiment of the invention provides methods of repairing the misalignment of pipe sections 250 A such as that shown in FIG. 14A. In this case, the non-linear conduit is buried below the ground surface 105 predominantly in a horizontal orientation as part of a pipe network, e.g., sewer system. The non-linear pipe consists of separate pipe or conduit segments 25 A, 25 B, 25 C, 25 D, 25 E, 25 F, 25 G that have moved from the original longitudinal axis 350 illustrated in FIG. 14 to a non congruous longitudinal orientation 351 and thus does not follow a strictly linear path.
[0067] The embodiment of the method taught by this invention comprises providing the inflatable bladder dimensioned to fit within the interior diameter 300 of the pipe 250 A, and particularly each non-congruous pipe segment 25 A, 25 B, 25 C, 25 D, 25 E, 25 F, 25 G. The bladder is dimensioned so as, when inflated, presses against the interior surface of each damaged, e.g. mis-aligned, cracked or broken, section of conduit. The bladder can be made of any strong flexible material. It will be appreciated that it may be advantageous to fit the bladder with one or more layers of protective outer sleeves or liners (“liners”). The liners can provide a repair material (sometime referred to as “material structure”) as discussed elsewhere herein, but may also provide protection to the bladder from sharp or jagged surfaces within the conduit sections. The bladder may be filled/inflated with fluid, such as water or air, and the effectiveness of the bladder would be compromised if the bladder was punctured.
[0068] [0068]FIGS. 15 and 15A illustrate an embodiment of the invention wherein the bladder 450 is placed within the diameter 300 of several mis-aligned pipe segments 25 A, 25 B, 25 C, 25 D, 25 E, 25 F, 25 G beneath the ground surface 105 . FIG. 15 illustrates the bladder with several pipe segments 25 B 25 E removed for clarity of illustration. The original or intended longitudinal axis of orientation 350 is also shown. It will be appreciated that the mis-alignment may be in any of the three axes of orientation (X, Y, Z).
[0069] [0069]FIG. 16 illustrates the next step of the repair method. Multiple chemical reactant insertion ports 650 are installed from the ground surface 105 to a desired location proximate to the pipe. In the illustrated situation, the ports are installed to be beneath the mis-aligned pipe segments 25 B, 25 C, 25 D, 25 E, 25 F. The goal of the repair is to push the pipe segments into closer alignment with the longitudinal axis 350 . A chemical reactant is injected through the ports into the ground 100 creating the expanding foam 600 . FIG. 16A illustrates the result of the injection of expanding thermosetting foam 600 , causing pipe segments 25 B, 25 C, 25 D, 25 E, 25 F to be pushed upward as shown by vector arrow 675 . The inflatable bladder 450 acts as a flexible mold having a control or guiding function in the realignment of the pipe sections, particularly with regard to the continuity of the pipe diameter 300 and common longitudinal axis of orientation 350 .
[0070] As suggested by the FIGS. 14 through 16A, substantial length of pipe can be simultaneously repaired by the invention. The length of inflatable and heatable bladder is not limited. Lengths of pipe extending from one access manhole to a second manhole may easily be simultaneously repaired by a single use of the method and apparatus of the invention.
[0071] Based upon the foregoing disclosure, it will be readily appreciated that the above method can be combined with the embodiment utilizing a repair material liner impregnated or containing a curing thermosetting or thermoplastic material to seal the pipe from the interior diameter. The repair material structure may be defined by a plurality of fibers such that the repair material is flexible and seamless. This structure is sometimes referred to as a woven “preform”.
[0072] Thee resin may be in the form of prepreg fibers or as a resin matrix surrounding the woven structure. The resin can be a polyester resin, a vinylester resin, a urethane polyester resin, a urethane-vinylester resin, an epoxy resin of a polyurethane resin. The resin is. introduced into the repair material by either injection of infusion depending on the type of resin utilized.
[0073] A flexible and seamless repair material is able to adapt and conform to of the interior repair material will neither bind nor wrinkle to cause obstructions to material flow in the conduit. The construction and selection of the repair material also allows it to be used in conjunction with the inflatable bladder. The repair material may be placed as an outer liner on the deflated bladder.
[0074] Next, the repair material and bladder is placed in the conduit in close proximity to a damaged portion of the conduit. As the bladder is inflated, the repair material is pressed against the inner surface of the conduit wall. Finally, the resin is cured. Curing can be achieved in a number of ways, including but not limited in using hot water, steam, resistive heating, or infrared and ultraviolet radiation.
[0075] Preferably the material structure 410 is substantially cylindrical (as shown in FIGS. 9 and 13) to facilitate conformity with the non-linear conduit. The cylindrical structure has an interior diameter 301 oriented about a longitudinal axis 350 . However, the material structure is flexible and can be formed by braiding the fibers. A repair material 410 having a braided configuration of fibers 411 is shown in FIG. 12. In braiding most, if not all, of the fibers 118 119 are arranged in a helical pattern (as shown in FIG. 13). However, triaxial braiding can be used to combine fibers at two different axial or helical angles with a non-helical, longitudinal fiber. Repair materials fabricated by braiding processes offer exceptional ability to conform to irregular conduit geometries. Because a braided repair material is formed with its reinforcing fibers positioned helically rather than perpendicularly to the longitudinal axis of the material structure, these fibers have the ability to change their braid angle 125 , and conform simultaneously in both the inside radius and outside radius of a section of a non-linear conduit.
[0076] Depending on the desired mechanical properties the density of the fiber braid can be varied to pack more fibers into the tubular arrangement to provide an increase in strength. Conversely, if the structural requirements are minimal, the braid density can be adjusted to where the material present in a volumetric area can be reduced. The angle 125 at which the fibers intersect each other, otherwise known as the braid angle, can also be varied. When the braid angle is increased, the fibers are positioned closer to perpendicular or vertical and the hoop strength of the finished repair material increases. This is desirable for conduits that are required to support a great amount of weight or withstand high internal pressures. The varying mechanical fiber compaction can be used, e.g., knitting, weaving and braiding.
[0077] Use of braid or similar types of mechanical fiber compaction construction also will facilitate the unlimited lengths of pipe that may be simultaneously repaired.
[0078] [0078]FIGS. 10, 10A, 11 A and 11 B are cross sectional representations of the fiber layers of a repair material illustrated in FIGS. 9 and 13. Various reinforcing materials can be included in the braided construction to accommodate both performance and cost issues. FIG. 10 illustrates a combined placement of reinforcing fibers 122 , e.g. glass or nylon, with fibers 124 constructed of thermoplastic material. These fibers can be one of a combination of various engineered thermoplastics. In addition, thermoplastic films 130 may be used. These fibers, films and reinforcing fibers can be consolidated using any of the aforementioned methods. FIG. 10A illustrates repair material 410 comprised of a combination of reinforcing fibers 122 impregnated within a matrix of resin 131 . Various non-electrically fibers can be employed as reinforcement. The fiber construction can be varied as shown in FIG. 11A. The combination of fibers forms the material structure 410 . Additionally FIG. 11A also shows a film 130 of thermoplastic material that forms part of the material structure 410 .
[0079] Additionally, FIG. 11B illustrates that the material can include electrically conductive fibers 120 , for example carbon fibers, in order to cure the resin and electric current can be caused to flow through the conductive fibers to resistively heat the repair material. The fibers can be a combination of electrically conductive fibers 120 , thermoplastic fibers 124 and non-conductive fibers 122 e.g., polyester, glass, aramid, and quartz fibers. Other combinations and architectures will be apparent to persons skilled in the art.
[0080] When electrically conductive fibers are used in conjunction with the thermoplastic fibers and films, as illustrated in FIG. 11B, resistive heating can be generated. The heat causes the thermoplastic materials to melt and flow, permeating the electrically conductive fibers and other non-electrically conductive fibers. A reinforced thermoplastic composite results when the materials cool and harden. In this embodiment, the need for liquid thermosetting resin (which phase change solidification may be enhanced by the addition of heat) is eliminated offering unlimited shelf life and case of handling. Finished composite properties can be customized with the selection of an appropriate thermoplastic matrix and reinforcing fibers.
[0081] As shown in cross section in FIGS. 10 and 11A the repair material can contain fibers having both structural properties 122 and thermoplastic fibers 124 . Alternatively separate bundles of electrically conductive fibers 120 can be co-mingled with bundles of thermoplastic fibers 124 and structural or reinforcing fibers 120 as shown in FIG. 11B. In both cases, the bundles may be braided together to form the repair material.
[0082] In another preferred embodiment, the electrically conductive fibers have an exterior layer or coating of electrically conductive fibers than are then braided. In another preferred embodiment, the seamless material structure is formed by knitting the fibers. In knitting, the repair material is produced by inter looping continuous chains of fibers in a circular fashion. An enlarged view of knitted fibers 118 119 120 is shown in FIG. 12A. In a rochelle knit, it is possible to introduce the fibers in a basically longitudinal direction. Because the fibers 118 119 are looped in a circular fashion at every stitch, the finished tubular structure is inherently flexible. For example, in one linear inch of fiber stitch, the actual fiber length may be as long as two inches. This allows continuity in the fibers throughout the length as well as allowing the fiber loops to stretch or open up to variances in the conduit geometry. Various reinforcing materials can also be included in the knit construction to accommodate both performance and cost issues. In addition, electrically conductive fibers 120 can be used such that resistive heating is feasible to cure the resin.
[0083] In another preferred embodiment, the seamless material structure is formed from a combination of two or more material layers. A first material layer is a seamless, cylindrical tube configured to fit within a second material layer that has a seamless, cylindrical tube configuration. The material layers are formed from an arrangement of fibers, preferably either braided or knitted fibers. The first material layer is nested, within the second material layer and then stitch-bonded together with a stitching thread to form the materials structure. Preferably, the stitch-in thread is elastic to further ensure flexibility of the repair material. In addition, electrically conductive fibers can be used such that resisitive heating is feasible to cure the resin.
[0084] Stitch bonding is a method by which different materials can be consolidated into various forms including seamless, tubular products. The consolidating results from either continuous or intermittent stitching or sewing through the various layers materials. Reinforcing fibers can be used and aligned in a helical arrangement to a accommodate geometry changes much like a braided composite. Stitch bonding also allows the use of a wider variety of electrically conductive material formats such as non-woven graphite formed into tapes. These tapes would be introduced into the composite at a helical angle.
[0085] In another preferred embodiment, the seamless material structure is formed from a combination of two ore more material layers. A first material layer is a seamless, cylindrical tube configured to fit within a second material layer that also has a seamless, cylindrical tube configuration. The material layers are formed from an arrangement of fibers, preferably either braided or knitted fibers. The first material layer is nested within the second material layer and then needle punched with a needle board to form the material structure. The needle board has a plurality of needles such that the needles penetrate the first material layer. When needles are driven through the first material layer, varying amounts of fibers from the first material layer are pulled through the cross section of the adjacent second material layer. These fibers effectively bind the material layers together. In addition to consolidation, the fibers also provide reinforcement in the Z axis, defined as the axis corresponding to the material layer thickness. The characteristics of the repair material, including flexibility, can be altered by varying the force applied to the needle board, the type and number of needles used, and the number of needle penetrations per square inch. In addition electrically conductive fibers can be used such that resistive heating is feasible to cure the resin.
[0086] In another preferred embodiment, an additive adapted to increase the resin viscosity is provided. The additive is mixed with the resin to form a resin-additive mixture whereby the resin viscosity is increased after a period of time has elapsed. The additive should be formulated such that the resin viscosity does not immediately increase because this could preclude either resin introduction or resin permeation of the repair material. The resin additive adheres to the fibers in the first and second material layers. As a result, the resin additive mixture stabilizes the fibers and the material layers. In addition electrically conductive fibers can be used such that resistive heating is feasible to cure the resin.
[0087] [0087]FIGS. 17A through 17G illustrate the sequential steps of the combined application of curing a foaming chemical reactant proximate to the exterior of underground 100 pipes, with placement of a curable liner on the interior pipe surface. FIG. 17A is a cross sectional view of a pipe 250 beneath the ground surface 105 and having an interior diameter 300 . The pipe has a longitudinal axis of orientation 350 . The pipe has an inner wall surface 256 , an exterior wall surface 254 and a wall thickness 251 . Also illustrated is an insertion port 650 for injecting expanding foam reactant at a selected location in relation to the buried pipe. Also shown is the deflated bladder 450 and separate material structure 410 positioned as an outer liner to the bladder.
[0088] [0088]FIG. 17B illustrates the same components within the ground 100 , but with the bladder 450 now inflated and placing the material structure/repair material 410 into near contact with the inner pipe surface 256 . The diameter 301 of the material structure is shown. In this cross sectional view, only a small portion of the original pipe diameter 300 is not occupied by the inflated bladder and material structure.
[0089] It will be appreciated that the bladder 450 is to be inflated to press the structural material 410 into contact with the inner pipe wall 254 and the space shown in the following Figures is for clarity of illustration only.
[0090] [0090]FIG. 17C illustrates the foaming chemical reactant 600 being injected into the ground 100 . The foam variously expands in all directions, as illustrated by the several vector arrows, creating a force compacting the underground soil, driving away interstitial groundwater and pressing against the outer pipe wall 254 now reinforced by the inflated bladder 450 . FIG. 17D illustrates this process with multiple injecting foams, causing the pipe to be substantially encased in the expanding foam 600 , thereby compacting the ground, driving interstitial groundwater, minimizing or filling voids adjacent to the pipe and thereby stabilizing the pipe.
[0091] [0091]FIG. 17E illustrates the curing of the foam assisted by electrically resistive heat created from current within the electrically conductive fibers within the repair material 410 . A portion of the radiating heat travels outward into the thickness of the pipe wall 251 and into the surrounding ground or foam. The distance or range of significant heat transfer 605 may be less than the area occupied by the foam 600 . However, within this area 605 , effective curing of the foam can be achieved, thereby effectively encapsulating the pipe wall, while simultaneously installing an interior reinforcing material. (In another embodiment discussed previously herein, the conductive fibers can be contained within the bladder or a protective liner of the bladder separate from any repair material.)
[0092] [0092]FIGS. 17F and 17G illustrate a cross sectional area of the invention, illustrating the interior diameter 301 of the repair material 410 containing the inflated bladder 450 , the pipe thickness 251 , the area 605 of foam cured by the radiant heat, the outer area of foam 600 and the surrounding ground 100 .
[0093] The present invention also provides methods and apparatus for repairing a section of non-linear pipe such as the junction or interface 400 between two pipes 200 500 as illustrated in FIG. 1. A preferred embodiment of the apparatus of the present invention is depicted in FIG. 5. In accordance with the invention, the apparatus includes a main body 460 that is positioned in a first conduit 200 . The first conduit 200 may be pipe forming a main line of a sewer system. The main line 200 intersects a second conduit or lateral line 500 . Lateral line 500 is shown here in a perpendicular position essentially at a 90 angle to the main line pipe and intersects the main line pipe at the top portion. This condition is typical but may also be arranged in other configurations. For example, the lateral pipe may intersect the main line pipe at ±45 and can be located radially anywhere from the nine o'clock position to the 3 o'clock position.
[0094] Radial and vertical positioning of the apparatus is achieved remotely using appropriate controls, and communicated to the apparatus through an umbilical 350 . The entire assembly 460 is delivered to the point of repair using a winch or similar device (not shown) attached to the unit via cable assemblies 345 . Also illustrated are the heatable caul plates 465 and the flange portion of the repair material 411 . (It will be appreciated after reading the following paragraphs that FIG. 5 illustrates the repair material in a loaded position within the main body 460 of the apparatus.
[0095] [0095]FIG. 5A provides a cross sectional view of the apparatus depicted in FIG. 5, showing the heatable caul plates 465 in a retracted position on an upper portion of the body 460 of the apparatus, thereby affording a minimal cross section and allowing passage into a main line that may contain offsets, protrusions, etc. The caul plates 465 (hereinafter referred to as “wings”) are articulated to allow this reduced cross section by the use of hinges 466 .
[0096] [0096]FIG. 5A illustrates the loading of the repair material 410 into the apparatus 460 in preparation for insertion at the intersection of the main line and lateral line. Repair material 410 is preferably constructed of a fibrous woven material capable of holding a heat hardenable or formable resin matrix. Material 410 is also constructed of a material that would be expected to include a portion 412 that conforms to the interior geometry of the lateral pipe wall, and be flexible enough to provide a flange face 411 in the main line pipe. (Reference is also made to FIG. 6C.) It is shown that the repair material is wrapped around the retractable/inflatable bladder segment 440 . In 5 C, the method for loading the repair material 410 is also illustrated. Applying a fluid pressure to the body 460 through umbilical 350 pressurizes an inflation device in the form of a bladder 440 . This fluid pressure is regulated through the use of electro-pneumatic regulators located in rear housing 461 in the body 460 , and controlled remotely through signal wires in umbilical 350 . Pressure sensing is accomplished by sending units located within main body and transmitted through umbilical. All of the signal wires in the umbilical terminate at an operator interface control station (not shown). The force required during this step in minimal and sufficient to cause the bladder 440 to rigidize.
[0097] The repair material is constructed in such a fashion as to incorporate both the tubular lateral lining portion 412 as well as the flanged area 411 without the undesirable effect of a potentially weak seam at the transition from tubular to planar. With the bladder 440 pressurized, the material 410 , which may be pre-impregnated with a resin as described elsewhere in this specification, is wrapped 412 around the extended bladder 440 as shown by the vector arrow 676 and caused to lay flat 411 on the surface of the wings 465 . Depending on the structural requirements, layers of material can continue to be plied to achieve the desired strengths. With the lay-up complete, the pressure of the bladder 440 is lowered the material 410 can be inverted into the main body of the apparatus as shown in FIG. 5C. The main body contains a spindle 453 capable of rotation that is fixably attached within the body 460 at a posterior location. The spindle is sealed from the atmosphere to the use of o-rings and protrudes slightly from the body to allow attachment of a tool to cause rotation.
[0098] As shown in FIG. 5D, the bladder construction contains an internal tether 451 that is permanently attached to the interior of the bladder at fitting and removably attached to spindle 453 within the main body 460 . To invert the bladder 440 and repair material 410 into the main body for safe transport to the repair location, the tether is wound about the spindle causing the bladder to retract. With the repair material loaded into the device, a winch, or similar device is employed to pull the apparatus to the desired location within the pipeline. A closed circuit television camera (not shown) can be used to assist in determining the correct location and positioning. Once the entire assembly has been satisfactorily located in proximity to the repair area, final positioning commences vial remote control.
[0099] [0099]FIG. 5D shows the internal working of the apparatus. In order to facilitate rotary position, the apparatus contains a powered rotation mechanism located in the rear housing 461 . The rotational mechanism is attached to the main body by use of a coupling. The front section 462 of the body 460 contains a rotary bearing to compliment this action. Skids 472 are attached to both the front 462 and rear 461 sections to afford minimal surface contact with the main line pipe and ease pulling forces required.
[0100] [0100]FIG. 5D illustrates the apparatus used for placement of the flexible bladder 440 at the pipe interface section 400 . The apparatus is positioned in radially and longitudinally within one pipe 200 . The lift cylinders can be elevated by hydraulics or compressed air using a suitable medium. The lift cylinders are firmly attached to the front section 462 and rear section 461 with cylinder rams attached to the main body. When activated, cylinders 473 effectively lift the main body to force the top portion of the caul plate 465 to be in contact with the interior wall of the main line pipe at the area surrounding the lateral pipe opening. As the main body lifts, actuator arms 474 encounter the main line pipe wall, as depicted in FIGS. 5D and 5E. In FIG. 5E, the actuator arm bearings 474 convert the vertical motion to a lifting motion through a fulcrum attached to the main body. The opposite ends of the actuator arms are position under the wings 465 and cause the wings to unfold and compress the flanged area 411 of the repair material firmly against the main line pipe walls.
[0101] By introducing pressure to the interior of the main body through umbilical, the bladder and repair material is caused to invert into the lateral pipe. Increasing the pressure inside the bladder causes the tubular section of the repair material to conform to the inside geometry of the lateral pipe section.
[0102] The bladder and the caul plates may be constructed of a temperature resistant material and contain within the outer skin surface, electrically conductive fibers that are employed to produce heat when an electrical current passes through the fibers. The material surrounding the conductive fibers is a flexible, resilient substance such as silicone, fluorosilicone or fluoropolymer. Electrical wires conduct the electrical energy from remotely stationed, controllable power supplies to the electrically conductive fibers. Heating temperatures may be produced range between 200 F. to 400 F. depending on the cure requirements of the resin matrix selected for use in the repair material. These temperatures can be achieved in as little as 10 minutes enabling an extremely fast cure cycle.
[0103] In conjunction with the inflation of the bladder into the interior diameter of the pipe interface and the heating of the bladder and caul plate, reactants can be injected into the ground proximate to the interface to compact the soil and stabilize the soils adjacent to the pipe similar to the manner discussed earlier in regard to FIGS. 2 through 4B above. The inverted bladder thereby also serves to minimize the infiltration of injected reactant or reaction product into the interior diameter. Further, it will be readily appreciated that the heat of the bladder, caul plates or liner may be available to radiate through the thickness of the pipe wall to facilitate the cure of the injected reactant. Again, this heat source may also allow the use of reactants that are not effective in the ambient subsurface environment.
[0104] An alternate method and apparatus to the inflatable bladder is the utilization of a radially expanding interior support. The support taught by this specification utilizes a tensionable and compressible coil. The coil possesses a memory of its original coil radius. After the compressive means are removed, the coil returns (“relaxes”) to its original radius. This characteristic is a property of material elasticity. When subjected to a stress, e.g. tensile or compressive, the dimensions of the material change, i.e., strain. For an elastic material, the strain is recovered when the stress is removed. When properly dimensioned, as taught herein, the interior pipe wall surface retains the coil in a partially tensioned stated, with a residual outer pressing force. This force, like the outward pressure of the inflated bladder, can be used to form a repair liner or surface patch within the pipe. Unlike the bladder, the coil does not impede the flow of liquid through the pipe and can remain in the pipe as a structural support element, as well as a mechanical means to press and cure repair materials such thermosetting or thermoplastic materials. It can also block the infiltration of injected reactant, or the resulting cured closed cell foams that are also taught by the invention.
[0105] The coil apparatus can be constructed in various forms. One embodiment may utilize a resinous plastic material having sufficient elasticity to allow compression without permanent deformation of shape. The material may be constructed to also include electrically conductive fibers or wire that can be connected to either a dc or ac power source to provide resistive or impedance heating (generally termed resistive heating herein). As already discussed herein, the heat may be utilized in curing or shaping thermally responsive materials that may be used in conjunction with this invention.
[0106] The coil support structure may also have a fibrous structure that may be impregnated with resinous thermal responsive materials. These materials may be thermal plastic or thermal setting resins. In the case of thermal setting materials, the ability to provide heat while in a pressed state to the interior pipe wall may shorten the repair cycle. It may also provide for improved repair by minimizing voids between the pipe wall and the material caused by shrinkage during the material cure or setting.
[0107] The material may utilize ester or epoxy resin systems that are allowed to partially cure, preferably to a B stage, without significant cross-linking, prior to release of the tension coil energy. At this partially cured stage, the impregnating resin remains malleable to conform to the vagaries of the interior surface of the pipe wall. This will minimize voids or undesired annular spacing remaining between the relaxed support surface and the interior pipe wall. It will be appreciated by persons skilled in the art that a B stage cured resin is at a highly viscous state, substantially able to retain a shape, but sufficiently plastic to be malleable to the irregularities of a contacting surface. As curing progresses to a C stage and to final cure, cross linking of the polymer molecules increases and thereby creating increasing rigidity of the material, resulting in a solid material at completion.
[0108] The support structure may also incorporate multiple layers of reinforcement material combined together as a single layer coiled within the interior with minimal overlap (as illustrated in FIG. 18B). The multiple layers may be attached by needle punching or mechanical means. Lateral movement of the layers as a result of the coiling process may be contained by the mechanical intra-laminar attachments, thereby enhancing the shape memory, i.e., the recovery of the shape after removal of the stress or tension force. The support structure may also utilize adhesive properties or materials to bind to the pipe wall.
[0109] [0109]FIG. 18A illustrates a cross section of a pipe 250 having an interior diameter of D 2 . FIG. 18B illustrates a flexible coil 480 having an outer diameter of D 1 that is larger than the interior diameter of the pipe. FIG. 18C illustrates the flexible coil wound into a tighter coil with a new diameter D 3 . This second diameter, achieved by the tighter winding of the coil, is smaller than the first diameter and the interior diameter of the pipe. This relationship can be expressed as D 1 >D 2 >D 3 .
[0110] [0110]FIG. 18D illustrates a prior art method of pipe 250 repair utilizing a tensioned coil 499 that is wrapped around the exterior of the pipe. The method utilizes wrapping a multi-layered coil having a radius smaller than the exterior diameter of the pipe. The coil material possesses memory of its first coil radius. It there for tends to adhere closely to the outer surface of the pipe (the circumference of the pipe having a larger radius than the first radius of the coil). Of course, the coil can only be wrapped around a pipe having a 360° exposed surface. This would require a buried pipe to be excavated for application of such a coil wrapping.
[0111] [0111]FIG. 19 illustrates a cross section view of a coil 480 in relation to the interior surface 256 of the pipe. Also illustrated are electrically conductive wires or fibers 122 that are surrounded by a B stage ester or epoxy resin matrix 130 . The shape memory properties of the coil material matrix cause the outer coil surface 481 to press the resin matrix to the inner pipe surface as shown by vector arrow 640 . Also illustrated is a tension support substrate 132 that may comprise a resinous plastic material or a metal or combination of both.
[0112] Another embodiment of the invention subject of this specification teaches utilization of internal support with the exterior wrapped tension coil support to create an interior and exterior walled mold. A defect cavity enclosed within the walled mold or “form” can be then injected with repair material. In one embodiment, the repair material can be injected closed cell foam creating chemical reactants. The reactants will be maintained under pressure within the form, thereby creating enhanced density of the foaming reaction products. The pressure or material strength of the repair mold is attributed to the combination of material strength and the tensioned architecture.
[0113] [0113]FIG. 20A illustrates a cross sectional view of across the longitudinal pipe axis 350 . FIG. 20B illustrates a cross sectional view of one section of pipe wall along the longitudinal axis 350 .
[0114] [0114]FIG. 20A shows the pipe wall 250 having a inner surface wall 256 and an outer surface 254 . Within the pipe annulus 301 , the tensioned coil 480 support is released and allowed to unwind, resulting in the outer surface of the support pressing radially outward in the direction of the vector arrows 640 . It will be appreciated that the radially directed force applied to the inner pipe surface 256 will be substantially uniform around the circumference of the pipe.
[0115] The outer surface of the tension support may be coated (not shown) with an adhesive or thermal responsive material, e.g., thermal setting, thermal plastic or a resin chemical reactant. Alternatively, the support material may impregnated with such components. As described elsewhere herein, the tensioned support may also incorporate electrically conductive materials for heating. The outer pipe wall surface 254 is tensioned wrapped with a material 299 similar to the internal tensioned support, i.e., an elastic material with a matrix memory resulting in it contracting to its relaxed radius (being smaller than the radius of the outer pipe wall). The inner surface of the outer wrap, placed in contact with the outer pipe wall, may also have an adhesive coating or coating of a thermal responsive material. The outer wrap also will have a radially inward compressive force illustrated by the vector arrows 641 . This compressive force will also be substantially uniform around the circumference of the pipe 250 . The outer wrap may also contain electrically conductive materials for heating. The pipe wrapping action is indicated by vector arrow 643 . The outer wrap may also have one or more inlets 498 through which expansive foaming chemical reactants may be injected. It will be appreciated that the gap or space shown in FIG. 20A between the pipe and each tensioned support is for clarity of illustration only and that the surfaces will be in close contact.
[0116] [0116]FIG. 20B illustrates a cross sectional view of the pipe 250 along the longitudinal axis 350 . The inner tensioned support 480 is shown in contact with the inner pipe wall 256 . The surface interface 484 may contain a coating or thermal responsive material. The outer wrapped tension support 499 has a similar interface 497 with the outer surface 254 of the pipe wall 250 . FIG. 20B also illustrates a hole or defect 255 in the pipe wall that is contained with the tension inner and outer supports. This void or “repair cavity” 255 may be filled by material injected through the injection port 498 via a pipe or hose 605 . The inner and outer tensioned support will have sufficient strength to contain the foam reactant. Due to the confined fixed volume of this repair cavity, the injected reactant (not shown) may achieve increased density that if permitted unrestricted expansion.
[0117] While specific embodiments have been illustrated and described, numerous modification are possible without departing from the spirit of the invention, as the scope of protection is only limited by the scope of the accompany claims.
[0118] This specification is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the manner of carrying out the invention. It is to be understood that the forms of the invention herein shown and describe are to be taken as the presently preferred embodiments. As already stated, various changes may be made in the shape, size and arrangement of components or adjustments made in the steps of the method without departing from the scope of this invention. For example, equivalent elements may be substituted for those illustrated and described herein and certain features of the invention may be utilized independently of the use of other features, all as would be apparent to one skilled in the art after having the benefit of this description of the invention.
[0119] Further modifications and alternative embodiments of this invention will be apparent to those skilled in the art in view of this specification. | The apparatus and method for eliminating ground water infiltration while stabilizing the ground and repairing underground pipe/ conduit and connections is taught in this art. The steps are to first inject, under pressure, expandable structural foam in the space adjacent and outside the pipe while blocking any infiltration of the foam into the interior of the pipe, conduit or connection. Concurrently or separately the inside diameter of the pipe is receiving a structural repair. The result is stabilized ground, elimination of ground water infiltration and repair of the host pipe conduit or connection. The invention also teaches a novel method of utilizing a tensioned and compressive support on the outer pipe surface. | 5 |
BACKGROUND TO THE INVENTION
a) Field of the Invention
This invention relates to containing apparatus for the storage of one or more products. In particular, this invention concerns such apparatus which is inflatable to define a storage chamber within which the products may be stored. Though such products may take a variety of different forms, the invention is particularly--but not exclusively--concerned with the storage of motor vehicles such as vintage cars, classic motor cycles and so on.
b) Description of the Prior Art
In my prior U.S. Pat. No. 5,566,512 I have described and claimed an inflatable storage chamber also intended for use with motor vehicles but which can be used for the storage of other products as well. That storage chamber comprises a base sheet, a cover sheet releasably connected to the base sheet, and a fan arrangement which blows air into the chamber in order to inflate that chamber, once a vehicle has been positioned on the base sheet and the cover sheet connected therearound. By controlling the flow of air through the chamber, it is found that the vehicle is stored in an excellent environment, protected against the harmful effects of moisture, dust, dirt and so on.
The storage chamber of my prior U.S. Pat. No. 5,566,512 is really only suitable for use within some other building, such as a garage. If the chamber is used out-of-doors, there are likely to be significant problems resulting from condensation within the chamber. Drops are likely to form on the inner surface of the cover sheet which then fall on the stored vehicle and this can give rise to damaged paint-work. Also, the plastics materials such as polyethylene from which the storage chamber of my prior patent are made are degraded by the UV rays in sunlight and the cover sheet thus has a relatively short life.
SUMMARY OF THE INVENTION
It is a principal object of the present invention to reduce the problems associated with the use out-of-doors of the storage chamber of my prior U.S. Pat. No. 5,566,512.
According to the present invention, there is provided containing apparatus for the storage of one or more products comprising:
a base sheet;
an inner cover sheet defining in combination with the base sheet a storage chamber;
an outer cover sheet substantially wholly overlying the inner cover sheet;
releasable fastener means permitting the inner and outer cover sheets to be at least partially disconnected from and re-attached to the base sheet so as to give access to the interior of the storage chamber;
fan means arranged to drive air from the external ambient into the storage chamber so as thereby to inflate the storage chamber;
means to control leakage of air from the storage chamber directly or indirectly to the external ambient; and
means to supply air to the space between the inner and outer cover sheets so as thereby to inflate said space.
The storage chamber is defined by a base sheet together with a cover sheet itself comprising inner and outer cover sheets which substantially wholly overlie each other, but with a space therebetween so as to permit air under pressure to be supplied thereto and thus to inflate that space and separate the sheets. By providing a storage chamber with a double skinned cover sheet, and arranging for there to be air flow through at least the chamber but possibly also through the space between the inner and outer cover sheets, problems associated with condensation can be essentially wholly eliminated. This allows the storage chamber to be used out-of-doors, without any significant probability of condensation droplets forming on the cover sheet, falling on a stored motor vehicle and damaging the paint-work.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may better be understood, it will now be described in greater detail, with reference to preferred arrangements thereof. Moreover two specific embodiments of storage apparatus of this invention will also be described by way of example, reference being made to the accompanying drawings:
FIG. 1 is a general perspective view of the apparatus, with parts partially cut away for clarity;
FIG. 2 is a vertical section transversely through the apparatus of FIG. 1 but with the fan units shown in end elevation;
FIG. 3 is a detailed view on the join between the cover sheet and the base sheet;
FIG. 4 is a vertical section through one embodiment of fan unit;
FIG. 5 is a vertical section through an alternative embodiment of fan unit;
FIG. 6 is a view similar to that of FIG. 4 but of a modified form of fan unit; and
FIG. 7 is a view similar to that of FIG. 1, but of a further embodiment of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In a preferred form of the apparatus of this invention, the air supply means to said space between the inner and outer cover sheets comprises means allowing air to bleed from within the storage chamber into the space between the inner and outer cover sheets, so as to inflate that space and separate the cover sheets. In this case, the air leakage control means may be arranged to control the leakage of air from the space between the inner and outer cover sheets. Separate air leakage control means may also be provided, to control the leakage of air directly from the storage chamber itself.
In an alternative arrangement, the fan means may be arranged to drive air from the external ambient into the space between the inner and outer cover sheets so as thereby to separate the cover sheets and inflate the space therebetween. In this case, air bleeds means may be provided to permit air in the space between the inner and outer cover sheets to bleed into and thus inflate the storage chamber defined by the base sheet and the inner cover sheet, the air leakage control means then controlling the leakage of air directly from the storage chamber to the external ambient.
In any embodiment of the invention, the air leakage control means may comprise one or more special vents provided for the purpose of allowing air flow. In such a case, the vents may be made adjustable in order that the air flow rate may be controlled to some suitable value to minimise power consumption by the fan means and yet to be high enough to prevent the formation of condensation. Alternatively, or possibly in addition, the inner cover sheet may be air-permeable, at least over a part of its area, whereby the air flow between the storage chamber and the space between the inner and outer cover sheets may take place by permeation of the air through the inner cover sheet.
As with the cover sheet of the storage chamber described in my U.S. Pat. No. 5,566,512, the inner and outer cover sheets may be releasably attached to the base sheet around the whole of the periphery of the base sheet. Alternatively, the inner and outer cover sheets could be permanently attached to the base sheet around one, two or even three sides of the base sheet, so long as when the releasable edges are freed from the base sheet, there is still adequate access to the interior of the chamber for the article to be stored within the chamber. In the case of apparatus intended for the storage of a motor vehicle, it is convenient for both the inner and outer cover sheets to be together wholly removable from the base sheet to permit the vehicle to be driven on to the base sheet, whereafter the cover sheet may be thrown over the vehicle and the peripheral edges of the rover sheet then secured to the edges of the base sheet, all the way around the base sheet.
Various forms of releasable fasteners means may be employed for securing the cover sheet to the base sheet. Conveniently, a clasp fastener (such as that conventionally sold under the name Zip fastener) may be used. Other forms of similar fastener, but not using interengageable clasps, may be employed. One such fastener has a continuous pair of ribs running in a parallel manner along the edge of one component and on the other component there is a similar corresponding pair of ribs, a fastener element being slidably engaged with the ribs to urge one pair into engagement with the other pair or to release one pair from the other, dependent upon the direction of movement of the fastener element. Other possibilities would include hook-and-loop type two-part fasteners (such as those sold under the Trade Mark Velcro), lacing systems and so on. Adjustment of the fasteners will allow a degree of control of the air leakage from the storage chamber and so in turn the air flow through that chamber.
In order better to isolate the interior of the chamber from the external ground, it is preferred for the base sheet to have two layers with thermal insulation between the layers.
At least the outer cover sheet is preferably made from a plastics material which has been UV stabilised. For example, the outer sheet may be made from a polyamide sheet, suitably treated for UV stabilisation. Such a sheet may be aluminium coated and impregnated with a silicone, so as to give the material advantageous properties, including protection from up to 99% of solar UV radiation and protection against the build-up of heat due to infra-red light, as well as air, water and moisture impermeability.
Though it would be possible to operate the fan means continuously and to control the air flow solely by means of adjustable vents and controlled leakage, for certain conditions it may be advantageous for the fans means to be operated with a duty cycle of less than 100% the operation of the fan could be controlled simply on a time basis, though the fan means may be operated under the control of a sensor so as to perform a cyclic action, thus inflating the chamber to a maximum value and then allowing partial collapsing of the chamber before re-inflating the chamber back to the maximum value. The sensor may be arranged to monitor the pressure within the chamber, or perhaps in the space between the inner and outer cover sheets, and to control the operation to the fan means dependent upon the sensed pressure. Other possibilities include having a humidity sensor or a temperature sensor and to control the fan means dependent upon the sensed humidity or temperature, respectively.
In a preferred form of the invention the fan means comprises a pair of electric motor driven fans, mounted spaced apart at one end of the storage chamber, on the cover sheet, so as to draw air from the external ambient and drive that air directly into the storage chamber. Preferably, each fan is a relatively small unit driven by a low-powered 12 v dc electric motor. Each fan may be mounted in a carrier which is secured to the cover sheet, the carrier including a filter panel and also a one-way valve to prevent air leaking out of the storage chamber when the fan is not operating. Such a valve conveniently comprises a flap valve located over the exit duct of the fan and which may move under gravity or under a spring to a closed position when the fan is not operating. The carrier may also include a drain hole to allow any moisture collecting within the carrier to drain externally of the storage chamber.
In a modified form of fan unit, there is provided a secondary electric motor driven fan mounted on the carrier of the main motor-driven fan. A control arrangement may be provided for the secondary fan selectively to cause operation of that fan dependent upon the conditions prevailing within the chamber and possibly also externally of the apparatus. For example, to increase the air flow through the chamber, the secondary fan may be operated so as also to drive air into the chamber, in parallel with the main fan. Should the external humidity be higher than the humidity within the chamber, then the secondary fan may be turned off so that air flows out of the chamber through the secondary fan, for recirculation into the chamber by the main fan. To assist this, the main and secondary fans may draw air from a common plenum chamber. A filter may be provided over the external inlet to that plenum chamber.
The power supply for the or each electric motor driven fan may comprise the battery of a vehicle stored within the chamber and in this case a suitable control unit should be provided to prevent the battery voltage falling below some minimum value. The battery may be recharged for example by one or more solar panels, a wind generator or a mains operated charger. Another possibility includes operating the fan motors from the mains supply via a suitable transformer.
The first embodiment of storage chamber will now be described with reference to FIGS. 1 to 6. Referring to those drawings, there is shown an inflatable storage chamber comprising a generally rectangular base sheet 10, an inner cover sheet 11 and an outer cover sheet 12, the inner and outer cover sheets being of substantially the same shape and size with the outer cover sheet overlying the inner cover sheet. The inner cover sheet is releasably secured to the base sheet around its four edges, by means of a two part clasp fastener 13 (such as that kind of fastener sold under the name Zip fastener) extending wholly around the base sheet. Rather than having one long continuous fastener, it may be more convenient for some applications to have four or even more separate fasteners extending along the sides of the base sheet. The outer cover sheet 12 is secured at 14 to the inner cover sheet around the entire periphery of the inner cover sheet, just above the fastener 13. That securing should be effected in a substantially air tight manner though drainage tubes 15 may be provided at intervals along the length of the join, which tubes also allow air to leak out of the space between the two cover sheets.
The base sheet 10 may be relatively stiff or even semi-rigid and though not shown in the drawings, may be made from upper and lower impermeable sheets together with a layer of thermal insulating material between those sheets. The inner cover sheet 11 may be of an air-permeable material such as a microporous plastic sheet. The outer cover sheet should be air and water impermeable and typically is a polyamide sheet carrying on its inner surface a coating of aluminium and on its outer surface a silicon coating. The silicone coating renders the sheet wholly waterproof and allows easy cleaning, whereas the aluminium coating makes the sheet substantially opaque and shields any object located within the inner cover sheet from harmful solar UV radiation. In addition, the coating will reflect infra-red light and so assist in preventing a build-up in temperature within the chamber, during hours of daylight.
Though not shown in FIGS. 1 to 3, an additional fastener may be provided between the free edge 17 of the outer sheet 12 and the base sheet 10, so as to permit joining of the outer sheet to the base sheet.
Mounted in end wall 18 of the inner and outer cover sheets 11 and 12 is a pair of electric motor driven fan units 19, each of the same construction. One such fan unit is shown in FIG. 4. This has an electric motor 20 mounted on a carrier 21 attached around an opening through the inner and outer cover sheets 11 and 12. The carrier has a louvered cap 22, a foam air filter 23 being mounted between the motor 20 and the cap 22. The motor 20 drives a fan impeller (not shown) to draw-air through the unit in the direction of the arrows, a flap valve 24 being mounted on the exit duct which flap valve opens during operation of the motor but which closes when the motor is not operated, to prevent back-leakage of air. A finger guard 25 may be mounted over the inlet side of the duct within which the fan impeller rotates.
FIG. 5 shows a similar fan unit, but having a significantly larger air filter, as well as better shielding from atmospheric precipitation. In this arrangement, like parts are given like numbers and will not be described again here. Water drain holes 26 are provided in the bottom of the cover sheet 12. Similar holes may of course be provided in the arrangement of FIG. 4, if required.
The motors of the two fan units are connected in parallel to a power supply unit, for the delivery of a 12 v dc supply to the fan motors when the fans are to inflate the chamber. The power supply unit may comprise a transformer for the 240 v domestic mains supply or may be arranged to supply power from the battery of a vehicle stored within the apparatus. The power supply unit may include a sensor for monitoring one or more of the air pressure, humidity and temperature within the chamber and to control the operation of the fans dependent thereon.
In use, the two cover sheets are removed from the base sheet and a motor vehicle is driven on to the base sheet. The cover sheets are thrown over the vehicle and then the inner cover sheet 11 is secured to the base sheet, using the fastener 13. If a further fastener is provided around the outer cover sheet 12, then that fastener is also secured to the base sheet 10. The fan units are then operated to draw air from the external ambient so as to inflate the volume between the base sheet and the inner cover sheet 11, so that the inner cover sheet is wholly free of the vehicle stored within the chamber defined by the base sheet and inner cover sheet. The air blown into the chamber permeates through the inner cover sheet into the space 27 between the inner and outer cover sheets so as also to inflate that space as shown in FIG. 2. From there, the air leaks out of the drain tubes 15, back to the external ambient. The double-sealed construction, if used around the free edge of the outer cover sheet 12, serves to restrict leakage of air out of the chamber and also to give better control of the air flow.
Air holes 28 may be provided in the inner cover sheet, so as to increase the air flow from the chamber to the space 27, to ensure complete inflation of that space and also increase air flow through the chamber. The air holes may be made adjustable (for example for providing flaps secured by hook and loop fasteners) or an adjustable vent may be mounted over each air hole. If a greater air flow is required through the chamber, for example to dry a vehicle put into the chamber when wet, the Zip fastener 13 may be released for a short distance, so allowing increased leakage directly from the chamber. Alternatively, adjustable vents (not shown) may be provided from the chamber direct to the external ambient and in this case such vents should be provided in the wall of the cover sheet opposed to the wall carrying the fan units.
FIG. 6 shows a modified form of the fan unit shown in FIG. 4. Here, a secondary electric motor-driven fan 30 is mounted on the carrier 21, to draw air (when operated) from the space between the carrier 21 and filter 23. The operation of the secondary fan may be under the control of internal and external humidity sensors. In the event that the humidity within the chamber is greater than the external humidity (for example if a wet vehicle has been placed within the chamber) then both main and secondary fans may be operated together, to increase the air flow through the chamber and so to assist drying of the air in the chamber. On the other hand, if the humidity externally is greater than that within the chamber, the secondary fan 30 may be turned off so that air will flow in the reverse direction through the secondary fan, back into the space between carrier 21 and filter 23. From there, the air will be recirculated into the chamber, so minimising the amount of relatively wet air drawn from the exterior, into the chamber.
FIG. 7 shows a second embodiment of storage chamber generally similar to that of FIG. 1 and like parts are given like reference characters; these parts will not be described in detail again here. The storage chamber of FIG. 7 differs from that of FIG. 1 in that there is a plurality of spaced, substantially parallel seams 32 joining together the inner cover sheet 11 and the outer cover sheet 12, so forming a multiplicity of elongate tubular pockets 33 extending up one side of the cover sheet, over the top and down the other side. Further more, similar seams are provided on the end panels of the inner and outer cover sheets, so forming further elongate tubular pockets 34 on those end panels. In the illustrated embodiment, a passageway 35 extends around the cover sheets adjacent there lower edges, interconnecting all of the tubular pockets 33 and 34, which passageway is provided with an inlet valve to permit the inflation of all of the pockets, simultaneously. In this embodiment, no communication is provided between the space between the inner and outer cover sheets and the principal volume of the storage chamber, between the inner cover sheet and the base sheet. Thus, the pockets may be inflated separately from the inflation of the main chamber and, when the pockets are inflated, the structure will be self-supporting even without the inflation of the main chamber.
In the embodiment of FIG. 7, means are provided to allow the leakage of air from the main chamber, such as one or more adjustable vents (not shown) provided at the opposite end of the chamber from the fan units 19, to permit a through-flow of air through that main chamber, during operation of those fan units. In other respects, the embodiment of FIG. 7 is similar to that of FIG. 1. | Apparatus primarily for the storage of a motor vehicle comprises a base sheet (10), an inner cover sheet (11) defining in combination with the base sheet (10) a storage chamber and an outer cover sheet (12) substantially wholly overlying the inner cover sheet. The inner and outer cover sheets are joined together around their peripheral edges and are at least partially releasable from the base sheet, so as to give access to the interior of the storage chamber. At least one fan assembly (19) is provided to drive air from the external ambient into the storage chamber so as to inflate it and air is allowed slowly to leak out of that chamber, either directly or indirectly through the space between the inner and outer cover sheets (11) and (12), to the external ambient. The space between the inner and outer cover sheets may be inflated by air bleeding from the storage chamber into that space, or that space may separately be inflated. | 4 |
FIELD OF INVENTION
This invention relates to aircraft and more particulary to relatively small, unmanned aircraft commonly referred to as model aircraft or planes.
BACKGROUND OF INVENTION
Throughout recorded history, there has been a universal fascination with things that fly. Most of this interest has been concentrated on heavier than air crafts and in its most rudimentary form includes a pair of opposed wings with a body and tail, following the basic configuration of soaring birds.
Even today with the secrets of aerodynamics having been thoroughly explored, the fascination in heavier than air craft remains. The great expense of training to become a pilot and operating an aircraft is cost prohibitive to most people. The thrill of watching pilotless planes and observing their characteristics remains a fascination which is available to people at all economic levels, particularly in the motorless or glider form.
Small pilotless aircraft, commonly referred to as models, come in a myriad of shapes and sizes from the most sophisticated, remotely controlled, power driven aircraft to the simplest hand launched gliders.
In its simplest form, hand launched gliders made of thin balsa wings and tails with an elongated body are inexpensive to purchase and easy to assemble. These gliders usually come two or three to a package since they are so easily broken. Additionally, the flight characteristics and distances achievable with these models are limited and the novelty of the same soon wears off.
Pop top-type soda and beer cans are also universally known and have intrigued many people for years. Some people even collect them. Perhaps, as in the inventor's case, the marvel of their construction along with their colorful decor is what has made them seem too valuable to throw away. For some time the inventor had sensed in himself and others the desire to use these cans for something worthwhile, even after they had served their intended function.
In a moment of inspiration, the inventor combined his love for airplanes and fascination with drink cans and conceived the idea of making drink cans fly.
BRIEF DESCRIPTION OF INVENTION
By drawing on the inventor's experience as a pilot, model builder, and design engineer, and after much research and study into the above mentioned problems, the present invention has been developed to provide a relatively simple, easy-to-assemble model-type aircraft which quickly and readily incorporates on an empty drink can as a fuselage. This aircraft has extremely high glide slope characteristics at relatively low air speeds to add further to the fascination of the same. The present invention also includes break away wings which effectively makes the same crash proof in that whenever an obstruction is encountered, the wings will come off without damage and can be easily reconnected for the next flight. Further, the user can select his favorite colors from the myriad of drink brands on the market, i.e., a Coke can for red, a Seven-Up can for green, etc. Also, of course, a person's favorite brand of beverage could be represented such as Pepsicola or Budwiser.
In the present embodiment, neither tools nor glue are required and assembly can be accomplished by the most methodical person in less than two minutes. The can takes the brunt of landings and the associated scraping and denting and can be readily replaced as necessary. Th user of the present invention can thus get many years of enjoyable service from the same due to the replacement feature and the fact that the remaining portions are made of water and weather proof materials such as thermal plastics.
In view of the above, it is an object of the present invention to provide a model-type aircraft utilizing at least one empty metal-type drink can as part of the aircraft.
Another object of the present invention is to provide a model-type aircraft utilizing at least one empty metal-type drink can as a fuselage with break away wing sections.
Another object of the present invention is to provide a model-type aircraft utilizing at least one empty metal-type drink can as a fuselage.
Another object of the present invention is to provide a model type aircraft utilizing at least one drink can as a fuselage with a combination wing saddle and tail supporting boom attached thereto.
Another object of the present invention is to provide a model-type aircraft using at least one empty drink can as a fuselage with a readily attachable and detachable tail supporting boom.
Another object of the present invention is to provide a combination wing saddle and tail supporting boom for mounting an empty drink-type can as a fuselage.
Another object of the present invention is to provide a model aircraft utilizing an empty drink-type can as a fuselage and having a streamlining nosecone attached thereto.
Other objects and advantages of the present invention will become apparent and obvious from a study of the following description and the accompanying drawings which are merely illustrative of such invention.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view of the aircraft of the present invention;
FIG. 2 is a sectional view of the can fuselage thereof;
FIG. 3 is a fragmentary view of the can fuselage showing the wing adjustment;
FIG. 4 is a bottom fragmentary view of the present invention;
FIG. 5 is a top fragmentary exploded view thereof; and
FIG. 6 is an exploded top plan view thereof.
DETAILED DESCRIPTION OF INVENTION
With further reference to the drawings, the aircraft of the present invention, indicated generally at 10, includes an empty drink can 11 which forms the fuselage and a wing saddle 12 which is secured to a rearwardly extending tail boom 13. This boom in turn supports an elevator 14 and a rudder 15, both of which function in the normal manner of such devices.
A pair of wings 16 formed from styrofoam or similar material are provided and nose cone 17 is mounted on the forward end of fuselage 11.
Referring more specifically to the drink can fuselage 11, this is a readily available item having a bottom 18, a top 19, and cylinderical sidewall 20. The can also includes the normal pop top opening 21 through which the contents of the can have been emptied.
The wing saddle 12 is airfoil shaped in cross-sectioned in the area of outer panels 22. The upper surface of the forward edges 23 of the trailing edges 24 of the panels 22 forms shoulders which contour to the inwardly projecting tabs 25 of wings 16 to form a smooth upper wing surface when installed as shown in FIG. 1.
Aligned pins 26 are provided on the forward and trailing edges of each of the outer panels 22 of saddle 12 and are adapted to hold an elastomer securing means such as rubber bands 27 in place as can clearly be seen in FIGS. 4 and 5.
Shoulders 42 of saddle 12 form an elongated slot and have elongated tail boom 13 mounted therebetween. An opening is provided in the forward upper portion of said boom to give the visual impression of a cockpit as indicated at 28. Also, a plurality of perforations can be provided to lighten the weight of the member if so desired. As shown in the drawings, the cockpit portion 29 or tail boom 13 is secured to the wing saddle 12 while the rear portion 30 secured thereto extends rearwardly to the tail.
The rearward end of tail boom 13, of course, terminates in normal elevator and rudder configurations. Since elevator and rudder configurations of this type are well known to those skilled in the art, further detailed discussion of the same is not deemed necessary.
An elongated, slot-like opening 31 is provided in cockpit portion 29 with a fixed, jaw-like member 32 extending forwardly thereof as shown clearly in FIG. 2. A locking lever 34 is pivotably secured at one end to pin 35 which is fixedly secured to portion 29. A biasing spring 36 is also mounted on pin 35 and has one arm 37 thereof secured to portion 29 and the other arm 38 thereof is secured to locking lever 34 as can clearly be seen in FIG. 2.
The end of locking lever 34 opposite mounting pin 35 includes a lever handle 39.
The mount nose cone 17 on drink can fuselage 11, a suction cup 40 having an outwardly projecting portion 41 is provided. The suction cup is preferably moistened and placed against the can bottom 18 and is held in place by the vacuum created by the cup. Next, the nose cone can be placed in engagement with the projecting portion 41 thus mounting the cone on the can in relative fixed position. Since suction cups of this type are well known to those skilled in the art, further detailed discussion of the same is not deemed necessary.
To assemble the aircraft of the present invention, an empty pop top type drink can is selected. Next, the central portion of wing saddle 12 is placed juxtaposed to the exterior of said can with the pop top opening 21 of can 11 adjacent to saddle 12 and in line with elongated slot formed by shoulders 42 of saddle 12. Therefore, the boom portion 13 of the present invention is manipulated so that the jaw-like member 32 of the cockpit portion 29 enters the pop top opening 21 in the top 19 of can 11. Spring 36 will allow locking lever 34 to pivot so that it can be pushed into the interior of can 11 along with jaw-like member 32.
Once the locking lever 34 has entered the can, biasing spring 36 moves such lever to the position shown in FIG. 2 wherein shoulder 34' of locking lever 34 engages the interior of top 19 thus preventing member 32 from being withdrawn from the can. The end of member 32 will also bear against the interior of the wall 20 providing stability to tail boom 13 which is essential for flight purposes. During the inserting procedure of the cockpit portion 29, the forward portion 29' of cockpit portion 29 will slide in the slot formed by raised shoulders 42 of wing saddle 12 providing further stability to tail boom 13 and will also bear against wing saddle 12, holding it in firm contact with the can which is essential for flight purposes.
Thus, it can be seen that once locking lever 34 engages the interior of top 19, biasing spring 36 will hold such locking lever tightly against the interior of wall 20 not only prevent member 32 from being withdrawn from the can 11, but also maintaining the cockpit portion 29' in the slot-like groove formed by shoulders 42.
Although the cockpit portion 29 is held in relative fixed position to can 11, saddle 12 can be moved longitudinally, forwardly and rearwardly under said cockpit portion, sliding between shoulders 42, as is clearly illustrated in FIG. 3. This allows not only for compensation to be made for different weights of fuselage cans 11, but also allows the glide angle to be adjusted. For example, a rearward adjustment of the saddle and, of course, the associated wings, will give a steeper glide slope and faster speed which are more suitable for windy conditions while adjusting the same forwardly will give a lesser or shallower glide slope and slower speed which are more suitable for calm wind conditions. Since the effects of adjustments of this type are well known to those skilled in the art, further detailed discussion of the same is not deemed necessary.
Once the cockpit portion/wing saddle/drink can fuselage have been interconnected and mounted as hereinabove described, the wing tabs 25 are placed over the outer panels 22 on opposite sides wing saddle 12. The elastomer or rubber bands 27 are then placed over one of the pins 26 and stretched the chord of the wing and into engagement with the second pin in longitudinal alignment therewith. The pressure of the rubber band 27 will hold the associated wing 16 in place and is strong enough to retain the connection in flight conditions. Should, however, the wing encounter an obstruction such as a tree, pole, or the earth, the rubber band will allow the wing 16 to be knocked loose from the saddle 12 thus providing a break away system which prevents damage to the wing and various parts of the aircraft itself.
After a crash as described above, the wing can simply be reinserted on the saddle 12 under the bands 27 and the aircraft is again ready to fly.
Whenever it is desired to remove the drink can fuselage 11 from the other parts of the present invention, the lever handle 39 is simply pushed downwardly, as shown in FIG. 2, to disengage shoulder 34' of lever 34 from the interior of drink can top 19. Such lever and its associated jaw-like member 32 can then be removed from the can through opening 21 and a new can can be mounted as hereinabove described.
Although the aircraft of the present invention can be readily hand launched, to reach greater heights with the associated much longer flights, downwardly and rearwardly projecting launch hooks 43 are provided on the underside of saddle 12. Loops or similar means in the ends of a "Y" shaped launch line can be placed over launch hooks 43 and as the launch line is rapidly retrieved, whether mechanically or manually, the aircraft 10 will rise in the air until it reaches a near vertical position relative to said launch line, at which time the launch hook 43 will automatically disengage the same. Since launch hooks of this general type and their manner of operation are well known to those skilled in the art, further detailed discussion of the same is not deemed necessary.
From the above it can be seen that the present invention has the advantage of providing a relatively simple, inexpensive, and yet highly efficient model type aircraft which utilizes, for both weight and balance purposes as well as aesthetics and novelty, commonly available pop top type drink cans. No tools or special skills are required to assemble and fly the aircraft of the present invention and the drink can fuselage can be readily changed as desired.
The present invention may, of course, be carried out in other specific ways than those herein set forth without departing from the spirit and essential characteristics of the invention. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive, and all changes coming within the meaning and equivalency range of the appended claims are intended to be embraced therein. | This invention is an unmanned aircraft which utilizes commonly available drink cans as a fuselage and central connecting point. The aircraft can be used with any pop top-type can, is easy to assemble without tools or adhesive materials, and gives above average performance relative to comparable sized craft. The wings are of break away type to prevent damage in landings or striking of other objects and the can fuselage which takes the brunt of landings can be readily replaced. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention concerns an apparatus for spatial modulation of an x-ray beam, of the type having a number of planar attenuation elements for x-ray radiation that are disposed in a grid-like manner on a carrier and that, independently of one another, can be pivoted or tilted piezoelectrically between at least two positions. The invention furthermore concerns an x-ray image system with such a modulation apparatus as well as different methods for operation of such an apparatus.
2. Description of the Prior Art
Laminar x-ray image systems are used primarily in medical diagnostics in order to acquire radiographic images of the inside of the body of a patient. The patient is penetrated by an x-ray field extending perpendicularly in two dimensions to the propagation direction, and the spatially dependent attenuation of the x-ray radiation received behind the patient is represented or evaluated as image information. In addition to conventional radiography, laminar x-ray imaging systems are used in fluoroscopy as well as, more recently, in so-called multi-slice systems in computed tomography.
The radiation dose to which the patient as well as the medical personnel is exposed during the examination plays a significant role in applications in medical x-ray diagnostics. A reduction of the applied x-ray dose can be achieved by use of a semi-transparent pre-filter that has a central opening for the unattenuated passage of x-ray radiation therethrough. By suitable placement of such a filter as is known, for example, from U.S. Pat. No. 5,278,887, only the region of the patient within the two-dimensional radiation field is charged with the necessary dose that is of interest for the user of the x-ray image system. The regions in the image lying outside of this ROI (region of interest) are nevertheless recognizable, albeit with reduced contrast. This technique in fact effects a significant dose reduction in the border regions of the image, but can be adapted only with difficulty to different subject shapes and sizes. Even with the use of such a filter technique, the dose at specific regions of the body to be examined is locally higher by multiple times more than would be necessary for a good contrast. This problem particularly occurs in body regions in which regions of much stronger x-ray absorption and regions of much weaker x-ray absorption lie next to one another. Since the diagnosing physician must normally examine all organs of an x-ray image, the applied x-ray dose is set such that a sufficient signal-to-noise ratio is achieved for all objects acquired in the image.
Apparatuses for spatial modulation of the radiation field that are positioned between the x-ray source and the patient are known in the field of x-ray imaging in which one-dimensional radiation fields are used in the form of fan-shaped x-ray beams for exposure such as, for example, in conventional computed tomography. In these apparatuses, for example, tongue-shaped attenuation elements are arranged in the form of a one-dimensional array corresponding to the one-dimensional extent of the radiation field. The attenuation elements can be controlled via separate actuators independently of one another, such that individual sections or channels of the one-dimensional radiation field can be weakened or modulated independently of one another by the introduction of the attenuation elements. Such an apparatus is known, for example, from U.S. Pat. No. 5,044,007, in which the attenuation elements are fashioned tongue-shaped and tiltable, and each can be tilted into the radiation field by its actuator. The control of the individual actuators ensues dependent on the x-ray radiation exiting from the body after irradiation of the body to be examined, relative to the respective channel that can be influenced with the attenuation element. The radiation dose necessary for a sufficient contrast can be locally reduced in this manner to the respectively necessary value, such that overall a reduced radiation exposure results for the patient.
Similar apparatuses are known from U.S. Pat. Nos. 5,054,048, and 4,715,056, and European Application 0 251 407. In U.S. Pat. No. 5,054,048, the attenuation elements are designed as sliding elements that are moved into or out of the beam by a sliding mechanism with an electromechanical drive. The attenuation elements are wedge-shaped, such that different degrees of attenuation can be achieved by displacement thereof perpendicular to the beam direction.
European Application 0 251 407 suggests the use of planar attenuation elements made from a piezoelectric material that can be tilted between two positions by the application of an electrical voltage.
From U.S. Pat. No. 4,715,056, a further one-dimensional attenuation apparatus is known in which tiltable pivotable planar attenuation elements are formed from a piezoelectric material as flex transducers that can be bent into the beam path by the application of an electrical voltage. This document furthermore discloses the possibility of an electromechanical drive as well as drive by means of a step motor. In the design with the electromechanical drive, the position of the attenuation elements is derived from the current strength of the current flowing through the electromagnet, namely the activating current.
A further apparatus for spatial modulation of a two-dimensional x-ray field is known from the German Application 102 21 634 (published after the priority date of the present application). In this apparatus, flex transducers (arranged in the form of a grid) to which self-supporting planar attenuation elements are attached, are aligned such that the attenuation elements stand in the beam direction. A minimal beam attenuation ensues in this position. By deflection of individual flex transducers via an electrical control, the attenuation at this location can be specifically increased. Knowledge of the position of each individual attenuation element during the image acquisition is necessary to damp the fluctuation behavior of the flex transducer and for image post-processing. The detection of the current position of each attenuation element ensues in this apparatus with an optical measurement arrangement that detects light passing through the grid of attenuation elements. For this purpose, a light source is necessary at the input side of the grid and a light deflection device is necessary at the output of the matrix. The respective positions of the attenuation elements are determined and evaluated by the shadowing thereof on a photodiode array caused by the attenuation elements. Errors can occur with such an optical detection due to light scattering and image blurring. Furthermore, light channels must be present in the grid mounting in order to be able to conduct the optical projection onto the photodiode array.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an apparatus for spatial modulation of an x-ray beam by means of planar attenuation elements arranged in a grid, which enables a precise determination of the position of every attenuation element in real time.
The object is achieved by an apparatus according to the present invention having a number of planar attenuation elements for x-ray radiation disposed in a grid arrangement on a carrier, which can be pivoted or tilted piezoelectrically independently of one another between at least two positions. One or more sensors with which a piezoelectrically-caused length and/or width and/or position change of the piezoelectrically influenced regions can be detected are disposed on piezoelectrically influenced (in terms of length and/or width and/or position change) regions of the attenuation elements or piezoelectric drive elements that are connected with the attenuation elements.
The background for the present invention—as well as some of the apparatuses of the prior art—is the realization that the spatial distribution of the radiation field before the passage through the body of the patient is, aside from interference effects, practically homogenous, while as a consequence of the absorption ratios of the patent body the dynamic range in the radiation field immediately before the x-ray detector can amount to 1:1000 or greater. With the present apparatus, a further dose reduction is achieved because, within the two-dimensional radiation field before the passage through the body, a dose is applied that has an intensity no higher than is sufficient for a good contrast at this location to be obtained from the x-ray radiation that strikes the x-ray detector. The present apparatus thus enables a fast, adaptive, image-content-controlled spatial radiation attenuation in the two-dimensional radiation field in front of the patient body. The achievable dose reduction is based on individually applying, via controlled pivoting or tilting of the individual attenuation elements within their respective grid region (also designated in the following as a beam channel or cell), in each image region only as much of a dose as is necessary and that location to achieve a satisfactory signal-to-noise ratio.
The image signal acquired by the x-ray detector must be corrected dependent on the set spatial transparency of the apparatus operating as a radiation attenuator before further processing or display. For this, knowledge about the current position of each individual attenuation element during the image acquisition is necessary. In the present apparatus, this position information is obtained via the sensor signals that respectively detect the current flexing or expansion state of each individual attenuation element, or the piezoelectric actuation of the attenuation element, such that the exact position can be derived therefrom. This position is linked with the degree of attenuation of the respective channel, such that with this information an x-ray image acquired with the inventive apparatus can be normalized. The entire radiation distribution thus can be reverse calculated using the individual settings or deflection positions of the attenuation elements determined with the sensors.
In contrast to the aforementioned method for the determination of the position via the controller, the inventive solution offers the advantage of a higher degree of precision and, with respect to the technique of the subsequently published document, additionally offers the advantage of a smaller technical expenditure. By the inventive direct detection of the attenuation element, or its actuation element, no interfering signals of other attenuation elements occur, as with optical detection. Moreover, the attenuation elements or their piezoelectric drives can be completely glued at one end into the carrier serving as a mounting. This simplifies the production and leads to a higher stability of the mounting. The present invention enables the direct detection of the current position of each attenuation element in real time without the need for elaborate optics. Modifying influences, such as fluctuations and external interferences that can be individually different for each of the attenuation elements, also can be compensated.
The present apparatus can be particularly advantageously used in an x-ray image system in connection with a controller, with the position of a respective attenuation element currently detected with the sensor being compared with a reference position to be reached, and the attenuation element is controlled to reach the desired reference position. Naturally, it is not necessary for this purpose to concretely, spatially calculate the current position of the attenuation element. Rather, a known association between the sensor signal and the position of the attenuation element is sufficient, such that control can be based directly on the sensor signal.
In an embodiment of the present apparatus, the attenuation elements are themselves piezoelectric flex transducers attached on one side of the carrier. These flex transducers either can be formed directly from a material that strongly absorbs x-ray radiation, or can be coated with such a material such as, for example, tungsten.
In a further embodiment, the attenuation elements are formed as self-supporting elements, made of a material that strongly absorbs x-ray radiation, that are connected with piezoelectric drive elements. The piezoelectric drive elements are fashioned as piezoelectric flex transducers attached approximately parallel to the flex transducers on one side of the carrier, each having a free end to which the attenuation elements are attached. A “self-supporting attenuation element” as used herein means a component that is stable, in contrast to a thin layer, and can be arranged and moved freely in space without further support. A much larger movement range can be traversed in less time by a suitable arrangement of these self-supporting attenuation elements relative to the flex transducers. For example, planar metal rods or metal plates can be used as attenuation elements.
In an embodiment, the sensors for the detection of the piezoelectrically induced length and/or width and/or position change of the piezoelectrically influenced regions are tensiometer (strain gauge) strips that are attached to the flex transducers. These tensiometer strips directly detect the piezoelectrically caused expansion and thus the curvature of the flex transducer. The tensiometer strips can hereby either be glued or directly imprinted onto the flex transducer.
In a further embodiment, the sensors are directly integrated into the flex transducers. This ensues by the use of a further layer made of a piezoelectric material that is a component of the flex transducer. Such flex transducers are known, and are called trimorph flex transducers. This second layer made from a piezoelectric material is used as a sensor with which the respective current flexing of the flex transducer can be detected.
A carrier made from a material that optimally slightly absorbs the x-ray radiation to be modulated is used as a carrier or mounting in the preceding embodiments. In particular material made from plastic or a metal with a low atomic number are suitable.
In a further embodiment of the apparatus a substrate is used as the carrier, the substrate being penetrated by passage channels running parallel to one another or aligned to the focus of an x-ray source, with the attenuation elements being disposed in these channels. The attenuation elements are arranged such that they can be tilted or pivoted within the passage channels, such that each element completely closes (blocks) its channel in one position of the element. In this case, for each attenuation element two piezo-stack actuators can be provided as drive elements that are offset from one another on respective main surfaces of the attenuation element, and that are connected to the inner wall of the passage opening. In this embodiment, the attenuation elements can be tilted on a central axis given activation of the drive elements. The sensors are arranged on the piezo-stack actuators in order to detect their expansion. This can ensue, for with tensiometer strips.
In their neutral position, in which they attenuate the x-ray radiation the least within the cell or the beam channel, the longitudinal axis of each attenuation element is aligned to the focus of the x-ray source of the x-ray image system in which the elements are used. Upon activation, these attenuation elements are tilted within their respective cells such that they occupy a larger portion of the cell cross-sectional area. Due to the grid-like arrangement of the individual attenuation elements, a grid of controllable beam channels is created. The grid does not need to be sub-divided nearly as finely as the grid of the laminar x-ray detector in the x-ray image system. Due to the proximity of the attenuation elements to the focus of the x-ray source, they are deliberately imaged out-of-focus on the x-ray detector. It is advantageous for the shadowing effect of adjacent attenuation elements to partially overlap on the x-ray detector, since in this manner a more spatially consistent shadowing is created. The control of the quantum flow of the x-ray radiation in each radiation channel ensues by the variation of the angle of inclination or tilt angle of the attenuation elements. When the attenuation element is aligned with its longitudinal axis exactly on the focus of the x-ray source, the absorption in the radiation channel is at a minimum. In this position, the maximum value of the radiation is allowed to pass in this channel. When the attenuation element is maximally pivoted or tilted, radiation attenuation ensues in a larger portion of the radiation channel. An effective width of the absorbing part of the attenuation element in the cell that is effective for the absorption of the x-ray radiation in the channel region, corresponding to 11.43 times the actual width of this absorbing part is obtained by tilting the attenuation element of 5° relative to the neutral position. Given a width of, for example, 125 μm, this yields an effective width of 1.5 mm for the attenuation of the x-ray radiation. From this, given an x-ray voltage of 50 to 80 keV, a quantum flow change >10–13 is obtained as an attenuation factor in the case of an attenuation element with an absorbing part made from tungsten. It is necessary for these elements to exhibit a high degree of radiation absorption in order to actually modulate the radiation, rather than merely harden it.
The present x-ray image system with the inventive apparatus for spatial modulation of the x-ray beam includes an x-ray source and a laminar x-ray detector on opposite sides of an examination volume in a known manner. The inventive apparatus is disposed at the side of the examination volume near the x-ray source, in the beam path of the x-ray radiation. Furthermore, the x-ray image system has a controller to control the attenuation elements of the apparatus, preferably dependent on the spatial distribution of the x-ray radiation striking the x-ray detector. With this controller, the attenuation elements can be electronically controlled dependent on the locally received x-ray radiation or on the image content so that a consistent signal-to-noise ratio is attained with an optimally low x-ray dose. As needed, the attenuation elements are set to allow a reduced quantum flow by partial tilting. The contrast reduction thereby effected can be compensated in the image reproduction chain, for example by digital post-processing, with the effective action of the attenuation elements being detected with sensors in real time in each channel. In the image post-processing, for each pixel of the x-ray detector the actual amplitude value is multiplied with the previously measured attenuation factor at this pixel. This attenuation factor can also be composed of the shadowing effect of a number of attenuation elements, since this shadowing effect can be partially overlapped on the x-ray detector by the arrangement of the attenuation elements near the x-ray source.
In an embodiment of the x-ray image system, the controller for the attenuation elements is integrated into a control loop in which the attenuation elements are controlled dependent on the measurement signals of the sensors to achieve the predetermined desired position. In this manner, even given scatterings or other influences individually acting on the attenuation elements or their drive elements, a reliable adjustment of the desired position can be achieved.
The present apparatus can be used for different tasks in the field of x-ray imaging technology. In one application, the present application can serve for dose reduction, dynamic increase and/or improvement of the image quality in radiography exposures or DSA. In this application, the quantum flow is determined in the effective region by a two-dimensional x-ray detector (for example a solid-state detector) with fast sampling rate. The attenuation of the individual cells of the apparatus is detected during a first part of the exposure and the control unit uses this information for the adjustment of the attenuation of the individual channels. Higher intensity locations in the image receive fewer or no further quanta in the further exposure by reduction of the transparency by means of the beam attenuators in the second part of the exposure, while the attenuation elements remain set to the highest transparency at dark, low-intensity image locations. This application can be implemented in real time by means of the fast pivoting or tilting capability.
In this application of the apparatus, a significantly smaller x-ray dose is applied in relatively transparent image regions. The factor of the achievable dose reduction is subject-dependent and can be more than a factor of 10 in an individual case. Given implementation of this application with the use of additional pre-scans, the image acquired with the pre-scan can be integrated into the end image, such that all applied x-ray quanta contribute to the end image. The reaction time of the individual radiation attenuators must be fast enough for this application and the sampling rate of the x-ray detector must be relatively high. Values from 100 ms up to 100 μs can be achieved as a reaction time of the radiation attenuator. The attenuation elements operate only in the in/out mode, meaning without the use of intermediate settings.
A further application field of the present apparatus in medical diagnostics concerns the dose reduction, dynamic increase and/or improvement of the image quality in fluoroscopy. In this application, the transparency of the preceding images is used as a basis for the adjustment of the individual attenuation elements of the apparatus. Since the image content of successive images for the most part differs only a little in fluoroscopy, relatively slowly reacting attenuation elements can be used. The use of the present apparatus in RBV-based systems is particularly advantageous since the decrease in the tip brightness in a significant area of the RBV input screen has a beneficial effect on the contrast in the output image. By the additional reduction of scatter radiation achieved with the use of the inventive apparatus, a lower-noise image results. If necessary, the buffered data of the radiation attenuation, meaning duration, location and degree of the attenuation, can be supplied to a digital image processor that normalizes the contrast over the entire image, as described above. In this application, the attenuation elements operate in intermediate settings (not just in/out) that can be optimally selected based on the information of the preceding images.
Multi-slice CT systems represent a further application field of the inventive apparatus. In contrast to conventional CT systems with a single-line detector for image acquisition, the current development trend is in the direction of laminar CT systems. Up to 256 CT slices are simultaneously acquired in such systems by laminar, two-dimensional x-ray detector arrays. The inventive apparatus likewise can be used in such a two-dimensional radiation field as already explained in connection with fluoroscopy applications. In CT systems, however, the absorption data continually change due to the continuous rotation of x-ray detector and focal spot of the x-ray tube. This change can be predicted to a certain extent from the data of the preceding images of the sinogram, such that the respective position of the attenuation elements can be established with suitable prediction electronics. In the simplest version, such prediction electronics assume that the registered translations of the image signals continue further in the preceding images in the sinogram. It is thereby possible to use the same strategies in the control of the attenuation elements as these have already been explained for dose reduction, dynamic increase and/or improvement of the image quality in connection with fluoroscopy. However, since no preceding image data exists at the start of the application, in this case a start condition can be attained, for example with a single pre-scan with reduced dose. By the use of the inventive apparatus in such CT devices, a significant dose reduction as well as an improved image quality result due to reduced scatter radiation intensity.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side view of a part of an exemplary apparatus according to the present invention.
FIG. 2 is a plan view of an apparatus according to FIG. 1 in section.
FIG. 3 shows, schematically in side view, three attenuation elements according to a further embodiment of the present invention that are in a neutral setting (position).
FIG. 4 shows the embodiment according to FIG. 3 in a deflected position of the attenuation elements.
FIG. 5 shows, schematically in side view, three attenuation elements according to a further embodiment of the present invention that are located in a neutral Setting (position).
FIG. 6 shows the embodiment according to FIG. 5 with the attenuation elements in a deflected position.
FIG. 7 shows an example for an attenuation element with an imprinted or glued-on tensiometer strip as a sensor;
FIGS. 8A and 8B show further example of an attenuation element with an additional piezoelectric layer as a sensor.
FIG. 9 shows an exemplary embodiment of an x-ray image system using the inventive apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 schematically shows a significantly enlarged section of an embodiment of the present apparatus disposed in the two-dimensional x-ray field of an x-ray image system. The apparatus 1 has a number of attenuation elements 2 , arranged in a matrix or grid, that are connected to a carrier substrate 4 via piezoelectric drive elements 3 . In this example, the carrier substrate 4 has a number of passage channels 8 , with walls to which the drive elements 3 (fashioned as piezo-stack actuators in this example) are attached. Both the webs 9 forming the walls of the carrier 4 through which the passage channels 8 are established as cells and the attenuation elements 2 themselves are, in the rest position, aligned to the focal spot 10 of the x-ray tube, as is to the situation of FIG. 1 . The surface of the carrier 4 alternatively can be fashioned in the form of a spherical surface instead of in the shown planar form, such that the x-rays originating from the focal spot 10 are incident perpendicularly at every location on this surface. The attenuation elements 2 are executed as flat paddles or plates of tungsten and each can be tilted around a virtual rotation axis 11 by means of the respective piezo-actuators 3 . The actuators 3 responsible for each individual element 2 are arranged within the channel 8 such that they operate in the same direction. They simultaneously expand or simultaneously contract when a corresponding voltage is applied. Since the pair of actuators 3 for element 2 are offset with respect to the virtual rotation axis, the simultaneous expansion or contraction of the pair of actuators 3 tilts or pivots the element 2 as indicated by the curved arrows. The deflected position of the element 2 is shown dashed in the center cell of FIG. 1 . In this tilted position, the maximum possible attenuation of x-ray radiation is achieved in the cell. By activation of the piezo-actuators 3 with a lower voltage, arbitrary intermediate positions can also be realized. The current positions of the respective piezo-actuators 3 and thus of the respective attenuation elements 2 is detected in this example by tensiometer strips 6 applied on the piezo-actuators 3 . In the neutral position of the attenuation elements, as illustrated with the solid lines, the maximum possible portion of the x-ray radiation is allowed through the present apparatus. The material of the carrier 4 can be selected such that it absorbs x-ray radiation either very significantly or very weakly. In the first case, a fixed ratio of attenuation of the x-ray radiation must always be accepted, while in the second case the x-ray radiation through the apparatus cannot be completely blocked in the shown embodiment.
The elements 2 preferably are slanted at their end surfaces such that they lie flat against the walls of the webs 9 , as shown by the dashed-line pivoted element 2 in FIG. 1 . The x-ray radiation is optimally attenuated by this embodiment given a completely deflected element 2 in the passage channel 8 .
Since the apparatus is designed for the activation of the drive elements 3 to operate in the same direction, the walls of the webs 9 can serve as electrical terminals (poles) for applying the voltage. The elements 2 thus do not have to be provided with electrical contacts. The contacting of the piezo-actuators 3 can be realized easily in this example, using thin metallic conductor runs on the webs 9 directly toward the edge of the apparatus in parallel or in a number of layers on one side of the carrier 4 while a common electrode is fashioned on the opposite surface of the carrier 4 . The surface of the carrier 4 directed toward the side of the focal spot preferably carries the common electrode while the side of the carrier 4 facing away from the focal spot 10 carries the individual conductor runs, since a greater conductor run cross-section can be achieved on this side.
In this exemplary embodiment, multi-layer ceramics are used as the piezoelectric actuators 3 because these generate many times the excursion of single-layer ceramics. In order to reduce the requirements on the ceramic excursion in the present embodiment, the actuators 3 should act optimally close to the rotation axis 11 , such that a small excursion of the actuators 3 effects a large displacement of the element 1 by lever action.
The present apparatus has a number of attenuation elements 2 , arranged in a grid, that the respective passage channels 8 of the carrier 4 . In this manner, a matrix of controllable absorption cells 12 is formed as can be seen in section in the plan view in FIG. 2 . FIG. 2 shows the webs of the carrier 4 that border the passage channels 8 . Paddle-shaped attenuation elements 2 that are connected with the walls of the carrier 4 via the piezo-actuators 3 can be seen within the passage channels 8 . The attenuation elements 2 are, in this example, held only the actuator elements 3 .
Such an apparatus can be realized with any desired number of absorption cells 12 . For example, a matrix can have 10×10 or 100×100 such absorption cells 12 . Since a certain wall thickness of the webs 9 of the carrier 4 is necessary for the stability of the apparatus, it can be advantageous to arrange two or more such apparatuses in succession in the beam direction. A finer degree of spatial modulation of the beam profile is achieved by the multiple attenuation planes obtained in this manner. A particularly advantageous arrangement is achieved when the channels 8 of the two planes disposed in sequence influence are equally large quadratic solid angle of the focal spot 10 of the x-ray tube and are arranged such that one plane influences the light fields of a (theoretical) checkerboard pattern and the other plane influences the dark fields.
In an embodiment, the matrix or grid of the absorption cells 12 is disposed within the x-ray image system such that it faces the image matrix of the x-ray detector.
The individual attenuation elements 2 of the present apparatus are electronically controlled dependent on the image content of the regulating x-ray image so that a leveling of homogenization of the contrast in the x-ray image is effected. In lighter image regions, the beam attenuators 2 are set to effect a reduced quantum flow, meaning stronger attenuation, while the neutral setting is maintained in darker image regions. The contrast reduction thereby effected at the x-ray detector must be electronically compensated for the image reproduction. For this purpose, the angle setting of the attenuation elements 2 is detected in real time with the sensors 6 and the attenuation linked with the angle setting is used for normalization of the x-ray image.
An embodiment of the present apparatus is shown in FIGS. 3 and 4 . Only three attenuation elements 2 are shown in side view in FIGS. 3 and 4 , but naturally a larger number are present in the actual apparatus. FIG. 3 shows the arrangement of attenuation elements 2 on a (in this example) flat carrier substrate 4 made of a material transparent for x-rays, for example plastic. The carrier 4 alternatively can be spherical, such that the rays from the focal spot 10 of the x-ray tube always strike perpendicularly on the carrier surface. In the present embodiment, the piezoelectric drive elements 3 are executed as flex transducers 5 that are aligned in the direction of the focal spot 10 and stand on the carrier substrate 4 . Each flex transducer 5 is preferably tongue-shaped or rod-shaped. The flat attenuation elements 2 that, in this example, are formed of tungsten and preferably exhibit a paddle or plate shape, are attached to the free ends of these flex transducers 5 . The connection between the flex transducers 5 and the self-supporting attenuation elements 2 can be realized by gluing, pressing or soldering and only ensues in an end region of the flex transducer 5 , which is indicated in FIGS. 3 and 4 with the reference character F. Each attenuation element 2 also forms an absorption channel of the apparatus together with the neighboring element 2 . Electrical contacting of the flex transducer 5 ensues on one or both surfaces of the carrier substrate 4 , similar to that explained in connection with FIGS. 1 , 2 and 3 . FIG. 3 shows the neutral setting of the attenuation elements 2 in which these are aligned to the focus 10 of the x-ray tube. A corresponding sensor to detect the curvature (flexing) is mounted on each flex transducer 5 , as explained in further detail using FIGS. 7 and 8 . The sensors 6 , 7 are not shown in FIGS. 3 and 4 (nor in FIGS. 5 and 6 , in which they are also used.
Given an activation of the piezoelectric flex transducers 5 , the attenuation elements 2 are tilted into the beam path of the x-ray radiation, as can be seen in FIG. 4 . In this state, the entirety of the radiation is absorbed by the attenuation elements 2 . The matrix-like arrangement of these attenuation elements 2 ensues in the same manner as explained in connection with FIGS. 1 and 2 . In the embodiment of FIGS. 3 and 4 , however, no passage channels are necessary in the carrier substrate 4 since the piezoelectric flex transducers 5 are arranged (with the attenuation elements 2 connected with them) directly on the surface of the substrate 4 .
FIGS. 5 and 6 show an embodiment of the inventive apparatus comparable to FIGS. 3 and 4 , wherein in the attenuation elements 2 are directly fashioned as flex transducers 5 . The flex transducers 5 can either be formed directly from a material that strongly absorbs x-ray radiation, for example lead zirconate titanate (PZT), lead metaniobate (PN) or lead nickel niobate (PNN), or can be coated with a layer of such a material, for example tungsten. Otherwise the same features as described in connection with FIGS. 3 and 4 are valid for FIGS. 5 and 6 .
FIG. 7 shows an example for a flex transducer 5 that can either be used as a piezoelectric drive element 3 for a self-supporting attenuation element 2 according to FIGS. 3 and 4 , or directly as an attenuation element 2 according to FIGS. 5 and 6 . At a region of the flex transducer 5 that is piezoelectrically influenced, meaning it can be mechanically varied by the application of an electrical voltage, a tensiometer strip 6 is attached with which the curvature of this flex transducer 5 can be detected by expansion or compression of the corresponding region. The tensiometer strip 6 can either be glued on or imprinted. The tensiometer strips 6 connected to measurement electronics 20 with which the deflection of the flex transducer 5 can be quantitatively determined.
FIGS. 8A and 8B show a further example of such a flex transducer 5 . In this embodiment, a double-layer flex transducer 5 is used, known as a trimorph flex transducer. With this transducer type, curvature is effected by application of an electrical voltage (via the controller 19 ) on the first layer of the flex transducer (the actuator). The second layer 7 of the flex transducer 5 serves as a sensor that emits a signal with which the curvature is quantitatively determined by the measurement electronics 20 . FIG. 8A shows the basic embodiment of such a flex transducer 5 that, as in FIG. 7 as well, can be used either directly as an attenuation element 2 or as a piezoelectric drive element 3 for a self-supporting attenuation element 2 . FIG. 8B shows (significantly schematized) the cross-section of such a flex transducer 5 with the additionally integrated piezoelectric layer 7 for the detection of the curvature. A coating 24 of a material that strongly absorbs x-ray radiation is indicated dashed. This coating is provided in the event that the flex transducer 5 is directly used as an attenuation element 2 and is not itself formed of material strongly absorbing x-ray radiation.
Furthermore, FIG. 8A shows an embodiment in which the curvature measured by the sensor and quantitatively determined by the measurement electronics 20 used in order to deflect each attenuation element to a desired degree in the form of a control loop. For this purpose, the measurement electronics 20 are connected to the controller 19 to form a control loop.
The apparatus described in the exemplary embodiments can be advantageously produced with techniques based on stereolithography. No tools or molds are necessary since changes as well as the design of these apparatuses can be realized on the software level. The carrier substrate in this case is formed of a polymer material, namely a suitably radiation-resistant polymer in order to achieve an acceptable lifespan of the apparatus. A further advantage of the technique of stereolithography for the production of the present apparatus is that the webs of the embodiment according to FIGS. 1 and 2 can be formed such that they are reinforced only where necessary for stability. The unwanted base absorption of the apparatus as well as undesirable radiation hardening due to the plastic body are thereby kept as low as possible.
FIG. 9 shows as an example an x-ray imaging system in which the inventive apparatus is used. In this system, the control of the attenuation elements 2 of the inventive apparatus 1 ensues according to the intensity distribution in the subject (the patient 16 ) determined in the detector output signal. FIG. 9 shows the high-voltage generator 13 for the operation of the x-ray tube 14 . The patient 16 who is irradiated by the x-rays is positioned between the x-ray tube 14 and the x-ray image detector 17 . A typical radiation diaphragm 15 to limit the radiation field as well as the inventive modulation apparatus 1 are disposed on the side near the x-ray tube. The intensity distribution within the image received by the detector 17 is evaluated by detector electronics 18 . Given detection of lighter image locations, the attenuation elements are cell-selectively or channel-selectively activated by the controller 19 in order to reduce the dose in particular radiation channels. The position of the individual attenuation elements 22 within the apparatus 1 is detected and processed in real time with the measurement device 20 that is connected to the sensors 6 , 7 of the attenuation elements 2 , in order to provide the channel-dependent attenuation to a digital image post-processing 22 via a storage unit 21 . The real value of the current attenuator setting is stored as a time curve in the storage unit 21 . In this manner, the applied dose can be calculated for all pixels. The value for the exact reproduction (normalization) of the contrast values for the image representation of the x-ray image on the screen 23 can be derived from this information, the image representation being executed by digital image post-processing electronics 22 . The image signal of pixels that (as a consequence of the setting of the attenuation elements 2 ) have received less quanta compared to others for which the attenuation elements are completely open (i.e. in the neutral position) is intensified corresponding to the calculated reduction of the quantum flow, thus increased in terms of contrast. The desired homogenous image impression results in this manner. The detected real values of the positions of the attenuation elements 2 can be simultaneously supplied to the attenuator controller 19 in order to form a control loop with which the position of the attenuation elements 2 can be exactly adjusted.
Although modifications and changes may be suggested by those skilled in the art, it is the intention of the inventors to embody within the patent warranted hereon all changes and modifications as reasonably and properly come within the scope of their contribution to the art. | An apparatus for spatial modulation of an x-ray beam has a number of planar attenuation elements for x-ray radiation that are disposed in a grid on a carrier and can be pivoted or tilted by a piezoelectric actuator, independently of one another, between at least two positions. One or more sensors with which a piezoelectrically-caused length and/or width and/or position change of the piezoelectrically influenced regions can be detected, are arranged on piezoelectrically influenced regions of the attenuation elements or the actuators. A significant dose reduction and/or dynamic adjustment thereof can be achieved with the apparatus by image adaptation in many areas of x-ray imaging, since a precise determination of the position of each attenuation element in real time is enabled. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
BACKGROUND OF THE INVENTION
The present invention relates to clothes washing machines and the like and specifically to a lock assembly for preventing access to the spin basket of such a washer during the spin cycle.
During the spin cycle of a washing machine, water is removed from wet clothes centrifugally by spinning the clothes at high speed in a spin basket. In order to reduce the possibility of injury to the user, the user must be prevented from having access to the spin basket while the spin basket is in motion.
One way of protecting the user from access to the rotating spin basket uses a lid switch on the washing machine to detect an opening of the washing machine lid. When the lid is opened by more than a predetermined amount, the lid switch disconnects power from the motor driving the spin basket and activates a brake to bring the rapidly spinning spin basket to a halt. The brake, which is required because of the large rotational momentum of a loaded spin basket, adds significant expense in the manufacture of the washing machine. Systems using brakes may be impractical for future washing machines using higher speed spin cycles to remove greater amounts of water from the wet clothes.
A second way of protecting the user from access to the rotating spin basket uses an electrically actuated lock for the washing machine lid. The lock holds the lid in a closed position for the duration of the spin cycle and for a period after the spin cycle necessary for the spin basket to coast to a stop. The locking mechanism typically uses a thermally actuated element, such as a bimetallic strip or a wax motor, to position a locking bolt into engagement with the washing machine lid; the bolt prevents the lid from opening. At the conclusion of the spin cycle, the thermally actuated element begins to cool and after a predetermined cooling period, retracts the locking bolt from the washing machine lid and allows the lid to be raised.
The intrinsic delay in the thermally actuated element (required by its need to cool) prevents the lock from being defeated simply by removing power to the washing machine. Nevertheless, the fixed cooling period of the thermally actuated element can be a drawback. The cooling period must be set to accommodate the longest anticipated period of coasting of the spin basket, a time which will vary greatly depending principally on the total weight of the clothes being washed. For this reason, there is inevitably a period of time after the conclusion of the spin cycle when the user will be denied access to the clothes even though the spin basket has clearly stopped. This delay may be irritating and may lead an inexperienced user to believe that the washing machine has malfunctioned.
BRIEF SUMMARY OF THE INVENTION
The present invention provides a fast acting electromagnetic lid locking mechanism that can release the lid instantly upon stopping of the spin basket. The stopping of the spin basket is detected by a sensor monitoring spin basket motion directly or indirectly. The electromagnetic lid locking mechanism is designed to be stable in either the locked or unlocked position when power is removed and hence the lock cannot be defeated by removing power from the washing machine. The circuitry driving the electromagnetic lid locking mechanism monitors and stores electrical power to ensure that the lid may be unlocked at the conclusion of the spin cycle, even if power is lost, reducing the possibility of the lid remaining locked when power fails. The same components and circuitry may be used to provide at small additional cost, a "lock-out" of the spin cycle in situations where a child might intentionally or unintentionally enter the spin basket after the spin cycle has been initiated while the lid is open.
Specifically, the present invention provides a lid locking assembly having an electromagnetic lid locking mechanism which, when locked, holds the washing machine lid closed until an unlock signal is received. A spin sensor produces a rotation signal when the washing machine spin basket is rotating, and a logic circuit receives this rotation signal and a spin cycle signal, indicating the washing machine is in the spin cycle, and provides an unlock signal to the lid locking mechanism when the rotation signal is no longer present.
Thus, it is one object of the invention to provide a lock for the lid of a washing machine that does not need to estimate how long it will take the spin basket to stop, but that senses movement of the spin basket and unlocks immediately after the spin basket stops.
The electromagnetic lid locking mechanism may be bistable, i.e., remaining in its last state of locked or unlocked when power is removed.
Thus, it is another object of the invention to provide an electromagnetic lid locking mechanism that responds rapidly to stopping of the spin basket but that cannot be defeated by disconnecting power from the washing machine. During a power failure or after an intentional unplugging of the washing machine, the electromagnetic lid locking mechanism will not automatically release while the spin basket is in motion.
The logic circuitry driving the electromagnetic lid locking mechanism may include an energy storage device that is charged to ensure that there is sufficient power to unlock the electromagnetic lid locking mechanism in the event of failure of the power from the power line.
Thus, it is another object of the invention to reduce the possibility of the electromagnetic lid locking mechanism remaining in the locked state when power is removed from the washing machine. The energy used to lock the electromagnetic lid locking mechanism automatically charges a storage capacitor to provide power for the later unlock signal.
The logic circuitry may apply repeated unlock signals to the electromagnetic locking mechanism when the rotation signal is no longer present.
Thus, it is another object of the invention to reduce the possibility of a mechanical jamming of the bistable electromagnetic lid locking mechanism if the consumer is, for example, opening the lid at the instant the unlock signal is received.
The lid locking assembly may also include a lid switch providing a lid closed signal when the lid is closed. The logic circuitry may receive the lid closed signal and provide power to the motor only when the lid switch indicates that the lid was closed.
Thus, it is yet another object of the invention to reduce the chance of entrapment of a small child if the lid were to close on the child at a time after the spin cycle signal was generated by the machine controls. The present logic circuitry provides this additional feature with a cost effective small addition of parts.
The logic circuitry receiving the rotation signal may remove power from the motor driving the spin basket if no rotation signal is received within a predetermined period of time after the start of the spin cycle signal.
It is thus yet another object of the invention to provide an indication to the user if the spin sensor has failed by stopping the spin basket.
The foregoing and other objects and advantages of the invention will appear in the following description. The description is that of a preferred embodiment which does not necessarily represent the full scope of the invention. The scope of the invention is described by the concluding claims.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a perspective view of a top loading washing machine showing placement of the lid locking assembly of the present invention beneath the lid and a rotation sensor near the spin basket;
FIG. 2 is a simplified perspective view of the electromechanical elements of the lid locking assembly of the present invention showing a rotating locking bolt for engaging an eye on the washing machine lid, the locking bolt attached to rotate in tandem with a ward plate interacting with contacts and an electrically operated stop;
FIG. 3 is a fragmentary elevational view of the rotating locking bolt and ward plate of FIG. 2 in a first unlocked position allowing opening and closing of the washing machine lid;
FIG. 4 is a figure similar to that of FIG. 3 showing the rotating locking bolt and ward plate in a second locked position holding the washing machine lid closed;
FIG. 5 is a simplified schematic diagram of the logic circuitry used to control the washing machine of FIG. 1 and electromechanical elements of FIG. 2;
FIG. 6 is a detailed schematic diagram of the logic circuitry of FIG. 5;
FIG. 7 is a flow chart describing the operation of the logical circuitry of FIG. 5 when connected in a washing machine; and
FIG. 8 is a detail view of an alternative embodiment of an electromagnet coil shown in FIGS. 2-4 using a donut shaped permanent magnet.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, a top loading washing machine 10 includes a lid 12 hinged at a rear edge to open over a spin basket 14 into which wet clothes may be received. During a spin cycle timed by a timer 13 on a rear console of the washing machine 10, the clothes in the spin basket 14 are to be spun about a vertical axis by a drive motor assembly 16 to centrifugally extract water from the clothes.
An outer surface of the spin basket 14 supports a magnet 18 which, when the spin basket 14 rotates, passes a sensor 20 attached to the stationary housing of the washing machine 10. The sensor 20 may be a magnetic reed switch closing in response to the approach of the magnet 18 such as will occur periodically during rotation of the spin basket 14.
In an alternative embodiment, the magnet 18 and sensor 20 are attached to components of the drive motor assembly 16 that move with respect to one another as the spin basket 14 rotates but that are not affected by any eccentricity in spin basket rotation.
An eye 22 extending downward from the front edge of the lid 12, opposite the hinging edge, may be received by a latch assembly 24 when the lid 12 is in a closed position.
As will be described in detail below, the latch assembly 24 includes a locking bolt that may engage the eye 22 thereby locking the lid 12 in its closed position preventing access to the spin basket 14 by the user. The mechanism is similar to that described in U.S. Pat. No. 5,520,424 issued May 28, 1996 and entitled: "Tamper-Proof Door Switch and Latch Device" and hereby incorporated by reference.
Referring now generally to FIGS. 2 through 4, the latch assembly 24 includes a locking bolt 28 mounted to rotate generally about a horizontal axis 31 and having an upper tooth 30 that may engage the eye 22. When the lid 12 is open, the locking bolt 28 is rotated so that the tooth 30 is tipped upward to allow the eye 22 to move downward past the tooth 30 unimpeded with a closing of the lid 12 as shown in FIG. 3. When the lid 12 is closed, pressure of the eye 22 against a lower lip 27 of the locking bolt 28 rotates the locking bolt 28 to bring the tooth 30 through the eye 22. After the lid 12 is closed, the eye 22 may not be freed to open the lid 12 without counter rotation of the locking bolt 28 caused by upward pressure on the tooth 30 by the eye 22.
The locking bolt 28 is joined by means of a shaft 32 to a ward plate 34 which rotates in tandem with the locking bolt 28. In a preferred embodiment, the ward plate 34 is a 90 degree sector of a circular disk. As such, the shaft 32 is attached to the center of the disk, perpendicular to the face of the disk. In the open position shown in FIG. 3, the ward plate 34 has its left and right radial faces oriented at approximately plus and minus 45 degrees from vertical. In the closed position of FIG. 4, the right face of the ward plate 34 is vertical and the left face of the ward plate 34 is substantially horizontal.
A return spring 56 connects to the ward plate 34 at a point near the top of its left wall at a point fixed with respect to the ward plate 34 and so that the line between these points passes above the axis of rotation 31 to provide a clockwise return torque to the ward plate 34. Thus, ward plate 34 and locking bolt 28 will move to a fully open position absent the influence of the eye 22.
Positioned beneath the left face of the ward plate 34 is a contact set providing a "lid closed" switch 36 which in the open position of FIG. 3 is closed but which is opened by pressure of the left face of the ward plate 34 on the support of the bottom contact of the "lid closed" switch 36, when the lid 12 is closed. Thus, "lid closed" switch 36 provides an indication that the lid 12 is closed.
Positioned over the top of the ward plate 34 is one end of an armature 38 of an electrically actuated stop 40. The armature 38 is hinged at its other end removed from the ward plate 34, to a coil frame 42 which supports an electromagnet coil 44 positioned about a vertical core 46 positioned beneath the armature 38. Core 46 is a permanent magnet insufficiently strong to attract armature 38 downward alone, but sufficient to hold armature 38 downward once contact between armature 38 and core 46 has been obtained. Alternatively, the core 46 may be a high remnant magnetizable material that will retain sufficient magnetization to hold the armature in a closed position.
A first polarity of electrical current passing through leads 48 of the coil 44 will produce a magnetic field such as will augment the magnetic field retained by the core 46 (or reverse the magnetization of the core 46 in the case of the high remnant magnetizable material), and will thereby attract armature 38 downward toward the top of core 46. Once so attracted, the armature 38 will remain in the downward position held by the magnetism of the core 46. A second polarity of electrical current, opposite to that of the first polarity of electrical current drawing the armature 38 downward, will release the armature 38 to move upward as biased by a spring 54.
Referring now to FIG. 8 in an alternative embodiment, a donut of permanent magnet material 47 may be placed about the core 46 to provide the necessary magnetic attraction instead of or in addition to the core 46.
When the lid 12 is in the open position as shown in FIG. 3, armature 38 may not be drawn downward into contact with core 46 because the free end of the armature 38 strikes the upper circumference of the ward plate 34. In the closed position of FIG. 4, however, the ward plate 34 has rotated such that armature 38 may move downward into contact with core 46 and, in doing so, the end of armature 38 is in a position to abut the right most wall of ward plate 34 preventing counter rotation to the open position of FIG. 3. As a result of the inner connection between the ward plate 34 and the locking bolt 28, the locking bolt 28 may not rotate when armature 38 is drawn downward against core 46 and locking bolt 28 therefore holds lid 12 closed in a locked position as a result of its inner action with the eye 22. Thus, this first polarity of electrical current may be termed a lock signal and the latch assembly 24 may be considered to be in a locked state when the armature 38 is attracted to the core 46.
Referring to FIG. 4, once armature 38 has been drawn down to core 46, power may be disconnected from leads 48 and yet armature 38 will remain downward held by the residual magnetism of core 46 or the donut 47.
The latch assembly 24 may be released by moving the armature 38 upward again by means of applying to leads 48 the second polarity of current previously described which causes the coil 44 to produce a magnetic field opposing that of the core 46 or donut 47 releasing the armature 38. This second polarity of electrical current is termed the unlock signal. The latch assembly 24 may be considered to be in an unlocked state when the armature 38 is released from the core 46.
Again, when power is disconnected from leads 48, the armature 38 will remain in an upward position held by the biasing spring 54. Thus, it will be noted that the latch assembly 24 is bistable requiring no power to remain in either the unlocked or locked state and remaining in the last unlocked or locked state indefinitely when power is removed.
A contact set forming a "lock enabled" switch 50 has one contact supported at the lower surface of armature 38 by a cantilevered contact support spring 52 (visible in FIG. 2) and the other contact positioned beneath the armature 38 so that the contact set is open when the armature 38 is in an unlocked state shown in FIG. 3 and closed when the armature 38 is in a locked state shown in FIG. 4. "Lock enabled " switch 50 provides a signal indicating that a locking has occurred as opposed to simply a closure of the lid 12 and allows the motor of drive motor assembly 16 to run.
Referring now to FIGS. 5 and 6, the mechanical elements of the latch assembly 24 described in FIGS. 2 through 4 are controlled by logic circuitry 57 receiving AC power from a power line 58 (that generally provides switched power to the washer 10) and completing a circuit through a ground 60. The washing machine timer 13 (shown generally in FIG. 1) provides a spin cycle signal 62 in the form of AC voltage when the spin basket 14 is to be spun by drive motor assembly 16.
During operation of the washing machine 10, the spin cycle signal 62 is received by a terminal 64 on the housing 55 of the latch assembly 24. The terminal connects the spin cycle signal 62 through the "lock enabled" switch 50 to a second terminal connected to the motor of the drive motor assembly 16. In the unlocked state, "lock enabled" switch 50 is open and therefore no current passes to the motor of the drive motor assembly 16.
The spin cycle signal 62 also connects through diode 66 and limiting resistor 68 to a "lock signal" capacitor 70 which, when the spin cycle signal 62 is present, begins charging. The charging is indicated by arrow 73. During this charging, "lock signal" capacitor 70 stores energy that will be shunted through the coil 44 of the latch assembly 24 to lock that mechanism as has been described and also provides a timing signal by means of its decreasing voltage as it discharges. Specifically, when the charge on capacitor 70 climbs to a first predetermined level of approximately 24 volts, it actuates switching circuit 72. Switching circuit 72 is connected to shunt an "unlock signal" capacitor 74 discharging that capacitor 74 when switching circuit 72 is actuated.
The "unlock signal" capacitor 74 is connected between ground, on one side, and a junction between "lid closed " switch 36 and coil 44 on the other side. The "lid closed " switch 36 and coil 44 are connected in parallel and their other end is connected through switching element 76 to the side of the "lock signal" capacitor 70 receiving current from limiting resistor 68.
When "lock signal" capacitor 70 reaches a second voltage (approximately 36 volts) greater than the voltage triggering switching element 72, switching element 76 conducts allowing current to flow from "lock signal " capacitor 70 through coil 44 (if the lid is closed and "lid closed" switch 36 is open) into "unlock signal" capacitor 74 which was previously discharged as indicated by arrow 77. When the lid 12 is closed, this current from the "lock signal" capacitor provides the lock signal causing armature 38 (shown in FIG. 4) to be drawn downward locking the lid 12 in the locked position. The latching of armature 38 closes "lock enabled" switch 50 which allows current to flow to motor of the drive motor assembly 16.
Note that if the lid 12 is open at the time the spin signal is received, such as would indicate a child may be entrapped, then "lid closed" switch 36 is closed and the current passes solely through short circuit created by "lid closed" switch 36. In this case, the armature 38 is not drawn downward into the locking position.
As the voltage on "lock signal" capacitor 70 drops with its discharge, switching element 72 opens allowing a charge to accumulate on the "unlock signal" capacitor 74 from the flow of current along path 77. "Unlock signal" capacitor 74 provides a reserve of power that will be used to unlock the latch assembly 24 at the end of a coast down after the spin cycle or in the event of a power failure both as will be described. The transfer of power from "lock signal " capacitor 70 to "unlock signal" capacitor 74 ensures that any time sufficient power is available to lock the latch assembly 24 that reserved power exists to unlock the latch assembly 24 and the form of charge on "unlock signal " capacitor 74. While power is available to the washing machine 10, as is normally the case, the charge on "unlock signal" capacitor 74 is maintained by a path from the line 58 through diode 78 and limiting resistor 81, through coil 44 or "lid closed" switch 36.
At the conclusion of the spin cycle, the spin cycle signal 62 is disconnected and switching element 76 resets to an open state. When the spin basket has coasted to a stop, switching element 80, which is connected between the side of the parallel connection of "lid closed" switch 36 and coil 44 that receives power from the spin cycle signal 62 and ground, serves to provide a discharge path for the energy in the "unlock signal" capacitor 74 backwards through coil 44 to ground in order to produce the unlock signal to unlock the latch assembly 24. Thus energy from the lock signal may be recycled as an unlock signal later if power is lost.
Switching element 80 provides a discharge path for "unlock signal" capacitor 74 if a periodic signal of a predetermined rate (rotation signal 21) is no longer received from sensor 20. Sensor 20 provides a path from switching element 80 to ground each time the magnet on the spin basket 14 passes the sensor 20 as the spin basket spins.
The "unlock signal" capacitor 74 effectively powers the switching element 80 and its associated logic circuitry in the event of a power failure.
When switching element 80 moves to a conducting state, it oscillates between a conducting and non-conducting condition such as allows capacitor 74 to slowly recharge (if power is available) and then rapidly discharge through switching element 80 providing repetitive unlock signals through coil 44. Such repetitive signals ensure that coil 44 unlocks in the unlikely event that one or more unlocking signals are jammed, for example, by the user pulling upward on the lid 12 such as may cause the armature 38 to be trapped against the ward plate 34 as shown in FIG. 4.
Note that if the wire from sensor 20 is broken, then shortly after the spin cycle is initiated, the "unlock signal" capacitor will charge up by virtue of the locking signal and an unlock signal may be produced by switching element 80. This unlock signal will open "lock enabled " switch 50 stopping the spinning of the motor despite the presence of the spin cycle signal 62. This stopping of the motor of the drive motor assembly 16 provides an indication to the user that a repair is required and avoids needless exposure of the user to the rotating spin basket 14 when the circuit cannot maintain a lock state for lack of information about whether the spin basket 14 is in motion.
Referring now to FIG. 7, the circuit of FIGS. 5 and 6 initially detects the initiation of a new spin cycle signal at decision block 100. A new spin cycle in this case indicates a transition from no spin cycle to a spin cycle signal.
If there is no new spin cycle signal during a washing cycle, the circuit proceeds to decision block 102 to determine whether the spin basket 14 is rotating as detected by sensor 20. If not, as would also be the case, for example, in a wash cycle, the circuit proceeds to process block 104 and an unlock signal in the form of a pulse is transmitted to the coil 44 of the electrically actuated stop 40 and the circuit returns back to the decision block 100. Thus, in situations where a lid lock is not required, that is, there is no spin cycle and the spin basket 14 is not rotating as might be the case in a recently concluded spill cycle, the electrically actuated stop 40 receives repeated unlocked pulses to ensure that the latch assembly 24 is unlocked.
Upon an initiation of a spin cycle signal at decision block 100, the circuit moves to decision block 106 where it is determined whether the lid 12 is closed (by means of "lid closed" switch 36). If the lid 12 is closed, the circuit proceeds to process block 108 and the lid 12 is locked by actuation of coil 44 of electrically actuated stop 40 which in turn closes "lock enabled" switch 50 allowing the motor to start. The circuit then proceeds to decision block 102 as has been described to test for rotation of the motor.
Normally at decision block 102, there will be rotation detected because the motor of the drive motor assembly 16 was started at process block 108 and the sensor 20 is properly connected and therefore the circuit loops back to the top of decision block 102 and continues to cycle through decision block 102 for as long as the spin basket 14 is rotating.
When the spin cycle ends, the motor of the drive motor assembly 16 no longer receives power and the spin basket 14 begins to coast. When rotation is no longer detected by sensor 20, the circuit breaks out of the loop of decision block 102 and proceeds to process block 104 where the latch assembly 24 is unlocked. The circuit then begins the cycling between decision block 100, decision block 102, and process block 104 as has been previously described, providing repeated unlock signals.
During spinning of the spin basket 14 when the circuit is checking rotation of the spin basket at decision block 102, power may be removed from the washing machine 10 in a power failure or an attempt to defeat the lid lock. Normally the spin basket 14 will coast down prior to enough energy being lost from capacitor 74 that a lid unlocking is no longer possible.
The basic circuitry used to provide a fast release lid lock when rotation of the spin basket ceases may also help prevent entrapment of a small child if the lid is closed while the spin cycle is activated. Referring still to FIG. 7, in this circumstance, at process block 100, a spin cycle signal is detected and the circuit proceeds to decision block 106. At decision block 106, the lid 12 is not closed and therefore the circuit proceeds to decision block 112 which again checks for the presence of a spin cycle signal 62. If that spin cycle signal 62 is still present, the circuit loops back to this decision block 112 indefinitely, thus avoiding a locking and starting of the motor of the drive motor assembly 16. Only when the spin cycle signal 62 is turned off and on again by the user with the lid closed, does the circuit proceed to decision block 102 to check for a rotation signal 21 per a normal end of a spin cycle, ultimately ending up again at decision block 100.
Thus, in order for the motor of the drive motor assembly 16 to be started for the spin cycle, the lid 12 must be closed prior to the initiation of the spin cycle signal 62 avoiding the entrapment situation.
The above description has been that of a preferred embodiment of the invention. It will occur to those that practice the art that many modifications may be made without departing from the spirit and scope of the invention. In order to apprise the public of the various embodiments that may fall within the scope of the invention, the following claims are made: | A lid lock for a washing machine or the like employs a rapid bistable electromagnetic actuator that can be released immediately upon detecting a ceasing of rotation of the spin basket. The actuator is bistable to operate despite possible power failure during which the spin basket may still be coasting, and is driven by circuitry that stores reserved power to unlock the lid in a power failure situation. These same components can provide protection against entrapment in which the lid closure activates the spin cycle and lock because of a previous initiation of the spin cycle signal. Here, for the spin cycle to be initiated, the spin cycle signal must occur after lid closure. | 8 |
FIELD OF THE INVENTION AND RELATED ART
[0001] The present invention relates to an organic luminescence device (also called an organic electroluminescence device or organic EL device) for use in a planar light source, a planar display, etc. Particularly, the present invention relates to a novel metal coordination compound and a luminescence device having a high luminescence efficiency and causing little change with time by using a metal coordination compound represented by formula (1) appearing hereinafter.
[0002] An old example of organic luminescence device is, e.g., one using luminescence of a vacuum-deposited anthracene film (Thin Solid Films, 94 (1982) 171). In recent years, however, in view of advantages, such as easiness of providing a large-area device compared with an inorganic luminescence device, and possibility of realizing desired luminescence colors by development of various new materials and drivability at low voltages, an extensive study thereon for device formation as a luminescence device of a high-speed responsiveness and a high efficiency, has been conducted.
[0003] As precisely described in Macromol. Symp. 125, 1-48 (1997), for example, an organic EL device generally has an organization comprising a pair of upper and lower electrodes formed on a transparent substrate, and organic material layers including a luminescence layer disposed between the electrodes.
[0004] In the luminescence layer, aluminum quinolinol complexes (inclusive of Alq3 shown hereinafter as a representative example) having an electron-transporting characteristic and a luminescence characteristic, are used for example. In a hole-transporting layer, a material having an electron-donative property, such as a triphenyldiamine derivative (inclusive of α-NPD shown hereinafter as a representative example), is used for example.
[0005] Such a device shows a current-rectifying characteristic such that when an electric field is applied between the electrodes, holes are injected from the anode and electrons are injected from the cathode.
[0006] The injected holes and electrons are recombined in the luminescence layer to form excitons, which emit luminescence when they are transitioned to the ground state.
[0007] In this process, the excited states include a singlet state and a triplet state and a transition from the former to the ground state is called fluorescence and a transition from the latter is called phosphorescence. Materials in theses states are called singlet excitons and triplet excitons, respectively.
[0008] In most of the organic luminescence devices studied heretofore, fluorescence caused by the transition of a singlet exciton to the ground state, has been utilized. On the other hand, in recent years, devices utilizing phosphorescence via triplet excitons have been studied.
[0009] Representative published literature may include:
Article 1: Improved energy transfer in electrophosphorescent device (D. F. O'Brien, et al., Applied Physics Letters, Vol. 74, No. 3, p. 422 (1999)); and Article 2: Very high-efficiency green organic light-emitting devices based on electrophosphorescence (M. A. Baldo, et al., Applied Physics Letters, Vol. 75, No. 1, p. 4 (1999)).
[0012] In these articles, a structure including four organic layers sandwiched between the electrodes, and the materials used therein include carrier-transporting materials and phosphorescent materials, of which the names and structures are shown below together with their abbreviations.
Alq3: aluminum quinolinol complex α-NPD: N4,N4′-di-naphthalene-1-yl-N4,N4′-diphenyl-biphenyl-4,4′-diamine CBP: 4,4′-N,N′-dicarbazole-biphenyl BCP: 2,9-dimethyl-4,7-diphenyl-1, 10-phenanthroline PtOEP: platinum-octaethylporphyrin complex Ir(ppy) 3 : iridium-phenylpyrimidine complex
[0019] The above-mentioned Articles 1 and 2 both have reported structures, as exhibiting a high efficiency, including a hole-transporting layer comprising α-NPD, an electron-transporting layer comprising Alq3, an exciton diffusion-preventing layer comprising BCP, and a luminescence layer comprising CBP as a host and ca. 6% of PtOEP or Ir(ppy) 3 as a phosphorescent material dispersed in mixture therein.
[0020] Such a phosphorescent material is particularly noted at present because it is expected to provide a high luminescence efficiency in principle for the following reasons. More specifically, excitons formed by carrier recombination comprise singlet excitons and triplet excitons in a probability ratio of 1:3. Conventional organic EL devices have utilized fluorescence of which the luminescence efficiency is limited to at most 25%. On the other hand, if phosphorescence generated from triplet excitons is utilized, an efficiency of at least three times is expected, and even an efficiency of 100%, i.e., four times, can be expected in principle, if a transition owing to intersystem crossing from a singlet state having a higher energy to a triplet state is taken into account.
[0021] However, like a fluorescent-type device, such an organic luminescence device utilizing phosphorescence is generally required to be further improved regarding the deterioration of luminescence efficiency and device stability.
[0022] The reason of the deterioration has not been fully clarified, but the present inventors consider as follows based on the mechanism of phosphorescence.
[0023] In the case where the luminescence layer comprises a host material having a carrier-transporting function and a phosphorescent guest material, a process of phosphorescence via triplet excitons may include unit processes as follows:
1. transportation of electrons and holes within a luminescence layer, 2. formation of host excitons, 3. excitation energy transfer between host molecules, 4. excitation energy transfer from the host to the guest, 5. formation of guest triplet excitons, and 6. transition of the guest triplet excitons to the ground state and phosphorescence.
[0030] Desirable energy transfer in each unit process and luminescence are caused in competition with various energy deactivation processes.
[0031] Needless to say, a luminescence efficiency of an organic luminescence device is increased by increasing the luminescence quantum yield of a luminescence center material.
[0032] Particularly, in a phosphorescent material, this may be attributable to a life of the triplet excitons which is longer by three or more digits than the life of a singlet exciton. More specifically, because it is held in a high-energy excited state for a longer period, it is liable to react with surrounding materials and cause polymer formation among the excitons, thus incurring a higher probability of deactivation process resulting in a material change or life deterioration.
[0033] A luminescence device is desired to exhibit high efficiency luminescence and show a high stability. Particularly, it is strongly desired to provide a luminescence material compound which is less liable to cause energy deactivation in a long life of excited energy state and is also chemically stable, thus providing a longer device life.
SUMMARY OF THE INVENTION
[0034] Accordingly, principal objects of the present invention are to provide a luminescence material which exhibits a high luminescence efficiency and retains a high luminance for a long period, and also provide a luminescence device and a display apparatus using the same.
[0035] In the present invention, a metal complex is used as a luminescence material, particularly a novel luminescent metal complex compound comprising iridium as a center metal and a benzofuran structure of formula (5) appearing hereinafter as a part of a ligand or as a substituent of a ligand.
[0036] More specifically, the present invention provides as a luminescence material a metal coordination compound represented by formula (1) below:
ML m L′ n (1),
wherein M is a metal atom of Ir, Pt, Rh or Pd; L and L′ are mutually different bidentate ligands; m is 1, 2 or 3 and n is 0, 1 or 2 with the proviso that m+n is 2 or 3; a partial structure MLm is represented by formula (2) shown below and a partial structure ML n is represented by formula (3) or (4) shown below:
wherein CyN1 and CyN2 are each cyclic group capable of having a substituent, including a nitrogen atom and bonded to the metal atom M via the nitrogen atom; CyC1 and CyC2 are each cyclic group capable of having a substituent, including a carbon atom and bonded to the metal atom M via the carbon atom with the proviso that the cyclic group CyN1 and the cyclic group CyC1 are bonded to each other via a covalent bond and the cyclic group CyN2 and the cyclic group CyC2 are bonded to each other via a covalent bond;
[0039] the optional substituent of the cyclic groups is selected from a halogen atom, cyano group, a nitro group, a trialkylsilyl group of which the alkyl groups are independently a linear or branched alkyl group having 1 to 8 carbon atoms, a linear or branched alkyl group having 1 to 20 carbon atoms of which the alkyl group can include one or non-neighboring two or more methylene groups that can be replaced with —O—, —S—, —CO—, —CO—O—, —O—CO—, —CH═CH— or —C≡C—, and the alkyl group can include a hydrogen atom that can be optionally replaced with a fluorine atom, or an aromatic group capable of having a substituent (that is a halogen atom, a cyano atom, a nitro atom, a linear or branched alkyl group having 1 to 20 carbon atoms of which the alkyl group can include one or non-neighboring two or more methylene groups that can be replaced with —O—, —S—, —CO—, —CO—O—, —O—CO—, —CH═CH— or —C≡C—, and the alkyl group can include a hydrogen atom that can be optionally replaced with a fluorine atom);
[0040] E and G are independently a linear or branched alkyl group having 1 to 20 carbon atoms of which the alkyl group can include a hydrogen atom that can be optionally replaced with a fluorine atom, or an aromatic group capable of having a substituent (that is a halogen atom, a cyano atom, a nitro atom, a trialkylsilyl group of which the alkyl groups are independently a linear or branched alkyl group having 1-8 carbon atoms, a linear or branched alkyl group having 1 to 20 carbon atoms of which the alkyl group can include one or non-neighboring two or more methylene groups that can be replaced with —O—, —S—, —CO—, —CO—O—, —O—CO—, —CH═CH— or —C≡C—, and the alkyl group can include a hydrogen atom that can be optionally replaced with a fluorine atom; and
[0041] at least one of the optional substituent(s) of the cyclic groups, and the cyclic groups CyC1 and CyC2 includes a benzofuran structure capable of having a substituent represented by the following formula (5):
wherein the benzofuran structure of the formula (5) is bonded to CyN1, CyN2, CyC1 or CyC2 via a single bond at any one of 2- to 7-positions when the benzofuran structure is the optional substituent(s) of the cyclic groups, and the benzofuran structure of the formula (5) is bonded to CyN1 or CyN2 via a single bond at any one of 2- to 7-positions and bonded to the metal atom M via a single bond at any one of 2- to 7-positions when the benzofuran structure is CyC1 or CyC2;
[0043] the optional substituent of the benzofuran structure of the formula (5) is selected from a halogen atom, cyano group, a nitro group, a trialkylsilyl group of which the alkyl groups are independently a linear or branched alkyl group having 1 to 8 carbon atoms, a linear or branched alkyl group having 1 to 20 carbon atoms of which the alkyl group can include one or non-neighboring two or more methylene groups that can be replaced with —O—, —S—, —CO—, —CO—O—, —O—CO—, —CH═CH— or —C≡C—, and the alkyl group can include a hydrogen atom that can be optionally replaced with a fluorine atom, or an aromatic group capable of having a substituent (that is a halogen atom, a cyano atom, a nitro atom, a linear or branched alkyl group having 1 to 20 carbon atoms of which the alkyl group can include one or non-neighboring two or more methylene groups that can be replaced with —O—, —S—, —CO—, —CO—O—, —O—CO—, —CH═CH— or —C≡C—, and the alkyl group can include a hydrogen atom that can be optionally replaced with a fluorine atom) with the proviso that an adjacent pair of substituents located at 4- to 7-positions of the benzofuran structure of the formula (5) can be bonded to form a cyclic structure.
[0044] Preferred embodiments of the metal coordination compound of the formula (1) according to the present invention include the following:
[0045] A metal coordination compound, wherein n is 0 in the formula (1).
[0046] A metal coordination compound having a partial structure ML′ n represented by the formula (3) in the formula (1).
[0047] A metal coordination compound having a partial structure ML′ n represented by the formula (4) in the formula (1).
[0048] A metal coordination compound wherein the cyclic groups CyC1 in the formula (1) and CyC2 in the formula (3) are independently selected from phenyl group, thienyl group, thianaphthyl group, naphthyl group, pyrenyl group, 9-fluorenonyl group, fluorenyl group, dibenzofuranyl group, dibenzothienyl group, carbazolyl group, or benzofuranyl group, as an aromatic cyclic group capable of having a substituent with the proviso that the aromatic cyclic group can include one or two CH groups that can be replaced with a nitrogen atom, particularly selected from phenyl group or benzofuranyl group.
[0049] A metal coordination compound, wherein the cyclic groups CyN1 in the formula (2) and CyN2 in the formula (3) are independently selected from pyridyl group, pyridazinyl group, and pyrimidinyl group, particularly pyridyl group, as an aromatic cyclic group capable of having a substituent.
[0050] A metal coordination compound, wherein the cyclic groups CyN1, CyN2, CyC1 and CyC2 are independently non-substituted, or have a substituent selected from a halogen atom and a linear or branched alkyl group having 1 to 20 carbon atoms {of which the alkyl group can include one or non-neighboring two or more methylene groups that can be replaced with —O—, —S—, —CO—, —CH═CH—, —C≡C—, or a divalent aromatic group capable of having a substituent (that is a halogen atom or a linear or branched alkyl group having 1 to 20 carbon atoms (of which the alkyl group can include one or non-neighboring two or more methylene groups that can be replaced with —O—, and the alkyl group can include a hydrogen atom that can be optionally replaced with a fluorine atom)), and the alkyl group can include a hydrogen atom that can be optionally replaced with a fluorine atom}.
[0051] A metal coordination compound, wherein M in the formula (1) is iridium.
[0052] A metal coordination compound represented by the following formula (6) or (7), particularly the formula (7):
wherein R 1 , R 2 , R 3 , R′ 3 and R 4 are independently
[0054] a hydrogen atom; a fluorine atom; a linear or branched alkyl group of formula: C n H 2n+1 — in which n is an integer of 1-20, the alkyl group can include one or non-neighboring two or more methylene groups that can be replaced with —O— and also can include a hydrogen atom that can be optionally replaced with a fluorine atom; a phenyl group capable of having a substituent; or a benzofuranyl group capable of having a substituent; the optional substituent of phenyl group and benzofuranyl group is a fluorine atom or a linear or branched alkyl group of formula: C n H 2n+1 — in which n is an integer of 1-20, the alkyl group can include one or non-neighboring two or more methylene groups that can be replaced with —O— and also can include a hydrogen atom that can be optionally replaced with a fluorine atom.
[0055] The present invention also provides an electroluminescence device, comprising: a pair of electrodes disposed on a substrate, and a luminescence unit comprising at least one organic compound disposed between the electrodes, wherein the organic compound comprises a metal coordination compound represented by the formula (1) described above.
[0056] In the luminescence device, a voltage is applied between the electrodes to emit phosphorescence.
[0057] The present invention further provides a picture display apparatus, comprising an electroluminescence device described above and a means for supplying electric signals to the electroluminescence device.
[0058] These and other objects, features and advantages of the present invention will become more apparent upon a consideration of the following description of the preferred embodiments of the present invention taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0059] FIGS. 1A, 1B and 1 C illustrate embodiments of the luminescence device according to the present invention, respectively.
[0060] FIG. 2 schematically illustrates a panel structure including an EL device and drive means.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0061] Basic structures of organic luminescence (EL) devices formed according to the present invention are illustrated in FIGS. 1A, 1B and 1 C.
[0062] As shown in these figures, an organic luminescence device generally comprises, on a transparent substrate 15 , a 50 to 200 nm-thick transparent electrode 14 , a plurality of organic film layers and a metal electrode 11 formed so as to cover the organic layers.
[0063] FIG. 1A shows an embodiment wherein the organic luminescence device comprises a luminescence layer 12 and a hole-transporting layer 13 . The transparent electrode 14 may comprise ITO, etc., having a large work function so as to facilitate hole injection from the transparent electrode 14 to the hole-transporting layer 13 . The metal electrode 11 comprises a metal material having a small work function, such as aluminum, magnesium or alloys of these elements, so as to facilitate electron injection into the organic luminescence device.
[0064] The luminescence layer 12 comprises a compound (metal coordination compound) according to the present invention. The hole-transporting layer 13 may comprise, e.g., a triphenyldiamine derivative, as represented by α-NPD mentioned above, and also a material having an electron-donative property as desired.
[0065] A device organized above exhibits a current-rectifying characteristic, and when an electric field is applied between the metal electrode 11 as a cathode and the transparent electrode 14 as an anode, electrons are injected from the metal electrode 11 into the luminescence layer 12 , and holes are injected from the transparent electrode 15 . The injected holes and electrons are recombined in the luminescence layer 12 to form excitons having high energy potential, which cause luminescence during transition to the ground state. In this instance, the hole-transporting layer 13 functions as an electron-blocking layer to increase the recombination efficiency at the boundary between the luminescence layer layer 12 and the hole-transporting layer 13 , thereby providing an enhanced luminescence efficiency.
[0066] Further, in the structure of FIG. 1B , an electron-transporting layer 16 is disposed between the metal electrode 11 and the luminescence layer 12 in FIG. 1A . As a result, the luminescence function is separated from the functions of electron transportation and hole transportation to provide a structure exhibiting more effective carrier blocking, thus increasing the luminescence efficiency. The electron-transporting layer 16 , may comprise, e.g., an oxadiazole derivative.
[0067] FIG. 1C shows another desirable form of a four-layer structure, including a hole-transporting layer 13 , a luminescence layer 12 , an exciton diffusion prevention layer 17 and an electron-transporting layer 16 , successively from the side of the transparent electrode 14 as the anode.
[0068] The luminescence materials used in the present invention are most suitably metal coordination compounds represented by the above-mentioned formulae (1) to (5), which are found to cause high-efficiency luminescence, retain high luminance for a long period and show little deterioration by current passage.
[0069] The metal coordination compound of the present invention emits phosphorescence, and its lowest excited state is believed to be an MLCT* (metal-to-ligand charge transfer) excited state or π-π* excited state in a triplet state, and phosphorescence is caused at the time of transition from such a state to the ground state.
[0070] Hereinbelow, methods for measurement of some properties and physical values described herein for characterizing the luminescence material of the present invention will be described.
[0071] (1) Judgment Between Phosphorescence and Fluorescence
[0072] The identification of phosphorescence was effected depending on whether deactivation with oxygen was caused or not. A solution of a sample compound in chloroform after aeration with oxygen or with nitrogen is subjected to photoillumination to cause photo-luminescence. The luminescence is judged to be phosphorescence if almost no luminescence attributable to the compound is observed with respect to the solution aerated with oxygen but photo-luminescence is confirmed with respect to the solution aerated with nitrogen. The phosphorescence of all the compounds of the present invention has been confirmed by this method unless otherwise noted specifically.
[0073] (2) Phosphorescence yield (a relative quantum yield, i.e., a ratio of an objective sample's quantum yield (sample) to a standard sample's quantum yield (st)) is determined according to the following formula:
(sample)/ (st)=[Sem(sample)/ I abs(sample)]/[Sem(st)/ I abs(st)],
wherein Iabs(st) denotes an absorption coefficient at an excitation wavelength of the standard sample; Sem(st), a luminescence spectral areal intensity when excited at the same wavelength; Iabs(sample), an absorption coefficient at an excitation wavelength of an objective compound; and Sem(sample), a luminescence spectral areal intensity when excited at the same wavelength.
[0075] Phosphorescence yield values described herein are relative values with respect to a phosphorescence yield =1 of Ir(ppy) 3 as a standard sample.
[0076] (3) A Method of Measurement of Phosphorescence Life is as Follows.
[0077] A sample compound is dissolved in chloroform and spin-coated onto a quartz substrate in a thickness of ca. 0.1 μm and is exposed to pulsative nitrogen laser light at an excitation wavelength of 337 nm at room temperature by using a luminescence life meter (made by Hamamatsu Photonics K.K.). After completion of the excitation pulses, the decay characteristic of luminescence intensity is measured.
[0078] When an initial luminescence intensity is denoted by I 0 , a luminescence intensity after t(sec) is expressed according to the following formula with reference to a luminescence life z(sec):
I=I 0 ·exp(− t /τ).
[0079] The luminescence material (metal coordination compound) of the present invention exhibited high phosphorescence quantum yields of 0.11 to 0.9 and short phosphorescence lives of 0.1 to 40 μsec. A short phosphorescence life becomes a condition for causing little energy deactivation and exhibiting an enhanced luminescence efficiency. More specifically if the phosphorescence life is long, the number of triplet state molecules maintained for luminescence is increased, and the deactivation process is liable to occur, thus resulting in a lower luminescence efficiency particularly at the time of a high-current density. The material of the present invention has a relatively short phosphorescence life thus exhibiting a high phosphorescence quantum yield, and is therefore suitable as a luminescence material for an EL device.
[0080] As a result of various studies of ours, it has been found that an organic EL device using the metal coordination compound of the formula (1) as a principal luminescence material causes high-efficiency luminescence, retains high luminance for a long period and shows little deterioration by current passage.
[0081] In the formula (1) representing the metal coordination compound of the present invention, n may preferably 0 or 1, more preferably 0. Further, the partial structure ML'n may preferably comprise the benzofuran structure represented by the above-mentioned formula (5).
[0082] In the present invention, by incorporating the benzofuran structure of the formula (5) into the metal coordination compound of the formula (1), it becomes possible to control an emission wave-length (particularly to provide a long emission wavelength). The presence of the benzofuran structure of the formula (5) is effective in enhancing a solubility of the metal coordination compound of the present invention in an organic solvent, thus facilitating a purification thereof by recrystallization or column chromatography. As a result, the metal coordination compound of the present invention is suitable as a luminescence material for the organic EL device.
[0083] Further, as shown in Examples appearing hereinafter, it has been substantiated that the metal coordination compound of the present invention exhibited an excellent stability in a continuous current passage test. This may be attributable to incorporation of the benzofuran structure of the formula (5) into the molecular structure of the metal coordination compound of the formula (1) according to the present invention. More specifically, a change in intermolecular interaction due to the introduction of the benzofuran structure of the formula (5) allows an intermolecular interact-ion of the metal coordination compound with, e.g., a host material to suppress formation of exciton associates-causing thermal deactivation, thus reducing a quenching process thereby to improve phosphorescence yield and device characteristics.
[0084] In the case where CyN1 (or CyN2) is benzofranyl group and CyC1 (or CyC2) is pyridyl or pyrimidinyl group in the metal coordination compound of formula (1) of the present invention, pyridyl or pyrimidinyl group (CyC1 or CyC2) may preferably have a substituent other than methyl group, methoxy group, butyl group and fluorine atom when benzofuran group (CyN1 or CyN2) is not substituted. In another preferred embodiment in the above case, benzofuran group (CyN1 or CyN2) has a substituent, particularly trifluoromethyl group or an aromatic group. In still another preferred embodiment in the above case, the metal coordination compound has a substituent such as trifluoromethyl group, an aromatic group or a cyclized group (e.g., —(CH═CH) 2 —).
[0085] The luminescence device according to the present invention may preferably be an electroluminescence device of the type wherein a layer of the metal coordination compound of the formula (1) is disposed between opposing two electrodes and a voltage is applied between the electrodes to cause luminescence, particularly phosphorescence, as shown in FIGS. 1A, 1B and 1 C.
[0086] The luminescence device according to the present invention may be applicable to devices required to allow energy saving and high luminance, such as those for display apparatus and illumination apparatus, a light source for printers, and backlight (unit) for a liquid crystal display apparatus. Specifically, in the case of using the luminescence device of the present invention in the display apparatus, it is possible to provide a flat panel display apparatus capable of exhibiting an excellent energy saving performance, a high visibility and a good lightweight property.
[0087] For the application to a display, a drive system using a thin-film transistor (TFT) drive circuit according to an active matrix-scheme may be used. Hereinbelow, an embodiment of using a device of the present invention in combination with an active matrix substrate is briefly described with reference to FIG. 2 .
[0088] FIG. 2 illustrates an embodiment of panel structure comprising an EL device and drive means. The panel is provided with a scanning signal driver, a data signal driver and a current supply source which are connected to gate selection lines, data signal lines and current supply lines, respectively. At each intersection of the gate selection lines and the data signal lines, a display pixel electrode is disposed. The scanning signal drive sequentially selects the gate selection lines G 1 , G 2 , G 3 . . . Gn, and in synchronism herewith, picture signals are supplied from the data signal driver to display a picture (image).
[0089] By driving a display panel including a luminescence layer comprising a luminescence material of the present invention, it becomes possible to provide a display which exhibits a good picture quality and is stable even for a long period display.
[0090] Some synthetic paths for providing a metal coordination compound represented by the above-mentioned formula (1) are illustrated below with reference to an iridium coordination compound (m+n=3) for example:
[0091] Other metal coordination compound (M=Pt, Rh and Pd) can also be synthesized in a similar manner.
[0092] Some specific structural examples of metal coordination compounds used in the present invention are shown in Tables 1 to Tables 17 appearing hereinafter, which are however only representative examples and are not exhaustive. Pi to Bf6 for CyN1, CyN2, CyC1 and CyC2 shown in Tables 1 to 17 represent partial structures shown below.
[0093] Further, aromatic group Ph2 to Bf8 as substituents for CyN1, CyN2, CyC1 and CyC2 shown in Tables 1 to 17 represent partial structures shown below.
TABLE 1 CyN1 R5 R6 R7 R8 CyN1-R1 CyN1-R2 CyC1 No M m n CyN1 CyC1 CyC1-R3 CyC1-R4 CyC1-R′3 CyC1-R′4 R5 R6 R7 R8 1 Ir 3 0 Pi Bf1 H H — — — — H H H H — — — — 2 Ir 3 0 Pi Bf1 CF 3 H — — — — H H H H — — — — 3 Ir 3 0 Pi Bf1 CF 3 CF 3 — — — — H H H H — — — — 4 Ir 3 0 Pi Bf1 H CF 3 — — — — H H H H — — — — 5 Ir 3 0 Pi Bf1 H NO 2 — — — — H H H H — — — — 6 Ir 3 0 Pi Bf1 H Cl — — — — H H H H — — — — 7 Ir 3 0 Pi Bf1 H F F — — — — H H H H — — — — 8 Ir 3 0 Pi Bf1 H CN — — — — H H H H — — — — 9 Ir 3 0 Pi Bf1 H OCH 3 — — — — H H H H — — — — 10 Ir 3 0 Pi Bf1 H Ph2 H H H H H H H H — — — — 11 Ir 3 0 Pi Bf1 H Ph2 CF 3 H H H H H H H — — — — 12 Ir 3 0 Pi Bf1 H Ph2 H H F F H H H H — — — — 13 Ir 3 0 Pi Bf1 Ph2 H H H H H H H H H — — — — 14 Ir 3 0 Pi Bf1 H Np4 H — — — H H H H — — — — 15 Ir 3 0 Pi Bf1 Tn7 H H H — — H H H H — — — — 16 Ir 3 0 Pi Bf1 H C 4 H 9 — — — — H H H H — — — — 17 Ir 3 0 Pi Bf1 H H — — — — H H OCH 3 H — — — — 18 Ir 3 0 Pi Bf1 H H — — — — H H Cl H — — — — 19 Ir 3 0 Pi Bf1 H H — — — — H H F H — — — — 20 Ir 3 0 Pi Bf1 H H — — — — H H C 8 H 17 H — — — — 21 Ir 3 0 Pi Bf1 H H — — — — H H NO 2 H — — — — 22 Ir 3 0 Pi Bf1 H H — — — — H H Ph2 H H H H H 23 Ir 3 0 Pi Bf1 H H — — — — H H Ph2 H H Si(C 3 H 7 ) 3 H H 24 Ir 3 0 Pi Bf1 Ph2 H H H H H H H Ph2 H H H H H 25 Ir 3 0 Pi Bf1 H H — — — — H H Br H — — — — 26 Ir 3 0 Pi Bf1 H H — — — — H H Bf7 H H H H H 27 Ir 3 0 Pi Bf1 H H — — — — H OC 4 H 9 H H — — — — 28 Ir 3 0 Pi Bf1 H Ph2 H OCH 2 C 5 F 11 H H H H H H — — — — 29 Ir 3 0 Pi Bf1 H H — — — — H Br H H — — — — 30 Ir 3 0 Pi Bf1 H H — — — — H Si(C 8 H1 7 ) 3 H H — — — — 31 Ir 3 0 Pi Bf2 H H — — — — H H H H — — — —
[0094]
TABLE 2
CyN1
R5
R6
R7
R8
CyN1-R1
CyN1-R2
CyC1
No
M
m
n
CyN1
CyC1
CyC1-R3
CyC1-R4
CyC1-R′3
CyC1-R′4
R5
R6
R7
R8
32
Ir
3
0
Pi
Bf2
CF 3
H
—
—
—
—
H
H
H
H
—
—
—
—
33
Ir
3
0
Pi
Bf2
CF 3
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
34
Ir
3
0
Pi
Bf2
H
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
35
Ir
3
0
Pi
Bf2
Ph2
H
H
H
H
H
H
H
H
H
—
—
—
—
36
Ir
3
0
Pi
Bf2
H
Np4
H
—
—
—
H
H
H
H
—
—
—
—
37
Ir
3
0
Pi
Bf2
Tn7
H
H
H
—
—
H
H
H
H
—
—
—
—
38
Ir
3
0
Pi
Bf2
H
C 4 H 9
—
—
—
—
H
H
H
H
—
—
—
—
39
Ir
3
0
Pi
Bf2
H
H
—
—
—
—
H
H
OCH 3
H
—
—
—
—
40
Ir
3
0
Pi
Bf2
H
H
—
—
—
—
H
H
Ph2
H
H
Si(C 3 H 7 ) 3
H
H
41
Ir
3
0
Pi
Bf2
Ph2
H
H
H
H
H
H
H
Ph2
H
H
H
H
H
42
Ir
3
0
Pi
Bf2
H
Np3
H
H
—
—
H
H
H
H
—
—
—
—
43
Ir
3
0
Pi
Bf2
H
Np4
H
—
—
—
H
H
H
H
—
—
—
—
44
Ir
3
0
Pi
Bf2
H
Pe2
H
—
—
—
H
H
H
H
—
—
—
—
45
Ir
3
0
Pi
Bf2
H
Qn2
H
H
—
—
H
H
H
H
—
—
—
—
46
Ir
3
0
Pi
Bf2
H
An
H
—
—
—
H
H
H
H
—
—
—
—
47
Ir
3
0
Pi
Bf2
H
Bf7
H
H
H
H
H
H
H
H
—
—
—
—
48
Ir
3
0
Pi
Bf2
Tn5
H
H
H
—
—
H
H
H
H
—
—
—
—
49
Ir
3
0
Pi
Bf2
H
Bf8
H
H
H
H
H
H
H
H
—
—
—
—
50
Ir
3
0
Pi
Bf2
H
Tn6
H
H
—
—
H
H
H
H
—
—
—
—
51
Ir
3
0
Pi
Bf3
H
H
—
—
—
—
Ph2
H
H
H
H
OCH 3
H
H
52
Ir
3
0
Pi
Bf3
H
CF 3
—
—
—
—
Ph2
H
H
H
H
C 6 H 13
H
H
53
Ir
3
0
Pi
Bf3
H
CF 3
—
—
—
—
Np3
H
H
H
H
H
—
—
54
Ir
3
0
Pi
Bf3
H
H
—
—
—
—
H
H
H
H
—
—
—
—
55
Ir
3
0
Pi
Bf3
CF 3
H
—
—
—
—
C 2 H 5
H
H
H
—
—
—
—
56
Ir
3
0
Pi
Bf3
CF 3
CF 3
—
—
—
—
C 10 H 21
H
H
H
—
—
—
—
57
Ir
3
0
Pi
Bf3
H
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
58
Ir
3
0
Pi
Bf3
H
H
—
—
—
—
Tn5
H
H
H
H
H
—
—
59
Ir
3
0
Pi
Bf3
H
H
—
—
—
—
Np3
H
H
H
H
H
—
—
60
Ir
3
0
Pi
Bf3
H
H
—
—
—
—
Np4
H
H
H
H
—
—
—
61
Ir
3
0
Pi
Bf4
H
CF 3
—
—
—
—
Ph2
H
H
H
H
C 5 H 13
H
H
[0095]
TABLE 3
CyN1
R5
R6
R7
R8
CyN1-R1
CyN1-R2
CyC1
No
M
m
n
CyN1
CyC1
CyC1-R3
CyC1-R4
CyC1-R′3
CyC1-R′4
R5
R6
R7
R8
62
Ir
3
0
Pi
Bf4
H
H
—
—
—
—
C 8 H 17
H
H
H
—
—
—
—
63
Ir
3
0
Pi
Bf4
H
H
—
—
—
—
Ph2
H
H
H
H
H
H
H
64
Ir
3
0
Pi
Bf4
Np4
H
H
—
—
—
Ph2
H
H
H
H
H
H
H
65
Ir
3
0
Pi
Bf4
FL4
H
H
H
H
—
Ph2
H
H
H
H
H
H
H
66
Ir
3
0
Pi
Bf4
CF 3
CF 3
—
—
—
—
C 15 H 31
H
H
H
—
—
—
—
67
Ir
3
0
Pi
Bf4
H
H
—
—
—
—
DBT2
H
H
H
H
H
H
—
68
Ir
3
0
Pi
Bf4
H
Bf7
H
H
H
H
Ph2
H
H
H
H
H
H
H
69
Ir
3
0
Pi
Bf4
H
Bf8
H
H
H
H
Ph2
H
H
H
H
H
H
H
70
Ir
3
0
Pi
Bf4
H
Pi3
H
H
—
—
Ph2
H
H
H
H
H
H
H
71
Ir
3
0
Pi
Bf5
H
CF 3
—
—
—
—
Ph2
H
H
H
H
C 6 H 13
H
H
72
Ir
3
0
Pi
Bf5
H
H
—
—
—
—
C 3 H 7
H
H
H
—
—
—
—
73
Ir
3
0
Pi
Bf5
CF 3
H
—
—
—
—
C 20 H 41
H
H
H
—
—
—
—
74
Ir
3
0
Pi
Ph1
H
Bf7
H
H
H
H
H
H
—
—
—
—
—
—
75
Ir
3
0
Pi
Ph1
H
Bf7
H
H
H
H
H
OCH 3
—
—
—
—
—
—
76
Ir
3
0
Pi
Tn1
H
Bf7
H
H
H
H
H
H
—
—
—
—
—
—
77
Ir
3
0
Pi
Np2
H
Bf7
H
H
H
H
H
H
—
—
—
—
—
—
78
Ir
3
0
Pi
Cn1
H
Bf7
H
H
H
H
H
H
—
—
—
—
—
—
79
Ir
3
0
Pi
DBT1
H
Bf7
H
H
H
H
H
H
—
—
—
—
—
—
80
Ir
3
0
Pi
Ph1
H
Bf8
H
H
H
H
H
H
—
—
—
—
—
—
81
Ir
3
0
Pi
Ph1
H
Bf8
H
H
H
H
H
H
—
—
—
—
—
—
82
Ir
3
0
Pi
Tn2
H
Bf8
H
H
H
H
H
H
—
—
—
—
—
—
83
Ir
3
0
Pi
Np2
H
Bf8
H
H
F
H
H
H
—
—
—
—
—
—
84
Ir
3
0
Pi
Cn1
H
Bf8
H
H
H
H
H
H
—
—
—
—
—
—
85
Ir
3
0
Pi
Cz
H
Bf8
H
H
H
H
CH3
H
—
—
—
—
—
—
86
Ir
3
0
Pr
Bf1
H
H
—
—
—
—
H
H
H
H
—
—
—
—
87
Ir
3
0
Py1
Bf1
H
—
—
—
—
—
H
H
H
H
—
—
—
—
88
Ir
3
0
Py2
Bf1
—
H
—
—
—
—
H
H
H
H
—
—
—
—
89
Ir
3
0
Pr
Bf2
H
H
—
—
—
—
H
H
H
H
—
—
—
—
90
Ir
3
0
Py1
Bf2
H
—
—
—
—
—
H
H
H
H
—
—
—
—
91
Ir
3
0
Pi
Bf1
H
H
—
—
—
—
—(CH═CH)2—
H
H
—
—
—
—
92
Ir
3
0
Pi
Bf1
H
H
—
—
—
—
H
—(CH═CH)2—
H
—
—
—
—
[0096]
TABLE 4
CyN1
R5
R6
R7
R8
CyN1-R1
CyN1-R2
CyC1
No
M
m
n
CyN1
CyC1
CyC1-R3
CyC1-R4
CyC1-R′3
CyC1-R′4
R5
R6
R7
R8
93
Ir
3
0
Pi
Bf1
H
H
—
—
—
—
H
H
—(CH═CH)2—
—
—
—
—
94
Ir
3
0
Pi
Bf1
H
CF 3
—
—
—
—
—(CH═CH)2—
H
H
—
—
—
—
95
Ir
3
0
Pi
Bf1
H
CF 3
—
—
—
—
H
—(CH═CH)2—
H
—
—
—
—
96
Ir
3
0
Pi
Bf1
H
CF 3
—
—
—
—
H
H
—(CH═CH)2—
—
—
—
—
97
Ir
3
0
Pi
Bf1
H
Np4
H
—
—
—
—(CH═CH)2—
H
H
—
—
—
—
98
Ir
3
0
Pi
Bf1
H
Ph2
H
OCH═CHC 7 H 15
H
H
—(CH═CH)2—
H
H
—
—
—
—
99
Ir
3
0
Pi
Bf1
H
Ph2
H
OC≡CC 8 H 17
H
H
H
—(CH═CH)2—
H
—
—
—
—
100
Ir
3
0
Pi
Bf1
Ph2
H
H
H
H
H
H
H
—(CH═CH)2—
—
—
—
—
101
Ir
3
0
Pi
Bf2
H
H
—
—
—
—
H
—(CH═CH)2—
H
—
—
—
—
102
Ir
3
0
Pi
Bf2
H
H
—
—
—
—
H
H
—(CH═CH)2—
—
—
—
—
103
Ir
3
0
Pi
Bf2
H
H
—
—
—
—
H
—(CH═CH)2—
H
—
—
—
—
104
Ir
3
0
Pi
Bf2
H
Np4
H
—
—
—
H
H
—(CH═CH)2—
—
—
—
—
105
Ir
3
0
Pi
Bf2
H
Ph2
H
H
F
F
H
H
—(CH═CH)2—
—
—
—
—
106
Ir
3
0
Pi
Bf1
H
Np3
H
H
—
—
—(CH═CH)2—
H
H
—
—
—
—
107
Ir
3
0
Pi
Bf1
H
An
H
—
—
—
H
—(CH═CH)2—
H
—
—
—
—
108
Ir
3
0
Pi
Bf1
H
Pe2
H
—
—
—
H
H
—(CH═CH)2—
—
—
—
—
109
Ir
3
0
Pi
Bf1
H
Cl
—
—
—
—
—(CH═CH)2—
H
H
—
—
—
—
110
Ir
3
0
Pi
Bf1
H
Tn8
H
H
—
—
H
—(CH═CH)2—
H
—
—
—
—
111
Ir
3
0
Pi
Bf1
H
Pi3
H
H
—
—
H
H
—(CH═CH)2—
—
—
—
—
112
Ir
3
0
Pi
Bf1
H
Qn2
H
H
—
—
—(CH═CH)2—
H
H
—
—
—
—
113
Ir
3
0
Pi
Bf1
H
Ph2
H
OCOC 7 H 15
H
H
—(CH═CH)2—
H
H
—
—
—
—
114
Ir
3
0
Pi
Bf1
H
Ph2
H
CN
H
H
H
—(CH═CH)2—
H
—
—
—
—
115
Ir
3
0
Pi
Bf2
H
Tn5
H
H
—
—
H
—(CH═CH)2—
H
—
—
—
—
116
Ir
3
0
Pi
Bf2
H
Tn6
H
H
—
—
H
H
—(CH═CH)2—
—
—
—
—
117
Ir
3
0
Pi
Bf2
H
Tn7
H
H
—
—
H
—(CH═CH)2—
H
—
—
—
—
118
Ir
3
0
Pi
Bf2
H
Pi2
H
H
—
—
H
H
—(CH═CH)2—
—
—
—
—
119
Ir
3
0
Pi
Bf2
H
Ph2
NO 2
H
H
H
H
H
—(CH═CH)2—
—
—
—
—
120
Ir
3
0
Pi
Bf2
H
DBF3
H
H
H
—
H
H
—(CH═CH)2—
—
—
—
—
121
Rh
3
0
Pi
Bf1
H
H
—
—
—
—
H
H
H
H
—
—
—
—
122
Rh
3
0
Pi
Bf1
CF 3
H
—
—
—
—
H
H
H
H
—
—
—
—
[0097]
TABLE 5
CyN1
R5
R6
R7
R8
CyN1-R1
CyN1-R2
CyC1
No
M
m
n
CyN1
CyC1
CyC1-R3
CyC1-R4
CyC1-R′3
CyC1-R′4
R5
R6
R7
R8
123
Rh
3
0
Pi
Bf1
CF 3
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
124
Rh
3
0
Pi
Bf1
H
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
125
Rh
3
0
Pi
Bf1
H
NO 2
—
—
—
—
H
H
H
H
—
—
—
—
126
Rh
3
0
Pi
Bf1
H
Cl
—
—
—
—
H
H
H
H
—
—
—
—
127
Rh
3
0
Pi
Bf1
H
F
F
—
—
—
—
H
H
H
H
—
—
—
—
128
Rh
3
0
Pi
Bf1
H
CN
—
—
—
—
H
H
H
H
—
—
—
—
129
Rh
3
0
Pi
Bf1
H
OCH 3
—
—
—
—
H
H
H
H
—
—
—
—
130
Rh
3
0
Pi
Bf1
H
Ph2
H
H
H
H
H
H
H
H
—
—
—
—
131
Rh
3
0
Pi
Bf2
H
H
—
—
—
—
H
H
H
H
—
—
—
—
132
Rh
3
0
Pi
Bf2
CF 3
H
—
—
—
—
H
H
H
H
—
—
—
—
133
Rh
3
0
Pi
Bf2
CF 3
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
134
Rh
3
0
Pi
Bf2
H
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
135
Rh
3
0
Pi
Bf2
Ph2
H
H
H
H
H
H
H
H
H
—
—
—
—
136
Rh
3
0
Pi
Bf2
H
Np4
H
—
—
—
H
H
H
H
—
—
—
—
137
Rh
3
0
Pi
Bf2
Tn7
H
H
H
—
—
H
H
H
H
—
—
—
—
138
Rh
3
0
Pi
Bf2
H
C 4 H 9
—
—
—
—
H
H
H
H
—
—
—
—
139
Rh
3
0
Pi
Bf2
H
H
—
—
—
—
H
H
OCH 3
H
—
—
—
—
140
Rh
3
0
Pi
Bf2
H
H
—
—
—
—
H
H
Ph2
H
H
Si(C 3 H 7 ) 3
H
H
141
Pt
2
0
Pi
Bf1
H
H
—
—
—
—
—(CH═CH)2—
H
H
—
—
—
—
142
Pt
2
0
Pi
Bf1
H
H
—
—
—
—
H
—(CH═CH)2—
H
—
—
—
—
143
Pt
2
0
Pi
Bf1
H
H
—
—
—
—
H
H
—(CH═CH)2—
—
—
—
—
144
Pt
2
0
Pi
Bf2
H
Tn5
H
H
—
—
H
—(CH═CH)2—
H
—
—
—
—
145
Pt
2
0
Pi
Bf2
H
Tn6
H
H
—
—
H
H
—(CH═CH)2—
—
—
—
—
146
Pt
2
0
Pi
Bf2
H
Tn7
H
H
—
—
H
—(CH═CH)2—
H
—
—
—
—
147
Pt
2
0
Pi
Bf2
H
Pi2
H
H
—
—
H
H
—(CH═CH)2—
—
—
—
—
148
Pd
2
0
Pi
Bf4
H
Pi3
H
H
—
—
Ph2
H
H
H
H
H
H
H
149
Pd
2
0
Pi
Bf5
H
CF 3
—
—
—
—
Ph2
H
H
H
H
C 6 H 13
H
H
150
Pd
2
0
Pi
Bf1
H
H
—
—
—
—
H
H
Ph2
H
H
Si(C 3 H 7 ) 3
H
H
[0098]
TABLE 6
CyN1
R5
R6
R7
R8
CyC1
R5
R6
R7
R8
CyN1-R1
CyN1-R2
CyN2
CyC1-R3
CyC1-R4
CyC1-R′3
CyC1-R′4
R5
R6
R7
R8
CyN1
CyC1
CyN2-R1
CyN2-R2
CyC2
No
M
m
n
CyN2
CyC2
CyC2-R3
CyC2-R4
CyC2-R′3
CyC2-R′4
R5
R6
R7
R8
151
Ir
2
1
Pi
Bf1
H
H
—
—
—
—
H
H
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
152
Ir
2
1
Pi
Bf1
CF 3
H
—
—
—
—
H
H
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
153
Ir
2
1
Pi
Bf1
CF 3
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
154
Ir
2
1
Pi
Bf1
H
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
155
Ir
2
1
Pi
Bf1
H
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
Pi
Np2
H
H
—
—
—
—
H
H
—
—
—
—
—
—
156
Ir
2
1
Pi
Bf1
H
Ph2
H
H
H
H
H
H
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
157
Ir
2
1
Pi
Bf2
H
H
—
—
—
—
H
H
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
158
Ir
2
1
Pi
Bf2
CF 3
H
—
—
—
—
H
H
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
159
Ir
2
1
Pi
Bf2
CF 3
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
160
Ir
2
1
Pi
Bf2
H
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
161
Ir
2
1
Pi
Bf2
H
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
Pi
Ph1
CF 3
H
—
—
—
—
H
H
—
—
—
—
—
—
[0099]
TABLE 7
CyN1
R5
R6
R7
R8
CyC1
R5
R6
R7
R8
CyN1-R1
CyN1-R2
CyN2
CyC1-R3
CyC1-R4
CyC1-R′3
CyC1-R′4
R5
R6
R7
R8
CyN1
CyC1
CyN2-R1
CyN2-R2
CyC2
No
M
m
n
CyN2
CyC2
CyC2-R3
CyC2-R4
CyC2-R′3
CyC2-R′4
R5
R6
R7
R8
162
Ir
2
1
Pi
Bf2
H
Ph2
H
H
H
H
H
H
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
163
Ir
2
1
Pi
Bf2
Ph2
H
H
H
H
H
H
H
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
164
Ir
2
1
Pi
Bf2
Tn7
H
H
H
—
—
H
H
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
165
Ir
2
1
Pi
Bf2
H
C 4 H 9
—
—
—
—
H
H
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
166
Ir
2
1
Pi
Bf2
H
H
—
—
—
—
H
H
Ph2
H
H
Si(C 3 H 7 ) 3
H
H
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
167
Ir
2
1
Pi
Bf2
Ph2
H
H
H
H
H
H
H
Ph2
H
H
H
H
H
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
168
Ir
2
1
Pi
Bf2
H
Qn2
H
H
—
—
H
H
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
169
Ir
2
1
Pi
Bf2
H
Bf7
H
H
H
H
H
H
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
170
Ir
2
1
Pi
Bf2
H
Bf8
H
H
H
H
H
H
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
171
Ir
2
1
Pi
Bf3
H
H
—
—
—
—
Ph2
H
H
H
H
OCH 3
H
H
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
172
Ir
2
1
Pi
Bf3
H
CF 3
—
—
—
—
Np3
H
H
H
H
H
—
—
Pr
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
[0100]
TABLE 8
CyN1
R5
R6
R7
R8
CyC1
R5
R6
R7
R8
CyN1-R1
CyN1-R2
CyN2
CyC1-R3
CyC1-R4
CyC1-R′3
CyC1-R′4
R5
R6
R7
R8
CyN1
CyC1
CyN2-R1
CyN2-R2
CyC2
No
M
m
n
CyN2
CyC2
CyC2-R3
CyC2-R4
CyC2-R′3
CyC2-R′4
R5
R6
R7
R8
173
Ir
2
1
Pi
Bf4
H
CF 3
—
—
—
—
Ph2
H
H
H
H
C 6 H 13
H
H
Py1
Ph1
H
—
—
—
—
—
H
H
—
—
—
—
—
—
174
Ir
2
1
Pi
Bf4
H
Bf7
H
H
H
H
Ph2
H
H
H
H
H
H
H
Py2
Ph1
—
H
—
—
—
—
H
H
—
—
—
—
—
—
175
Ir
2
1
Pi
Ph1
H
Bf7
H
H
H
H
H
OCH 3
—
—
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
176
Ir
2
1
Pi
Np2
H
Bf7
H
H
H
H
H
H
—
—
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
177
Ir
2
1
Pi
Tn2
H
Bf8
H
H
H
H
H
H
—
—
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
178
Ir
2
1
Pi
Cn1
H
Bf8
H
H
H
H
H
—
—
—
—
—
—
—
Pi
Ph1
H
Np3
H
H
—
—
H
H
—
—
—
—
—
—
179
Ir
2
1
Pi
Bf1
H
H
—
—
—
—
—(CH═CH)2—
H
H
—
—
—
—
Pi
Np2
H
H
—
—
—
—
H
H
—
—
—
—
—
—
180
Ir
2
1
Pi
Bf1
H
H
—
—
—
—
H
—(CH═CH)2—
H
—
—
—
—
Pi
Ph1
H
CF 3
—
—
—
—
H
H
—
—
—
—
—
—
181
Ir
2
1
Pi
Bf1
H
H
—
—
—
—
H
H
—(CH═CH)2—
—
—
—
—
Pi
Bf2
H
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
182
Ir
2
1
Pi
Bf1
H
CF 3
—
—
—
—
—(CH═CH)2—
H
H
—
—
—
—
Pi
Ph1
H
CF 3
—
—
—
—
H
H
—
—
—
—
—
—
183
Ir
2
1
Pi
Bf1
H
CF 3
—
—
—
—
H
—(CH═CH)2—
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
[0101]
TABLE 9
CyN1
R5
R6
R7
R8
CyC1
R5
R6
R7
R8
CyN1-R1
CyN1-R2
CyN2
CyC1-R3
CyC1-R4
CyC1-R′3
CyC1-R′4
R5
R6
R7
R8
CyN1
CyC1
CyN2-R1
CyN2-R2
CyC2
No
M
m
n
CyN2
CyC2
CyC2-R3
CyC2-R4
CyC2-R′3
CyC2-R′4
R5
R6
R7
R8
184
Ir
2
1
Pi
Bf1
H
CF 3
—
—
—
—
H
H
—(CH═CH)2—
—
—
—
—
Pi
Bf2
H
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
185
Ir
2
1
Pi
Bf1
H
Np4
H
—
—
—
—(CH═CH)2—
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
186
Ir
2
1
Pi
Bf1
H
Ph2
H
OCH═CHC 7 H 15
H
H
—(CH═CH)2—
H
H
—
—
—
—
Pi
Ph1
H
CF 3
—
—
—
—
H
H
—
—
—
—
—
—
187
Ir
2
1
Pi
Bf1
H
Ph2
H
OC≡CC 8 H 17
H
H
H
—(CH═CH)2—
H
—
—
—
—
Pi
Np2
H
H
—
—
—
—
H
H
—
—
—
—
—
—
188
Ir
2
1
Pi
Bf1
Ph2
H
H
H
H
H
H
H
—(CH═CH)2—
—
—
—
—
Pi
Bf2
H
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
189
Ir
2
1
Pi
Bf2
H
H
—
—
—
—
H
—(CH═CH)2—
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
190
Ir
2
1
Pi
Bf2
H
H
—
—
—
—
H
H
—(CH═CH)2—
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
191
Ir
2
1
Pi
Bf2
H
H
—
—
—
—
H
—(CH═CH)2—
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
192
Ir
2
1
Pi
Bf2
H
Np4
H
—
—
—
H
H
—(CH═CH)2—
—
—
—
—
Pi
Ph1
H
CF 3
—
—
—
—
H
H
—
—
—
—
—
—
193
Ir
2
1
Pi
Bf2
H
Ph2
H
H
F
F
H
H
—(CH═CH)2—
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
194
Ir
2
1
Pi
Bf1
H
Np3
H
H
—
—
—(CH═CH)2—
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
[0102]
TABLE 10
CyN1
R5
R6
R7
R8
CyC1
R5
R6
R7
R8
CyN1-R1
CyN1-R2
CyN2
CyC1-R3
CyC1-R4
CyC1-R′3
CyC1-R′4
R5
R6
R7
R8
CyN1
CyC1
CyN2-R1
CyN2-R2
CyC2
No
M
m
n
CyN2
CyC2
CyC2-R3
CyC2-R4
CyC2-R′3
CyC2-R′4
R5
R6
R7
R8
195
Ir
2
1
Pi
Bf1
H
An
H
—
—
—
H
—(CH═CH)2—
H
—
—
—
—
Pi
Bf2
H
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
196
Ir
2
1
Pi
Bf1
H
Pe2
H
—
—
—
H
H
—(CH═CH)2—
—
—
—
—
Pi
Ph1
H
CF 3
—
—
—
—
H
H
—
—
—
—
—
—
197
Ir
2
1
Pi
Bf1
H
Cl
—
—
—
—
—(CH═CH)2—
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
198
Ir
2
1
Pi
Bf1
H
Tn8
H
H
—
—
H
—(CH═CH)2—
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
199
Ir
2
1
Pi
Bf1
H
Pi3
H
H
—
—
H
H
—(CH═CH)2—
—
—
—
—
Pi
DBT1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
200
Ir
2
1
Pi
Bf1
H
Qn2
H
H
—
—
—(CH═CH)2—
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
201
Ir
2
1
Pi
Bf1
H
Ph2
H
OCOC 7 H 15
H
H
—(CH═CH)2—
H
H
—
—
—
—
Pi
Bf2
H
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
202
Ir
2
1
Pi
Bf1
H
Ph2
H
CN
H
H
H
—(CH═CH)2—
H
—
—
—
—
Pi
Ph1
H
CF 3
—
—
—
—
H
H
—
—
—
—
—
—
203
Rh
2
1
Pi
Bf2
H
Tn6
H
H
—
—
H
H
—(CH═CH)2—
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
204
Rh
2
1
Pi
Bf2
H
Ph2
NO 2
H
H
H
H
H
—(CH═CH)2—
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
205
Rh
2
1
Pi
Bf2
H
DBF3
H
H
H
—
H
H
—(CH═CH)2—
—
—
—
—
Pi
Bf2
H
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
[0103]
TABLE 11
CyN1
R5
R6
R7
R8
CyC1
R5
R6
R7
R8
CyN1-R1
CyN1-R2
CyN2
CyC1-R3
CyC1-R4
CyC1-R′3
CyC1-R′4
R5
R6
R7
R8
CyN1
CyC1
CyN2-R1
CyN2-R2
CyC2
No
M
m
n
CyN2
CyC2
CyC2-R3
CyC2-R4
CyC2-R′3
CyC2-R′4
R5
R6
R7
R8
206
Rh
2
1
Pi
Bf2
H
H
—
—
—
—
H
H
Ph2
H
H
Si(C 3 H 7 ) 3
H
H
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
207
Rh
2
1
Pi
Bf2
Ph2
H
H
H
H
H
H
H
Ph2
H
H
H
H
H
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
208
Rh
2
1
Pi
Bf2
H
Pe2
H
—
—
—
H
H
H
H
—
—
—
—
Pi
Ph1
H
GF 3
—
—
—
—
H
H
—
—
—
—
—
—
209
Rh
2
1
Pi
Bf2
H
An
H
—
—
—
H
H
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
210
Rh
2
1
Pi
Bf2
H
Bf8
H
H
H
H
H
H
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
211
Ir
1
2
Pi
Bf1
H
H
—
—
—
—
H
H
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
212
Ir
1
2
Pi
Bf1
CF 3
H
—
—
—
—
H
H
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
213
Ir
1
2
Pi
Bf1
CF 3
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
214
Ir
1
2
Pi
Bf1
H
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
215
Ir
1
2
Pi
Bf1
H
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
Pi
Np2
H
H
—
—
—
—
H
H
—
—
—
—
—
—
216
Ir
1
2
Pi
Bf2
H
H
—
—
—
—
H
H
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
[0104]
TABLE 12
CyN1
R5
R6
R7
R8
CyC1
R5
R6
R7
R8
CyN1-R1
CyN1-R2
CyN2
CyC1-R3
CyC1-R4
CyC1-R′3
CyC1-R′4
R5
R6
R7
R8
CyN1
CyC1
CyN2-R1
CyN2-R2
CyC2
No
M
m
n
CyN2
CyC2
CyC2-R3
CyC2-R4
CyC2-R′3
CyC2-R′4
R5
R6
R7
R8
217
Ir
1
2
Pi
Bf2
CF 3
H
—
—
—
—
H
H
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
218
Ir
1
2
Pi
Bf2
CF 3
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
219
Ir
1
2
Pi
Bf2
H
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
220
Ir
1
2
Pi
Bf2
H
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
Pi
Ph1
CF 3
H
—
—
—
—
H
H
—
—
—
—
—
—
221
Ir
1
2
Pi
Bf2
H
Ph2
H
H
H
H
H
H
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
222
Ir
1
2
Pi
Bf1
H
H
—
—
—
—
—(CH═CH)2—
H
H
—
—
—
—
Pi
Np2
H
H
—
—
—
—
H
H
—
—
—
—
—
—
223
Ir
1
2
Pi
Bf1
H
H
—
—
—
—
H
—(CH═CH)2—
H
—
—
—
—
Pi
Ph1
H
CF 3
—
—
—
—
H
H
—
—
—
—
—
—
224
Ir
1
2
Pi
Bf1
H
CF 3
—
—
—
—
H
H
—(CH═CH)2—
—
—
—
—
Pi
Bf2
H
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
225
Ir
1
2
Pi
Bf1
H
Np4
H
—
—
—
—(CH═CH)2—
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
226
Ir
1
2
Pi
Bf1
H
Ph2
H
OCH═CHC 7 H 15
H
H
—(CH═CH)2—
H
H
—
—
—
—
Pi
Ph1
H
CF 3
—
—
—
—
H
H
—
—
—
—
—
—
227
Ir
1
2
Pi
Bf1
H
Ph2
H
OC≡CC 8 H 17
H
H
H
—(CH═CH)2—
H
—
—
—
—
Pi
Np2
H
H
—
—
—
—
H
H
—
—
—
—
—
—
[0105]
TABLE 13
CyN1
R5
R6
R7
R8
CyC1
R5
R6
R7
R8
CyN1-R1
CyN1-R2
CyN2
CyC1-R3
CyC1-R4
CyC1-R′3
CyC1-R′4
R5
R6
R7
R8
CyN1
CyC1
CyN2-R1
CyN2-R2
CyC2
No
M
m
n
CyN2
CyC2
CyC2-R3
CyC2-R4
CyC2-R′3
CyC2-R′4
R5
R6
R7
R8
228
Ir
1
2
Pi
Bf1
H
Qn2
H
H
—
—
—(CH═CH)2—
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
229
Ir
1
2
Pi
Bf1
H
Ph2
H
OCOC 7 H 15
H
H
—(CH═CH)2—
H
H
—
—
—
—
Pi
Bf2
H
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
230
Ir
1
2
Pi
Bf1
H
Ph2
H
CN
H
H
H
—(CH═CH)2—
H
—
—
—
—
Pi
Ph1
H
CF 3
—
—
—
—
H
H
—
—
—
—
—
—
231
Ir
1
2
Pi
Bf2
H
Tn6
H
H
—
—
H
H
—(CH═CH)2—
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
232
Ir
1
2
Pi
Bf2
H
Ph2
NO 2
H
H
H
H
H
—(CH═CH)2—
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
233
Ir
1
2
Pi
Bf2
H
DBF3
H
H
H
—
H
H
—(CH═CH)2—
—
—
—
—
Pi
Bf2
H
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
234
Ir
1
2
Pi
Bf2
Ph2
H
H
H
H
H
H
H
Ph2
H
H
H
H
H
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
[0106]
TABLE 14
CyN1
R5
R6
R7
R8
CyC1
R5
R6
R7
R8
CyN1-R1
CyN1-R2
CyN2
CyC1-R3
CyC1-R4
CyC1-R′3
CyC1-R′4
R5
R6
R7
R8
CyN1
CyC1
CyN2-R1
CyN2-R2
CyC2
No
M
m
n
CyN2
CyC2
CyC2-R3
CyC2-R4
CyC2-R′3
CyC2-R′4
R5
R6
R7
R8
235
Rh
1
2
Pi
Bf2
H
Pe2
H
—
—
—
H
H
H
H
—
—
—
—
Pi
Ph1
H
CF 3
—
—
—
—
H
H
—
—
—
—
—
—
236
Rh
1
2
Pi
Bf2
H
An
H
—
—
—
H
H
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
237
Rh
1
2
Pi
Bf2
H
Bf8
H
H
H
H
H
H
H
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
238
Rh
1
2
Pi
Bf1
Ph2
H
H
H
H
H
H
H
—(CH═CH)2—
—
—
—
—
Pi
Bf2
H
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
239
Pt
1
1
Pi
Bf2
H
H
—
—
—
—
H
—(CH═CH)2—
H
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
240
Pd
1
1
Pi
Bf2
H
H
—
—
—
—
H
H
—(CH═CH)2—
—
—
—
—
Pi
Ph1
H
H
—
—
—
—
H
H
—
—
—
—
—
—
[0107]
TABLE 15
CyN1
R5
R6
R7
R8
CyC1
R5
R6
R7
R8
CyN1-R1
E
CyN1
CyC1
CyC1-R3
CyC1-R4
R5
R6
R7
R8
E
R″
R″′
CyN1-R2
G
No
M
m
n
G
R″
R″′
CyC1-R′3
CyC1-R′4
R5
R6
R7
R8
241
Ir
2
1
Pi
Bf1
H
H
—
—
—
—
H
H
H
H
—
—
—
—
CH 3
—
—
—
—
—
—
CH 3
—
—
—
—
—
—
242
Ir
2
1
Pi
Bf1
CF 3
H
—
—
—
—
H
H
H
H
—
—
—
—
CF 3
—
—
—
—
—
—
CF 3
—
—
—
—
—
—
243
Ir
2
1
Pi
Bf1
CF 3
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
CH 3
—
—
—
—
—
—
CH 3
—
—
—
—
—
—
244
Ir
2
1
Pi
Bf1
H
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
Ph2
—
—
H
H
H
H
Ph2
—
—
H
H
H
H
245
Ir
2
1
Pi
Bf1
H
Ph2
H
H
H
H
H
H
H
H
—
—
—
—
Ph2
—
—
H
C 3 H 7
H
H
Ph2
—
—
H
C 3 H 7
H
H
246
Ir
2
1
Pi
Bf2
H
H
—
—
—
—
H
H
H
H
—
—
—
—
CH 3
—
—
—
—
—
—
FL5
CH 3
CH 3
H
H
H
—
247
Ir
2
1
Pi
Bf2
CF 3
H
—
—
—
—
H
H
H
H
—
—
—
—
Tn5
—
—
H
H
—
—
Tn5
—
—
H
H
—
—
248
Ir
2
1
Pi
Bf2
CF 3
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
Tn6
—
—
H
H
—
—
Tn6
—
—
H
H
—
—
249
Ir
2
1
Pi
Bf2
H
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
CH 3
—
—
—
—
—
—
CH 3
—
—
—
—
—
—
250
Ir
2
1
Pi
Bf2
H
Ph2
H
H
H
H
H
H
H
H
—
—
—
—
CF 3
—
—
—
—
—
—
CF 3
—
—
—
—
—
—
251
Ir
2
1
Pi
Bf2
Ph2
H
H
H
H
H
H
H
H
H
—
—
—
—
Np3
—
—
CH 3 O
H
—
—
Np3
—
—
CH 3 O
H
—
—
[0108]
TABLE 16
CyN1
R5
R6
R7
R8
CyC1
R5
R6
R7
R8
CyN1-R1
E
CyN1
CyC1
CyC1-R3
CyC1-R4
R5
R6
R7
R8
E
R″
R″′
CyN1-R2
G
No
M
m
n
G
R″
R″′
CyC1-R′3
CyC1-R′4
R5
R6
R7
R8
252
Ir
2
1
Pi
Bf2
Tn7
H
H
H
—
—
H
H
H
H
—
—
—
—
Np4
—
—
F
—
—
—
Np4
—
—
F
—
—
—
253
Ir
2
1
Pi
Bf2
H
C 4 H 9
—
—
—
—
H
H
H
H
—
—
—
—
Tn7
—
—
CH 3
H
—
—
Tn7
—
—
CH 3
H
—
—
254
Ir
2
1
Pi
Bf2
H
H
—
—
—
—
H
H
Ph2
H
H
Si(C 3 H 7 ) 3
H
H
Tn8
—
—
H
H
—
—
Tn8
—
—
H
H
—
—
255
Ir
2
1
Pi
Bf2
Ph2
H
H
H
H
H
H
H
Ph2
H
H
H
H
H
Pe2
—
—
H
—
—
—
Pe2
—
—
H
—
—
—
256
Ir
2
1
Pi
Bf2
H
Qn2
H
H
—
—
H
H
H
H
—
—
—
—
Pi2
—
—
H
H
—
—
Pi2
—
—
H
H
—
—
257
Ir
2
1
Pi
Bf2
H
Bf7
H
H
H
H
H
H
H
H
—
—
—
—
Pi3
—
—
CH 3
CH 3
H
H
Pi3
—
—
CH 3
CH 3
H
H
258
Ir
2
1
Pi
Bf2
H
Bf8
H
H
H
H
H
H
H
H
—
—
—
—
FL4
—
—
H
H
H
—
FL4
—
—
H
H
H
—
259
Ir
2
1
Pi
Bf3
H
H
—
—
—
—
Ph2
H
H
H
H
OCH 3
H
H
FL5
C2H5
C2H5
H
H
H
—
FL5
(CH2)5Ph3
(CH2)5Ph3
H
H
H
—
260
Ir
2
1
Pi
Bf4
H
CF 3
—
—
—
—
Ph2
H
H
H
H
C 6 H 13
H
H
DBF2
—
—
H
H
H
—
DBF2
—
—
H
H
H
—
261
Ir
2
1
Pi
Ph1
H
Bf7
H
H
H
H
H
OCH 3
—
—
—
—
—
—
DBT3
—
—
H
H
H
—
DBT3
—
—
H
H
H
—
262
Rh
2
1
Pi
Bf1
H
H
—
—
—
—
—(CH═CH)2—
H
H
—
—
—
—
CH 3
—
—
—
—
—
—
CH 3
—
—
—
—
—
—
[0109]
TABLE 17
CyN1
R5
R6
R7
R8
CyC1
R5
R6
R7
R8
CyN1-R1
E
CyN1
CyC1
CyC1-R3
CyC1-R4
R5
R6
R7
R8
E
R″
R″′
CyN1-R2
G
No
M
m
n
G
R″
R″′
CyC1-R′3
CyC1-R′4
R5
R6
R7
R8
263
Rh
2
1
Pi
Bf1
H
H
—
—
—
—
H
—(CH═CH)2—
H
—
—
—
—
CF 3
—
—
—
—
—
—
CF 3
—
—
—
—
—
—
264
Rh
2
1
Pi
Bf1
H
H
—
—
—
—
H
H
—(CH═CH)2—
—
—
—
—
Qn2
—
—
H
H
—
—
Qn2
—
—
H
H
—
—
265
Rh
2
1
Pi
Bf2
H
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
Np3
—
—
H
H
—
—
Np3
—
—
H
H
—
—
266
Pt
1
1
Pi
Bf1
H
CF 3
—
—
—
—
H
H
—(CH═CH)2—
—
—
—
—
CH 3
—
—
—
—
—
—
CH 3
—
—
—
—
—
—
267
Pt
1
1
Pi
Bf1
H
Np4
H
—
—
—
—(CH═CH)2—
H
H
—
—
—
—
CF 3
—
—
—
—
—
—
CF 3
—
—
—
—
—
—
268
Pd
1
1
Pi
Bf1
H
Ph2
H
OCH═CHC 7 H 15
H
H
—(CH═CH)2—
H
H
—
—
—
—
CH 3
—
—
—
—
—
—
CH 3
—
—
—
—
—
—
269
Pd
1
1
Pi
Bf2
H
CF 3
—
—
—
—
H
H
H
H
—
—
—
—
CF 3
—
—
—
—
—
—
CF 3
—
—
—
—
—
—
270
Ir
1
2
Pi
Bf1
H
Ph2
H
OC≡CC 8 H 17
H
H
H
—(CH═CH)2—
H
—
—
—
—
CH 3
—
—
—
—
—
—
CH 3
—
—
—
—
—
—
[0110] In the case where the metal coordination compound of the formula (1) is used as a luminescent material, the metal coordination compound used singly (as a single luminescent material) or in combination with another luminescent material (host compound).
[0111] In the latter case, the resultant luminescence material (composition or mixture) may preferably contain the metal coordination compound of the formula (1) in an amount of at most 50 wt. %, more preferably 0.1-20 wt. %. Above 50 wt. %, a resultant luminescence strength is undesirably be lowered due to quenching with an increasing concentration in some cases.
[0112] Hereinbelow, the present invention will be described more specifically based on Examples.
EXAMPLE 1
Synthesis of Example Compound No. 34
[0113]
[0114] In a 100-ml-three-necked flask, 2.80 g (15.4 mM) of 2-chloro-5-trifluoromethylpyridine, 2.50 g (15.4 mM) of 2-benzofuranylboronic acid, 14 ml of toluene, 7 ml of ethanol and 14 ml of 2M-sodium carbonate aqueous solution were placed and stirred at room temperature under nitrogen stream, and 0.55 g (0.48 mM) of tetrakis(triphenylphosphine)palladium (0) was added thereto. Thereafter, reflux under stirring for 4 hours was performed under nitrogen stream. After the reaction, the reaction mixture was cooled on an ice bath and stirred at room temperature after addition of ethyl acetate and saturated saline water. The organic layer was washed with water and dried with anhydrous magnesium sulfate, and the solvent was removed under reduced pressure to obtain a residue. The residue was purified by alumina column chromatography (eluent: toluene) and recrystallized from methanol to obtain 0.72 g of 2-(5-trifluoromethylpyridine-2-yl)benzofuran (Yield: 17.7%).
[0115] In a 100 ml-four-necked flask, 25 ml of glycerol was placed and heated at 130-140° C. under stirring and bubbling with nitrogen for 2 hours. Then, the glycerol was cooled by standing down to 100° C., and 0.70 g (2.66 mM) of 2-(5-trifluoromethylpyridine-2-yl)benzofuran and 0.23 g (0.47 mM) of iridium (III) acetylacetonate were added, followed by 7 hours and 10 minutes of heating at 192-230° C. under stirring and nitrogen stream. The reaction product was cooled to room temperature and injected into 150 ml of 1N-hydrochloric acid to form a precipitate, which was filtered out, washed with water, and dissolved in acetone to remove the insoluble content. The acetone was distilled off under reduced pressure to obtain a residue. The residue was washed with methanol and purified by silica gel column chromatography with toluene as the eluent to obtain 0.11 g (yield=23.4%) of red powdery tris[2-(benzofuran-2-yl)-5-trifluoromethyl-pyridine-C 3 ,N]iridium (III).
[0116] A toluene solution of the compound exhibited a photoluminescence spectrum showing λmax (maximum emission wavelength)=622 nm and a quantum yield of 0.12.
EXAMPLES 2-10
[0117] Each of luminescence devices having a layer structure shown in FIG. 1B were prepared in the following manner.
[0118] On a 1.1 mm-thick glass substrate (transparent substrate 15 ), a 100 nm-thick film (transparent electrode 14 ) of ITO (indium tin oxide) was formed by sputtering, followed by patterning to form a stripe electrode including 100 lines each having a width of 100 nm and a spacing with an adjacent line of 10 nm (i.e., electrode pitch of 110 nm).
[0119] On the ITO-formed substrate, three organic layers and two metal electrode layers shown below were successively formed by vacuum (vapor) deposition using resistance heating in a vacuum chamber (10 −4 Pa).
[0120] Organic layer 1 (hole transport layer 13 ) (40 nm): α-NPD
[0121] Organic layer 2 (luminescence layer 12 ) (30 nm): co-deposited film of CBP:metal complex (metal coordination compound shown in Table 18) (95:5 by weight)
[0122] Organic layer 3 (electron transport layer 16 ) (30 nm): Alq3
[0123] Metal electrode layer 1 (metal electrode 11 ) (15 nm): Al—Li alloy (Li=1.8 wt. %)
[0124] Metal electrode layer 2 (metal electrode 11 ) (100 nm): Al
[0125] The above-deposited metal electrode layers 1 and 2 (Al—Li layer and Al layer) had a stripe electrode pattern including 100 lines each having a width of 100 nm and a spacing of 10 nm (electrode pitch=110 nm) and arranged so that the stripe electrode pattern intersected with that of the ITO electrode at right angles to form a matrix of pixels each having an effective electrode area of 3 mm 2 comprising 20 ITO lines-bundled together at a lead-out portion and 15 Al (Al—Li) lines bundled together at a lead-out portion.
[0126] Each of the thus-prepared luminescence devices was taken out of the vacuum-chamber and was subjected to a continuous energization (current passage) test in an atmosphere of dry nitrogen gas stream so as to remove device deterioration factors, such as oxygen and moisture (water content).
[0127] The continuous energization test was performed by continuously applying a voltage at a constant current density of 70 mA/cm 2 to the luminescence device having the ITO (transparent) electrode (as an anode) and the Al (metal) electrode (as a cathode), followed by measurement of emission luminance (brightness) with time so as to determine a time (luminance half-life) required for decreasing an initial luminance (80-250 cd/m 2 ) to ½ thereof.
[0128] The results are shown in Table 18 appearing hereinafter.
COMPARATIVE EXAMPLE 1
[0129] A comparative luminescence device was prepared and evaluated in the same manner as in Examples 2-10 except that the Ir complexes (metal coordination compounds shown in Table 185) was changed to Ir-phenylpyrimidine complex (Ir(ppy) 3 ) shown below.
[0130] The results are also also shown in Table 18 below.
TABLE 18 Ex. No. Compound No. Luminance half-life (Hr) Ex. 2 4 800 Ex. 3 10 900 Ex. 4 31 750 Ex. 5 34 900 Ex. 6 92 800 Ex. 7 115 650 Ex. 8 135 750 Ex. 9 156 850 Ex. 10 238 600 Comp. Ex. 1 Ir(ppy) 3 350
[0131] As is apparent from Table 18, compared with the conventional luminescence device using Ir(ppy) 3 , the luminescence devices using the metal coordination compounds of formula (1) according to the present invention provide longer luminance half-lives, thus resulting in an EL device having a high durability (luminance stability) based on a good stability of the metal coordination compound of formula (1) of the present invention.
EXAMPLE 11
[0132] A color organic EL display apparatus shown in FIG. 2 was prepared in the following manner.
[0133] An active matrix substrate had a planar structure basically similar to a structure described in U.S. Pat. No. 6,114,715.
[0134] Specifically, on a 1.1 mm-thick glass substrate, top gate-type TFTs of polycrystalline silicon were formed in an ordinary manner and thereon, a flattening film was formed with contact holes for electrical connection with a pixel electrode (anode) at respective source regions, thus preparing an active matrix substrate with a TFT circuit.
[0135] On the active matrix substrate, a 700 nm-thick pixel electrode (anode) of ITO having a large work function was formed in a prescribed pattern. On the ITO electrode, prescribed organic layers and a 100 nm-thick Al electrode (cathode) were successively formed by vacuum deposition with a hard mask, followed by patterning to form a matrix of color pixels (128×128 pixels).
[0136] The respective organic layers corresponding to three color pixels (red (R) green (G) and blue (B)) were consisting of the following layers.
<R pixel region>
α-NPD (40 nm)/CBP: Ex. Comp. No. 34 (93:7 by weight) (30 nm)/BCP (20 nm)/Alq 3 (40 nm)
<G pixel region>
α-NPD (50 nm)/Alq 3 (50 nm)
<B pixel region>
α-NPD (50 nm)/BCP (20 nm)/Alq 3 (50 nm)
[0143] When the thus-prepared color organic EL display apparatus was driven, desired color image data can be displayed stably with good image qualities.
EXAMPLE 12
Synthesis of Ex. Comp. No. 31
[0144] It is easy to synthesize the following compound in the same manner as in Example 1 except for using 2-bromopyridine (made by Tokyo Kasei Kogyo K.K.) instead of 2-chloro-5-trifluoromethylpyridine in Example 1.
[0145] Tris[2-(benzofuran-2-yl)pyridine-C 3 ,N]iridium (III).
EXAMPLE 13
Synthesis of Ex. Comp. No. 32
[0146] It is easy to synthesize the following compound in the same manner as in Example 1 except for using 2-chloro-4-trifluoromethylpyridine (made by Florochem USA) instead of 2-chloro-5-trifluoromethylpyridine in Example 1.
[0147] Tris[2-(benzofuran-2-yl)-4-trifluoromethyl-pyridine-C 3 ,N]iridium (III).
EXAMPLE 14
Synthesis of Ex. Comp. No. 33
[0148] It is easy to synthesize the following compound in the same manner as in Example 1 except for using 2-chloro-4,5-bis(trifluoro-methyl)pyridine (made by Oakwood Products Inc.) instead of 2-chloro-5-trifluoromethylpyridine in Example 1.
[0149] Tris[2-(benzofuran-2-yl)-4,5-bis(trifluoro-methyl)pyridine-C 3 , N]iridium (III).
EXAMPLE 15
Synthesis of Ex. Comp. No. 35
[0150] It is easy to synthesize the following compound in the same manner as in Example 16 except for using 4-phenyl-2-bromopyridine (made by General Intermediates of Canada) instead of 2-chloro-5-trifluoromethylpyridine in Example 1.
[0151] Tris[2-(benzofuran-2-yl)-4-pyridine-C 3 ,N]-iridium (III).
EXAMPLE 16
Synthesis of Ex. Comp. No. 36
[0152] It is easy to synthesis the following compound in the same manner as in Example 1 except that 2-(benzofuran-2-yl)-5-bromopyridine was synthesized from 2,5-dibromopyridine (made by Tokyo Kasei Kogyo K.K.) and 2-benzofuranboronic acid (made by Aldrich Co.) and is reacted with 1-naphthylboronic acid (made by Tokyo Kasei Kogyo) to obtain 2-(benzofuran-2-yl)-5-(naphthalene-1-yl)pyridine, which is used instead of 2-(5-trifluoromethylpyridine-2-yl)benzofuran.
[0153] Tris[2-(benzofuran-2-yl)-5-(naphthalene-1-yl)pyridine-C 3 ,N]iridium (III).
EXAMPLE 17
Synthesis of Ex. Comp. No. 42
[0154] It is easy to synthesize the following compound in the same manner as in Example 16 except for using 2-naphthylboronic acid (made by Tokyo Kasei Kogyo K.K.) instead of 1-naphthylboronic acid in Example 16.
[0155] Tris[2-(benzofuran-2-yl)-5-(naphthalene-2-yl)pyridine-C 3 ,N]iridium (III).
EXAMPLE 18
Synthesis of Ex. Comp. No. 47
[0156] It is easy to synthesize the following compound in the same manner as in Example 1 except for reacting 2 equivalent amount of 2-benzofuran boronic acid (made by Aldrich Co.) with 2,5-dibromopyridine (made by Tokyo Kasei Kogyo K.K.) to synthesis 2,5-bis(benzofuran-2-yl)pyridine, which is used instead of 2-(5-trifluoromethylpyridine-2-yl)benzofuran, in Example 1.
[0157] Tris[2,5-bis(benzofuran-2-yl)pyridine-C 3 ,N]iridium (III).
EXAMPLE 19
Synthesis of Ex. Comp. No. 50
[0158] It is easy to synthesis the following compound in the same manner as in Example 1 except that 2-(benzofuran-2-yl)-5-bromopyridine was synthesized from 2,5-dibromopyridine (made by Tokyo Kasei Kogyo K.K.) and 2-benzofuranboronic acid (made by Aldrich Co.) and is reacted with 3-thiopheneboronic acid (made by Aldrich Co.) to obtain 2-(benzofuran-2-yl)-5-(thiophene-3-yl)pyridine, which is used instead of 2-(5-trifluoromethylpyridine-2-yl)benzofuran.
[0159] Tris[2-(benzofuran-2-yl)-5-(thiophene-3-yl)pyridine-C 3 , N]iridium (III).
EXAMPLE 20
[0160] An organic EL device shown in FIG. 1C was prepared in the following manner.
[0161] On a 100 nm-thick patterned ITO electrode (anode) formed on a 1.1 mm-thick no-alkali glass substrate, a 40 nm-thick charge transport layer of α-NPD was formed by vacuum deposition (10 −4 Pa) at a deposition rate of 0.1 nm/sec. On the charge transport layer, a 40 nm-thick luminescence layer (co-deposited film) of CBP: iridium complex of Ex. Comp. No. 34 prepared in Example 1 (97:3 by weight) was formed by co-vacuum deposition at deposition rates of 0.1 nm/sec (for CBP) and 0.08 nm/sec (for the iridium complex) by controlling heating conditions of deposition vessel. On the luminescence layer, a 10 nm-thick exciton diffusion prevention layer of BCP (Bathocuproine) was formed by vacuum deposition at a deposition rate of 0.1 nm/sec, and or the exciton diffusion prevention layer, a 20 nm-thick electron transport layer of Alq 3 was formed by vacuum deposition at a deposition rate of 0.1 nm/sec. Thereafter, or the electron transport layer, a 150 nm-thick aluminum electrode (cathode) was formed by vacuum deposition at a deposition rate of 1 nm/sec.
[0162] The thus-prepared organic EL device exhibited an EL spectrum showing λmax=625 nm and luminescent efficiencies of 1.5 lm/W at a luminance of 100 cd/m 2 .
EXAMPLE 21
Synthesis of Ex. Comp. No. 62
[0163]
[0164] In a 2 liter-three-necked flask, 145.8 g (718 mM) of 5-bromo-2-hydroxybenzyl alcohol, 246.5 g (718 mM) of triphenyl phosphine.HBr, and 730 ml of acetonitrile were placed and refluxed under stirring for 3 hours. The reaction liquid was cooled down to room temperature to precipitate a crystal of 5-bromo-2-hydroxybenzyltriphenylphosphonium bromide (I), which was recovered by filtration (Yield: 362.0 g (95.5%)).
[0165] In a 1 liter-three-necked flask, 50.0 g (94.7 mM) o the phosphonium bromide (I), 31.1 g (104 mM) of 1-nonanoic acid anhydride, 450 ml of toluene and 39.6 g (392 mM) of triethylamine were placed and refluxed under stirring for 6 hours. The reaction liquid was cooled down to room temperature to precipitate a crystal, which was filtered out. The solvent of the filtrate was distilled off under reduced pressure to obtain a residue. The residue was purified by silica gel column chromatography (eluent: hexane) to a colorless oily product of 2-octyl-5-bromobenzofuran (II) (Yield: 25.1 g (85.8%)).
[0166] In a 500 ml-three-necked flask, 19.0 g (61.5 mM) of 2-octyl-5-bromobenzofuran (II) and 190 ml of anhydrous tetrahydrofuran (THF) were placed. To the mixture, 45 ml (72.0 mM) of 1.6 M-n-butyllithium solution in hexane was added dropwise under argon stream at −70° C. or below in 30 min., followed by stirring at that temperature for 4 hours. To the resultant mixture, a solution of 17.8 g (171 mM) of trimethylborate in 70 ml of anhydrous THF was added dropwise at −70° C. or below in 20 min., and stirred at that temperature for 2 hours. The system was heated up to room temperature and stirred for 17 hours. To the reaction mixture, 100 ml of 10%-hydrochloric acid was added dropwise, followed by extraction with ether. The organic layer was washed with water and dried with anhydrous sodium sulfate, followed by distilling-off of the solvent under reduced pressure to obtain a residue. The residue was purified by silica gel column chromatography (eluent: hexane/ethyl acetate=4/1) to obtain a white crystal of 2-octylbenzofuran-5-boronic acid (III) (Yield: 10.8 g (64.1%)).
[0167] It is easy to synthesize the following compound in the same manner as in Example 1 except for using 2-octylbenzofuran-5-boronic acid (III) instead of 2-benzofuran boronic acid in Example 1.
[0168] Tris[2-(2-octylbenzofuran-5-yl)pyridine-C 3 ,N]iridium (III).
EXAMPLE 22
Synthesis of Ex. Comp. No. 61
[0169] It is easy to synthesis the following compound in the same manner as in Example 1 except for using, instead of 2-(5-trifluoromethylpyridine-2-yl)benzofuran, 2-phenyl-5-(5-trifluoromethylpyridine-2-yl)benzofuran synthesized in the same manner as in Example 21 except that 2-phenyl-5-bromobenzofuran was synthesized from benzoic acid chloride used instead of 1-nonanoic acid and 2-phenyl-5-(5-trifluoromethyl-pyridine-2-yl)benzofuran was synthesized from 2-phenyl-5-bromobenzofuran.
[0170] Tris[2-(2-phenylbenzofuran-5-yl)-5-trifluoro-methylpyridine-C 3 ,N]iridium (III).
EXAMPLE 23
Synthesis of Ex. Comp. No. 72
[0171] 4-bromo-2-hydroxybenzyl alcohol (IV) is synthesized from 4-aminosalicylic acid (made by Aldrich Co.) in the following reaction scheme, and 4-bromo-2-hydroxybenzyltriphenylphosphon bromide (V) is synthesized in the same manner as in Example 21.
[0172] It is easy to synthesize the following compound in the same manner as in Example 21 except for using 1-butanoic acid anhydrate instead of 1-nonanoic acid anhydrate in Example 21.
[0173] Tris[2-(2-propylbenzofuran-6-yl)pyridine-C 5 ,N]iridium (III).
[0174] As described above, according-to the present invention, the metal coordination compound of the formula (1) characterized by the benzofuran structure of the formula (5) as a partial structure is an excellent material which exhibits a high emission quantum efficiency. The electroluminescence device (luminescence device) of the present invention using, as a luminescent center material, the metal coordination compound of the formula (1) is an excellent device which not only allows high-efficiency luminescence but also retains a high luminance for a long period and shows little deterioration by current passage. Further, the display apparatus using the electroluminescence device of the present invention exhibits excellent display performances. | An electroluminescence device having a layer containing a specific metal coordination compound is provided. The metal coordination compound is represented by formula (1) below:
ML m L′ n (1),
wherein M is a metal atom of Ir, Pt, Rh or Pd; L and L′ are mutually different bidentate ligands; m is 1, 2 or 3 and n is 0, 1 or 2 with the proviso that m+n is 2 or 3; a partial structure MLm is represented by formula (2) shown below and a partial structure ML′ n is represented by formula (3) or (4) shown below:
at least one of the optional substituent(s) of the cyclic groups, and the cyclic groups CyCl and CyC2 includes a benzofuran structure capable of having a substituent represented by the following formula (5):
The metal coordination compound having the benzofuran structure is effective in providing high-efficiency luminescence and long-term high luminance. | 8 |
This invention relates to seals in general, and specifically to a one-piece seal that can be used to block the annular interface between a pair of mutually rotating, cylindrical components.
BACKGROUND OF THE INVENTION
A difficult sealing challenge is presented when pressurized fluid must travel across the annular interface formed between a pair of coaxial, relatively rotating cylindrical components. An example of such an environment can be found in a typical vehicle automatic transmission. Various hydraulically operated clutches in the system include cylindrical drums that closely surround the outer surface of an input shaft, forming a thin, annular interface. The pressurized hydraulic fluid needed to operate the clutch piston is supplied by an oil pump, and travels down the center of the input shaft until it reaches the point where the clutch drum surrounds the shaft. From there, a cross drilled feed passage takes the fluid through the shaft and to the interface. From there, the pressurized fluid travels through a port in the piston drum, so as to supply the pressure necessary to operate the piston. Obviously, it is important to prevent too much of the pressurized fluid from leaking into the interface if enough pressure is to be left for the piston.
To prevent fluid loss, a pair of circular grooves is cut into the surface of the input shaft bordering the outlet of the pressurized fluid feed passage, each of which holds an annular seal ring. The sides of the seal rings are flat, so as to closely engage the side walls of the grooves, and the free state diameter of the seal ring is close to the diameter of the inner surface of the piston drum, against which it must seal. In addition, the seal ring is often cut at one point, so that the diameter of the ring can expand and contract to accommodate temperature expansion and contraction, or eccentricity between the shaft and drum, thereby maintaining the radial continuity of the seal. The ring may be cut on a diagonal, so as to create two sloped- or wedge-shaped free ends that overlap and slide back and forth over one another, maintaining the circumferential continuity of the seal ring as it expands and contracts. One drawback of this type of seal ring is that it works best only if there is no axial gap between the seal rings and the side walls of the grooves when the pressurized fluid first leaves the feed passage. If contact is not complete, then pressurized fluid can find its way out the gap and into the interface, threatening the axial continuity of the seal. Likewise, in the case where the seal ring has overlapping, slanted ends, part of the seal may tend to get pried away from the side wall of the groove by the underlying sloped end, also threatening the axial continuity of the seal.
SUMMARY OF THE INVENTION
The invention provides a new seal means for the type of environment described which uses a one-piece blocking seal, as opposed to two separate rings.
In the preferred embodiment disclosed, a single trough of predetermined depth is machined into the outer surface of the input shaft, opening into the annular interface between the shaft and piston drum, and aligned with both the shaft feed passage and the piston drum port. The trough has two axially opposed side walls, and is considerably axially wider than a typical seal ring groove would be.
The blocking seal is molded or otherwise formed in one piece from a resilient, flexible sealing material, with a pair of annular side rails that are interconnected by a bridging section. Each side rail has a free state outer diameter basically equal to that of the inner surface of the piston drum, and a radial thickness greater than the interface. Therefore, each ring is capable of making complete contact with the inner surface of the piston drum, and with the side walls of the trough, thereby completely blocking the interface. Each side rail also has a diagonal cut of the type that creates overlapping, sloped ends, to allow the side rail to expand and contract in diameter to maintain complete contact with drum.
The bridging section connects the side rails together, as a single, integral unit, but is discrete in the sense that it does not block all of the axial space between the side rails, and so will still allow cross flow of pressurized fluid. In one embodiment, it is simply a short beam that extends diagonally across the side rails. In another, it is a series of convolutions that touches the side rails in several spots. In both cases, the bridging section is radially thinner than the side rails, and so does not touch the inner surface of the piston drum. More importantly, the bridging section serves to press the side rails slightly apart, preloading them into the trough side walls, and to press the overlapping, slanted rail ends together. Therefore, when pressurized fluid enters the trough, the side rails are already in their sealing, blocking position, tight to the trough walls, a condition that the pressurized fluid will only serve to reinforce and maintain. Furthermore, the mutual wedging action of the sloped side rail ends is resisted. The radial, axial, and circumferential continuity of the seal is improved, all in a seal that is simpler to handle and install.
It is, therefore, a general object of the invention to provide a one-piece seal to be used to block the kind of interface generally found between the input shaft and piston drum of an automotive transmission.
It is another object of the invention to provide such a seal that is uniquely configured to act in cooperation with a single, wider circular trough cut into the input shaft, as opposed to a pair of grooves.
It is another object of the invention to provide such a seal in which the unifying, integrating structure of the seal also serves to preload the seal into an initial, solid sealing condition, so that the pressurized fluid will only be in a position to maintain the blocking seal, not interfere with it.
DESCRIPTION OF THE PREFERRED EMBODIMENT
These and other objects and features of the invention will appear from the following written description, and from the drawings, in which:
FIG. 1 is a partial cross sectional view of the input shaft and piston drum of a transmission incorporating a first embodiment of the seal means of the invention;
FIG. 2 is a perspective view of the first embodiment of the invention in a free state;
FIG. 3 is an axial view of the seal of FIG. 2;
FIG. 4 is a side view of the FIG. 2 seal;
FIG. 5 is a perspective view of a second embodiment in a free state;
FIG. 6 is an axial view of the FIG. 5 seal;
FIG. 7 is a side view of the FIG. 5 seal.
Referring first to FIG. 1, a typical vehicle automatic transmission includes a cylindrical input shaft (10) surrounded closely by the piston drum (12) of a hydraulically operated clutch. Shaft (10) and drum (12) are basically coaxial, but rotate independently, and at different rates. Therefore, the outer surface of shaft (10) and surrounding inner surface of drum (12) cannot actually touch, forming instead a thin annular space or interface of thickness I. Even the thickness I is not necessarily a constant, since there will be some inevitable running eccentricity between shaft (10) and drum (12). Shaft (10) has a cross drilled hydraulic feed passage (14) that opens into the annular interface in alignment with a port (16) through drum (12). Pressurized hydraulic fluid must exit feed passage (14) and get to and through port (16) without excessive leakage between shaft (10) and drum (12). A circular trough is cut into shaft (10), comprised of two axially spaced side walls (18) of predetermined radial depth, square to the axis of shaft (10). The side walls (18) border feed passage (14) and port (16).
Referring next to FIGS. 2-4, a first embodiment of the blocking seal of the invention, indicated generally at (20), is designed to cooperate with the spaced trough side walls (18). Seal (20) is molded in one piece from a suitably flexible and resilient sealing material, such as nitrile rubber. However, seal (20) could be formed out of another material, even roll formed steel stock, which still has some flexibility and resilience, at least in thin sections. Seal (20) has three basic parts, two identical, axially spaced annular side rails (22), and an interconnecting bridging section (24). Each side rail (22) has a radial thickness t that is significantly greater than I, but somewhat less than the radial depth of the side walls (18). In addition, each side rail (22) is severed at one point on a diagonal, thereby producing two overlapping sloped ends, an underlying end (26) and an overlying end (28), each diagonally opposed to the cut end on the opposite side rail (22). The overlapping ends (26) and (28) can slide back and forth on one another to allow each side rail (22) to independently contract or expand, thereby maintaining close contact with the inner surface of drum (12), so as to compensate either for temperature effects or running eccentricity at the interface, or both.
Referring to FIGS. 1-4, the bridging section (24) cooperates with the side rails (22) to increase their sealing effectiveness. Bridging section (24) is a short beam that extends diagonally between the two overlying sloped ends 28. Therefore, seal (20) is one continuous, integral piece, moving from an end (26) to the other. However, the bridging section is discrete in the sense that it occupies very little of the total space between the side rails (22). The bridging section (24) is also radially thinner than t and, more important, is radially inset from the cylindrical surface that the outer edges of the side rails (22) lie upon. The bridging section (24) is effectively long enough to keep the outer surfaces of the side rails (22) spaced axially apart by an amount indicated at A that is just slightly greater than the degree to which the trough side walls (18) are spaced apart. These dimensions allow seal (20) to be installed and operate in a manner described next.
Referring again to FIG. 1, seal (20) is installed to input shaft (10) before the piston drum (12) is assembled by running it over the shaft (10) until it reaches and seats itself between the trough side walls (18). Then, the piston drum (12) and the rest of the transmission are assembled. Given the free state diameter and radial thickness of seal (20) described above, the outer edge of the side rails (22) makes solid contact with the inner surface of drum (12), blocking the interface, but any excessive diameter differential relative to drum (12) can be relieved by the overlapped ends (26) and (28) sliding past one another, preventing buckling or wrinkling. There is also a slight compression of the bridging section (24). As a consequence, the side rails (22) are preloaded axially outwardly and against the trough side walls (18). When hydraulic fluid leaves the shaft feed passage (14) between the trough side walls (18), it is blocked from going anywhere but through piston port (16). It cannot leak or escape between the preloaded side rails (22) and trough side walls (18), and only serves to load the rails (22) harder against the walls (18). More specifically, the axially outward force provided by the bridging section (24) is directly applied between and against the two overlying side rail ends (28). Therefore, should contraction of the side rails (22) for any reason cause the underlying sloped side rails ends to wedge the overlying ends (28) away from the trough side walls (18), the tension of the bridging section (24) will tend to counteract, maintaining snug, continuous side rail (22) to side wall (18) contact. Total continuity of the blocking seal, radial, axial and circumferential, is maintained, with a seal that can be installed in one step.
A second embodiment of the blocking seal of the invention, indicated generally at (30), is designed to be installed in the same environment and to cooperate with the same trough side walls (18). It provides the same basic features and advantages, and may be described more briefly. Blocking seal (30) also has two annular side rails (32), which are the same size as the side rails (22). They are also each locally severed to produce underlying and overlying sloped ends (34) and (36). These overlap in the same basic relation as in seal (20). However, the overlying sloped ends (36) are directly axially opposed, not diagonally opposed. The side rails (32) are integrated by a bridging section which is significantly different in shape, being comprised not of a single, short beam but of a series of interengaged, sinuous convolutions (38). The convolutions (38) form one complete loop that begins at one overlying sloped end (36) and ends at another. Each convolution (38) presses against an axially opposed convolution (38), keeping the side rails (32) at the same free state separation A. When installed, however, the axial preload they provide will be stronger and more evenly distributed around the entire circumference of the side rails (32). In addition, even more preload force against the overlying sloped ends (36) is provided, because the convolutions (38) begin and end near them. The extra axial preload would make seal (30) even more suitable for maintaining seal continuity in high pressure environments, but would not add appreciably to seal torque, since the convolutions (38) are also radially inset from the side rails (32) and will not rub on the piston drum (12). Furthermore, the convolutions (38), since they are not directly attached to the the side rails (32), would not significantly retard their radial expansion and contraction.
In conclusion, both seal embodiments provide improved sealing in the intended environment, along with simpler handling and installation. If radial contraction and expansion of the side rails were not needed, then they would not have to be severed to produce the overlapping ends. The bridging section would then provide an axial preload for the side rails, but would not need to prevent the end wedging action described. Other shapes could be provided for the bridging section that joins the side rails, so long as it did not block the radial path from passage (14) to port (16), provided the same free state axial spacing of the side rails, and was radially clear of the drum (12) when installed. Theoretically, the side walls (18) could be cut into the surface of either the inner member or the surrounding outer member that forms the interface, although, in the environment disclosed, the drum (12) would generally not be thick enough to have a trough machined into it. Therefore, it will be understood that it is not intended to limit the invention to just the embodiments disclosed. | A seal for the rotating annular interface between a transmission input shaft and surrounding piston drum is uniquely configured as a single, integral part. A circular trough with two annular side walls is machined into the input shaft. The seal includes two annular side rings sized to contact the inside of the piston drum radially, and to contact the side walls of the trough axially. A bridging section joins the two side rails, and also preloads them into the trough side walls. Therefore, when hydraulic fluid is pumped between the side rails, it is prevented from leaking between the side rings and side walls and into the interface. | 5 |
CROSS-REFERENCES TO RELATED APPLICATIONS
Not Applicable
FEDERALLY SPONSORED RESEARCH
Not Applicable
SEQUENCE LISTING OF PROGRAM
Not Applicable
BACKGROUND OF THE INVENTION—FIELD OF INVENTION
This invention relates to acquiring rock data in oil and gas wells, specifically to the mechanics of running the measuring instruments past sidewall obstructions to the bottom of the well during the logging operation.
BACKGROUND OF THE INVENTION—SUMMARY OF THE PROBLEM TO BE SOLVED BY THE PRESENT INVENTION
The measurement, or logging, of rock properties in wells drilled for hydrocarbons has become an increasingly essential part of petroleum exploration since the first downhole wireline electrical log was invented by Schlumberger in 1939. Paper data strips (or digital data displays), referred to as well logs, now constitute the main record of the rock formations penetrated by oil and gas wells. But throughout the 65-year history of electrical logging, obstructions on the borehole sidewall have caused difficulties in running logging sondes down the hole. Logging sondes comprise various sets of instruments that can be lowered into the borehole on an electrical cable, with the data thereby recorded at the surface. A problem that has never been completely solved is that of reliably getting the sonde to run in all the way to the bottom of the well.
As modem boreholes become deviated farther and farther from vertical, this problem is exacerbated. Instead of dropping freely down the center of the borehole, the logging sonde then tends to slide along the lower sidewall of the borehole. In this position, the sonde is slowed by friction or stopped by minor sidewall obstructions. Once the considerable down-hole momentum of the sonde has been lessened or lost, it becomes difficult to urge the sonde to pass even minor obstructions or sidewall roughness.
Despite the use of the many previous inventions for urging the logging sonde past borehole obstructions, it often happens that the borehole must be repeatedly reconditioned with the drilling bit, a time-consuming and costly remedy. In the worst cases, the logging sonde never reaches the lower part of the borehole, and that part of the hole does not get logged. In petroleum exploration and production drilling, it is usually the bottom part of the hole that is most important, as that is where the potential petroleum producing zones often lie. Failure to log these potentially producing zones may lead to inaccurate assessment of the potential producing zones or even the premature abandonment of an expensive borehole that might have become a profitable oil or gas well. In addition to the financial loss is the potential loss of valuable resources.
BACKGROUND OF THE INVENTION—PRIOR ART
In the petroleum drilling industry, determining the characteristics of the rock formations that have been drilled has been of critical importance since the birth of the industry over a hundred years ago. Since the 1940s, increasingly sophisticated rock measurements have been made by lowering logging sondes into the borehole or producing well. The logging sondes are suspended from the surface by an electrical cable that normally allows the recording of the information at the surface.
Prior Art
Since the inception of the well logging industry, various devices have been employed to ease the running in hole of the logging sondes. These devices have been partly successful, but as wells become deeper and the well angles become farther from the vertical, the difficulty of logging has increased apace. Consequently, sondes still frequently fail to reach bottom. However, none of the prior art bears much resemblance to the present invention and therefore they will be discussed mainly to highlight the differences.
One attempt to a solution that is still used is a tractor device, wherein a tiny tracked vehicle with an electric motor is attached to the sonde and is employed to pull the sonde along. However, the tractor can only be used when the sonde has come to a stop or nearly so. A related solution to the problem of running in hole involves small wheels, pressed against the sidewall and powered by motors in the sonde. These approaches have been patented, but they are unrelated to my invention and so will not be discussed further.
Pushing the sonde down the borehole with the drill pipe is another method currently in use, especially in boreholes with high deviation. This method has the disadvantages of being very slow, as running drill pipe in the borehole is an inherently slow process, and of potentially damaging or destroying the sonde and the logging cable. Damaging the logging equipment leads to long delays in the logging operation for repairs. Often the specific logging operation must be abandoned for lack of available replacement tools. Destruction of the logging sonde may leave junk in the borehole, leading to lost time in the retrieval of the junk or drilling past the junk in a parallel borehole.
An increasingly popular solution is to incorporate the logging sensors into the drilling assembly, wherein information is relayed to the surface acoustically via pulses in the drilling mud. The process is called measurement-while-drilling, or MWD. This is at best an imperfect solution and is limited to certain kinds of logs. However, the technology is utilized in some of the prior art discussed below.
Previous Patents
Several auger-like tools were found among prior patents, mainly war machines and hole-digging tools. None closely resemble the current invention beyond the novel use of an augering tool, itself an ancient device. They are described briefly below to demonstrate the evolution of auger tool patents:
(1) Auger. Perhaps it should be mentioned that my invention, in common with several of the patented inventions described below, makes some use of the auger, an ancient tool. The auger is fundamentally a coiled version of an inclined plane, or a screw. The auger dates at least as far back as the ancient Greek Empire, and probably much earlier. It was employed by Archimedes some 2200 years ago as the water-pumping device now known by his name, the Archimedes Screw. However, my invention introduces a new and unanticipated use of this basic tool. (2) Push screw driver. The present invention employs a helical gear in somewhat the same manner as the old push screw driver, in which the rotation of the blade is activated by pushing the handle. (3) U.S. Pat. No. 1,276,706—Issued August, 1918 to Mr. Gurdy L. Aydelotte. Land Torpedo. This ground torpedo appears to be a clever war machine developed to burrow in mud, soil or soft alluvium. It is powered by an electric motor energized by a trailing electric cable that is connected to a power source at the ground surface or possibly a trench. It is designed to carry a bomb that can be detonated by the operator.
Aydelotte's patented device has little in common with the current invention. Aydelotte's land torpedo is electrically powered, whereas my passive logging sonde auger derives its energy from the momentum of the logging sonde. Aydelotte's land torpedo is designed to progress by boring its way continuously through the soil in a generally horizontal direction, whereas my passive logging sonde auger is designed to operate occasionally in an open borehole in a generally downward direction. Neither the passive nature nor the spring return of my passive logging sonde auger is anticipated by Aydelotte's land torpedo, and these two features are the main mechanical innovations of my invention.
(4) U.S. Pat. No. 1,303,764—Issued May, 1919, to Mr. Prentice C. Broadway. Armored War Apparatus. This war apparatus is an innovative battle tank that uses an auger device on both the front and back ends to aid the tank in penetrating forests and walls. (An application not specifically mentioned, and apparently never used, might have been to aid the tanks in penetrating dense hedges such as those encountered in the Normandy invasion during World War II.)
Broadway's patented armored war apparatus has little in common with the current invention. Broadway's war apparatus is designed to be actively powered, whereas my passive logging sonde auger derives its energy only from the momentum of the logging sonde to which it is attached. Broadway's war apparatus is designed for use above ground in a generally horizontal direction to penetrate obstacles, whereas my passive logging sonde auger is designed to operate in an open borehole in a generally downward direction and to bypass obstacles. Most importantly, Broadway's war apparatus anticipates neither the passive nature nor the spring return of my passive logging sonde auger, and these two features are the main mechanical innovations of my invention.
(5) U.S. Pat. No. 1,372,318—Issued Mar. 22, 1921, to Mr. Alois B. Saliger and assigned to Saliger Ship Salvage Corporation. Burrowing Machine. Like Aydelotte's land torpedo (U.S. Pat. No. 1,276,706), Saliger's burrowing machine is a device for burrowing semi-horizontally through soft material, in this case mud. It was invented to draw a line under a sunken ship to aid in its salvage. Also like the land torpedo, Saliger's burrowing machine employs auger-like attachments for this purpose, termed propellers in the patent description. The burrowing machine is to be powered by an included fluid hydraulic motor, either gas or liquid, with a pump at the surface. An electric motor is suggested as an alternative power source.
Saliger's patented device has little in common with the current invention. Saliger's burrowing machine requires a hydraulic or electrical power source, whereas my passive logging sonde auger derives its energy from the momentum of the logging sonde. Saliger's burrowing machine is designed to progress by boring its way continuously through the mud in a generally horizontal direction, whereas my passive logging sonde auger is designed to operate only as needed in an open borehole in a generally downward direction. Neither the passive nature nor the spring return of my passive logging sonde auger is anticipated by Saliger's burrowing machine, and these two features are the main mechanical innovations of my invention.
(6) U.S. Pat. No. 1,388,545—Issued Aug. 23, 1921, to William J. Bohan. Self-intrenching Subsurface Land-Torpedo. This ground torpedo appears to be a sophisticated version of Aydelotte's land torpedo (U.S. Pat. No. 1,276,706). It is also powered by an electric motor and energized by a trailing electric cable that is connected to a power source at the ground surface, in this case a personnel trench. Like Aydelotte's land torpedo, it is designed to carry a bomb that can be detonated by the operator by means of an electrical signal transmitted along the trailing electrical cable.
Bohan's patented device has little in common with the current invention. Bohan's self-intrenching land torpedo is electrically powered, whereas my passive logging sonde auger derives its energy from the inertia of the logging sonde. Bohan's land torpedo is designed to progress by boring its way continuously through the soil in a generally horizontal direction, whereas my passive logging sonde auger is designed to operate only as needed in an open borehole in a generally downward direction. Neither the passive nature nor the spring return of my passive logging sonde auger is anticipated by Aydelotte's land torpedo, and these two features are the main mechanical innovations of my invention.
(7) U.S. Pat. No. 2,216,656—Issued Oct. 1, 1940, to Roy Smythe and partly assigned to Angelo J. Giannone. Toy. Smythe's invention is basically a clever toy version of the war machines described above, employing a windup motor as a power source. Aside from the novel power source, Smythe's toy contributes nothing to the technology of augering tools. Like the inventions upon which it is based, it in no way anticipates my passive logging sonde auger. (8) U.S. Pat. No. 3,375,885—Issued Apr. 2, 1968, to R. F. Scott, et al. Burrowing Mechanism. Scott's invention is basically an industrial version of the clever toy of Smythe (U.S. Pat. No. 2,216,656). Like other inventions described above, it uses an electrical motor as a power source. Each of the basic elements were covered in the patents described above, and Scott's burrowing machine contributes nothing to the technology of augering tools. Like the inventions upon which it is based, it in no way anticipates my passive logging sonde auger. (9) U.S. Pat. No. 3,710,877—Issued Jan. 16, 1973, to Harry Michasiw. Auger Device. This patent describes one of what must be many augering devices designed for digging holes, particularly for posts. The device combines an auger, a shaft, and a power source. The power source in the generic digging auger may be manual, hydraulic, or machine. (10) U.S. Pat. No. 6,691,871—Issued Jan. 24, 2004, to Arthur E. Drumm and Thomas B. Mash. Auger tool for boring. Drumm's auger patent illustrates 31 years of progress in digging auger design since the issuing of the Auger Device patent to Harry Michasiw, above. Neither Drumm's patent, his prior art patent documents (U.S. Pat. Nos. 1,993,365, 2,221,680, 3,710,877, 5,487,432, 5,782,310, 6,089,334), nor patents referenced in the prior art (U.S. Pat. Nos. 6,161,631, 6,168,350, 6,283,321, 6,308,789, 6,675,916) provide material that anticipates my passive logging sonde auger.
The augering devices described above have little in common with my invention. Each is externally powered, whether by hand or by machine, whereas my passive logging sonde auger derives its energy from the inertia of a logging sonde. Neither the passive nature nor the automatic re-extension of my passive logging sonde auger is anticipated in the augers designed for digging holes. These two features are the main mechanical innovations of my invention.
The following items of patented prior art all relate specifically to drilling devices or measurement devices used in the oil and gas drilling industry:
(11) U.S. Pat. No. 4,270,620—Issued Jun. 2, 1981, to Mr. James D. Lawrence. Constant Bottom Contact Tool. Lawrence's invention pertains to maintaining constant bottom contact with a borehole bit during drilling operations, especially those conducted at sea. This field of invention is unrelated to my invention, which pertains to the lowering of a measuring sonde into a well bore.
In Lawrence's Constant Bottom Contact Tool, a spring and helical gear within the bottom hole drilling assembly function as a shock absorber, both for unavoidable vertical motion of the drilling assembly and for sudden changes in torque on the drill bit. The intent is to reduce vertical and torsional loads on the drill string without substantially interfering with normal drilling operations. In doing so, the entire drill pipe and drilling assembly suffers less stress that might otherwise cause it to break.
In contrast, my invention employs a helical gear and spring assembly in a measuring sonde to convert some on the kinetic energy of the sonde to rotational energy in the auger, thus causing the auger to rotate in a manner that pulls the sonde past the obstruction that caused the assembly to be activated. Thus even though Lawrence's and my inventions utilize similar mechanical elements, my invention uses these elements in a totally different manner so as to achieve a different and unrelated result.
(12) U.S. Pat. No. 4,422,043—Issued Dec. 20, 1983 to Mr. Richard A. Meador. Electromagnetic Wave Logging Dipmeter. Meador's invention pertains to an improvement in the dipmeter measuring sonde. My invention pertains to lowering measuring sondes into boreholes and is therefore unrelated in purpose.
In Meador's invention, a longitudinal spring is employed to provide force to extend measuring pads laterally to contact the sidewalls of the borehole. This is a common use of longitudinal springs in many modern logging devices. My invention uses a longitudinal spring in a contrasting manner as a means of resistance and to re-extend an augering tool to its initial position after pulling the attached sonde past an obstruction. Thus the use of a longitudinal spring in my invention bears no similarity the use in Meador's invention or to similar patented measuring sondes with pad-mounted sensors.
(13) U.S. Pat. No. 4,912,415—Issued to Kurt I. Sorensen on Mar. 27, 1990. Sonde of Electrodes on an Earth Drill for Measuring the Electric Formation Resistivity in Earth Strata. The field of Sorensen's invention pertains to measuring instruments that are incorporated into a drilling assembly, for logging during the drilling operation. It is an attempt to improve on the relatively new MWD (measurement while drilling) technology that is now in wide use in high-angle wells. My invention pertains to lowering measuring sondes into boreholes and is therefore unrelated in operational function.
Sorensen's invention makes use of a spiral winding to aid in the removal of drill cuttings from the vicinity of the MWD sonde. The spiral winding does not engage any other part of the mechanism and therefore does not function as a gear. The tool's function as an auger is limited to moving material up the borehole; it plays no part in the drilling operation or in the running-in-hole of the drilling and MWD assembly. In contrast, my invention employs a helical gear and spring assembly in a conventional cable-operated measuring sonde to convert some of the kinetic energy of the sonde to rotational energy in the auger, thus causing the auger to rotate in a manner that pulls the sonde past the obstruction that caused the assembly to be activated. Thus it can be seen that the spiral winding in Sorensen's invention is used in an entirely different manner than the helical gear and auger in my invention, in order to achieve a totally different end.
(14) U.S. Pat. No. 4,676,310—Issued to Mr. Serge A. Scherbatskoy and Mr. Jacob Neufeld on Jun. 30, 1987. Apparatus for Transporting measuring and/or Logging Equipment in a Borehole. Scherbatskoy and Neufeld's invention utilizes a motor-driven helix mounted on a logging sonde that can be expanded to the sidewalls, fitting then snugly in the entire diameter of the borehole. The helix is then rotated by a motor within the logging sonde, causing it to rotate in screw fashion and pull the logging sonde along. Although the helix of Scherbatskoy and Neufeld's invention can be compared to the auger of my invention, the inventions themselves are very different, in that:
(a) The auger of my invention is powered by the momentum of a rapidly moving logging sonde, whereas the helix of Scherbatskoy and Neufeld's invention is powered by a motor in a stationary or near-stationary logging sonde. (b) The auger of my invention is designed to be an extension of the logging sonde and of similar diameter, whereas the helix of Scherbatskoy and Neufeld's invention is designed to be mechanically forced into the entire diameter of the sidewall, (c) The purpose of my invention is to keep the logging sonde moving down the borehole and maintain its momentum, whereas Scherbatskoy and Neufeld's invention has the purpose of pulling a logging sonde that has already become stuck or has otherwise lost its downward momentum.
(15) U.S. Pat. No. 4,771,830—Issued to Mr. William R. Peate on Sep. 20, 1988, and assigned to Schlumberger Technology Corp. Apparatus for Positioning Well Tools in Deviated Well Bores. Like my invention, Peate's invention employs an external augering tool on a logging sonde. However, they are not mounted on the nose of the logging sonde for the running in hole operation, but on the sides of the logging sonde to aid in tool orientation during the unrelated logging out operation. Peate's drawings show that the nose of the logging sonde has been left squared off, so that the projecting ribs of his invention could not have aided in the running-in-hole operation of the logging sonde. (16) U.S. Pat. No. 5,259,467—Issued to Mr. William N. Schoeffler on Nov. 9, 1993. Directional Drilling Tool. Schoeffler's invention pertains to the directional drilling of boreholes, more specifically to the operation of a hydraulic down-hole motor. This field of invention is unrelated to that of my invention, which pertains to the lowering of a measuring sonde into a well bore on a wireline.
Schoeffler's Directional Drilling Tool employs an internal longitudinally mounted spring to apply an upward force to a wash pipe and piston within the tool, as part of the operation of the hydraulic down-hole motor. In contrast, my invention employs a helical gear and spring assembly in a conventional cable-operated measuring sonde to convert some on the kinetic energy of a measuring sonde to rotational energy in an auger, causing the auger to rotate in a manner that pulls the sonde past the obstruction that caused the assembly to be activated. Thus it can be seen that the spring in Schoeffler's invention is used in an entirely different manner than the spring in my invention, in order to achieve a totally different end.
(17) U.S. Pat. No. 5,396,966—Issued to Mr. Albert E. Roos, Jr., Steven W. Drews, and William J. McDonald on Mar. 14, 1995. Roos, Drews, and McDonald's patent pertains to the downhole steering sub assembly for the drilling of horizontal wells for various purposes. This field of invention is unrelated that of my invention, which pertains to the lowering of a measuring sonde into a well bore on a wireline.
Roos, Drews, and McDonald's patent uses a longitudinally mounted compression spring only to provide pressure to expand bow springs that are mounted laterally on the side of the steering sub. There is no similarity to my invention in the purpose or function of the longitudinally mounted spring.
(18) patent application Publication 2004/0129457 A1—Application by Mr. Keith McNeilly dated Jul. 8, 2004. Torque Absorber for Downhole Drill Motor. The field of McNeilly's invention pertains to hydraulic down-hole motors used in the drilling of boreholes. This field of invention is unrelated to that of my invention, which pertains to the lowering of a measuring sonde into a well bore on a wireline.
McNeilly's invention uses a longitudinally mounted spring element to automatically adjust the weight on the drill bit, so as to prevent stalling of the downhole hydraulic motor due to resistance to bit rotation. In contrast, my invention employs a helical gear and spring assembly in a conventional cable-operated measuring sonde to convert some on the kinetic energy of a measuring sonde to rotational energy in an auger, thus causing the auger to rotate in a manner that pulls the sonde past the obstruction that caused the assembly to be activated. Thus it can be seen that the spring in McNeilly's invention is used in an entirely different manner than the spring in my invention, in order to achieve a totally different end.
BACKGROUND OF INVENTION—OBJECTIVES AND ADVANTAGES
The present invention introduces a unique solution to the age-old problems related to running in and logging out of oil and gas wells with logging sondes. (running in hole is the literal term used in the petroleum industry for lowering either a logging sonde or a string of drillpipe into a well. Similarly, pulling out of hole is used for the reverse operation; logging out applies to pulling the logging sonde out of the well during the logging operation with the sensors and recorders turned on. The term hole is in common use to mean either a well or a borehole. These terms are integral parts of drilling jargon and as such are incorporated in many terms.) Several objectives and advantages of the present invention are:
(a) to facilitate the running-in-hole of logging sondes, (b) to provide a means for logging sondes to bypass sidewall obstructions in boreholes, particularly washouts, boulders, ledges, keyseat grooves, and cave-ins, as illustrated in the drawings, (c) to increase the likelihood that the logging sonde will reach the bottom of the hole where the critical oil and gas reservoir data may be recorded, (d) to thereby reduce the need for repeatedly cleaning out and reconditioning the borehole with expensive and time-consuming bit runs, (e) to reduce the chances of losing the hole because of delays in the logging operation, and (f) generally, to make the borehole logging process more efficient, complete, and cost effective.
BACKGROUND OF THE INVENTION—SUMMARY
The present invention is a passive auger device that is attached to the downhole end of a borehole logging sonde in the oil and gas drilling industry. The auger device is integrated with a spring means and a spiral gear means. When, during running in a borehole, a sidewall obstruction impedes the progress of the logging sonde, downward momentum will compress the auger against the spring, and at the same time the spiral gear will cause the auger to rotate. In rotating, the auger both deflects the sonde away from the sidewall obstruction with its rotary motion and pulls it through the area of the obstruction with its auger. When the obstruction has been thus bypassed, the spring extends the auger to its initial extended position where it is then in place to encounter subsequent obstructions.
DRAWINGS
Sidewall obstructions that are commonly encountered and can be passed more easily with the benefit of the passive logging sonde auger include ledges, projecting boulders, eroded washouts, caved out zones, key seat grooves, and general sidewall roughness or rugosity. These terms are well understood in the drilling industry and are illustrated by the sketches in FIGS. 1 a through 1 f in order to augment understanding of the utility of the invention. When the sonde assembly is pulled out or logged out of the borehole, the passive logging sonde auger trails the sonde and is inactive.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified diagram of a borehole in which a wireline logging operation is being conducted.
FIG. 2 a shows a longitudinal cross section of the downhole portion of a deviated borehole in which a wireline logging operation is being conducted. It illustrates somewhat diagrammatically various sidewall obstacles to the running-in-hole of a logging sonde, that the present invention is designed to bypass. Details of the individual obstructions are discussed below with the transverse cross sections.
FIG. 2 b is a lateral cross section of an in-gauge borehole, approximately the same diameter as the nominal drill bit size. The bit size used may vary, but is commonly between 10 cm and 50 cm in diameter in the deeper and more important part of the hole that is usually most difficult to log. In contrast, most logging sondes are around 10 cm in diameter.
FIG. 2 c is a lateral cross section of an enlarged section of the borehole. These are common occurrences in softer rock formations. A common cause is erosion by the rotating drill pipe and the flow of drilling fluid. Enlarged sections can be very long, wide, and highly irregular.
FIG. 2 d is a lateral cross section of a sidewall cave-in, sometimes found in faulted rock formations. They can partly block the well bore, making it difficult for logging sondes to pass, especially if they occur on the part of the sidewall along which the sonde is running.
FIG. 2 e is a lateral cross section of boulder projecting into an enlarged section. Large boulders may also become dislodged and re-oriented so that they partly block the borehole.
FIG. 2 f is a lateral cross section of a keyseat groove. These are usually formed because of erosion by the drill pipe in cases where it continuously lies along one side of the hole. As the drill pipe and logging sonde are of similar diameter, the sonde can enter the keyseat groove and become stuck.
FIG. 2 g is a lateral cross section of a rock ledge in a washed out zone, a very common sidewall obstruction. Such ledges are normally composed of very hard rock. They can extend all around the hole and obstruct the sonde in any position.
FIG. 2 h is a lateral cross section of a rough sidewall, normally found in rock formations of rapidly varying strength and resistance to erosion. Rough patches in the sidewall can slow the progress of the sonde as it runs in the hole, robbing it of important downhole velocity and kinetic energy.
FIG. 3 a is an exterior view of the present invention in its initial extended position, attached to the lower end of a logging sonde.
FIG. 3 b is a cut-away view of the present invention in which the spiral gear and extended and the relaxed return spring can be seen.
FIG. 4 a shows an exterior view of the present invention in its collapsed position, attached to the lower end of a logging sonde.
FIG. 4 b shows a cut-away view of the present invention in its collapsed position, attached to the lower end of a logging sonde. The spiral gear and compressed spring are shown.
FIGS. 5 a – 5 f show some of the many auger designs suggested as alternate embodiments of the present invention. The normal diameter of the logging sonde and the body of the present invention is normally around four inches; the length of the augers can be short, as shown these illustrations, or much longer.
FIG. 5 a is a thick and rounded auger used in the preferred embodiment, emphasizing rounded nose and spirals.
FIG. 5 b adds a sharp ridge on the spirals.
FIG. 5 c is similar to the preferred embodiment of FIG. 5 a but with a nose similar in diameter to the logging sonde.
FIG. 5 d is a rounded, spade-shaped auger somewhat larger than the logging sonde.
FIG. 5 e shows a thick, rounded auger with a steep pitch.
FIG. 5 f is a more conventional auger with a deeply incised trough, commonly used in boring operations.
FIG. 6 a is a cut-away view of an embodiment of the present invention in which a pneumatic device replaces the spring as the compression resistance.
FIG. 6 b is a cut-away view of an embodiment of the present invention in which only gravity is employed to keep the auger in extended position.
FIG. 7 shows the borehole sketch of FIG. 1 a , in which the lower end of a logging sonde to which the present invention has been attached is shown striking two separate obstructions with the augering action set to commence.
DRAWINGS—REFERENCE NUMERALS
10 Earth borehole
12 Drilling fluid filling borehole
14 Sidewall of borehole
16 Oil and gas reservoir
18 Drilling rig
20 Logging sonde
22 Bull nose of logging sonde
24 Logging unit
26 Pulley
28 Logging cable
30 Surface of ground
32 Sidewall of in-gauge borehole
34 Nominal hole size, or bit diameter
36 Enlarged borehole due to erosion
38 Sidewall cave-in
40 Projecting boulder in sidewall
42 Keyseat groove
44 Ledge of hard rock
46 Rough, irregular sidewall
50 Apparatus of the present invention
52 Auger tool
54 Lower tool casing that also constitutes the exterior part of a spiral gear
55 Outside teeth of a spiral gear
56 Upper tool shaft that extends as the inside part of a spiral gear
58 Means of connection to logging sonde
60 Spring
62 Chamber
64 Inside shaft of a spiral gear
66 Mud ports
68 Safety stop
70 Logging sonde combined with the present invention as a unit
72 Cylinder portion of pneumatic device
74 Piston portion of pneumatic device
80 Sharp ridge on auger tool
82 Blunt nose on auger tool
84 Broad shoulder on auger tool
86 Steep pitch on auger tool
88 Deeply incised trough on auger tool
90 Sonde with auger tool striking a sidewall obstruction in the form of a cave-in
92 Sonde with auger tool striking a sidewall obstruction in the form of a ledge
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A general view of a logging operation in which the present invention is intended to be used is shown in FIG. 1 . The borehole (also referred to as the hole or well), 10 is normally in the range of 10–50 cm in diameter. Boreholes commonly decrease in diameter with depth as sections are sequentially protected behind pipe. A 30 cm diameter well is common. It is filled with viscous drilling fluid 12 during drilling operations. The wall of the open part of the hole is called the sidewall 14 , and it is on the sidewall that obstructions normally are found that impede the running-in-hole of logging operations. At the surface, the drilling rig 18 and associated equipment controls virtually all of the operations in the well.
Oil and gas reservoirs 16 are normally located near the bottom of the well, which may be anywhere from 200 meters to more than 10,000 meters in depth. The fluid content of these reservoirs is assessed with wireline logs obtained in a logging operation. Based on this assessment, the borehole may be completed as a producing oil or gas well or abandoned as a dry hole.
A basic logging operation is also illustrated in FIG. 1 . A logging sonde 20 with a rounded “bull nose” 22 is lowered into the borehole on a conductive logging cable 28 . The logging sonde may range from 3 m to 10 m in length and may weigh as much as 100 kg. The logging cable 28 extends to the surface, where it threads through the drilling rig 18 via a pulley 26 to the logging unit 24 located on the ground surface 30 or on the deck of an offshore drilling platform or ship. This unit contains the computers, recording equipment, and human operators and is the nerve center of the logging operation. Rock formation measurements of the entire borehole are made by instruments in the logging sonde 20 . The actual sensors may be centrally located in the logging sonde 20 or extended against the sidewall 14 .
The present invention deals with the problem of getting the logging sonde all the way to the bottom of the borehole to log the potentially producing formations. The running-in-hole operation may be especially difficult in a deviated well, as sidewall friction is increased and the down-hole component of gravity is decreased. In such wells, the logging sonde 20 slides dwonward along the low side of the borehole where it may encounter various sidewall obstructions and irregularities that have the potential of slowing or stopping its downward progress. As the logging sonde 20 is normally around 10 cm in diameter, the center of the bull nose 22 is therefore only 5 cm from the sidewall. Consequently, its progress can be impeded by relatively small sidewall irregularities.
FIG. 2 shows some examples of sidewall irregularities, among them enlarged sections or washouts 36 , cave-ins 38 , boulders 40 , keyseat grooves 42 , ledges 44 , and general sidewall roughness 46 . Any of these features can cause the logging sonde to hang up, thus slowing or stopping its progress down the hole. Once the downward momentum of the logging sonde 20 has been lost, it becomes difficult or impossible to urge it to proceed. Sidewall friction prevents easily restarting the logging sonde and the original momentum cannot be regained.
The preferred embodiment of my invention replaces the standard rounded nose (“bull nose”) of the logging sonde assembly 70 with a blunt-nosed augering device 50 powered by the momentum of the logging sonde. The augering device 50 comprises only a few main parts, shown and labeled in FIGS. 3A and 3B in the initial unstressed, extended position. These parts are:
(a) an auger tool 52 , (b) an external tool casing 54 that is connected to the auger tool, which functions also as the external tube component of a spiral gear assembly, (c) a plurality of mud ports 66 connecting an open chamber 62 inside of the tool casing and the borehole, to allow free circulation of drilling fluid in the tool to prevent pressure buildup during compression, (d) an internal shaft component of a spiral gear assembly 64 , that meshes with the external spiral gear component 55 and continues upward as a non-geared shaft 56 to a means of connection 58 with the main logging sonde 20 , (e) a spring resistance mechanism 60 contained within the open chamber 62 within the lower part of the apparatus that permits the lower tool component 54 to be compressed against the spiral gear assembly 64 of the upper tool component.
The spring resistance mechanism 60 is attached at one end to the top of the auger nose 52 and on the other end to the lower end of the internal shaft of the spiral gear 64 , so as to prevent the tool pulling apart. A conventional safety stop means 68 may also be placed within the spiral gear mechanism to supplement this same end.
OPERATION OF THE PREFERRED EMBODIMENT
During the making up of the logging sonde assembly in the drilling rig 18 , either at the surface of the ground 30 or on a drilling vessel, the augering tool of the present invention 50 is attached at the downhole end, in place of the conventional bull nose. The logging sonde thus modified 70 is then lowered into the borehole 10 in the conventional manner, suspended by the logging cable 28 . During this running-in-hole operation, the modified logging sonde 70 may strike an obstruction on the sidewall, such as a ledge cave-in 38 or a ledge 44 as illustrated in FIG. 7 . When this happens, the momentum of the heavy measuring sonde 20 then forces the auger nose assembly of the present invention 52 to compress rearward against the spring 60 , FIGS. 4A and 4B , so that the auger tool 52 is urged to rotate by the spiral gear 64 . The augering action thereby produced allows the auger tool 52 to pull the entire sonde assembly 90 past the cave-in, ledge, or any of the other sidewall obstructions displayed in FIG. 2 . In this way, sidewall obstructions that would have slowed or stopped logging sondes of older design can be bypassed with ease. Once the obstruction has been bypassed, the compressed spring resistance mechanism 60 urges the auger nose 52 to return to its original extended position FIG. 2 , whereupon it is ready to encounter and bypass the next sidewall obstacle by the same process.
Although the present claims broadly cover multiple design options, they work in general as the specific example described herein.
It will be appreciated by the reader that the example described herein represents but one of many tool designs which may be constructed and which will accomplish the result claimed in this patent application in basically the same way—that being to rotate an auger using the kinetic energy of the sonde, and that the patent should be broadly construed to include any tool design that produces that specific result in the same basic manner and using the same basic energy transfer. For example, there are many designs of spiral or helical gears that might be used. Instead of a spring 60 in the upper portion, a fluid-filled pneumatic device 72 or other form of resistance might be employed. The auger nose 26 might be given any of multiple pitches and shapes as shown in FIG. 5 ; or the upper or lower casing and mud ports might be given different design or eliminated altogether.
ALTERNATE EMBODIMENTS
While only a single embodiment of the present invention has been illustrated and described herein, it is apparent that various modifications and changes may be made without departing from the principles of this invention in its broader aspects, and, therefore the aim in the appended claims is to cover such modifications and changes as fall within the spirit and scope of this invention.
FIG. 5 illustrates a few of the many possible designs of the auger nose 25 of the present invention. Each may have its best use in specific situations, and this patent should not be construed as limited by auger design. In FIG. 4 a , the spring resistance device 27 in the augering tool is replaced by a pneumatic resistance device comprising a cylinder 40 and piston 41 , which could be constructed in numerous designs other than the one illustrated. The resistance devices depicted are standard mechanical products and are not claimed in this patent, but their function of storing kinetic energy as potential energy in the present invention is regarded as a new application that is claimed below. FIG. 4 b shows the simplest design of the present invention, in which the force of gravity is utilized to return the auger to initial extended position. This technique may be effective in a vertical hole. | The auger is attached to a spiral gear and a spring, the apparatus then being connected to the downhole, leading end of the logging sonde. When the auger nose of the modified sonde assembly strikes any of various obstructions on the sidewall that cause it to lose momentum, such as a rock ledge, the momentum of the heavy sonde causes the auger nose assembly to compress, forcing the auger to rotate on the spiral gear. The rotational action thus produced allows the auger to pull the sonde to pass the obstruction. After the obstruction has been passed, the potential energy stored in the spring induces the auger to return to its original extended position, whereupon it is ready to encounter and pass another obstacle. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority to and the benefit of U.S. Provisional Application Ser. No. 61/791,466, filed Mar. 15, 2013, the full disclosure of which is hereby incorporated by reference herein for all purposes.
BACKGROUND OF THE INVENTION
1. Field of Invention
The present disclosure relates in general to a system and method for maintaining backpressure in a seawater discharge line of a bladder pump.
2. Description of Prior Art
Subsea drilling systems typically employ a vessel at the sea surface, a riser connecting the vessel with a wellhead housing on the seafloor, and a drill string. A drill bit is attached on a lower end of the drill string, and used for excavating a borehole through the formation below the seafloor. The drill string is suspended subsea from the vessel into the riser, and is protected from seawater while inside of the riser. Past the lower end of the riser, the drill string inserts through the wellhead housing just above where it contacts the formation. Generally, a rotary table or top drive is provided on the vessel for rotating the string and bit. Drilling mud is usually pumped under pressure into the drill string, and is discharged from nozzles in the drill bit. The drilling mud, through its density and pressure, controls pressure in the well and cools the bit. The mud also removes formation cuttings from the well as it is circulated back to the vessel. Traditionally, the mud exiting the well is routed through an annulus between the drill string and riser. However, as well control depends at least in part on the column of fluid in the riser, the effects of corrective action in response to a well kick or other anomaly can be delayed.
Fluid lift systems have been deployed subsea for pressurizing the drilling mud exiting the wellbore. Piping systems outside of the riser carry the mud pressurized by the subsea lift systems. The lift systems include pumps disposed proximate the wellhead, which reduce the time for well control actions to take effect.
SUMMARY OF THE INVENTION
Disclosed herein is system for lifting mud from a subsea wellbore to sea surface. In one example, the system includes a mud pump in fluid communication with a flow of mud from the subsea wellbore, a working fluid supply line in communication with the mud pump and having a supply of working fluid, a working fluid discharge line in communication with the mud pump and having a flow of working fluid discharged from the mud pump, and a pressure control circuit having an upstream end in communication with the working fluid supply line and a downstream end in selective communication with the working fluid discharge line. A lead line can be included that is in a flow path between the mud pump and the working fluid supply line, where an inlet valve is in the lead line, and where the pressure control circuit selectively equalizes pressure in portions of the lead line on opposite sides of the inlet valve. In one example, the downstream end of the pressure control circuit selectively communicates to ambient of the system. In an embodiment, the mud pump is made up of a housing having a chamber, a bladder in the chamber with an outer periphery that is in sealing contact with an inner surface of the housing to define a mud space and a working fluid space. In this example, selectively communicating the downstream end of the pressure control circuit with the working fluid discharge line maintains a back pressure in the working fluid space to resist a surge of mud flow into the mud space. The system can further include a plurality of mud pumps, wherein each of the mud pumps is in communication with the flow of mud, the working fluid supply line, and the working fluid discharge line. In this example, the plurality of mud pumps includes a module, the system further being made up of a plurality of modules. A control valve is optionally included in the working fluid discharge line for controlling the flow of working fluid in the working fluid discharge line, and a flow meter in the working fluid discharge line upstream of the control valve and that is in signal communication with the control valve. The working fluid can be sea water.
Also disclosed herein is a system for pumping mud subsea which includes a water supply line and a series of mud pumps. In this example, each mud pump includes a housing having an attached manifold, a selectively opened and closed water inlet valve having an end in communication with the manifold and an end in communication with the water supply line, a water space in the housing in communication with the manifold, a selectively opened and closed water exit valve having an end in communication with the manifold and an end in communication with a water discharge line, a mud space in the housing that is in pressure communication with the water space, and a bladder mounted in the housing having a side in contact with the water space and an opposing side in contact with the mud space. Where the bladder defines a flow barrier between the water and mud space. In this example the system also includes a pressure control circuit having an upstream end in communication with the water supply line and a downstream end selectively switchable between communication to ambient of the pressure control circuit and communication with the water discharge line. Optionally, the mud space in each pump is in fluid communication with mud flowing in a mud return line, and wherein selectively flowing water into the water space pressurizes the mud for return to sea surface. In this example, when a pressure of the mud entering the pumps communication of the downstream end to ambient switches to communication with the water discharge line when pressure of the mud exceeds a threshold value. A control valve may optionally be included in the water discharge downstream of where the pressure control circuit communicates with the water discharge. The pressure control circuit can selectively equalize pressure across each water inlet valve.
Another embodiment of a system for lifting mud from a subsea wellbore to above the sea surface includes a series of pump modules each having mud pumps. In this example, each mud pump includes a housing in communication with a water supply line, a water discharge line, a mud supply line, and a mud discharge line, and a bladder that selectively pushes mud from the housing in response to flowing water into the housing, and pushes water from the housing in response to mud flowing into the housing. Further included in this example is a means for resisting an influx of mud into the housing when a pressure of the mud exceeds a threshold value by creating a backpressure in the water discharge line. Optionally included with this embodiment is a means for equalizing pressure across water inlet valves disposed in water lead lines that connect the water supply line to each of the housings.
BRIEF DESCRIPTION OF DRAWINGS
Some of the features and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a side sectional view of an example of a subsea drilling system in accordance with the present invention.
FIGS. 2 and 3 are partial side sectional views of an example of a subsea pump for use with the drilling system of FIG. 1 in different pumping modes and in accordance with the present invention.
FIG. 4 is a schematic representation of an example of a lift pump assembly having backpressure control on a seawater discharge line and in accordance with the present invention.
While the invention will be described in connection with the preferred embodiments, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF INVENTION
The method and system of the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments are shown. The method and system of the present disclosure may be in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey its scope to those skilled in the art. Like numbers refer to like elements throughout.
It is to be further understood that the scope of the present disclosure is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. In the drawings and specification, there have been disclosed illustrative embodiments and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation.
Shown in FIG. 1 is a side partial sectional view of an example embodiment of a drilling system 10 for forming a wellbore 12 subsea. The wellbore 12 intersects a formation 14 that lies beneath the sea floor 16 . The wellbore 12 is formed by a rotating bit 18 coupled on an end of a drill string 20 shown extending subsea from a vessel 22 floating on the sea surface 24 . The drill string 20 is isolated from seawater by an annular riser 26 ; whose upper end connects to the vessel 22 and lower end attaches onto a blowout preventer (BOP) 28 . The BOP 28 mounts onto a wellhead housing 30 that is set into the sea floor 16 over the wellbore 12 . A mud return line 32 is shown having an end connected to the riser 26 above BOP 28 , which routes drilling mud exiting the wellbore 12 to a lift pump assembly 34 schematically illustrated subsea. Within the lift pump assembly 34 , drilling mud is pressurized for delivery back to the vessel 22 via mud return line 36 .
FIG. 2 includes a side sectional view of an example of a pump 38 for use with lift pump assembly 34 ( FIG. 1 ). Pump 38 includes a generally hollow and elliptically shaped pump housing 40 . Other shapes for the housing 40 include circular and rectangular, to name a few. An embodiment of a flexible bladder 42 is shown within the housing 40 ; which partitions the space within the housing 40 to define a mud space 44 on one side of the bladder 42 , and a water space 46 on an opposing side of bladder 42 . As will be described in more detail below, bladder 42 provides a sealing barrier between mud space 44 and water space 46 . In the example of FIG. 2 , bladder 42 has a generally elliptical shape and an upper open space 48 formed through a side wall. Upper open space 48 is shown coaxially registered with an opening 50 formed through a side wall of pump housing 40 . A disk-like cap 52 bolts onto opening 50 , where cap 52 has an axially downward depending lip 53 that coaxially inserts within opening 50 and upper open space 48 . A portion of the bladder 42 adjacent its upper open space 48 is wedged between lip 53 and opening 50 to form a sealing surface between bladder 42 and pump housing 40 .
A lower open space 54 is formed on a lower end of bladder 42 distal from upper open space 48 , which in the example of FIG. 2 is coaxial with upper open space 48 . An elliptical bumper 56 is shown coaxially set in the lower open space 54 . The bumper 56 includes upper and lower segments 58 , 60 coupled together in a clam shell like arrangement, and that respectively seal against upper and lower radial surfaces on the lower open space 54 . The combination of sealing engagement of cap 52 and bumper 56 with upper and lower open spaces 42 , 54 of bladder 42 , effectively define a flow barrier across the opposing surfaces of bladder 42 . Further shown in the example of FIG. 2 is an axial rod 62 that attaches coaxially to upper segment 56 and extends axially away from lower segment 58 and through opening 50 .
Still referring to FIG. 2 , a mud line 64 is shown having an inlet end connected to mud return line 32 , and an exit end connected with mud return line 36 . A mud inlet valve 66 in mud line 64 provides selective fluid communication from mud return line 32 to a mud lead line 68 shown branching from mud line 64 . Lead line 68 attaches to an annular connector 70 , which in the illustrated example is bolted onto housing 40 . Connector 70 mounts coaxially over an opening 72 shown formed through a sidewall of housing 40 and allows communication between mud space 44 and mud line 64 through lead line 68 . A mud exit valve 74 is shown in mud line 64 and provides selective communication between mud line 64 and mud return line 36 .
Water may be selectively delivered into water space 46 via a water supply line 76 ( FIG. 1 ) shown depending from vessel 22 and connecting to lift pump assembly 34 . Referring back to FIG. 2 , a water inlet lead line 78 has an end coupled with water supply line 76 and an opposing end attached with a manifold assembly 80 that mounts onto cap 52 . The embodiment of the manifold assembly 80 of FIG. 2 includes a connector 82 , mounted onto a free end of a tubular manifold inlet 84 , an annular body 86 , and a tubular manifold outlet 88 , where the inlet and outlet 84 , 88 mount on opposing lateral sides of the body 86 and are in fluid communication with body 86 . Connector 82 provides a connection point for an end of water inlet lead line 78 to manifold inlet 84 so that lead line 78 is in communication with body 86 . A lower end of manifold body 86 couples onto cap 52 ; the annulus of the manifold body 86 is in fluid communication with water space 46 through a hole in the cap 52 that registers with opening 50 . An outlet connector 90 is provided on an end of manifold outlet 88 distal from manifold body 86 , which has an end opposite its connection to manifold outlet 88 that is attached to a water outlet lead line 92 . On an end opposite from connector 90 , water outlet lead line 92 attaches to a water discharge line 94 ; that as shown in FIG. 1 , may optionally provide a flow path directly subsea.
A water inlet valve 96 shown in water inlet lead line 78 provides selective water communication from vessel 22 ( FIG. 1 ) to water space 46 via water inlet lead line 78 and manifold assembly 80 . A water outlet valve 98 shown in water outlet lead line 92 selectively provides communication between water space 46 and water discharge line 94 through manifold assembly 80 and water outlet lead line 92 .
In one example of operation of pump 38 of FIG. 2 mud inlet valve 66 is in an open configuration, so that mud in mud return line 32 communicates into mud line 64 and mud lead line 68 as indicated by arrow A Mi . Further in this example, mud exit valve 74 is in a closed position thereby diverting mud flow into connector 70 , through opening 72 , and into mud space 44 . As illustrated by arrow A U , bladder 42 is urged in a direction away from opening 72 by the influx of mud, thereby imparting a force against water within water space 46 . In the example, water outlet valve 98 is in an open position, so that water forced from water space 46 by bladder 42 can flow through manifold body 86 and manifold outlet 88 as illustrated by arrow A Wo . After exiting manifold outlet 88 , water is routed through water outlet lead line 92 and into water discharge line 94 .
An example of pressurizing mud within mud space 44 is illustrated in FIG. 3 , wherein valves 66 , 98 are in a closed position and valves 96 , 74 are in an open position. In this example, pressurized water from water supply line 76 is free to enter manifold assembly 80 where as illustrated by arrow A Wi , the water is diverted through opening 50 and into water space 46 . Introducing pressurized water into water space 46 urges bladder 42 in a direction shown by arrow A D . Pressurized water in the water space 46 urges bladder 42 against the mud, which pressurizes mud in mud space 44 and directs it through opening 72 . After exiting opening 72 , the pressurized mud flows into lead 68 , where it is diverted to mud return line 36 through open mud exit valve 74 as illustrated by arrow A Mo . Thus, providing water at a designated pressure into water supply line 76 can sufficiently pressurize mud within mud return line 36 to force mud to flow back to vessel 22 ( FIG. 1 ).
FIG. 4 is a schematic illustration of an example of a lift pump assembly 34 having pumps 38 A-C arranged in parallel. In this example, and similar to that of FIG. 2 , mud flows to pumps 38 A-C respectively from mud lines 64 A-C that each have an inlet end connected to mud return line 32 . Outlet ends of the mud lines 64 A-C discharge into mud return line 36 . Leads 68 A-C respectively communicate mud flow between pumps 38 A-C and lines 64 A-C, where valves 66 A-C, 74 A-C respectively regulate flow through lines 64 A-C. In similar fashion, water from water supply line 76 flows to pumps 38 A-C via water inlet lead lines 78 A-C and manifold assemblies 80 A-C; and water from pumps 38 A-C is delivered to water discharge line 94 via manifold assemblies 80 A-C and water outlet lead lines 92 A-C. Water to and from pumps 38 A-C is controlled by valves 96 A-C and 98 A-C, which are shown respectively in lines 78 A-C and lines 92 A-C. Optionally, one or more of valves 66 A-C, 74 A-C, 96 A-C, 98 A-C, 106 A-C, 108 A-C may be in communication with a controller 100 for selective opening and/or closing the valves, or throttling flow through the valves.
The lift pump assembly 34 of FIG. 4 is equipped with a pressure balance circuit 102 for minimizing a pressure differential across valves 96 A-C. In the example of FIG. 4 , pressure balance circuit 102 includes pressurization tubing 104 A-C, each having inlets respectively connected to water inlet lead lines 78 A-C. Optionally, pressurization tubing 104 A-C can connect directly to water supply line 76 . Pressurization valves 106 A-C are provided within each run of pressurization tubing 104 A-C. Each run of tubing 104 A-C includes depressurization valves 108 A-C downstream of pressurization valves 106 A-C. Tubing leads 110 A-C branch respectively from pressurization tubing 104 A-C in the portions between pressurization valves 106 A-C and depressurization valves 108 A-C. The ends of tubing 110 A-C distal from pressurization tubing 104 A-C connect to water inlet lead lines 78 A-C downstream of inlet valves 96 A-C. In an example of operation, when water is being discharged from pumps 38 A-C, outlet valves 98 A-C are in the open position, and inlet valves 96 A-C are in the closed position, a pressure differential can exist across inlet valves 96 A-C that can approach pressure in water supply line 76 . Further in this example, opening valves 106 A-C, while valves 96 A-C and 108 A-C are in a closed position, communicates pressure from line 76 through pressurization tubing 104 A-C, tubing leads 110 A-C, and into inlet lead lines 78 A-C downstream of valves 96 A-C. In this example embodiment, fluid in lines 78 A-C upstream and downstream of valves 96 A-C is in pressure communication with line 76 , thereby minimizing pressure differential across valves 96 A-C.
Downstream of valves 108 A-C, pressurization tubing 104 A-C connects to a tubing header 112 , through which water in the pressure balance circuit 102 can be discharged to ambient. In the example of FIG. 4 , pumps 38 A-C and the associated piping disclosed herein are referred to as a pump module 114 A. Example embodiments exist wherein the lift pump assembly 34 includes two or more modules. As such, a water discharge line 116 from another module 114 B, that is substantially similar to module 114 A. Block valves 118 , 120 are respectively provided in discharge lines 94 , 116 for isolating water flow from modules 114 A, 114 B. Also in line 94 is an optional block valve 122 downstream of the intersection of line 116 with line 94 ; and a control valve 124 and flow meter 126 downstream of block valve 122 . An optional bypass line 128 connects tubing header 112 to water discharge line 94 between control valve 124 and flow meter 126 . A block valve 130 is shown in tubing header 112 downstream of bypass line 128 , and a block valve 132 is provided in bypass line 128 . In an alternative embodiment, block valves 130 , 132 are in communication with controller 100 .
Still referring to the example of FIG. 4 , line 94 discharges to ambient downstream of control valve 124 , thus depending on the flow rate of fluid in line 94 , pressure in line 94 downstream of control valve 124 is substantially equal to ambient pressure. In the illustrated embodiment, control valve 124 and flow meter 126 are shown in communication with one another, so that a flow area through control valve 124 automatically adjusts in response to a flow rate detected by flow meter 126 to “throttle” flow across control valve 124 . Optionally as shown, control valve 124 is in communication with controller 100 , so that the amount of throttling can vary based on operating conditions of the lift pump assembly 34 . As such, a pressure differential can be generated across control valve 124 so that pressure in line 94 upstream of control valve 124 is greater than pressure at ambient and introduces a backpressure in line 94 . Where the backpressure in line 94 suppresses flow rate spikes in lines 92 A-C, which in turn reduces cycling forces on components of pumps 38 A-C during pumping operations.
In some examples of use, pumps 38 A-C operate under “managed pressure drilling operations” where mud flow rates are reduced, but pressure of the mud to the pumps 38 A-C is increased. During these conditions, the flow path to ambient through the pressure balance circuit 102 and from lines 78 A-C can allow pressure in pumps 38 A-C to drop below a threshold value so that pumps 38 A-C will uncontrollably fill with mud during a subsequent pumping cycle. One example of operation to address the unacceptable pressure drop includes diverting flow in tubing header 112 that is being discharged from pressure balance circuit 102 through bypass line 128 . In this example, block valve 130 is set into a closed position and block valve 132 is open. In an optional example, controller 100 delivers instructions for opening/closing of the block valves 130 , 132 . As indicated above, bypass line 128 terminates into water discharge line 94 upstream of control valve 124 , which is maintained at a pressure sufficiently above ambient so that a backpressure can be exerted onto pressure balance circuit 102 . In the example of FIG. 4 , the backpressure on the pressure balance circuit 102 communicates to the water side 46 ( FIG. 2 ) of each pump 38 A-C; which maintains a minimum pressure in the water side 46 of each of the pumps 38 A-C to avoid an uncontrolled influx of mud flow into the pumps 38 A-C.
The present invention described herein, therefore, is well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While a presently preferred embodiment of the invention has been given for purposes of disclosure, numerous changes exist in the details of procedures for accomplishing the desired results. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present invention disclosed herein and the scope of the appended claims. | A method and system for lifting drilling mud from subsea to a drilling vessel includes a pump having a body with a chamber, and a bladder in the chamber. The bladder spans the chamber to define water and mud sides in the chamber. A mud inlet valve allows mud into the mud side of the chamber; which moves the bladder into the water side and urges water from the water side of the chamber through a water exit valve. Pressurized water enters the chamber through a water inlet valve, which in turn pushes the bladder and mud from the chamber through a mud exit valve. The bladder separates the mud and water as it reciprocates in the chamber. A pressure control circuit equalizes pressure across the water valves, and a control valve provides a back pressure in a discharge of the pressure control circuit. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to a cling packaging film. More specifically, the present invention is directed to a transparent, cling packaging film for wrapping consumer products, especially fresh meat and produce. The film of the invention comprises at least two layers, a skin layer principally comprising linear low density polyethylene and a core layer principally comprising a copolymer of ethylene and an ethylenically unsaturated polar comonomer and also containing an elastomeric polymer. These films are often referred to as PVC food wrap replacement films.
2. Description of the Background
Many food products, particularly fresh meat and produce, are wrapped in transparent, thin film. This film must be both transparent to provide an aesthetically pleasing product for the consumer and sufficiently strong to provide the protection desired. For example, in meat packaging, a crystal clear, transparent film is desired to provide a visually attractive wrapping for fresh meat typically placed on a plastic or foam package and then wrapped with the film. The film must be sufficiently strong to withstand the wrapping process, whether automated or manual, wherein the film is rapidly stretched about the product and sealed by clinging to itself or by heat sealing. Further, the film when stretched about the food product must provide protection from puncture upon deformation by being poked with fingers or other packages, and the film must exhibit good recoverability so that the deformation quickly disappears.
Fresh foods, particularly meat products, are wrapped automatically on processing lines with cling wrap film. The procedure involves the intermittent, high speed removal of film from a supply roll, the pushing of a tray filled with food upward until it impacts against the film, the stretching of the film around the tray to the lower side thereof and the sealing of the film. The film may be sealed by clinging to itself or by heat sealing the edges of the film. The elasticity of the film must maintain the stretched film in a tight fit about the product. These films must be transparent, tear resistant, puncture resistant and exhibit good recovery from deformation.
Polyvinyl chloride (PVC) film has long been the film of choice in the food wrap industry. However, the food wrap industry has expressed a desire for an alternative, PVC-free replacement film. It has been difficult to formulate compositions based on olefinic polymers for making a cling wrap film. These compositions must both satisfy the characteristics described above and satisfy the many food law requirements.
Films made of low density polyethylene have been used in stretch packaging. These films are often rigid, have low elongation and low tear strength. Although ethylene vinyl acetate films are free from many of the previously mentioned problems, EVA films suffer from poor tear resistance. In order to overcome these problems, laminated films comprising two or more layers of different materials having differing characteristics have been developed. Many patents have been directed to stretch and cling films comprising multiple layers of these and other principal and minor components. However, none of those patents have solved the long felt but unfulfilled need for a satisfactory PVC replacement film. None of these films have exhibited the desirable combination of tear strength, recoverability, optical clarity, sealability and other attributes important to a PVC replacement film.
SUMMARY OF THE INVENTION
The present invention is directed to a transparent, cling packaging film having at least two layers, including a skin layer comprising linear low density polyethylene and a core layer comprising a copolymer of ethylene and an ethylenically unsaturated polar comonomer together with an elastomeric polymer. Preferably the polar comonomer is an ethylenically unsaturated ester or carboxylic acid. Most preferably the core layer comprises about 70-90 percent by weight ethylene vinyl acetate (EVA) containing at least 18 percent by weight vinyl acetate and about 5-30 percent by weight styrene isoprene styrene (SIS) block copolymer.
The packaging film of the present invention provides an ideal PVC replacement wrap for use in food processing. The film compares favorably with PVC food wrap. A film in accord with the present invention is simple to manufacture and is cost effective. It does not require the addition of a tackifying agent to provide cling. This film is easily treated and printed. It provides overall barrier properties at least equivalent to those of PVC film. It is free from extractable plasticizers often found in PVC film. Further, a film in accord with the present invention may also contain common additives, e.g., anti-fogging agents, anti-oxidants, colorants and tackifiers. Finally, these films may be produced using conventional cast and blown film forming processes and used with conventional PVC food wrapping equipment. These and other meritorious features and advantages of the present invention will be more fully appreciated from the following detailed description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and intended advantages of the present invention will be more readily apparent by the references to the following detailed description in connection with the accompanying drawings, wherein:
FIG. 1 is a cross-sectional representation of a three layer packaging film of an ABA configuration in accord with the present invention; and
FIG. 2 is a perspective illustration of a packaged food article in accord with the present invention.
While the invention will be described in connection with the presently preferred embodiment, it will be understood that it is not intended to limit the invention to this embodiment. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included in the spirit of the invention as defined in the appended claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention provides a transparent, cling packaging film 10 having at least two layers, i.e., a skin layer 12 and a core layer 14. The skin layer is characterized by a higher crystallinity than the core layer. The skin layer contributes substantially to the tear and tensile strength of the film. The skin layer is also responsible for the optical characteristics of haze and gloss. The core layer has a lower crystallinity and is more highly amorphous than the skin layer. The core layer provides the improved recoverability to deformation by poking. The core layer is also chiefly responsible for the oxygen transmission characteristics of the film. The right degree of oxygen transmission is required in meat packaging films to provide the correct bloom to the meat to provide the desired visual appearance of the product sought by consumers.
The skin layer comprises linear low density polyethylene (LLDPE). The linear low density polyethylene is preferably a polymer containing up to about 10 percent of a comonomer derived unit to give a density of from 0.915 to 0.925. The comonomer derived units may be obtained from a C 4 to C 9 alphaolefin, preferably a C 8 alphaolefin. The melt index is from about 0.4 to 10.0, preferably about 1.0 to 3.5. The density is from about 0.90 to 0.93, preferably from about 0.915 to 0.925.
In an alternative embodiment the skin layer may also include up to about 10 percent by weight of a polymer selected from the group consisting of ethylene vinyl acetate (EVA), low density polyethylene (LDPE), very low density polyethylene (VLDPE) and blends thereof. Further, the skin layer may include other conventional additives including anti-fogging agents, anti-oxidants, colorants and the like. Glycerine mono-oleate (GMO) in quantities up to about 2 percent by weight is often used as an anti-fogging agent.
In another embodiment, the skin layer comprises about 90-100 % by weight linear low density polyethylene, about 0-2% by weight glycerine mono-oleate and about 0-10% by weight of a polymer selected from the group consisting of ethylene vinyl acetate, low density polyethylene and blends thereof.
The core layer is principally comprised of a copolymer of ethylene and an ethylenically unsaturated polar comonomer. The polar comonomer is selected from the group consisting of ethylenically unsaturated esters, ethylenically unsaturated carboxylic acids and blends thereof. The preferred comonomers are vinyl acetate, methyl acrylate, methyl methacrylate, acrylic acid, methyl acrylic acid, methyl methacrylic acid and acrylic acid/methyl acrylate.
Preferably the ethylenically unsaturated ester is vinyl acetate and the copolymer contains about 5 to 50 percent by weight vinyl acetate, preferably at least 18 percent by weight vinyl acetate and most preferably about 20-30 percent by weight vinyl acetate. The melt index of the ethylene copolymer is from 0.3 to 12.0, preferably from 1.0 to 7.0 and most preferably from 2.0 to 6.0. The core layer contains about 70-90 percent by weight of the above described copolymer.
The preferred elastomeric polymer is a block copolymer, preferably selected from the group consisting of styrene/isoprene styrene (SIS) block copolymers, styrene/butadiene/styrene (SBS) block copolymers and styrene/ethylene butylene/styrene (SEBS) block copolymers. The most preferred elastomeric polymer is a styrene/isoprene/styrene block copolymer. The elastomeric polymer should be used in amounts which do not give rise to compatibility problems with the ethylene copolymer. Compatibility and imparting of the desired characteristics are achieved when the elastomeric polymer is present from about 5-30 percent by weight in the core layer.
In an alternative embodiment the core layer may also include up to about 10 percent by weight of a polymer selected from the group consisting of linear low density polyethylene (LLDPE), low density polyethylene (LDPE), very low density polyethylene (VLDPE) and blends thereof.
In another embodiment, at least one of the layers of the packaging film comprises less than about 10% low density polyethylene.
Conventional additives may be included in either the core or skin layers. For example, anti-fogging and anti-blocking agents may be added. Although low molecular weight additives may produce added plasticity, excessive amounts of anti-blocking agents may give an oil-like feel to the film and thus should be avoided.
The film of the present invention typically has a thickness within the range of 0.2 to 1.4 mil, preferably 0.4 to 0.7 mil and most preferably 0.5 to 0.6 mil. The film is preferably formed having two skin layers of identical composition, one on each side of the core layer. In such a construction the core layer comprises about 70 to 80 percent by weight of the film while each of the skin layers comprises about 10 to 15 percent by weight of the film.
The components for the skin and core layers may be individually blended by kneading the respective resin components in conventional mixers. Production of films from these components may be accomplished by conventional methods, including blown tubular film extrusion and chill roll cast film extrusion. The film may be used with conventional food packaging, preferably meat packaging equipment. In use the film 10 is removed from a roll, contacted with the product 16, optionally disposed on tray 18, to be wrapped, stretched about the product and sealed by clinging to itself or by heat sealing to produce the packaged product 20 for display to the consumer.
EXAMPLE 1
A film having an ABA structure was produced in accord with the present invention. The skin layers were comprised of hexene linear low density polyethylene having a melt index of 3.2 and a density of 0.9175. The skin layers also contained about 2 percent glycerine mono-oleate as an anti-fogging agent. Each skin layer comprised about 15 percent by weight of the total film. The core layer was comprised of about 85 percent by weight ethylene vinyl acetate having a melt index of 3.0 and containing about 28 percent vinyl acetate. Also present in the core layer was about 15 percent styrene/isoprene/styrene block copolymer. The core layer comprised about 70 percent by weight of the total film. Films were produced utilizing a conventional slot, cast extrusion process.
EXAMPLE 2
A second film in accord with the present invention was produced. The skin layers were comprised of hexene linear low density polyethylene having a melt index of 3.2 and a density of 0.9175. The skin layers also contained about 2 percent glycerine mono-oleate as an anti-fogging agent. Each skin layer comprised about 10 percent by weight of the total film. The core layer was comprised of about 70 percent by ethylene vinyl acetate having a melt index of 3.0 and containing about 28 percent vinyl acetate. Also present in the core layer was about 30 percent styrene/isoprene/styrene block copolymer. The core layer comprised about 80 percent by weight of the total film.
COMPARATIVE EXAMPLE 3
A comparative film not including the elastomeric polymer in the core layer was produced. This comparative film was identical to the film of Example 2 with the exception that no elastomeric polymer was included. Accordingly, the core layer was comprised entirely of the specified ethylene vinyl acetate.
The films produced in accord with the above examples were tested together with a conventional PVC food wrap film. Table 1 summarizes the results of many tests of the physical characteristics of a conventional PVC food wrap film, an ABA film in accord with the present invention and a similar ABA film without the elastomer in the core layer.
TABLE 1__________________________________________________________________________COMPARISON WITH PVC Example 2 ABA Film With Example 3Film Property PVC Elastomer ABA Film Without__________________________________________________________________________Thickness (mil) 0.6 0.71 .53Haze (%) 2.9 1.3 0.3Gloss (at 45°) 86 95 98Shrinkage (%) MD 37 88 87 TD 14 -32 -50Elongation MD 230 400 300at Break (%) TD 320 950 1020Tensile Strength MD 3850 2790 4540at 200% (psi)Tensile Strength MD 4440 4240 7010at Break (psi) TD 4110 2890 4200Recovery after MD 2.0 7.3 8.950% Elongation TD 5.9 8.6 10.3(% Set).sup.1Recovery after MD 14.7 29.5 37.7100% Elongation TD 17.5 30.1 36.3(% Set).sup.11% Secant Modulus MD 8.2 8.0 20.2(kpsi) TD 5.6 6.4 10.7Elmendorf Tear MD 45 90 65(gm/mil) TD 90 345 405Dart Impact TD 680 290 250(gm/mil)__________________________________________________________________________ .sup.1 Test defined by ASTM D 882 as modified herein.
Of a particular concern in the meat packaging industry is the recoverability of the film after being poked and deformed by fingers and other objects. In order to examine the elastic recoverability characteristics of the films produced in the above examples together with a PVC food wrap film, those films were subjected to a test to determine percent set. The test was defined by ASTM D 882 modified to provide a single cycle comprising a one minute hold at the specified percent elongation, followed by a one minute relaxation period after return to the initial unstretched position, and immediately followed by determination of percent change in length (reported as percent set). The results of these comparative test are reported in Table 2.
The inventive film has an elastic recoverability of less than 35% set after 100% elongation for one minute followed by relaxation to its initial unstretched position for one minute.
TABLE 2__________________________________________________________________________RECOVERY COMPARISON Example 1 Example 2 Example 3 ABA Film With ABA Film With ABA Film Without PVC Elastomer Elastomer Elastomer__________________________________________________________________________Recovery at50% Stretch.sup.1Deformation MD 2.0 6.0 7.3 8.9(% Set) TD 5.9 7.9 8.6 10.3Load at MD 1020 890 1630 14501 Minute TD 530 310 310 360(psi)Recovery at100% Stretch.sup.1Deformation MD 14.7 24.0 29.5 37.7(% Set) TD 17.5 23.2 30.1 36.3Load at MD 1210 900 1780 16001 Minute TD 690 320 310 340(psi)__________________________________________________________________________ .sup.1 Recovery determined per ASTM D 882 modified with 1 minute hold and 1 minute relax for one cycle only
The foregoing description of the invention has been directed in primary part to a particular embodiment in accordance with the requirements of the patent statutes and for purposes of explanation and illustration. It will be apparent, however, to those skilled in the art that many modifications and changes in the specifically described cling packaging film may be made without departing from the scope and spirit of the invention. Therefore, the invention is not restricted to the preferred embodiment illustrated but covers all modifications which may fall within the scope of the following claims. | The present invention is directed to a cling packaging film for use in wrapping food products, particularly fresh meat and produce. The film comprises a core layer containing a copolymer of ethylene and an ethylenically unsaturated polar comonomer together with an elastomeric polymer. The film further comprises a skin layer containing linear low density polyethylene. Both the core and skin layers may contain additional components. A film in accord with the present invention compares favorably with PVC food wrap film and is intended to provide a replacement therefor. | 1 |
FIELD OF THE INVENTION
The present invention relates to automated enumeration generally and, more particularly, to a method, software and/or apparatus for automated enumeration, simulation identification and/or irradiation of device attributes.
BACKGROUND OF THE INVENTION
Conventional methods exist to automate enumeration of all fuse locations on a die. The conventional methods do not associate fuse locations with a schematic path and/or a verilog path. Conventional methods exist to manually associate a fuse path to a fuse location or the fuse location to the fuse path, one at a time. The conventional methods to manually associate the fuse path to the fuse locations, or vise versa, use a layout versus schematic (LVS) cross-probe user-interface. Conventional verilog simulation paths are derived by manual translation of schematic paths aided by visual inspection of a netlist.
Additionally, conventional methods do not effectively collect thorough and accurate fuse path versus fuse location data. The manual LVS cross-probe cannot process the fuse path versus fuse location data for large numbers of devices in a timely, cost-effective manner. Without a thorough and accurate path versus location data, methods to verify repair programs and redundancy documentation are tedious and error prone.
SUMMARY OF THE INVENTION
The present invention concerns a method of automated enumeration of one or more devices comprising the steps of (A) generating an enumeration of a plurality of fuses and (B) compiling data for each one of said plurality of fuses, wherein the data comprises (i) one or more schematic path data, (ii) one or more simulation path data and/or (iii) one or more physical location data.
The objects, features and advantages of the present invention include providing a method and/or apparatus that may provide (i) automatic enumeration of all fuses in the design and collection of a schematic path and annotated properties for each fuse, (ii) automatic determination of a verilog simulation netlist path for each fuse, (iii) automatic determination of a physical location for each fuse, (iv) automatic verification of fuse locations against additional identifying shapes drawn in the layout, (v) coordinates, such as from repair program output, are automatically translated to verilog programming statements (vi) automatic and/or manual ad-hoc queries and searches to isolate groups of fuses for tabular listings or to program them in verilog, (vii) automatic translation of existing program statements to their physical locations, (viii) manual annotation of the schematic hierarchy at multiple levels with descriptive fuse properties, and/or (ix) manual searches or look-ups based on expression matching against this description property.
Additionally, fuse data is generally enumerated and collected from the design flow into a separate file. The file may thereafter be used independently of the original design flow data and tools. Traditional access to cross-probing functionality of simulation netlisters and LVS tools may require simultaneous availability of (i) original design data, (ii) specific version of vendor software, (iii) specific architecture of host computer, and (iv) licenses to enable the vendor software.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects, features and advantages of the present invention will be apparent from the following detailed description and the appended claims and drawings in which:
FIG. 1 is a block diagram of a preferred embodiment of the present invention;
FIG. 2 is a block diagram of an example apparatus implementing the present invention; and
FIG. 3 is a flow chart of an operation of the method of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 , a block diagram of a method 100 is shown in accordance with a preferred embodiment of the present invention. Fuses in a design may be enumerated and data collected and stored in a file. The data may include schematic path data, verilog simulation path data and/or physical fuse location data. Multiple representations of the design and/or data may be accessible by other tools, such as netlister and/or layout versus schematic (LVS). The data may be used to enumerate the fuses. The data may be implemented in order to test and/or repair the design. References to “verilog” refer to the verilog hardware description language (HDL) as defined by the IEEE 1364-1995 standard.
The file may be implemented to answer look-ups and translations as directed by an operator or apparatus. Automated programming of fuses in a design simulation may verify (i) accuracy of a laser repair program and/or (ii) design redundancy functionality. The file may also be implemented to ensure accurate documentation of redundancy methodology for the design. The look-ups and translations may be constrained to include and/or exclude fuses based on (i) physical location range specifications, and/or (ii) exact or pattern matching of (a) schematic paths, (b) verilog paths and/or (c) description properties.
The method 100 may comprise a design data block 102 , a netlist block 104 , a simulation block 106 , a generation block 108 , a table block 110 , an application block 112 , a program statement block 114 , a location block 116 , a schematic/simulation block 118 , a repair program or repair block 120 and a test block 122 . The generation block 108 may receive fuse data from the design data block 102 . The generation block 108 may write the fuse data into a file and perform error checking on the file.
The generation block 108 may perform enumeration of fuses and the collection (compilation) of data for each fuse. The schematic design data may comprise (i) schematic path data and (ii) property data formed from hierarchical contributions. For each fuse, the generation block 108 may generate verilog path data. The generation block 108 may generate the verilog path data depending on the methodology implemented in netlist block 104 . The generation block 108 may generate the verilog path data using either a first or a second method.
The first method may translate the schematic path data to the verilog path data via dead-reckoning. The first method may implement the same algorithm known to be used by the netlist block 104 . The netlist block 104 may be implemented as FNL-based netlisters, HNL-based netlisters, or any other type netlister in order to meet the criteria of a particular implementation. The second method may map the schematic path data to the verilog path data by direct lookup using netlister map files that may be implemented within the netlist block 104 . An associated netlister API (application-programming-interface) may be represented in the block 102 . The netlister map files and the netlister API may be implemented within the netlist block 104 . If an operator or apparatus requests a non-LVS mode (for example if clean LVS is not available yet), the fuse generation block 108 may write the fuse data collected to a file and terminate.
The LVS data is generally used to collect the physical location data for each schematic path. LVS tools may access the physical location data in one of two methods. The first method may comprise a LVS tool that may provide (i) one or more APIs or (ii) one or more cross-referenced output files. The schematic path is generally translated from the files to one or more matching x/y device locations through one or more steps. The second method may comprise a LVS tool that may provide (i) an API or (ii) cross-referenced output files. The second method may translate a device x/y location into one or more matching schematic device paths.
When the LVS data is available, the data is generally used to extract partial information of which fuses may be electrically connected in parallel. The information is generally recorded to warn an operator or apparatus in the event of a request to program a strict subset of such a parallel group.
When the LVS data is available and is requested by an operator or apparatus, fuse locations given by the LVS may be compared against additional drawn layout shapes. If differences are found in the fuse locations, a heuristic is generally used to attempt to matchup the differences. The heuristic may report the differences in a user-friendly manner to help an operator make layout corrections if desired. For example the LVS and the drawn layout may report different fuse locations. The fuse locations may be closer to each other than to any other unmatched locations. The close fuse locations may be listed together as probable intended matches. The generator block 108 may write the fuse data collected to the file and terminate. The generation block 108 may present the file to the table 110 . The fuse data for each fuse of the device may be stored in the table 110 .
The application block 112 may receive constraints and options given by the operator or another apparatus. The application block 112 may read each fuse data stored in the table 110 while applying the constraints to decide whether to retain or discard the fuse data.
The application block 112 may present one or more matching fuses in a first or a second format. The first format may present a tabular listing to the location block 116 . The second format may present verilog programming statements to the program statements block 114 . Options support how to sort fuses prior to output. The application block 112 may control the order in which fields may be presented in the tabular method. The application block 112 may name a verilog path name prefix to be applied to the verilog paths, in order to program a device nested within one or more test-bench modules.
If the one or more matching fuses only partially represent a group of electrically parallel fuses (as indicated by grouping information stored within the fuse database file), warnings may be generated.
Construction of the repair program 120 may rely on part-specific redundancy information and errors found after a first-silicon delay part production. The repair program 120 may receive the errors from the defect block 122 . The repair program 120 may be exercised in advance of the first-silicon for specific part failures. The repair program 120 may predict fuse locations that, if programmed, may correct a part experiencing failure. The method 100 may provide an easy and reliable method to perform simulations that emulate a design as if those locations were programmed on the die by the laser.
Referring to FIG. 2 , a block diagram of an example apparatus 200 implementing the present invention is shown. The circuit 200 may comprise a design flow block or design flow circuit 202 and a stand-alone block or stand-alone circuit 204 . The design flow block or circuit 202 may comprise a fuse network block 206 , a fuse LVS block 208 and a design/database circuit 210 . The fuse network block 206 and the fuse LVS block 208 may provide data to the stand-alone block or circuit 204 . In one example the design/database circuit 210 may be implemented as a design flow and Opus design database.
The fuse network block 206 may collect data relevant to (i) schematic paths, (ii) properties, (iii) hierarchy and/or (iv) verilog paths. The fuse LVS block 208 may collect data relevant to (i) layout locations, (ii) parallel fuses, and/or (iii) LVS cross-reference to schematic paths.
The fuse network block 206 and the fuse LVS block may be implemented to drive applications within the stand-alone circuit 204 . The stand-alone circuit 204 may comprise a fuse applications block 220 . The fuse application block 220 may utilize either or both the fuse network block 206 and/or the fuse LVS block 208 . The fuse application block may determine what data must be accessed and when the data will be accessed (e.g., within a software design tool with or without the flow schematic data only or schematic data plus layout data).
The fuse application block 220 may write one or more ASCII report files. A repair memo, also referred to as a repair file, may be manually assembled from the report files. One or more steps may be manually determined and may be incorporated into the repair memo or file. The repair memo or file may be exercised to predict coordinates to program. The coordinates may be mapped to verilog paths. Simulations of the verilog paths may be performed to verify the expected function.
The design flow circuit 202 may further comprise a browse block 240 . The browse block 240 may capture, in the schematic, enough knowledge of the fuses to elevate the fuses to a higher level of abstraction. The user may describe, in application terms, the desired redundancy event. For example, the redundancy event may comprise replacing column C in quadrant Q. The coordinates to program may be automatically determined. However, the simulation may still be required to verify the function (e.g., to verify that the application specific knowledge captured in the schematic describing specific intent of each fuse is correct).
The Vampire LVS database may be used to generate a fuse database (e.g., fuse.fdb). The fuseGen may be run in the following ways (i) as a side effect of Vampire LVS, (ii) by invoking a skill function from the CIW, and/or (iii) from the command line. The fuseGen may also be statically configured (e.g., using trf variables) to run for a set of specified cells. The fuseGen may also be run on a design tool schematic database (e.g., Opus) to get schematic instance paths, verilog paths and info strings for each fuse in the schematic hierarchy. The FuseGen may also be configured to run during verilog netlisting.
A file fuse.txt may be a text file listing all fuse co-ordinates. User inputs may be provided to fuseapp to output only certain groups of fuses (based on criteria defined in the user inputs). The fuse.txt file (or other text file(s) generated via fuseapp) may be included in the fuse repair document.
Referring to FIG. 3 a flow chart 300 of the operation of the method 100 is shown. The flow chart 300 may describe the procedure for using the present invention. The flow chart 300 may comprise a generate block 302 , a repair memo block 304 , a repair program 306 , a test simulate bock 308 , a feedback block 310 , a map block 312 , a logic simulation block 314 , a SIMS check block 316 , an error program check block 318 and an error memo check block 320 .
The generate block 302 may generate a list of layout co-ordinates and schematic instance paths. The generation block 302 may initialize the fuse generation block 108 . Next, the repair memo block 304 may initialize the fuse application block 112 . The fuse application block 112 may generate a repair memo. The repair program block 306 may implement the repair memo generated by the repair memo block 304 into a repair program.
The test engineer may run a set of simulations to check the laser repair program. The output of these simulations may be a list of co-ordinates of fuses that need to be blown for the desired repair and the corresponding logical address used. The co-ordinates of the fuse may be stored in the location block 116 . The output of the simulation is generally fed back to the design engineer.
The feedback block 310 may allow the Design engineer to feed the sets of co-ordinates from the simulations to the fuse application block 112 . The fuse application block 112 may generate a set of verilog statements that may be used to program selected fuses. The map fuse block 312 may map fuse co-ordinates to the verilog program statements stored in the program statements block 114 . The logic simulation block 314 may allow the design engineer to run a simulation to check the correctness of the blown fuses utilizing the logical address information.
In case of a discrepancy found in the logic simulation block 314 the SIMS check block 316 may present (i) the repair program to the repair program block 306 or (ii) the repair memo to the repair memo block 304 .
In this alternative, essentially the blocks 302 , 314 , a reversed block 312 are performed first. The particular test cases “sufficient to ensure coverage” are documented in the repair memo block 304 . Such documentation may include coordinates (e.g., derived thru an inverse of block 312 : program statements are mapped to fuse coordinates (using block 112 ) and the coordinates are embedded in the memo block 304 ). The test engineer may then create the repair program as before (e.g., the block 306 ) from the repair memo block 304 . The test engineer may then employ the repair program in a simulate-mode (e.g., in the block 308 ) to output coordinates from each test case. Next, a compare of these coordinates to the coordinates documented in the repair memo is performed that may decide whether an error exists in the memo or the program. Such a comparison may be similar to the block 316 , although the “simulation” being verified is generally very different. For a program error, the blocks 306 , 308 , and 316 may be repeated. For a memo error, the blocks 304 , 306 , 308 , and 316 may be repeated.
While the invention has been particularly shown and described with reference to the preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the spirit and scope of the invention. | A method of automated enumeration of one or more devices comprising the steps of (A) generating an enumeration of a plurality of fuses and (B) compiling data for each one of said plurality of fuses, wherein the data comprises (i) one or more schematic path data, (ii) one or more simulation path data and/or (iii) one or more physical location data. | 6 |
RELATED APPLICATION
This application claims priority from provisional application Ser. No. 60/946,782, which was filed on 28 Jun. 2007, and Ser. No. 60/955,141, which was filed on 10 Aug. 2007, both of which are incorporated herein by reference in their entirety.
STATEMENT OF GOVERNMENT RIGHTS
The work leading to this application was supported at least in part by a grant from the Department of Defense. Accordingly, the government may have certain rights in the invention, as specified by law.
FIELD OF THE INVENTION
This invention relates to the field of neurobiology and, more specifically, to therapeutic targets for treatment of neurofibromatosis type 2 (NF2).
BACKGROUND OF THE INVENTION
Neurofibromatosis is an autosomal dominant genetic disorder. It encompasses a set of distinct genetic disorders that cause tumors to grow along types of nerves and, in addition, can affect the development of non-nervous tissues such as bones and skin. The tumors can grow anywhere on or in the body. Apart from the common form, there are two rarer forms and several even rarer forms. Neurofibromatosis type I (was known as Von Recklinghausen disease after Friedrich Daniel von Recklinghausen) has an incidence of 1:3500. Neurofibromatosis type II (or “MISME Syndrome”) has an incidence of 1:40,000.
Schwannomatosis is a rare form that is clinically and genetically distinct from types I and II. Multiple Schwannomas (rather than Neurofibromas) occur, and about one-third of patients have these tumors in only one part of the body. Incidence is 1:40,000. The vestibular nerve is spared. Pain is the primary symptom, although numbness, tingling and weakness can also occur. Schwannomas are always benign. Additionally, six other, extremely rare, forms are also recognized but won't be discussed here.
Symptoms of these Diseases
Neurofibromatosis type 1, is a mutation of neurofibromin chromosome 17q11.2. Symptoms include multiple neurofibromas on the skin and under the skin, the sub-cutaneous lumps are characteristic of the disease and increase in number with age; freckling of the groin and the arm pit; a predisposition to particular tumors (both benign and malignant); Café au lait spots (pigmented birthmarks). Six or more of these symptoms form one of the diagnostic criteria, but are not essential for diagnosis. Skeletal abnormalities such as scoliosis or bowing of the legs might occur. Also occurring are Lisch nodules (hamartomas of iris), tumor on the optic nerve and plexiform neurofibroma. Neurofibromatosis type 2, caused by mutation of merlin chromosome 22q12.
Other symptoms include bilateral tumors; acoustic neuromas on the vestibulocochlear nerve, as the hallmark of NF 2 is hearing loss due to acoustic neuromas around the age of twenty. The tumors may cause headache, balance problems, and Vertigo, facial weakness/paralysis. Patients with NF2 may also develop other brain tumors, as well as spinal tumors, deafness and tinnitus. Schwannomatosis, the gene involved has yet to be identified.
Multiple Schwannomas occur. The Schwannomas develop on cranial, spinal and peripheral nerves. Chronic pain is present, and sometimes numbness, tingling and weakness. About ⅓ of patients have segmental Schwannomatosis, which means that the Schwannomas are limited to a single part of the body, such as an arm, a leg or the spine. Unlike the other forums of NF, the Schwannomas do not develop on vestibular nerves, and as a result, no loss of hearing is associated with Schwannomatosis. Patients with Schwannomatosis do not have learning disabilities related to the disease.
Neurofibromatosis type 1 is due to mutation on chromosome 17q11.2, the gene product being Neurofibromin (a GTPase activating enzyme). Neurofibromatosis type 2 is due to mutation on chromosome 22q, the gene product is Merlin, a cytoskeletal protein. Both NF1 and NF2 are autosomal dominant disorders, meaning that only one copy of the mutated gene need be inherited to pass the disorder. A child of a parent with NF1 or NF2 and an unaffected parent will have a 50% chance of inheriting the disorder.
Complicating the question of heritability is the distinction between genotype and phenotype, that is, between the genetics and the actual manifestation of the disorder. In the case of NF1, no clear links between genotype and phenotype have been found, and the severity and specific nature of the symptoms may vary widely among family members with the disorder. In the case of NF2, however, manifestations are similar among family members; a strong genotype-phenotype correlation is believed to exist. Both NF1 and NF2 can also appear spontaneously through random mutation, with no family history. These spontaneous or sporadic cases account for about one half of neurofibromatosis cases.
SUMMARY OF THE INVENTION
With the foregoing in mind, the present invention advantageously provides a method for inducing neurofibromatosis type 2 (NF2) in Schwann cells. Accordingly, one utility of the invention is in providing a model of neurofibromatosis type 2 which, as known by the skilled, would allow for testing of new treatment drugs.
The method comprises contacting the cells with laminin-1 so as to bind α6β1 integrin sufficiently to activate endogenous kinase Cdc42-Pak; and, in response, phosphorylating Schwannomin-S518 in the cells by the activated kinase, effectively inactivating Schwannomin's tumor suppressor activity and allowing proliferation of subconfluent Schwann cells, thereby modeling NF2.
In another embodiment, the method of inducing neurofibromatosis type 2 (NF2), the method comprises contacting Schwann cells with NRG-1 so as to bind ErbB2 and/or ErbB3 receptors sufficiently to activate protein kinase A (PKA) and phosphorylating Schwannomin-S815 in the cells by the activated PKA effectively inactivating Schwannomin's tumor suppressor activity and allowing proliferation of subconfluent Schwann cells, thereby modeling NF2.
The invention further provides a method of preventing inactivation of Schwannomin's tumor suppressor activity in Schwann cells. This method comprises contacting the Schwann cells with an effective amount of a blocking agent that inhibits normal function of a receptor selected from ErB2, ErB3, β1 integrins and combinations thereof, thereby preventing phosphorylation of Schwannomin-S815 by one or more endogenous kinases. In this method the blocking agent preferably comprises a tyrphostin and, particularly, tyrphostin AG825.
BRIEF DESCRIPTION OF THE DRAWINGS
Some of the features, advantages, and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, presented for solely for exemplary purposes and not with intent to limit the invention thereto, and in which the following figure descriptions apply.
FIG. 1 shows phosphorylated forms of ErbB2, Sch, and Pak co-localize with paxillin and Cdc42 in processes, their distal tips and radial protrusions following acute stimulation with NRG. Subconfluent SCs plated on PLL/laminin-1 coated coverslips were serum-starved overnight and were then stimulated with NRG1 for 30 minutes. Immunostaining was conducted for the indicated proteins to assess phosphorylation status and localization. All proteins were found in SC processes and were focally enriched at radial membrane protrusions and distal tips.
FIG. 2 : NRG1 and Laminin-1 Induce Sch Phosphorylation in SC Processes. A) Subconfluent SCs grown on PLL/laminin-1 were starved overnight (D0.5) and were left untreated, or were stimulated for 30 minutes with NRG1 (10 ng/ml). Phosphorylation of ErbB2 (P-ErbB2), Sch (PS518-Sch), and Pak (P-Pak) was assessed by immunostaining with phospho-specific antibodies. B) Quantification of mean fluorescence intensity in 15-20 isolated SC processes per condition is shown. C) Subconfluent SCs grown on PLL were starved overnight and were left untreated (D0.5), or were stimulated with soluble laminin-1 (Lam; 10 mg/ml) for 30 minutes. SCs were immunostained with the indicated antibodies. D) Quantification of the change in mean fluorescence intensity in 15-20 isolated SC processes per condition is shown. The graphs represent the average fold increase in each condition in three or more experiments. Error bars represent the SEM for each condition. P values are <0.05(*).
FIG. 3 : NRG1 stimulates phosphorylation of Sch by PKA. A, C) Subconfluent SC cultures grown on PLL were serum-starved overnight and were stimulated for 30 minutes with NRG1 (10 ng/ml) in the absence and presence of AG825 (1 μM). Western blot analysis was used to determine the levels of phosphorylated and total ErbB2, Sch, and Pak. B, D) Quantification of the western blots of starved (D0.5), NRG1 stimulated (NRG) and NRG1 plus AG825 (N+A) stimulated cultures is shown. E) Subconfluent SCs grown as above were stimulated for 30 minutes with NRG in the presence and absence of PKI 14-22 (50 nM), and with forskolin (FSK; 2 μM) alone. F) Quantification of the Western blots for ErbB2, Sch, and Pak in starved (D0.5) cultures, and in those stimulated with NRG1 (NRG), NRG1 with PKI 14-22 (N+P), and forskolin (FSK) is shown. GAPDH was used as a loading control for all blots. The graphs represent the average fold increase in each condition in three or more experiments. Error bars represent the SEM for each condition. P values are <0.05(*) with respect to starved SCs or as indicated.
FIG. 4 : Soluble Laminin-1 Stimulates Phosphorylation of Sch. A, C) Subconfluent SC cultures grown on PLL were stimulated with laminin-1 (10 μg/ml) for 30 minutes after overnight serum starvation. Western blot analysis using antibodies specific for the phosphorylated forms of Sch (PS518-Sch) and Pak (P-Pak) and antibodies against total Sch (Sch-C18), Pak, and β1 integrin are shown. B, D). Quantification of Western blots for starved (D0.5) and laminin-1 stimulated (Lam) cultures is shown. The graphs represent the average fold increase in each condition observed in three or more experiments. GAPDH was used as a loading control for all blots. Error bars represent the SEM for each condition. P values are <0.05(*) and <0.01(**).
FIG. 5 : Catalytically Inactive Pak Inhibits Sch Phosphorylation in SCs Adhering to Laminin-1. SCs plated on PLL and laminin-1 were transiently transfected with GFP-tagged full length Sch (Sch-GFP) alone or with Myc-tagged catalytically inactive Pak (Myc-PakK299A) or Myc-tagged constitutively active Pak (Myc-PakT423E), and were immunostained to assess Sch-S518 phosphorylation (PS518-Sch) and Myc-Pak expression (Myc).
FIG. 6 : β1 integrin and ErbB2 Exist as a Complex on the Plasma Membrane. A) Subconfluent SC cultures grown on PLL and laminin-1 were starved overnight and were stimulated with NRG1 for 30 minutes. SCs were triple-labeled with the indicated antibodies to assess protein co-localization. B) Subconfluent SC cultures were extracted and lysates (TE) were pre-cleared (PC) with normal IgG and were immunoprecipitated with β1 integrin antibody (β1 IP). Western blots analysis was conducted with the indicated antibodies. C) Intact SCs in suspension were incubated with β1 integrin antibody immobilized on magnetic beads to induce clustering. SCs were lysed, and the immunoprecipitate (β1IP) and total protein lysate (TE) were immunoblotted with the indicated antibodies. D) Subconfluent and serum-starved SCs grown on PLL were stimulated for 30 minutes with NRG1 (10 ng/ml) in the presence and absence of AG825 (1 μM). Western blot analysis was conducted with the indicated antibodies. E) Quantification of total β1 integrin and ErbB2 expression was assessed by densitometry in starved (D0.5), NRG1 stimulated (NRG) and NRG with AG825 (N+A) stimulated cultures. F) Subconfluent SCs were starved overnight in D0.5 and then were stimulated for 30 minutes with laminin-1 (10 mg/ml) in the presence and absence of AG825 (1 μM). Western blot analyses were conducted to examine changes in receptor expression levels. G) Quantification of total β1 integrin and ErbB2 expression in starved (D0.5), laminin-stimulated (Lam) and laminin+AG825 (L+A) stimulated cultures is shown. GAPDH was used as a loading control for all blots. The graphs represent the average fold increase in each condition in three or more experiments. Error bars represent the SEM for each condition. P values are <0.05(*) with respect to starved SCs or as indicated.
FIG. 7 : AG825 Increases Sch Phosphorylation in Response to Laminin-1 and NRG1. Subconfluent SC cultures grown on PLL were serum-starved overnight and were stimulated for 30 minutes with NRG1 (10 ng/ml) and laminin-1 (10 mg/ml) together, in the absence and presence of AG825 (1 μM). A, C, E, G) Western blot analyses were conducted using phospho-specific antibodies for Sch (PS518-Sch), Pak (P-Pak), and CREB (P-CREB). Total protein expression was analyzed using antibodies against Sch (Sch-C18), Pak, β1 integrin, and ErbB2. B, D, F) Quantification of the expression levels of phosphorylated forms of Sch (PS518-Sch) and Pak (P-Pak) were assessed in starved (D0.5), NRG1 and laminin-1 stimulated (NRG+Lam), and NRG1 plus laminin-1 and AG825 (N+L+A) stimulated cultures. The amount of total Sch (Sch-C18), Pak, β1 integrin, and ErbB2 proteins were measured by densitometry. GAPDH was used as a loading control. The graphs represent the average fold increase in each condition in three or more experiments. Error bars represent the SEM for each condition. P values are <0.05(*) with respect to starved SCs, or as indicated.
FIG. 8 : Model of ErbB and β1 Integrin Induced Phosphorylation of Sch and Inactivation of its Tumor Suppressor Function in Subconfluent SCs. Unphosphorylated Sch restricts proliferation by inhibiting activation of the Rac-Pak pathway in confluent cells. In a regulatory loop, Pak phosphorylates Sch, inactivating its tumor suppressor ability. In subconfluent SCs. Sch is phosphorylated in response to activation of ErbB2/ErbB3 and α6β1 integrin receptors by NRG1 and laminin-1, respectively. through two distinct pathways involving PKA and Pak. Simultaneous co-activation of both receptors does not synergistically increase Sch phosphorylation but rather ErbB2, through PKA, inhibits Pak phosphorylation of Sch (dashed line). Phosphorylated Sch is unable to inhibit Rac-Pak and allows transduction of ErbB and α6β1 integrin signals that promote G1 progression. Additionally, the presence of this complex at the motile distal tip of SC processes coordinates motility along axons and other cytoskeletal changes in response NRG and basal lamina necessary for myelination of peripheral nerves during development.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods and materials are described below. Any publications, patent applications, patents, or other references mentioned herein are incorporated by reference in their entirety. In case of conflict, the present specification, including any definitions, will control. In addition, the materials, methods and examples given are illustrative in nature only and not intended to be limiting. Accordingly, this invention may be embodied in different forms and should not be construed as limited to the illustrated embodiments set forth herein. Rather, these illustrated embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Other features and advantages of the invention will be apparent from the following detailed description, and from the claims.
Abbreviations used herein are as follows: cyclic-AMP response element binding protein (P-CREB); Neurofibromatosis type 2 (NF2); p21-activated kinase (Pak); neuregulin-1 (NRG1); protein kinase A (PKA); Schwann cells (SCs); and Schwannomin (Sch).
The Neurofibromatosis type 2 (NF2) tumor suppressor Schwannomin (Sch), also known as merlin, is a membrane-cytoskeleton linking protein (Rouleau et al., 1993; Trofatter et al., 1993). Mutations in the NF2 gene predispose individuals to benign, slow-growing schwannomas. Sch's conformation, localization, and phosphorylation are important determinants of its ability to regulate proliferation and actin organization (reviewed in McClatchey and Giovannini, 2005). The tumor suppressor function of Sch is associated with its closed, intracellular form lacking phosphorylation on serine 518 (S518; Rong et al., 2004; Shaw et al., 2001). In this conformation, Sch inhibits Rac-mediated signaling cascades and progression through the G1 phase of the cell cycle (reviewed in Okada et al., 2007). Phosphorylation of Sch-S518 is believed to stabilize Sch in the open conformation, inhibiting its tumor suppressor function while unmasking binding sites for trans-membrane receptors and actin-associated proteins (James et al., 2001; Rong et al., 2004). P21-activated kinase (Pak) and protein kinase A (PKA) phosphorylate Sch on S518, but the receptor mechanisms leading to Sch phosphorylation are unknown (Kissil et al., 2002; Xiao et al., 2002; Alfthan et al., 2004).
Previously, we demonstrated that Sch localization to the plasma membrane, and its phosphorylation on S518 requires direct binding of residues 50-70 within Sch's N-terminus to the scaffold protein, paxillin (Fernandez-Valle et al., 2002, Thaxton et al., 2007). We also demonstrated that Sch is present at the plasma membrane of subconfluent Schwann cells (SCs), where Sch and paxillin interact with β1 integrin and ErbB2; receptors critical for SC adhesion, motility, proliferation and myelination (Fernandez-Valle et al., 2002; reviewed in Garratt et al., 2000; reviewed in Chernousov and Carey, 2000). Paxillin also recruits Pak to the plasma membrane, and serves as a scaffold for Sch-Pak interactions by binding multiple regulators of Rac and Cdc42, members of the Rho family of GTPases, as well as actin binding proteins and components of focal complexes and adhesions (reviewed in Turner, 2000).
Here, we demonstrate that NRG1 and laminin-1, ligands for ErbB and β1 integrin receptors, respectively, induce Sch phosphorylation in SCs through two independent pathways, NRG1 by PKA, and laminin by Pak. NRG1 and laminin-1 do not synergize to increase Sch phosphorylation, but rather NRG1 through PKA partially antagonizes laminin-induced, and Pak-mediated Sch phosphorylation. These findings show that Sch is a convergence point for transduction of signals from ErbB and β1 integrin receptors that regulate proliferation, differentiation and cytoskeletal dynamics in SCs during peripheral nerve development.
Material and Methods
Materials
The following materials were used: Natural mouse laminin-1 and Lipofectamine 2000 (Invitrogen; Carlsbad, Calif., USA), AG825 and PKI 14-22 amide (EMD Biosciences; San Diego, Calif., USA). Sch-GFP constructs were described previously (Thaxton et al., 2007). Recombinant human NRG-1 beta/type II was a generous gift from Mark Marchionni. Myc-Pak K299A and Myc-Pak L107F. T423E (Myc-Pak T423E) constructs were generous gifts from Gary Bokoch (The Scripps Research Inst., La Jolla, Calif., USA). Antibodies were purchased from the following sources: ErbB2 and Sch (C18) from Santa Cruz Biotechnology (Santa Cruz, Calif., USA); β1 integrin from BD Transduction Labs (San Jose, Calif., USA); Pak, Myc, and P-CREB from Cell Signaling (Boston, Mass., USA); PS518-Sch and P-ErbB2 (Y1248) from Abcam (Cambridge. Mass., USA); P-Pak (T423) from Rockland Immunologicals, Inc. (Gilbertsville, Pa., USA); Xpress from Invitrogen; ErbB2 from EMD Biosciences; and Alexa Fluor conjugated secondary antibodies from Invitrogen.
Cell Culture
Primary rat SC cultures were prepared from neo-natal day 1 rat pups as described previously (Chen et al., 2000). Subconfluent SC cultures were grown on glass coverslips coated with poly-L-lysine (PLL; 200 mg/ml) alone or sequentially with laminin-1 (25 mg/ml). Cultures were starved overnight in Dulbecco's Modified Eagle Medium (DME) with 0.5% fetal bovine serum (D0.5) before use. The SCs were either left unstimulated, or were stimulated with NRG (10 ng/ml) for 30 minutes. For laminin-1 stimulation, primary rat SCs were grown on PLL coated glass coverslips and were starved overnight in D0.5. The SCs were then stimulated with soluble laminin-1 (10 mg/ml) or were left unstimulated.
Immunostaining
The SCs were immunostained as described previously (Fernandez-Valle, 2002). Cells were analyzed with a Zeiss laser scanning microscope and LSM 510 software. Images shown in each figure are single planes, and were collected with identical settings, and were processed identically.
Western Blotting
Primary rat SCs were grown to approximately 60% confluency on PLL coated dishes. The cultures were serum starved overnight in D0.5 and were either left in D0.5 or were pre-incubated with AG825 (1 mM) or PKI 14-22 (50 nM) for 1 hour. Next, the SCs were either left unstimulated or were stimulated with NRG1 (10 ng/ml) and/or laminin-1 (10 mg/ml) in the presence and absence of AG825 (1 mM) or PKI 14-22 (50 nM) for 30 minutes. The SCs were extracted as described previously (Fernandez-Valle et al., 2002) in either TAN buffer (10 mM Tris-acetate pH8.0, 100 mM NaCl, and 1% IGEPAL) or HEPES buffer (50 mM HEPES, 1 mM DTT, 150 mM NaCl, 1% IGEPAL) containing protease inhibitors. Following extraction, the SC lysate was measured for protein concentration, and 10 mg of total SC lysate was separated by SDS-PAGE and was transferred to PVDF membranes. The indicated primary antibodies were used, followed by corresponding HRP-conjugated secondary antibody and chemiluminescence detection. Densitometric analysis was conducted on all Western blots. Bands intensities were quantified and normalized to GAPDH, and to their respective total proteins for phosphorylated forms. Statistical analysis was acquired using the Student t-test by paired analysis.
Immunoprecipitation
Subconfluent SC cultures grown in medium containing 10% FBS, forskolin (2 mM) and pituitary extract (20 mg/ml) were extracted in TAN buffer and 500 mg of lysate were immunoprecipitated with β1 integrin antibody, as described previously (Chen et al., 2000). Immunoprecipitation with 31 integrin antibody covalently linked to magnetic beads was performed as described previously (Taylor et al., 2003).
Transfections
Primary rat SC cultures were transfected using Lipofectamine 2000 as described previously (Thaxton et al., 2007). Thirty-six hours after transfection, the SCs were immunostained.
Results
NRG and Laminin Induce Phosphorylation of Sch at SC Distal Tips and Radial Membrane Protrusions
NRG and laminin activate Cdc42/Rac GTPases and Pak in other cell types (Adam et al., 1998; Del Pozo et al., 2000). Work from this laboratory has demonstrated that Sch can interact with both ErbB2 and β1 integrin, and that paxillin-dependent localization to the plasma membrane is required for phosphorylation of Sch by Cdc42-Pak (Fernandez-Valle et al., 2002; Thaxton et al. 2007). Here, we sought to identify receptor(s) that trigger Pak activity and Sch phosphorylation. We stimulated subconfluent and serum-starved primary rat SCs grown on laminin-1 with NRG1 for 30 minutes, and assessed the phosphorylation states and localization of ErbB2, Sch and Pak. ErbB2, ErbB3, and Sch were found along SC processes, and were concentrated at the distal tips. NRG1 stimulation induced a focal enrichment of P-ErbB2 and PS518-Sch at the distal tips of SC processes and within membrane protrusions ( FIG. 1 ). These molecules co-localized with Cdc42 and paxillin. Phosphorylated Pak was also enriched in membrane protrusions and at the distal tips where it co-localized with ErbB2.
We quantified the changes in phosphorylation of ErbB2, Sch, and Pak in serum starved and NRG1 stimulated SC processes ( FIG. 2 A, B). We found marked increases in fluorescence intensity along SC processes for P-ErbB2, PS518-Sch, and P-Pak, particularly at process tips of stimulated versus starved SCs ( FIG. 2A ). P-ErbB2 levels increased by 1.6-fold, PS518-Sch by 1.5-fold, and P-Pak by 1.9-fold in NRG1 stimulated versus starved SCs ( FIG. 2 B). These results demonstrate that acute stimulation of SCs with NRG1 induces phosphorylation of Sch downstream of ErbB2/ErbB3, possibly by Pak.
As the SCs were grown on laminin-1, a ligand for β1 integrin that mediates SC adhesion (Fernandez-Valle et al., 1994), we tested whether a 30-minute exposure to soluble laminin-1 stimulated Sch phosphorylation in subconfluent and serum-starved SCs grown on PLL. Laminin-1 promoted a strong increase in Sch and Pak phosphorylation compared to starved SCs ( FIG. 2 C). Quantification of fluorescence intensity along the processes revealed a 1.4-fold increase in PS518-Sch and a 1.7-fold increase in P-Pak compared to untreated SCs ( FIG. 2 D). These results demonstrate that adhesion to laminin-1 induces Sch phosphorylation at the plasma membrane, possibly by Pak.
NRG Promotes Sch Phosphorylation Through PKA
To determine the relative contributions of ErbB2/ErbB3 and β1 integrin activation on Sch phosphorylation, we repeated the experiments using SCs plated on PLL rather than laminin-1, and employed the use of AG825 to specifically inhibit ErbB2 kinase activity (Osherov et al., 1993). Subconfluent SCs were starved and then were stimulated with NRG1 in the presence and absence of AG825 ( FIG. 3 ). NRG1 promoted a 4.8-fold increase in P-ErbB2 and a 2.7-fold increase in PS518-Sch compared to starved SCs. AG825 reduced NRG1 stimulated phosphorylation of ErbB2 significantly, as well as Sch-S518 phosphorylation ( FIG. 3A , B). Surprisingly, no Pak phosphorylation was observed in NRG1 stimulated SCs. When total protein levels were assessed, we found that stimulation with NRG1 reduced the amount of ErbB2 by 50% ( FIG. 3C , D). This is consistent with rapid, ligand-induced degradation of ErbB2 receptors (Lotti et al., 1992). AG825 attenuated the reduction in ErbB2 levels. These results suggest that NRG1 triggers Sch phosphorylation independently of Pak in SCs.
PKA has been reported to phosphorylate Sch at S518 in vitro (Alfthan et al., 2004). Additionally, NRG1 stimulation has been suggested to induce PKA activity in SCs (Kim et al., 1997). Therefore, we tested whether PKA phosphorylated Sch in response to NRG1 activation of ErbB2/ErbB3 receptors on SCs. Subconfluent SCs were serum starved and were stimulated with NRG1 in the presence and absence of PKI 14-22 amide, a specific inhibitor of PKA activity ( FIG. 3 E, F). NRG1 alone stimulated a 2.1-fold increase in phosphorylated Sch compared to starved SCs, and induced phosphorylation of the cyclic-AMP response element binding protein (P-CREB), a known substrate for PKA. PKI 14-22 reduced the levels of Sch and CREB phosphorylation to near basal levels observed in starved controls. Additionally, stimulation of starved SCs for 30 minutes with forskolin, an activator of adenylyl cyclase that increases intracellular cyclic-AMP and activates PKA, also induced phosphorylation of Sch and CREB. These results provide evidence for PKA-dependent phosphorylation of Sch following NRG1 binding to ErbB2/ErbB3 in SCs.
Laminin Promotes Phosphorylation of Sch-S518 by Pak
To determine if laminin-1 induced phosphorylation of Sch by Pak, we stimulated SCs grown on PLL with soluble laminin-1 for 30 minutes and conducted western blot analyses ( FIG. 4 ). Laminin-1 promoted a substantial 3.5-fold increase in Sch-S518 phosphorylation and a 1.5-fold increase in Pak phoshorylation compared to starved SCs ( FIG. 4 A, B). The levels of total Sch and β1 integrin did not significantly change in response to laminin-1, while the levels of total Pak fell by 25% ( FIG. 4 C, D). We additionally tested whether laminin-1 activated ErbB2 and PKA. Laminin-1 stimulated SCs had no change in the basal level of P-ErbB2 and did not contain P-CREB (data not shown). These findings are consistent with Pak mediated phosphorylation of Sch-S518 following laminin binding to β1 integrins expressed on the surface of subconfluent SCs.
To obtain additional evidence that Pak phosphorylates Sch in response to stimulation with laminin-1, we transiently transfected SCs plated on PLL and laminin-1 with GFP-tagged Sch and Myc-tagged Pak kinase mutant constructs ( FIG. 5 ). As shown previously, expression of wild-type Sch (Sch-GFP) resulted in Sch phosphorylation at the plasma membrane within discrete membrane protrusions that contain P-Pak (Thaxton et al., 2007). Co-expression of Sch-GFP with catalytically inactive Pak (Myc-Pak K299A) resulted in a loss of PS518-Sch fluorescence in these domains and throughout the SC, whereas co-expression with constitutively active Pak (Myc Pak T423E) resulted in unrestricted Sch phosphorylation. These results support Pak-mediated phosphorylation of Sch induced by β1 integrin adhesion to laminin-1.
β1 integrin and ErbB2 Exist as a Functional Co-Receptor Complex on the SC Surface
To investigate the possibility that ErbB2 and β1 integrin act as co-receptors to regulate Sch phosphorylation, we tested their ability to co-localize and co-immunoprecipitate. We found that β1 integrin and ErbB2 co-localized with PS518-Sch and P-ErbB2 at the distal tips of SC processes acutely stimulated with NRG1 ( FIG. 6 A). β1 integrin immunoprecipitations prepared from lysates of subconfluent SC cultures contained β1 integrin and ErbB2, as well as, PS518-Sch and paxillin ( FIG. 6 B). To ascertain whether the receptors associated on the cell surface, (31 integrins were clustered on suspended intact SCs using a β1 integrin antibody immobilized on magnetic beads and were subsequently lysed and the clustered receptor complexes were isolated ( FIG. 6 C). A subset of ErbB2 receptors and PS518-Sch were present in the β1 integrin immunoprecipitate. RhoA, used as a control, was not present in the immunoprecipitate.
Trans-activation of integrins and receptor tyrosine kinases occurs, and can produce changes in receptor protein expression (reviewed in Lee and Juliano, 2004). To determine if this occurs in SCs, β1 integrin and ErbB2 protein levels were measured following stimulation with NRG1 or laminin-1 for 30 minutes. Stimulation with NRG1 significantly increased β1 integrin levels 2.3-fold, but decreased ErbB2 levels by half as compared to starved SCs ( FIG. 6 D, E). Stimulation of SCs with NRG1 and AG825 suppressed NRG1's effect on both β1 integrin and ErbB2 protein levels. Stimulation of SCs with laminin-1 did not alter β1 integrin protein levels, but did increase ErbB2 protein levels by a statistically significant 1.3-fold compared to untreated SCs ( FIG. 6 F, G). Surprisingly, stimulation with laminin-1 and AG825 decreased β1 integrin levels by 50%, but did not alter ErbB2 levels with respect to laminin-stimulated SCs. This is consistent with a basal level of autocrine activation of ErbB2/ErbB3 in SCs. SCs have been shown to synthesize and secrete NRGs in response to serum deprivation, thereby transducing survival signals (Rosenbaum et al., 1997).
Dual Stimulation with NRG and Laminin does not Synergistically Increase Sch Phosphorylation
To determine if simultaneous activation of ErbB2/ErbB3 and β1 integrin in SCs synergize to increase phosphorylation of Sch, we stimulated serum-starved SCs grown on PLL for 30 minutes with NRG1 and soluble laminin-1, in the presence and absence of AG825 ( FIG. 7 ). Dual stimulation resulted in a significant 1.8-fold increase in PS518-Sch and a 2.1-fold increase in P-Pak compared to unstimulated SCs. This level of Sch phosphorylation was not higher than levels observed in SCs stimulated with either NRG1 or laminin-1 alone, which were 2.7-fold and 3.5-fold higher than starved SCs, respectively ( FIG. 7 A, B). Surprisingly, stimulation with NRG1 and laminin-1 in the presence of AG825 promoted greater phosphorylation of Sch-S518 (a 4.6-fold increase) and Pak (a 3.1-fold increase) compared to starved SCs, suggesting that ErbB2 kinase activity partially inhibits Pak and its phosphorylation of Sch. PKA has been shown to directly phosphorylate and inhibit Pak (Howe and Juliano, 2000). We found that AG825 inhibited phosphorylation of CREB in response to NRG1 in dually stimulated SCs, consistent with PKA inhibition of Pak ( FIG. 7 G). Sch, Pak and β1 integrin protein levels were not significantly changed in SCs stimulated with NRG1 and laminin-1 in the presence and absence of AG825 ( FIG. 7 C, D). Stimulation with NRG1 and laminin-1 resulted in a 30% decrease in ErbB2 compared to starved SCs. This result indicates that PKA activated downstream of ErbB2 kinase activity partially inhibits Pak-dependent phosphorylation of Sch in response to laminin-1. A model consistent with our results is shown ( FIG. 8 ).
Discussion
Phosphorylation of S518 is a critical switch that controls Sch's tumor suppressor activity. Pak and PKA have been shown to phosphorylate Sch on S518 when overexpressed with Sch in cell lines and in in vitro kinase assays, but neither kinase has been linked to receptor activation and phosphorylation of endogenously expressed Sch in any cell type (Kissil et al., 2002; Xiao et al., 2002; Alfthan et al., 2004). Here, we identify two receptors that lead to rapid phosphorylation of Sch-S518 in SCs. Laminin-1 binding to β1 integrin activates Pak, whereas NRG1 binding to ErbB receptors activates PKA. Each kinase phosphorylates Sch-S518 within 30 minutes of stimulation. Both receptors regulate all stages of Schwann cell development including proliferation, and both play central roles in the tumorigenic and metastatic capacities of many additional cell types.
Two Distinct Receptor Mediated Pathways Promote Sch Phosphorylation
Our data provide strong evidence that NRG1 binding to ErbB2/ErbB3 induces PKA-dependent phosphorylation of endogenous Sch. This conclusion is supported by the following results. First, serum-starved SCs have basal levels of phosphorylated Pak and Sch. NRG1 inhibits basal Pak activity while increasing the amount of phosphorylated Sch, 2.7-fold. Second, inhibition of ErbB2 kinase activity by AG825 reduces Sch-S518 phosphorylation in response to NRG1 by 50%. Third, the PKA inhibitor, PKI 14-22 similarly reduces Sch-S518 phosphorylation in response to NRG1 by 70%. Lastly, although not as effective as NRG1, forskolin increases Sch phosphorylation. We also show that NRG1 promotes phosphorylation of CREB and that both AG825 and PKI 14-22 inhibit this phosphorylation, consistent with NRG stimulation of PKA activity. In support, others have also found evidence of PKA activation by NRG in SCs (Kim et al., 1997). Overall, our results indicate that NRG binds to ErbB2/ErbB3 receptors and stimulates rapid phosphorylation of Sch on S518 by PKA.
Cell adhesion to extracellular matrix through integrins activates Pak (Del Pozo et al., 2000). Laminin-1 is present in the endoneurium of nerves in perinatal mice, and promotes strong in vitro adhesion, migration and proliferation of SCs (Milner et al., 1997; Dubovy et al., 2000). Previously we demonstrated that α6β1 integrin is the predominant laminin-1 binding integrin present in SCs at this stage of development (Fernandez-Valle et al., 1994). Our new findings indicate that laminin-1 binding to α6β1 integrin promotes Sch-S518 phosphorylation by Pak. Our evidence is as follows: First, stimulation of SCs with soluble laminin-1 increases both P-Pak (1.5-fold) and PS518-Sch (3.5-fold) over basal levels. Similarly, P-Pak and PS518-Sch are increased within SC processes as assessed by quantification of immunofluorescence. Second, Sch-GFP expressed in SCs adhering to laminin-1 is phosphorylated by an endogenous kinase, predominantly when localized at the plasma membrane of cellular processes and particularly in radial membrane protrusions. Previously, we reported that Cdc42-Pak rather than Rac-Pak was associated with phosphorylation of Sch in these domains (Thaxton et al., 2007). Consistently, we find that expression of catalytically inactive Pak inhibits phosphorylation of Sch-GFP in SCs adhering to laminin-1. Lastly, laminin-1 does not activate PKA or trans-activate ErbB2, as P-ErbB2 and P-CREB were not found, ruling out PKA dependent phosphorylation of Sch in response to laminin-1. It has been established that Pak is recruited to focal complexes through an indirect interaction with paxillin, stimulated by Cdc42 and Rac activity (Brown et al., 2002). Together, our results indicate that aggregation of α6β1 integrins by laminin-1 triggers translocation of a Pak-paxillin-Sch complex to nascent focal complexes where Sch-S518 is phosphorylated by Cdc42-Pak.
ErbB2 Modulates β1 Integrin Signaling
Our data demonstrate that ErbB2/ErbB3 and β1 integrin physically interact and function as co-receptors that regulate both the turnover rate of each receptor and their downstream signals. ErbB2/ErbB3 and β1 integrin co-immunoprecipitate and co-localize on the SC surface and are enriched at the distal tips of SC processes stimulated with NRG1. Simultaneous activation of ErbB2/ErbB3 and β1 integrin receptors does not synergistically increase Sch phosphorylation, but rather ErbB2 activity appears to antagonize Pak-dependent phosphorylation of Sch. In SCs stimulated with NRG1, laminin-1 and AG825, PS518-Sch and P-Pak levels increase over dually stimulated SCs while P-CREB is eliminated. AG825, in the absence of NRG1 also increases basal levels of phosphorylated Pak and Sch (data not shown), consistent with autocrine stimulation of ErbB2 and PKA activity (Rosenbaum et al., 1997). PKA has been shown to directly phosphorylate and inhibit Pak in NIH3T3 cells (Howe and Juliano, 2000). Together, these findings indicate that ErbB2, through PKA, antagonizes Pak dependent phosphorylation of Sch downstream of β1 integrin.
Implications for Schwannoma Development
β1 integrin and ErbB receptors regulate SC proliferation during development. Conditional inactivation of genes encoding their respective ligands, the laminin g1 gene and the neuregulin gene, in mice are associated with low proliferative capacity of SCs during development, demonstrating that both receptors are essential for SC proliferation (reviewed in Garratt et al., 2000; Chen and Strickland, 2003; Yang et al., 2005). Cooperation between receptor tyrosine kinase and integrin signaling is required for activation of the Ras-Raf-Mek-Erk pathway, which is active in both human and rodent SCs (reviewed in Lee et al., 2004; Monje et al., 2006). Activation of mitogenic receptor tyrosine kinases, in the absence of integrin-dependent adhesion, is coupled only to Ras and Raf and does not lead to Mek and Erk activity. Adhesion of integrins to extracellular matrix activates the Rho family of GTPases and Pak, allowing Pak phosphorylation of c-Raf and Mek. Mek then associates with, and phosphorylates Erk (Del Pozo et al., 2000; Coles and Shaw 2002). One mechanism by which Sch restricts proliferation is by inhibiting Rac-Pak activity in confluent cells (reviewed in Okada et al., 2007). Phosphorylation of Sch downstream of both ErbB and β1 integrin receptors would inactivate this ability and would allow Rac-Pak signaling to couple to Ras-Erk pathways and stimulate proliferation of subconfluent cells.
Consistent with the rapid turnover of focal contacts in subconfluent, motile cells, we find that β1 integrin and ErbB2 protein levels are rapidly modulated by receptor activity. NRG1 has a greater effect on ErbB2 and β1 integrin levels than laminin-1. Whereas laminin-1 stimulates a 30% increase in ErbB2 protein expression over starved SCs, NRG1 promotes a 50% decrease in ErbB2 receptors while increasing β1 integrin levels 2.3 fold over starved SCs. AG825 attenuates the loss of ErbB2 protein in response to NRG1 and inhibits the increase in β1 integrin, confirming that ErbB2 kinase activity modulates the fate of each receptor. In laminin-1 stimulated SCs, AG825 decreases β1 integrin levels, consistent with autocrine stimulation of ErbB2 in SCs. These effects are likely mediated through changes in protein stability and/or degradation, as they occur within 30 minutes of stimulation. Moreover, our results show that each receptor has a different fate after activation, β1 integrins are stabilized following NRG1 stimulation, whereas ErbB2 is degraded. This also implies that ErbB2 dependent inhibition of Pak is transient, and that β1 integrin and Pak dependent phosphorylation of Sch occurs during the time ErbB2 receptor expression on the plasma membrane is low.
Sch is at a critical convergence point for transduction of signals from these receptors, and reveals why loss of this protein in SCs predisposes them to tumor formation. There is evidence that Sch controls endocytosis of ErbB family members, possibly through its interaction with HRS (Scoles et al., 2005; Maitra et al., 2006). Additionally, other paxillin binding proteins regulate vesicle trafficking and receptor degradation (reviewed in Turner, 2000). Of note, human schwannoma cells have increased expression of β1 integrin and activated ErbB2, Rac and Pak (Hansen and Linthicum, 2004; Kaempchen et al. 2003; Utermark et al., 2003). Loss of Sch expression in SCs could allow unrestricted autocrine stimulation of ErbB2/ErbB3, resulting in increased β1 integrin levels and prolonged activation of PKA, Rac-Pak, Ras-Erk and PI3K/AKT pathways. Activation of these signaling cascades would stimulate a slow, but continuous proliferation of SCs, characteristic of schwannoma growth in individuals with NF2.
In summary, we have shown that activation of ErbB2/ErbB3 and β1 integrin receptors promotes phosphorylation of Sch through distinct PKA- and Pak-dependent pathways. In vivo, these signaling cascades would cooperate to promote SC proliferation in response to axonal NRG and basal lamina adhesion. In its phosphorylated state, Sch would also permit Rac-Pak dependent changes in the actin cytoskeleton associated with extension of processes along axons, a critical function for myelination. Our findings shed light on Sch's function during development and pathogenesis in the peripheral nervous system.
Accordingly, in the drawings and specification there have been disclosed typical preferred embodiments of the invention and although specific terms may have been employed, the terms are used in a descriptive sense only and not for purposes of limitation. The invention has been described in considerable detail with specific reference to these illustrated embodiments. It will be apparent, however, that various modifications and changes can be made within the spirit and scope of the invention as described in the foregoing specification and as defined in the appended claims.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of provisional application No. 61/586,196, filed on Jan. 13, 2012, which is hereby incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to batteries and to battery circuits.
BACKGROUND OF THE INVENTION
[0003] A typical battery has two terminals. One terminal is marked (+), or positive, and the other is marked (−), or negative. In normal flashlight batteries, such as conventional AA, C or D cell batteries, the terminals are located at the opposed ends of the battery. To harness the electric charge produced by a battery, the battery must be connected to a load, such as a light bulb, a motor, or an electrical circuit.
[0004] The internal workings of a battery are housed within a metal or plastic case. Inside this case are a cathode, which connects to the positive terminal, and a corresponding anode, which connects to the negative terminal. These components, which are electrodes, occupy most of the space in a battery and are the place where the chemical reactions occur to produce electricity. An insulator or separator creates a barrier between the cathode and anode isolating the cathode from the anode preventing the electrodes from touching while allowing electrical charge to flow freely between them. The medium that allows the electric charge to flow between the cathode and anode is known as the electrolyte. A collector conducts the charge to the outside of the battery and through the applied load.
[0005] When a load completes the circuit between the positive and negative terminals, the battery produces electricity through a series of electromagnetic reactions between the anode, the cathode, and the electrolyte. The anode experiences an oxidation in which two or more ions from the electrolyte combine with the anode, producing a compound and releasing one or more electrons. At the same time, the cathode goes through a reduction reaction, in which the cathode substance, ions, and free electrons also combine to form compounds. The reaction in the anode creates electrons, the reaction in the cathode absorbs them, and the net product is electricity. The battery will continue to produce electricity until one or both of the electrodes run out of the substance necessary for the reactions to occur. Modern batteries use a variety of chemicals to power their reactions. Common battery chemistries include zinc-carbon batteries, alkaline batteries, lithium-ion batteries, and lead-acid batteries.
[0006] The zinc-carbon chemistry of zinc-carbon batteries is common in many inexpensive AAA, AA, C, and D dry cell batteries, in which the anode is zinc, the cathode is manganese dioxide, and the electrolyte is ammonium chloride or zinc chloride. The chemistry of alkaline batteries is also common in AA, C, and D dry cell batteries. In alkaline batteries, the cathode is composed of a manganese dioxide mixture, the anode is a zinc powder, and the electrolyte is potassium hydroxide, which is an alkaline substance. The lithium chemistry of lithium-ion batteries is often used in high-performance devices, such as cell phones, digital cameras, and electric cars. Lithium-ion batteries are rechargeable, and a variety of substances are used in lithium batteries, and a common combination is a lithium cobalt oxide cathode and a corresponding carbon anode. Lead-acid batteries are also rechargeable, and the corresponding chemistry, which is used in conventional car batteries, includes lead dioxide and metallic lead for the electrodes, and a sulfuric acid solution for the electrolyte. The most common form of rechargeable battery is the lithium-ion battery.
[0007] With the rise of portable electronic devices, such as laptops, cell phones, flashlights, cordless power tools, and the like, the need for rechargeable batteries has grown substantially in recent years. Many portable electronic devices that use rechargeable batteries incorporate one contact region for an operating circuit for operating the load, and a second contact point for a charging circuit used to recharge the battery. The operating circuit operates separately from the charging circuit. This is normally achieved by using either a battery cradle that contains the necessary circuits, or an inner barrel inside the body of the electronic device to carry the extra current. Although both methods are effective, they add extra weight and increased cost in the product of the electronic devices and in some instances make it inconvenient and cumbersome to remove or replace a battery as may be necessary from time-to-time. Given these and other deficiencies in the art of batteries, the need for continued improvement in the field is evident.
SUMMARY OF THE INVENTION
[0008] An aspect of the invention involves a battery having a battery case including battery chemistry for supplying electricity, a first end, and a second end opposite the first end; a first positive terminal, a first negative terminal, and a first insulator therebetween at the first end that together form a first positive terminal and negative terminal configuration; a second positive terminal, a second negative terminal, and a second insulator therebetween at the second end that together form a second positive terminal and negative terminal configuration, wherein the second positive terminal and the second negative terminal configuration is a minor image of the first positive terminal and the first negative terminal configuration.
[0009] One or more implementations of the aspect of the invention described immediately above include one or more of the following: the battery is rechargeable; the battery chemistry lithium-ion chemistry; the battery chemistry is zinc-carbon chemistry; the battery chemistry is lead-acid chemistry; the battery chemistry is alkaline chemistry; the battery is elongated and cylindrical in shape; the first positive terminal and the second positive terminal are circular, located at a geometric center of the first and second ends, and are symmetrical about a longitudinal axis of the battery, the first and second insulators are continuous circular rings, encircle the first and second positive terminals, are located between the first and second positive terminals and the first and second negative terminals, and are symmetrical about the longitudinal axis of the battery, and first and second negative terminals are continuous circular rings that concurrently encircle first and second separators and first and second positive terminal, and are symmetrical about the longitudinal axis of the battery, the first and second positive terminals, the first and second negative terminals, and first and second insulators are concentric and share the longitudinal axis as a common center; a first load connected to the first positive terminal and the first negative terminal at the first end and a second load connected to the second positive terminal and the second negative terminal at the second end; a load connected to the first positive terminal and the first negative terminal at the first end and a charger connected to the second positive terminal and the second negative terminal at the second end; a first charger connected to the first positive terminal and the first negative terminal at the first end and a second charger connected to the second positive terminal and the second negative terminal at the second end; a battery-powered electronic device comprising a body; and a load carried by the body and powered by the battery; a charger coupled to the battery to charge the battery; the battery-powered electronic device is a portable flashlight, the body is a handle of the flashlight, the load is a lamp of the flashlight, and the battery is carried in the handle of the flashlight; a charger coupled to the battery to charge the battery; a battery-powered electronic device including a body and a load carried by the body and powered by the battery, comprising: receiving a first battery in the battery-powered electronic device, the first battery having the construction of the battery and being disposed in a first orientation with the second positive terminal and second negative terminal configuration facing in one direction and the first positive terminal and first negative terminal configuration facing in an opposite direction; replacing the first battery with a second battery in the battery-powered electronic device, the second battery having the construction of the battery of claim 1 and being disposed in a second orientation opposite the first orientation; a method of using a battery-powered electronic device including a body and a load carried by the body and powered by the battery, comprising: receiving a first battery in the battery-powered electronic device, the first battery having the construction of the battery and being disposed in a first orientation with the second positive terminal and second negative terminal configuration facing in one direction and the first positive terminal and first negative terminal configuration facing in an opposite direction; receiving a second battery in the battery-powered electronic device adjacent to the first battery and in direct series connection therewith, the second battery having the construction of the battery of claim 1 and being disposed in a second orientation opposite of the first orientation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a perspective of a battery constructed and arranged in accordance with the principle of the invention;
[0011] FIG. 2 is another perspective view of the battery of FIG. 1 ; and
[0012] FIG. 3 is a schematic diagram of the battery of FIGS. 1 and 2 incorporated into a battery-powered electronic device having a load component and a charging component, and further illustrating a load circuit for powering the load component formed between one end of the battery and the load component, and a charging circuit for charging the battery formed between the opposed end of the battery and the charging component.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] Turning now to the drawings, in which like reference characters indicate corresponding elements throughout the several views, attention is first directed to FIGS. 1 and 2 in which there is seen a battery 10 constructed and arranged in accordance with the principle of the invention. Battery 10 is elongate and cylindrical in shape, has opposed ends 11 and 12 , and is symmetrical along its central, longitudinal axis X extending centrally through battery 10 from end 11 to end 12 . The internal workings of battery 10 are housed within a metal or plastic case 13 , which extends along the length of battery 10 from end 11 to end 12 . End 11 of battery 10 as illustrated in FIG. 1 is formed with a positive terminal denoted at 20 and a negative terminal denoted at 21 , and end 12 of battery 10 as shown in FIG. 2 is formed with a positive terminal denoted at 30 and a negative terminal denoted at 31 . Positive and negative terminals 20 and 21 are located at end 11 of battery 10 , and positive and negative terminals 30 and 31 are located at end 12 of battery 10 . Positive terminal 20 and negative terminal 21 at end 11 of battery 10 are separated by an insulator or separator 22 at end 11 of battery 10 that electrically isolates positive terminal 20 from negative terminal 21 . Positive terminal 30 and negative terminal 31 at end 12 of battery 10 are separated by an insulator or separator 32 at end 11 of battery 10 that electrically isolates positive terminal 30 from negative terminal 31 .
[0014] As seen in FIG. 1 , positive terminal 20 is circular, is located at the geometric center of end 11 of battery 10 , and is symmetrical about longitudinal axis X of battery 10 . Separator 22 is a continuous circular ring, encircles positive terminal 20 , and is, like positive terminal 20 , symmetrical about longitudinal axis X of battery 10 . Separator 22 is located between positive terminal 20 and negative terminal 21 . Negative terminal 21 is located distally of positive terminal 20 and separator 22 , is a continuous circular ring that concurrently encircles separator 22 and positive terminal 20 , and is, like positive terminal 20 and separator 22 , symmetrical about longitudinal axis X of battery 10 . Positive terminal 20 , negative terminal 21 , and separator 22 at end 11 of battery 10 are concentric in arrangement in that they encircle and share a common center, namely, longitudinal axis X of battery 10 .
[0015] As seen in FIG. 2 , positive terminal 30 is circular, is located at the geometric center of end 12 of battery 10 , and is symmetrical about longitudinal axis X of battery 10 . Separator 32 is a continuous circular ring, encircles positive terminal 30 , and is, like positive terminal 30 , symmetrical about longitudinal axis X of battery 10 . Separator 32 is located between positive terminal 30 and negative terminal 31 . Negative terminal 31 is located distally of positive terminal 30 and separator 32 , is a continuous circular ring that concurrently encircles separator 32 and positive terminal 30 , and is, like positive terminal 30 and separator 32 , symmetrical about longitudinal axis X of battery 10 . Positive terminal 30 , negative terminal 31 , and separator 32 at end 12 of battery 10 are concentric in arrangement in that they encircle and share a common center, namely, longitudinal axis X of battery 10 .
[0016] Positive terminal 30 at end 12 of battery 10 is identical in size and shape to positive terminal 20 at end 11 of battery 10 , negative terminal 31 at end 12 of battery 10 is identical in size and shape to positive terminal 21 at end 11 of battery 10 , and separator 32 at end 12 of battery 10 is identical in size and shape to separator 22 at end 11 of battery 10 . The arrangement and geometry of positive and negative terminals 30 and 31 and separator 32 at end 12 of battery 10 is identical to or otherwise the minor image of the arrangement and geometry of positive and negative terminals 20 and 21 and separator 22 at end 11 of battery 11 .
[0017] The internal workings of battery 10 inside case 13 are not shown as they are conventional. As with a conventional battery, inside case 13 are a cathode that connects to opposed positive terminals 20 and 30 , and a corresponding anode that connects to opposed negative terminals 21 and 31 . These components, which are electrodes, occupy most of the space in battery 10 and are the place where the chemical reactions occur to produce electricity. An insulator or separator creates a barrier between the cathode and anode isolating the cathode from the anode preventing the electrodes from touching while allowing electrical charge to flow freely between them. In a preferred embodiment, separators 22 and 33 form part of the separator separating the cathode from the anode. However, the separator separating the cathode from the anode can be different from separators 22 and 32 in an alternate embodiment. The medium that allows the electric charge to flow between the cathode and anode is the electrolyte, and, as in a conventional battery, a collector conducts the charge to the outside of the battery and through the applied load. Battery 10 is a rechargeable battery, and preferably utilizes lithium chemistry to power its reactions to produce electricity. The lithium chemistry used by battery preferably includes lithium cobalt oxide for the cathode, and carbon for the corresponding anode.
[0018] Because both ends 11 and 12 of battery 10 have positive and negative terminals according to the principle of the invention, harnessing the electric charge produced by battery 10 can be produced at end 11 of battery 10 with positive and negative electrodes 20 and 21 , and can also be identically produced at end 12 of battery with positive and negative electrodes 30 and 31 . Recharging battery 10 can also be made at end 11 of battery 10 with positive and negative electrodes 20 and 21 , and can further be identically made at end 12 of battery with positive and negative electrodes 30 and 31 .
[0019] As a matter of example, FIG. 3 is a schematic diagram of battery 10 incorporated into a body 40 of a battery-powered electronic device 35 having a load component 41 and a charging component 42 , a load circuit 45 for powering load component 41 formed between end 11 of battery 10 and load component 41 , and a charging circuit 46 for charging battery 10 formed between end 12 of battery 10 and charging component 42 . In FIG. 3 , positive and negative terminals at end 11 of battery 10 are denoted generally at 20 and 21 , respectively, and are shown as they would appear connected to load component 41 forming or otherwise completing load circuit 45 between load component 41 and positive and negative terminals 20 and 21 at end 11 of battery 10 causing battery 10 to produce electric power for powering load component 41 . Positive and negative terminals at end 12 of battery 10 are denoted generally at 30 and 31 , respectively, and are shown as they would appear connected to charging component 42 forming or otherwise completing charging circuit 46 between charging component 42 and positive and negative terminals 30 and 31 at end 11 of battery 10 causing battery 10 to receive charging energy from charging component 42 for charging battery 10 . Because the positive and negative terminal geometry and configuration is the same at ends 11 and 12 of battery 10 , the orientation of battery 10 in body 40 of battery-powered electronic device 35 can be reversed for forming load circuit 45 between load component 41 and positive and negative terminals 30 and 31 at end 12 of battery 10 , and for forming charging circuit 46 between charging component 42 and positive and negative terminals 20 and 21 at end 11 of battery 10 , in accordance with the principle of the invention. Regardless of the position of battery 10 in the battery receptacle of body 40 , whether end 11 to load component 41 and end 12 to charging component 42 or end 11 to charging component 42 and end 12 to load component, the positive and negative terminal geometry and configuration at ends 11 and 12 of battery 10 are able to produce the corresponding load and charging circuits 45 and 46 , in accordance with the principle of the invention. In FIG. 3 , battery-powered electronic device 35 is generally representative of a portable flashlight, where body 40 is the body of the flashlight, load component 41 is the lamp of the flashlight, and charging component 42 is the charging cap of the flashlight. Battery 10 can be similarly used in other portable electronic devices having corresponding load and charging components.
[0020] By providing battery 10 with identical positive and negative terminals at ends 11 and 12 , the need for incorporating dedicated load and charging contacts and circuits, a battery cradle wired with dedicated load and charging circuitry, or an inner barrel to carry the extra current in a battery-powered electronic device is no longer necessary, which reduces the overall weight and cost of a battery-powered electronic device. Furthermore, because the positive and negative terminals at ends 11 and 12 of battery 10 are identical, battery 10 may be installed into a battery cradle or receptacle of a battery-powered electronic device simply and efficiently without the need to find the correct way of inserting the battery as it can be inserted both ways or otherwise in either direction. This is especially useful when a battery needs to be replaced urgently and quickly, such as in the dark. In the present embodiment, terminals 20 and 30 are positive and terminals 21 and 31 are negative, and this can be reversed if so desired.
[0021] While illustrative embodiments of the invention are disclosed herein, it will be appreciated that numerous modifications and other embodiments can be devised by those skilled in the art. Features of the embodiments described herein, can be combined, separated, interchanged, and/or rearranged to generate other embodiments. Therefore, it will be understood that the appended claims are intended to cover all such modifications and embodiments that come within the spirit and scope of the present invention. | A battery includes a battery case including battery chemistry for supplying electricity, a first end, and a second end opposite the first end; a first positive terminal, a first negative terminal, and a first insulator therebetween at the first end that together form a first positive terminal and negative terminal configuration; a second positive terminal, a second negative terminal, and a second insulator therebetween at the second end that together form a second positive terminal and negative terminal configuration, wherein the second positive terminal and the second negative terminal configuration is a mirror image of the first positive terminal and the first negative terminal configuration. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority under 35 USC 119 to Japanese Patent Application No. 2008-021052 filed on Jan. 31, 2008 the entire contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an airbag device for a vehicle such as a motorcycle or four-wheeled vehicle.
2. Description of Background Art
There has been a motorcycle equipped with an airbag device. The airbag device includes an inflator, an airbag, and a module cover. The inflator and the airbag are accommodated in a casing provided on the vehicle body. The module cover openably covers a top opening of the casing, thereby hiding the inflator and the airbag. The module cover includes a tear line. When the airbag is deployed, the module cover is torn along the tear line to be forwardly opened by being pushed by the deploying airbag, thereby allowing the airbag to be deployed further. See, for example, JP-A No. 2007-69792.
In the above technique, however, the module cover makes up a vehicle body exterior, so that there can be cases where it is difficult to secure an exterior design integrity between the module cover and other exterior parts of the vehicle body. Furthermore, to allow the module cover to make up a vehicle body exterior while being capable of appropriate opening movement, it is necessary to design the module cover differently for different models of motorcycles. This reduces the applicability of the airbag device.
SUMMARY AND OBJECTS OF THE INVENTION
An object of the present invention is to provide an airbag device which, while excelling in applicability, can improve exterior design integrity between the airbag device and a vehicle body exterior.
According to an embodiment of the present invention, an airbag device is provided that includes a case 53 which accommodates an airbag 51 and an inflator 52 with a lid 62 which, when the airbag deploys, releases a side of the case. A lid cover 70 is provided for covering the lid.
Designing a lid cover which is to make up an exposed exterior part of a vehicle body requires consideration to be made to prevent sink lines from being formed on the lid cover and also to secure integrity, in terms of both material and exterior design, between the lid cover and other exterior parts of the vehicle body. The lid cover structured as in the above embodiment of the present invention, however, requires no such consideration to be made, so that the lid cover is only required to be capable of being released when the airbag is deployed.
According to an embodiment of the present invention, the lid cover makes up an exterior design of a vehicle.
It is, therefore, possible to form the lid cover using a material similar to that of other exterior parts of the vehicle body separately from the lid closely related with the deploying function of the airbag.
According to an embodiment of the present invention, the lid cover is structured to be easily released from a peripheral part (for example, the fixing seat 77 of the following embodiment) when the airbag deploys.
Therefore, the lid cover does not hinder the opening movement of the lid.
According to an embodiment of the present invention, the lid cover is provided with a fixture part for fixation to a peripheral part, the fixture part includes a fragile portion.
It is, therefore, possible, by adjusting the fragile portion, to adjust the way the lid cover opens when the lid is opened by the deploying airbag.
According to an embodiment of the present invention, the lid cover is forwardly openable along a forward direction of the vehicle. This allows the airbag to be deployed effectively.
According to an embodiment of the present invention, an exterior surface of the lid cover makes up a panel section 32 a or top shell 32 are positioned rearward of a handlebar 43 and forward of a seat 27 of a motorcycle.
In this arrangement, the lid cover does not spoil the appearance of the conspicuous exterior portion of the motorcycle.
According to an embodiment of the present invention, the lid cover itself can be formed of an exterior member of the vehicle body. Therefore, unlike in cases where a lid is exposed on the vehicle body, the lid cover can be designed without giving consideration for the prevention of sink line generation or for securing integration, in terms of both material and exterior design, between the lid cover and other exterior parts of the vehicle. Namely, the lid cover is only required to be capable of being released when the airbag is deployed. Thus, integrity between the lid cover and other exterior parts of the vehicle can be easily secured without special consideration. Furthermore, the case and the lid can be commonly used for different models of motorcycles, enhancing the applicability of the airbag device.
According to an embodiment of the present invention, the lid cover can be formed of a material similar to that of other exterior parts of the vehicle body separately from the lid closely related with the deploying function of the airbag. This facilitates improving the external appearance quality of the motorcycle.
According to an embodiment of the present invention, the lid cover does not hinder the opening movement of the lid, so that the airbag can be deployed smoothly.
According to an embodiment of the present invention, it is possible, by adjusting the fragile portion, to adjust the way the lid cover opens when the lid is opened. That is, the fragile portion can be adjusted to allow the lid cover to open without fail.
According to an embodiment of the present invention, the airbag can hold the occupant.
According to an embodiment of the present invention, the lid cover does not spoil the appearance of the conspicuous exterior portion of the motorcycle, and allows the external appearance quality of the motorcycle to be improved.
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:
FIG. 1 is a side view of a motorcycle according to an embodiment of the invention;
FIG. 2 is a plan view of the motorcycle according to the embodiment of the invention;
FIG. 3 is a perspective view of a front portion of the motorcycle according to the embodiment of the invention;
FIG. 4 is an exploded perspective view of an airbag device according to the embodiment of the invention;
FIG. 5 is a schematic front view of the airbag device according to the embodiment of the invention;
FIG. 6 is a schematic right side view of the airbag device according to the embodiment of the invention;
FIG. 7 is a schematic rear view of the airbag device according to the embodiment of the invention; and
FIG. 8 is a plan view of a lid according to the embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of the present invention will be described below with reference to drawings. The directions front, rear, left, and right referred to in the following description are as seen in the forward direction of the motorcycle unless otherwise specified. In the attached drawings, arrows FR, LH, and UP represent the forward, leftward, and upward directions, respectively, of the vehicle.
As shown in FIGS. 1 to 3 , a front wheel 2 of a motorcycle 1 is journaled to a lower end portion of a pair of left and right front forks 3 . An upper portion of each of the front forks 3 is steerably connected, via a steering system 4 , to a head pipe 6 provided in a front end portion of a body frame 5 . A handlebar 43 for steering the front wheel is attached to an upper portion of the steering system 4 . A pair of left and right main frames 7 extend downwardly and rearwardly from the head pipe 6 . A water-cooled, 4-stroke, horizontally-opposed six-cylinder engine 10 as a prime mover for the motorcycle 1 is mounted below the main frames 7 .
A front end portion of a swing arm 11 to which a rear wheel 9 is journaled is swingably connected to a pivot plate 8 connected to a rear end portion of each of the main frames 7 . The swing arm 11 is of a hollow one-sided type, and the rear wheel 9 is journaled to a rear end portion thereof. A drive shaft, not shown, extending from the engine 10 is inserted through the one-sided swing arm. Power generated by the engine 10 is transmitted to the rear wheel 9 via the drive shaft and a gear box 12 disposed in a central portion of the rear wheel.
A front portion of a seat frame 14 supporting front and rear seats 27 and 28 for occupants is joined to near the pivot plate 8 . The front seat 27 is for a rider. The rear seat 28 is for a pillion passenger. The front seat 27 includes a front seat body 27 a and a backrest 27 b . The rear seat 28 includes a rear seat body 28 a and a seat back 28 b . The front and rear seat bodies 27 a and 28 a are integrally formed, and the backrest 27 b is disposed between them. A rear trunk 29 is disposed behind the rear seat body 28 a . The seat back 28 b is positioned in front of the rear trunk 29 . A fuel tank 30 and an air cleaner box 31 for cleaning intake air are disposed forwardly of the front seat 27 with the fuel tank 30 extending to below the front seat 27 . These parts are covered by a top shelter 32 which is an exterior part.
A large front cowl 34 provided with a pair of left and right headlamps 33 is disposed in a front body portion of the motorcycle 1 . A large windscreen 35 is provided above a front portion of the front cowl 34 . A meter panel 36 provided with, for example, a speedometer and a tachometer is disposed on a rear side of an upper portion of the front cowl 34 . The top shelter 32 extending downwardly and rearwardly of the meter panel 36 covers a motorcycle body portion ranging from the rear side of the front cowl 34 to the front seat 27 . Left and right mirrors 38 each provided with a front winker 37 are attached to both sides of an upper portion of the front cowl 34 . A radiator 39 for the engine is disposed laterally inwardly of the front cowl 34 (inwardly in the vehicle width direction), the radiator 39 being oriented approximately perpendicularly to the lateral direction of the motorcycle.
Left and right saddle bags 40 are disposed on both sides below the rear seat 28 and rear trunk 29 . Rear combination lamps 41 each of which functions as tail lamps, brake lamps, and rear winkers are disposed on both sides of a rear portion of the left and right saddle bags 40 and both sides of a rear portion of the rear trunk 29 . A muffler 42 for engine exhaust is disposed downwardly of each of the left and right saddle bags 40 .
The top shelter 32 is provided with an openable/closable shelter lid 44 disposed in front of the front seat 27 . The shelter lid 44 allows fuel to be fed to the internal fuel tank through a filler opening of the fuel tank. A panel section 32 a is formed in front of the shelter lid 44 to be rearward of a handlebar 43 and forward of the front seat 27 . The panel section 32 a has a cut-out portion 44 a in which an airbag device 50 is disposed. Alternatively, the top shelter 32 may be provided with a depressed part, and the airbag device 50 may be disposed in the depressed part, or such a depressed part to accommodate the airbag device 50 may be provided in the panel section 32 a.
FIG. 4 is an exploded perspective view of the airbag device. FIGS. 5 to 8 each show the airbag device schematically. As shown in FIGS. 4 to 8 , the airbag device 50 has a case 53 which accommodates an airbag 51 and an inflator 52 . The case 53 is shaped like a rectangular box having an open top, left and right sidewalls 54 , front wall 55 , rear wall 56 , and bottom wall 57 . A bracket 58 to be fixed to the body frame 5 is fixed to each of the sidewalls 54 . The bracket 58 varies in type between different models of motorcycles.
Fixing holes 60 for rivets 80 are formed in an upper portion of each of the front wall 55 , rear wall 56 , and side walls 54 . The number of the fixing holes 60 formed in each of the front wall 55 and rear wall 56 is, for example, three. The number of the fixing holes 60 formed in each of the side walls 54 is, for example, two. Two pins 61 are provided in a lower portion of the front wall 55 .
The airbag 51 is made of, for example, nylon cloth. The inflator 52 is provided with an electric igniter, an ignition agent, and a nitrogen gas generating agent. The airbag 51 accommodated in the case 53 may be attached with one end of a belt member, not shown, the other end of which is attached to the vehicle body. In such an arrangement, when the airbag 51 is deployed, the belt member can keep the airbag 51 in an appropriate position.
The open top of the case 53 is fixedly covered by the lid 62 such that the lid 62 is released when the airbag 51 is deployed. The lid 62 is a rectangular member having an upper wall 63 , a front wall 64 , side walls 65 , and a rear wall 66 , the upper wall 63 being surrounded by the other walls. It has fixing holes 67 corresponding to the fixing holes 60 for the rivets 80 provided in the case 53 , i.e. three each of the fixing holes 67 in the front wall 64 and rear wall 66 , and two each in the side walls 65 . The upper wall 63 of the lid 62 includes a U-shaped tear line 68 formed of three portions with one portion extending along the rear wall of the lid 62 and the rest of two portions extending along the two side walls of the lid 62 . When the airbag 51 deploys, the U-shaped portion, i.e. an opening portion L, defined by the tear line 68 of the top wall 63 of the lid 62 is torn open along the tear line 68 , allowing the airbag 51 to be deployed outward.
A lid cover 70 is, like the top shelter 32 and panel section 32 a , a member to make up the exterior design of the motorcycle 1 , so that it is formed of, for example, a material similar to that of the panel section 32 a to look harmonious with the panel section 32 a . The lid cover 70 has an upper wall 72 and a peripheral wall 73 surrounding the upper wall 72 and extending diagonally downwardly. The peripheral wall 73 is, in a front edge portion thereof, provided with a pair of downwardly extending guide bars 74 . The guide bars 74 each have a guide slot 75 . The pins 61 of the case 53 are inserted through the guide slots 75 , so that, when the airbag 51 is deployed, the lid cover 70 is guided to move upwardly. A peripheral portion of the peripheral wall 73 of the lid cover 70 is designed to cover a peripheral portion of the cut-out portion 44 a of the top shelter 32 so that the cut-out portion 44 a is not visible from the outside.
The peripheral wall 73 of the lid cover 70 has, in a middle portion of its rear edge, a fixture piece 71 having a screw hole 76 . The fixture piece 71 is fixed, with a screw 78 , to a fixing seat 77 provided on the vehicle body. In this arrangement, when the lid cover 70 is set in place, a distance D is secured between the lid cover 70 and the lid 62 . The distance D secures a space required to allow an initial opening movement of the opening portion L.
The fixture piece 71 includes a tear line 79 formed in a base portion thereof. When receiving a load from below in deployment of the airbag 51 , the fixture piece 71 is broken off along the tear line 79 and separated from the peripheral wall 73 .
When the fixture piece 71 is broken off the lid cover 70 , the lid cover 70 is allowed to move up, relative to the case 53 , being guided by the guide bars 74 and subsequently open forwardly (in the direction indicated by the arrows in FIG. 3 ) being led by its rear edge. As a result, the airbag 51 is allowed to inflate outward.
According to the above embodiment, when a frontal collision of the motorcycle 1 is detected, the inflator 52 is caused, by an ignition current from an airbag controller, not shown, to generate, for example, nitrogen gas. The nitrogen gas enters the airbag 51 to deploy it.
When, in an initial stage of inflation of the airbag 51 , the lid 62 is pushed from below by the airbag 51 inflated in the case 53 , the upper wall 63 of the lid 62 is torn along the tear line 68 . This causes the opening portion L to forwardly open about a front portion thereof, allowing the airbag 51 to inflate outward.
As the airbag 51 further deploys causing the opening portion L of the lid 62 and the airbag 51 to push the lid cover 70 from the back side, the lid cover 70 is subjected to an upward force which eventually causes the fixture piece 71 of the lid cover 70 to be broken off along the tear line 79 . As a result, the fixture piece 71 is left attached only to the fixing seat 77 provided on the vehicle body, and the lid cover 70 is moved upward causing the pins 61 to relatively move along the guide slots 75 of the guide bars 74 . This causes the lid cover 70 to further open forwardly (in the direction indicated by the arrows in FIG. 3 ) about a front end portion thereof, allowing the airbag 51 to further deploy. The airbag 51 thus deployed can absorb the forward displacement of the occupant.
The lid cover 70 is only required to be capable of being released, when the airbag 51 deploys, by being pushed by the lid 62 . Whereas the lid 62 including the tear line 68 is required to meet requirements in terms of its strength, rigidity, shape, and material so as to make the airbag 51 appropriately deployable, no such requirements are imposed on the lid cover 70 . Therefore, the shape of the lid cover 70 can be designed, as an exterior part of the motorcycle 1 , with higher flexibility; the lid cover 70 can be shaped not to cause the generation of sink lines; and the lid cover 70 can be formed of the same material as that of the panel section 32 a . Thus, the lid cover 70 can be easily designed to be harmonious with the vehicle body design. The case 53 , airbag 51 , inflator 52 , and lid 62 included in the airbag device 50 can be made common to different models of motorcycles. Therefore, to install the airbag device in different models of motorcycles, only the lid cover 70 and brackets 58 of the case 53 are required to be designed differently to suit different models of motorcycles. Thus, the airbag device has flexible applicability, being easily applicable to different models of motorcycles.
The lid cover 70 is, like the top shelter 32 and panel section 32 a , a member to make up the exterior design of the motorcycle 1 . Therefore, unlike the lid 62 that is closely related with the deploying function of the airbag 51 , the lid cover 70 can be formed of a material similar to that of the panel section 32 a so as to improve the external appearance quality of the motorcycle.
The lid cover 70 can be easily broken along the tear line 79 , so that, when the airbag 51 is deployed, the lid cover 70 opens without fail not to hinder the deployment of the airbag 51 .
The present invention is not limited to the above embodiment. For example, the fixture piece 71 of the lid cover 70 may be fixed to the rear wall 66 of the lid 62 .
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims. | To provide an airbag device for improving integrity between the airbag and exterior parts of a vehicle body and which excels in applicability. An airbag device is provided with a case which accommodates an airbag and an inflator. A lid is provided for releasing a side of the case when the airbag deploys together with a lid cover for covering the lid. | 1 |
BACKGROUND
Spark-gap tools are known in the hydrocarbon industry. These tools have not, however, gained strong acceptance in permanent completions primarily because they require a large voltage to function acceptably. Such voltage is often delivered to the spark-gap tool in a downhole environment through electrical conductors from a surface supply system. As one of ordinary skill in the art clearly recognizes, the longer the electrical conductor, the greater the voltage drop. For this reason the voltage at the surface supply needs to be even greater than that required to produce an acceptable arc at the spark-gap tool. Since many rig operators are uncomfortable with utilizing systems employing greater than 200 volts from a surface supply, the spark-gap tools' functionality has been limited. Moreover, because of the electrical requirements, other compromises are also made throughout the wellbore to accommodate power at the site of the spark-gap tool. Each of the above issues creates a lack of interest in the industry in using the spark-gap tools.
SUMMARY
Disclosed herein is a spark-gap tool which includes a housing, a plurality of electrodes at the housing, a mandrel nested with the housing, transductive element(s) located at one of the housing and the mandrel, and a force transmission configuration located at the other of the housing, and the mandrel, the initiator, upon relative movement between the housing and the mandrel, causing a physical distortion of one or more transductive elements, whereby an electrical potential is generated by the one or more transductive elements.
Further disclosed herein is a method for powering the spark-gap tool by physically distorting one or more transductive elements cyclically by moving the mandrel within its housing axially and rotationally thereby creating sufficient voltage potential to cause an arc of selected magnitude across a spark-gap in the tool.
Further disclosed herein is a method for treating a borehole by physically distorting one or more transductive elements thereby creating sufficient voltage potential to cause an arc of selected magnitude across a spark-gap in the tool.
Further disclosed herein is a downhole power generation arrangement including a first member, a second member, at least one of the first member and second member being movable relative to the other of the first member and the second member; and a piezoelectric element of one of the first member and the second member and in force transmissive communication with the other of the first member and the second member, at least one of the first member and the second member being mechanically movable from a surface location.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings wherein like elements are numbered alike in the several Figures:
FIGS. 1A and 1B are an extended schematic elevation view of a wellbore with the spark-gap tool deployed therein;
FIG. 2 is an expanded view of the circumscribed Section 2 - 2 in FIG. 1B ;
FIG. 3 is an expanded view of the circumscribed view Section 3 - 3 in FIG. 1B ;
FIG. 4 is a schematic elevation view of an alternate voltage operation arrangement.
FIG. 5 is a schematic elevation view of another alternate voltage generation arrangement.
DETAILED DESCRIPTION
Referring to FIGS. 1A and 1B , an overview is provided of a wellbore 10 , a pump jack 12 for a rod pump and a spark-gap tool 14 . As illustrated, the spark-gap tool includes a pair of electrodes 16 a and 16 b located within a section of pipe 18 having a plurality of openings 20 . Further illustrated, generally, is a voltage generation arrangement 22 . With arrangement 22 utilizing mechanical function in conjunction with one or more transducers, the problem in the prior art of supplying high voltage from surface and carrying that voltage to the spark tool has been eliminated. Because the voltage generation arrangement can be located proximate the spark-gap electrodes 16 a and 16 b , voltage loss (due to distance) is not a factor.
Referring to FIG. 2 , one embodiment of a mechanical voltage generation arrangement 22 is depicted in more detail. Central to this embodiment is a piezoelectric element 24 (transductive element). A piezoelectric element is a transducer and thereby capable of creating a voltage potential when subjected to a mechanical energy input in any selected direction or combination of directions causing physical distortion of the element.
In this embodiment, mechanical energy input is provided through a configuration described hereunder, to the piezoelectric element(s) 24 to produce the desired voltage. In specific embodiments hereof, the mechanical energy may be imparted to the element(s) 24 any number of times from one to infinity in order to produce a buildup of charges or a continuous charge or some combination of these. In one embodiment, the mechanical energy is provided by set down weight of an inner mandrel 26 of the spark-gap tool 14 . Set down weight is operative when a tool housing 28 of the spark-gap tool 14 is anchored such that the mandrel 26 is moveable relative to the tool housing 28 . The housing 28 may be anchored within casing 10 in any of a number of conventional ways and not shown. Because of the anchoring of the housing 28 , that housing will no longer move downhole when further set down weight from the pump rig 12 is applied to the mandrel 26 . Such application of mechanical energy is transmitted to a compression piston 30 (embodiment of force transmission configuration), which in turn is force transmissive communication with the piezoelectric element(s) 24 . Mechanical energy (more generically deformative energy, which may include hydraulic, pneumatic, and even optic energy could be used. The phrase “mechanical energy” as used herein is intended to also encompass these other ways of physically distorting the element(s) 24 .) applied to the compression piston causes a compression of the piezoelectric element 24 thereby creating the desired voltage potential in that element. It should be noted in passing that the piezoelectric element contemplated may be of a single crystalline variety or a polycrystalline variety, such as a ceramic material. Single crystalline varieties are more efficient but also are more costly to procure. Some ceramic materials operable as piezoelectric materials include barium titanate, lead zirconate, lead titanate, and lead zirconate titanate, etc. Since most ceramic materials are composed of random crystalline structure, in order to reliably produce the desired voltage potential upon mechanical energy input, the ceramic material must be polarized thereby aligning the individual crystals therein prior to use to generate a voltage potential. Polarization allows the structure to act more like a single crystalline piezoelectric material. Axiomatically, single crystalline varieties of piezoelectric elements do not require poling prior to use. The voltage potential generated is proportional to the thickness of the material in element 24 and the amount of physical distortion of the element, in turn related to the applied force thereon. In this particular embodiment the compression piston 30 is configured, at an internal dimension thereof, with a profile 32 . The profile 32 includes specific features allowing it to engage and then release a collet mechanism or series of collet mechanisms 34 . The specific features are rounded ridge type projections known in the art. Such ridges transfer a load until a predetermined maximum load is reached whereafter the ridge yields and drops the load.
In the particular embodiment illustrated in FIG. 3 , collet mechanisms 34 are depicted. As illustrated, this embodiment provides for voltage buildup in a capacitor 36 by creating multiple compressive and release cycles on the piezoelectric element 24 . As the mandrel 26 moves in the direction of arrow 38 , profile 32 of compression piston 30 is picked up on collet ridge 40 and released, then picked up on collet ridge 42 and released, and then picked up on collet ridge 44 . As illustrated, collet ridge 42 is at the release position with the collet 34 deforming to allow the ridge 42 to release the piston 30 . During each compression cycle, the piezoelectric element generates a voltage which is sent for storage to the capacitor 36 . As the collet mechanism 34 deflects, the compression piston 30 is released thereby removing mechanical energy from the piezoelectric element 24 . This will, in turn, eliminate the production of voltage from the piezoelectric element 24 and reset it to its natural position. Upon further motion of the mandrel 26 , the next ridge 42 picks up profile 32 , transmitting mechanical energy once again to the piezoelectric element 24 . Upon release of each ridge 40 , 42 , 44 , the collet mechanism 34 is deflected regularly inwardly relative to the mandrel 26 . This can be seen in FIG. 2 with respect to the collet mechanism ridge 42 . Although three collet mechanisms 34 are illustrated, more or fewer can be utilized as desired. Limitation in the number of collet mechanisms employable relates only to stroke possibilities for the mandrel 26 . This may be limited by the pump jack 12 on the surface or may be limited by available open space within the wellbore or within the tool. In the illustrated embodiment, in order to generate additional voltage, one need merely move the mandrel 26 uphole resetting the collet mechanism(s) for a further movement in the downhole direction and thereby create three more pulsed electrical signals to be stored in the capacitor. Depending upon exactly how much voltage a particular application requires, the above-stated procedure may be repeated indefinitely to fully charge the capacitor prior to creating an arc across the electrodes 16 a and 16 b.
Referring to FIG. 3 , the spark-gap portion 46 is illustrated very schematically. The device comprises a rectifier diode 48 , the capacitor identified previously as 36 , and a switch 50 which completes the circuit to either side of the spark-gap 52 . Once the circuit is completed, electrodes 16 a and 16 b function together to generate an arc that jumps over the spark-gap. Upon the formation of the arc, fluid located in the spark-gap 52 is vaporized and a shockwave is initiated. Referring back to FIG. 1 , and still referring to FIG. 3 , this embodiment illustrates that the tool housing 28 includes perforated interval 54 located adjacent to spark-gap 52 . The perforated interval may be a slotted pipe, a holed pipe, or other construction configured to allow propagation of the shockwave generated at spark-gap 52 through the tool housing 28 . Since it may be desirable to propagate the shockwave into the formation itself, a casing segment radially outwardly disposed of the spark-gap tool would also have a perforated interval, schematically illustrated as 56 .
Mechanical energy may also be imparted utilizing rotational initiation. Referring to FIG. 4 , a rotary mandrel 60 may be provided with one or more actuator bumps 62 . In a tool housing 64 surrounding the mandrel 60 , one or more piezoelectric elements 66 are installed. In this embodiment, one or more compression pistons 68 are located between the piezoelectric elements 66 and the bump or bumps 62 . It is noted that in some applications the pistons 68 may be omitted and contact between bump or bumps 62 directly with element or elements 66 may be had. Upon rotation of mandrel 60 , sequential elements 66 will be compressed and released. This will generate a voltage potential which may then be stored in a capacitor similar to that depicted in FIG. 3 or may simply be used without storage if appropriate for the application. This arrangement will then be connected to the spark-gap electrodes.
In yet another embodiment of the mechanical energy arrangement, referring to FIG. 5 , a mandrel 70 is configured with a shoulder 72 that has an offset profile such that a portion of shoulder 72 will be in contact with a relatively small portion of a counter shoulder 74 located within the spark-gap tool housing 76 . Located at 78 , around the periphery of housing 76 , is one or more piezoelectric elements which can be mechanically compressed one after the other as mandrel 70 rotates. It should also be noted that a compression piston arrangement such as, for example, a metal disk may be placed atop the element 78 to protect them from direct frictional degradation due to rotation of mandrel 70 but still allow the compressive force of shoulder 72 to cause the desired voltage potential in element(s) 78 . As is clear from the drawing, however, such disk is not required but merely is optional.
While preferred embodiments have been shown and described, modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustrations and not limitation. | A spark-gap tool includes a plurality of electrodes, a mandrel, transductive element(s), and a force transmission configuration. Upon relative movement between components a physical distortion of one or more transductive elements occurs, whereby an electrical potential is generated. A method for powering the spark-gap tool is by physically distorting one or more transductive elements by moving components axially and/or rotationally. A method for treating a borehole is by physically distorting one or more transductive elements thereby creating sufficient voltage potential to cause an arc of selected magnitude across a spark-gap in the tool. A downhole power generation arrangement includes a first member and a second member that are movable and a piezoelectric element on one of the first member and the second member and in force transmissive communication with the other of the first member and the second member. | 4 |
FIELD OF THE INVENTION
The present invention relates to an improved dispenser for providing a rinse water additive to an automatic washing machine, and more particularly to such a dispenser wherein the reliability of operation and reduction in messiness of handling is improved.
BACKGROUND OF THE INVENTION
Rinse water additive dispensers are well known in the art. Examples include U.S. Pat. Nos. 5,267,671 to Baginski et al.; 3,108,722 to Torongo, Jr. et al.; 3,888,391 to Merz, and 4,835,804 to Arnau-Munoz et al. Centrifugal force applied to a weight inside the dispenser during a spin cycle of an automatic clothes washer causes a dispenser valve to become unseated so that additive from the dispenser may spill out of the dispenser and mix with rinse water that is added to the washer after the spin cycle. Additives include fabric softeners. The dispenser is normally inserted into the washer before the wash cycle begins. It must remain closed during the agitation of the wash cycle, yet reliably open during the spin cycle at the conclusion of the wash cycle in order to deliver the rinse water additive at a point in time which will be effective.
The dispenser is typically a cylinder or a ball shaped container which has a large circular opening at one end. The dispenser is normally only partially filled with an additive, such that the dispenser primarily contains air and space for a valve to be actuated. A dispenser valve is typically a resilient rubber device, such as a pair of interconnected rubber disks acting as a grommet at the edge of the circular opening. A rigid arm extending from the pair of rubber disks, parallel to the axis of the opening, has a counterweight connected to the arm. In a closed valve position the rubber disks seal the opening from both sides such that washwater cannot enter and additive cannot leave. Gravity acting upon the counterweight is insufficient to cause the disks to be deformed and pop out of the opening to open the valve. However, centrifugal force generated by the spin cycle of the washer, is sufficient to pull the arm at an angle to the axis of the opening, thereby distorting the rubber disks and causing them to pop out of engagement with the edges of the opening. The valve remains open thereafter so that as the washer fills with rinse water, the additive from the dispenser may spill out, and/or the rinse water may fill the dispenser and mix with the additive.
Upon completion of the total wash and rinse cycle, the washer attendant removes the clothes and the dispenser. With the valve open, the attendant may refill the dispenser with additive for another wash load. To reclose the valve, which is normally attached into the dispenser by a chain or flexible cord, the attendant pulls the valve device such that the rubber disks snap back into engagement with the edge of the opening.
Various problems with the conventional dispenser reduce the reliability associated with dispensing additive at the correct time. For example, when a room temperature dispenser is placed in the wash, the valve is sealed by the resilience of the rubber disks. However, when the hot washwater is added, the dispenser heats up and air pressure builds inside the dispenser, causing added resistance to open the valve during the spin cycle. Sufficient air pressure may prevent centrifugal force opening the valve, in which case the dispenser will fail to provide its intended function.
Alternatively, a cold water wash cycle may generate a vacuum inside the dispenser and cause it to open prematurely during the wash cycle agitation. Although the attendant will not realize that the additive has been dispensed at the wrong time, the dispenser will still have failed in its function.
Vents have been used to prevent pressure or vacuum from developing within a dispenser, but eventually the vents become plugged with the additive fluid, which may dry to leave a waxy residue. What is needed is another way to relieve pressure or vacuum developed within the dispenser.
Another problem with conventional dispensers is the messiness involved with reclosing the valve. Chains or cords connected to the valve are ultimately contaminated with additive when the dispenser is filled because they extend into the inside of the dispenser when the valve is open. It is by the chain or cord that the attendant must pull the valve back into its closed position. What is needed is another way to close the valve which does not involve touching components exposed to the additive.
Still another problem with conventional dispensers is the pull chain or cord can get caught up in the clothes being washed such that during the spin cycle, the valve cannot be opened by centrifugal force. What is needed is a dispenser that has no exposed chain or cord outside the dispenser.
SUMMARY OF THE INVENTION
In one aspect of the present invention, an improved rinse water additive dispenser for an automatic washer having a spinning drum comprises a substantially rigid body having a resilient portion and an internal volume. The dispenser further includes an opening therein and a valve for sealing the opening closed so that the rinse water additive is maintained within the dispenser until the valve is acted upon by centrifugal force applied to the dispenser during a spin cycle of the automatic washer to unseat the valve. The resilient portion provides for volumetric expansion and contraction of the dispenser when the dispenser is placed in variable temperature water. The volumetric expansion and contraction substantially relieves an air pressure differential between ambient and the internal volume so that the centrifugal force unseats the valve without interference from the pressure differential. The dispenser opening may be in the resilient portion or in the substantially rigid body. If in the resilient portion, there may be a separate member attached to the resilient portion in order to provide a flat and smooth valve seat around the opening for properly seating the valve.
In another aspect of the present invention, an improved rinse water additive dispenser for an automatic washer having a spinning drum comprises a substantially rigid portion having an internal volume and a resilient bellows portion connected to and in fluid communication with the rigid portion. Either the rigid portion or the resilient bellows portion has an opening therein surrounded by a valve seat. The dispenser further comprises a valve seated on the valve seat to seal the opening and provide a closed dispenser. The valve has a rigid counterweight extending downward therefrom. The counterweight has a center of gravity along an axis substantially perpendicular to and centered on the opening. The counterweight is sized to be pulled away from the axis in the presence of centrifugal force acting thereon during a washer spin cycle so as to unseat the valve and thereby open the dispenser so that an additive in the dispenser may thereafter mix with rinse water when the automatic washer fills with rinse water. The resilient bellows portion provides for voluntary expansion and contraction of the closed dispenser when the dispenser is placed in variable temperature water. The volumetric expansion and contraction substantially relieves an air pressure differential between ambient and the internal volume so that the centrifugal force unseats the valve with minimal interference from the pressure differential. The resilient bellows preferably has a collapse resistance sufficient to minimize bellows distortion when centrifugal force pulls the counterweight away from the axis, so that the force may unseat the valve.
The rigid counterweight preferably has a base which mates with an internal bottom surface of the dispenser when the valve is unseated, in order to substantially center the valve along the axis of the opening. The resilient bellows portion may then be manually deformed to lower the valve seat into engagement with the valve after refilling the dispenser.
The internal bottom surface may have an upright projection for engagement with a recessed surface of the counterweight, or the internal bottom surface may have a recessed surface for engagement with a matingly shaped counterweight to align the counterweight along the axis after it falls from the valve seat position.
BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims which particularly point out and distinctly claim the present invention, it is believed that the present invention will be better understood from the following description of preferred embodiments, taken in conjunction with the accompanying drawings, in which like reference numerals identify identical elements and wherein:
FIG. 1 is a front elevation view of a preferred embodiment of the improved dispenser of the present invention, disclosing a rigid lower portion and a resilient bellows upper portion;
FIG. 2 is a sectioned side elevation view thereof, taken along section line 2--2 of FIG. 1, showing the dispenser having fluid ready to dispense and a valve seated in a seat located in the resilient bellows upper portion;
FIG. 3 is a sectioned side elevation view thereof, similar to FIG. 2, disclosing the valve being opened by centrifugal force acting against a counterweight suspended from the valve during a spin cycle of an automatic washer;
FIG. 4 is a sectioned side elevation view thereof, similar to FIG. 2, disclosing the emptied dispenser with valve centered and resting on the bottom surface of the lower body portion;
FIG. 5 is a sectioned side elevation view thereof, similar to FIG. 2, disclosing the upper portion being pushed downward such that the valve seat engages the valve after fluid is added to the lower body portion;
FIG. 6 is a front elevation view of an alternative preferred embodiment of the improved dispenser of the present invention, disclosing a substantially rigid upper body portion and a resilient bellows lower portion;
FIG. 7 is a sectioned side elevation view thereof, taken along section line 7--7 of FIG. 6, showing the dispenser having a valve seated in a seat located in the substantially rigid portion;
FIG. 8 is a sectioned side elevation view thereof, similar to FIG. 7, disclosing the upper body portion being pushed downward such that the valve seat engages the valve, as would normally happen after fluid is added to the lower portion; and
FIG. 9 is a front elevation view of yet another alternative preferred embodiment of the improved dispenser of the present invention, disclosing a substantially rigid body and a resilient bellows portion located between upper and lower body portions of the dispenser.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, and more particularly to FIGS. 1 and 2, there is shown a first preferred embodiment of the present invention, which provides an improved dispenser generally indicated as 10. Dispenser 10 has a construction which is generally in accordance with the teachings of commonly assigned U.S. Pat. No. 5,267,671, issued to Baginski et al. on 12/7/93, which is hereby incorporated herein by reference. Improvements to the dispenser of Baginski et al are: a) the addition of a resilient bellows to the body of the dispenser, which allows for the internal volume of the dispenser to be changed; and b) the addition of a centering feature to the base of the counterweight, which enables the unseated valve to be positioned upright and centered on the dispenser opening and valve seat. The benefits of these two improvements is explained hereinafter.
Dispenser 10 has a substantially rigid body 12 and a resilient bellows portion 14, which are preferably injection-blow molded as one piece from a clarified polyolefin or PET. It is beneficial for the body to be clear so that the level of fluid additive may be observed from outside the dispenser when filling it to a fill line marked on the dispenser. Body 12 typically has a thicker wall than bellows portion 14. Alternatively, a separate pre-formed bellows is connected to rigid body 12 in a fluid-tight manner, such as by adhesive or fusion bonding, or by a gasketed mechanical fastening. The material and construction of body 12 and resilient portion 14 must be able to withstand the heat of hot laundry water and detergent.
Dispenser 10 also has an opening 16 for fluid communication with an internal volume 18. Opening 16 is surrounded by an annular valve seat 20. Because of the need for valve seat 20 to be flat and smooth, opening 16 is preferably made in an injection molded, substantially rigid, member 22, which is connected to bellows portion 14 in a fluid-tight manner, such as by adhesive or fusion bonding, or by a gasketed mechanical fastening.
Seated in opening 16 on valve seat 20 is a valve 24. Valve 24 has two parallel resilient disks 26 and 28 connected by a resilient cylinder. Valve 24 is mounted on a substantially rigid plastic stem 32. Valve 24 is preferably made of Shore A 58 durometer polyisoprene elastomer by an injection molding process. Plastic stem 32 is preferably made of polypropylene. Stem 32 extends downward along an axis 34 through the center of opening 16 from valve 24 to a counterweight 36, also made of polypropylene. Counterweight 36 extends into internal volume 18, but short of an internal bottom surface 38 of body 12.
Counterweight 36 preferably has a center of gravity 40, which is located substantially along; axis 34 when valve 24 is properly seated. Counterweight 36 also has a base 42, which is preferably recessed to mate with bottom surface 38. Bottom surface 38 preferably has an upright projection, such as a domed pushup, so that when valve 24 is unseated, base 42 is easily centered on bottom surface 38. Alternatively, the internal bottom surface may be recessed or funnel-shaped and the mating base of the counterweight may be convex or a truncated cone, as shown in FIGS. 7 and 8, to mate with a bottom surface to provide the centering function.
FIGS. 3 and 4 show how valve 24 is typically opened. Valve 24 is similar to a grommet, acting to seal against both sides of member 22 to close dispenser 10 by plugging opening 16. Counterweight 36 is sized to provide a torque on valve 24 when a centrifugal force C acts through center of gravity 40 during an automatic washer spin cycle, assuming dispenser 10 rests against its side on washer drum 44. Force C pulls counterweight 36 out of alignment with axis 34, causing outermost disk 26 to progressively slip and then totally pop inside opening 16, thereby unseating valve 24. Once unseated, valve 24 falls into internal volume 18 and rinse water is free to enter and mix with an additive fluid 46 in dispenser 10, and/or additive fluid 46 is free to spill out of dispenser 10 into the rinse water.
For a fabric softener, such as DOWNY®, a Trademark of The Procter & Gamble Company of Cincinnati, OH, it is desired to maintain the dispenser closed during a wash cycle, but to open and mix this fluid with rinse water during the rinse cycle. When fabric softener is dispensed in this manner, the dispenser may be conveniently placed in the laundry load at the very beginning of a wash cycle and removed only after the complete wash & rinse cycles are finished. Such a dispenser avoids the need to manually interrupt the wash and rinse cycles to add a fabric softener to the rinse water.
Resilient bellows portion 14 solves a problem with rinse water dispensers, wherein hot or cold wash water tends to heat or cool internal volume 18 of dispenser 10 and generate either a pressure or a vacuum. An internal pressure or vacuum act to influence the timing of opening of the dispenser. A vacuum caused by dispenser contact with cold water will provide a preload force on the valve which enables it to open prematurely, such as when the dispenser is impacted during the wash cycle. A pressure caused by dispenser contact with hot water will provide an opposite preload force, which may prevent the valve opening at all during the spin cycle when maximum centrifugal force is developed. However, the resilient bellows expands or contracts with the pressure or vacuum developed in the internal volume of the dispenser and thereby reduces the magnitude of the pressure or vacuum to an acceptable level such that there is minimal interference with the normal opening force applied to the valve.
Valve seat 22 is shown connected to resilient bellows 14 in FIGS. 2-5 or connected to a substantially rigid body in FIGS. 7 and 8. Either alternative is feasible. When valve seat 22 is part of the resilient end of the dispenser, the resilience of the bellows portion must be limited such that centrifugal force C does not distort or deform the bellows portion an amount that prevents the valve from unseating. In order to minimize the bellows portion distortion or to reduce the stiffness needed in the bellows, the valve seat and dispenser opening may more preferably be located in the substantially rigid body opposite the resilient bellows portion. FIG. 9 shows an arrangement wherein the bellows portion is centrally located between two ends of the dispenser, such that the dispenser opening and the valve seat may be located at either end of the dispenser.
Another important aspect of the resilient bellows solves a second problem. Conventional dispensers have a chain or cord with a pull ring attached to the valve. This enables the unseated valve resting inside the dispenser to be pulled into engagement with the valve seat after refilling the dispenser. However, because the chain or cord extend through the opening for access by the attendant, the chain or cord become contaminated with additive fluid and are therefore messy to use when pulling the valve into a seated position. Improving the dispenser by adding both a resilient bellows and a counterweight centering feature permits the chain or cord to be eliminated. Instead of pulling the valve into valve seat engagement, the attendant merely shakes the dispenser to guarantee alignment of the valve and counterweight along axis 34 and then presses the opening end of the dispenser downward with force F until the valve reseats with the valve seat. This is shown in FIGS. 5 and 8.
The design of the centering feature must take into account the angle to which the counterweight must be pulled away from axis 34 in order to cause the valve to unseat. The angle is a function of the stiffness and thickness of the rubber disks and diameter of the opening relative to the diameters of the disks. In order for the allowable swing angle to be large, the diameter of base 42 must be limited. In order for base 42 to be centered by internal bottom surface 38, the diameter of the bottom surface must substantially correspond with that of base 42. Although self-centering is the objective, gentle shaking of the upright dispenser may be beneficial in aligning the counterweight base with the bottom surface. As a last resort for centering the valve and counterweight, the attendant may extend a finger into the dispenser to align the counterweight and valve prior to pouring fluid into the dispenser.
When resilient bellows portion 14 is compressed by force F, it has a tendency to spring back to the position shown in FIGS. 2, 6, and 9. In order to do so, air must vent into dispenser 10. However, if air vents into and out of dispenser 10, one might wonder how a pressure or vacuum, discussed hereinbefore, can be developed in dispenser 10. The answer is that when essentially dry, although the fluid additive may contaminate some surfaces of valve seat 22 and valve 24, valve 24 passes air into and out of dispenser 10 quite readily, allowing for bellows expansion to its normal position. However, when wet from a wash cycle, valve 24 tends to seal against valve seal: 22 in an air-tight manner. When the valve is sealed tightly, pressure or vacuum may be developed inside the dispenser.
FIGS. 6-8 show an alternative construction of a dispenser of the present invention, generally indicated as 50. Dispenser 50 has a substantially rigid body 52 and a resilient bellows portion 54, which are preferably made similarly to rigid body 12 and resilient bellows portion 14. Dispenser 50 also has an opening 56 for fluid communication with an internal volume 58. Opening 56 is surrounded by an annular valve seat 60. Valve seat 60 and opening 56 may be molded as part of rigid body 52 or made into a separate member which is connected to body 52 in a fluid-tight manner.
Seated in opening 56 on valve seat 60 is a valve 64. Valve 64 has two parallel resilient disks 66 and 68 connected by a resilient cylinder. Valve 64 is preferably made of the same material as valve 24 and is mounted on a substantially rigid plastic stem 72. Plastic stem 72 extends downward along an axis 74 through the center of opening 56 from valve 64 to a counterweight 76. Counterweight 76 extends into internal volume 58, but short of an internal bottom surface 78 of resilient bellows portion 54. Stem 72 and counterweight 76 are made similarly to stem 32 and counterweight 36.
Counterweight 76 preferably has a center of gravity 80, which is located substantially along axis 74 when valve 64 is properly seated. Counterweight 76 also has a base 82, which is preferably shaped to mate with internal bottom surface 78. Bottom surface 78 preferably has a recess or funnel-shaped internal surface, so that when valve 64 is unseated, base 82 is easily centered on bottom surface 78. Alternatively, the internal bottom surface may be an upright projection, such as a domed pushup, and the mating base of the counterweight may be concave, as shown in FIGS. 2-5, to provide the centering function. Internal bottom surface 78 may be a separate injection molded member connected to resilient bellows portion 54 in a fluid-tight manner. FIG. 8 shows no fluid present, in order to avoid obscuring the view of the centering of base 82 in the recess of internal bottom surface 78. The attendant applies force F to cause the seating of valve 64, just as in FIG. 5.
FIG. 9 shows still another alternative embodiment of the dispenser of the present invention, generally indicated as 90. Dispenser 90 has a resilient bellows portion 92 located between substantially rigid upper and lower body portions 94 and 96, respectively. Dispenser 90 has internal centering valve features (not shown) similar to those of either dispenser 10 or dispenser 50. Dispenser 90 also has a valve seat and dispenser opening (not shown) located in either of body portions 94 or 96, similar to that of dispenser 50.
While particular embodiments of the present invention have been illustrated and described, it will be obvious to those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention, and it is intended to cover in the appended claims all such modifications that are within the scope of the invention. | An improved rinse water additive dispenser for an automatic washer has a substantially rigid body having a resilient portion and an internal volume. The dispenser further includes an opening therein and a valve for sealing the opening closed so that the rinse water additive is maintained within the dispenser until the valve is acted upon by centrifugal force applied to the dispenser during a spin cycle of the automatic washer to unseat the valve. The resilient portion provides for volumetric expansion and contraction of the dispenser when the dispenser is placed in variable temperature water. The volumetric expansion and contraction substantially relieves an air pressure differential between ambient and the internal volume so that the centrifugal force unseats the valve without interference from the pressure differential. The opening may be in the resilient portion or in the substantially rigid body. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
My invention relates generally to the processing of coatings of aggregate materials of varying sizes to distribute the aggregate in a level layer or coating over a fragile membrane such as rubber, plastic, or the like.
2. Prior Art
A search for a suitable rake to perform the objects of my invention has failed to disclose a device possessing the desired characteristics. One form of rake that has been attempted for use in performing the leveling of an uneven layer of aggregate material on a surface has been the common asphalt rake typically used in the road construction industry for distributing asphalt over a surface prior to the rolling or compacting operation. Other forms of garden and other special purpose rakes have been tried, but none have provided the novel and unobvious advantages of my invention.
The following is a listing of United States Patents that were collected in the course of a pre-filing search of the records of the U.S. Patent Office, and none of them are considered relevant or pertinent to the objectives provided by my invention:
______________________________________U.S. Pat. No. Patentee Issue Date______________________________________2,317,916 Kallal April 27, 19434,414,797 Archer Nov. 15, 1983Des.274,118 Cochrane June 5, 19844,520,621 Archer June 4, 1985Des.282,621 Nuorivaara Feb. 18, 1986______________________________________
Of the above listing patents, the Archer U.S. Pat. No. 4,414,797 includes a raking element of serpentine configuration. However, the purposes and operation thereof are considered highly dissimilar to those of my invention.
BRIEF DESCRIPTION OF THE INVENTION
My invention comprises a rigid, substantially planar frame of substantial mass, including top, bottom and intermediate cross members and side members disposed in a plane, that is provided with a handle extending angularly upwardly from the top of the frame and is configured so as to present a rounded lower portion adjacent each end of the bottom cross member. The bottom cross member may be of serpentine configuration, extending upwardly and downwardly in an undulating fashion with the tops and bottoms of the undulations in a substantially straight line. The intermediate cross member, extending from one side to the other side of the frame, is disposed at a predetermined distance above the upper portions of the undulations. The spacing between the top of the bottom portion and the bottom of the intermediate member is somewhat less than the size of the largest particle of material contained in an aggregate.
My invention is particularly useful in connection with the fabrication of contemporary roofing structures for generally flat roofed buildings as will be described below.
It is an object of my invention to provide a rake for leveling aggregate materials disposed on a surface over a flexible membrane.
Another object of my invention to provide a rigid rake capable of displacing heavy aggregate materials without causing damage to a surface upon which the aggregate is disposed as the rake is moved over a surface and through the aggregate.
It is a further object of my invention to provide an aggregate leveling rake of improved efficiency of operation.
These and other objects and advantages will become apparent from a consideration of the following specification, claims and drawings in which;
FIG. 1 is a partly broken away perspective sketch of a building structure of the flat roofed variety;
FIG. 2 is a side elevational view of a rake embodying the principles of my invention;
FIG. 3 is an end elevational view of the rake shown in FIG. 2;
FIG. 4 is a top plan view thereof
FIG. 5 is a bottom view thereof;
FIG. 6 is a side/top perspective view of an aggregate leveling rake illustrating my invention; and
FIG. 7 is an end elevational view of a further embodiment of the subject matter of FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings in which like elements have been identified with like reference characters, an aggregate leveling rake is generally indicated by reference character 10 and includes a planar frame 11 having a top 12, a pair of sides 13 and 14, and a bottom 15 having ends 16 and 17 depending from side portions 13 and 14 respectively. Bottom 15 is comprised of a plurality of semi-circular portions extending downwardly as indicated by reference characters 18, 19, 20 and 21, and a lesser plurality of semi-circular portions extending upwardly and identified by reference characters 22, 23 and 24. An intermediate cross-member 25 extends generally horizontally from side 13 to side 14. A cylindrical handle receiving socket 28 is shown disposed at the center 26 of intermediate cross-member 25 and the center 27 of top 12 and is fastened in place by suitable means, such as welding or the like. Cylindrical handle socket 28 is reinforced and further held in place by web portions 29 and 30 connected to cylindrical handle socket 28 and to portions of intermediate cross-member 25 by suitable means, such as welding, etc. A handle 31 is received and held within cylindrical handle socket 28.
In one operative embodiment of my invention, successfully operative to level a gravel aggregate of 3/4 to 11/2 inch size, frame 11 was fashioned of 3/8ths inch steel rod configured to lie in a common plane after assembly of the individual parts as by welding or the like. The frame was approximately 18 inches wide and 5 inches high. The semi-circular portions were formed to a radius of approximately 1.25 inches and the intermediate cross-member 25 disposed approximately 2 inches below top 12 so that the spacing between intermediate cross-member 25 and the top portions of the upwardly extending semi-circles 22, 23 and 24 on bottom 15, was approximately 1 inch.
In the further embodiment of FIG. 7, intermediate member 25 is shown having a generally serpentine configuration, extending generally parallel to top 12, that is complementary to the shape illustrated for bottom 15 and is spaced therefrom a distance substantially the same as top portions 22, 23 and 24 are spaced from intermediate member 25 in FIG. 3 of the drawings.
Planar frame 11 and cylindrical handle socket 28 are preferably of substantial mass and rigidity so that frame 10 will tend to be submerged in and adjacent to a surface underneath a layer of aggregate material 38 and the downwardly extending semi-circular portions 18, 19, 20 and 21 will slide upon the surface underneath the aggregate material to thereby preserve the integrity of membrane 37 disposed on the surface.
As the rake is moved through and across a volume and area of the multi-sized aggregate 38 and 39, the aggregate material will flow through the upwardly and downwardly extending semi-circular portions of bottom 15 of rake 10 and the thickness of the layer of aggregate will be rendered level, the ultimate desired posture for an aggregate covered structure.
Referring to FIG. 1 of the drawings, a structure in the form of a building is indicated generally by reference character 33. Building 33 includes a plurality of laterally disposed joists 34 for supporting a roof-deck 35 intermediate the bounds of a peripherally extendent parapet 36. Deck 35 is preferably covered with a continuous rubber or plastic membrane 37 that forms an impervious barrier extending completely over the surface of the deck and vertically upwardly along the lower boundary of parapet 36. A quantity of suitable gravel, or stone, aggregate, 38, is intended to be disposed in a level layer of uniform thickness to maintain the continuous membrane in place so that it may withstand the onslaught of various and sundry environmental conditions.
In all known typical installations of weather-proof roofing materials which do use a top layer comprised of an aggregate, it is virtually impossible to apply the layer of aggregate material in a uniform thickness or in a level condition. In one common aggregate distribution arrangement, the aggregate is deposited in a plurality of parallel, overlapping rows of aggregate material distributed from a portable hopper of finite width. The rows are indicated by reference character 39 and the overlapping material is illustrated as a mound identified by reference character 40.
My novel and unobvious improvement provides a rake which is placed on the upper surface of the deposited aggregate material adjacent to or on a mound 40 and the rake, after immersion and submersion to contact with the upper surface of membrane 37, is caused to move back and forth and the aggregate material will flow through the rake as it moves back and forth to assume a level condition and thereby provide a level uniform layer of aggregate 38 over the entire surface of a roof as shown on the lower portion of FIG. 1.
It may be desirable to fabricate aggregate leveling rakes according to my invention for various sizes of particles contained in an aggregate. For example, the distance between the top portions 22, 23 and 24 of the bottom of the rake is generally less than the size of the largest particle of an aggregate. This is provided so that the aggregate will flow through the rake as the rake is moved relative to a volume of aggregate without substantially blocking the flow of the aggregate and so that the flow of the aggregate may proceed downwardly on either side of the top portions 22, 23 and 24 of bottom 15 and thereby is displaced laterally as leveling occurs. | A rake for leveling aggregate, such as one-half to two-inch size aggregate used in roofing or landscaping applications, is comprised of a heavy, rigid, generally vertically disposed frame including a downwardly depending portion extending thereunder for immersion, submersion and movement through a volume of aggregate to be levelled over a flexible membrane. The downwardly depending portion has rounded ends and may be of a symmetrical serpentine shape intermediate the ends. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to torque wrenches used for rotating mechanical components, e.g. for tightening or loosening nuts, bolts and screws.
Generally these wrenches use a wrench head, for example a removable standard socket spanner, carried by holding means on the wrench, normally a shaft mounted rotatably in a housing. As an alternative, special sockets may be used, these sockets having a polygonal bore for the nut or other polygonal head to be rotated by the wrench and a shaft which fits into a hole in the wrench, this hole then constituting the holding means for the socket. At least one drive lever extending radially from and pivotable coaxially with the said holding means is connected to it by a ratchet, and a piston rod of a reciprocating fluid piston cylinder arrangement is pivotally connected to the drive lever or levers at a location radially spaced from the said holding means, to oscillate the lever and thus drive the said holding means in rotation through the ratchet.
Since in most known arrangement the drive lever oscillates in an arc about the axis of the said holding means, the distance between the line of action of the piston rod and the said axis varies throughout the oscillation. In theory when a constant force is applied the torque exerted on the said holding means is proportional to this distance.
U.S. Pat. No. 4,027,561 shows a torque wrench of this kind in which the hydraulic cylinder is pivoted at the end remote from the drive levers to accommodate the arcuate movement of the end of the piston rod remote from the cylinder, the piston rod itself reciprocating on the axis of the cylinder. In FIGS. 1 to 3 of United Kingdom Pat. No. 2,028,204,B the cylinder bore is formed in the housing of the wrench so that the cylinder has a fixed axis and the piston rod is swivelably mounted in the piston, again so as to accommodate the movement of the far end of the piston rod in an arc round the shaft axis.
SUMMARY OF THE INVENTION
The new scientific frontiers through which modern industry is passing demand great accuracy in predicting and providing accurate bolt loads. Equipment capable of providing this facility is now essential and would be available through exercising a substantially constant torque on the said means for holding the socket. An arrangement with this in mind is shown in FIG. 4 of UK Pat. No. 2,028,204,B above mentioned. Here the piston rod is screwed into the piston and the free end of the piston rod, which rotates the drive lever, has a pin operating in the slot in the drive lever.
An object of the present invention is to provide a hydraulic torque wrench which will exercise a substantially constant torque, while ensuring the minimum of wear at the connection between the end of the piston rod and the drive lever or levers, and avoidance of unnecessary bending stresses on the piston rod.
In order to meet this object we form a slot with parallel sides at or near the end of the drive lever, a shoe guided in the parallel sides and which can reciprocate in the slot, the remote end of the piston rod being pivotally mounted to the shoe by a pin which passes through the shoe and is guided in guide channels which are formed in the wrench body or otherwise fixed in position in relation to the wrench housing. Inevitably, there is some loss of power when the shoe is moving in the slot, with the result that the torque exerted on the means for holding the socket is not exactly proportional to the distance from the said holding means to the line of movement of the piston rod. In order to create a still more constant torque, the guide channel for the end of the pin passing through the shoe may be curved. The curve may be such that the aforesaid distance, i.e. the length of the perpendicular from the said holding means to the line of movement of the piston rod, is at a minimum at the point where friction due to movement of the mechanism is a minimum.
A torque wrench according to the invention can be readily so constructed that the drive lever and ratchet mechanism can be removed from the device by taking out a drive shaft, and we further provide a ratchet link which can be utilised with wrenches where the drive lever and ratchet mechanism can be so removed. Such a ratchet link according to the present invention comprises a member forming a lever of which one end is constructed to cooperate with and be moved by the piston rod of the fluid piston-cylinder arrangement of the wrench and the other end forms a housing for a ratchet wheel having a ratchet connection between the wheel and the said member, the said member having a bore between its ends to fit a drive shaft of the torque wrench or another shaft replacing the said drive shaft, and the ratchet wheel being constructed to fit over a nut so as to rotate the same.
A ratchet link so constructed can be used to tighten or loosen nuts which are situated so close to an obstruction in the axial direction of the nut that access is not available for a tool utilising standard sockets.
In another aspect of the invention, we seek to provide a compact and reliable ratchet for torque wrenches. In the past, these ratchets have usually comprised a pawl on the drive lever which abuts the teeth of a ratchet wheel mounted coaxially on the means for holding the socket. According to this aspect of our invention the pawl is replaced by one or more rollers, but not more than three such rollers, which float between grooves in the ratchet wheel and a socket or sockets in the drive lever. When the drive lever is executing a driving stroke the roller or rollers are located in the grooves on the ratchet wheel and are propelled by shoulders on the drive lever whereas, when the drive lever is on its return stroke, the roller or rollers move back into the socket or sockets in the drive lever. A spring may be provided for each roller to urge it towards the ratchet wheel. We are aware that rollers have been used in place of pawls in the ratchet arrangements of torque wrenches. U.S. Pat. No. 3,745,858 shows such a device in which the rollers are located at places right round the circumference of the ratchet wheel. This arrangement is however bulky, and we have found that it is quite sufficient to have one, two or three such rollers, all positioned on that side of the ratchet wheel which is towards the operating mechanism or, more precisely, opposite the hemicylindrical surface of the ratchet wheel nearest the guide channels, with a consequent improvement in size, accessibility and weight.
It is clear that the ratchet of the present invention is utilisable in the torque wrench or in the ratchet link.
BRIEF DESCRIPTION OF THE DRAWINGS
Various embodiments of the invention are shown in the accompanying drawings in which
FIG. 1 is an end view of one form of torque wrench according to the invention;
FIG. 2 is a section on the line II--II in FIG. 1;
FIG. 3 is a part section on the line III--III in FIG. 2;
FIG. 4 shows a modification of the cylinder arrangement;
FIG. 5 is a longitudinal section through another embodiment, taken on the line V--V in FIG. 6;
FIG. 6 is a section on the line VI--VI in FIG. 5;
FIG. 7 is a view in the direction of the arrow `A` in FIG. 6 with the cover plate removed;
FIG. 8 shows a modification of the cylinder mounting;
FIG 9 illustrates a situation where a conventional torque wrench cannot be used;
FIG. 10 is a side view, partly sectioned, of a torque wrench as illustrated in any one of FIGS. 1 to 8, in which the drive lever and ratchet mechanism have been removed and replaced by one embodiment of ratchet link according to the invention, and a roller attachment has been added;
FIG. 11 is an end view of FIG. 10;
FIG. 12 is a view similar to FIG. 2 but showing a straight configuration for the guide channel.
In all the embodiments shown similar parts are given the same reference numeral.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIG. 1 to 3 the torque wrench comprises a housing 10 in which a square shaft 12 is mounted for rotation by means of support bearings 13 in the housing 10. This shaft can be fitted with a removable standard socket spanner appropriate for the nut or bolt head to be turned by the device. Between the sides of the housing 10 the shaft 12 carries a ratchet wheel 14 driven in a counterclockwise direction (as viewed in FIG. 2) by a drive lever 18 which surrounds the ratchet wheel 14.
As seen in FIG. 3 the ends 16 of the ratchet wheel 14 have a smaller diameter than the centre portion, and similarly the sides 20 of the drive lever 18 extend inwardly to a greater extent than the centre part so as to be journalled on the ends 16 of the ratchet wheel 14. The sides 20 also form flanges constituting end stops for rollers 22 which constitute the driving connection between the drive lever 18 and ratchet wheel 14, replacing the pawl which is the usual driving connection to a ratchet wheel. The drive lever is made in two halves, as shown in FIG. 3, to enable it to be fitted over the ratchet wheel 14, the two halves of the drive lever being rigidly connected together after assembly by screws (not shown).
The rollers 22 float between grooves 24 found in the outer circumference of the ratchet wheel 14 and sockets 28 in the drive lever 18. On a driving stroke of the drive lever 18 each roller 22 lies between a shoe 30 located in a shoulder of the drive lever 18 and the forward end 25 of a groove 24. When, on the other hand, the drive lever 18 is performing a reverse stroke, the rollers 22 each run back up the rear end 26 of the groove 24 in which it is located and move into one of the sockets 28 in the drive lever 18. Springs 32 anchored to the drive lever 18 bias the roller 22 towards the ratchet wheel 14, so that they slip into the grooves 24 at the beginning of the next driving stroke of the drive lever 18. A holding pawl 34, pivoted to the housing 10 at 35 has the free end 36 shaped as a part-cylinder of the same diameter as that of the rollers 22. The holding pawl is biased towards the ratchet wheel 14 by a leaf spring 37, and prevents any substantial rearward movement of the ratchet wheel.
Power for the torque wrench is provided by a hydraulic cylinder 40 and double-acting piston 42, hydraulic fluid being fed and exhausted through ports 48, 50 according to the direction of movement of the piston 42. At one end the piston 42 has a head 44, which fits in the bore of the cylinder through a suitable packing such as an O-ring 45, and is provided with a cap 46 screwed into the piston head 44. The cylindrical body of the piston 42 passes through a gland 52 in the open end of the cylinder, this gland being sealed to the cylinder; a packing 54 between the gland 52 and the piston 42 forms a seal against hydraulic fluid at this point.
The piston 42 is hollow to accommodate a piston rod 56. At one end the piston rod 56 has a head 58 located between the piston cap 46 and a shoulder 60 in the piston head 44. The end face of the head 58 and the adjacent face of the cap 46 are spherical in shape to allow for some degree of pivoting of the piston rod 56 in all directions. The other end of the piston rod has been cut away in FIG. 2, but is the same as shown in FIG. 4, being also illustrated in section in FIG. 3. At this end the piston rod has a head 62 bored to take a pin 64 through a spherical bearing 66. The pin 64 is journalled in two drive shoes 68, one each side of the piston rod head 62, and is mounted at each end in a support shoe 70 through spherical bearings 72. The support shoes 70 can move along guide channels 74, each formed in the housing 10 or in a member secured to the housing. The guide channels are in any event stationary in relation to the housing.
At its upper end (in the position seen in FIG. 2) the drive lever 18 is bifurcated to leave upstanding ears 76,76 and 77,77, the head 62 of the piston rod 56 passing between the ears 76. Also at its upper end the drive lever 18 is formed with a parallel sided recess which is divided centrally by the ears 76 to provide a slot 78, one on each side, to form guideways for the drive shoes 68.
In operation it can be seen that the driving stroke of the piston forces the pin 64 to the left (as seen in FIG. 2) and rotates the ratchet wheel 14 counterclockwise through the drive lever 18, the rollers 22 and the ratchet wheel 14. During the return stroke the rollers 22 move into the sockets 28 in the drive lever 18, and the drive lever moves clockwise without moving the ratchet wheel 14 which is held by the holding pawl 34.
During the reciprocation of the piston 42, head 62 of the piston rod is guided by the pin 64, the movement of which is controlled by the shape of the guide channels 74. The guide channels 74 could be straight, as shown in FIG. 12 in which case, ignoring the effect of friction, there would be a constant torque system, the movement of torque being calculated as the force exerted by the piston multiplied by the length of the normal from the centre of the ratchet wheel 14 to the straight axis of movement of the piston rod 56. However, it will be appreciated that, as the drive lever 18 rotates, the drive shoes 68 move along the slots 78, and the effect of the frictional forces between the shoes 68 and the slots 78 and between the support shoes 70 and the guide channels 74 will vary according to the position of the shoes 68 in the slots. To counter this, the guide channel 74 of the embodiments shown in the drawings other than FIG. 12 is curved so that, as the shoes 68 move up the slots 78 and the frictional force becomes greater, the normal from the centre of the ratchet wheel 14 to the axis of movement of the piston rod 56 becomes greater. In this way a still closer approximation to constant torque can be obtained over the whole stroke of the piston.
It will be seen from the above description that some up and down movement of the head 62 of the piston rod is called for when the guide channels 74 are curved. Additionally there is always some distortion of the housing 10 when the torque wrench is used. One aspect of this is the simple counter-torque on the device when a nut is tightened, this being in the plane of the drawing of FIG. 2. If this counter-torque is taken by the end of a laterally extending plate attached to the casing, so that the reaction force between the plate and the stationary object against which it is laid is not in the plane of the drawing, there is then a torque which can be resolved into a torque in the plane of the drawing, and a torque at right angles to this plane. It is to meet the distortions caused by this that the piston rod 56 is given a freedom of rotational movement in all directions and the bearings 66 and 72 are spherical bearings.
In the modification shown in FIG. 4 both the piston 42 and piston rod 56 are allowed a degree of rotational movement. To this end the piston rod 56 passes through a gland 80 with a normal seal 82 against egress of hydraulic fluid. The gland 80 is held in place between a shoulder 84 and a support ring 86, which is firmly attached to the inside of the cylinder 40, and which is bored centrally so that the piston rod 56 can pass through with sufficient clearance to allow pivotal movement of the piston rod. A face seal 87 prevents passage of fluid between the gland 80 and the support ring 86. The diameter of the gland 80 is less than that of the part of the cylinder 40 in which it is located, and it can therefore move laterally as the piston rod 56 swings out of the line of the axis of the cylinder.
The mode of operation of the embodiment shown in FIGS. 5 to 7 is similar to that of FIGS. 1 to 3, and only the differences in design need be explained. In this embodiment the front end of the cylinder 40 has a part spherical surface 90 which abuts a complementarily shaped bearing 92, being held there by a part spherical thrust bearing 96 which abuts a complementarily shaped shoulder 94 on the cylinder, the thrust bearing 96 being held in place by a thrust collar 98. In this embodiment the piston rod 56 always moves along the axis of the cylinder 40 and it is the cylinder which rotates as necessary according to the movement of the head 62 of the piston rod, sufficient space being allowed for this between the cylinder 40 and the thrust bearing 96 and thrust collar 98.
In this embodiment there is only one roller 22, but otherwise the actuation of the ratchet wheel 14 is the same as with the embodiment of FIGS. 1 to 3. Moreover, the holding pawl 34 does not operate on the ratchet wheel 14 but on a similarly shaped wheel 100 fixed on the drive shaft 12 beside the ratchet wheel 14. The wheel 100 is journalled in the housing 10 at 102 and in effect acts also as a support bearing for the shaft 12 opposite the support bearing 13. A release lever 99 allows the holding pawl 34 to be disengaged when this is desired. The holding pawl 34 and the grooves in the wheel are protected by a cover plate 104.
The modification shown in FIG. 8 shows a different cylinder mounting. Here the cylinder 40 is mounted with projections 106 on each side journalled in bearings 108 in the housing 10 so that the cylinder 40 can move at right angles to the plane of the figure, i.e. in the plane of FIG. 5. Otherwise the modification is the same as that of FIGS. 5 to 7.
In all the embodiments the drive shaft 12 can be pushed through from one side to the other so that nuts and bolts may be both tightened and unscrewed.
In all the forms of the torque wrench shown in the drawings, the end of the casing 10 which lies adjacent the hydraulic cylinder 40 is provided with ears 110 leading to a flat lower surface 112, a construction which allows ancillary fitments to be slid onto the housing. One such ancillary fitment can be a laterally extending plate as referred to above.
The design of torque wrench which we have described and illustrated in FIGS. 1 to 8 has allowed us to evolve a useful accessory in the form of a ratchet link for specialised flange use in those cases where the conventional torque wrench cannot be employed. An example of such a case is shown in FIG. 9 which illustrates two sections of pipe 114, each having a circular flange 116 at the end connected through a threaded bolt and nuts 118. Cladded insulation 119 prevents the torque wrench and socket spanner being used and another tool must be employed. Specialised hydraulic tools have been evolved for this purpose, and it is also known to adapt normal hydraulic wrenches by fitting a roller attachment and a torque link. However, in this latter case, the ratchet mechanism built into the machine cannot be used and as a result the tool has to be manually repositioned after each forward stroke of the piston, which is time consuming and tiring for the operator.
According to a further aspect of the present invention we provide a ratchet link which can be utilized with a hydraulic wrench which is so constructed that the drive lever and ratchet mechanism can be removed from the device by taking out the drive shaft. It can readily be seen from the above description that this applies to the torque wrench illustrated in FIGS. 1 to 8.
Reference may now be made to FIGS. 10 and 11 of the drawings. The reference numeral 10 in FIG. 10 designates the housing of any of the torque wrenches described by reference to FIGS. 1 to 8. As can be seen in FIG. 10 the drive lever 18 and the ratchet wheel 14, together with the parts thereon, have been removed as a unit after withdrawing the drive shaft 12 and this unit has been replaced by the ratchet link generally designated at 120, this being held in place by reinserting the drive shaft 12 in its normal position in the torque wrench, but on this occasion passing it also through the hole 122, thus retaining the upper part of the ratchet link 120 between the sides of the housing 10. In this position, the upper end of the ratchet link 120 (in the position seen in the drawings) fits over the drive shoes 68, being formed with upstanding ears 76,77 for this purpose. It can be seen that the body 124 of the ratchet link 120 acts as a lever which pivots round the drive shaft 12.
At its lower end the body 124 of the ratchet link 120 forms a housing 126 for a ratchet wheel 128, the connection between the ratchet wheel and the body 124 being a roller 22 which floats between grooves 24 in the ratchet wheel and a socket 28 in the body 124 in the same manner as is noted above in reference to FIG. 5. A spring 32 exercises the same function as the spring 32 in FIG. 5.
The end of the housing 10 adjacent the cylinder is fitted with a roller or pad attachment, a roller attachment being shown in FIGS. 10 and 11. This comprises a sleeve 142 which can be slid over the ears 110 of the torque wrench. Depending members 144 attached to the sleeve 142 are bored to receive an axle 146 carrying the rollers 148.
The ratchet wheel 128 is suitably bored to accommodate nuts of the correct size to be tightened or loosened. The piston rod 56 is reciprocated in the usual way. Forward movement of the piston rod causes the ratchet link 120 to pivot round the drive shaft 12 and the roller 22 to engage with a groove 24 in the ratchet wheel, thus turning the nut. On the return stroke of the piston rod 56 the drive roller 22 moves into the socket 28 and thus into an adjacent groove 24 on the ratchet wheel 128.
On every forward movement of the piston rod 56 the housing 10 will try to rotate in the opposite direction to the nut. This is prevented by the reaction roller 148 which rests against the periphery of the flange (for example the flange 116 shown in FIG. 9). At the same time the whole apparatus is pulled forward as the ratchet link rotates about the axis of the nut 118. | The double-acting piston of a torque wrench has a piston rod, the free end of which receives a pin which is guided at each end in straight or curved guide channels in the wrench housing. The pin passes through drive shoes which are slidably received in slots at the upper end of a drive lever. As it reciprocates, the driver lever rotates a ratchet wheel, the ratchet wheel having a square central bore to receive a square drive shaft journaled in the housing. If the constant force is applied, the torque wrench provides a substantially constant torque, particularly if the guide channels are curved to compensate for frictional losses. The ratchet mechanism includes rollers which float between grooves in the ratchet wheel and sockets in the drive lever. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 60/703,290, filed Jul. 27, 2005, pending, the disclosure of which patent application is incorporated by reference as if fully set forth herein.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
[0003] Not Applicable
BACKGROUND OF THE INVENTION
[0004] This invention relates to a crop processing element for a rotary combine. In particular, the invention relates to a rasp bar assembly for a rotor for a rotary combine, a cylinder for a rotary combine, and a rotary combine having such a cylinder.
[0005] Background art rotary combines comprise an axial crop processing unit that houses a rotor. The rotor comprises a cylindrical drum upon which crop engaging elements are mounted. These crop engaging elements often comprise rasp bars having fins. These background art fins are oriented at an angle of sixty degrees relative to a radial plane of the cylindrical drum or rotor or thirty degrees relative to an axial plane of the cylindrical drum or rotor. The leading edge of the rasp bar is typically coincident with an axial plane of the cylindrical drum or rotor, and the background art fins are oriented at an angle of sixty degrees relative to the rasp bar leading edge.
[0006] The background art is characterized by U.S. Pat. Nos. 4,796,645; 4,889,517; 4,909,772; 4,964,838; 5,192,245; 5,192,246; 5,376,047; 5,487,703; 5,556,337; 5,688,170; and 6,036,598; the disclosures of which patents are incorporated by reference as if fully set forth herein.
BRIEF SUMMARY OF THE INVENTION
[0007] The purpose of the invention is to improve the crop processing efficiency of a rotary combine. One advantage of preferred embodiments of the invention is that it can significantly increase the yield of a combine that incorporates it. Another advantage of preferred embodiments of the invention is that it can reduce the amount of straw that is processed by the combine from being broken up into small particles. Another advantage of preferred embodiments of the invention is that the portion of the crop engaging element that is most exposed to wear, the rasp bar portion, is separately replaceable from the mounting structure portion. Another advantage of preferred embodiments of the invention is that it will allow the harvesting of pharmaceutical crops. Crops are now grown for harvesting to gain components used in the pharmaceutical industry which require a less harmful harvesting process. Another advantage of preferred embodiments of the invention is that it moves the material being threshed as a slower rate, which results in more thorough threshing or separation of the crop, less damage to the crop and reduced plugging of the threshing system.
[0008] The invention is an apparatus and method for improving the ability of a rotary combine to gently thresh a crop and to gently convey the crop through the threshing section of the combine. In a preferred embodiment, the threshing elements of the present invention are mounted on the threshing section of the rotor of a crop processing unit of a rotary combine. In this embodiment, the threshing section downstream from the helical blades of the infeed section and upstream from the separator tines of the separation section of the crop processing unit. In this embodiment, the rotor is housed in a rotor housing that has cage vanes mounted in a helical orientation along its upper surface and a concave along its lower surface. In use, the threshing elements of a preferred embodiment of the present invention move crop between the rotor housing and the rotating rotor and simultaneously thresh the crop.
[0009] In a preferred embodiment, the invention is a crop engaging element for the rotor of a rotary combine, said crop engaging element comprising: a hollow mounting structure having a ramp portion terminating in a flat top portion that is provided with at least one hole; a rasp bar comprising a base having a flat bottom surface and a curved convex top surface and a plurality of fins extending from said top surface, each of said plurality of fins having a fin longitudinal axis, and said base being provided with at least one (and preferably two) mounting holes through which a threaded fastener is passed to mount said rasp bar to said hollow mounting structure; a leading mounting flange and a trailing mounting flange that extend from the hollow structure for mounting the crop engaging element to the rotor, wherein one of said mounting flanges is provided with at least one (and preferably two) circular mounting apertures and the other of said mounting flanges is provided with at least one (and preferably two) mounting apertures in the form of a slot through which mounting bolts are passed to mount the crop engaging element on the rotor. Preferably, said hollow mounting structure is a single structure of unitary construction. Preferably, said fin longitudinal axes are substantially parallel. In a preferred embodiment, the crop engaging element further comprises a rear wall, wherein said trailing mounting flange is provided with at least one (and preferably two) gussets extending between said trailing mounting flange and said rear wall. Preferably, said rear wall is open forming a rectangular frame.
[0010] In another preferred embodiment, the invention is a crop engaging element for the rotor of a rotary combine, said crop engaging element comprising: a hollow structure having a ramp portion terminating in a flat top portion that is provided with a rasp bar, said rasp bar comprising a base having a curved convex top surface and a plurality of fins (preferably nine) extending from said surface, each of said plurality of fins having a fin longitudinal axis; and a leading mounting flange and a trailing mounting flange extend from the hollow structure for mounting the crop engaging element to a rotor, wherein one of said mounting flanges (preferably the leading mounting flange) is provided with a first mounting aperture and the other of said mounting flanges (preferably the trailing mounting flange) is provided with a second mounting aperture (preferably a slot) through which mounting bolts are passed to mount the crop engaging element on the rotor.
[0011] In yet another preferred embodiment, the invention is a crop processing rotor for a rotary agricultural combine or a rotary pharmaceutical combine, said crop processing rotor comprising: a cylindrical drum; and a plurality of crop processing elements mounted to said cylindrical drum, each of said crop processing elements comprise a crop engaging disclosed herein.
[0012] In a further preferred embodiment, the invention is a rotary agricultural or pharmaceutical combine comprising: a concave; and a crop processing rotor disclosed herein, said crop processing rotor being rotatably mounted in said concave.
[0013] In another preferred embodiment, the invention is a method for improving the ability of a rotary combine to gently thresh a crop and to gently convey the crop through the threshing section of the rotary combine, said method comprising: introducing the crop to the threshing section of the rotary combine; and rotating within said threshing section a rotor upon which are mounted a plurality of crop engaging elements (preferably in a helical pattern), each said crop engaging element comprising a single, unitary, hollow structure having a ramp portion terminating in a flat top portion that is provided with at least one hole, a rasp bar comprising a base having a flat bottom surface and a curved convex top surface and a plurality of fins extending from said top surface, and said base being provided with at least one mounting hole through which a threaded fastener is passed to mount said rasp bar to said hollow structure, and a leading mounting flange and a trailing mounting flange that extend from the hollow structure for mounting the crop engaging element to the rotor, wherein one of said mounting flanges is provided with at least one circular mounting aperture and the other of said mounting flanges is provided with at least one mounting aperture in the form of a slot through which mounting bolts are passed to mount the crop engaging element on the rotor.
[0014] In another preferred embodiment, the invention is a method for improving the ability of a rotary combine to gently thresh a crop and to gently convey the crop through the threshing section of the rotary combine, said method comprising: introducing the crop to the threshing section of the rotary combine; and rotating within said threshing section a rotor upon which are mounted a plurality of crop processing elements, each said crop engaging element comprising a crop engaging element disclosed herein.
[0015] In another preferred embodiment, the invention is a crop engaging element for the rotor of a rotary combine, the rotor having a plurality of radial planes, said crop engaging element comprising: a hollow structure having a ramp portion terminating in a top portion; a rasp bar that is attached to said top portion, said rasp bar comprising a base having a curved convex top surface and a plurality of fins extending from said surface, each of said plurality of fins having a fin longitudinal axis; whereas said fin longitudinal axes are substantially parallel to one another and are oriented at an angle relative to one of the radial planes of rotation, said angle being in the range of about forty-one to about fifty-nine degrees or in the range of about sixty-one degrees to about eighty-nine degrees. Preferably, said angle is about fifty degrees. Preferably, said angle is about seventy degrees. Preferably, said angle is in the range of about forty-two degrees to about fifty-eight degrees. Preferably, said angle is in the range of about sixty-two degrees to about eighty-eight degrees.
[0016] In yet another preferred embodiment, the invention is a crop engaging element for the rotor of a rotary combine, the rotor having a plurality of radial planes, said crop engaging element comprising: a rasp bar mount that is attached to the rotor, said rasp bar mount having a ramp portion and a rasp bar portion, said rasp bar having a plurality of fins, each of said fins having a longitudinal fin axis, each longitudinal axis being disposed at an angle relative to one of said radial planes; wherein said angle is in the range of about forty-two degrees to about fifty-eight degrees or about sixty-two degrees to about eighty-eight degrees. Preferably, said angle is about fifty degrees. Preferably, said angle is about seventy degrees. Preferably, said rasp bar mount and said rasp bar portion make up a single, unitary cast metal structure.
[0017] Further aspects of the invention will become apparent from consideration of the drawings and the ensuing description of preferred embodiments of the invention. A person skilled in the art will realize that other embodiments of the invention are possible and that the details of the invention can be modified in a number of respects, all without departing from the concept. Thus, the following drawings and description are to be regarded as illustrative in nature and not restrictive.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0018] The features of the invention will be better understood by reference to the accompanying drawings which illustrate presently preferred embodiments of the invention. In the drawings:
[0019] FIG. 1 is a schematic elevation view of a rotary agricultural or pharmaceutical combine in accordance with a preferred embodiment of the present invention.
[0020] FIG. 2 is an elevation view of a rotor of an axial crop processing unit in accordance with a preferred embodiment of the present invention with the rotor housing shown partially cut away.
[0021] FIG. 3 is a cross-sectional view of the threshing section of an axial crop processing unit in accordance with a preferred embodiment of the present invention.
[0022] FIG. 4 is an elevation view of a first portion of a crop engaging element in accordance with a preferred embodiment of the present invention.
[0023] FIG. 5 is a plan view of a first portion of a crop engaging element in accordance with a preferred embodiment of the present invention.
[0024] FIG. 6 is a cross-sectional view of a first portion of a crop engaging element in accordance with a preferred embodiment of the present invention.
[0025] FIG. 7 is a plan view of a second portion of a crop engaging element in accordance with a preferred embodiment of the present invention.
[0026] FIG. 8 is a cross-section view of the second portion of a crop engaging element in accordance with a preferred embodiment of the present invention.
[0027] FIG. 9 is a cross-section view of three of the fins of the second portion of a crop engaging element in accordance with a preferred embodiment of the present invention.
[0028] FIG. 10 is an elevation view of a crop engaging element in accordance with a preferred embodiment of the present invention.
[0029] The following reference numerals are used to indicate the parts and environment of the invention on the drawings:
10 rotary agricultural or pharmaceutical combine, rotary combine, combine 12 supporting structure 14 wheels 16 harvesting platform 18 feeder house 20 crop beater 22 inlet transition section 24 axial crop processing unit, crop processing unit 26 cleaning system 28 clean grain tank 30 unloading auger 32 outlet 34 discharge beater 36 operator's cab 38 rotor housing, housing 39 rotor 42 helical blades 44 separator tines 46 concave 50 crop engaging elements, threshing elements 74 cage vanes 76 first portion, mounting bracket, rasp bar mount 80 structure 82 ramp portion 84 top portion 85 threaded hole 86 leading mounting flange 88 trailing mounting flange 89 plane of rotation 90 circular mounting aperture 92 slot 94 rear wall 96 gusset 98 rectangular frame 100 second portion, rasp bar 102 base 104 fins 105 fin longitudinal axis 106 bottom surface 108 top surface 110 mounting hole 112 radial plane
DETAILED DESCRIPTION OF THE INVENTION
[0072] Referring to FIG. 1 , a preferred embodiment of rotary agricultural or pharmaceutical combine 10 is presented. Agricultural or pharmaceutical combine 10 comprises supporting structure 12 having ground engaging wheels 14 . In this embodiment, harvesting platform 16 harvests a crop and directs it to feeder house 18 . The harvested crop is directed by feeder house 18 to crop beater 20 . Crop beater 20 directs the crop upwardly through inlet transition section 22 to axial crop processing unit 24 .
[0073] Axial crop processing unit 24 threshes and separates the harvested crop material. Grain and chaff fall through concaves and grates on the bottom of axial crop processing unit 24 into cleaning system 26 . Cleaning system 26 removes the chaff and directs the clean grain to a clean grain elevator (not shown). The clean grain elevator deposits the clean grain in grain tank 28 . The clean grain in the tank can be unloaded into a grain cart or truck by unloading auger 30 .
[0074] Threshed and separated straw is discharged from axial crop processing unit 24 through outlet 32 to discharge beater 34 . Discharge beater 34 in turn propels the straw out the rear of combine 10 . The operation of combine 10 is controlled from operator's cab 36 .
[0075] Referring to FIG. 2 , axial crop processing unit 24 preferably comprises rotor housing 38 and rotor 39 located inside rotor housing 38 . The front part of rotor 39 and rotor housing 38 define the infeed section of the crop processing unit. In this section, rotor 39 is preferably provided with a drum having helical blades 42 for engaging crop material that is discharged from crop beater 20 . Immediately downstream from the infeed section is the threshing section of crop processing unit 24 . In the threshing section, rotor 39 preferably comprises a cylindrical drum upon which a plurality of crop engaging elements 50 are mounted, preferably in multiple helical paths. Immediately downstream of the threshing section is the separating section of crop processing unit 24 . In the separating section, a plurality of separator tines 44 are preferably mounted on the cylindrical drum. Preferably, cage vanes are mounted on the top of rotor housing 38 , preferably in multiple helical paths.
[0076] Referring to FIG. 3 , a preferred embodiment of the threshing section of crop processing unit 24 is illustrated. Crop processing elements 50 are shown mounted on rotor 39 . Preferably, cage vanes 74 are mounted on the top of rotor housing 38 , preferably in multiple helical paths. Concave 46 is mounted below rotor 39 . Radial plane 112 of rotor 39 is illustrated.
[0077] Referring to FIG. 4 , a preferred embodiment of first portion 76 of crop engaging element 50 is presented in a side view. In this embodiment, structure 80 of crop engaging element 50 is hollow and comprises ramp portion 82 and top portion 84 that is preferably flat and provided with at least one threaded hole 85 . Leading mounting flange 86 forms the structure leading edge of structure 80 . Trailing mounting flange 88 forms the structure trailing edge of structure 80 . At least one of mounting flanges 86 or 88 is provided with at least one circular mounting aperture 90 and the other of said mounting flanges 86 or 88 is provided with at least one mounting aperture in the form of slot 92 through which mounting bolts (not shown) are passed to mount each of the crop engaging elements 50 on rotor 39 . In this embodiment, structure 80 comprises rear wall 94 and trailing mounting flange 88 is provided with at least one gusset 96 extending between trailing mounting flange 88 and rear wall 94 .
[0078] Referring to FIG. 5 , a preferred embodiment of first portion 76 of crop engaging element 50 is presented in a top view. In this embodiment, two circular mounting apertures 90 , two slots 92 , two threaded holes 85 and two gussets 96 are provided. Preferably, the centers of one of the pairs of circular mounting apertures 90 , slots 92 and threaded holes 85 lie in plane of rotation 89 of rotor 39 when each crop engaging element 50 is mounted on rotor 39 .
[0079] Referring to FIG. 6 , a cross-sectional view of a preferred embodiment of first portion 76 of crop engaging element 50 is presented. In this embodiment, rear wall 94 is open, forming rectangular frame 98 . In this view, the leading edge of crop engaging element 50 is on the right and the trailing edge of crop engaging element 50 is on the left.
[0080] Referring to FIG. 7 , second portion or rasp bar 100 of a preferred embodiment of crop engaging element 50 is shown in plan. In this view, the leading edge of rasp bar 100 is on the top and the trailing edge of rasp bar 100 is on the bottom. In this embodiment, rasp bar 100 preferably comprises base 102 and plurality of fins 104 extending from top surface 108 . When installed, each rasp bar 100 preferably has plane of rotation 89 that is perpendicular to radial plane 112 . Each of the fins 104 preferably has fin longitudinal axis 105 .
[0081] In a preferred embodiment, each fin longitudinal axis 105 is oriented at angle A of about 70 degrees relative to radial plane 112 of rotor 39 when each crop engaging element 50 is mounted on rotor 39 . In another preferred embodiment, angle A is in the range of about sixty-one degrees to about eighty-nine degrees. In another preferred embodiment, angle A is about fifty degrees plus or minus about eight degrees. In another preferred embodiment, angle A is about seventy degrees plus or minus about eight degrees. Base 102 is preferably provided with at least one (and preferably two) mounting holes 1 10 through which a threaded fastener, e.g., a bolt, (not shown) is passed to mount rasp bar 100 on structure 80 .
[0082] Referring to FIGS. 8 and 9 , portions of rasp bar 100 of crop engaging element 50 is shown in cross section. The leading edge of rasp bar 100 is on the left and the trailing edge is on the right in FIG. 8 . In this embodiment, base 102 has flat bottom surface 106 and curved convex top surface 108 . Fins 104 extend from bottom surface 106 . Both base 102 and fins 104 preferably have smooth surfaces and rounded edges. Preferably, structure 80 and rasp bar 100 are fabricated of cast metal.
[0083] Referring to FIG. 10 , first portion 76 and second portion or rasp bar 100 of a preferred embodiment of crop engaging element 50 are shown assembled. In this embodiment, two bolts (not shown) are used to fasten second portion 100 to first portion 76 . As is the case in FIG. 6 , in this view, the leading edge of crop engaging element 50 is on the right and the trailing edge of crop engaging element 50 is on the left.
[0084] In the preferred embodiments described above, crop engaging element 50 does not have the concave trough or the radially extending lip of the crop engaging assembly disclosed in U.S. Pat. No. 5,688,170 (see FIG. 4 of that patent) and the crop engaging element disclosed in U.S. Pat. No. 6,036,598 (see FIGS. 2-4 of that patent), the disclosures of which patents are incorporated by reference as if fully set forth herein. The crop processing unit disclosed herein is an improvement in part because it imposes much lower shearing forces on the crop that it processes, resulting in much less straw breakage. Moreover, in the preferred embodiments disclosed above, crop processing element 50 has utility in axial crop processing units other than those in which the axis of threshing section is offset from the axes of the other sections as is claimed in U.S. Pat. No. 5,688,170. For example, the applicant believes that crop processing element 50 also has utility as a component of other axial flow harvesting machines, including those disclosed in U.S. Pat. Nos. 4,889,517; 4,964,838 and 5,192,245, the disclosures of which patents are incorporated by reference as if fully set forth herein, as a replacement for the rasp bar/rasp bar mounts assemblies disclosed therein. Furthermore, in the preferred embodiments described above, rasp bar 100 does not have first portion of U.S. Pat. No. 5,192,245, the disclosure of which patent is incorporated by reference as if fully set forth herein, because ramp portion 82 serves a similar purpose.
[0085] In an alternate embodiment, rasp bar 100 is cast as part of mounting bracket 76 . In this embodiment, rasp bar 100 and mounting bracket are a cast metal, one piece structure.
[0086] Many variations of the invention will occur to those skilled in the art. Some variations include a two-part crop engaging element. Other variations call for a single part crop engaging element. All such variations are intended to be within the scope and spirit of the invention.
[0087] Although some embodiments are shown to include certain features, the applicant(s) specifically contemplate that any feature disclosed herein may be used together or in combination with any other feature on any embodiment of the invention. It is also contemplated that any feature may be specifically excluded from any embodiment of the invention. | An apparatus and method for improving the ability of a rotary combine to gently thresh a crop and to gently convey the crop through the threshing section of the combine. In a preferred embodiment, the invention is a crop engaging element for the rotor of a rotary combine, said crop engaging element comprising: a mounting structure having a ramp portion terminating in a top portion; a rasp bar comprising a base having a bottom surface and a curved convex top surface and a plurality of fins extending from said top surface; a leading mounting flange and a trailing mounting flange that extend from the mounting structure for mounting the crop engaging element to the rotor. | 0 |
BACKGROUND
The present invention relates generally to laser resonators, and more particularly, to an improved dual cavity laser resonator having multiple operating modes.
Multi-functionality is typically a requirement for low-cost laser sensors. Multi-functionality many times involves physically opposing laser requirements that are typically solved by compromising performance in any one function. It would be desirable to have a single laser that may be optimized to provide multiple functions.
More particularly, new laser sensors, such as those used in military systems, for example, require multiple-functionality from the laser transmitters used therein to reduce the size, weight, and cost of the sensors. When the requirements have physically opposing characteristics, one may take a compromising approach and not meet all relevant requirements, or use separate lasers optimized for each mode of operation. The first approach typically does not meet customers' desires and/or requirements, and the second approach involves a design of a laser that is double the cost and size. It would therefore be desirable to have a single laser that can meet multi-functional requirements using a single laser transmitter.
Particularly, it would be beneficial to have a single laser resonator that provides one set of operating modes that provides low repetition rates (5-20 Hz), high energy per pulse, and long, pulse-width, and a second set of operating modes that provides high repetition rates (100-2000 Hz), low energy per pulse, and short pulsewidth. Accordingly, it would be advantageous to have an improved dual cavity multi-functional laser resonator that meets these diverse requirements.
SUMMARY OF THE INVENTION
The present invention provides for an innovative approach that implements a dual-cavity resonator that allows for a single laser to be optimized for multiple functions (operating modes). The dual-cavity resonator provides a first set of operating modes that exhibits low repetition rates (5-20 Hz), high energy per pulse, and long, pulse-width, and a second set of operating modes that exhibits high repetition rates (100-2000 Hz), low energy per pulse, and short pulse-width. The multi-cavity resonator is an elegant compact and inexpensive solution to implement such multi-functionality. Using the present invention, multi-functional requirements may be met using a single laser transmitter. The present invention may be advantageously employed in laser systems that require multi-mode operation.
In one embodiment, the dual cavity laser resonator comprises a diode-pumped slab laser, and first and second cavities that are selectively made operational by a spoiler. An electro-optical Q-switch and an output coupler are common to both cavities.
In another embodiment, the dual cavity laser resonator comprises a diode-pumped slab laser, first and second cavities, and a spoiler that selectively inhibits lasing in the selected cavity. The first cavity has a relatively long cavity length and comprises an electro-optical Q-switch and an output coupler. The second cavity has a relatively short cavity length and comprises a passive Q-switch and a partial reflector. The spoiler is selectively disposed in one of the cavities to inhibit lasing in the selected cavity. This embodiment does not require the spoiler to be critically aligned.
BRIEF DESCRIPTION OF THE DRAWINGS
The various features and advantages of the present invention may be more readily understood with reference to the following detailed description taken in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which:
FIG. 1 illustrates a first exemplary embodiment of a dual cavity laser in accordance with the principles of the present invention; and
FIG. 2 illustrates a second exemplary embodiment of a dual cavity laser in accordance with the principles of the present invention.
DETAILED DESCRIPTION
Referring to the drawing figures, FIG. 1 illustrates a first exemplary embodiment of a dual cavity laser 10 , or laser resonator 10 , in accordance with the principles of the present invention. In particular, FIG. 1 shows a dual cavity Nd:YAG slab laser 20 employing a flip in/out rotatable mirror 23 . The dual cavity slab laser 20 comprises two resonators 10 a , 10 b that share a common gain medium 22 , but have different bounce patterns. The operational lasing resonator 10 a , 10 b (or cavity 10 a , 10 b ) is selected by inhibiting the non-lasing resonator 10 b , 10 a using the rotatable mirror 23 .
Implementations of the dual cavity laser 10 are described in detail below using specific operating parameters, but it is to be understood that the present invention is not limited to these specific operating parameters. In order to produce a laser transmitter capable of generating up to 100 mJ pulses at 10 to 20 Hz with long pulse-widths (15-20 ns) and 40 mJ at 100 Hz with short pulsewidth (<8 ns, for example), the present invention comprises a diode-pumped slab laser 20 along with an output coupler 13 . The approach of the present invention extends existing single cavity resonator technology to provide a dual cavity resonator 10 , which allows the generation of either short (5-8 ns) low energy or long (15-20 ns) high energy pulses, depending on the chosen mode of operation.
FIG. 1 illustrates a first exemplary embodiment of a dual cavity laser 10 in accordance with the principles of the present invention. The dual cavity laser 10 comprises a diode-pumped, slab laser 20 . The diode-pumped, slab laser 20 comprises a diode pumped gain medium 20 that is common to both resonators 10 a , 10 b . The gain medium 22 may comprise a Nd:YAG gain medium 22 . A plurality of pump diodes 24 are provided to pump light into the gain medium 22 .
The first embodiment of the dual cavity laser 10 comprises a rear high reflectance reflector 11 (HR) disposed at a first end thereof. An electro-optical Q-switch 12 and an output coupler 13 are disposed between the rear high reflectance reflector 11 and the gain medium 22 . Pulse control electronics 30 are coupled to the diode stack 24 and the electro-optical Q-switch 12 . The pulse repetition rate is controlled by the diode-pumping rate and the timing of the electro-optical Q-switch 12 .
A long pulsewidth high energy cavity 10 a comprises one or more high reflectance reflectors 11 disposed on the opposite side of the gain medium 22 from the electro-optical Q-switch 12 adjacent a second end of the high energy cavity 10 a . A short pulsewidth, low energy/pulse, high repetition rate cavity 10 b comprises a single high reflectance reflector 11 disposed on the opposite side of the gain medium 22 from the electro-optical Q-switch 12 at the second end of the cavity 10 b.
The optical switch 23 or flip in/out rotatable mirror 23 is disposed in the optical paths of the cavities 10 a , 10 b . If the optical switch 23 or flip in/out rotatable mirror 23 is rotated out of the optical path, the short pulsewidth, low energy/pulse, high repetition rate cavity 10 b is energized. If the flip in/out rotatable mirror 23 is rotated into the optical path, the long pulsewidth high energy cavity 10 a is energized. Rotation is illustrated by the dashed arrow.
As is shown in FIG. 1, both cavities 10 a , 10 b share the rear high reflectance reflector 11 , electro-optical Q-switch 12 , and Nd:YAG slab gain medium 22 . If short pulse operation is desired, the optical switch 23 or rotatable mirror 23 is rotated out of the optical path, which causes laser light to propagate between the rear high reflectance reflector 11 and the high reflectance reflector II at the opposite end of the short pulsewidth, low energy/pulse, high repetition rate cavity 10 b . The short pulsewidth, low energy/pulse, high repetition rate laser beam is reflected off the output coupler 13 as a short pulsewidth, low energy, high repetition rate output beam. The resulting, 5-8 ns, 1.06 μm pulse may be used to pump a nonlinear crystal, such as a KTA OPO or other crystal, for example, to provide 1.5 μm short pulse generation.
For long pulse generation (15-20 ns), the long pulsewidth high energy cavity 10 a is used to provide a longer cavity length. If long pulse operation is desired, the optical switch 23 or rotatable mirror 23 is rotated into the optical path, which causes laser light to propagate between the rear high reflectance reflector 11 and the high reflectance reflector 11 at the opposite end of the long pulsewidth high energy cavity 10 a . The long pulsewidth high energy laser beam is reflected off the output coupler 13 as an long pulsewidth high energy output beam.
One drawback of the simple approach shown in FIG. 1 is that optical switch 23 or rotatable mirror 23 when in the “on” position (long resonator mode as implemented in FIG. 1) must be critically aligned to the optical axis of the laser 10 . In other words, the final resting angle of the optical switch 23 or rotatable mirror 23 determines the direction of the laser beam out of the laser 10 .
Another implementation is one that does not require the optical switch 23 or rotatable mirror 23 to be critically aligned. One approach that achieves this is shown in FIG. 2, and is shown using specific numbers of components, but is not limited to the specific configuration that is shown.
Referring now to FIG. 2 it illustrates a second exemplary embodiment of a dual cavity laser 10 in accordance with the principles of the present invention. In the dual cavity laser 10 shown in FIG. 2, each cavity 10 a , 10 b has its own Q-switch 12 , 14 . In the exemplary dual cavity laser 10 of FIG. 2, an electro-optical Q-switch 12 is used for the long pulsewidth high energy cavity 10 a , and a passive Q-switch 14 is used for the short pulsewidth, low energy/pulse, high repetition rate cavity 10 b . In the second embodiment of the dual cavity slab laser 10 , except for the gain medium 22 , the two cavities 10 a , 10 b do not share optical components.
More particularly, the long pulsewidth high energy cavity 10 a of the second embodiment of the dual cavity slab laser 10 comprises high reflectance reflectors 11 at each end of the high energy cavity 10 a . An electro-optical Q-switch 12 is disposed adjacent one of the rear high reflectance reflectors 11 . An output coupler 13 is disposed between the electro-optical Q-switch 12 and the gain medium 22 . The gain medium 22 has a plurality of pump diodes 24 (diode stack 24 ) that couple pump light into the gain medium 22 . Pulse control electronics 30 are coupled to the diode stack 24 and electro-optical Q-switch 12 . The pulse control electronics 30 functions described in the discussion of FIG. 1 .
One or more high reflectance reflectors 11 is used on the opposite side of the gain medium 22 adjacent a second end of the long pulsewidth high energy cavity 10 a to create a relatively long resonator path for the laser light produced by the long pulsewidth high energy cavity 10 a . A flip in/out spoiler 25 is selectively disposed in the long pulsewidth high energy cavity 10 a in order to selectively inhibit lasing in the long cavity 10 a.
The short pulsewidth, low energy/pulse, high repetition rate cavity 10 b is comprised of a high reflectance reflector 11 at one end and a partial reflector (PR) 26 at the other end of the cavity 10 b . The output from the short pulsewidth, low energy/pulse, high repetition rate cavity 10 b is provided by the partial reflector 26 . A passive Q-switch 14 is disposed between the high reflectance reflector 11 and the gain medium 22 . The flip in/out spoiler 25 is selectively disposed in the short pulsewidth, low energy/pulse, high repetition rate cavity 10 b in order to selectively inhibit lasing in the short cavity 10 b.
The primary advantage of using two cavities 10 a , 10 b is that each cavity 10 a , 10 b can be optimized for its specific mission. In particular, the temporal and transverse spatial profile (diameter) of the beam derived from the short cavity 10 b can be tailored (as flat-topped as possible) for the purpose of efficiently pumping the nonlinear crystal, such as a KTA OPO or other crystal, for example, without having the additional burden of serving as a high quality, long pulse used for designation. After conversion to 1.5 μm, the beam may be combined with the 1.06 m beam using a dichroic element for collinear output.
An electronically controlled shutter may be used as the flip in/out spoiler 25 to inhibit (spoil) either the short or long cavity 10 b , 10 a , depending on the choice of operating mode. Pulse control electronics for the diode stack 24 and electro-optical Q-switch 12 will dictate the output pulse formats for each mode of operation while maintaining constant heat load to the slab gain medium 22 so that vertical lensing in the slab gain medium 22 is invariant in all operating modes, regardless of average power requirements.
Thus, improved dual cavity multi-functional laser resonators have been disclosed. It is to be understood that the described embodiments are merely illustrative of some of the many specific embodiments that represent applications of the principles of the present invention. Clearly, numerous and other arrangements can be readily devised by those skilled in the art without departing from the scope of the invention. | Dual-cavity resonators that may be optimized for multiple functions (operating modes). The dual-cavity resonators provide a first set of operating modes that exhibits low repetition rates (5-20 Hz), high energy per pulse, and long, pulse-width, and a second set of operating modes that exhibits high repetition rates (100-2000 Hz), low energy per pulse, and short pulse-width. | 7 |
BACKGROUND OF THE INVENTION
The present invention relates generally to convenient tool storage and more particularly, this invention pertains to a socket holder with a quick release feature.
Several United States Patents are directed to various storage assistance devices for sockets. These include: U.S. Pat. No. 1,712,473, issued to McWethy on Aug. 18, 1927; U.S. Pat. No. 5,228,570, issued to Robinson on May 11, 1992; U.S. Pat. No. 5,467,874, issued to Whitaker on Jan. 10, 1995; U.S. Pat. No. 5,501,342, issued to Geibel on Jun. 26, 1995; U.S. Pat. No. 6,032,797, issued to Kao on Feb. 26, 1999; U.S. Pat. No. 6,070,745, issued to Dembicks on Jan. 21, 1998; U.S. Pat. No. 6,092,655, issued to Ernst on May 10, 1999; and U.S. Pat. No. 6,168,018, issued to Ramsey et al. on Sep. 20, 1999. Each of these patents is hereby incorporated by reference.
U.S. Pat. No. 1,712,473 teaches a holder for a set of sockets comprising a bar to which a plurality of posts are attached. Each post has a transverse opening in which two balls and a spring are mounted such that the balls slightly protrude from each side of the opening. When a socket is forced over the post, the balls are forced inward slightly so that the expansion of the spring grips the socket firmly. The '473 Patent does not address the problem of easily removing a socket from a post without exerting force.
U.S. Pat. No. 5,228,570 teaches an improved wrench socket storage rack which not only enables the organization of socket sets by dimensional graduations, but also includes means providing instantaneous socket release from the wrench socket storage rack with the touch of a fingertip on a release button. A ball locks into an indentation on the inside of a socket. The release button is on the underneath of the rack. When it is pushed, the ball retracts into a cavity in the pin and allows the socket to slide off the post. This requires that the underside of the rack be available to access the button.
U.S. Pat. No. 5,467,874 teaches an improved socket holder which provides a positive means of attachment and retention of all socket tools while allowing of a simple mechanical maneuver to readily release the socket from the holder. This device includes a ball and recess in the post. When rotated a quarter-turn, the ball retreats into the recess and allows a socket to slide on and off easily. The holding force is limited by the strength of the spring pressing against the ball.
U.S. Pat. No. 6,070,745 teaches a holder system for interchangeable sockets which prevents the sockets from being removed from a rack when the holder system is being used to display the sockets for sale. The system comprises a lock which is inserted in the cavity of the socket to hold it in place.
U.S. Pat. No. 6,092,655 teaches a wrench socket holder having a boss on a resilient member which holds sockets on a socket holder. The '655 Patent does not teach a means of removing a socket other than by force.
The remaining patents show alternative designs known in the art.
What is needed, then, is a socket holder to provide improved strength holding power while providing an easy release action for the socket to holder connection.
SUMMARY OF THE INVENTION
The novelty of the invention is an improved apparatus and method to store sockets. The base of the invention comprises a head including an outer shell with an internal ball for holding the socket. When a socket is placed on the head, the ball maintains a snug grip on the socket by pressing against the sidewall or pressing into the indentation in the socket. To remove the socket, the head is rotated a quarter-turn, causing the ball to recess into the head and allowing the socket to slide easily off the head. This allows a user to remove a socket using only one hand.
A major improvement of this invention is the increased holding power for maintaining a socket in position on the head when the head is inserted into the socket base. The head forms an outer shell with a vertical opening in which a ball is partially recessed and held in place against an internal pin by a spring. The internal pin has a cone shaped body. The ball is held in position between coils of the spring such that it is biased in an extended position in relation to the head. The cone shaped internal pin and the internal wall of the socket base form a wedge such that once the head is inserted into the socket base, the application of a removal force to the socket wedges the ball between the internal wall of the socket base and the internal pin of the socket holder increases the holding power as the removal force is increased.
To overcome the improved holding force of the present invention, a flat or reduced curvature face is formed on the internal pin of the head to allow for the ball to recess within the head for removal of the socket. The ball is rotatably positioned between an increased diameter section and a reduced diameter section of the pin by rotation of the outer shell in relation to the internal pin. The rotation of the outer shell is improved in the present invention by biasing the relationship of the outer shell and the internal pin into a holding position such that it automatically returns to the holding position once the rotational force is removed.
The holding position is also improved by allowing insertion of a socket onto the head while the head is in the holding position. This only requires a pressing force of the socket onto the head. The conical section of the internal pin allows the ball to be pressed down against the spring and recessed into the outer shell until the socket has sufficient clearance to be mounted on the head. This allows the easy connection of the socket onto the head by a pressing force against the head and allows for variations in the clearances of the socket recesses while still maintaining improved holding power for the socket holder.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of the socket holder.
FIG. 2 is an exploded view of the components of the socket holder.
FIGS. 3A, 3 B, and 3 C show a cutaway view of the action of pressing a socket onto the socket holder head.
FIGS. 4A and 4B show a cutaway view of the action of the recessing of the ball on the flat portion of the internal pin and extending the ball on the conical portion of the pin.
FIGS. 5A, 5 B, and 5 C show a cutaway view of the retraction of the ball following the shape of the internal pin when the outer shell is rotated.
FIG. 6 is an isometric view of the outer shell.
FIG. 7 is a top view of the outer shell.
FIG. 8 is a left side view of the outer shell.
FIG. 9 is a front view of the outer shell.
FIG. 10 is a right side view of the outer shell.
FIG. 11 is a back side view of the outer shell.
FIG. 12 is a bottom view of the outer shell.
FIG. 13 is a top view of the internal pin.
FIG. 14 is a left side view of the internal pin.
FIG. 15 is a front view of the internal pin.
FIG. 16 is a right side view of the internal pin.
FIG. 17 is a back side view of the internal pin.
FIG. 18 is a bottom view of the internal pin.
FIG. 19 is an isometric view of the outer shell.
FIG. 20 is a top view of the rack base.
FIG. 21 is a left side view of the rack base.
FIG. 22 is a front view of the rack base.
FIG. 23 is a right side view of the rack base.
FIG. 24 is a back side view of the rack base.
FIG. 25 is a bottom view of the rack base.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 of the drawing shows an assembled socket head 10 and FIG. 2 of the drawings shows and exploded view of the socket head 10 . The socket head 10 includes an outer shell 14 mounted by an internal pin 12 on a base 20 . The preferred embodiment of the invention shown in the drawings uses a rail base 20 for slideable engagement with a standard socket rail as is well known in the prior art. However, the base 20 may be of any type appropriate for the application.
The base 20 is shown as a rail base 20 with rail ears 22 and a base platform 24 defining a base pin hole 26 , base spring hole 28 , and movement control slot 30 . The rail ears 22 are designed to engage a socket rail as is known in the art. A spring 16 is mounted on the rail base 20 by insertion into the base spring hole 28 . The spring 16 is a coil spring with coils 32 and a lower end 34 and an upper end 36 . The lower end 34 of the spring 16 is inserted into the base spring hole 28 . The ball 18 is placed between two coils 32 of the spring 16 . An outer shell 14 is then inserted over the spring 16 and ball 18 assembly.
The internal pin 12 is then inserted into the pin hollow 44 in the outer shell 14 and extended through the pin opening in the rail base 20 . The pin is then fixed in position to the rail base 20 such that rotation of the outer shell 14 in relation to the rail base 20 also rotates the relative position of the outer shell 14 in relation to the internal pin 12 . In the preferred embodiment, the socket holder is constructed of steel and the pin is welded to the rail base 20 although any type of connection known in the art may be provided. The orientation of the flat portion 46 of the pin in relation to base 20 is important to achieve the advantages of the present invention and will be discussed further herein.
The outer shell 14 defines a limiting finger 38 on the external portion of the shell 14 and an internal central pin hollow 44 with a shell spring hole 42 and a ball opening 40 that are both connected with the central pin hollow 44 . The ball opening 40 extends from the pin hollow 44 through the outer wall 45 of the outer shell 14 such that a portion of the ball 18 can extend outward from the outer shell 14 . This also allows the position of the ball opening 40 to control the position of the ball 18 in the pin hollow 44 . The ball opening 40 is sized such that the ball 18 cannot pass through the ball opening 40 .
The spring 16 is inserted into the pin hollow 44 and the upper end 36 of the spring 16 is inserted into the shell spring hole 42 (shown in FIG. 8 ). The limiting finger 38 of the outer shell 14 is inserted into the movement control slot 30 on the base 20 . In this manner the spring 16 biases the outer shell 14 in relation to the base 20 to a normal position where the ball 18 contacts the conical portion 48 of the internal pin 12 . The outer shell 14 can then be rotated in relation to the base 20 to a rotated position where the ball contacts the flat portion 46 of the internal pin 12 . The extent of the rotation is controlled by the limiting finger 38 and movement limiting slot 30 connection.
The installation of a socket 50 onto the holder is shown in FIGS. 3A, 3 B, and 3 C. The internal pin 12 should be fixed in position on the base such that the conical portion 48 of the internal pin 12 presses against the ball 18 when the outer shell 14 is in its normal position. The normal position is also known as the holding position and will be discussed further herein.
The sequence of FIGS. 3A, 3 B, and 3 C show the installation of a socket 50 onto the holder 10 by using a pressing force 52 pushing the socket 50 onto the holder 10 . The ball 18 is designed to move along the sloping angle of the conical section 48 such that the ball 18 can controllably extend outward from the outer shell 14 . The conical section 48 is smaller in diameter towards the base and larger in diameter towards the top of the pin 12 . As the ball 18 moves upward to the larger diameter section along the conical shape 48 of the internal pin 12 , the distance that the ball 18 extends from the wall 45 of the outer shell 14 is increased. As the ball 18 is moved downward towards the small diameter section along the conical portion 48 of the internal pin 12 , the ball 18 is recessed further into the outer shell 14 to decrease the amount of extension of the ball 18 from the outer shell 14 .
As can be seen in FIGS. 3A, 3 B, and 3 C, the spring 16 biases the ball 18 in the upward direction to press against the top of the ball opening 40 . As a socket 50 is inserted onto the holder 10 , the socket 50 presses down on the ball 18 to compress the spring 16 until the ball 18 is sufficiently recessed to allow the socket 50 to be fully inserted onto the holder 10 . The ball 18 is then wedged by the spring 16 between the conical section 48 of the internal pin 12 and the internal wall 54 of the socket 50 . If an upward force is now applied to the socket 50 in an attempt to remove the socket 50 from the holder 10 , then the ball 18 will be further wedged between the pin 12 and the socket wall 54 such that an additional wedging force is created between the internal pin 12 and the socket wall 54 . In this manner, the socket 50 is secured onto the holder 10 with a design that increases holding power as the removal force is increased. This allows for the holder 10 to maintain the position of the socket 50 on the holder 10 with an improved retention ability over prior art designs. The ball may also extend into an internal depression 51 on the socket 50 for additional holding power.
FIGS. 4A and 4B of the drawings show the removal of the socket 50 from the holder 10 using the flat portion 46 of the internal pin 12 . The flat portion 46 does not actually have be flat, but can be made with a reduced curvature to reduce the diameter of the pin 12 to the proper clearance. However, the preferred embodiment uses the flat portion 46 discussed herein. We viewed in a cross sectional view, the conical section 48 has an increased curvature when compared against the flat section 46 . Additional reference may be had to FIG. 5A which shows the outer shell 14 in the normal or holding position 60 in relation to the internal pin 12 such that the ball 18 is against the conical portion 48 of the internal pin 12 , FIG. 5B which shows a partial rotation of the outer shell 14 in relation to the internal pin 12 , and FIG. 5C which shows the rotated position 62 of the outer shell 14 with the ball 18 positioned against the flat portion 46 of the internal pin 12 . Thus, the ball 18 will be against the conical section 48 of the internal pin 12 when the socket holder 10 is in the normal holding position 60 and the ball 18 will be against the flat portion 46 of the pin when the socket holder 10 is in its rotated removal position 62 . This controls the ability of the ball 18 to be recessed into the pin hollow 44 for easy removal of the socket 50 . Note that the prior art teaches a sharp edge on the transition between a flat and arcuate section of a cam element. This invention provides a further improvement to that design by using a radius 64 between the flat portion 46 and the conical section 48 of the preferred design of the socket holder 10 to improve the smoothness of the action of the holder 10 between the holding position 60 and the removal position 62 .
FIGS. 6 through 12 show the various views of the outer shell 14 of the socket holder 10 . The outer shell 14 is an elongated cube with an internal pin hollow 44 formed by drilling a bore from the bottom 70 of the elongated cube. A smaller top opening 72 is then formed by boring through the top 74 of the outer shell 14 . This construction provides for a pin hollow 44 while still allowing a top 74 that may be contacted by a shoulder 80 on the internal pin 12 to retain the outer shell 14 .
The outer shell 14 also includes a shell spring hole 42 for connection of the upper end 36 of the spring 16 . The upper end 36 of the spring 16 is inserted into this shell spring hole 42 to bias the outer shell 14 in relation to the base 20 . The outer shell 14 also defines a limiting finger 38 on the external portion of the shell 14 . The limiting finger 38 of the outer shell 14 is inserted into the movement control slot 30 on the base 20 . This limits the rotational movement of the outer shell 14 in relation to the base 20 so that excessive rotation is not applied to the spring 16 and also provides a positive stop for the rotational movement to define both the rotated position 62 and the normal position 60 .
As may be seen in FIG. 6 and as shown by the dashed outline of the ball opening 40 and ball 18 shown in FIG. 12, the ball opening 40 is provided with angled sides 41 such that the ball 18 may extend outward from the front wall 45 of the outer shell 14 while still maintaining an appropriate thickness for the remaining walls 45 of the outer shell 14 . This may also be partially achieved by reducing the distance between the bore of the pin hollow 44 and the edge of the outer shell 14 by either moving the bore of the pin hollow 44 off of center or increasing the size of the bore to reduce the wall 45 thickness. For the preferred embodiment, the relieved angled edges 41 of the ball opening 40 are used to maintain an appropriate wall 45 thickness.
FIGS. 13 through 18 show the different views of the internal pin 12 . The internal pin 12 includes a top shoulder 80 and an upper bearing 82 adapted to mate with the top opening 72 of the outer shell 14 . The top shoulder 80 retains the outer shell 14 on the internal pin 12 and the upper bearing surface 82 allows the outer shell 14 to rotate around the internal pin 12 . The conical portion 48 angles in from the bearing surface 82 at approximately a two degree angle to form an upside down cone. The flat portion 46 is also formed at a two degree angle to provide the relief clearance necessary to allow for the ball 18 to recess. The edge 84 between the flat portion 46 and the conical portion 48 is radiused to provide for a smoother action as the ball 18 travels around the surface of the internal pin 12 . A lower shoulder 86 is provided for a fixed insertion depth of the internal pin 12 into the rail base 20 . This allows a controlled amount of clearance for the outer shell 14 to rotate around the internal pin 12 once the pin 12 is fixed to the base 20 . Finally, the internal pin 12 includes a base extension 88 designed to fit into the rail base 20 where it may be welded or otherwise fixed to the rail base 20 .
FIGS. 19 through 25 show the various views of the rail base 20 . The rail base 20 defines the base pin hole 26 , base spring hole 28 , and movement control slot 30 . The base pin hole 26 allows the internal pin 12 to be inserted and fixed in position on the rail base 20 . It is envisioned that the base pin hole 26 can be constructed with a pattern to control the alignment of the internal pin 12 the rail base 20 to properly align the internal pin 12 onto the rail base 20 . The insertion of the outer shell 14 with the limiting finger 38 inserted into the movement control slot 30 will then properly align the outer shell 14 with the internal pin 12 . The base spring hole 26 is used to hold the lower end 34 of the spring 16 in position in relation to the rail base 20 .
The spring 16 functions in two ways to provide biasing for the socket holder 10 . The connection of the spring 16 between the base spring hole 26 on the rail base 20 and the shell spring hole 42 on the outer shell 14 acts to bias the rotational movement of the outer shell 14 on the rail base 20 to the normal position 60 . The spring 16 biases the rotation of the outer shell 14 back to the normal position 60 when the outer shell 14 is rotated on the internal pin 12 . The extent of this movement is controlled by the limiting finger 38 in the movement control slot 30 on the rail base 20 .
The spring 16 also acts to bias the ball 18 upward in the ball 18 slot to press the ball 18 against the socket 50 when it is installed to ensure proper positioning of the ball 18 for the wedge action of the socket holder 10 .
The ball 18 is a simple spherical steel bearing of appropriate size for coordinated movement in the ball 18 slot with the cylindrical portion 48 and flat portion 46 of the internal pin 12 .
Thus, although there have been described particular embodiments of the present invention of a new and useful socket holder with wedge retention and rotational release, it is not intended that such references be construed as limitations upon the scope of this invention except as set forth in the following claims. | A socket holder for providing increased holding power, rotational release, and biased position return. The socket holder including a base with a pin extending from the base. The pin has a conical section with an increasing diameter at the distal end of the pin. The conical section has a reduced curvature side and an increased curvature side such that a ball can be wedged between the increased curvature side and a socket base to hold the socket on the holder. The reduced curvature side allowing the ball to be rotated around the pin to reduce the wedge force between the ball and the socket to release the socket from the holder. A spring is used to both bias the ball against the pin and the socket base and to automatically return the holder to a state of readiness for holding a new socket once a socket is removed from the holder. | 1 |
FIELD
[0001] The disclosure generally relates to the technical area of customer service provided by contact centers, and pertains more particularly to service for customers traveling in aircraft.
BACKGROUND
[0002] An important function of contact centers is providing service for customers of enterprises who host such centers, such as banks, airlines and the like. Customers of the host enterprises who call or message the contact centers are served by one or both of automated systems and connection to and interaction with agents operating on behalf of the center contact centers. Customers may connect to contact centers using a wide variety of communication appliances, and may interact through any known communication system, such as voice calls, either through the Internet network or land-line systems, text messaging, video conferencing, chat sessions, and email.
[0003] As mobile devices, like smart phones and tablet devices, have gained in computing power and memory capacity, and software applications have been provided to enhance communication capability for mobile devices, customers have become capable of interacting with contact centers from just about any place, stationary or in motion. It is quite common, for example, for a customer of an enterprise to use a mobile computing appliance like a smart telephone, enabled for voice and text communication, to interact with a contact center serving that enterprise and its customers. Such devices may operate through cellular telephone networks or, in some cases, directly though the internet where direct Internet connection is available, such as through a WiFi network.
[0004] There are some circumstances, however, where interaction with a contact center may be relatively complicated. One such circumstance is for persons in flight in private or commercial aircraft.
BRIEF SUMMARY
[0005] An aspect of an embodiment of the present invention is directed toward a system for allowing airline passengers to obtain customer service from the airline on which they are passengers.
[0006] According to an embodiment of the present invention there is provided a method including: receiving a transaction request in a contact center at a server having a processor; retrieving, from data accompanying the transaction request: identifying information regarding an originating node for the transaction request; and identity of a sender of the transaction request; comparing the identifying information with stored data associating identifying information with specific aircraft providing on-board Internet service; discovering an association indicating whether the sender of the request is currently transacting as a passenger, having a passenger ID, on a specific aircraft; retrieving further information regarding the passenger if available; retrieving information about the specific aircraft, including at least current flight status; routing the transaction request to an available contact center agent having an agent ID; connecting the passenger in a communication session with the agent; and providing the information regarding the passenger, if any, and the information regarding the specific aircraft for use by the agent during the communication session with the passenger.
[0007] In one embodiment, the transaction request is a chat request, the method further including: engaging the passenger in a chat session with the agent to whom the request is routed.
[0008] In one embodiment, the method includes: retrieving itinerary information regarding the passenger and flight status of aircraft other than the aircraft upon which the passenger is currently traveling as aids to the agent to whom the request is routed, in providing customer service to the passenger.
[0009] In one embodiment, the method includes: determining by the agent through interaction with the passenger, the passenger's desires regarding changes in travel itinerary, and making appropriate alterations based upon the determination.
[0010] In one embodiment, the method includes: composing a record of activity accomplished during the communication session; associating the record with one or more of the passenger ID, the agent ID, and the specific aircraft; and in the event that the communication session is interrupted, storing the activity record for possible resumption of the interrupted communication session.
[0011] In one embodiment, the method includes: receiving a new transaction request; determining from data accompanying the request whether there is a stored activity record of an interrupted communication session associated with the originator of the request; determining the original agent involved in the interrupted communication session; and attempting to route the new request to the original agent; failing to route to the original agent, routing the new request to an available agent.
[0012] In one embodiment, the method includes: resuming the communication session from the stored activity record, and continuing to update the record.
[0013] According to an embodiment of the present invention there is provided a method including: receiving a transaction request in a contact center at a server having a processor; retrieving, from data accompanying the transaction request, the identity of a sender of the transaction request; establishing a communication session between: an agent having an agent ID; and the sender of the transaction request; if the sender of the request is determined from stored information to be a passenger, having a passenger ID, scheduled to board a specific aircraft within a preprogrammed time duration: composing a record of activity accomplished during the communication session; associating the record with one or more of the passenger ID, the agent ID, and the specific aircraft upon which the sender is scheduled to board; and in the event that the communication session is interrupted, storing the activity record for possible resumption of the interrupted communication session.
[0014] In one embodiment, the method includes: receiving a new transaction request identified as originating through a WiFi system on the aircraft the passenger was scheduled to board; determining from data accompanying the request whether there is a stored activity record of an interrupted communication session associated with the originator of the request; determining the original agent involved in the interrupted communication session; attempting to route the new request to the original agent; and failing to route to the original agent, routing the new request to an available agent.
[0015] In one embodiment, the method includes: resuming the communication session from the stored activity record, and continuing to update the record.
[0016] According to an embodiment of the present invention there is provided a apparatus, including: a processor and a memory, the memory storing instructions that, when executed by the processor, cause the processor to: receive a transaction request; retrieve, from data accompanying the transaction request, identifying information regarding an originating node for the transaction request and the identity of a sender of the transaction request; compare the identifying information with stored data associating identifying information with specific aircraft providing on-board Internet service; discover an association indicating the sender of the request is currently transacting as a passenger, having a passenger ID, on a specific aircraft; retrieve further information regarding the passenger if available; retrieve information about the specific aircraft, including at least current flight status; route the transaction request to an available contact center agent having an agent ID; connect the passenger in a communication session with the agent; provide the information regarding the passenger, if any, and the information regarding the specific aircraft for use by the agent during the communication session with the passenger.
[0017] In one embodiment, the instructions, when executed by the processor, further cause the processor to: engage the passenger in a chat session with the agent to whom the request is routed, when the transaction request is a chat request.
[0018] In one embodiment, the apparatus includes causing the processor to: retrieve itinerary information regarding the passenger and flight status of aircraft other than the aircraft upon which the passenger is currently traveling as aids to the agent to whom the request is routed, in providing customer service to the passenger.
[0019] In one embodiment, the instructions, when executed by the processor, further cause the processor to: compose a record of activity accomplished during the communication session; associate the record with one or more of the passenger ID, the agent ID, and the specific aircraft; and in the event that the communication session is interrupted, store the activity record for possible resumption of the interrupted communication session.
[0020] In one embodiment, the instructions, when executed by the processor, further cause the processor to: receive a new transaction request; determine from data accompanying the request whether there is a stored activity record of an interrupted communication session associated with the originator of the request; determine the original agent involved in the interrupted communication session; attempt to route the new request to the original agent; and failing to route to the original agent, route the new request to an available agent.
[0021] In one embodiment, the instructions, when executed by the processor, further cause the processor to: resume the communication session from the stored activity record; and continue to update the record.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is an architectural diagram illustrating a contact center and connectivity to the contact center for a variety of communication appliances.
[0023] FIG. 2 is a diagram illustrating connectivity for persons in flight to contact centers.
[0024] FIG. 3 is a plan view of a portion of a seating plan in an airliner, showing the in-aircraft base station and a few representative wirelessly-enabled appliances.
[0025] FIG. 4 is a flow chart illustrating acts in providing customer service for an airline through chat.
[0026] FIG. 5 is a schematic diagram illustrating connectivity transition situations both ascending and descending according to an embodiment of the present invention.
[0027] FIG. 6 is a flow chart illustrating a transition of communication for a passenger as a plane takes off and ascends to altitude, and eventually descends to landing according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0028] One relatively complicated and under-served circumstance for interactions of customers with contact centers is the circumstance where a customer of an enterprise, on-board, for example, a commercial airline flight, wishes to contact the enterprise and transact business services. A particularly urgent circumstance is the situation where the enterprise is the airline providing the commercial flight.
[0029] At the time of filing the present patent application cellular voice calls from passengers in aircraft are not allowed, so such communication is restricted to communication which may be accomplished in text over data networks, such as the Internet network. This artificial limitation, however, is not a limitation to the present invention, which may be applicable regardless of the mode and protocol of communication from a customer to a contact center. To provide communication services for mobile devices on board aircraft at altitude is relatively more complicated than to provide similar services for the same devices at ground level, partly because the devices in the aircraft at altitude may be far removed from cellular base stations or any service for direct connection to the Internet network. Moreover, the device used by the customer in the aircraft may be moving at a high rate of speed relative to ground stations to which they may connect. To solve this problem some commercial enterprises have introduced systems for connecting in-flight customers with the Internet wherein an aircraft may have an on-board station to connect to mobile devices used by customers on the aircraft, and also to connect to a series of ground stations over which the aircraft may fly, or alternatively to one or more satellites enabled to provide connection to ground-based systems. More detail of such an arrangement is provided below.
[0030] The systems provided by enterprises to airlines to connect passengers on the airline to communication networks are relatively sophisticated, and charges may be higher than for similar services at ground level. In the application of these systems, a customer, who may, for example, be a frequent flyer wishing to connect to the Internet during a flight, may subscribe to a service and pay a monthly fee. One such service is GOGO™. A customer desiring to access the Internet as a passenger on commercial flights that are served by GOGO™ may subscribe to GOGO™ and pay a periodic fee, such as by the month, or may access the service and pay for the connection service for a particular flight, or a particular set of flights.
[0031] Of particular interest is the circumstance in which customers as passengers on a flight of a commercial aircraft may interact with a contact center representing the airline providing the flight. It is well-known that many things might go awry in the planned schedule of a particular commercial flight, such as, for example, late departure, mechanical difficulty, weather delay, and more, which may result in passengers arriving too late to make a connecting flight, or even arriving at a different airport. In these situations there is often a crush of activity after a delayed flight arrives, to book passengers on alternative flights, to make financial adjustments, to book passengers into hotels, and much more. It is often known long before a delayed flight arrives that such amendments in schedules will have to be made, but automatic adjustments do not work, because the passengers may have preferences for accommodations, optional connecting flights, preferences due to different costs for different flights, and so on. To make such adjustments it is necessary for agents of the airline to interact with each passenger affected. Due to the frustration potential of delayed flights and missed connections, particularly the frustration of having to wait in long lines to reschedule after an aircraft has landed, a service that would allow customers as passengers on a flight that has a problem to interact with a contact center providing services for customers of the airline would be a valuable asset for the airline. Passengers could interact with an agent to select connecting flights, accommodations, ground transportation and the like during the flight after it is known that there may be problems.
[0032] FIG. 1 is a diagram illustrating a contact center 115 and a plurality of networks with interconnections whereby customers and remote agents may interact with the contact center. Customers and agents may interact with contact center 115 through communication appliances such as land-line telephones 104 (1-n), IP-enabled devices 108 (1-n), or through mobile appliances 110 , 111 or 112 . In some circumstances interaction may be limited to voice, but in other circumstances interaction my include text interaction, such as, for example, email, messaging services chat, and so on.
[0033] Persons interacting through land-line telephones 104 may connect firstly over trunk lines as shown to a network switch 102 . Switch 102 may interact with hardware and software of a Service Control Point (SCP) 128 , which may execute intelligent operations to determine to connect an incoming call to different ones of possible contact centers or to route an incoming call directly to an agent in a contact center or to an agent operating as a remote agent outside a contact center premises. Incoming calls in some circumstances may also be routed through a gateway 103 into the well-known Internet network 106 as packet-switched calls. The interconnections in the Internet are represented by backbone 121 . In this circumstance such a call may be further processed as a packet-switched IP call. Equipment providing SCP services may also connect to the Internet and may allow SCP functionality to be integrated with Internet-connected servers and intelligence at contact centers.
[0034] A call from a land-line telephone 104 connecting to switch 102 may be routed to contact center 115 via trunk lines as shown to either a land-line switch 116 in contact center 115 or to a Traffic Processor 117 . A contact center 115 may operate with just one of the land-line switch or the Traffic Processor, but in some circumstances may employ both incoming paths. Traffic Processor 117 may provide Session Border Control (SBC) functionality, may operate as a Media Gateway, or as a Softswitch, or in some combination.
[0035] Persons interacting through IP-enabled devices 108 ( 1 - n ) may interact through the Internet network via backbone 121 , enabled by a variety of service providers 105 which operate to provide Internet service for such devices. Devices 102 ( 1 ) and 102 ( 2 ) may be IP-enabled telephones, operating under a protocol such as Session Initiation protocol (SIP). Appliance 108 ( 3 ) is illustrated as a lap-top computer, which may be enabled by software for voice communication over packet networks such as the Internet, and may also interact in many other ways, depending on installed and operable software, such as SKYPE™ or WebRTC. Similarly appliance 108 ( n ) illustrated as a desktop computer, may interact over the Internet in much the same manner as laptop appliance 108 ( 3 ).
[0036] Many IP-enabled devices provide capability for users to interact both in voice interactions and text interactions, such as email and text messaging services and protocols. Internet 106 may comprise a great variety of Internet-connected servers 107 and IP-enabled devices with Internet access may connect to individual ones of such servers to access services provided. Servers 107 in the Internet may comprise email servers, text messaging servers, social networking servers, Voice over IP servers (VoIP), and many more, many of which users may leverage in interaction with a contact center such as contact center 115 .
[0037] Another arrangement by which users and agents may interact with contact centers is through mobile devices, illustrated in FIG. 1 by devices 110 , 11 and 112 . Such devices may include, but are not limited to laptop computers, iPad devices and smart telephones. Such devices are not limited by a land-line connection or by a hard-wired Internet connection as shown for telephones 104 or IP-enabled devices 108 , and may be used by customers and agents from changing geographic locations and while in motion. Devices 110 , 111 and 112 are illustrated in FIG. 1 as connecting through a wireless network 109 , which may occur through individual ones of cell towers 113 associated with base stations having gateways such as gateway 114 illustrated, the gateways connected to Internet backbone 121 .
[0038] In some circumstances mobile devices such as devices 110 , 111 and 112 may connect to supplemental equipment operable in a moving vehicle. For example, cellular smartphones may be enabled for near-field communication such as BLUETOOTH™, and may be paired with equipment in an automobile, which may in turn connect to the Internet network through satellite equipment and services, such as ON-STAR™. Wireless communication may be provided as well in aircraft, which may provide an on-board base station, which may connect wirelessly to the Internet through either a series of ground stations over which an aircraft may pass in flight, or through one or more satellites.
[0039] Regardless of the variety of ways that Internet access may be attained by mobile devices, users of these devices may leverage Internet-connected servers for a great variety of services, or may connect through the Internet more directly to a contact center such as contact center 115 , where users may interact as customers or as agents of the contact center.
[0040] Contact center 115 , as described above, may represent one of a plurality of federated contact centers, a single center hosted by a single enterprise, a single contact center operating on behalf of a plurality of host enterprises, or any one of a variety of other arrangements. Architecture of an individual contact center 115 may also vary considerably, and not all variations may be illustrated in a single diagram such as FIG. 1 . The architecture and interconnectivity illustrated in FIG. 1 is exemplary.
[0041] Equipment in a contact center such as contact center 115 may be interconnected through a local area network (LAN) 125 . Land-line calls may arrive at a land-line switch 116 over trunk lines as shown from land-line network 101 . There are a wide variety of land-line switches such as switch 116 , and not all have the same functionality. Functionality may be enhanced by use of computer-telephony integration (CTI), which may be provided by a CTI server 118 , which may note arriving calls, and may interact with other service units connected to LAN 125 to route the calls to agents connected to LAN 125 , or in some circumstances may route calls to individual ones of remote agents who may be using any of land-line telephones 104 , IP-enabled devices 108 or mobile devices represented by devices 110 , 111 or 112 . Calls may be queued in any one of a variety of ways before connection to an agent, either locally-based or remote from the contact center, depending on circumstances.
[0042] Incoming calls to switch 116 may also be connected to an IVR server 119 , which may serve to ascertain the purpose of the caller and other information useful in further routing of the call to final connection. A router and conversation manager server 120 may be leveraged for routing intelligence, of which there may be a great variety, and for association of the instant call with previous calls or future calls that might be made.
[0043] Land-line calls thusly treated may be connected to agents at agent stations 127 ( 1 ) or 127 ( 2 ), each of which is shown as comprising a land-line telephone connected to switch 116 by destination number (DN) lines. Such calls may also be connected to remote agents using land-line telephones back through the land-line network. Such remote agents may also have computing appliances connected to call center 115 for interaction with agent services such as scripting through an agent desktop application, also used by agents at agent stations 127 .
[0044] Incoming calls from land-line network 101 may alternatively be connected in contact center 115 through Traffic Processor 117 , described briefly above, to LAN 125 . In some circumstances Traffic Processor 117 may convert incoming calls to SIP protocol, and the such calls may be further managed by SIP Server 122 .
[0045] Incoming calls from IP-enabled devices 108 or from mobile devices 110 , 111 or 112 , and a wide variety of text-based electronic communications may come to contact center 115 through the Internet, arriving in the Contact Center at an eServices Connector 130 . eServices Connector 130 may provide protective functions, such as a firewall may provide in other architecture, and may serve to direct incoming transactions to appropriate service servers. For example, SIP calls may be directed to SIP Server 122 , and text-based transactions may be directed to an Interaction Server 131 , which may manage email, chat sessions, Short Message Serice (SMS) transactions, co-browsing sessions, and more. Interaction Server 131 may leverage services of other servers in the contact center, and available remotely as well.
[0046] Agent station 127 ( 3 ) is illustrated as having a connected headset from a computing device, which may execute telephony software to interact with packet switched calls. Agent station 127 ( n ) is illustrated as having an IP-enable telephone connected to LAN 125 , through which an agent at that station may connect to packet-switched calls. Every agent station may have a computerized appliance executing software to enable the using agent to transact by voice, email, chat, instant messaging, and any other known communication process.
[0047] A statistics server 124 is illustrated in contact center 115 , connected to LAN 125 , and may provide a variety of services to agents operating in the contact center, and in some circumstances to customers of the contact center. Statistics may be used in contact center management to vary functionality in routing intelligence, load management, and in many other ways. A Data Base 126 may be provided to archive data and to provide temporary storage for many of the activities in contact center 115 . An outbound server 123 is illustrated and may be used to manage outbound campaigns in the contact center, wherein calls may be made to destinations from a campaign list, and answered calls may be connected directly or be queued to be connected to agents involved in the outbound campaigns.
[0048] As described above, contact center 115 , and the architecture and connectivity of the networks through which transactions are accomplished between customers and agents is exemplary, and there are a variety of ways that similar functionality might be attained with somewhat different architecture. The architecture illustrated is exemplary.
[0049] FIG. 2 is a diagram illustrating a commercial airliner 201 in flight, the airliner equipped with on-board hardware and a system providing Internet access to passengers on board. There are a number of ways Internet access for passengers on an aircraft may be provided. One is a well-known service provided by GOGO™. In the GOGO™ service, the in-air equipment connects wirelessly with base stations at ground level represented by towers 203 a , 203 b and 203 c . Towers 203 a , 203 b and 203 c are coupled to gateways 204 a , 204 b and 204 c , which in turn provide Internet connectivity. As airliner 201 progresses, base station 202 sequentially transitions from ground base stations over which the airliner may pass. A customer in the aircraft may connect to base station 202 providing WiFi service in the aircraft, hence to one of the ground base stations, and into the Internet via the gateway serving the active base station. Referring back to FIG. 1 , one may consider tower 113 as one of towers 203 a , 203 b or 203 c , and mobile devices 110 , 111 and 112 as mobile devices that may be used by passengers on airliner 201 .
[0050] FIG. 3 is a plan view of a portion of a seating plan in airliner 201 , showing the in-aircraft base station 202 and a few representative wirelessly-enabled appliances 301 ( a ) through 301 ( n ) that may be used by passengers in the aircraft. The appliances represented are exemplary, as there well may be hundreds of passengers on the flight, many who may have wirelessly-enabled appliances capable of connecting to station 202 . In the architecture and operation of aircraft equipment enabling passengers to access the Internet with mobile devices, under some circumstances a set of IP addresses, as illustrated in list 204 , may be reserved for temporary assignment to wirelessly-enabled appliances used by passengers on the aircraft. Further station 202 may be assigned a unique Service Set Identifier (SSID) number in the network. Three appliances are represented in FIG. 3 , these being a smart phone 112 , communicating with station 202 with IP address (1), a laptop computer 110 communicating via IP address (3), and a tablet device 111 communicating via IP address (2).
[0051] The description above is exemplary, and there may be other characteristics of in-aircraft equipment and service which may be leveraged to indicate that a contact in a call center has originated in a particular aircraft.
[0052] It was described briefly above that a particularly important circumstance is that circumstance in which the Airline enterprise may wish to provide customer service in-flight. Referring again to FIG. 1 , the Airline enterprise may be represented for customer service by agents operating either locally at stations 127 in contact center 115 or remotely using appliances connecting to contact center 115 . Customers seeking service may connect with the agents through on-board station 202 and then through a wireless network represented in FIG. 1 by network 109 . These connections may come to contact center 115 through eServices Connector 130 in contact center 115 .
[0053] For in-air customer service it is important that the contact center determine that an incoming transaction, whether a voice call or a text-based message, is from a customer in an aircraft associated with the airline host of the contact center. This may be done in either of two ways. The incoming transaction may have associated data identifying the SSID of station 202 in the aircraft, and/or one of the IP addresses reserved for the station assigned that SSID. It is important also that communication in aircraft is restricted at the time of filing the instant patent application to operation at or above 10,000 feet. Under 10,000 feet station 202 must be disabled, but this threshold is arbitrary and may change.
[0054] In one implementation of in-air customer service provided by an airline enterprise Internet service may be provided by GOGO™ or another service provider. base station 202 may operate much like similar base stations in, for example, fixed ground locations. A passenger's appliance, enabled for detecting wireless networks, when the appliance is turned on, will detect and list available networks, which in most cases may be limited to the WiFi hotspot provided in the aircraft. When the passenger selects that wireless network the appliance's browser will be directed to a home page of the Internet service provider. The home page may be hosted jointly by the service provider and the airline, so the airline may have a link for “Customer Service”. The link may also indicate the airline name.
[0055] In one implementation the passenger (a customer of the airline) may not be a subscriber to the Internet service. In this instance selecting the “Customer Service” link may direct that passenger/customer to a website hosted by the airline without any charge to the passenger. So the customer service for that customer is free. The web site hosted by the airline may provide services for the passenger, such as checking the itinerary and enabling certain changes to be made. Service interacting with an agent, however, may not be available in this path. If the web site is enabled for Chat, there may be a link for the customer to initiate a chat request, in which case the customer may be immediately connected in a chat session, or may be placed in a hold queue to be connected in a chat session with an agent for the airline. Further description of customer service interaction through chat is provided below.
[0056] In some implementations the airline may announce availability of Internet connection and of availability of free customer service, and may provide written materials in individual ones of seatbacks instructing passengers how to connect for customer service.
[0057] In some instances a passenger may be subscribed to the service provider, paying, for example, a monthly fee for in-flight Internet access. In these instances the “free” aspect may be superfluous. If the passenger is not subscribed, the home page of the service provider may provide links and entry fields for the passenger to subscribe, or to purchase Internet access for the instant flight, or for a specified time period.
[0058] In some implementations a passenger may have a mobile device storing an executable chat application provided by the airline. In these implementations the passenger by launching the chat application may access the on-board WiFi and transmit a chat request to a contact center, such as contact center 115 in FIG. 1 . Customer service chat operations are described in more detail below.
[0059] At the time of filing the present application chat is a preferred channel for interaction for customer service in flight, because at least in the US, in-flight telephone interaction is not allowed. In future, however, much or all of what is described herein accomplished through chat may be accomplished through voice interaction with an agent of the contact center hosted by the airline.
[0060] FIG. 4 is a flow chart illustrating acts in providing customer service for an airline through chat. At act 401 the contact center receives a chat request. This request may be processed through an eServices connector such as connector 130 illustrated in FIG. 1 . Connector 130 leverages services of a server such as Interaction Server 131 illustrated in FIG. 1 , which provides, among other functions, chat functions. Through software executed by a processor of server 131 it is determined at act 402 if the chat request received is from a passenger currently in an airline flying above 10,000 ft, or whatever other altitude limitation may be imposed. This determination may be made by data accompanying packets of the chat request, which data may identify the passenger, identify the SSID of a WiFi hotspot currently associated with a particular aircraft, and also may check the accompanying IP address of the sender of the request with a list of IP addresses currently associated with a particular SSID and/or aircraft.
[0061] If it is determined at act 402 that the chat request is not from a customer currently a passenger on a flight at altitude, then it is determined at act 403 whether an agent is available. If not, the chat request is held in queue at act 406 until an agent is available. At act 404 , when an agent is available the customer is connected in a chat session with an agent. At act 407 the agent interacts with the customer, and provides services in response to customer's queries.
[0062] If it is determined at act 402 that the chat request is indeed from a passenger in an airline, and the passenger and the airline are identified, then at act 405 rich data concerning the customer/passenger and real-time flight status (as closely as is practical) is accessed from data stores available in the contact center, or accessible over one or more networks.
[0063] At act 405 , depending on various data retrieved, intelligence may be exercised to provide alternatives for an agent who will serve the customer in a chat session. For example, it may be determined that customer Ethan Francois is a first-class passenger on AMERICAN AIRLINES™ (AA) flight 1127 in route from Chicago to Denver, and that the flight is twenty minutes ahead of schedule. In this example the contact center is providing customer service on behalf of AMERICAN AIRLINES™. It may also be determined that customer Francois is a “gold” customer for AA, that is a VIP, and historical transactions for customer Francois may be retrieved and processed.
[0064] The rich data available and assembled at act 405 may be organized in any of a variety of ways for an agent, and may be presentable to an agent through the agent's desktop application when the chat request is served and the customer is connected in a chat session with an agent.
[0065] While processing is accomplished at act 405 , at act 409 it is determined whether or not an agent is available, or has capacity to handle the new chat request. If the answer is Yes, the customer may be connected at act 410 in a chat session, and the data retrieved and processed at act 405 may be presented to the agent and associated with the chat request and the customer.
[0066] If there is no agent available, or with bandwidth to serve, then the chat request is queued at act 411 until an agent is available. The customer may be notified of this circumstance in the display of the mobile appliance the customer is using on the aircraft. When an agent is available the chat request is connected at act 410 .
[0067] An example of information that may be displayed to the customer in the customer's display, in response to queries the customer may make, may be flights earlier than a connecting flight upon which the customer is currently booked (it was determined the flight is twenty minutes ahead of schedule). AA may have a further motive for promoting booking on an earlier flight for this customer (and other customers on this flight as well) in the event that the earlier flights may be underbooked and the original connection may be overbooked. AA may offer one or more incentives for the customer to switch to the earlier flight.
[0068] In the event a flight is late and the customer may certainly miss a connection, AA may organize status of later flights that may be available for the customer to reach her final destination, and display this information for the agent who gets the chat request. In this circumstance AA may also show the agent available hotel accommodations, travel reservations, and restaurant reservations, among other services.
[0069] The organized alternative schedules and information are provided to the connecting agent in a manner that the agent may present attractive options to the customer in response to customer queries. In many implementations the agent may be enabled to present alternatives to the customer in the chat window on the customer's mobile appliance. There are a wide variety of services that may be provided to customers in flight in response to customer queries and desires, driven by near real-time circumstances of the customer and the status of the flight upon which the customer is a passenger.
[0070] FIG. 4 illustrates that a variety of focused services may be provided for customers who are, in fact, engaging customer service at altitude as passengers in an aircraft. The near real-time status information that may be available may determine a rich organization of alternatives that may be presented to a customer.
[0071] The above implementations are described as leveraging chat as a communication channel. This is because chat may be a preferred channel for a number of reasons. In circumstances where voice interaction is allowed in aircraft at altitude, other channels, including voice may be used. The data and information that may be retrieved based on the customer ID and flight status and the like may be the same or very similar regardless of the channel or channels of communication.
[0072] It was described above that Internet access is permitted in aircraft cruising above 10,000 feet presently, administered by the Federal Aviation Administration in the US. As an aircraft equipped for on-line access leaves the ground and gains altitude, when the aircraft has passed the 10,000 foot minimum, on-board control associated with station 202 may be exercised, and an announcement may be made to passengers that Internet access is available and may be used. Similarly, when the aircraft is approaching a destination and descending, there is a time when the aircraft will descend below the 10,000 foot minimum, and Internet access will be interrupted, which may be done by control associated with station 202 and/or announcement to passengers to turn off mobile devices.
[0073] FIG. 5 illustrates transition situations both ascending and descending. From left to right the situation is shown first as a passenger at ground level using a telephone 501 , engaged in voice communication with an agent in contact center 115 . This passenger may be in a terminal waiting to board a flight, on the aircraft parked on the ground prior to takeoff before cellular communication is denied for takeoff, in a ground vehicle traveling toward the terminal, or in a restaurant or other facility at the terminal.
[0074] There may be a circumstance wherein this passenger has perhaps completed a part of his or her desired business with the agent at the contact center, but transaction is not finished at the time that the aircraft is ready to take off and mobile devices must be powered off. Thus there are two transition points in which communication between a passenger and an agent in the contact center may be interrupted. It is desirable that such interruption not force a passenger to start over in accomplishing needed changes in scheduled flights and other services.
[0075] In one implementation the agent with whom the passenger has been engaged, with aid of intelligence in the contact center, may suspend transaction with the passenger, with understanding that the session may be resumed at a later time at initiation of the passenger. There are a number of ways this function may be accomplished. In one implementation a step-by-step summary of transaction between the passenger and the agent may be recorded as steps occur, and at suspension that summary may be saved and associated with the passenger's ID, as an “unfinished session” summary. The aircraft that the passenger may board or have boarded, and hence the WiFi SSID, may also be known, and the summary may be associated at the contact center with the aircraft and the SSID as well, and may be associated with the agent with whom the passenger has been engaged. In one circumstance the passenger or the agent may voluntarily terminate the session and save the summary, or the saving may be automatic, forced by termination of communication from an external source, such as station 202 .
[0076] FIG. 6 is a flow chart illustrating a transition of communication for the passenger as the plane takes off and ascends to altitude, and eventually descends to landing. At act 601 a passenger is engaged at ground level in a customer service session with an agent of a contact center for the airline host of a flight that the passenger has booked. At act 602 the passenger is on the aircraft and communication is suspended for takeoff. Suspension may be a trigger for preparing an “unfinished session” summary, which is associated at least with the passenger ID, and may also be associated with the flight and the agent.
[0077] After takeoff the aircraft gains altitude, and there is a silent period during which passengers may not access the Internet. Above 10,000 feet Internet access is enabled, and an announcement may be made that passengers may access the Internet. The passenger for whom a customer service session was interrupted at act 602 may now contact the contact center. The contact may now be through a chat application, rather than the voice channel originally used when the passenger was at ground level.
[0078] Assuming the passenger does transmit a chat request to the contact center after the aircraft ascends above 10,000 feet, that chat request will come to the contact center along with many other media requests. At act 604 a new transaction request is received at the contact center from the Internet through eService connector 130 . At step 605 the request is processed against known “unfinished session” summaries. The association may be made through data in the request identifying both the aircraft (through station SSID) and the passenger ID. If an association is found, it may also be determined if the timing is reasonable for a reconnect and resumption of the interrupted session. If no association is found, at act 606 the incoming request is routed to an available agent.
[0079] If the association is found, the associated interrupted session summary is retrieved at act 607 . At act 608 it is determined if the original agent is available to resume the interrupted session. If not, at act 612 the request is routed to an available agent. If the original agent is available, or will shortly be available, the request is routed to that agent as the best choice to continue the customer service session. Regardless of the agent to whom the request is routed, at act 610 the summary is displayed through the desktop application for the agent to whom the request is routed. At act 611 the session is resumed, and the passenger is engaged.
[0080] It may be that during the flight the session is completed. However a summary may be updated in the resumed session as well against the possibility that the passenger may reconnect later in the flight and wish to make some further change. It may be that the passenger reconnects too late in the flight to complete the session before the aircraft descends at destination, and communication is again suspended for the descent and landing of the aircraft. If this should be the case the passenger may reconnect after landing, using the same or another channel, and the contact center intelligence may find association with the twice interrupted session, and attempt to reconnect the passenger with the same agent to complete the session.
[0081] It may be that the passenger first makes contact for service while in the aircraft at altitude. The same logic applies as described above. Each time the passenger is forced to break off communication, an unfinished summary is prepared, associated and stored. In many implementations there may be a mechanism for the agent or the passenger to signal that the goals are accomplished and that the session is finished. In this circumstance the summary or summaries may be further tagged as to completion.
[0082] It is not required that the passenger/customer use the same media channel each time that he or she requests resumption of a session. It is only necessary that the contact center intelligence check association of the customer and accompanying data against identity of unfinished session summaries for each incoming request, regardless of media channel.
[0083] There are many alterations possible in implementations described above. The breadth of the invention is limited only by the claims below. | A method has acts for receiving a transaction request in a contact center at a server having a processor, retrieving from data accompanying the transaction request identifying information regarding an originating node for the transaction request and identity of a sender of the transaction request, comparing the identifying information with stored data associating identifying information with specific aircraft providing on-board Internet service, discovering an association indicating the sender of the request is currently transacting as a passenger on a specific aircraft, retrieving further information regarding the passenger if available, retrieving information about the specific aircraft, including at least current flight status, routing the transaction request to an available contact center agent, connecting the passenger in a communication session with the agent, and displaying the information regarding the passenger, if any, and the information regarding the specific aircraft for use by the agent during the communication session with the passenger. | 6 |
FIELD OF INVENTION
[0001] The present invention relates to the testing of new and/or recently changed network elements in a communications system in order to bring the system into a state in which it is able to carry traffic.
BACKGROUND OF THE INVENTION
[0002] System Lineup and Testing (SLAT), in general, is the process of bringing a system, which has already been installed at a telecommunications site, into steady-state service capable of carrying traffic. The process also generally applies when expanding an existing, in-service system, by providing a procedure to test new network elements (NEs) before they are added to the system.
[0003] For existing optical carrier standards, in-bay testing requires approximately 9 hours to complete and end-to-end testing takes approximately 34 hours. Conventional SLAT processes consist mostly of manual processes. Networks employing high-density cross-connect (HDX) network elements, such as Nortel's OpTera™ Connect HDX, require similar SLAT. However, there is a concern with respect to HDX SLAT in that HDX port density is 96 times that of OC-192. If the same SLAT strategy that has been used for OC-192 were to be used for HDX, the total HDX SLAT time would be in the order of weeks, which is clearly unacceptable to customers. Furthermore, there are many limitations associated with the mostly manual SLAT processes known in the art, many of which allow for errors to be introduced or omissions to be made in the SLAT process. Therefore, a different network element SLAT strategy is required, particularly for use with high-density network elements.
SUMMARY OF INVENTION
[0004] The present invention affords the ability to provide an improved SLAT scheme that is suitable for practical implementation with a variety of network elements.
[0005] According to an aspect of the invention, there is provided an apparatus for use in a network comprising: means for accepting user input relating to a first set of system lineup and testing (SLAT) tasks for a network element, said first set of SLAT tasks constituting part of a SLAT session; means for guiding a user through tasks of said first set of SLAT tasks in an automated manner; means for transmitting received user input to a network element server; means for performing at least some tasks of said first set of SLAT tasks; means for receiving and displaying network element information from said network element server; and means for coordinating the completion of performed SLAT tasks with a second set of SLAT tasks, said second set of SLAT tasks constituting part of said SLAT session, such that essential tasks in said SLAT session are completed in proper sequence and some tasks of said SLAT session are performed in parallel.
[0006] According to another aspect of the invention, there is provided a method, comprising the steps of: accepting user input relating to a first set of system lineup and testing (SLAT) tasks for a network element, said first set of SLAT tasks constituting part of a SLAT session; communicating user information to said network element; guiding a user through tasks of said first set of SLAT tasks in an automated manner; performing at least some tasks of said first set of SLAT tasks; receiving network element information from said network element; and coordinating the completion of performed SLAT tasks with a second set of SLAT tasks, said second set of SLAT tasks constituting part of said SLAT session, such that essential tasks in said SLAT session are completed in proper sequence and some tasks of said SLAT session are performed in parallel.
[0007] According to a farther aspect of the invention, there is provided a method of coordinating multiple system lineup and testing (SLAT) activities for one or more network elements, each activity running on a client computer, comprising the steps of: preparing a network element initialization file; providing said initialization file to an apparatus operably connected to said network element as well as to at least one client computer; transferring said initialization file, upon request, to a selected operably connected client computer from which SLAT activities relating to said network element are capable of being initiated; preparing an updated SLAT report file following the completion of a SLAT task; and providing said updated SLAT report file to said apparatus.
[0008] According to yet another aspect of the invention, there is provided an apparatus for use in a network comprising: means for receiving user input for a plurality of sets of tasks relating to system lineup and testing (SLAT) for a network element, each of said sets of SLAT tasks originating from a client computer capable of communicating with said network element, said sets of SLAT tasks constituting part of a SLAT session; means for transmitting received user input to a network element server; means for receiving network element information from said network element server; means for performing at least some tasks of said plurality of sets of SLAT tasks; means for transmitting said network element information to said client computer for presentation to a user; and means for coordinating the completion of performed SLAT tasks such that essential tasks in said SLAT session are completed in proper sequence and some tasks of said SLAT session are performed in parallel.
[0009] According to a further aspect of the present invention, there is provided a computer program product having a medium with a computer program embodied thereon, the computer program comprising: computer program means for accepting user input relating to a first set of system lineup and testing (SLAT) tasks for a network element, said first set of SLAT tasks constituting part of a SLAT session; computer program means for guiding a user through tasks of said first set of SLAT tasks in an automated manner; computer program means for facilitating transmittal of received user input to a network element server; computer program means for facilitating performance of at least some tasks of said first set of SLAT tasks; computer program means for facilitating receipt of network element information from said network element server; computer program means for facilitating display of said network element information; and computer program means for coordinating the completion of performed SLAT tasks with a second set of SLAT tasks, said second set of SLAT tasks constituting part of said SLAT session, such that essential tasks in said SLAT session are completed in proper sequence and some tasks of said SLAT session are performed in parallel.
[0010] According to a yet further aspect of the present invention, there is provided a computer program product having a medium with a computer program embodied thereon, the computer program comprising: computer program means for receiving user input for a plurality of sets of tasks relating to system lineup and testing (SLAT) for a network element, each of said sets of SLAT tasks originating from a client computer, said sets of SLAT tasks constituting part of a SLAT session; computer program means for facilitating transmittal of received user input to a network element server; computer program means for facilitating receipt of network element information from said network element server; computer program means for facilitating performance of at least some tasks of said first set of SLAT tasks; computer program means for facilitating transmittal of said network element information to said client computer for presentation to a user; and computer program means for coordinating the completion of performed SLAT tasks such that essential tasks in said SLAT session are completed in proper sequence and some tasks of said SLAT session are performed in parallel.
[0011] According to a still further aspect of the present invention, there is provided a computer program product comprising a computer-readable memory storing statements and instructions for use in the execution in a computer of any of the methods described above.
[0012] Among the advantageous features afforded by the present invention are:
[0013] SLAT that supports both local and remote users;
[0014] SLAT that supports multiple users each performing distinct tasks in the same SLAT session;
[0015] SLAT that permits users to collaborate while ensuring that essential tasks are completed in proper sequence and some tasks are performed in parallel;
[0016] SLAT that produces a report that is saved for reference, providing a persistent record of session data;
[0017] SLAT that permits a user to discontinue, resume and continue an incomplete session; and
[0018] SLAT whereby errors are reported to users.
[0019] The present invention, in a preferred embodiment, provides a software wizard that allows the user to proceed through the various phases of SLAT while ensuring that no critical step is omitted without displaying a warning.
[0020] The present invention may be used with one or many high-density network elements, for which the present invention may provide significant advantages over existing methods and systems. The automated, centralized features of the present invention may also provide advantages for use with lower density network elements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Embodiments of the present invention will be further described with reference to the accompanying drawings, in which:
[0022] [0022]FIG. 1 illustrates an HDX configuration showing a consolidated node and HDX as a DX hub;
[0023] [0023]FIG. 2 illustrates an example of an HDX NE configuration according to an embodiment of the present invention;
[0024] [0024]FIG. 3 illustrates client access to the NE node according to an embodiment of the present invention;
[0025] [0025]FIG. 4 illustrates the high-level architecture design of a SLAT Assistant according to an embodiment of the present invention; and
[0026] [0026]FIGS. 5A & 5B illustrate representative screen shots of a user interface in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0027] HDX SLAT according to the present invention is the process of bringing an HDX cluster, which has already been installed at a Telco site, to a “sane” state. The SLAT mode can be entered at a shelf, quadrant and/or slot level. As such, the HDX SLAT also applies when expanding an existing, in-service HDX NE, or providing a procedure to test a new shelf/quadrant/slot before being added to the in-service HDX NE.
[0028] [0028]FIG. 1 illustrates an HDX configuration showing a consolidated node and HDX as a DX hub. An HDX in the high level view can be configured as: consolidated node 110 (or HDX cluster) composed of: HDX core 101 and HDX I/Os 102 ; or HDX core shelf 101 acting as a DX hub. The term network element (NE) will be used hereinafter to refer to an HDX cluster, as described above.
[0029] To reduce the HDX SLAT time, the present invention facilitates automating SLAT tests, such as: automating site testing (signal continuity testing); automating receive sensitivity testing; automating transmit output power testing; providing a fiber connectivity tool (to verify/troubleshoot fiber connections); guiding a user through SLAT using a SLAT GUI wizard; and storing SLAT test results on the system (thereby eliminating hardcopy SLAT forms).
[0030] Embodiments of the present invention seek to simplify test procedures, and yet provide sufficient test coverage so as to advantageously: reduce or eliminate external testsets; use internal testing capability; reduce or eliminate optical loopbacks; minimize fiber manipulation; automate tasks as much as possible; run SLAT remotely (skilled people at remote site) or locally.
[0031] The term SLAT “session” as employed herein represents the totality of SLAT tasks necessary for full and complete SLAT of a network element. The term SLAT “activity” as employed herein represents one or more SLAT tasks that may be performed at a particular client computer. The terms tests and tasks are used interchangeably.
[0032] When a new HDX NE is being assembled in the field, the process used to bring the NE “live” typically consists of the following steps:
[0033] Pre-commissioning checks: tests that are executed on the test equipment brought by the installation team to ensure calibrated and functionally correct results.
[0034] NE commissioning: procedures of entering initial data that is required by software to define the configuration of the NE. This rudimentary data allows the NE to carry traffic and interwork with other NEs and a main control center software in the network.
[0035] NE software upgrade: procedures of ensuring that the NE is tested against the customer release load. The load can be downloaded from a CD-ROM of the SLAT user's PC, or from an FTP server. The user must specify to the NE from where to download the load.
[0036] Site testing: tests that are executed on a single NE node that is configured so as to be independent of the rest of the system. Tests for HDX node include backplane continuity test for HDX core and HDX I/O, optics test for port cards on HDX I/O.
[0037] Site testing cluster: tests that are executed on the connection from HDX core to HDX PO with Parallel Optical Interface (POD) cards. These tests would be performed by the system and would rely on a POI interface to test and diagnose problems.
[0038] As described earlier, each set of HDX core platform and HDX I/O platform will together be SLATted/managed as a single NE. This will be accomplished by an NE-resident “Network Element Controller” (NC) function. The NC function is preferably achieved via software running on a Shelf Controller (SC) card, although other similar implementations are possible. The software can be installed on a separate external machine or alternatively in the SC card on one of the core shelves.
[0039] Parallel Optical Interface (POI) connectivity between the HDX core and the I/O shelves is hidden by the NC function. One command issued to the NE TL1 interface will be capable of testing all platforms (core and I/O) comprising the NE. On the I/O shelf, mapping between the port card facilities within slots 2 , 3 , and 4 and the POI facilities within slot 1 (connecting back to the core switch) will be wholly managed by the NE and known to the NC. The POI card in slot 1 together with the port cards in slots 2 , 3 and 4 will be treated as a quadrant during SLAT.
[0040] [0040]FIG. 2 illustrates an example of an HDX NE configuration according to the present invention. Interaction and connectivity between ports of the HDX core 201 and the HDX I/O shelves 202 is represented by working lines W and protection lines P.
[0041] SLAT Assistant
[0042] Nodal SLAT is concerned with getting the NE up and running. The HDX SLAT Assistant is a user-friendly task based application that will step the user through the process of commissioning/provisioning and testing the shelves and the NE. This SLAT Assistant will preferably be installed on an apparatus for performing SLAT tasks, be it a server computer, client computer or other computer, such as a craft PC. (A craft PC is a terminal that is used for on-site installation and maintenance of individual network elements.)
[0043] The SLAT Assistant is composed of a SLAT GUI (Graphical User Interface) client component and a SLAT server component. The SLAT GUI client component, or means for guiding a user through SLAT tasks in an automated manner, is designed as a “wizard” that interacts with the user and guides the user through the processes to complete the necessary tasks. The SLAT server component, or means for co-ordinating the completion of SLAT tasks, will perform some more intelligent tasks underneath the interface, passing the user inputs on to the NE server, and forwarding the messages received from NE server to the SLAT GUI for presentation to the user.
[0044] In the HDX nodal SLAT stage, a pre-physical installation of the bays and shelves has been assumed. It is also assumed that for a newly installed HDX NE, a member of the local SLAT team will connect his craft PC to the HDX LCAP (Local Craftsperson Access Panel) and perform pre-commissioning tests as well as nodal commissioning. After the node has been provisioned external IP Datacomms parameters and connected to the customer data network, the SLAT team at a centralized location may start to run nodal testing tools through the SLAT Assistant. Alternatively, the local SLAT team can perform the nodal tests if they wish. Each team will have the same SLAT GUI application software installed on a client PC. This client PC may be a craft PC or GUI desktop for the main control center software, element management system (EMS), or a simple client computer.
[0045] Referring now to FIG. 3, a user may execute SLAT Assistant 310 on a local craft terminal 320 , such as a laptop, or at a PC or workstation located at a centralized location, such as Remote Validation Center 330 . The SLAT Assistant 310 can connects into NE 340 directly via Ethernet or similar connection, as in the case of craft terminal 320 . Alternatively, the SLAT Assistant 310 can connect to the NE 340 via a customer data network 350 , as in the case of Remote Validation Center 330 . Users are presented with the same options when they connect by different means, and the user interface will preferably have the same look and feel for all users.
[0046] In terms of configuration, in a preferred embodiment of the present invention, both the client and server components of the SLAT Assistant are installed on a single craft PC. This craft PC would communicate directly with any NEs requiring SLAT. In such a case, the client and server computers could be described as being integral with one another. In an alternative embodiment, the client component of the SLAT Assistant is installed on a client computer, whereas the server component of the SLAT Assistant is installed on a separate server computer. Other functional distributions, such as peer-to-peer distribution, of the SLAT Assistant components on network computers may alternatively be implemented.
[0047] For SLATting an in-service HDX node (e.g. adding a new shelf, or a quadrant, or a card), SLAT can be performed either locally at a craft PC or remotely at a Remote Validation Center (RVC).
[0048] With respect to the SLAT Assistant according to an embodiment of the present invention, the following advantages may be realized: showing users all steps relating to tasks, with an appropriate level of task granularity; allowing users to skip tasks if necessary and return to them later or carry out tasks in a different order than normal, ensuring that essential tasks are completed in proper sequence; enabling a user to discontinue, resume and continue an incomplete SLAT task or session; reminding a user to complete a non-completed or incomplete task, ensuring that a critical step is not omitted without triggering a warning; enabling a user to review and modify a complete SLAT task or session; enabling local and remote SLAT activities; providing a common user interface is presented at an apparatus capable of performing local SLAT activities and at an apparatus capable of performing remote SLAT activities; providing a user interface to allow a remote user to carry out certain SLAT tasks in parallel with other SLAT tasks being performed.
[0049] Examples of SLAT Tasks that may be performed are listed below, with optional tasks being indicated by an asterisk (*)
[0050] Install SLAT Assistant
[0051] Perform Power-up Procedure
[0052] Connect PC to HDX
[0053] IP Datacomms parameters provisioning (Connect to data network)
[0054] Enter NE Specific Data
[0055] Download HDX Software
[0056] Install HDX Software
[0057] Perform Site Tests*
[0058] Perform Site Backplane Extension Tests*
[0059] Provision HDX
[0060] Review SLAT Results*
[0061] Among the advantages provided by embodiments of the present invention, an apparatus according to an embodiment of the present invention comprises means for coordinating the completion of a first set of performed SLAT tasks with a second set of SLAT tasks, both sets of SLAT tasks being part of the same SLAT session, such that essential tasks in said SLAT session are completed in proper sequence and some tasks of said SLAT session are performed in parallel. Such co-ordination enables a user to make better use of time spent on SLAT and permits both local and remote users to perform certain tasks in a controlled manner in which each party is preferably made aware of the status of other tasks being performed.
[0062] With respect to navigation in the user interface, an embodiment of the present invention advantageously provides the ability to: show all tasks and sub-tasks in tree; provide a Back button as a means of returning to the previous step; and provide a Next button as a means of proceeding to the next step.
[0063] With respect to remote SLAT, an embodiment of the present invention advantageously provides the ability to: show the same UI to local and remote users; and only allow remote users access to certain tasks that can be performed remotely. An embodiment of the present invention may advantageously provide a GUI component such that anyone can access a current task status at any given time. This may be accomplished by, for example: showing tasks being carried out by another user as locked (pad lock icon); disabling tasks that are locked out (grey); allowing either user to override the lock-out and bump the other user (e.g. if connectivity is lost during SLAT). In this manner, the present invention restricts access to SLAT tasks depending on user permissions.
[0064] In terms of the specific means employed to provide access to remote users, and to multiple users in general, an embodiment of the present invention advantageously utilizes two data files: a NE specific initialization file (SLAT.ini) and a SLAT session, or report, file (SLAT.rep). An alternative to the NE specific initialization file is to provide default values that will be built-in to the system and will not be NE specific.
[0065] In the case of using the NE specific initialization file (SLAT.ini), the file will preferably be in ASCII format. The initialization file provides default system information for SLAT. This information can be used to compare the expected system configuration (i.e. number of port cards and I/O shelves) to the observed system delivered by the equipment provider.
[0066] The initialization file can be completed before the equipment is shipped by an equipment provider customer service representative or by an expert SLAT user before the beginning of SLAT. The presence of this initialization file provides inexperienced SLAT users with sufficient information in order to be able to correctly provision a network element, such as an HDX NE.
[0067] The initialization file may preferably be supplied to the customer on a floppy disk or other such computer-readable medium, and copied to a directory (such as C:\SLAT) when installing the SLAT Assistant. A backup copy will be made in another directory (such as C:\SLAT\NEid\). For each different NE there will be a different directory in which to store its SLAT.ini backup data. The SLAT.ini will preferably include: an NE Serial Number that is printed on the HDX core, NE ID, TID, NE alias, NE location, NE role, Facility mode, Catalog name (release name), default external NE IP address for access by the craft PC, IP provisioning parameters, number of I/O shelves and card type in each slot, etc. The SLAT.ini file will be updated with the data that the user enters at the NE commissioning step. As a precaution, a backup copy of the SLAT.ini may be made before the user starts a SLAT session.
[0068] There is, however, a possibility that the wrong initialization file may be used. The SLAT Assistant may, therefore, preferably ensure that the user does not accidentally use a wrong SLAT.ini file (e.g., an outdated initialization file or a file written for a different HDX NE or previously installed HDX). In such a preferred embodiment, the SLAT Assistant may validate the file by comparing the NE Serial Number in the initialization file to the Serial Number of the network element, or HDX core. For example, on the start up of the SLAT Assistant, the Assistant pops up the Serial Number obtained from the SLAT.ini to the user and asks the user to verify it. Alternatively, this task may be performed automatically by the software.
[0069] The SLAT session, or report, file (SLAT.rep) will be created automatically after the SLAT Assistant is started and is preferably stored in the same directory as the SLAT.ini file (e.g. C:\SLAT\). Once again, a backup copy will preferably be made in the same other directory (e.g. C:\SLAT\NEId\). All the steps carried out during SLAT and the results associated therewith will be recorded in the report file. This SLAT.rep file is NE specific and identified by the TID found in the file.
[0070] This report file, or portions thereof, are transferred back and forth from/to an NE during SLATting. For instance, a portion of the file identifying changed values may be sent from the NE, as opposed to sending the entire file, whereas the entire file may be sent to the NE. Apart from eliminating hardcopy SLAT forms by storing SLAT test results on the system, this file will also advantageously be used for synchronizing multiple SLAT users.
[0071] There is, however, a possibility that transferring a SLAT report file from a client PC to a NE by FTP may cause a security concern. The present invention may preferably avoid this potential problem by requesting the NE to retrieve the SLAT.rep file from the SLAT server platform, using FTP (or HTTP). SLAT.rep can also be sent to the NE via TL1 interface. However, the transfer of files with TL1 is often inefficient and increases the TL1 traffic.
[0072] The SLAT Assistant is a client application that accepts user inputs and displays information from the NE. The SLAT Assistant is preferably written in Java, which will run on a client host computer, although any other suitable programming language/environment may be used.
[0073] The SLAT Assistant may be run on a standalone craft EMS terminal platform as well as on an EMS desktop. The Assistant application is designed in such a way that it can be run either with or without presence of the EMS server. As such, the SLAT Assistant of the present invention has been designed as preferably comprising two components:
[0074] SLAT GUI
[0075] SLAT server component
[0076] [0076]FIG. 4 illustrates an example of the high-level architecture design of a SLAT Assistant according to an embodiment of the present invention.
[0077] SLAT GUI
[0078] SLAT GUI 410 , or Wizard, is a thin client application that will be deployed on the client PC (craft PC or EMS GUI). Only at runtime does the SLAT GUI application 410 know if the EMS server is in craft mode or not.
[0079] The Craft EMS server contains only a subset of all EMS server applications. One of the main differences between craft EMS server and the EMS server is that the database is removed and replaced by an in-memory cache of the data. All data modeled and stored in the cache is lost when the user logs out of a NE or the EMS craft server is restarted. Therefore, when the SLAT Assistant is designed to take care of an incomplete SLAT session after restart, the SLAT Assistant has to know where to obtain the information on the incomplete SLAT session. In an embodiment of the present invention, the SLAT Assistant will create a “Report File” on the client PC the first time that a user starts the SLAT session. The Report File will continue to be updated as SLAT proceeds. By examining the Report File, the Wizard will be able to detect whether there is an incomplete SLAT session left.
[0080] To access the craft EMS server, a set of default user profiles is preferably used for access control. A user profile will correspond to the user's TL1 access level. User authentication is performed at the NE level. User authentication in this case is performed at the EMS level.
[0081] SLAT Server Component
[0082] SLAT server component 420 is the SLAT application server that will be deployed together with other server applications on the craft EMS platform (or EMS platform). The SLAT server component runs in the same virtual machine, e.g. Java Virtual Machine (JVM), as Common Object Model 430 . It provides the RMI (Remote Method Invocation) interface 440 to the SLAT GUI 410 .
[0083] During application execution, the SLAT GUI 410 will invoke a remote method on the remote object defined in the SLAT server component. The SLAT server component 420 is an “NE Proxy” on the craft EMS server for the SLAT GUI to send/receive messages to/from the NE server for NE commissioning and testing.
[0084] The SLAT server component 420 is a layer built on top of the Common Object Model 430 to create a SLAT object that holds a summary of SLAT information. The SLAT GUI 410 extracts information from the SLAT object and preferably displays it on a display means, such as a display screen.
[0085] Except for VT-100 450 access to the NE, all communications between client PC and the NE are performed via the SLAT server component. This is a typical tree-tier client/server model.
[0086] Advantages of the proposed SLAT GUI / SLAT server component architecture are:
[0087] Software maintenance: If further features or enhancements are developed for the NE or EMS, such as IP Datacomms parameters provisioning with TL1, then only the SLAT server component needs to be upgraded and the SLAT GUI remains unchanged.
[0088] Communication efficiency: The SLAT server component has the intelligence that collects the summary information required by the SLAT GUI, and as such, the RMI overhead will be reduced considerably.
[0089] RMI overhead may not be a significant concern for the craft EMS terminal application that runs on the same platform that the server runs on. However, if the client application runs on the EMS GUI and the server application runs on the EMS server, the RMI overhead will degrade the network performance.
[0090] During integration exercises, it was discovered that GUI applications (NE Topology and Shelf Level Graphics) that access to COM 430 directly via RMI interface 440 could take a painfully long time to start. A number of solutions have been provided. One of these solutions is to limit unnecessary large class (such as the Common Object Model) exposure to the client application. One way to limit class exposure and remote method invocation is to create a remote proxy that limits access to only the class structures and methods that will need to be accessed remotely. The remote proxy interface should not be included as part of the Common Object Model since it will be addressed on a UI case-by-case basis.
[0091] SLAT GUI is a candidate for creating a remote proxy interface. It requires some simple NE information such as NE type, NE ID, shelf information (number of shelves, shelf types (Core, I/O), etc), shelf configuration (type of card in each slot), NE entity (shelf/quad/slot) mode (SLAT mode, in-service mode, etc), and events generated for site testing results (pass, fail, incomplete) and methods supporting SLAT requests (software upgrade, upload files, site testing cmds, etc). Creating a proxy definition that runs on the same JVM as the Common Object Model and summarizes the information required by the SLAT GUI will reduce the RMI overhead considerably. Likewise, more “UI business logic” implemented on the server side would contribute to reducing the amount of data that needs to be transferred across the network.
[0092] It is believed that using the above strategy would help control the RMI costs and allow the desktop to run more efficiently over slower speed data communications links.
[0093] Common Object Model
[0094] SLAT server component 420 will invoke local methods defined in the Common Object Model (COM) 430 . The COM defines abstraction and storage and EMS data in support of nodal and networked applications. It models each NE's physical or logical entity as an encapsulated object, e.g., a shelf or an alarm.
[0095] The COM 430 interacts with Lumos translation/mediation and event management components (NE Mediation Management) for communication to the NE in the following tasks:
[0096] Send/receive TL1 messages to/from NE;
[0097] Receive NE events; and
[0098] Retrieve shelf-description data.
[0099] The SLAT Assistant will also utilize the following functionalities supported by the COM:
[0100] Interact with NE discovery component to retrieve NE's data files;
[0101] Provide application interface (local and RMD to access NE; and
[0102] Provide event notification for object model.
[0103] NE Topology
[0104] NE Topology/Shelf Level Graphics component 460 provides a shelf map for multi-shelf NEs. Support for shelves, the physical relationships between the shelves, and alarm displays (for logged in NE only) will be provided.
[0105] Changes to shelves or NE configuration will automatically be reflected in the NE Topology GUI 460 . For example, the addition of a shelf to an NE will result in a graphical view update with a new shelf, POI connectivity, and alarm status.
[0106] In addition to the above, from the NE Topology GUI 460 , the user can also launch Shelf Level Graphics and the Menu Driven TL1 UI.
[0107] The primary usage of launching the NE Topology GUI 460 from the SLAT Assistant is to display SLAT alarms at the shelf level and to launch the Shelf Level Graphics from the NE Topology GUI 460 to display SLAT alarms at the slot level.
[0108] The Menu Driven TL1 will be launched from the NE Topology GUI in certain cases to support launching scripts. This is provided to allow any last minute changes that the SLAT Assistant may have forgotten and provide users the ability to customize customer setups.
[0109] Shelf Level Graphics
[0110] The NE Topology GUI 460 will provide a graphical view of multi-shelf NEs while Shelf Level Graphics is available for single shelf NEs. Shelf Level Graphics (SLG) will be launched from the NE Topology GUI 460 during site testing.
[0111] Shelf Level Graphics is a nodal surveillance function that provides users a photo realistic view of shelves on a specific NE. Many functions are supported by the SLG. The main functionality of the SLG that will be used by the SLAT Assistant is to display the SLAT alarms on the NE shelf faceplate and to access the properties panel against selected alarm.
[0112] The NE Topology and the SLG are among the few exceptions in the SLAT Assistant in that they will be using their own defined UI. Another exception is the NTP online Help system 470 . The rest of the tasks supported by the SLAT Assistant will be wizard like UI developed by the SLAT feature.
[0113] VT-100 Emulator
[0114] The SLAT Assistant will provide the function to access a VT- 100 emulator 450 developed for the craft EMS platform. The VT-100 Emulator 450 is a client side application that provides a character-based terminal for access to the TL1/CLI (interfaces of legacy NEs.
[0115] The purpose of accessing the VT-100 Emulator 450 is to provide users a way to connect to and manage a legacy NE, in case there is a bandwidth limitation or to debug a problem on the NE. In cases where some new CLI (Command Line Interface) test tools have been developed for the NE but the SLAT Assistant does not have time to upgrade, the VT-100 emulation tool will provide a user with a way to access these test tools.
[0116] The other use of the VT-100 emulator in the SLAT Assistant is to communicate with the NE in case the only communication channel is through CLI, such as IP Datacomms parameters provisioning for the HDX NE.
[0117] NTP Help
[0118] SLAT Assistant will allow users access to online help 470 in the form of Notices to Proceed (NTPs) or procedural instructions for software tasks. The help system developed for the EMS GUI Desktop, which provides the context-sensitive online Help system, will be launched from the SLAT Assistant.
[0119] File Transfer To support file transfer, it is assumed that EMS server and/or the craft EMS server shall have an FTP server 480 installed. However, for the EMS user, the client PC may or may not have the FTP server installed on it. Therefore, to send files (such as the SLAT.ini and the SLAT.rep) to the NE, the files will have to first be sent to the EMS server via RMI call, and from the server files can then be transferred to the NE. To receive files from the NE, the files will first be transferred to the EMS server, and then the client PC will obtain the files from the server via RMI call. Alternatively, the client PC can retrieve the file directly from the NE with FTP.
[0120] In the case of the SLAT Assistant running on the craft EMS terminal, both the server applications and the client applications run on the same platform and therefore there is no need to make the RMI call for the file transfer.
[0121] To send a file to the NE, the SLAT server component will send a TL1 message to the NE with the source location and the file to be transferred. The NE server will then retrieve the file from the source using FTP protocol. This approach is used to prevent security leaks on the NE server.
[0122] To transfer a file from the NE to the craft EMS/EMS server, however, there are two alternatives: the NE “puts” the file to the server, or the server “gets” the file from the NE by the FTP protocol.
[0123] With respect to the NE putting the file to the EMS (or craft EMS) server, an advantage is that the user does not have to know the file's location on the NE. However, a disadvantage is that the EMS server has to send a file transfer request to the NE via TL1 interface before the NE can put the file onto the EMS server. Allowing the NE to put files on the EMS server by FTP may open a door for security leaks.
[0124] With respect to the EMS (or craft EMS) server retrieving the file from the NE, an advantage is that the EMS server does not need to send a TL1 file transfer request to the NE before retrieving the file. The EMS server security is thus protected. However, a disadvantage is that the user has to know the file location on the NE before retrieving the file.
[0125] A preferred embodiment of the present invention requests the NE put the file on to the EMS (or craft EMS) server in order to accomplish such file transfer.
[0126] The EMS (or craft EMS) server will cache the data files (SLAT.ini and SLAT.rep) on its file system. In order to keep these files together, a separate directory may be created per NE to store the cached and override files pertaining to that NE.
[0127] When a NE exits the SLAT mode, these files, along with the directory, will be removed from the EMS server. In a preferred embodiment, the directory name will be the NE identifier string provided by the NE ID in the SLAT.ini.
[0128] However, if the SLAT Assistant runs on the craft EMS platform, the files will be kept on the local file system after the NE exiting the SLAT mode until the user manually removes them.
[0129] IP Parameters Provisioning
[0130] The EMS platform communicates with the NE using a TL1 interface. Ideally, IP Datacomms parameters provisioning for the HDX NE should be effected with the TL1 protocol from the software architecture and maintainability point of view. However, since NE server does not always support IP parameters provisioning with TL1, two alternatives are: IP parameters provisioning with CLI TCP/IP socket; and IP parameters provisioning with VT-100 Emulator.
[0131] With respect to IP parameters provisioning with CLI TCP/IP socket, an advantage is that the user will have the same look-and-feel user interface as other SLAT tasks. The user will not be affected by the implementation of the IP parameters provisioning protocol. However, a disadvantage is that a separate TCP/IP socket needs to be opened for IP parameters provisioning whereas the rest of the communications are effected with TL1. If future releases of TL1 support the IP provisioning, then SLAT will need to update this feature accordingly.
[0132] With respect to IP parameters provisioning with VT-100 Emulator, an advantage is that there is no development work needed for the SLAT Assistant for provisioning IP parameters. However, a disadvantage is that users will not get the same look-and-feel user interface as other tasks. Users have to know the CLI command for IP parameters provisioning.
[0133] A preferred embodiment of the present invention provisions the IP parameters with CLI TCP/IP socket, pending the development of resources.
[0134] Server Applications
[0135] The SLAT Assistant will directly utilize many applications on the craft EMS server, such as:
[0136] SLAT server component
[0137] Craft Access Control
[0138] Common Object Model
[0139] Lumos TMS and TL1 Interface
[0140] NE Topology
[0141] Shelf Level Graphics
[0142] Logging and Tracing
[0143] FTP server
[0144] Client Applications
[0145] The SLAT Assistant will directly utilize the following client applications:
[0146] SLAT GUI
[0147] NE Topology GUI
[0148] Shelf Level Graphics GUI
[0149] VT-100 Emulator terminal
[0150] Online Help System
[0151] The SLAT GUI shall be able to run even if the rest of the client applications above are not installed. However, in that case, the services provided by them will not be accessible to the user.
[0152] File Transfer Interaction
[0153] This section describes the interactions between the SLAT Assistant and the HDX NE during file transfer.
[0154] Two files will be needed to coordinate multiple SLAT activities related to the same SLAT session, or to co-ordinate multiple SLAT sessions: SLAT.ini (SLAT Initialization file) and SLAT.rep (SLAT report file). The files will preferably be in XML format, although other formats may alternatively be used.
[0155] SLAT.ini
[0156] SLAT.ini will be pre-prepared by a SLAT utility tool. Upon start up of the SLAT Assistant, if the Wizard cannot find the file on the client PC, it will create a new one.
[0157] SLAT.ini will be used to provide default values of the SLAT Assistant data fields and options. SLAT.ini will be updated if the user makes changes on the data fields and options in the Wizard. The SLAT.ini will be NE specific. It does not contain any user information (such as userid, password and craft EMS IP address, etc). Therefore, all the users connected to the NE will use the same SLAT.ini file.
[0158] SLAT.ini will be transferred to the NE from the craft EMS terminal upon completion by the craft user of the NE commissioning/provisioning step (this step will be performed by the craft user only).
[0159] The craft EMS server sends a TL1 message to the NE and tells the NE where to download the SLAT.ini. The NE then downloads the SLAT.ini from the craft EMS with FTP. A remote client PC will then download SLAT.ini from the NE with FTP after the user logs into the NE.
[0160] SLAT rep
[0161] SLAT.rep will be created upon the craft user starting up the SLAT Assistant. SLAT.rep will be updated after each task is completed and will be transferred to the NE after the craft user logs into the NE.
[0162] The craft EMS server sends a TL1 message to the NE and tells the NE from where to download the SLAT.rep. Then, the NE downloads the SLAT.rep from the craft EMS with FTP. Remote client PC will then download SLAT.rep from the NE with FTP after the user logs into the NE.
[0163] Both the craft user and the remote user can update the SLAT.rep file and transfer the SLAT.rep file to the NE after it is updated. Before the users update the SLAT.rep file, they should retrieve the latest version of SLAT.rep from the NE and update the latest version. After the SLAT.rep file is updated, the file is sent to the NE right away.
[0164] The SLAT.rep should preferably be made available to the client even after exiting SLAT mode. SLAT.rep will preferably be in ASCII format, however the NE should not be concerned with the contents of the file.
[0165] It is up to the client (SLAT Assistant) to interpret the contents of the report file. To avoid collisions, each client only appends his completed task to the SLAT report file.
[0166] Interface Design
[0167] The user interface for a SLAT apparatus according to an embodiment of the present invention facilitates the automation of the SLAT process, while providing a means by which a user may be guided through the SLAT process. The user interface also facilitates the coordination of the completion of a plurality of sets of SLAT tasks constituting part of the same SLAT session, such that essential tasks in said SLAT session are completed in proper sequence and some tasks of said SLAT session are performed in parallel. Preferably, the user interface provides graphical access to a software assistant (wizard) that guides the user through the various phases of SLAT in an automated fashion, while ensuring that no critical step is omitted without displaying a warning.
[0168] [0168]FIGS. 5A and 5B illustrate representative screen shots of a user interface in accordance with an embodiment of the present invention. The figures illustrate the manner in which tasks are presented to a user, including a tree view that provides an indication of previous and upcoming tasks, as well as an indication of which tasks are already completed and the hierarchy of such tasks. This tree view can be seen on the left-hand side of the screen shots.
[0169] [0169]FIG. 5A illustrates a screenshot of an example of SLAT step 18 . 0 , the step of commissioning a network element. Task area 510 of the user interface includes an identification of each of the SLAT steps, as well as an indication of the state of completion thereof. In this particular example, a checkmark is placed beside steps that have been completed. An “X” is placed beside essential steps that have been skipped (otherwise referred to as non-completed), whereas no indication is placed beside non-essential steps that have been skipped, such as step 17 . 0 . Instruction area contains any instructions necessary in order for a user to perform the current task. In many instances, the instruction area 520 contains non-interactive text instructing the user on what steps to perform. However, FIG. 5A provides an example of advanced options that may be provided in the instruction area 520 , such as fill-in boxes, pull-down menus, and other such means for selecting and/or inputting relevant information. Comment area 530 is provided for a user to enter observations and comments regarding the completion of a given task. Task button area 540 contains navigation buttons allowing a user to go to previous and next tasks, and to view a report of all SLAT tasks in a particular SLAT session. Other alternative functions that may be provided in the task button area 540 include obtaining help (context-sensitive or general help) and saving a SLAT session for later completion. Status message area 550 is provided for the SLAT Assistant to provide status messages to the user. In FIG. 5A, a status message is given regarding the fact that the user has skipped the previous step. As mentioned above, because it is a non-essential step, there is no “X” beside step 17 . 0 as there is beside essential step 15 . 0 that was skipped in this example. Finally, alarm area 560 provides an indication of any alarms, alerts, errors or warnings that may be applicable at any point in time during SLAT. In this example, there is an indication of one error in each of the critical, major and minor categories.
[0170] [0170]FIG. 5B illustrates an example of a warning indication 570 according to an embodiment of the present invention. In this example, the warning indication 570 comprises a pop-up window that indicates the applicable warning. This particular warning has popped up due to the fact that a user attempted to exit SLAT before an essential task was completed. Other instances causing warnings may include, for example: proceeding to a subsequent step when an essential step has not yet been completed; inputting values in an incorrect format; confirmation of proceeding with a requested task; confirmation of completion of a task; and any other informational message or error message associated with the execution of the SLAT tasks. The term warning is used herein to represent any type of alarm, error, alert or any other notification intended to report a deviation from an expected value or result.
[0171] The following features are advantageously provided by the user interface in a preferred embodiment of the present invention:
[0172] Navigation tree: Users may navigate among tasks by selecting items in the navigation tree.
[0173] Mandatory tasks: Tasks that must be performed in order are represented in distinctive text, e.g. plain text (not underlined), as numbered parent nodes in the tree.
[0174] Available tasks: Tasks are enabled (represented, for example, by a black font) in the tree when they are available.
[0175] Unavailable tasks: Tasks are disabled (represented, for example, by a gray font) in the tree when they are not available.
[0176] Subtasks: Tasks that may be performed in any order are represented as child tasks and may be numbered as subcomponents (e.g. 1.1, 1.2, etc.).
[0177] Multiple users: Remote users are represented in the navigation tree. An icon may be displayed in the tree beside the task the remote user is actively carrying out.
[0178] Completed tasks: A checkmark, or a similar indicator, may be displayed in the tree beside tasks that are complete.
[0179] The following user behaviors are advantageously enabled by the user interface in a preferred embodiment of the present invention:
[0180] Skipping tasks: Tasks that can be skipped may be highlighted with blue underlined text (hyperlinks), or any similar indication, in the task tree. Users can skip tasks using the “Next¢ button or by clicking the next item in the navigation tree, or performing a similar step.
[0181] Performing tasks in a different order: Users may click hyperlinks in the navigation tree to perform tasks in a different order than originally anticipated.
[0182] Reviewing complete tasks: Users may review tasks that are complete by selecting nodes in the tree.
[0183] Modifying complete tasks: Users may review tasks that are complete by selecting nodes in the tree, modify the task contents, and click the “Next” button to apply changes. After the user clicks “Next”, a dialog may pop-up indicating that changes have been made and the user may have the option to apply changes or cancel.
[0184] Previewing tasks: Users may click unavailable tasks in the tree to preview the task requirements. The “Next” button is disabled (represented by, for example, a gray font) when a selected task is unavailable.
[0185] Embodiments of any of the aspects of the present invention can be implemented as a computer program product for use with a computer system. Such implementation may include a series of computer instructions fixed either on a tangible medium, such as a computer readable medium (e.g., a diskette, CD-ROM, ROM, or fixed disk) or transmittable to a computer system, via a modem or other interface device, such as a communications adapter connected to a network over a medium. The medium may be either a tangible medium (e.g., optical or electrical communications lines) or a medium implemented with wireless techniques (e.g., microwave, infrared or other transmission techniques). The series of computer instructions embodies all or part of the functionality previously described herein.
[0186] Those skilled in the art should appreciate that such computer instructions can be written in a number of programming languages for use with many computer architectures or operating systems. Furthermore, such instructions may be stored in any memory device, such as semiconductor, magnetic, optical or other memory devices, and may be transmitted using any communications technology, such as optical, infrared, microwave, or other transmission technologies. It is expected that such a computer program product may be distributed as a removable medium with accompanying printed or electronic documentation (e.g., shrink wrapped software), preloaded with a computer system (e.g., on system ROM or fixed disk), or distributed from a server over the network (e.g., the Internet or World Wide Web). Of course, some embodiments of the invention may be implemented as a combination of both software (e.g., a computer program product) and hardware. Still other embodiments of the invention may be implemented as entirely hardware, or entirely software (e.g., a computer program product). For example, in a method according to an embodiment of the present invention, various steps may be performed at each of a craft PC, client computer, or server computer. These steps may be implemented via software that resides on a computer readable memory located at each of said craft PC, client computer, or server computer.
[0187] Although various exemplary embodiments of the invention have been disclosed, it should be apparent to those skilled in the art that various changes and modifications can be made which will achieve some of the advantages of the invention without departing from the true scope of the invention. | The present invention provides a method and apparatus for system lineup and testing (SLAT) that is suitable for practical high-density cross-connect implementation. Preferably, a software assistant (wizard) guides a user through the various phases of SLAT in an automated fashion, and is able to co-ordinate tasks in a SLAT session possibly being performed at a plurality of locations such that essential tasks in said SLAT session are completed in proper sequence and some tasks of said SLAT session are performed in parallel. The present invention advantageously provides SLAT with the following benefits: support for both local and remote users; supports for multiple users; facility for users to collaborate; production of a report that is saved for reference, providing a persistent record of session data; permitting users to quit, resume and continue an incomplete session; reporting errors to users; SLAT that may be run locally (stand-alone) or remotely (on a server). | 7 |
FIELD OF THE INVENTION
Embodiments of the present invention relate generally to disk drive systems and to lubrication of recording media within the systems.
RELATED ART
Hard disk drive systems typically include one or more rotatable disks having concentric data tracks defined for storing data, a recording head or transducer for reading data from and writing data to the various data tracks on each disk, and an air bearing slider for precisely holding the transducer element in close proximity to a selected track. Lubricants have been placed on the disk surfaces in order to prevent undesirable interactions between the head and the disk.
The head and disk interface in a disk drive can be continuously lubricated by use of a vapor phase lubricant reservoir system. U.S. Pat. No. 4,626,941 describes a system in which a bulk lubricant source is kept at a warmer temperate than the heads and disks. However, this approach led to problems related to the need to prevent excessive bulk-phase lubricant from condensing onto the head and disk surfaces. Other approaches are described in U.S. Pat. No. 4,789,913 to Gregory et al., U.S. Pat. No. 5,229,899 to Brown et al., and U.S. Pat. No. 5,331,487 to Gregory et al., which are each hereby incorporated by reference in their entirety.
SUMMARY
Embodiments include a method for forming a lubricating perfluoropolyether (PFPE) film on one or more disks in a disk drive system, including providing a first component of PFPE molecules having an aggregate vapor pressure in the range of 1×10 −6 to 1×10 −11 atm and a second component of PFPE molecules comprising at least 5% of the total number of molecules of the first component, wherein the second component includes an aggregate vapor pressure lower than that of the first component. The method also includes mixing the first and second components to obtain a homogeneous composition.
Embodiments also include a method for lubricating a rotating disk in a disk drive within an enclosure, comprising positioning a reservoir within the enclosure and spaced a distance from the rotating disk, and filling the reservoir with a single phase liquid comprising a first component of PFPE molecules having an aggregate vapor pressure in the range of 1×10 −6 to 1×10 −11 atm and a second component of PFPE molecules comprising at least 5% of the total number of molecules of the first component, wherein the second component includes an aggregate vapor pressure lower than that of the first component.
Embodiments also include a disk drive system including at least one disk adapted to store data, at least one transducer adapted to read and write data to and from the disk, and a lubricant composition disposed in a reservoir spaced a distance from the disk, the lubricant composition includes a single phase liquid comprising a first plurality of molecules having a first vapor pressure and a second plurality of molecules having a second vapor pressure that is less than the first vapor pressure.
Embodiments also include a lubricant system for use in a disk drive system, including a homogeneous mixture including a first group of perfluoropolyether molecules having a first mean molecular weight and a second group of perfluoropolyether molecules having a second mean molecular weight, wherein the first mean molecular weight is less than the second mean molecular weight.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention are described with reference to the accompanying drawings, which, for illustrative purposes, are schematic and not necessarily drawn to scale.
FIG. 1 shows the individual molecular weight distribution for 10 fractions obtained from a perfluoropolyether material by use of CO 2 critical phase chromatography.
FIG. 2 shows the lubricant reservoir response for a blend of a first molecular weight distribution component combined with a second molecular weight distribution component in accordance with an embodiment of the present invention, compared with a control drive.
FIG. 3 shows the reservoir response for disk drives operated for various times using a lubricant blend in accordance with embodiments of the present invention.
DETAILED DESCRIPTION
In general, a bulk supply of liquid or solid lubricant may become a reservoir source when positioned within a disk drive's enclosure. Vapor from this source communicates with the head and disk surfaces so as to provide them with a dense, uniform adsorbate film of lubricant.
Certain disk drive products show a tendency for lubricant on the surfaces of their disks to mimic classical lubricant spin-off. This problem has occurred on particulate magnetic disks, where radial lubricant-flow caused by centrifugal force could lead to a substantial lubricant loss from the inner annular region of a disk's surface (ID) with initial buildup toward the outer region (OD), followed by eventual depletion from the disk's magnetic surface. This has also been observed to a minor extent in analyses of some commercially available drives employing thin-film disk, where the heads are operated at or below 20 nm and above 7200 RPM. In all of these cases on thin-film disks, the mechanism appears to be the result of an acceleration in the rate of radial surface migration of mobile lubricant caused by high air shear between the spinning disks and pseudo-stationary components. Mechanistically, it is thought that the normally compliant lubricant film suffers from localized regions of disruption caused by a high rate of air shear thereby allowing centrifugal force to significantly accelerate the thicker domains of the non-uniform lubricant layer.
Although heads are the largest contributor to air-shear that alone can induce depletion of the lubricant, the suspension(s), elements of the comb, and close proximity of the cover and base casting to disk surfaces are also important contributing factors. The major known factors that may relate to the depletion of lubricant are: (1) lower flying height of the head(s); (2) higher spindle speed (RPM); (3) enhanced smoothness of a disk(s) and in particular the lack of or minimum circumferential disk texture; (4) an increase in the operational temperature of a drive; and (5) a smaller disk spacing that results in a closer separation of the head suspension(s), actuator comb, the drive's cover and base of the casting relative the spinning disk(s). It is observed that a mobile PFPE (perfluoropolyether) lubricant can be more readily depleted as the applied thickness of a PFPE lubricant is increased (all other parameters being held constant). It is also observed that the loss of a given thickness of mobile PFPE lubricant is accelerated by increasing the thickness of the bonded PFPE lubricant (of the same lubricant type; e.g., for the case of PFPE lubricant Z-DOL 4000 Fomblin® perfluoropolyether fluid; Ausimont; Bollate, Italy). Although bonded lubricant is not depleted, it eventually migrates toward the disk's OD via debonding, a phenomenon that is accelerated by temperature, high humidity and the depletion of overlying mobile lubricant. Unfortunately, the mobile phase of any lubricant is tribologically more beneficial than is bonded lubricant. Because many of the factors that accelerate lubricant spin-off are necessary to enable higher aerial density, and to increase the performance of disk drives, there is an apparent impediment to the ultimate advancement of disk drive technology without a solution to lubricant loss.
Hard disk drives may show an increase in tribochemical products and interfacial wear as the total lubricant level on a disk's surface(s) becomes depleted. Data indicates that mobile lubricant is more efficacious in tribology than is the same thickness of bonded lubricant. Thus, it appears that it is advantageous to maintain a lubricant film on the head and disk surfaces in a disk drive over the useful lifetime of the drive.
The head and disk interface in a disk drive can be continuously lubricated by use of a vapor phase lubricant reservoir system as described by U.S. Pat. No. 4,789,913 to Gregory et al., U.S. Pat. No. 5,229,899 to Brown et al., and U.S. Pat. No. 5,331,487 to Gregory et al., which are each hereby incorporated by reference in their entirety. In general, a bulk supply of liquid or solid lubricant becomes the reservoir source when positioned within the disk drive's enclosure. Vapor from this source communicate with the head and disk surfaces so as to provide them with a dense, uniform adsorbate film of lubricant.
A very low-flying head(s) can benefit from a lubrication technology that can continuously maintain a lubricant film at or above 0.6 nm total thickness with more than 0.2 nm of this film being comprised of mobile lubricant.
It has been observed that large linear molecules having finite volatility can form a dense, nearly continuous adsorbed film on interfacial surfaces ranging from a sub-monolayer thickness up to several monolayers of thickness. The resulting adsorbate film is of moderate to high density because a significant number of the atoms that comprise the backbone of most molecules contribute to substantial Van der Waals' bonding with the carbon overcoated surfaces used on heads and thin-film disks. Thus, a volatile PFPE lubricant can result in an adsorbate film that is very similar to that obtained by the common dip-lubrication process typically used in thin-film disk manufacturing, but without the bath-induced irregularities associated with the latter process.
The characteristic thickness of an adsorbate film can be reasonably well approximated by Type I Langmuir adsorption kinetics. (In Type I adsorption, interaction between an adsorbate molecule and the subject surface substantially prevails over the intermolecular interactions.) The tribologically desirable Type I films typically obtain an equilibrium thickness of about 0.6 nm to 1.6 nm depending on the molecular structure of the adsorbate material. For linear molecules above a molecular weight of approximately 150 Daltons, single monolayer adsorption coverage prevails over a wide range of partial-pressure conditions (P/Po of about 0.1 up to approximately 0.95) depending on the surface energy of the COC and the selected lubricant molecule. The low end of this range will usually allow sufficient lubricant adsorbtion so as to approach a monolayer of thickness, but the rate will be slower compared to a higher condition of P/Po. The upper end of the P/Po range provides an accelerated rate of adsorbtion response, but excessive lubricant thickness may result due to Type II adsorption. (Type II adsorption occurs when adsorbate molecules undergo substantial interaction with their neighboring adsorbate molecules typical of films exceeding a monolayer of coverage.) Type II adsorption may be significantly avoided in PFPE materials by the use of any molecular end-group that strongly adsorbs to physical surfaces of heads and disk(s). An effective functional end-group typical involves hydrogen atoms replacing fluorine atoms along with the use of oxygen and/or nitrogen in the backbone chain. The aforementioned Z-DOL 4000 Fomblin® perfluoropolyether fluid is an example including a functional end-group often generally designated by R. The adsorbate thickness of PFPE compounds with functional end-groups is found to be essentially invariant over the wide temperature range that can occur in hard drives usage. Thus, it is possible to continuously maintain a lubricant film at a mean thickness of at least 0.6 nm in a operating drive. Because the process of film maintenance is always dynamically adjusted, any damage imparted to the interface can be quickly repaired by the lubricant reservoir system and any excessive thickness is readily reduced.
A preferred condition for obtaining continuous lubrication in an operational drive is to bathe the interface in lubricant vapor that are always maintained within a somewhat wide P/Po range as previously discussed. From thermodynamic considerations, it can be shown that this condition prevails when the lubricant reservoir supply is generally kept a few degrees cooler than that of the interface. Another method employs any form of capillary containment of the pure lubricant so as to result in the desired P/Po condition. This approach includes adsorption onto a large-surface medium (e.g., activated carbon or other medium with large surface-area or internal volume) that would be in equilibrium with the desired adsorbate film on heads and disks.
Certain embodiments of the present invention relate to the use of homogeneous blended liquids comprised of a volatile perfluoropolyether (PFPE) fluid lubricant material having functional end-groups mixed with an essentially nonvolatile (PFPE) fluid lubricant material in which the former material is miscible. In general, desirable performance is obtained when the essentially nonvolatile fraction of PFPE fluid has identical functional end-groups. In this case, the preferred condition of isothermal mixing may occur together with no volumetric change having occurred so as to allow an estimate the consequential P/Po condition of the blend by use of Raoult's Law. For blends that do not obey Raoult's Law, a desired P/Po condition can be established by a series of graded measurements or through trial and error. The blended PFPE lubricants suppress the vapor pressure of the volatile fraction by an approximate application of Raoult's Law, which states that the vapor pressure of component A, is suppressed by the addition of component B according to the following relationship.
P A =P A o [n A /( n A +n B )]
where P A is the reduced vapor pressure, P A o is the vapor pressure of pure component A and n A and n B are the number of molecules of species A and B respectively. In case of component B having no appreciable vapor pressure, the blended fluids will exhibit a reduced vapor pressure that is adjustable such that P A =P/Po=0.75 as an example. Thus, the aforementioned blended components can be formulated so as to prevent the adsorbed lubricant film from becoming too thick.
Raoult's Law is generally not strictly obeyed. Necessary conditions for adherence require both components to be miscible, for there to be no volume change on mixing and that the heat of mixing of both components should be zero. Additionally, the molecular cross-section at the surface of the liquid should be essentially equivalent for both components; otherwise a correction for occupational area of the components must be applied. Rarely are all of these physical criteria met, so a departure from this simple mathematical relationship is usually expected. Nevertheless, Raoult's Law has been found to provide a good stating point in formulating a blend of PFPE materials, which can be further, adjusted by actually measuring P/Po and also by assessing reservoir performance in a disks drive.
In certain embodiments it is important to select a higher molecular weight component that is substantially nonvolatile. To assure an attainable P/Po from a given blend, it may be desirable to employ an equivalent polymer backbone in the high molecular weight component as is used for the low molecular weight volatile component, which may include having the same end groups as are used on the volatile lubricant. This concept is shown in the equations below.
Volatile molecule: R—O—(ab) x —R
Nonvolatile molecule: R—O—(ab) y —R
In the above equations, y is significantly greater than x so as to establish the required differentiation in volatility. The backbone of the molecule is represented by the molecular units (ab) replicated x or y times, respectively, and E is the molecular end-group of the molecule. The (ab) molecular unit may be any combination of molecular groups. Z-DOL is provided as an example. The —O— generally refers to an ether linkage. In this case the end-group denoted by R is —CH 2 —OH and (ab) are segments of (CF 2 —O—)n and (CF 2 CF 2 —O—)m, where m and n are integers of comparable magnitude as stated by the manufacturer.
FIG. 1 shows the individual molecular weight distribution for 10 fractions obtained from Z-DOL 2000 by use of CO 2 critical phase chromatography.
FIG. 2 shows the lubricant reservoir response for a blend of a rather narrow molecular weight distribution of Z-DOL centered at 1304 Daltons (volatile component) combined with a similar distribution of Z-DOL centered at 5707 Daltons (essentially nonvolatile). The referenced blend was formulated to approximately provide P/Po=0.8 (roughly an equal-mass blend of the two referenced distributions). In this experiment a matched pair of drives were aggressively operated for several months until the topically applied Z-DOL 4000 lubricant had been redistributed from its original flat radial thickness profile to be compared to that shown in FIG. 2 labeled “control.” This conditioning caused the uniformly applied film of Z-DOL 4000 lubricant at 0.9 nm thickness to have become considerably depleted at the ID region of the disks in both of these drives, with an excessive thickness of lubricant forming at the OD region of these disks. The above referenced blended of lubricants (1304 mean amu and 5707 mean amu) was then placed into a felt structure that was installed into one of the two drive to create a lubricant reservoir drive. The other drive served as an experimental control. Both drives were then additionally operated under identical conditions for a 7-day period followed by disassembly for FTIR lubricant thickness analyses shown in FIG. 2 . It can be seen that the lubricant reservoir system substantially restored the lubricant that had been lost in the ID region of all disks in this drive. It is also noted that the total lubricant thickness at the OD of the reservoir drive became even thicker due to the fact that the volatile lubricant became adsorbed into the Z-DOL 4000 lubricant that had become inordinately thick at the OD annular region of all disks. Thus the thick, nonvolatile Z-DOL 4000 fluid at the ID region approached equality with the chemical potential of the volatile component in the reservoir source resulting in substantial adsorption in volatile lubricant. The lack of a flat profile resulted from the fact that the redistributed Z-DOL 4000 is not appreciably volatile.
FIG. 3 shows the reservoir response for three drives operated for 0.3 hours, 1 day and 4 days. In this experiment each file was started with unlubricated disks and with each drive having a reservoir system identical with that described in the experiment relative to FIG. 2 . This experiment reveals the initial response time for the reservoir system determined to be 1 Angstrom per hour and a system response time of about 0.5 days (1/e value). Additionally, a flat radial response is observed for the case of only volatile Z-DOL being the adsorbate on the disk. This experiment reveals a flat radial lubricant thickness profile measured at 1.3 nm (13 Angstroms). Results obtained from a fourth file that was operated for 40 days prior to analysis were essentially identical to the thickness response and radial thickness profile obtained for the 4-day run period. In addition, when the disks are pre-lubricated with the volatile Z-DOL 1304 amu fluid, a thickness response essentially identical to the 4-day run time was obtained for analyses conducted over a period of several months.
Because the vapor pressure of the blended fluids will gradually decline as the volatile component is withdrawn, an adequate quantity of this material would be required in a drive to accommodate losses over its lifetime (so P/Po will not become too low).
One aspect of the certain embodiments using blended fluids is described because of the high cost of fractionating a PFPE stock fluid into it various pseudo-monodispersed lubricant components, especially since only about one-fifth of the refined material may be used in embodiments such as the previously described experiments. Realizing that the vapor pressure of every component in a broadly dispersed lubricant material is modified by the environment of its different companion molecules, a generalized partial pressure equation can be derived based on Raoult's law for use as guidance in formulation. The total aggregate vapor pressure of all volatile components in a broadly dispersed lubricant, such as Z-DOL 2000, may be given by the following equation:
P T =∫P o ( mw ) D ( mw ) d ( mw ),
where
∫ D ( mw ) d ( mw )=1;
P T is total vapor pressure of all volatile species, P o (mw) is the vapor pressure of the pure component of molecular weight mw, D(mw) is the number of molecules at molecular weight mw and d(mw) is the independent variable for integration, which is performed over the entire range of molecular weight present in the lubricant fluid. This computation made for the case of broadly dispersed Z-DOL 2000 yields an aggregate vapor pressure of 4 to 6 times that for the aforementioned blended formulation at effective P/Po of approximately 0.8, which gives a reservoir thickness response nearly identical to that shown in FIG. 2 . The higher volatility of this fluid can be readily reduced by vacuum pumping a thin film of this fluid at elevated temperature and/or by blending Z-DOL 2000 with Z-DOL 4000 as an example. This methodology provides an equivalent low cost fluid for reservoir application in a hard drive.
Another aspect of embodiments of the reservoir concept relates to the deliberate departure from the use of an ideal mixture of fluids. Due to the higher molecular weight component of such a mixture progressively occupying more volume as the molecular weight is increased so as to suppress volatility, better economy can be obtained by using multiple pendant end-groups juxtaposed along the length of the molecular backbone. For example, the CH 2 —OH end-group exhibits significant hydrogen bonding with other similar or identical end-groups. Thus, a single molecule with this functional moiety replicated p times along its backbone could be as efficient in suppression of the volatile component of the lubricant as would p/2 of the high molecular weight component cited in FIG. 1 . Further enhancement via hydrogen bonding could be obtained by use of an ether linkage (e.g., end-group —CH 2 —O—CH 2 CH 2 —OH), or any other variation thereof.
It will, of course, be understood that modifications of the present invention, in its various aspects, will be apparent to those skilled in the art. Other embodiments are possible, their specific features depending upon the particular application. For example, a variety of disk drive configurations, geometries, and components may be may be employed in disk drive systems instead of or in addition to those discussed above. | A lubricating perfluoropolyether (PFPE) composition for lubricating one or more disks in a disk drive system may be formed by providing a first component of PFPE molecules having an aggregate vapor pressure in the range of 1×10 −6 to 1×10 −11 atm and a second component of PFPE molecules comprising at least 5% of the total number of molecules of the first component, wherein the second component includes an aggregate vapor pressure lower than that of the first component. The first and second components are mixed together to form a homogeneous composition, which may be in the liquid form. The composition may be introduced into a reservoir in a vapor phase lubricant reservoir system in a disk drive enclosure. | 6 |
This invention relates to apparatus for curing coating materials, and more particularly to apparatus for irradiating a coated fiber or wire-like element.
BACKGROUND OF THE INVENTION
Optical fibers, such as are used to transmit light in various applications, including communications, typically are coated with one or more polymeric layers which are designed to protect the optical fibers from moisture and abrasion, to reduce microbending losses, and to allow easier handling of the fiber.
In a typical method of coating an optical fiber, a liquid photocurable polymeric material is applied to the surface of the fiber and it is then cured by irradiating the coated fiber with radiant energy, as for example, ultraviolet rays.
Attempts have been made in the prior art to improve the efficiency of the coating and curing process by techniques such as modifying the polymer composition and/or the coating method and selecting optimum wavelengths of the curing radiation. One area in which it has appeared that improvements can be made in the curing process is in more efficient use of the radiant energy which is used to cure the polymer.
SUMMARY OF THE INVENTION
It is accordingly one object of this invention to provide apparatus for concentrating radiant energy onto material being treated with such energy.
It is another object to provide improved apparatus for curing liquid polymers coated onto optical fibers.
In accordance with this invention, there is provided apparatus for treating material with concentrated radiant energy comprising three (3) reflectors for concentrating radiant energy which is emitted from a source onto material which is to be irradiated. The combination of first and second reflectors, referred to herein as an elliptical reflector, comprises an elliptical surface having a first, or source focus and a second, or object focus. A light source is positioned at the first focus and material to be treated is positioned at the second focus. The third reflector, referred to herein as an auxiliary reflector, is provided with a concave reflecting surface and is positioned near the object focus with the concave reflecting surface facing towards both foci of the elliptical reflector.
This apparatus increases to a substantial extent the amount of light which is emitted at or near one focal point of an elliptical reflector and reaches the other focal point.
In the case of reflectors which have elliptical shapes, all light rays which are emitted from one focus of the ellipse will reach the other focus as long as the source is a point source; however, when the light source is not a point source but is, in fact, a volume source, the predominant portion of the light which is emitted from the light source does not originate at the focus but instead originates from points in the volume of the source which are spaced from the focus. A good portion of the light rays from a volume source will not pass through the second focus, although they will in general pass near it. In this invention, the curing apparatus includes an auxiliary reflector comprising a concave reflecting surface which is located near the object focus. This auxiliary reflector is oriented so that light rays which pass near the object focus impinge on the concave surface and are redirected in a line which passes near or through the object focus. The increased radiation which impinges on material in or near the object focus is increased to an unexpectedly large degree.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic in elevation of an embodiment of this invention.
FIG. 2 is a plan view of the embodiment of FIG. 1.
FIG. 3 is a graphical representation of the relative intensities of light coming from various directions toward the objective focus of apparatus similar to the embodiment of FIGS. 1 and 2 with and without the auxiliary reflector.
FIG. 4 is a plan view of an alternative embodiment of this invention.
DETAILED DESCRIPTION OF THE INVENTION
The apparatus of this invention may be used in a variety of processes in which a wire-like or rod-like material is coated with a material which is to be treated with radiant energy. For example, it may be use to cure or dry paint or ink on wires or rods; however, the invention will herein be described in detail by its use in curing photocurable material which is coated onto optical fibers and is treated with ultraviolet light.
The apparatus of this invention comprises a source of radiant energy and reflectors which are adapted to concentrate the light rays emitted from the source onto a glass fiber which is coated with an uncured polymer. Compositions which are useful as coatings, methods of applying the coatings and methods for curing the coating as by the use of ultraviolet radiation are well-known in the art, and are described, for example, in U.S. Pat. No. 4,099,837 to Vazirani, U.S. Pat. No. 4,115,087 to Martin, U.S. Pat. No. 4,324,575 to Levy, and to U.S. Pat. No. 4,514,037 to Bishop et al. The composition of the coating material and the method of applying the coating material to the glass fibers do not constitute a part of this invention, and those portions of the above-mentioned patents which relate to compositions of coating materials and methods of applying coating materials to glass fibers are incorporated herein by reference.
This invention is not limited by the nature of the curing radiation and may be used, for example, with infrared or ultraviolet radiation. In the preferred embodiment of using ultraviolet radiation an electrodeless discharge lamp which is energized by microwaves is utilized, and the invention will therefore be illustrated in more detail by describing the preferred embodiment.
FIG. 1 shows the apparatus of this invention mounted within a housing 54 and supplied with microwave energy from magnetron 50 through waveguide 52. Apparatus for energizing electrodeless discharge lamps is well-known in the art and one embodiment is described in U.S. Pat. No. 4,359,668 to Ury.
In FIGS. 1 and 2, tubular electrodeless ultraviolet source 30, which is energized by microwave energy, is centered on the inner focus 26 of reflector 20, herein referred to as the source focus, and glass fiber 44 is shown at the outer focus of reflector 20, herein referred to as the object focus. Reflector 10 is disposed so that its foci are coincident with the foci of reflector 20. Transparent tube 40, preferably made of substantially pure quartz, is located with its axis substantially coincident with the object focus of reflector 20.
Reflectors 10 and 20, which in combination form an elliptical reflector, are secured together by lips 12 and 14 of reflector 10 and lips 22 and 24 of reflector 20. In the preferred embodiment of the invention, the reflectors 20 and 10 are each trough-like structures having a cross-section in the form of half an ellipse. Such an arrangement of the reflectors is not novel and is shown, for example, in Japanese Patent No. 55-152567 published Nov. 27, 1980.
In accordance with the invention, the apparatus includes auxiliary reflector 42 which is shown in FIG. 2 as being on the outer surface of tube 40. In this embodiment, the reflective surface 42 could be either on the inner portion of the tube or the outer portion of the tube; however, in the embodiment wherein the reflective surface is on tube 40, the reflective surface preferably is on the outside of the tube as shown.
Instead of being located on the surface of a cylindrical body as shown in FIG. 2, the auxiliary reflector may be an independent body such as 42a shown in FIG. 4. Auxiliary reflector 42a is held in place by support means 43 which extends through gap 41 between reflector portions 10a and 10b. It is obvious that this arrangement permits the use of an auxiliary reflector in the absence of tube 40a.
The reflective material for auxiliary reflector 42 may be any substance which reflects ultraviolet and is nonabsorbent to microwave energy. An aluminized coating which is applied by techniques well-known in the art is suitable.
While there may be some variation in the shape of the arc occupied by the auxiliary reflective surface 42 and its orientation, in the preferred embodiment the arc is a portion of a circle, its midpoint lies on a line extended between the two foci of the elliptical reflector and it subtends an angle from about 80° to 100°, preferably about 90°. In the preferred form of the invention, tube 40 is a cylindrical body with its axis substantially on the object focus.
As is well known, light rays emanating from one focus of an ellipse will impinge on the other focus of the ellipse. In the embodiment of FIG. 2, light rays represented by a, which are emitted from source 30 on a line going through focus 26 will be reflected from the inner surface of reflector 20 directly towards the object focus. However, light rays which are emitted from the source at points other than those at focus 26 such as, for example, rays emitted at a tangent to the surface 32 of the source 30 as represented by line b, will not strike the other focus, althrough they will pass near it. However, a substantial portion of those rays which do not impinge directly on the object focus, are intercepted by reflector 42 and are reflected back towards the object focus. In the absence of reflector 42, these rays would strike reflector 10 and also be reflected; however, in general, those rays which do not originate on a line which passes through focus 26, and which are reflected from reflector 10 would not pass through the object focus.
EXAMPLE
In order to determine the extent to which the use of an auxiliary reflector in accordance with the invention changes the intensity of the light which passes through the object focus, an optical probe was mounted within a quartz tube in a system constructed in accordance with FIGS. 1 and 2. The quartz tube was about 1.9 cm. in diameter and the elliptical reflector had a major axis about 6 inches in length and a minor axis about 4 inches in length. The probe was rotatable and adapted to collect light directed toward the object focus from any direction within a 360° arc. The relative intensities of light rays striking the probe were measured for a system without an auxiliary reflector and for an identical system with an auxiliary reflector arranged in accordance with FIGS. 1 and 2 with the reflector occupying a 90° arc.
The resulting data were plotted on the graph of FIG. 3.
The lower line which is identified as "A" is for the system without the auxiliary reflector and the upper line identified as "B" is for the system with the auxiliary reflector. The angles referred to on the abscissa are as shown at the quartz tube in FIG. 2.
As can be seen, the auxiliary reflector significantly increases the intensity of light directed toward the object focus from 0° to about 90° and from about 270° to about 360°. The increase in intensity was about 18.5% in the arcs from 0° to 45° and 315° to 360°, and the overall increase in intensity was about 14°.
The embodiments described herein are intended only to illustrate the invention, and it is applicant's intention to cover all modifications which come within the scope of the invention which is to be limited only by the claims appended hereto. | Apparatus for treating material with radiant energy, especially adapted for curing photocurable polymeric materials coated onto an optic fiber. The apparatus includes first and second reflectors which in combination form an elliptical reflector, a light source positioned at one focus of the elliptical reflector and a photocurable polymer-coated wire-like material or a fiber such as an optical fiber positioned at the second focus. An auxiliary reflector is located near the second focus in such a position as to direct light rays impinging thereon towards the second focus, thus increasing the amount of energy which impinges on the polymer coating. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates generally to telecommunication transmission facilities and, more particularly, to a performance monitoring system that may, for example, periodically report on the error rate experienced by a plurality of T1 transmission lines.
Many telecommunication transmission systems include a central office that may transmit useful data, or "payload," signals over transmission lines to equipment on customer premises. Typically, digital payload signals are sent over the transmission lines through a series of regenerative repeaters, to a digital network interface unit, and in turn via an analog subscriber loop to customer premises equipment.
As described in U.S. patent application Ser. No. 08/145,771, filed on Oct. 29, 1993 by Bergstrom et al. ("Bergstrom"), which is incorporated herein by reference, the digital network interface is the demarcation between the telephone operating company's side of the telephone line and the customer's side of the telephone line. Electrically, the digital network interface is generally transparent to payload signals but can be used for special maintenance functions such as loopback. The digital network interface, in combination with a channel bank, receives payload signals from the transmission lines and converts the signals from digital to analog. The channel bank then transmits the resulting analog signals for each of a series of channels differentially on two wire conductors known as tip-ring pairs.
The Bell telephone system in the United States, for instance, has widely utilized a digital time-domain multiplexing pulse code modulation system known as the T1 transmission system. Each T1 transmission system carries 24 8-KB/second voice or data channels on two pairs of exchange grade cables. One pair of cables provides communication in each direction. T1 transmission systems are used in multiples "N", thus providing N×24 channels on N×2 cable pairs.
For convenience and simplification of terminology, the pair of cables carrying signals from the central office to the customer premises equipment may be referred to as a "transmit" line, and the pair of cables transmitting data from the customer premises equipment to the central office may be referred to as a "receive" line. These designations are made only as a matter of convenience; when an observer (such as a testing technician) changes position from a central office to the customer premises, what used to be a "transmit" line can be come a "receive" line, and what used to be a "receive" line can become a "transmit" line.
In the T1 system, the data to be transmitted over the lines, such as speech, is sampled at a rate of 8,000 hertz, and the amplitude of each sample is measured. The amplitude of each sample is compared to a scale of discrete values and assigned a numeric value. Each discrete value is then encoded into binary form.. Representative binary pulses appear on the transmission lines. The binary form of each sample pulse consists of a combination of seven pulses, or bits. An eighth bit is periodically added to allow for signaling.
As described in U.S. patent application Ser. No. 08/193,946, filed on Feb. 9, 1994 by Sheets et al. ("Sheets"), and U.S. patent application Ser. No. 07/943,859, filed on Sep. 11, 1992 by Pesetski et al. ("Pesetski"), each of which are incorporated herein by reference, a coding system is typically used to convert the analog signal to a digital signal. The system guarantees some desired properties of the signal, regardless of the pattern to be transmitted. The most prevalent code in the United States is bipolar coding with an all zero limitation (also called Alternative Mark Inversion or "AMI"). With bipolar coding, alternating one's (high bits) are transmitted as alternating positive and negative pulses, assuring a direct current balance and avoiding base line wander. Further, an average density of one pulse in eight slots, with a maximum of fifteen zeros between "ones," is required. This is readily obtained in voice-band coding, however, by simply not utilizing an all zero word. Contrasted with bipolar coding is unipolar coding, in which every occurrence of a high bit is seen as a positive pulse.
In many telecommunication systems, data may be transmitted sequentially in discrete groups of bits called "frames." In the T1 system, for instance, each of the 24 channels in the T1 system is sampled within a 125 microsecond period (equivalent to 1/8,000) of a second, constituting one frame. A synchronizing bit, or "frame bit," is added to each frame to serve as a flag, enabling line elements to distinguish each frame from the preceding frame or from noise on the line. Since there are 8 bits per channel and there are 24 channels and one frame bit at the end of each frame, the total number of "bits" needed per frame is 193. Thus, the resulting line bit rate for T1 systems is 1.544 million bits per second.
As further explained by Sheets and Pesetski, signals that violate either the coding rules or the framing rules established in a particular system are detected as errors. Thus, for example, under a bipolar coding scheme, two positive pulses should never occur in sequence. To the extent such pulses do occur adjacent to each other, such a signal may be noted as a bipolar coding violation. Similarly, a digital signal that violates framing rules (such as framing bit requirements) established in a given system is detected as a "frame error." In a given encoding protocol, a sufficient number of frame errors may be detected as a frame loss.
In a typical telecommunications transmission system, the central office occasionally wishes to investigate the performance characteristics of a particular transmission line. In such a case, for example, the central office may send a signal to the digital network interface, instructing the network interface to fall into "logical loopback mode" or simply "loopback." In loopback, all signals sent down the transmit line to the network interface are shunted back and sent down the receive line. While in loopback, if the same test signal that is sent down the transmit line for a substantial period of time is received by the central office along the receive line, then the central office can be substantially assured that the conductors in the T1 line are functioning properly. Alternatively, if the same signal applied to the transmit line does not return along the receive line, then the central office can determine that an error or malfunction has occurred at a point along that T1 line.
Unfortunately, placing a digital network interface in loopback mode can be disruptive for the consumer, because, during loopback, the customer premises equipment is essentially cut off from the central office and is precluded from communicating via the T1 line. This problem can be avoided by installing a spare T1 line and shunting the customer premises equipment to the spare T1 line during loopback. However, such a spare T1 line cannot itself be interrogated by the central office unless a second or even third T1 line is also in place. Further, the installation of additional T1 lines is expensive and therefore not desirable.
Another method of investigating errors in T1 transmission lines is to provide the network interface unit with a substantial electronic memory. The network interface unit may then monitor the data that passes from the central office to the customer premises equipment and detect certain bit patterns as errors or events such as bipolar violations or loss of frame. The network interface may then store in its memory an indication of the type of error or event that was detected. Thereafter, upon receiving an authorization signal from the central office, the network interface unit can be placed in loopback, and the network interface unit can download the contents of its memory on the receive line for transmission to the central office.
Unfortunately, this modified method of investigating T1 errors also suffers from the above-discussed problem of cutting off the customer premises equipment from communication with the central office. Furthermore, this method also requires the addition of substantial memory to each digital network interface, thus greatly increasing the expense of manufacturing the network interface units.
SUMMARY OF THE INVENTION
In a principal aspect, the present invention is system for monitoring performance of T1 lines in a digital transmission line network. The present invention incorporates a common control unit interconnected to a spare T1 transmission line as well as to each of the payload transmission lines in proximity to the digital network interface units. Preferably in cooperation with one or more memory circuits and one or more detector circuits, the common unit is configured to serially receive status information or error data from the transmission lines or network interface units and to selectively transmit the information or data to the central office via the spare transmission line.
By dedicating a common unit to oversee error detection and/or error reporting, the present invention eliminates the need to cut off communication with the customer premises equipment when testing transmission line performance. Further, the present invention thereby greatly reduces or eliminates the need to build substantial memory circuits in each network interface unit or to add additional spare transmission lines.
Accordingly, a principal object of the present invention is an improved system for monitoring T1 transmission line performance. Another object of the present invention is a common unit interconnected to a plurality of transmission lines or to a plurality of network interface units, configured to oversee the detection of errors in payload data and/or the reporting of such errors to the central office.
Still another object of the present invention is to eliminate the need to cut off communication between the central office and the customer premises equipment when monitoring transmission line performance between the central office and the customer premises equipment. Yet another object of the present invention is a cost efficient method of monitoring T1 transmission lines for errors such as bipolar violations or frame loss. These and other objects, features, and advantages of the present invention are discussed or apparent in the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the present invention are described herein with reference to the drawings, wherein:
FIG. 1 is a block diagram of a prior art T1 telecommunication system;
FIG. 2 is a block diagram of a preferred embodiment of the present invention;
FIG. 3 is a detailed block diagram of the preferred embodiment of the present invention;
FIG. 4 is a block diagram of an alternative embodiment of the present invention; and
FIG. 5 is a block diagram of another alternative embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIG. 1, there is shown a block diagram depicting a prior art digital transmission line network 10. The transmission line network 10 includes a central office 12 interconnected via a plurality of transmission line spans 14, 16 and regenerative repeaters 18, 20 to a series of network interface units or digital network interfaces 22, 24. Each network interface unit includes circuitry that may be referred to as a network interface circuit. The transmission lines 14, 16 are typically T1 type lines. However, depending on the network, the transmission lines may alternatively be any of a variety of other types of lines including but not limited to copper or fiber optic based cables. Each network interface unit 22, 24 is in turn respectively connected to customer premises equipment 26, 28. While FIG. 1 illustrates only two network branches originating from the central office 12 and extending respectively to two network interface units and two respective sets of customer premises equipment, those skilled in the art will appreciate that, in practice, many additional branches may stem from the central office, each to other sets of customer premises equipment.
In a typical T1 transmission system, multiple network interface units are placed together in the same physical location. In this regard, the network interface units are typically grouped together and mounted in a maintenance shelf, such as the Teltrend Rack-Mount Digital Shelf Assemblies Models DSA-120/A and DSA/111/A. Commonly, multiple sets of customer premises equipment are dispersed among separate buildings or facilities. In such a configuration, a remotely positioned maintenance shelf usually holds network interface units interconnected respectively to the various customer premises equipment. On the other hand, in larger or more complex buildings or facilities that use more than 24 phone lines, multiple sets of customer premises equipment may actually be located within the building itself. In such case, the maintenance shelf containing the respective network interface units may also be located within the building.
Referring now to FIGS. 2-4, preferred embodiments of the present invention are shown as a performance monitoring system for T1 transmission lines or for other types of transmission lines. In these embodiments, a "common unit" or common control unit 30 is interconnected to the plurality network interface units (e.g., 22, 24) via lines 32, 34. Lines 32, 34 may be T1 transmission lines or other types of transmission lines known to those skilled in the art. The common unit 30 may be interconnected in parallel to the group of network interface units and is also interconnected via a spare transmission line or status transmission line 36 and a series of regenerative repeaters (e.g., 38) to the central office 12. In the preferred embodiment, the common unit 30 is stored proximately to the network interface units 22, 24 to which it is interconnected, and in this regard it may be desirable to store the common unit in the same maintenance shelf unit that holds the plurality of network interface units.
Generally speaking, the common unit 30 includes circuitry sometimes referred to as a "common circuit," which is configured to receive error status information from any or all of the network interface units and to transmit an error report signal along the spare transmission line 36 to the central office 12. In this way, a technician or computer system at the central office 12 can analyze the performance of the transmission line (e.g., 14) leading to a given network interface unit (e.g., 22) without necessitating a break in communication between the central office 12 and the respective customer premises equipment (e.g., 26). As discussed below, the status information processed by the common unit 30 may include, for example, a list of errors such as bipolar violations or frame loss that are detected in the payload signal transmitted in either direction along the given transmission line. Alternatively, the status information may simply comprise a copy of at least a portion of the payload signal received by the network interface unit from the respective transmission line. In any event, the common unit 30 may selectively or automatically store, further analyze and/or transmit to the central office 12 a report signal indicative of transmission line performance.
As illustrated by FIG. 3, the common unit 30 preferably contains interrogating circuitry 40 that is configured to interrogate any one or more of the network interface units (e.g., 22, 24) and to receive status information from the network interface units. In one embodiment of the present invention, the common unit 30 is configured to serially and repetitively interrogate each of the network interface units, for example, by polling or multiplexing through each network interface unit and serially receiving information from each of the units. The common unit can thus download information from each network interface unit, for example, every few seconds, thereby eliminating the need for substantial, expensive memory circuits in each of the individual network interface units. Alternatively, the common unit 30 may be configured to interrogate any one or more of the network interface units 22, 24 either selectively on command or pursuant to a preprogrammed schedule. Still alternatively, the common unit may be configured to continuously interrogate any one or more of the network interface units on a substantially real time basis.
Errors or other aspects of the signal transmitted through a network interface unit along a given transmission line are detected in the preferred embodiment by a detector circuit 42, 44 that can be built into or coupled to each network interface unit and/or the common unit. A detector circuit or error detector (e.g., 42) built into the network interface unit (e.g., 22) can continuously, periodically or selectively examine the signal transmitted along the transmission line (e.g., 14) in either direction through the network interface unit (e.g., 22) in order to detect status information such as a number or rate of bipolar or framing errors. Small amounts of such status information can be temporarily stored in a small, inexpensive memory circuit 46, 48 interconnected to the detector circuit 42, 44 in the network interface unit 22, 24, for subsequent interrogation by and transfer to the common unit 30.
Still alternatively, a detector circuit or error detector 50 can be incorporated into the common unit itself in order to examine signals passed to the common unit from any of the network interface units, and to extract errors or other status information from those signals. In an alternative embodiment in conjunction with this configuration, as shown in FIG. 2, a switching circuit 52, 54 can be coupled to each network interface unit 22, 24 in order to enable the payload signal passing through the network interface unit to be shunted to the common unit for analysis. In this embodiment, for instance, a switching signal may be transmitted from the central office along a given T1 line (e.g., 14) to a respective network interface unit (e.g., 22). The switching signal is then detected by either the switching circuit (e.g., 52) or a detector circuit (e.g., 42) within the network interface unit. In response, the switching circuit associated with the given T1 line then shunts traffic from that line into the common unit and out of the common unit before the signal passes fully through the network interface unit. In this way, the common unit 30 may then directly monitor the traffic passing between the central office 12 and the customer premises equipment (e.g., 26) and, as will be discussed below, store in its memory an indication of any errors noted. Alternatively or in addition, the common unit 30 may then provide transmission status information on a real time basis to the central office 12 via the spare T1 line 36.
In a closely related embodiment, as illustrated by FIG. 5, a similar shunting effect can be accomplished by interconnecting the common unit directly to the transmission lines (e.g., 14, 16), via shunt lines 56, 58, 60, 62. In this embodiment, the location of the central office may be referred to as a first line position, and the location of the common unit may be referred to as a second line position. The second line position may, but need not necessarily, be proximate to the plurality of network interface units. In the configuration of this embodiment, a payload signal transmitted in either or both directions along any or all of the transmission lines (e.g., 14, 16) can be selectively or continuously shunted to pass through the common unit on its way to or from the central office. Thus, for example, a payload signal traveling along transmission line 14 toward customer premises equipment 26 can be diverted along line 56 to the common unit 30, through the common unit 30, and back along line 58 to the transmission line 14 for continued transmission to the customer premises equipment 26. In this embodiment, the common unit can be selectively commanded or preprogrammed to poll any or all of the transmission lines for error data or other status information. Alternatively, the common unit can be configured to continuously examine the payload signal traveling down any one or more of the transmission lines, and to report occurrences of transmission errors to the central office on a substantially real time basis.
In the preferred embodiment, the common unit also includes a memory circuit 64 designed to store information such as status signals received from network interface units. In this embodiment, as the common unit 30 receives information from the network interface units regarding errors in the transmitted data, the common unit may store the error data in its memory 64. Periodically, the common unit may then transmit to the central office 12 a report signal indicating the transmission status of the various lines. In part for this purpose, the common unit 30 may include a reporting circuit 66 (shown in FIG. 3) configured to generate and transmit a report signal along the spare line 36. As indicated above, the report signal may represent status information comprising an analysis or list of transmission errors such as bipolar violations or frame loss, or the report signal may simply comprise a periodic sample of the signal transmitted to the network interface unit (e.g., 22) on the given transmission line (e.g., 14). In either case, the common unit 30 is configured to examine, store and/or transmit the report signal to the central office 12, based for example on information received directly from the network interface units 22, 24 or on information stored in the memory circuit 64 of the common unit. In this regard, as the reporting of transmission status from the common unit 30 to the central office 12 becomes more frequent, the amount of required memory in the common unit decreases. Ultimately, in the event the common unit is configured to report transmission status information to the central office on a substantially real time basis, the amount of required memory in the common unit is substantially reduced or entirely eliminated.
Still further, in the preferred embodiment, the common unit 30 is configured to send a report signal to the central office 12 only upon detection of a status request signal. In this embodiment, for instance, the central office 12 can send a status request signal along a given transmission line (e.g., 14) or along the status transmission line 36. In the event the status request signal is sent along the transmission line (e.g., 14) leading to a network interface unit (e.g., 22), a detector circuit (e.g., 42) in the network interface unit (e.g., 22) is configured to detect the status request signal and to responsively forward to the common unit 30 a status signal representative of pertinent status information. The common unit in turn stores or analyzes the status signal or transmits a report signal embodying the status information to the central office 12. Alternatively, in the event the common unit 30 receives a status request signal along the status transmission line 36, a detector circuit and/or signaling circuit (not shown) within the common unit 30 identifies the status request signal. The common unit responsively interrogates any designated network interface unit and downloads a status signal from the network interface unit. In turn, by means of a reporting circuit (not shown) included in the common circuit 30, the common unit transmits a report signal via the status line 36 to the central office 12.
In any embodiment of the present invention, the common unit 30 may also serve as a "second half" of a loopback circuit, so that a loopback test can be performed on any transmit line without sending a return signal to the central office 12 on the receive line. In this embodiment, the central office 12 can monitor a payload signal being sent along a transmit line, and the common unit 30 can be instructed to enter loopback mode with respect to the given transmit line. A substantial copy of the signal carried by the transmit line is then transmitted to the common unit and in turn transmitted by the common unit via the spare line 36 back to the central office 12. In this way, the central office can compare the transmitted and received signals to ensure transmission quality up to the point of the network interface unit, without disrupting communication between the customer premises equipment and the central office.
Preferred embodiments of the present invention have been described above. Those skilled in the art will understand, however, that changes and modifications may be made in these embodiments without departing from the true scope and spirit of the present invention, which is defined by the following claims. | A system for monitoring the performance of T1 digital transmission lines by incorporating a common unit interconnected to a plurality of network interface units as well as to a spare transmission line leading to a central office. The common unit is configured to interrogate any or all of the network interface units in order to obtain status information such transmission error rates, and to report such status information via the spare transmission line to the central office. By dedicating a common unit to oversee error detection and/or status reporting, communication between the central office and customer premises equipment need no longer be disrupted while transmission performance is being monitored. | 7 |
FIELD OF THE INVENTION
The present invention relates to electrically connecting an opto-electronic module to a printed circuit board.
BACKGROUND
Opto-electronic modules are modules that transmit and/or receive data optically, for example, using lasers or receivers. An optical connector of some type provides for data passage between the optical devices in the module and other optical components. Typically, such modules also send and/or receive electrical signals, for example, via an electrical connector on a printed circuit board or a backplane. In general, an optical device, which is found in the module, requires several electrical connections. Due to the large number of optical devices that may be present in the module, the number of electrical connections can be numerous. Thus, depending upon the number of optical devices, for space considerations the electrical connector can be configured as a linear or, for a larger of number of optical devices, a two-dimensional array.
In instances where multiple modules are used, they are typically configured in front loading rack-mount systems, which contain racks for receiving modules in much the same way as the frame of a household dresser receives a drawer. Connectors mounted on a backplane at the rear of the drawer or rack mate with connectors mounted on the modules when the modules are seated. Since each rack can contain from a few to hundreds of modules, for ease of maintenance it is important that each module can be serviced (i.e. inserted or removed) independent of as many, preferably every, other module(s) because each unrelated module that must be disrupted in the course of servicing another represents lost capability and, accordingly, potential loss of time and/or revenue. As a result, modules are configured so that they can be inserted and removed through the front panel of the front loading rack-mount system to avoid having to disengage the rack from the backplane and thereby potentially disrupt the operation of one or more unaffected modules.
As the demand for optical communication capability increases, the need for greater numbers of optical devices will similarly increase. However, as noted above, greater numbers of optical devices generally result in larger modules and much larger electrical connectors. Hence, the number of modules that can be fit within a given size front loading rack-mount system decreases. Moreover, since the size of the connector (due to increased numbers of pins or other contact elements) grows faster than the number of devices, the ability to fit more modules within a given size front loading rack-mount system quickly becomes limited by the connector size.
For example, FIG. 1 shows an exemplary opto-electronic module 100 of the prior art. The module 100 has an optical connector 110 on its front side 120 providing access to, in this example, twenty-four optical devices (not shown) such as lasers and/or photoelectors and an electrical connector 130 on its back side 140 . The electrical connector 130 is configured to pass through the front panel 170 of the rack (not shown) in order to mate with a complementary connector 150 on a circuit board or a backplane 160 at the rear of the rack. Thus, for ease of maintenance, the connection between the module 100 and the backplane 160 is made by insertion of the module 100 longitudinally through the front panel 170 towards the backplane 160 until the two connectors 130 , 150 mate.
FIG. 2 shows the module 100 of FIG. 1 following mating of the two connectors 130 , 150 in the above described manner.
FIG. 3 is a rear view of the module 100 of FIG. 1 so that the electrical connector 130 is visible. The electrical connector 130 has an array 180 of pins 190 through which electrical signals can pass between the module 100 and the backplane 160 . As noted above, and as is typically the case, the size of the electrical connector on the back side is much larger and contains many more pins than the number of optical devices. Thus, it will be recognized that a mere doubling of the number of optical devices in this example to forty-eight may result in no change in the overall of the module 100 but may require a connector approaching twice the illustrated overall area and thereby far exceed the overall area taken up by the back of the module. As a result, for a given size drawer, the crossover point between increased devices per module versus total number of modules that can be accommodated can shift to a net loss quite quickly.
Thus, there is presently no easy way, for a given size front panel accessible drawer of a rack and a given size and number of modules, to substantially increase the number of optical devices.
SUMMARY OF THE INVENTION
We have recognized that, because the bottom of the module has a larger surface area than the rear of the module (i.e. it can accommodate a larger connector within its boundaries), moving the connector to the bottom of the module solves part of the problem. However, since the electrical connector is then actually or substantially perpendicular to the optical connector, movement of the electrical connector to the bottom detrimentally affects front panel accessibility, since longitudinal insertion of the module through the front panel does not allow for making the electrical connection because it requires movement of the module in a direction other than the direction of insertion. Advantageously, we have developed a way that allows such modules (i) to be used in a front loading rack despite the electrical connector being on the bottom of the module, and (ii) make the electrical connection. As a result, the bottom connector modules can still be independently serviced while causing minimum, and in many cases no disruption to surrounding modules. Through use of a device that receives the module through the front panel (for example, in a plane defined by the module's electrical connector) and can then move the module in the direction necessary to make the electrical connection (for example, substantially perpendicular to the plane defined by the module's electrical connector) the above problems are addressed.
The above advantages and features are of representative embodiments only, and are presented only to assist in understanding the invention. It should be understood that they are not to be considered limitations on the invention as defined by the claims, or limitations on equivalents to the claims. For instance, some of these advantages may seem mutually contradictory, in that they cannot be simultaneously implemented in a single embodiment. Similarly, some advantages are primarily applicable to one aspect of the invention. Thus, this summary of features and advantages should not be considered dispositive in determining equivalence. Additional features and advantages of the invention will become apparent in the following description, from the drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an exemplary opto-electronic module of the prior art;
FIG. 2 shows the module of FIG. 1 following the mating of two connectors;
FIG. 3 is a rear view of the module of FIG. 1 so that the module's connector is visible;
FIG. 4 shows a simplified example of an opto-electronic module configured for use in accordance with the present invention;
FIG. 5 shows, for example, the implementation of a device suitable for use with the present invention;
FIG. 6 is a simplified front view of an opto-electronic module seated in a frame similar to that shown in FIG. 5 in accordance with the present invention;
FIG. 7 is a front view of the opto-electronic module of FIG. 6 following the mating of two connectors in accordance with the present invention;
FIG. 8 is a front view of an example rack from a front loading rack-mount system implementing the present invention with its front panel in place;
FIG. 9 is a partial internal view of the rack of FIG. 8 with its front panel removed;
FIG. 10 shows an alternative variant in accordance with the present invention;
FIG. 11 shows another alternative variant in accordance with the present invention;
FIG. 12 shows yet another alternative variant in accordance with the present invention;
FIG. 13 shows another alternative variant in accordance with the present invention;
FIG. 14 shows another alternative variant in accordance with the present invention;
FIG. 15 shows a further variant in accordance with the present invention;
FIG. 16 shows another variant in accordance with the present invention; and
FIG. 17 a through 17 c show simplified examples of opto-electronic modules suitable for use with the present invention.
DETAILED DESCRIPTION
In general, a device is used that receives the opto-electronic module through the faceplate of the rack drawer (e.g. in a plane defined by the module's electrical connector) and then moves the module in a direction substantially perpendicular to the plane of the electrical connector to connect the module to the printed circuit board. This approach enables an increasing number of opto-electronic devices to be contained in the opto-electronic module (due to the additional area provided by positioning the electrical connector at the bottom of the module) while still providing insertion and removal of the module through the front panel of a front loading rack-mount system. Moreover, the number of devices is only limited by the area defined substantially by the width of the module and the depth of the rack drawer (i.e. the frontal area can remain the same but the electrical connector size can be increased depth-wise until a limit related to the depth of the rack is reached).
FIG. 4 shows a simplified example of an opto-electronic module 400 , for example, an opto-electronic transmitter, receiver or transceiver configured for use in accordance with the present invention. As shown in FIG. 4 , the opto-electronic module 400 is oblong in shape and also contains various optical and electronic components (not shown because the details are unimportant for understanding the invention). The module 400 includes a body 410 . The module 400 also includes an optical connector 420 and an electrical connector 430 positioned such that they define a pair of planes substantially perpendicular to one another. The electrical connector 430 is configured for mating with a complementary electrical connector located on, for example, a printed circuit board. The module 400 further includes at least one guide structure 440 , shown for purposes of example, in the form of a rail positioned on a side of the body 410 .
By way of background, the optical connector 420 is the interface through which optically encoded data signals pass when transiting between the module 400 and elsewhere.
If optically encoded data signals are received by the module 400 through the optical connector 420 , they are converted into electrical signals (by the module's 400 internal components) and, in some cases, are further transmitted electrically elsewhere via the electrical connector 430 .
Similarly, if electrically encoded data will be transmitted optically by the module 400 , it is received by the module 400 via the electrical connector 430 . The data is then converted to optically encoded data within the module before being transmitted from the module 400 via the optical connector 420 .
In the case of a transceiver, the optical connector 420 and the electrical connector 430 together provide for the bi-directional transmission of data through the module 400 as described above.
FIG. 5 shows, by way of example, one example implementation of a device suitable for use with the present invention. A frame 500 has an opening on its front for receiving a module and two guides 515 , one on each side, configured to accept a complementary pair of guides of an opto-electronic module. The frame 500 is configured to also move in a direction other than that of module insertion, for example, slidably along several posts 560 . As shown in this example, the posts 560 are perpendicular to the plane of the frame 500 and are encircled by springs 540 that urge the frame 500 into a normally disengaged position, for this implementation, that is away from the printed circuit board 505 . To prevent the guides 515 from being urged off the posts 560 by the force of the springs 540 if necessary, a retaining clip or pin 545 is provided at the top of at least one of the posts 560 .
The frame 500 of FIG. 5 is also coupled to a lever 520 that moves the frame 500 from a normally disengaged position to an engaged position. The lever 520 is connected to the frame 500 by a pin through a slot 555 in the lever 520 or some other suitable known manner. A lock 550 is optionally provided to secure the lever 520 when the lever 520 is in an engaged position. Optionally, the frame 500 may also or alternatively include alignment features, for example, one or more alignment boss(es) 530 or alignment pin(s). One or more complementary elements, for example, tapered pins 525 , on the circuit board 505 can be used to engage the, in this example, bosses(es) 530 to, in different implementations, act as stops for when the frame 500 is in an engaged position and/or assist in alignment by forcing the frame into a particular position in the X-Y plane.
In general, the frame is configured to move an opto-electronic module in a direction other than the direction of the module's insertion so that its electrical connector will mate with its complementary electrical connector. Thus, for the example of FIG. 4 and FIG. 5 , the process of mating the two electrical connectors 430 , 510 proceeds as follows. The module 400 of FIG. 4 is inserted into the frame 500 . By aligning the guide 440 with the complementary guide 515 in the frame 500 and, then longitudinally inserting the module 400 through the front panel into the frame 500 , in this example, along a plane defined by the electrical connector 430 so that it becomes secured in the frame 500 . The guide 440 of FIG. 4 is thus used to align, constrain and control insertion of the module 400 into the frame 500 . Once the module 400 is fully inserted into the frame 500 the lever 520 is moved downward to cause the frame 500 to move the module 400 in a direction substantially perpendicular to its electrical connector 430 to connect or disconnect the electrical connector 430 of the module 400 to the electrical connector 510 of the circuit board 505 . This movement is referred to as “substantially” perpendicular because, depending upon the implementation some pivotal, arcuate or other translational movement beyond pure perpendicular movement can also be involved.
As the frame 500 is moved downward, if one or more of the optional alignment bosses 530 are used, movement of the lever 520 to mate the electrical connectors 430 , 510 will cause the alignment bosses 530 to act in conjunction with the tapered pins 525 to, in the example shown, center and thereby ensure proper x-y alignment of the electrical connector 430 relative to its complementary connector 510 .
Once the electrical connectors 430 , 510 are mated, if the urging spring force is too great it can cause the electrical connectors 430 , 510 to separate unintentionally. In such cases, a lock 550 can be optionally used to secure the frame 500 in the engaged position, for example, by constraining or clamping the lever 520 . By releasing the lever 520 from the lock 550 (i.e. unclamping the lock 550 ) the spring force alone and/or moving the lever 520 in an upward direction will cause the electrical connectors 430 , 510 to become disengaged.
FIG. 6 is a simplified front view of an opto-electronic module that has been inserted through the front faceplate of a rack drawer (not shown) so it is now seated in a frame similar to that shown in FIG. 5 in accordance with the present invention. As shown in FIG. 6 , the opto-electronic module 600 includes an optical connector 605 on its front, an electrical connector 610 on its bottom side and two guides 615 each in the form of a rectangular rail. A frame 620 includes two guides 625 each in the form of a channel and is positioned to slidably move along at least two posts 630 each encircled by a spring 635 . The frame 620 accurately positions the electrical connector 610 over the electrical connector 650 on the circuit board 645 so that no alignment boss is required. A lock 655 is provided on the circuit board 645 to maintain the lever 640 in the lower position when the module 600 is seated and the electrical connectors 610 , 650 are mated.
FIG. 7 is a front view of the opto-electronic module 600 of FIG. 6 following the mating of the electrical connectors 610 , 650 in accordance with the present invention. As shown in FIG. 7 , the lever 640 has been moved downward (along the arrow 660 ) bringing the frame 620 in a downward direction to compress the springs 635 and cause the mating of the connectors 610 , 650 . As illustrated, the lever 640 is positioned just prior to being secured by the lock 655 through slight movement to the side. Releasing the lever 640 from the lock 655 (i.e. unclamping the lock 655 ) and moving the lever 640 in the opposite direction along the arrow 660 disengages the electrical connectors 610 , 650 and moves the frame 620 towards a position where the module 600 can be removed from the rack via the front panel. Thereafter, once the frame 620 reaches the position shown in FIG. 6 , in order to remove the module 600 , a user need only pull the module 600 from the frame 620 and need not disturb any other adjacent or nearly module.
FIG. 8 is a front view of an example rack 800 from a front loading rack-mount system implementing the present invention, viewed from the front, with its front panel 805 in place. As shown in FIG. 8 , the rack 800 includes a front panel 805 and several rows 810 , 815 , 820 , 825 of slots 830 ( a . . . x ) each having frames 835 ( a . . . x ) as described above. As shown, each frame 835 ( a . . . x ) includes a lever 845 ( a . . . x ) and an optional lock 850 ( a . . . x ) similar to that described above. In general, the openings in the front panel 805 are dimensionally slightly larger than the modules 840 ( a . . . x ) to allow for clearance of the guides and unmated part of the electrical connector on each of the modules 840 ( a . . . x ). As shown, each of the modules 840 ( a . . . x ) in the lower three rows 815 , 820 825 is seated such that their individual electrical connectors (not shown) are mated. This is nevertheless evident from the levers 845 ( a . . . x ) being secured in the downward position by the locks 850 ( a . . . x ).
As further shown in FIG. 8 , the uppermost row 810 includes an empty slot 830 c , such that the frame 835 c is visible. Another slot 830 f contains a module 840 f that has been disengaged so that it is ready for removal. The module 840 f is removed by simply pulling the module 840 f outward from the frame 835 f
FIG. 9 is a partial internal view of a portion of three rows 815 , 820 , 825 in the example rack 800 of FIG. 8 viewed as if its front panel 805 was removed. As shown in FIG. 9 , the electrical connectors 855 ( a . . . x ) of the modules 840 ( a . . . x ) are mated to the electrical connectors 860 ( a . . . x ) of several printed circuit boards 865 a , 865 b , 865 c that would not be visible with the front panel 805 in place. In the example of FIG. 8 and FIG. 9 , the printed circuit boards 865 ( a . . . x ) can also be removable and may, in turn, be connected to components via, for example, backplane or cabling (not shown) at the rear of this drawer of the rack 800 .
Although the above examples have all used guides of square cross section formed as rails, in alternative variants of the present invention, guides of different sizes, forms and shapes can be used. This, different guides can be used as a form of “keying” to ensure that only the correct modules can be inserted and/or accepted into a particular frame. In this manner, for example, it is possible to differentiate between two modules using the same physical connectors but having incompatible electrical differences, for example, reversed power and ground connections or reversed data input and output connections. Similarly, this approach makes it possible to provide a visual commonality to a family of modules while preserving a difference among individual modules in the family. For example, all modules in a particular family of modules could have a specific size and shape left side guide but be differentiated from others in the family through different and incompatible right side guides.
FIG. 10 shows an alternative variant in accordance with the present invention. In this example, the guides 1010 , 1015 on the module 1000 are each still in the form of rails, but each is of a different cross sectional shape and size. Complementary guides 1005 , 1025 in the form of channels on the frame 1030 are configured to accept the guide 1010 , 1015 as described above. Because the guides on the left side 1005 , 1010 and right side 1015 , 1025 are incompatibly different with respect to each other, the module 1000 can only be inserted in the manner shown and another module, such as the module 600 of FIG. 6 and FIG. 7 , could not be used because its left side rail 615 could not be accommodated by the channel 1005 of the left side frame 1020 of FIG. 10 .
FIG. 11 shows another alternative variant in accordance with the present invention. As shown in FIG. 11 , the guides 615 , 1110 on the module 1120 are again in the form of rails but one guide 615 is the same as in FIG. 6 but the other guide 1110 has a triangular cross sectional shape. Thus, this configuration would not allow the module 1120 of FIG. 11 to be used in the frames of FIG. 6 or FIG. 10 . Similarly, neither the module 600 nor the module 1000 could be used in the frame of FIG. 11 .
Although the above examples in FIG. 10 and FIG. 11 used a set of rails and complementary channels for the guides, this approach is not specifically required. Instead, for example, other elements suitable for aligning, constraining and controlling insertion of the opto-electronic module into the frame can be used, for example, posts, pins or other elements. In addition, it is to be understood that the guides need not be formed as outwardly extending pieces on the module. Instead, the module can have one or more channels with the frame having complementary elements in the form of outwardly extending rails, pins or other elements that go into the channels on a module. Advantageously, with this approach, the modules can be narrower and the opening in the front panel can be made smaller because the overall insertion footprint will be smaller. Of course, different combinations of the above can also be used, including the mixing and matching of rails, pins or grooves on modules or frames. Any manner that still achieves the constraint and placement aspects described herein can be part of an implementation of the invention.
FIG. 12 shows yet another alternative variant in accordance with the present invention. As shown in FIG. 12 , the optoelectronic module 1200 includes several guides 1205 , 1210 in the form of multiple individual posts (only those on one 1215 side being visible). The guides 1205 in the upper row are tapered posts whereas the guides 1210 in the lower row are cylindrical posts. The rows of guides 1205 , 1210 are linearly aligned for sliding into and along complementary shaped guide slots 1220 , 1225 in one side of the frame 1230 .
Just as different configurations and elements can perform the guide functions, other aspects can be changed or substituted. For example, instead of, or in addition to, using springs coiled about posts as described above other mechanisms to move the frame can be used.
For example, in other alternative variants of the present invention, a variety of types of springs including coil, helical, leaf and torsion springs can be used to urge the frame into a normally disengaged position. The following are a few representative illustrative examples showing, for purposes of simplification, only the relevant details.
FIG. 13 shows one such example alternative variant suitable for use in an implementation of the invention. As shown in FIG. 13 , instead of using individual coil springs about the posts along which the frame moves, as described above, this variant incorporates a leaf spring 1305 located between the frame 1300 and the circuit board 1315 . In the normal position, the leaf spring 1306 is fully bowed and the frame 1300 merely rests on the top of the bowed portion. In some implementations, it may be necessary to prevent movement of the spring in undesirable directions, for example, when the spring is unloaded. This can be accomplished many different ways too numerous to name. For purposes of completeness, one simple example is provided with the understanding that others can be readily substituted without the application of anything more than a basic understanding of mechanical engineering. In the example, the ends of the spring 1305 are split to form a pair of tines, with one tine on one end being on one side of the post and the other tine on that end being on the other side of the post. As the spring 1305 is compressed, the split/tines constrain the movement to essentially only follow along the length of the split. In addition, a bent or highly curved portion 1310 near each end of the spring 1305 in conjunction with a retainer element, such as a clip, channel or flange 1320 is used to keep the spring ends from undesirable upward movement or and prevent either end from passing beyond the post. In this implementation, movement of the frame 1300 from the disengaged towards the engaged position, for example to seat a module inserted into the frame 1300 , compresses the leaf spring and causes the two ends to move away from each other such that, at the maximum compression point, the electrical connector on the bottom of an inserted module will be mated to the electrical connector 1310 on the circuit board 1315 .
FIG. 14 shows another example alternative variant suitable for use in an implementation of the invention using a helical coil spring 1405 . As shown in FIG. 14 , the frame 1400 is urged into a disengaged position by the helical coil spring 1405 positioned underneath a “wing” 1410 attached to a side of the frame 1400 .
FIG. 15 shows yet another representative example more complex variant of a frame moving mechanism in accordance with the present invention. As shown in FIG. 15 , a rotatable knob 1505 is coupled to gears 1510 via a shaft 1515 . A cam 1515 is configured with an appropriate profile so that, when the knob 1505 is rotated, the cam 1515 applies a force to a fixed element 1520 on the frame 1520 and thereby causes it to move down the posts 1525 and compress the springs 1535 until the peak 1530 of the cam 1515 is touching the element 1520 . At this point, when the frame 1520 contains a module, the electrical connector of the opto-electronic module will be fully coupled to the electrical connector 1310 on the circuit board 1315 . Reverse (or as shown further) rotation of the knob 1505 eases the compression of the springs 1535 and thereby causes the frame 1520 to move back toward the normally disengaged position.
In yet other variants of the present invention a spring need not be used at all—all that is required is some mechanism that moves the frame between the disengaged and engaged positions. For example, by movably coupling cam 1515 of FIG. 15 to the element 1520 , an arrangement can be formed that will move the frame in the directions that cause mating and un-mating of the two electrical connectors without the use of a spring at all.
In addition, in some variants, the movement of the frame need not be purely linear, nor must it be in only one direction. For example, the movement could be in two linear directions so that the frame itself can be configured to slide in the plane of insertion and perpendicular to it to, for example, to cause the frame to be closer to the face plate when no module is present and thereby facilitate acceptance of a module.
In another example, a portion of the movement could be a pivoting or arcuate movement. FIG. 16 shows a simplified representative further example variant of a frame moving mechanism in accordance with the present invention involving pivoting or arcuate movement in addition to movement perpendicular to the connector 1310 .
As shown in FIG. 16 , the mechanism 1600 is made up of a frame 1605 configured to accept an opto-electronic module as described above. A spring 1610 , located above the frame 1605 and connected to it, is used to maintain the frame 1605 in a normally disengaged position. The rear of the frame is connected to a rear collar 1615 by a pin 1620 that allows the frame to move about the pin 1620 . The rear collar is itself movable along a post 1625 of a specified height. In addition, a flange 1630 on the collar acts as a pivot stop to prevent the frame 1605 from moving in a pivotal manner beyond a parallel to the circuit board 1315 . Near the front of the frame 1605 is another post 1640 that is taller than the rear post 1625 . Each of the front and rear posts 1625 , 1640 have a stopper 1630 on its top to prevent the spring 1610 from pulling the frame 1605 off of the posts 1625 , 1640 . A slot 1645 and pin 1650 arrangement couples the frame 1605 to a front collar 1655 to accommodate pivoting of the frame 1605 . The front collar 1655 is also slidably moveable along the front post 1640 . As a result, the operation of this mechanism is as follows. When a module is inserted into the frame 1605 , it is at an angle θ with respect to the connector 1310 . A lever, cam or other element (not shown) is used to apply a force to the frame 1605 that extends the spring 1610 and causes the frame 1605 (and accordingly the module) to move both in an arc and along the posts 1625 , 1640 until, immediately before the connector on the module mates with the connector 1310 on the board 1315 , the two are parallel to each other. Depending upon the particular implementation, this may involve complete movement through an arc angle θ before any movement along the rear post 1625 occurs or some combination of movement along the post 1625 during the pivotal movement.
At this point it is to be understood that, for each implementation described herein, the connector on the module will be parallel to the connector on the board immediately before the two electrical connectors mate, irrespective of their orientation relative to each other at the time of module insertion through the front panel.
In view of all of the above, it should be appreciated that through use of the invention, much larger connectors can be used with a given size module in a given size front loading rack than was otherwise possible. This advantage is shown most clearly in the simplified modules of FIG. 17 a through 17 c.
FIG. 17 a shows an opto-electronic module 1700 suitable for use with the invention having an electrical connector 1705 , equal in size to the rear footprint 1710 of the module 1700 , and located on its bottom side 1715 .
FIG. 17 b shows a second module 1720 , identical in body size to the module of FIG. 17 a except it has an electrical connector 1725 that is 50% larger than the electrical connector 1705 shown in FIG. 17 a.
FIG. 17 c shows yet another opto-electronic module 1730 , also identical in body size to the module of FIG. 17 a . However, in this case, it has an electrical connector 1735 that is significantly longer than the electrical connectors 1705 , 1725 shown in FIG. 17 a and FIG. 17 b to the point of extending well beyond the end of the body of the module 1730 . Of course, in such a case, it may be desirable to provide a support 1740 of some sort to provide rigidity to the overhanging part of the connector 1735 and/or to act as a conduit for wiring (not shown) that is provided to pins of the electrical connector 1735 located in the overhanging portion beyond the end of the body. Should a sufficiently long connector be used such that a support 1740 must be used, in such a case, it is unimportant from the standpoint of the invention whether the support 1740 is part of, attached to, or wholly independent of body of the opto-electronic module.
As a result, and as shown in FIG. 17 c , through use of the invention with a given size opto-electronic module, the size of the electrical connector is only really constrained by the total available depth of a rack (“d”) since increasing the length of the connector will not increase the insertion footprint of a given module.
Having described several different examples, it should be apparent that individual aspects may also be modified or implemented differently without departing from the invention to achieve additional or alternative advantages. For example, if a lock of some sort is used to constrain a module in the mated position, it need not be part of circuit board. Instead it could be part of some other component including the frame, the faceplate, or some other part of a rack drawer, to name a few. Similarly, the frame need not be affixed to the circuit board, but instead could be affixed to or part of the drawer or even could be affixed to a board, in a hanging configuration, above the connector to which the module will connect. In addition, instead of using one or more springs to urge the frame into a “normally disengaged position” one or more springs could be used to urge the frame into a normally “engaged” position, whether or not the frame contained a module. In such an arrangement, a lever, screw, cam or other element would be used to move the frame from the normally engaged position to a disengaged position so that a module could be inserted or removed. In addition, in some arrangements having a normally engaged configuration, it will be advantageous, although not necessary, to use a locking mechanism to maintain the frame in the disengaged position during module insertion or removal.
It should therefore be understood that the above description is only representative of illustrative embodiments. For the convenience of the reader, the above description has focused on a representative sample of possible embodiments, a sample that is illustrative of the principles of the present invention. The description has not attempted to exhaustively enumerate all possible variations. That alternate embodiments may not have been presented for a specific portion of the invention, or that further undescribed alternate embodiments may be available for a portion, is not to be considered a disclaimer of those alternate embodiments. Other applications and embodiments can be straightforwardly implemented without departing from the spirit and scope of the present invention. It is therefore intended, that the invention not be limited to the specifically described embodiments, since numerous permutations and combinations of the above and implementations involving non-inventive substitutions for the above can be created, but the invention is to be defined in accordance with the claims that follow. It can be appreciated that many of those undescribed embodiments are within the scope of the following claims, and others are equivalent. | A system and method to facilitate receipt of an optoelectronic module in a first direction and make an electrical connection by movement of the module in a second direction different from the first direction. | 6 |
BACKGROUND AND SUMMARY
The invention relates to semiconductor devices. More particularly the invention relates to improvements in the switchable routing networks used in many semiconductor devices to route signals across the device.
Throughout the specification, P and N-channel MOS (metal oxide semiconductor) devices (PMOS and NMOS) are described in terms of their respective gate, drain and source nodes to help clarify the structure and operation of the alternative embodiments. PMOS devices transmit positive current when the signal on the gate is low, and cease transmitting current when the signal on the gate is high. NMOS devices transmit positive current when the signal on the gate is high, and cease transmitting positive current when the signal on the gate is low.
According to standard convention, positive current flows from the drain to the source node in NMOS devices, and flows from the source to the drain in PMOS devices. The source and drain node conventions are used only to help describe the structure and operation of embodiments of the invention and are not intended to limit the scope of the invention. It is possible to operate MOS transistors in reverse, especially if the source and drain regions are symmetrical. As such, the relative positions of the drain and source are not critical to the disclosed embodiments of the invention.
Turning to FIG. 12 , many semiconductor devices are composed of a number of processing elements 10 connected via a configurable routing network 20 . For example, reconfigurable devices, such as field programmable gate arrays (“FPGAs”), processor arrays and reconfigurable arithmetic arrays (“RAAs”), normally include a number of processing elements connected together by a general-purpose interconnect network capable of making links between various combinations of processing elements. Similarly, integrated devices include several processors, peripherals and memories connected via one or more shared busses. FIG. 12 depicts a portion of such a semiconductor device. The semiconductor device of FIG. 12 includes additional processing elements, which are omitted from FIG. 12 in order to clearly show the details of the circuit. It is sometimes useful to provide input buffer circuits 80 between the configurable routing network 20 and the processing elements 10 . These input buffer circuits 80 can be buffers that simply propagate an input value, or simple logic devices such as CMOS inverters, NAND gates, or NOR gates, or can be more complex circuits adapted to perform various functions as desired by the designer of the semiconductor device.
The configurable routing network 20 carries signals from one processing element 10 to another. The signals proceed from the processing device outputs 12 of the various processing elements 10 across the configurable routine network 20 to the processing device inputs 15 of the various processing elements 10 . For CMOS circuits these signals are typically a series of binary values, expressed as either a high voltage corresponding to a logic “1” and normally equal to V dd , the positive supply voltage 60 , or a low voltage, corresponding to a logic “0” and normally equal to Gnd, the ground supply voltage 70 .
The routing network 20 typically comprises a set of wire segments 30 and a set of active devices, configured as switches 40 , that can make or break connections between the wire segments 30 . By selectively making and breaking connections between wire segments 30 , the routing network 20 is capable of making a variety of connections between the various processing elements 10 on the device. The switches 40 at the top and bottom of FIG. 12 provide connections to the additional processing elements which are not shown in FIG. 12 . These connections can be dynamically varied as the requirements of the processing elements 10 change. The switches 40 are controlled by signals on the control wires 50 , typically by the state of the device they are part of, or sometimes by the state of another device.
There are various types of switches 40 that can be used in switchable routing networks. One type of switch 40 that is useful in designing routing networks is a single transistor, known as a pass transistor, with its source and drain connected to a pair of the wire segments 30 in the routing network. Pass transistors are a good choice because they do not take up much space on the semiconductor device, they can propagate signals across the wire segments 30 in either direction, and they do not consume very much power, because there are no active circuits in the routing path. Power is only used to charge and discharge the wire segments 30 .
However, implementing the switches 40 as pass transistors also suffers from a disadvantage. Depending on the type of pass transistor used, either the highest voltage that can propagate through the pass transistor is less than the gate voltage (normally V dd to turn on an NMOS transistor), or the lowest voltage that can propagate through the pass transistor is greater than the gate voltage (normally Gnd to turn on a PMOS transistor). For an NMOS pass transistor, the reduced high signal is lower than the gate voltage by an amount equal to the threshold voltage V t of the transistor, yielding a reduced high signal V dd −V t . For a PMOS pass transistor, the increased low signal is greater than the gate voltage by an amount equal to the absolute value of the threshold voltage V t of the transistor, yielding an increased low signal of Gnd−V t . (PMOS transistors by convention have negative threshold voltages, so Gnd−V t is greater than Gnd.) Therefore an undegraded signal varying between V dd and Gnd will be degraded as it propagates through a pass transistor. Other active devices may similarly alter either the high or low signals, depending on the active device. Because of this voltage alteration effect of the pass transistors, logic devices such as the input buffer circuits 80 which receive the signals sent through the pass transistors receive signals that may not be high enough or low enough to guarantee to turn the transistors within the logic devices on or off.
For example, if a reduced high signal from an NMOS pass transistor is provided to the gate of a PMOS transistor, in an input buffer circuit 80 , that has the positive supply voltage V dd provided on the source, then the reduced high signal will be insufficient to turn the PMOS transistor fully off, and some current will leak through the PMOS transistor. Similarly, if an increased low signal is provided to the gate of an NMOS transistor, in an input buffer circuit 80 , that has the ground voltage Gnd provided on the source, then the increased low signal will be insufficient to turn the NMOS transistor fully off, and some current will leak through the NMOS transistor. This phenomenon is not unique to pass transistor switches in routing networks. Similar issues arise anytime a high signal is reduced or a low signal is increased as it is propagated across any active or powered device (e.g. transistors, rectifiers, amplifiers, etc.).
Various means have been used to attempt to resolve the voltage alteration problem caused by active devices such as the pass transistors in a routing network. For example, the reduced high signal on the output of the pass transistor can be raised to a level high enough to ensure that other devices attached to the output of the pass transistor can be turned on or off, by reducing the threshold voltage V t of the pass transistor.
In order to reduce V t , a more complex process of creating the silicon substrate is required. It is possible to design devices with a lower V t , but an extra processing stage is required. Additionally, this extra step typically means that the lower V t elements have to be physically spaced further from the normal V t elements, which consumes valuable space on the silicon. Also, a lower V t means that there is a stronger leakage current when the transistor is switched off, which wastes power.
Another solution to the voltage alteration problem is to use a level-restoring circuit to pull the reduced high signal back up to the high signal, or pull the increased low signal back down to the low signal. There are two popular types of circuits for restoring voltages. First a circuit known as a “weak pull-up” circuit can be used to pull up a reduced high signal (similarly a weak pull-down can pull down an increased low signal.) Second, a differential amplifier circuit can be used to push both reduced high and increased low signals to the respective high or low values.
The circuit of FIG. 1 is an example of a weak pull-up circuit. The circuit of FIG. 1 is shown using an inverter 140 as the logic device to which the reduced high signal is provided. The weak pull-up circuit functions similarly for other devices such as NAND gates. Weak pull-up circuits, however, are not useful for devices such as NOR gates. In order for a weak pull-up to be useful, the output of the gate must be low if and only if the input to which the pull-up is attached is high. This condition is met for inverters and NAND gates, but not NOR gates—the NOR output could be low if the other input was high.
The inverter 140 requires a high signal equal to V dd in order to be certain of being fully activated. A reduced high signal is received on the input 110 . This reduced high signal is propagated to the inverter 140 , which causes the inverter 140 to emit the inverse of this reduced high signal, an increased low signal somewhere above the low signal (the low signal being equal to Gnd). This increased low signal is passed to the gate of the PMOS transistor 130 , which causes the PMOS transistor 130 to turn on. The PMOS transistor 130 is then able to pull the input 110 up to the full V dd level present on the positive voltage supply input 120 . Thus, the reduced high signal on the input 110 is pulled up to the full V dd level and the inverter 140 is fully activated, propagating the full low voltage Gnd to the output 150 . Alternatively, an increased low signal on the input 110 can be pulled down to a full low voltage Gnd by replacing the PMOS transistor 130 with an NMOS transistor, and replacing the V dd voltage on the positive voltage supply input 120 with a Gnd voltage.
This circuit has a significant drawback, however. Selecting the proper strength of the transistor 130 is important for efficient operation of the circuit, yet non-trivial. Transistor strength is a measurement of the resistance of the transistor when it is conducting current. Strong transistors conduct a greater current than weak transistors. If the transistor 130 is too weak, then it takes a long time for the transistor 130 to pull the input all the way up (or down for NMOS pull down transistors), during which time the inverter 140 is dissipating power. If the transistor 130 is too strong, then it takes time for the driving circuit to pull against the transistor when trying to drive a low onto the input 110 in order to flip the inverter, or for an NMOS pull down transistor when trying to drive a high onto the input 110 . The need to pull against the resistive load from the transistor 130 also increases power dissipation.
Selecting the proper strength for the transistor is especially difficult in reconfigurable arrays, since the optimal strength is dependent on the resistance of the path through the array from the original source of the signal to the device targeted by the signal. Since the array is reconfigurable, this path is variable in length depending on the application configured onto the array, and thus the resistance is variable, not constant. Therefore the only way to select a safe value for the pull-up transistor is to use a value that is safe for the worst case path—i.e. a value that is guaranteed to be sub-optimal for the vast majority of paths. The safe value is a value that is weak enough that its resistance can always be overcome by any path through the array.
Another solution is the differential amplifier circuit shown in FIG. 2 . In this circuit, the input signal on the input 210 is compared with a reference signal V ref on the reference input 280 . V ref is selected to be halfway between the high signal and the low signal that propagate through the routing network. The positive voltage supply input 220 supplies the positive supply voltage V dd to the two PMOS transistors 230 , 240 . The ground voltage supply input 270 supplies the ground supply voltage Gnd to the two NMOS transistors 250 , 260 . The drains of the two PMOS transistors 230 , 240 connect to the ground 270 , via the two NMOS transistors 250 , 260 . The drains of each of the two PMOS transistors 230 , 240 also connect to the gate of the other PMOS transistor. The first NMOS transistor 250 is controlled by the input signal on the input 210 . The second NMOS transistor 260 is controlled by the V ref signal on the reference input 280 . Finally, the output 290 is connected to the drain of the second PMOS transistor 240 .
The differential amplifier is constructed such that the two PMOS transistors 230 , 240 will not both normally be on simultaneously. If one of the two PMOS transistors 230 , 240 has a low drain voltage it will turn the other on, and thereby cause the other's drain voltage (and its own gate voltage) to be high, turning itself off and ensuring that its own drain voltage remains low. The drain voltages are controlled by the NMOS transistors 250 , 260 trying to pull down the voltage to Gnd. Whichever of the two NMOS transistors 250 , 260 has a higher signal on its gate will pull down more strongly, forcing a lower voltage onto the drain of the corresponding PMOS transistor 230 , 240 and consequently turning on the other PMOS transistor. Therefore, if the signal on the input 210 is less than the V ref signal on the reference input 280 , then the first PMOS transistor 230 is turned on, the second PMOS transistor 240 is turned off, and the output 290 goes down to Gnd. If the signal on the input 210 is greater than the V ref signal on the voltage input 280 , then the second PMOS transistor 240 is turned on, the first PMOS transistor 230 is turned off, and the output 290 goes up to V dd . Thus, since V ref is selected to be halfway between the high and low input signal levels, any input signal which is closer to a high than a low results in an output equal to V dd , and any input signal that is closer to a low than a high results in an output equal to Gnd.
This circuit, however, wastes power, because of the resistive paths from V dd to Gnd across the transistors 230 , 240 , 250 , 260 . Since the second NMOS transistor 260 is always partially conducting, there is a constant power drain through the amplifier whenever the output 290 is high. The extra power consumption of the differential amplifier circuit compromises the power benefits of using a pass transistor network in the first place.
Therefore, systems are needed to easily and optimally compensate for the effects of the routing network on the voltages propagated through the network, without increasing power dissipation in the semiconductor device, and with a small number of additional components.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings are included to provide a further understanding of embodiments of the invention and together with the Detailed Description, serve to explain the principles of the embodiments disclosed.
FIG. 1 is a depiction of a weak pull-up circuit.
FIG. 2 is a depiction of a differential amplifier.
FIG. 3 is a depiction of an inverter implemented in CMOS logic.
FIG. 4 is a depiction of a voltage modulation circuit connected to the positive voltage supply input of the inverter of FIG. 3 , according to an embodiment of the invention.
FIG. 5 is a depiction of a voltage modulation circuit connected to the ground of the inverter of FIG. 3 , according to a second embodiment of the invention.
FIG. 6 is a depiction of a voltage modulation circuit connected to both the positive voltage supply input and the ground voltage supply input of the inverter of FIG. 3 , according to a third embodiment of the invention.
FIG. 7 is a depiction of a voltage modulation circuit connected to a CMOS NAND gate, according to an embodiment of the invention.
FIG. 8 is a depiction of a voltage modulation circuit connected to a CMOS NOR gate, according to an embodiment of the invention.
FIG. 9 is a depiction of a voltage modulation circuit having a control signal connected to both the converter and the bypass circuit, according to an embodiment of the invention.
FIG. 10 is a depiction of a voltage modulation circuit which derives the control signal from the inverse of the output of the target circuit, according to an embodiment of the invention.
FIG. 11 is a graph of the relationship between the length of a transistor and the threshold voltage of the transistor.
FIG. 12 is a depiction of a reconfigurable device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning to FIG. 3 , an example CMOS logic device is shown. The logic device of FIG. 3 is an inverter 300 , but those skilled in the art will appreciate that the embodiments disclosed herein can be used with any standard logic devices or any combinations of standard logic devices. With reference to FIG. 12 , the inverter 300 may be, for example, a component of an input buffer circuit 80 on a reconfigurable device. For purposes of simpler discussion, the disclosed embodiments are discussed with reference to CMOS logic devices. Other embodiments using other forms of logic devices are also possible. The CMOS inverter shown in FIG. 3 is connected to an input 310 , a positive voltage supply 320 , a ground voltage supply 350 and an output 360 . The positive voltage supply 320 supplies power at a high CMOS voltage V dd , which is also used as the voltage to represent a high value (logic “1”) to CMOS logic devices. The ground voltage supply 350 provides a ground value Gnd, also used as the voltage to represent a low value (logic “0”) to CMOS logic devices. The inverter 300 includes a positive voltage supply input 325 , a first PMOS transistor 330 , a first NMOS transistor 340 and a ground voltage supply input 355 .
The inverter 300 operates to propagate the inverse of the signal on the input 310 through the output 360 . If the signal on the input 310 is a low value (i.e. Gnd, CMOS low, etc.) then the first PMOS transistor 330 is turned on, allowing current to flow from the positive voltage supply 320 through the positive voltage supply input 325 to the output 360 . This sends the high signal to the output 360 . The first NMOS transistor 340 is turned off by the low signal, and the path to the ground voltage supply 350 is therefore blocked, preventing current from flowing to the ground voltage supply 350 . If the signal on the input 310 is a high value (i.e. V dd , CMOS high, etc.), then the first PMOS transistor 330 is turned off, preventing current from flowing from the positive voltage supply 320 . The first NMOS transistor 340 is turned on by the high value, thus causing the output 360 to be connected through the ground voltage supply input 355 to the ground voltage supply 350 . This sends the low signal to the output 360 .
A voltage modulation circuit 400 is used in conjunction with a target circuit such as the inverter 300 to provide a high and/or low output signal, as shown in FIG. 4 . The voltage modulation circuit 400 is connected between the positive voltage supply 320 and the positive voltage supply input 325 of the inverter 300 , such that power supplied to the inverter 300 is first routed through the voltage modulation circuit 400 , and then provided to the inverter 300 . Since the voltage modulation circuit 400 is placed between the positive voltage supply 320 and the positive voltage supply input 325 of the inverter 300 , no additional current paths are created, other than the already existing path created by the inverter 300 . Therefore, the voltage modulation circuit 400 creates no additional source of power dissipation beyond that already existing in the inverter 300 .
The voltage modulation circuit 400 includes a converter and a bypass circuit. In an embodiment, the converter is a second NMOS transistor 410 , and the bypass circuit is a second PMOS transistor 420 . In alternate embodiments, the converter is composed of other types of devices, such as one or more other types of transistors, diodes or other devices which convert the voltage on the positive voltage supply 320 to a reduced level useful to ensure that the first PMOS transistor 330 is turned off, even where the signal on the input 310 is a reduced high signal. In alternative embodiments, the bypass circuit is composed of other types of devices, such as one or more switches or other devices which selectably control the signal presented to the inverter 300 between the high value and the reduced high value.
The positive voltage supply 320 is connected to both the gate and the drain of the second NMOS transistor 410 , as well as to the source of the second PMOS transistor 420 . The control input 430 is connected to the gate of the second PMOS transistor 420 . The source of the second NMOS transistor 410 and the drain of the second PMOS transistor 420 are both connected to the positive voltage supply input 325 of the inverter 300 .
When the inverter 300 is in normal operation, the signal on the input 310 alternates between a low value and a reduced high value. When the input signal is a low value, the control input 430 is adapted to provide a low value to the second PMOS transistor 420 . When the input signal is a reduced high value, the control input 430 is adapted to provide a high value to the second PMOS transistor 420 . These control input values can be derived by inverting the signal on the output 360 , or from any other available source of a signal which is the inverse of the output signal. More generally for any logic device, the control input values are configured such that the second PMOS transistor 420 is off (i.e. the control input high) whenever there is no conductive path through the PMOS transistors in the logic device, and such that the second PMOS transistor 420 is on (control low) whenever there is a conductive path through the PMOS transistors in the logic device. For a standard CMOS gate (where there is a path through either the NMOS or the PMOS devices, but not both simultaneously) the “PMOS conduct” state equates to a high signal on the output, and the “PMOS don't conduct” state equates to a low signal on the output. Therefore the value of the control signal is the inverse of the output signal. Since the voltage modulation circuit 400 connects to the supply connection to the CMOS gate, and not to the individual data inputs to the CMOS gate (e.g. the input 310 ), it is not always necessary for the control input 430 to track the input 310 . This is a difference from the weak pull-up circuit of FIG. 1 , which does try to control the individual inputs, so requires a control signal for the pull-up that is low when the input is high, and therefore only works for gates where the required control signal can be provided. The circuit of FIG. 1 is not applicable to a NOR gate for example, whereas the circuit of the embodiment of the present invention shown in FIG. 4 is applicable to any CMOS gate.
When the input signal is a low value and the control input 430 therefore provides a low value to the second PMOS transistor 420 , the second PMOS transistor 420 propagates the full voltage V dd from the positive voltage supply 320 to the positive voltage supply input 325 . This full voltage V dd overrides the reduced voltage being propagated through the second NMOS transistor 410 . Thus, the control signal on the control input 430 operates to select the second PMOS transistor 420 to provide the full positive supply voltage V dd to the positive voltage supply input 325 .
Since the input signal is a low value, the first PMOS transistor 330 supplies V dd from the positive voltage supply input 325 to the output 360 . The first NMOS transistor 340 is turned off by the low value, thus there is no current path to the ground voltage supply 350 through the transistor 340 . Therefore, a full CMOS high signal is provided on the output 360 of the inverter 300 .
When the input signal is a reduced high signal and the control input 430 therefore provides a high signal to the second PMOS transistor 420 , the second PMOS transistor 420 is turned off, thereby blocking the current flow through the second PMOS transistor 420 . There is still a connection to the positive voltage supply 320 through the second NMOS transistor 410 , however, since the gate of the second NMOS transistor 410 is connected to V dd and the second NMOS transistor 410 is therefore always conducting. Recall that NMOS transistors cannot propagate a high signal greater than their gate voltage less their threshold voltage. The best an NMOS transistor can do is propagate a reduced high signal, in this case V dd −V t(N2) , where V t(N2) is the threshold voltage of the second NMOS transistor 410 . This reduced high signal is provided to the positive voltage supply input 325 . Thus the control signal on the control input 430 operates to select the second NMOS transistor 410 to provide the reduced high signal to the positive voltage supply input 325 .
The positive voltage supply input signal is a reduced high value of V dd −V t(N2) , and the input signal from the input 310 is a reduced high value of V dd −V t(pass) (where V t(pass) is the threshold voltage of the device or devices through which the input signal is connected to the input 310 ). Thus, assuming that the second NMOS transistor 410 is selected such that it has a threshold voltage substantially equivalent to the threshold voltage of the device or devices connected to the input 310 , the input signal and the positive voltage supply input signal are substantially the same voltage, the gate-source voltage differential across the first PMOS transistor 330 is therefore substantially zero, and the first PMOS transistor 330 is turned off. Exact equivalence between V t(N2) and V t(pass) is not necessary, the requirement is that the gate-source voltage is such as to guarantee that negligible current flows through the first PMOS transistor 330 . This condition is typically met if the gate-source voltage is more than ½V t(P1) . This equates to a requirement that V t(N2) −V t(pass) >=½ V t(P1) . (Recall that PMOS transistors are turned on by a sufficiently low gate voltage and off by a high gate voltage.)
There is no leakage current through the first PMOS transistor 330 , even though the positive voltage supply 320 is providing a full V dd voltage, because the full V dd voltage signal is converted to the reduced high signal by the second NMOS transistor 410 . The reduced high signal on the input 310 is still strong enough to overcome the threshold voltage on the first NMOS transistor 340 , thereby turning it on, and the signal on the output 360 is thus pulled to Gnd by the ground voltage supply 350 . Therefore, a full CMOS low is provided on the output 360 of the inverter 300 .
In a second embodiment shown in FIG. 5 , a modified form of the voltage modulation circuit is used to handle situations where the input 310 can provide high signals, but can only provide increased low signals, not low signals. A second voltage modulation circuit 500 is used in conjunction with the inverter 300 to provide a high and/or low output signal. The second voltage modulation circuit 500 is connected between the ground voltage supply 350 and the ground voltage supply input 355 of the inverter 300 , such that current drawn from the inverter 300 is first routed through the second voltage modulation circuit 500 and then to the ground voltage supply 350 . Since the second voltage modulation circuit 500 is placed between the ground voltage supply 350 and the ground voltage supply input 355 of the inverter 300 , no additional current paths are created, other than the already existing path created by the inverter 300 . Therefore, the second voltage modulation circuit 500 creates no additional source of power dissipation beyond that already existing in the inverter 300 .
The second voltage modulation circuit 500 includes a converter and a bypass circuit. In an embodiment, the converter is a third PMOS transistor 510 , and the bypass circuit is a third NMOS transistor 520 . In alternate embodiments, the converter is composed of other types of devices, such as one or more other types of transistors, diodes or other devices which convert the low signal on the ground voltage supply 350 to an increased low level useful to ensure that the first NMOS transistor 340 is turned off, even where the signal on the input 310 is an increased low signal. In alternative embodiments, the bypass circuit is composed of other types of devices, such as one or more switches or other devices which selectably control the voltage provided to the inverter 300 between the low value and the increased low value.
The ground voltage supply 350 is connected to both the gate and the drain of the third PMOS transistor 510 , as well as to the source of the third NMOS transistor 520 . The second voltage modulation circuit 500 also includes a control input 530 , connected to the gate of the third NMOS transistor 520 . The source of the third PMOS transistor 510 and the drain of the third NMOS transistor 520 are both connected to the ground voltage supply input 355 of the inverter 300 .
When the inverter 300 is in normal operation, the signal on the input 310 alternates between an increased low value and a high value. When the input signal is a high value, the control input 530 is adapted to provide a high value to the third NMOS transistor 520 . When the input signal is the increased low value, the control input 530 is adapted to provide a low value to the third NMOS transistor 520 . These control input values can be derived by inverting the signal on the output 360 , or from any other available source of a signal which is the inverse of the output signal. More generally for any logic device, the control input values are configured such that the third NMOS transistor 520 is off (i.e. the control input low) whenever there is no conductive path through the NMOS transistors in the logic device, and such that the third NMOS transistor 520 is on (control high) whenever there is a conductive path through the NMOS transistors in the logic device. For a standard CMOS gate (where there is a path through either the NMOS or the PMOS devices, but not both simultaneously) the “NMOS conduct” state equates to a low signal on the output, and the “NMOS don't conduct” state equates to a high signal on the output. Therefore the value of the control signal is the inverse of the output signal. Since the second voltage modulation circuit 500 connects to the supply connection of the CMOS gate, and not to the individual data inputs to the CMOS gate (e.g. the input 310 ), it is not always necessary for the control input 530 to track the input 310 . This is a difference from the weak pullup circuit of FIG. 1 , which does try to control the individual inputs, so requires a control signal for the pull-up that is low when the input is high, and therefore only works for gates where the required control signal can be provided. The circuit of FIG. 1 is not applicable to a NOR gate for example, whereas the circuit of the embodiment of the present invention shown in FIG. 5 is applicable to any CMOS gate.
When the input signal is a high value and the control input 530 therefore provides a high value to the third NMOS transistor 520 , the third NMOS transistor 520 propagates the full ground voltage Gnd from the ground voltage supply 350 to the ground voltage supply input 355 . This full ground voltage Gnd overrides the increased low signal being propagated through the third PMOS transistor 510 . Thus, the signal on the control input 530 operates to select the third NMOS transistor 520 to provide the ground signal to the ground voltage supply input 355 .
Since the input signal is a high value, the first PMOS transistor 330 is turned off and thus no current flows from the positive voltage supply 320 to the output 360 . The first NMOS transistor 340 is turned on by the high value, thus the ground voltage supply 350 is connected to the output 360 and the output 360 is pulled down to Gnd. Therefore a full CMOS low signal is provided on the output 360 of the inverter 300 .
When the input signal is an increased low value and the control input 530 therefore provides a low value to the third NMOS transistor 520 , the third NMOS transistor 520 is turned off, thereby blocking the current from flowing through the third NMOS transistor 520 . There is still a connection to the ground voltage supply 350 through the third PMOS transistor 510 , however, since the gate of the third PMOS transistor 510 is connected to Gnd and the third PMOS transistor 510 is therefore always conducting. Recall that PMOS transistors cannot propagate a full low signal. The best a PMOS transistor can do is propagate an increased low signal, in this case −V t(P2) , where V t(P2) is the threshold voltage of the third PMOS transistor 510 (PMOS transistors are normally quoted as having negative threshold voltages, so−V t(P2) is a positive value). This increased low signal is provided to the ground voltage supply input 355 . Thus the signal on the control input 530 selects the third PMOS transistor 510 to provide the increased low signal to the ground voltage supply input 355 .
The ground voltage supply input signal is an increased low value of −V t(P2) , and the input signal from the input 310 is an increased low value of −V t(pass) (where V t(pass) is the threshold voltage of the device or devices through which the input signal is connected to the input 310 , also a negative value for PMOS devices). Thus, assuming that the third PMOS transistor 510 is selected such that it has a threshold voltage substantially equivalent to the threshold voltage of the device or devices through which the input signal is connected to the input 310 , the input signal and the ground voltage supply input signal are substantially the same voltage, the gate-source voltage across the first NMOS transistor 340 is therefore substantially zero, and the first NMOS transistor 340 is turned off. Exact equivalence between V t(P2) and V t(pass) is not necessary, as long as the gate-source voltage is sufficiently low to guarantee that negligible current flows through the first NMOS transistor 340 . This condition is typically met if the gate-source voltage is less than ½ V t(N1) . This equates to a requirement that V t(P2) −V t(pass) <=½ V t(N1) .
There is substantially no leakage current through the first NMOS transistor 340 , even though the ground voltage supply 350 is providing a full Gnd voltage, because the full Gnd voltage signal was converted to the increased low signal by the third PMOS transistor 510 . The increased low signal on the input 310 is still low enough to keep the gate-source voltage of the first PMOS transistor 330 below the threshold voltage, thereby turning it on, and the signal on the output 360 is thus pulled to V dd . Therefore, a full CMOS high is provided on the output 360 of the inverter 300 .
The voltage modulation circuit 400 and the second voltage modulation circuit 500 can also be used in combination, to manage situations where the input 310 provides signals that do not reach either a high value or a low value. This combination is shown in FIG. 6 .
Either or both of the voltage modulation circuits 400 , 500 can be used with any CMOS logic device. For example, FIG. 7 depicts the voltage modulation circuit 400 in use with a CMOS NAND gate 700 . A NAND gate generates a high output signal whenever either input signal is low, and generates a low output signal when both input signals are high. Therefore, when either the first input 730 or the second input 740 provides a low signal, the corresponding PMOS transistor 710 , 720 is turned on, allowing the voltage V dd to propagate from the positive voltage supply 320 through the second PMOS transistor 420 , then through the PMOS transistor 710 , 720 that was turned on, and on to the output 780 . Since at least one of the inputs 730 , 740 is providing a low signal, at least one of the corresponding NMOS transistors 750 , 760 is turned off, thus blocking any current from flowing to the ground voltage supply 350 . When both input signals are high, then both PMOS transistors 710 , 720 are turned off, and both NMOS transistors 750 , 760 are turned on. This causes the voltage V dd to be blocked and establishes a connection between the ground voltage supply 350 and the output 780 , thus drawing the output signal to Gnd.
If both input signals are reduced high signals, then the control input 430 provides a high signal and the voltage modulation circuit 400 provides a reduced high signal, as discussed above, to the PMOS transistors 710 , 720 . The control signal on the control input 430 is the inverse of the output signal on the output 780 , generated as discussed above. This prevents any significant current from leaking through the PMOS transistors 710 , 720 , thus saving power. Note that here as well the voltage modulation circuit 400 is placed along the already existing current path between V dd and Gnd, so no additional current paths are created. The reduced high signals on the inputs 730 , 740 are sufficient to make the connection between the ground voltage supply 350 and the output 780 , so the low signal is properly provided on the output 780 .
As another example, shown in FIG. 8 , the voltage modulation circuit 400 is used with a CMOS NOR gate 800 . A NOR gate generates a low output signal whenever either input signal is high, and generates a high output signal when both input signals are low. Therefore, when either the first input 850 or the second input 860 provides a high signal, the corresponding NMOS transistor 810 , 820 is turned on, closing the connection from the ground voltage supply 350 to the output 870 , and thus drawing the output 870 down to Gnd. Since at least one of the inputs 850 , 860 is providing a high signal, then at least one of the corresponding PMOS transistors 830 , 840 is turned off, thus blocking any current from flowing from the positive voltage supply 320 . When both input signals are low, then both NMOS transistors 810 , 820 are turned off, and both PMOS transistors 830 , 840 are turned on. This causes the connection between the ground voltage supply 350 and the output 870 to be blocked, and makes the connection between the positive voltage supply 320 and the output 870 , thus drawing the output signal to V dd .
If either input signal is a reduced high signal, then the control input 430 provides a high value and the voltage modulation circuit 400 provides a reduced high signal, as discussed above, to the PMOS transistor 840 . The control signal on the control input 430 is the inverse of the output signal on the output 870 , generated as discussed above. This prevents any significant current from leaking through the PMOS transistor 840 , thus saving power. Note that the voltage modulation circuit 400 is placed along the already existing current path between V dd and Gnd, so no additional current paths are created. The reduced high signals on the inputs 850 , 860 are sufficient to make the connection between the ground voltage supply 350 and the output 870 , so a low signal is properly provided on the output 870 .
Turning to FIG. 9 , the control input 430 can alternatively be connected to the gates of both the second NMOS transistor 410 and the second PMOS transistor 420 , as shown. This results in an increased capacitative load on the control input 430 . Since transistor gates have an intrinsic capacitance, the capacitance is increased because there is a connection to an additional transistor gate. This layout, however, may be more compatible with certain silicon layout styles, such as those use in metal mask programmable gate arrays, which tend to arrange transistors in N/P pairs with their gates tied together.
An advantage to the voltage modulation circuits 400 , 500 described above, as compared with weak pull-up transistors, is that it is easier to choose device strengths for the voltage modulation circuits 400 , 500 , since the optimal device strength is not dependent on the resistance in the signal path coming in to the input 310 . Turning to FIG. 10 , a circuit 1000 similar to the circuit of FIG. 4 is shown, with the control signal being provided by the inverted output of the inverter 300 , via the connection 1020 and an output inverter 1010 .
In order for the circuit 1000 to function, a change in the input signal at input 310 needs to propagate to the output 1030 . This in turn means that the output inverter 1010 has to be able to flip even if the control signal on the connection 1020 is in the wrong state. Since the control signal is derived from the output inverter 1010 , there will be a non-zero propagation delay, such that the input to the output inverter 1010 will be high at the same time that the signal on the connection 1020 is high. Since the signal on the connection 1020 is high, the voltage modulation circuit 400 is only providing the reduced high signal V dd −V t(N2) to the inverter 300 . If the input 310 is low, then the inverter 300 will provide the reduced high signal to the output of the inverter 300 , which is the input to the output inverter 1010 . Therefore the output inverter 1010 needs to have a switching threshold voltage (the voltage at which the output inverter 1010 transitions from high to low) of less than V dd −V t(N2) to ensure that the output inverter 1010 can flip under all possible circumstances. This is a constraint on the relative strengths of the devices in the output inverter 1010 , and is not dependent on anything coming into the input 310 .
The constraints on the strengths of the second NMOS transistor 410 and second PMOS transistor 420 are more relaxed than the constraints on the inverter 1010 . If either transistor 410 , 420 is made stronger or weaker than optimal, the circuit 1000 will operate at a slower speed, but it will still function properly. The constraints on the sizes of the transistors 410 , 420 are similar to the constraints on any other transistor size in a logic circuit, and can be approached in the same manner. Those skilled in the art are readily able to appreciate these constraints and make appropriate choices as to the strengths of the transistors 410 , 420 . For the circuit of FIG. 10 , choosing the second NMOS transistor 410 to be the same strength as the first NMOS transistor 340 , and the second PMOS transistor 420 to be the same strength as the first PMOS transistor 330 typically results in a circuit that is functional and easy to make physically compact. (More generally for any logic device, selecting transistors for the voltage modulation circuit that are the same strength as those in the logic device will typically produce a functional result.)
As noted above the optimal size of the pull-up transistor 130 in FIG. 1 depends on the resistance of the circuit driving the input, which is a function of the path through the routing network that the signal has followed. In the voltage modulation circuit 400 the input 310 connects to the gates of the transistors 330 , 340 forming the inverter 300 rather than to the source or drain of a transistor. Correct operation of the inverter 300 depends on its switching threshold lying between the maximum and minimum voltages that can be propagated through the routing network. These voltages are independent of the path that a signal might follow through the routing network, and therefore the required inverter threshold is independent of the input signal route. Similarly, the required threshold of the second NMOS transistor 410 also depends on the maximum voltage that propagates through the routing network, but is otherwise independent of the properties of that network.
A further consideration is the selection of the length of the second NMOS transistor 410 . As discussed above, the leakage current through the first PMOS transistor 330 is dependent on the difference in the threshold voltage between the first NMOS transistor 410 and the devices connected to the input 310 (such as NMOS pass transistors in a routing network). It is desirable to have the threshold voltage of the first NMOS transistor 410 be higher than the threshold voltage of the devices connected to the input 310 , in order to prevent leakage current from flowing across the first PMOS transistor 330 . The higher that V t(N2) is, the lower the source voltage V dd −V t(N2) of the first PMOS transistor 330 is, and the less likely that the gate voltage V dd −V t(pass) (provided by the input 310 ) will be lower than the source voltage, and thus cause leakage.
For many CMOS processes, threshold voltage of a transistor is a function of transistor length. The graph of FIG. 11 shows an example of this function for an example CMOS process. The vertical line represents the minimum transistor length actually fabricated by the example CMOS process. In the region close to the minimum length, the threshold voltage increases steeply as the transistor length increases. The curve then levels off at about twice the minimum length, and eventually declines slightly. NMOS pass transistors such as those connected to the input 310 in some embodiments will typically be of minimum length. Therefore, by choosing the length of the second NMOS transistor 410 to correspond to a higher point on the threshold voltage curve, the risk of variations in the lengths of the pass transistors or other devices connected to the input 310 causing leakage is minimized, since the second NMOS transistor 410 is selected to have a relatively high threshold voltage.
In an alternate embodiment, the voltage degrading effects of the active devices in a configurable routing network are compensated for by providing a different voltage to the active devices than to the logic circuits. For example, with an NMOS pass transistor routing network a second high supply voltage is provided to the pass transistors, so that the gate voltage of the pass transistors is higher than the first high supply voltage V dd provided to the logic circuits. The first high supply voltage V dd may be set below the most positive allowable operating voltage for the circuit technology in order to achieve the required difference between the first and second high supply voltages. This second high supply voltage is provided to the gates of the pass transistors, so that the pass transistors can propagate a maximum voltage up to V dd . Similarly, for PMOS pass transistor routing networks a second low supply voltage is provided to the pass transistors, which decreases the gate voltage of the pass transistors below the first low supply voltage Gnd provided to the logic circuits. The first low supply voltage Gnd may be set above the most negative allowable operating voltage for the circuit technology in order to achieve the required difference between the first and second low supply voltages. This second low supply voltage is provided to the gates of the pass transistors, to reduce the minimum voltage the pass transistors can propagate down to Gnd. A second high or low supply voltage routing network is provided, and level-shifting buffers may be provided on those signals that propagate between elements using the different supply voltages. For active devices that degrade both highs and lows, both the second high supply voltage and the second low supply voltage are provided.
Turning again to FIG. 12 , the second supply voltage V control is provided on the control wires 50 . The description so far has assumed that V control equals V dd , in which case the NMOS pass transistors 40 can only propagate a reduced high signal of V dd −V t(pass) . In this alternative embodiment where the second supply voltage V control is not equal to V dd , then the NMOS pass transistors 40 can propagate a high signal of V control −V t(pass) . If V control is chosen to be greater than or equal to V dd +V t(pass) , then the high signal propagated by the NMOS pass transistors can be as high as V dd . Hence reconfigurable networks containing NMOS pass transistors can propagate undegraded high signals of V dd if V control is chosen to be greater than or equal to V dd +V t(pass) . Similarly, reconfigurable networks containing PMOS pass transistors, which have negative values of V t(pass) , can propagate undegraded low signals of Gnd if the second supply voltage V control is chosen to be less than or equal to Gnd+V t(pass) .
In the foregoing specification, the invention has been described with reference to specific embodiments thereof. It will, however, be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope of the invention. For example, the reader is to understand that the specific composition and combination of components shown in the circuit diagrams described herein is merely illustrative, and the invention can be performed using different or additional components, or a different combination or composition of components. The specification and drawings are, accordingly, to be regarded in an illustrative rather than restrictive sense, and the invention is not to be restricted or limited except in accordance with the following claims and their legal equivalents. | Power supply voltages are selectively modulated to correspond with degraded input voltages to a logic device. Modulated power supply voltages are provided to transistors within the logic device, so that the degraded input voltages supplied to the transistors are sufficient to turn the transistors substantially on or off. Leakage currents are prevented thereby from flowing across the transistors. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Provisional Patent application No. 61/753,315 precedes this non-provisional application.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] Not Applicable
REFERENCE TO A SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM, LISTING COMPACT DISC APPENDIX
[0003] Not Applicable
BACKGROUND OF THE INVENTION
[0004] The present invention relates to the field of swimming pool accessories and more specifically the present invention relates to buoyant or floating chairs. There are a number of devices for sale on the market that use an inflatable air bladder to float a user as in U.S. Pat. No. 6,485,344. These devices are easily manufactured and inexpensive but are always in danger of being popped or leaking air. There are many devices that float a user above the water line that should not be compared to the present invention since the present invention floats the majority of the user's body below the water line. There are some inventions that incorporate buoyant closed cell foam tubing over a rigid frame as in U.S. Pat. No. 7,998,031, but do not incorporate lengths of rope that affix to the rigid frame members that are weaved through the hollow of straight, rigid, tube members and or closed-cell foam tube sections to form a flexible and adjustable support assembly that serve to cradle and support the weight of a user as the back and seat of a reclined chair would. Other inventions such as U.S. Pat. No. 5,520,561 and U.S. Pat. No. 5,571,036 use a buoyant pool noodle inserted into a fabric webbing with no structural members. Any fabric webbing has the disadvantage of having to be cut, sewn and seamed which means more manufacturing time will be necessary in production. The obvious benefits that all of these products would strive to be able to offer, are ease of manufacturing, use of inexpensive materials, small or collapsible size for shipping, design appeal, functionality and durability as well as variations in style, function and characteristics that create wide ranging appeal. Most, if not all of the conventional floating chairs are missing at least one of the afore-mentioned benefits.
[0005] It is thus an object of the present invention to provide an easily built and inexpensive floating chair. It is another object of the present invention to provide a collapsible floating chair for easy storage and shipment. It is still another object of the present invention to provide a floating chair with variations in style and function that would better appeal to a wide market. It is finally an object of the present invention to provide a functional and durable floating chair that is designed to be customized by the user, to that user's own specifications.
BRIEF SUMMARY OF THE INVENTION
[0006] The present invention accomplishes the above-stated objectives, as well as others, as may be determined by a fair reading and interpretation of the entire specification. The present invention consists of two main parts, wherein part one is a rigid frame that is buoyant due to the closed cell foam tubing sections that wrap and surround the rigid frame members and part two is a support assembly that is comprised of length(s) of rope that weave through support sections that are comprised of additional members of rigid tube and or buoyant foam tube sections and attach to the rigid frame members to form a flexible, comfortable and customizable support. The additional features such as the ability to break down for shipment, customizability, the variety of models and user seating modes and suggestive selling products such as the optional headrest set it apart from the prior art. The present invention addresses all seven of the afore mentioned obvious benefits that a product in the current field of scope should offer by incorporating inexpensive materials in its production, ease of assembly with the use of few if any power tools which leads to a low carbon footprint, it can be packaged substantially flat or be broken down into smaller components for shipment, each of the similar yet different models are well designed for form and function, and will not pop or lose buoyancy. The present invention also offers the benefit of being available in different styles with different flotation characteristics and each style can be used in several different seating modes, each having the ability to be manipulated by the user to create customized comfort positions to fit any body type. The ability to carry the product on the shoulders leaves hands free to carry other pool or beach supplies. A total product weight of less than 2 pounds allows any user to carry the product regardless of size. All of these aspects combine to offer an original product that the marketplace has not seen, at the premium product level, with a substantial reduction in price. The invention is used by placing the floating chair in a body of water and sat or laid upon by a user, with the head of the user usually placed upon the headrest. The invention may be flipped over and the support assembly can adjusted to offer the user many different seating positions.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0007] Various other objects, advantages, and features of the invention will become apparent to those skilled in the art from the following description taken in conjunction with the following drawings, in which:
[0008] FIG. 1 is a perspective view from the side showing a substantially flat and rectangular version of the present invention with the support sections pushed near to each other causing slack in the flexible members.
[0009] FIG. 1A is a perspective view from the side that shows the same apparatus in FIG. 1 depicting the support sections pushed apart toward the outer ends of the frame which removes the slack from the flexible members.
[0010] FIG. 1B is a depiction of the apparatus of FIG. 1 shown with all of the buoyant foam sections removed to make the rigid frame members and support members visible. In this view the knot or rope crimp becomes visible at the four points where flexible members are attached to the frame members.
[0011] FIG. 1C is a cross section view of the rectangular apparatus of FIG. 1A that cuts through buoyant foam headrest, rigid frame members with sleeved buoyant foam sections, and the four support assembly members with the support flexible members weaved through the hollows of support members.
[0012] FIG. 2 shows a style variation of the apparatus in FIG. 1 in which the two lateral buoyant foam sections of FIG. 1 and underlying frame members of FIG. 1B have been changed to create the “armchair” version of the present invention.
[0013] FIG. 2A shows the same apparatus as in FIG. 2 but turned upside down to form a “bucket seat” version with the two support sections pushed slightly apart to increase the tautness of the support ropes to demonstrate user customized adjustability.
[0014] FIG. 3 is a perspective view from the side showing a high buoyancy version of the present invention similar to the apparatus in FIG. 2 wherein the use of and orientation of frame members, buoyant foam sections, elbow joints, mechanical fastener and headrest are shared but there is a variation in the support assembly.
[0015] FIG. 3A is a perspective view from the side depicting the same high buoyancy apparatus of FIG. 3 , however, it is flipped upside down where the support assembly is then pushed downward to form a high buoyancy “bucket seat” version of the present invention.
[0016] FIG. 3B is a perspective view of the apparatus of FIG. 3 with all of the buoyant foam sections removed to expose the rigid frame members and flexible support members beneath. The path and situation of the flexible support members are visible.
[0017] FIG. 4 shows yet another version of the present invention where there is no use of rigid frame members and the buoyant foam tubes are only held together with a length of flexible member that is coursed through the hollows of said buoyant foam tubes and connected back to itself.
[0018] FIG. 4A shows the same apparatus of FIG. 4 as if all of the buoyant foam members have been cut in half lengthwise and the top halves removed to illustrate the path taken by the flexible member through the hollows of said buoyant tubes.
[0019] FIG. 5 shows another version of the present invention that is similar to that of FIG. 4 where there is no use of rigid frame members and the buoyant foam tubes are only held together with a length of flexible member that is coursed through the hollows of said buoyant foam tubes and connected back to itself.
[0020] FIG. 5A shows the same apparatus of FIG. 5 as if all of the buoyant foam members have been cut in half lengthwise and the top halves removed to illustrate the path taken by the flexible member through the hollows of said buoyant tubes.
[0021] FIG. 6 Depicts a user seated in a reclined position in the second preferred embodiment of the present invention.
[0022] FIG. 7 Depicts a user seated in an upright position in the first preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0023] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.
[0024] Reference is now made to the drawings, wherein like characteristics and features of the present invention shown in the various FIGURES are designated by the same reference numerals.
First Preferred Embodiment
[0025] Looking at FIG. 1 , FIG. 1A and FIG. 1B together, you will see a version of the preferred embodiment 10 wherein FIG. 1 features the external members and FIG. 1B depicts preferred embodiment 10 with all of the buoyant foam sections removed to make the rigid frame members 13 , 17 , 26 & 27 and tubular support members 7 visible. The outline of support members 7 has been shown as a hidden line to clearly show the path taken when flexible members 4 and 5 are weaved through the hollow of the tubular support members. In this view connection point 16 is a knot and becomes visible at the four points where flexible members 4 and 5 are attached to the frame members 13 & 26 . One end of each flexible member 4 & 5 is attached to frame member 13 at connection points 16 , the other ends of members 4 & 5 are routed through opposite hollow ends of one of the tubular support members 7 , members 4 & 5 pass each other as they go through this same hollow. Note that support member 7 rests inside the hollow of support member 6 . As the ends of 4 & 5 emerge from the opposite hollow ends, they are then routed through the opposing hollows of another tubular support member 7 . As the ends of 4 & 5 emerge from the opposite end hollows of the second support member 7 , they are affixed to the frame member 26 at connection knots 16 . If one end of flexible member 4 was affixed to the right side of frame member 13 , then the other end of flexible member 4 will be affixed to the right side of frame member 26 . The four rigid frame members 13 , 17 , 26 & 27 (visible in FIG. 1B ) composed of a rigid tube such as polyvinylchloride (pvc) are obscured by corresponding buoyant foam sections 2 , 1 , 22 & 21 that are composed of a lightweight, buoyant material such as expanded polyethylene (epe) or ethylene-vinyl acetate (eva) foam and sleeved over the said rigid frame members. The said frame members that are sleeved over with said foam sections are positioned to form a rectangle and four pvc elbow joints 3 are positioned in the four corners of the rectangle and affixed to each end of the shorter frame members 13 & 26 and the longer frame members 17 & 27 with a pvc cement to form a unified rectangular frame assembly. It should be noted that before assembling and gluing the parts, a larger buoyant foam tube 8 with a larger interior diameter may be fitted over one or more of the buoyant foam parts to provide additional flotation, or a headrest. The pre measured flexible members such as rope lengths 4 and 5 are affixed to the obscured frame members 13 & 26 at the attachment points 16 between elbow joint 3 and foam sections 2 & 22 and weaved through support sections 6 and 7 in a way that is visible in FIG. 1B and together make up the members of the support assembly. It should be noted that the support assembly simply falls into a lower position by way of gravity when the apparatus is flipped over and that the flexible members 4 & 5 are cut to a length that is long enough to allow the support assembly to hang below said buoyant frame assembly.
[0026] FIG. 1A is a perspective view from the side that depicts the same apparatus 10 in FIG. 1 that shows each support section pushed apart toward the outer ends of the frame which removes the slack from the flexible members 4 and 5 due to the technique used to weave the flexible members through the support sections visible in FIG. 1B . This causes the flexible members 4 & 5 to become taut to consolidate the apparatus and allow for easy storage and shipping.
Second Preferred Embodiment
[0027] Looking at FIG. 2 , you will see the “armchair” version 20 of the invention, a variation of the apparatus in FIG. 1 in which the lateral buoyant foam sections 1 & 21 of FIG. 1 and underlying frame members 17 & 27 visible in FIG. 1B are replaced with shorter frame members 14 , 15 , 28 & 29 (Visible in FIG. 3B ) and shorter foam sections 11 , 23 , 24 & 31 to form lateral sides of the frame assembly. Looking now at FIG. 3B , a forty-five degree pvc elbow joint 25 is adhered to frame member 15 with pvc cement and then attached to frame member 14 with a mechanical fastener 9 , such as a stainless steel screw, to allow the frame to be disassembled at the joint member 25 for shipping and storage. The same assembly technique used for frame members 14 , 15 , and joint 25 are repeated with frame members 28 , 29 and the remaining joint 25 and combined with the remaining parts of the rectangular apparatus 10 as depicted. One end of each flexible member 4 & 5 are attached to frame member 13 between foam section 2 and elbow joint 3 , the other ends of members 4 & 5 are routed through opposite hollow ends of one of the tubular support members 7 , they cross each other as they go through this same hollow. Note that tubular support member 7 rests inside the hollow of support member 6 . As the ends of 4 & 5 emerge from the opposite end hollows, they are then routed through the opposing hollows of another support member 7 . As the ends of 4 & 5 emerge from the opposite end hollows of the second support member 7 , they are affixed to the frame member 26 at connection knot 16 . If one end of flexible member 4 was affixed to the right side of frame member 13 , then the other end of flexible member 4 will be affixed to the right side of frame member 26 .
[0028] In FIG. 2A , the same apparatus 20 as in FIG. 2 is turned upside down to form a “bucket seat” version with the two tubular support sections comprised of 6 and 7 pushed slightly apart to increase the tautness of the support ropes 4 and 5 to demonstrate user customized adjustability. The support sections can be adjusted with one at each end, both at one end, both in the middle and anywhere in between these three positions. It should be noted that the support assembly simply falls into a lower position by way of gravity when the device is flipped over and is of sufficient length to allow it to hang lower than the frame assembly.
Third Preferred Embodiment
[0029] FIG. 3 is a perspective view from the side showing a high buoyancy version 30 of the present invention similar to the apparatus 20 in FIG. 2 wherein the frame members 13 , 14 , 15 , 26 , 28 , & 29 (visible in FIG. 3B ), buoyant foam sections 2 , 11 , 22 , 23 , 24 & 31 elbow joints 3 , 25 , mechanical fastener 9 and headrest 8 are shared between apparatus 20 and apparatus 30 . Flexible members 18 and 19 that attach to one short member 13 of the rigid frame, are each weaved through the hollow of a section of buoyant foam 12 , they then cross and overlap one another in the middle and each pass through another section of buoyant foam 12 , before re-attaching to the other short frame member 23 to form an “X” in the interior frame region. If one end of flexible member 18 was affixed to the right side of frame member 13 , then the other end of flexible member 18 will be affixed to the right side of frame member 26 . This forms a semi rigid, yet flexible support assembly that incorporates a larger amount of buoyant foam to offer increased flotation for those users with a body type that is high in lean muscle and low in body fat as an example. In FIG. 3A , the same high buoyancy apparatus 30 of FIG. 3 is flipped upside down where the support assembly of flexible members 18 and 19 within buoyant tubing 12 are pushed downward to form a high buoyancy “bucket seat” version of apparatus 30 .
[0030] FIG. 3B shows all of the buoyant foam sections 2 , 11 , 12 , 22 , 23 , 24 & 31 of apparatus 30 removed to expose the rigid frame members 13 , 14 , 15 , 26 , 28 & 29 and flexible members 18 and 19 beneath. The path and situation of the flexible members 18 and 19 are visible. The attachment area 16 may be a knot in the support rope or a rope crimp device and are attached to the frame members 13 & 26 . It is important to note that the six frame members 13 , 14 , 15 , 26 , 28 , 29 , the four elbow joints 3 , along with the two forty-five degree joints 25 are used and assembled in the same way for the two similar devices depicted in FIG. 2 and FIG. 3
Fourth Preferred Embodiment
[0031] Looking at FIG. 4 and FIG. 4A together, you will see another embodiment 40 of the present invention where there is no use of rigid frame members. The six buoyant foam sections 43 , four buoyant foam sections 44 , and four buoyant foam sections 45 are joined together using at least one flexible member 42 that is routed through the hollows of all buoyant foam sections and then fastened back to itself at point 41 in the form of a knot or mechanical connecter. The said route of flexible member 42 is exposed in the section view FIG. 4A which shows how one end of the flexible member is routed through the hollow of a lower tube section 44 and the other end of 42 is routed similarly through a second lower tube 44 . The two ends of 42 cross each other as they are routed through opposing end hollows of a tube section 45 . As the ends of 42 emerge from the opposite end hollows of foam section 45 , they are each routed up through the hollows of two foam sections 43 . The ends of flexible member 42 repeat this routing process as illustrated in FIG. 4A until they are passed through the hollows of the last two buoyant foam sections 44 , it is there that the two opposing ends of flexible member 42 meet and are connected together to form a continuous loop. The flexible nature of member 42 allows the buoyant foam sections to be folded at all junctions to minimize the overall size of embodiment 40 . The resulting embodiment of the present invention is exceptionally light weight, completely flexible, can be folded into a small area for packaging and storage, and can be worn on the user's body during use in water.
Fifth Preferred Embodiment
[0032] Looking at FIG. 5 and FIG. 5A together, you will see another embodiment 50 of the present invention where there is no use of rigid frame members. The two upper buoyant foam sections 55 , two lower buoyant foam sections 58 , head rest buoyant foam sections 51 , 52 , and hinge buoyant foam section 57 are joined together using at least one flexible member 56 that is routed through the hollows of all buoyant foam sections and then fastened back to itself using a fastening method. The preferred fastening method illustrated in FIGS. 5 and 5A is a mechanical connecter or ring 53 and two knots 54 . Once the flexible member 56 is routed through all of the buoyant foam sections, each end of member 56 is passed through the hollow of ring 53 and an overhand knot is tied on each end of member 56 . The interior diameter of ring 53 is of sufficient size to allow only the diameters of both ends of member 56 to pass through its hollow easily but prohibits these ends from being removed once the overhand knots have been applied. This ring and knot fastener system allows for reduced packing size and shipping cost due to partial assembly during manufacture and a very easy reassembly by the end user. The said route of flexible member 56 is exposed in the section view FIG. SA which shows how one end of the flexible member 56 is routed through fastener ring 53 , down through the hollow of the left side upper tube section 55 , through hinge tube 57 , down through the right lower tube 58 , up through the left lower tube 58 , back through hinge tube 57 , up through the right side upper tube section 55 , through head rest tube section 52 , through head rest section 51 , back through head rest section 52 , and back through the other side of fastener ring 53 , where the overhand knots 54 are tied at each end of flexible member 56 effectively unifying all of these members as one preferred embodiment 50 . The hinge buoyant foam section is called so because the two lower foam sections 58 can be rotated up with member 57 acting as the pivot point, so that they nest between upper members 55 to minimize the overall size of embodiment 50 . The shape of embodiment 50 is essentially two triangles, which hold shape well without a rigid framework, which is preferable over a square shape for example. The resulting embodiment of the present invention has a minimum of parts, is exceptionally light weight, completely flexible, can be folded into a small area for packaging and storage, and can be worn on the user's body during use in water.
How a Person Rests in the Seat
[0033] A person may rest in the seat in a variety of ways. A user would typically enter into a body of water and arrange the tubular support sections 6 & 7 into the middle of the surrounding frame and place their rear end onto the support sections, with their head at one short end of the frame and their feet at the other short end of the frame and rest in a reclined position as demonstrated in FIG. 6 . A user may shift their weight forward, placing their rear end on the lower frame members 22 & 26 to sit in an upright position as demonstrated in FIG. 7 . Some users may prefer to lay facing the apparatus. The apparatus may be flipped over, or turned upside down to provide other flotation characteristics or seating options that may be preferred by the user.
Method of Assembly
[0034] In order to manufacture or produce the floating chair invention depicted in FIG. 1 and FIG. 1A , first, all parts shown must be sized, cut and or otherwise procured. The optional buoyant foam headrest 8 is sleeved over the buoyant foam section 2 , then frame member 13 is inserted into the hollows of foam section 2 which carries the headrest 8 . The inside of one hollow end of a ninety-degree pvc elbow joint 3 is coated with pvc cement and applied to each end of the frame member 13 , so that the two open ends of the elbow joints 3 face in the same direction and are parallel when viewed from the side or laid onto a horizontal surface to rest on the open ends of parts 3 . This same assembly is repeated with frame member 26 , foam section 22 and the remaining two elbow joints 3 without headrest 8 . Rigid frame members 17 are inserted through the hollow of buoyant foam sections 1 and are then inserted into the remaining open ends of elbow joints 3 after coating the inside of remaining open ends of the elbow joints 3 with pvc cement. The resulting apparatus is a rectangular pvc pipe or tube frame that has all four frame members wrapped inside the hollow of buoyant foam tubing sections and are mainly obscured from sight. Looking at FIG. 1 , one end of rope length 4 is affixed to the right side of upper frame member 13 between foam section 2 and upper right elbow joint 3 by looping the rope length 4 around frame member 13 and tying a knot or applying a rope crimp 16 . As illustrated in FIG. 1B , the other end of rope length 4 is passed through the right side hollow end of the topmost support assembly, (made of rigid tube member 7 inserted into buoyant tube section 6 ) and out the left side of the hollow moving from right to left. Rope length 4 is then brought down and through the hollow of the remaining support member 7 from left to right, out of the hollow and down to be attached to the right side of lower frame member 26 via a knot or rope crimp 16 . Looking again at FIG. 1 with the headrest 8 at the top, one end of rope length 5 is affixed to the left side of upper frame member 13 between foam section 2 and upper left elbow joint 3 by looping the rope length 5 around frame member 13 and tying a knot or applying a rope crimp 16 . As illustrated in FIG. 1B , the other end of rope length 5 is passed through the left side hollow end of the topmost support member and out the right side of the hollow moving from left to right. Rope length 4 is then brought down and through the hollow of the remaining support member from right to left, out of the hollow and down to be attached to the left side of lower frame member 26 via a knot or rope crimp 16 . The resulting apparatus is the rectangular buoyant frame and headrest, with attached flexible members and adjustable support sections that form the support assembly, as illustrated in FIG. 1 and FIG. 1A .
[0035] The production and assembly of the embodiments depicted in FIG. 2 and FIG. 3 are substantially similar to that of the production of the apparatus of FIG. 1 and FIG. 1A above. The notable differences being that instead of one long frame member inserted into one long buoyant foam tube length at each lateral side, there are two frame members inserted into two separate buoyant foam tube lengths, with the frame members being joined together by a forty-five degree pvc elbow joint 25 via pvc adhesive at one end of the elbow joint and a mechanical fastener 9 at the other. This mechanical fastener 9 makes it possible to break down the apparatus into a smaller form for shipping and storage. The apparatus should not be limited to any material types or part sizes.
[0036] While the invention has been described, disclosed, illustrated and shown in various terms or certain embodiments or modifications which it has assumed in practice, the scope of the invention is not intended to be, nor should it be deemed to be, limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of the claims here appended. | A buoyant, submersible chair that is comprised of a framework of buoyant foam tube sections and a support assembly of rope and buoyant foam tube sections that may be broken down into smaller units that is used to float a user in a body of water. The present invention is lightweight, buoyant, adjustable for personal preference of flotation and comfort, and can be carried on the back in a way that is similar to a back-pack. The present invention is proposed in several different embodiments, each style having numerous seating positions. | 0 |
[0001] Priority is claimed to German patent application DE 10 2005 016 815.9, filed Apr. 7, 2005, the entire subject matter of which is hereby incorporated by reference herein.
[0002] The invention relates to a method for operating, especially for generating and/or updating, a database containing personal information such as, for instance, an address database and/or an appointment database.
BACKGROUND
[0003] Databases containing personal information are acquiring ever-greater significance, both in the private and business realms. Thus, for example, it is known that companies access address databases and then send their advertising to persons stored in these databases in order to acquire new customers in this manner. Consequently, owing to the financial significance of such databases, it has now become common practice to buy and sell the contents of such databases, so as to also make the stored personal information available to other companies in exchange for payment. In this context, the value of such a database or of its contents depends to a decisive extent on the scope of the stored personal information and on how up-to-date this information is.
[0004] It is known nowadays that such databases or their contents are compiled essentially manually. To this end, potential customers are requested, for instance, through the modality of sweepstakes, to provide their addresses and other items of personal information. By the same token, information can be accessed that is typically available at mail-order companies, provided that the customers stored there have not explicitly prohibited their data from being passed on to others.
[0005] In addition to the above-mentioned databases essentially containing information about potential customers or recipients of advertising, another typical area of application for databases containing personal information is, for example, an address database and/or an appointment database. Nowadays, many people keep databases of the above-mentioned type for their business activities and sometimes also for their private sphere listing the contacts these persons use such as, for instance, business partners, friends, physicians, attorneys, public addresses, etc.
[0006] Also in the case of the latter databases, the problem of keeping the databases updated arises, for instance, when persons whose information is stored in such a database have moved elsewhere, thus changing their addresses, or else the person has contact data that has changed in the meantime for other reasons such as changed phone numbers, e-mail addresses, mailing addresses and the like.
SUMMARY OF THE INVENTION
[0007] It is an object of the present invention to provide a simple method with which, for example, the above-mentioned databases can be operated, especially generated and maintained.
[0008] According to the present invention, in that the content of a message sent via a telecommunication network—especially a voice, text and image message, a video message or a message in a website—is checked for the presence of personal information, and in that, once personal information has been found, it is extracted from a message, associated with at least one person and then stored in the database.
[0009] This above-mentioned invention is based on the fact that telecommunication networks are often employed nowadays to send all kinds of messages in order to transmit personal information. This personal information encompasses, for instance, name information, address information and contact information. Examples of telecommunication networks are the landline phone system, the cellular network, the Internet as well as any other type of network through which messages can be exchanged.
[0010] Thus, for instance, the telephone system is a preferred means to notify a contact person, especially by means of a switched-on answering machine/voice mailbox even when the person is not available, that personal information about the caller or about a third person to whom the message refers has changed, for example, the address, a phone number, an e-mail address or other contact information. The phone system can also consist of a network for Internet-based telephony (IP telephony). Here, if applicable, such contact information can also be valid for a limited period of time, for example, in the case of absence due to a vacation, a business trip, appointments and the like.
[0011] The invention makes use of the fact that messages sent via telecommunication networks contain a large amount of personal information that can be evaluated and further utilized. Thus, when personal information such as, for instance, a change of address, is found in a message, this information can then be extracted from the message, after which it has to be ascertained which person is to be associated with this found information, in order to then generate a database entry for this person with the information found, or else, if applicable, to change an existing database entry.
[0012] This provides the possibility to build up and maintain or update a database of a large size within a short period of time, for instance, by constantly querying and checking messages in telecommunication networks.
[0013] According to the invention, it can be provided that all kinds of messages are checked and evaluated whereby, for example, voice, text and video messages (e.g. still images, video images, e.g. streaming video) and websites can all be used here. Prior to checking a message for the presence of personal information, it can be necessary, for instance, to convert such a message into a format that can be evaluated or checked insofar as the message is not already in such a format, which is the case, for instance, with e-mails or text messages in the cellular network. This format can be, for example, a text format, for instance, with ASCII characters, since text information is essentially very easy to check and evaluate.
[0014] For messages that are not originally already in such a format, according to the invention, first a conversion can be carried out. For instance, voice messages, especially those that are left in voice mailboxes, can be converted into a format that can be evaluated such as, for example, text, following a speech analysis. Such conversions can also be provided, for instance, for fax messages or for any other messages that are not originally present in a format that can be evaluated.
[0015] Basically, it can be provided that a message that travels through a telecommunication network on its way from the sender to the recipient can be checked for the presence of personal information. In this context, according to the invention, it is immaterial at what point in time or at what stage of the passage through a telecommunication network such a checking procedure takes place.
[0016] In a preferred embodiment, however, it is provided that messages are checked which are stored within a telecommunication network, especially temporarily, and/or in a receiving telecommunication device, particularly a telecommunication terminal. Such storage, optionally even only temporarily, allows existent stored messages to be checked in a manner that is not time-critical, that is to say, a message traveling through the telecommunication network does not necessarily have to be analyzed at the moment when it is passing through the telecommunication network, which, in case of a high volume of messages, would place a severe strain on the network or on any infrastructures that are provided for such a checking procedure such as, for instance, computer systems.
[0017] The checking of messages that are stored optionally even only temporarily entails the advantage that the work needed to check messages can be spread out over time.
[0018] Generally speaking, the possibility also exists of fundamentally not checking every single message, but rather, for instance, only the messages contained in special memory units or memory areas within the telecommunication network or in telecommunication devices.
[0019] For instance, for data-protection reasons, it can be provided that a checking procedure is performed only for those messages for which the user in question, i.e. for example, the sender of such messages, has authorized such a checking procedure. Optionally, it can also be provided that an authorization has to be given by the appertaining recipients of the messages or else by both parties, in other words, by the receiving party as well as by the sending party.
[0020] According to the invention, it can be provided to check, for example, those messages that are stored, e.g. temporarily, especially in an exchange. Here, the term “exchange” does not necessarily refer to the exchange of a telephone network, but rather fundamentally to any exchange within a telecommunication network that ensures that a message is forwarded from a sender to a certain selected recipient.
[0021] Thus, a provision can be made for the intermediate storage of messages, optionally also in several exchanges of one or more telecommunication networks on their way from the sender to the recipient such as, for instance, when fax messages or e-mail messages are sent.
[0022] By the same token, the possibility also exists to check messages and to extract relevant information as soon the messages are stored in a receiving telecommunication device, especially in a telecommunication terminal such as, for example, a mailbox or an answering machine. Such a memory unit in which the messages accumulate and can be stored can already be provided, for instance, within a telecommunication network or optionally at the premises of a customer who operates a telecommunication terminal.
[0023] Likewise important for the method according to the invention is the fact that the personal information obtained from a message can be associated with a person so as to ensure that a database entry associated with this person can be generated or, if applicable, changed. In this context, it has proven to be advantageous if the personal information is associated with a person on the basis of the message itself and/or on the basis of data that is linked to such a message during the telecommunication such as, for instance, a communication data record.
[0024] Thus, for example, it is advantageous if the personal information is associated, for instance, on the basis of an analysis of the content of the message and/or of an identity of the telecommunication device that is sending or receiving the message such as, for example, on the basis of a call line identity (CLI), home location register (HLR), IMEI, SIM and/or on the basis of the identity of the person sending or receiving the message, for example, a PIN, PAN, SIM or, if applicable, biometric data and/or on the basis of key data, especially keywords or key images, in a message and/or other database information of a database edited according to the invention, or else any other database or on the basis of link addresses or communication addresses, particularly those that appear in a message.
[0025] An important aspect for the above-mentioned approaches according to the invention is that a message containing personal information is normally associated with additional data about a person to whom the above-mentioned information refers and which can be obtained, for instance, from an analysis of the content of the message, for example, by means of knowledge management. Thus, for example, it can be provided that names are mentioned in a message such as, for example, the name of the person sending the message, or else the recipient is addressed directly by name. Optionally, it can also be the case that a sender mentions a third person by name during communication with the recipient.
[0026] Especially the fact that telecommunication identities—such as, for example, the identity of the sending telecommunication connection or of the device connected thereto as well as, for instance, the identity of a receiving telecommunication connection or device—are associated with a message in a telecommunication network can be instrumental in identifying and creating an association with a person to whom the transmitted information refers.
[0027] Additional information can be obtained from the device identities or else, for instance, from the SIM cards of cell phones since normally these SIM cards are contractually associated with a certain person.
[0028] According to the invention and to one of the above-mentioned options that can be employed alternatively or cumulatively, it can also be provided that it is not only a message that is checked and evaluated, but also the biometric data that might be associated with the message so as to allow an association with a person. In the case of speech information, for example, such biometric data can be the transmitted speech data.
[0029] Especially in the case of key information such as, for instance, keywords, a simplified association can be achieved or at least facilitated. Such key information or keywords can be, for example, the mention of names or the naming of telephone numbers or typical identities in telecommunication networks such as e-mail addresses, Internet sites, etc.
[0030] In conjunction with other database information from a database operated according to the invention or from other databases, an attempt can also be made to allow or facilitate the association with a person, for example, in that a procedure checks in other databases or in the database according to the invention whether additional information matching the information found in the specifically checked message can be found that allows a correlation of the information concretely found in the checked message with the other information from the same database or from another database.
[0031] According to the invention, it can be provided that a database that is generated or maintained or updated by means of the method according to the invention is associated with at least one telecommunication participant and/or a telecommunication identity, especially with a memory unit operated by or under this telecommunication identity such as, for example, a mailbox.
[0032] As a result, it can be achieved according to the invention that, for example, the user of a telecommunication network who operates a telecommunication device within the network under a telecommunication identity that has been assigned to him/her can also operate a database to store the contact data about other persons that is important for this user. Such a database can be, for instance, a typical address database or appointment database.
[0033] Therefore, according to the invention, it can be provided, for example, that messages sent via the telecommunication network can optionally be stored in this network temporarily or permanently, then evaluated so as to generate, augment or maintain, that is to say, update, a database specifically associated with a given telecommunication participant.
[0034] For example, in this case it can be provided that, in order to generate or update this particular database, only those messages are used that are directed to this specific user or to his/her telecommunication identity or to a mailbox operated under that identity. In this manner, it can be ensured that any message that reaches this telecommunication participant via a telecommunication network and that contains information of a personal type about one of his/her contact persons according to the address database or appointment database is automatically evaluated so that the database associated with this person can be generated, augmented or corrected.
[0035] Thus, for instance, the address and contact database of a telecommunication participant can be automatically corrected if the owner of this database receives the message that one of the stored contact persons now has new or changed information, for instance, a different phone number. Following an evaluation, this information can be directly integrated into the database so that the owner of this database automatically receives the new contact information without having to personally evaluate the received message and to transfer the information into the database.
[0036] Telecommunication participants may be any participants who take part in a telecommunication in a direct or indirect manner.
[0037] Alternatively or cumulatively, the possibility also exists that a database of the type according to the invention is associated not only specifically with one telecommunication participant or with one telecommunication identity, but rather, it is available globally within a telecommunication network. Such a database can be, for instance, a generally accessible information database such as, for example, a telephone directory database or a business directory database.
[0038] Hence, it can be provided according to the invention that messages encompassing personal information about a person stored in such a database are automatically checked and utilized for purposes of changing, checking or updating the database entry pertaining to this person. To this end, the telecommunication network can be, for example, systematically scanned.
[0039] According to the invention, it can also be provided that, when several databases are operated that are associated, for instance, with various telecommunication participants or else that are available globally or on a broader basis, then the information pertaining to a certain reference person that is obtained from a message is automatically distributed among all of the databases that contain information about this reference person. Accordingly, the acquired information can be automatically distributed whereby, for example, it is first checked whether a given database contains information about the reference person and, if this is the case, then this information stored in the database is updated or augmented, optionally preceded by a plausibility check, particularly for purposes of verifying the information.
[0040] Especially with reference to the above-mentioned possibilities, it can be provided according to the invention that a database that is generated or maintained according to the invention, is then operated, for instance, in a centralized manner, especially within a telecommunication network, and/or in a decentralized manner, especially in a telecommunication device, for example, in a telecommunication terminal and/or in a server. Thus, such a database can be operated especially in a decentralized manner in a telecommunication terminal or at least in a telecommunication device assigned to a user or in a server located in a telecommunication network, provided that these databases are associated with persons.
[0041] According to the invention, it can also be alternatively or cumulatively provided that a database that is generated or maintained by the method according to the invention, especially, for example, a decentralized database, is merged with another database, particularly a centralized database.
[0042] This can also be done, for instance, upon request by a telecommunication participant, especially by the telecommunication participant to whom an above-mentioned decentralized database has been assigned.
[0043] Thus, the possibility exists, for example, for the user of a cell phone to update the address database or appointment database that is stored in his/her cell phone and to merge it with the information kept in a database generated according to the invention, for example, within a telecommunication network, either specifically for the user or else globally. For this purpose, it can be provided, for instance, that the telecommunication participant presses a special key on his/her cell phone or, for example, requests an update by means of, for instance, a text message addressed to his/her network provider.
[0044] By virtue of the fundamental possibilities of merging various databases with each other, the option also exists according to the invention to merge a database of a telecommunication network operator with a database of another telecommunication network operator. Thus, it is known that various telecommunication network operators such as, for instance, cellular network operators, operate their own databases, for example, with information about their customers. In order to make this information available among a plurality of networks, it can be provided according to the invention to carry out a corresponding data merge among a plurality of networks.
[0045] The method according to the invention also entails special advantages to the effect that, for example, when a telecommunication is established between a first and a second telecommunication participant, a database query can be made either automatically or else upon request to ascertain whether alternative or additional contact information about the second selected telecommunication participant is available.
[0046] In this manner, for example, a telecommunication participant who would like to communicate with a second telecommunication participant does not have to be concerned about whether he/she has the current communication identity such as, for instance, a telephone number. After all, he/she makes use of the telecommunication identity associated with a person and normally stored in his/her database, whereby then, either automatically or upon specific request, for instance, on the part of the sending telecommunication participant, a query of the database according to the invention is made in order to ascertain whether, in the meantime, the database has been updated within the scope of the method according to the invention so that then, if applicable, the selected network identity is automatically replaced by the now current network identity.
[0047] Thus, for instance, the selected telecommunication identity can be automatically forwarded to a telecommunication identity stored in the database. According to the invention, it can be provided that this preferred latter option is only carried out if the desired telecommunication partner cannot be reached under the telecommunication identity that was called first.
[0048] According to the invention, it can also be provided that information stored in a database is forwarded to registered users or user groups. In order to do so, for example, a distribution list can be associated with a database, said distribution list specifying to whom the information stored in the database will be distributed either automatically or upon request. In one application, this can comprise, for example, mail order companies or official agencies that have an interest in keeping their address data and, if applicable, customer data, up to date. Thus, for instance, it can be provided that a database operated by means of the method according to the invention is offered by a service provider and interested users or user groups can acquire contact data from said database, for instance, by purchasing said data.
[0049] According to a preferred embodiment of the invention, it can be provided, for instance, that a central data change service is made available within the network to which a telecommunication participant transmits a message of any type, for example, a voice text or an image message, whereby then the personal information stored in the message is extracted from the message and distributed to interested third parties or third-party services whereby, if applicable, it can be provided that the sender of such a message can optionally indicate in the message or in a predefined distribution list to whom the change information is to be transmitted. Thus, for instance, by means of the method according to the invention, it can be achieved that, if a person changes his/her address because of a move, the new contact data is automatically distributed, for instance, to all third parties with whom this person maintains contact.
[0050] The method described above can preferably also be executed in parallel to a telecommunication that is taking place, whereby the telecommunicated data constitutes the messages as defined by the invention.
BRIEF DESCRIPTION OF THE DRAWING
[0051] The present invention is elaborated upon below based on exemplary embodiments with reference to the drawing.
[0052] The FIGURE shows a flowchart depicting how the method according to the invention can be executed.
DETAILED DESCRIPTION
[0053] Referring to flowchart of the FIGURE, in step 1 , it can be provided, for example, that a customer A calls a customer B, whereby then a communication data record is automatically generated during the establishment of this telecommunication and it encompasses the call line identity of the telephone connection of customer A (CLI(A)), calls—or else the home location register of customer A (HLR(A)) if he/she is using a cellular phone—as well as the called telecommunication identity, that is to say, the call line identity of customer B (CLI(B)). If, for instance, customer B is not available, in step 2 the voice mailbox, for example, within the telecommunication network, can receive and especially store a message left by customer A.
[0054] According to the invention, in step 3 it can then be provided that the stored message of step 2 , which can be, for instance, a voice message, is then converted into text, for example, within the scope of speech recognition, after which the converted message can be analyzed, for instance, with reference to the transmitted communication identities, in order to associate the personal information found in the message with a corresponding person. Once this has been done, the appropriate personal information in the database can be updated or else can be generated for the first time. The current data may be sent and/or merged.
[0055] In step 4 , the changes made in the database are distributed in accordance with a stored distribution list to other databases where the same person to whom the personal information refers is stored. In step 5 , third-party subscribers receive the changes in the database and can thus make use of them. Therefore, in step 6 , the changes are then also available in the internal databases of the third parties.
[0056] An example also serves to demonstrate how sent information can be evaluated and associated. The example below is, for instance, a voice message that, prior to be being checked and evaluated, undergoes a conversion, for example, into text.
[0057] Thus, for instance, caller Thomas can inform his friend George that he now has a new phone number as follows: “Hello George, this is Thomas, my new phone number is 12345.”
[0058] Along with this phone number, the call line identity of Thomas's new telecommunication connection is transmitted—but it is not yet stored in George's database since it is a new connection. Moreover, in the communication data record, the call line identity is also transmitted to George, who is the party who has been called, so that here, by means of the method according to the invention, it can be checked in a database assigned to George whether contact information pertaining to someone named Thomas exists in the database.
[0059] Once the information in the message and the names “George” and “Thomas” extracted in this process have been evaluated—whereby the software recognizes that the typical “hello” proceeding the name George indicates that he is the person being addressed, especially in conjunction with the fact that the telecommunication identity of George was ascertained in the communication data record—it becomes clear that Thomas is the reference person.
[0060] Therefore, an unambiguous association can be assumed, at least if there is not more than one person named Thomas stored in George's database, so that now the contact data, that is to say, the new phone number for this person, can be stored in the database. Accordingly, George's address database was automatically updated with Thomas's new phone number as a result of the transmission of the message.
[0061] Due to the fact that, according to the above-mentioned part of the invention, an association with a person can take place on the basis of a wide variety of measures such as, for instance, checking the call line identity of the HLR, of the SIM, of the IMEI, of biometric data, etc., within the scope of the method according to the invention, it can be ascertained with a high degree of probability with which person the personal information ascertained in a message has to be associated.
[0062] If the option of making an association does not entail a sufficient level of probability, then it can also be provided according to the invention that, prior to the integration of the data, that is to say, prior to updating the database, a query is made to the owner of the database. Then, prior to the integration of the information that is meant to be integrated, this information can be offered or displayed to the database owner, so that the person in question can once again check the plausibility and then either confirm or reject the integration of the information. | A method for operating a database containing personal information includes checking the content of a message sent via a telecommunication network for the presence of personal information. If personal information is found, then the personal information is extracted from the message, the extracted information is associated with at least one person, and the extracted information is stored in a database. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates to packaging and casing systems and specifically to a packaging process whereby a plurality of articles may be removed from a supply, or infeed conveyor and alternatively placed into shipping boxes or cartons transported on outfeed conveyors located on opposite sides of the supply conveyor.
[0002] The process may be performed using a single, two-axis robot arm for pickup, transporting and release of an article or articles.
BACKGROUND OF THE INVENTION
[0003] Past efforts in the field of packaging and casing of processed articles involved tedious and time-consuming manual operations, usually required a large number of personnel possessing a high degree of dexterity. Early mechanical innovations were also beset with numerous problems, such as high initial cost of apparatus involved, inability of such apparatus to adapt itself for use with other existing equipment utilized in the production of such articles, inability of such apparatus to meet the demands for high production of articles, or objects, to be packaged and encased in shipping cartons, and the susceptibility of such apparatus to repeated breakdown and repair, and thus incurring a high maintenance cost.
[0004] A known current operating system of which the applicant herein is aware, provides a single conveyor line used for transporting containers, or empty cartons, to be filled and operating in an “open” position and a “load” position. A box or carton is formed and opened at the “open” position. Articles are placed in the carton at the “load” position. In that location, the single conveyor line must be stopped during loading and a package-transporting robot arm is also stopped when the carton has been filled, and is retained in the stopped position until a new empty carton is placed in front of the robot arm. In contrast, the present system is continuous in operation. The present loading system for transferring manufactured articles into shipping boxes eliminates the need to stop the conveyor or the robot arm movement.
SUMMARY OF THE INVENTION
[0005] The present invention, in a preferred embodiment, provides a packaging and casing system, wherein a plurality of articles are removed from a supply, or infeed conveyor and are alternatively placed into shipping boxes or cartons transported on outfeed conveyors located at opposite sides of the supply conveyor. This embodiment may also include the use of a single, two-axis robot arm operating in a path transverse to the longitudinal, parallel paths of an intermediately disposed supply, or infeed conveyor, and a pair of outfeed conveyors located at opposite sides of the infeed conveyor. The robot arm and its end effector are designed to reach across its closest outfeed conveyor, the infeed conveyor, and thereafter to the outermost outfeed conveyor.
[0006] Thus, it is a principal object of the present invention to provide a continuously operated packaging and casing system which will overcome the disadvantage of prior systems, wherein a single conveyor line must be stopped during loading and its cooperating robot arm must be stopped when a carton has been filled, and until a new empty carton has been placed in filling position directly in the operating path of the robot arm.
DESCRIPTION OF THE DRAWINGS
[0007] [0007]FIG. 1 is a top plan view of the various cooperating elements or components involved in the operation of the improved system encasing process of this invention.
[0008] FIGS. 2 - 7 , inclusive, are end views, with respect to FIG. 1, and are arranged in sequence of operation of the improved system depicted in FIG. 1.
DETAILED DESCRIPTION
[0009] Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structure. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims herein.
[0010] Like elements illustrated and described herein are denoted by like reference characters.
[0011] The packaging and casing system of the present invention is illustrated in the various FIGS. 1 - 7 , inclusive, and is generally indicated by the reference character S. With reference to the plan view of FIG. 1, the system S is preferably contained within the confines of a workstation W, and is preferably arranged to utilize a two-axis robot R. The controller C and the I/O cabinet I for the robot R are each conventional, and are usually positioned externally of the workstation W for convenience and safe operation of the system components. The robot R and its operating arm 50 , along with its end effector 14 , are arranged for transverse operational movement in a plane substantially normal to the respective longitudinal planes of the infeed conveyor 10 and outfeed conveyors 11 and 12 . The outfeed conveyors 11 , 12 are respectively located at opposite sides of the infeed conveyor 10 , and are preferably in general parallel arrangement therewith.
[0012] The outfeed conveyors 11 and 12 may move from left to right, as shown by the arrow 16 , in the view of FIG. 1. The intermediate infeed conveyor 20 may move in either longitudinal direction, as shown by the arrow 18 , relative to the pre-selected direction of the outfeed conveyors 11 and 12 , depending upon the location of the source of an object or article 20 and transporting tray 21 carried thereby. The infeed conveyor 10 may carry unpacked product, such as produce, or prepackaged product, such as baked muffins, or the like. For purpose of illustration, the product, or article, identified by the reference numeral 20 , will have been conventionally placed on trays 21 during and/or after processing.
[0013] The product 20 and respective trays 21 are transported on the conveyor 10 to a workstation area designated herein by the phantom lines identified by the letter W. There is no particular configuration assigned to the workstation W, other than an unloading/loading area for alternative disposal of an article or product 20 from the infeed conveyor 10 to either of outfeed conveyors 11 and 12 .
[0014] It is usual to supply an end-effector 14 of the robot arm 50 with suction cups 22 or other grasping means (see FIG. 2). The product 20 is lifted by the suctions cup or cups 22 , or other grasping means, from the infeed conveyor 10 and placed in the empty cartons 25 a of the outfeed conveyor 11 and, alternatively, from the infeed conveyor 10 to an empty box or container 25 b resting on the outfeed conveyor 12 . Previously, where only one outfeed conveyor (not shown) was supplied, it was necessary to stop the action of the robot R after filling an empty box 25 , and after that box was filled, it would have been released, and a new empty box 25 would have been placed in line with the arm 50 for filling. When either box 25 a or 25 b has been filled, the robot arm 50 immediately begins filling box 25 a or 25 b located on the opposite outfeed conveyor 11 or 12 without interruption, and there will be continuous operation which may be readily controlled to provide for heavy-duty items, as well as delicate items, such as bottled medicine, or the like.
[0015] The present system S exhibits increased speed of operation and ease in product handling, and completely eliminates the need for expensive manual labor. This will become apparent with reference to the views of FIGS. 2 - 7 , inclusive, wherein FIG. 2 is considered as illustrative of a pickup position of the end effector 14 , and its suction cup(s) 22 being positioned to remove an article 20 (shown in phantom) from the infeed conveyor 10 . The empty carton 25 b will have been momentarily held in place during loading, against its stop 26 b . Upward, movement of the stop 26 b is controlled by the robot controller C, and is timed to work in sequence with movement of the conveyors 10 , 11 and 12 , in order to minimize any prolonged stopping during transfer and loading operations.
[0016] Next, with reference to FIG. 3, the robot R controller C causes the arm 50 to place the article to be transported into its empty carton 25 b resting on outfeed conveyor 12 , and against its stop 26 b . Meanwhile, an empty container 25 a has been moved by conveyor 11 to loading position, resting against raised stop 26 a.
[0017] [0017]FIG. 4 is illustrative of the components of the system S disposed in relative operating position for movement of the arm 50 of the robot R to operating position of its end effector 14 and grasping element(s) 22 , relative to infeed conveyor 10 and its contents 20 ready for removal of the articles 20 and transfer to an awaiting unfilled carton, or container 25 a , supported by outfeed conveyor 11 . The next sequential position of the cooperating components of the system S is illustrated in the view of FIG. 5, wherein it will be observed that the arm 50 of the robot R has been moved to the position with its end effector 14 being located directly above the outfeed conveyor 11 for encasement of the transported article 20 in the empty container 25 a.
[0018] Next, with respect to the view of FIG. 6, the robot arm 50 is moved for pickup position of the product, or article, previously moved to that location by the infeed conveyor 10 . FIG. 7 illustrates the movement of the robot arm 50 back to the original position shown in FIG. 1, ready for transfer to and loading of the container 25 b , which has been momentarily restrained by its stop 26 b.
[0019] It will be apparent that each of the various stages of operation of the components illustrated in the sequential views of FIGS. 2 - 7 , inclusive, are completed with minimal interruption of the respective operating movements of the conveyors 10 , 11 , or 12 or of the robot arm 50 . Furthermore, it should be appreciated that the sequence of operation of the robot arm 50 may be varied without departing from the present invention. For example, the robot arm 50 may grasp, transport and release articles 20 between infeed conveyor 10 and outfeed conveyor 12 multiple times before grasping articles and transferring them to outfeed conveyor 11 . As a further example, the requisite number of articles 20 required to fill tray 21 may be conveyed from the infeed conveyor 10 to the outfeed conveyor 12 before articles a transferred to outfeed conveyor 11 .
[0020] Alternatively, the invention may be described as a method for alternatively transferring objects from a source to a work station, said method comprising the steps of: providing an infeed conveyor and a pair of outfeed conveyors; providing a two-axis robot having a continuously operating arm arranged to pickup an object from said infeed conveyor and transfer said object to one of said outfeed conveyors; controlling said arm to effect pickup of said object at said infeed conveyor; moving said operating arm from said infeed conveyor to said one of said outfeed conveyors; controlling said arm to release and deposit said object on said outfeed conveyor; returning said operating arm to said infeed conveyor; controlling said arm to effect pickup of a second object at said infeed conveyor; moving said continuously operating arm from said infeed conveyor to said other of said outfeed conveyors; controlling said arm to release and deposit said second object on said other of said outfeed conveyors; and returning said operating arm to said infeed conveyor for subsequent pickup and transfer of additional objects to a selected one of said outfeed conveyors.
[0021] The above-described embodiments of this invention are merely descriptive of its principles and are not to be limited. The scope of this invention instead shall be determined from the scope of the following claims, including their equivalents. | A system and method for case-packing articles utilizing an infeed conveyor and spaced apart outfeed conveyors positioned at opposite sides of the infeed conveyor and a robotic operating arm arranged for transverse operation with respect to the longitudinal movement of each of said conveyors. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation of U.S. patent application Ser. No. 10/947,131, filed Sep. 23, 2004, and is based upon and claims the benefit of priority from prior Japanese Patent Application No. 2003-433173, filed Dec. 26, 2003. The entire contents of these applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a nonvolatile semiconductor memory device capable of electrically rewriting data and, more particularly, to a pattern layout of transfer transistors that supply a voltage to word lines in a NAND flash memory which executes a subblock erase.
[0004] 2. Description of the Related Art
[0005] EEPROMs are known as semiconductor memories that can electrically rewrite data. Of these EEPROMs, NAND EEPROMs (NAND flash memories) have received a great deal of attention because of its possibility of higher integration degree. A NAND flash memory has NAND cells each of which is formed by serially connecting a plurality of memory cells, i.e., units that store 1-bit data. NAND flash memories are used in memory cards to store, e.g., image data of digital still cameras.
[0006] Along with the recent increase in capacity of NAND flash memories, the write unit (page size) and erase unit (block capacity) are also becoming large. Generally, the block capacity of a NAND flash memory corresponds to an integer multiple (size) of the page capacity. When the block capacity increases, the efficiency in erasing or rewriting data in small capacity becomes low. To prevent this, the present applicant has proposed a method (referred to as a subblock erase) of erasing only part of the block capacity (e.g., Jpn. Pat. Appln. KOKAI Publication No. H11-177071).
[0007] In the subblock erase, since the block capacity is partially erased, data in small capacity can efficiently be erased or rewritten.
[0008] The subblock erase in a NAND flash memory will be described first.
[0009] A memory cell of a NAND flash memory has a MOSFET structure in which a floating gate and control gate (word line) are stacked, via an insulating film, on a semiconductor substrate serving as a channel region. A NAND cell is formed by serially connecting a plurality of memory cells while making adjacent memory cells share the source/drain. The source/drain means an impurity region having at least one of the functions of the source and the drain.
[0010] FIG. 1 shows the memory cell array of a NAND flash memory and some of its peripheral circuits. One NAND cell 4 a of the NAND flash memory includes two select transistors S 1 and S 2 and memory cells MC 0 to MCi. The gates of the select transistors S 1 and S 2 are connected to select gate lines SGS and SGD, respectively. The current paths of the memory cells MC 0 to MCi are connected in series between the select transistors S 1 and S 2 . The control gates of the memory cells MC 0 to MCi are connected to word lines WL 0 to WLi, respectively. One end of the current path of each of the select transistors S 1 is commonly connected to a source line CELSRC. One end of the current path of each of the select transistors S 2 is connected to a corresponding one of bit lines BL 0 to BLj. The control gates of cell transistors acting as the memory cells MC 0 to MCi and the gates of the select transistors S 1 and S 2 are commonly connected to the control gate lines (word lines WL 0 to WLi) and select gate lines SGS and SGD, which are arranged in the row direction of a memory cell array MCA, for each row.
[0011] An erase unit means a set 4 b of memory cells MC which belong to the NAND cell 4 a and are connected to a predetermined number of word lines WL. A set of the memory cells MC 0 to MCi connected to all the word lines WL 0 to WLi, including the erase units 4 b , and the select transistors S 1 and S 2 will be referred to as a block (NAND cell block) 4 or 4 ′. That is, each block 4 or 4 ′ includes a plurality of erase units 4 b or 4 b′.
[0012] The word lines WL 0 to WLi in the block 4 have transfer transistors (word line transfer transistors) Tr 0 to Tri, respectively. The drain of each of the transfer transistors Tr 0 to Tri is connected to a corresponding one of the word lines WL 0 to WLi so that a voltage is supplied to the word lines WL 0 to WLi. The gates of the transfer transistors Tr 0 to Tri are commonly connected to a node G. The source of each of the transfer transistors Tr 0 to Tri is connected to a corresponding one of word line driving signal lines (driving lines) CG 0 to CGi. The word line transfer transistors Tr 0 to Tri construct a part of a row decoder.
[0013] The remaining blocks (e.g., the block 4 ′) also have the same structure as that of the block 4 .
[0014] FIG. 2 is a schematic view for explaining voltage application conditions in the erase in the NAND cell 4 a . The data erase is executed in the following way. A ground potential is applied to all control gates (word lines WL 0 to WLi) in the selected block. All control gates in unselected blocks and the select gate lines SGS and SGD, bit lines BL 0 to BLj, and source lines CELSRC in all blocks are set in a floating state. Then, a high erase potential (about 20V) is applied to the well regions of the cells MC 0 to MCi. Accordingly, in the cells MC 0 to MCi in the selected block, electrons in the floating gates are drained to the well regions so that the erase is executed for one block. At this time, even in all control gates in the unselected blocks and the select gate lines SGS and SGD, bit lines BL 0 to BLj, and source lines CELSRC in all blocks, the potential increases almost upto the erase potential due to capacitive coupling (for example, in the select gate line SGS, capacitive coupling occurs between the gate capacitance of the select transistor S 1 and the other capacitance of the select gate line SGS against ground potential). The ground potential is supplied to the word line driving signal lines CG 0 to CGi. The transfer transistors Tr 0 to Tri in the selected block are turned on because a power supply voltage Vdd is applied to the node G. The ground potential is applied from the word line driving signal lines CG 0 to CGi to the control gates of the cells MC 0 to MCi in the selected block. In the unselected blocks, the transfer transistors are turned off because the ground potential is applied to the node G. The control gates of the cells MC 0 to MCi in the unselected blocks are set in the floating state.
[0015] FIG. 3 is a schematic view showing voltage application conditions in the subblock erase in the NAND cell 4 a . In this example, the memory cells MC 0 , MC 1 , MC 2 , and MC 3 are erased. In the subblock erase, in the selected block, the ground potential is applied to the control gates (word lines) of the cells to be erased, and the control gates of cells not to be erased are set in the floating state. All control gates in unselected blocks and the select gate lines, bit lines, and source lines in all blocks are set in the floating state. Then, a high erase potential (about 20V) is applied to the well regions of the cells. Accordingly, in the cells to be erased in the selected block, electrons in the floating gates are drained to the well regions so that the erase is executed for each selected control gate line. At this time, even in all control gates in the unselected blocks and the select gates, bit lines, and source lines in all blocks, the potential increases almost to the erase potential due to capacitive coupling (for example, in the select gate line, capacitive coupling occurs between the gate capacitance of the select transistor and the other capacitance of the select gate line against ground potential). The ground potential is supplied to the word line driving signal lines CG 0 to CG 3 corresponding to the cells to be erased. To the contrary, the power supply voltage Vdd is supplied to the word line driving signal lines CG 4 to CGi corresponding to the cells not to be erased.
[0016] The transfer transistors Tr 0 to Tri in the selected block are turned on because the power supply voltage Vdd is applied to the node G. The ground potential is applied to the control gates of the cells to be erased in the selected block. The control gates of the cells not to be erased are charged to “Vdd-Vt” (Vt is the threshold voltage of the word line transfer transistors) and set in the floating state. In the unselected blocks, the transfer transistors are turned off because the ground potential is applied to the node G. The control gates in the unselected blocks are set in the floating state. The breakdown voltage of an element isolation insulating film which isolates the transfer transistors from each other must be determined on the basis of the maximum potential difference between adjacent transistors and, more specifically, a case wherein one of adjacent transistors has a potential of 20V, and the other has a potential of 0V.
[0017] As described above, in the unselected block in the erase operation, the floating state (20V) of a word line is sometimes present next to the ground potential of a word line driving signal line. In the subblock erase operation, in addition to the above case, the floating state (20V) of the word line of a cell not to be erased may be present next to the ground potential of a word line driving signal line or the ground potential of the word line of a cell to be erased. A leakage current flows between the junction portions of transistors through the element isolation insulating film between the junction portions in accordance with the potential difference between them. When a junction portion in the floating state (20V) is present next to a junction portion having the ground potential, the potential difference becomes large, and the leakage current also becomes large. When a large leakage current flows, the potential of the node in the floating state, i.e., the potential of the word line not to be erased drops. When the potential drop in the word line connected to the cell not to be erased is large, the potential difference between the well region and the gate of the cell increases, as described above, and the cell is readily erroneously erased. Especially, when the number of junction portions which have the ground potential and are present next to junction portions in the floating state (20V) is large, the potential drop is conspicuous. The leakage current between the junction portions becomes large as the width of the element isolation insulating film becomes narrow. For this reason, when the number of junction portions which have the ground potential and are present next to those in the floating state (20V) is large, the element isolation insulating film must be wide, and the area of the row decoder increases. On the other hand, as the micropatterning technology advances, the pitch of word lines decreases. Then, the width of the row decoder also decreases, and the element isolation insulating film must be narrower. The increase in area of the row decoder goes against the requirement for micropatterning.
[0018] FIG. 4 is a plan view showing a conventional pattern layout of word line transfer transistors. In this example, the number of word lines is 32 (WL 0 , . . . , WL 31 ). Word line transfer transistors Tr 0 to Tr 31 are arrayed in three lines. The Y direction indicates the direction in which bit lines BL run. The X direction indicates the direction in which word lines WL run. In the pattern layout shown in FIG. 4 , a word line transfer transistor connected to a word line is not present next to those connected to adjacent word lines. This pattern layout of word line transfer transistors takes the element isolation breakdown voltage into consideration and is described in, e.g., Jpn. Pat. Appln. KOKAI Publication No. 2002-141477.
[0019] FIG. 5 shows the relationship between the word line transfer transistor pattern layout and the potentials of nodes when the subblock erase is executed for cells connected to the word lines WL 8 , WL 9 , WL 10 , and WL 11 in the cell 4 b shown in FIG. 1 . The transfer transistor Tr 6 at 20V (floating state), which is connected to the word line WL 6 of the cell not to be erased, opposes the transfer transistors Tr 8 , Tr 9 , and Tr 11 at 0V in three directions, which are connected to the word lines of cells to be erased. The leakage currents between the junction portion of the transfer transistor Tr 6 and those of the transfer transistors Tr 13 and Tr 14 do not greatly affect because the opposing area is small. However, the potential difference between the junction portion of the transfer transistor Tr 6 and those of the word line transfer transistors Tr 8 , Tr 9 , and Tr 11 , which are adjacent in the X and Y directions, largely affects the leakage current. In the above-described case, leakage currents flow from the junction portion of the transfer transistor Tr 6 to the transfer transistors Tr 8 , Tr 9 , and Tr 11 in the three directions, as indicated by arrows. Each leakage current to flow through transfer transistors Tr 8 and Tr 9 is slightly larger than a leakage current the flow through transfer transistor Tr 11 . For this reason, the potential drop in the word line is maximized. The device breakdown voltage must be designed in consideration of the maximum leakage current. To do this, the width of the element isolation insulating film or the gate length of the transfer transistor must be increased. This leads to an increase in area of the row decoder.
BRIEF SUMMARY OF THE INVENTION
[0020] According to an aspect of the present invention, there is provided a semiconductor device comprising a memory cell array which comprises a plurality of blocks in each of which a plurality of nonvolatile memory cells capable of electrically rewriting data are arranged in an array, a first selection circuit configured to select the block, a plurality of word lines which are arranged in each block and each of which is commonly connected to memory cells of the same row, a second selection circuit configured to select several memory cells in the block to erase the memory cells corresponding to a plurality of word lines in the block, a plurality of driving lines each of which is arranged for a corresponding one of the plurality of word lines and supplies a voltage to the corresponding word line, and a plurality of transfer transistors which act as switches that selectively connect, of the plurality of word lines and the plurality of driving lines, word lines and corresponding driving lines for each block, when the plurality of word lines are divided into word lines connected to memory cells to be erased and those connected to memory cells not to be erased, the plurality of transfer transistors being laid out so that the number of transfer transistors connected to the word lines connected to the memory cells to be erased and arranged on both and opposite sides of a transfer transistor of a word line connected to a memory cell not to be erased becomes not more than two.
[0021] According to another aspect of the present invention, there is provided a semiconductor device comprising a memory cell array which comprises a plurality of blocks in each of which a plurality of nonvolatile memory cells capable of electrically rewriting data are arranged in an array, first selection means for selecting the block, a plurality of word lines which are arranged in each block and each of which is commonly connected to memory cells of the same row, second selection means for selecting several memory cells in the block to erase the memory cells corresponding to a plurality of word lines in the block, a plurality of driving lines each of which is arranged for a corresponding one of the plurality of word lines and supplies a voltage to the corresponding word line, and a plurality of transfer transistors which act as switches that selectively connect, of the plurality of word lines and the plurality of driving lines, word lines and corresponding driving lines for each block, when the plurality of word lines are divided into word lines connected to memory cells to be erased and those connected to memory cells not to be erased, the plurality of transfer transistors being laid out so that the number of transfer transistors connected to the word lines connected to the memory cells to be erased and arranged on both and opposite sides of a transfer transistor of a word line connected to a memory cell not to be erased becomes not more than two.
[0022] According to still another aspect of the present invention, there is provided a semiconductor device comprising a memory cell array which comprises a plurality of blocks in each of which a plurality of NAND cells are arranged, a first selection circuit configured to select the block, a plurality of word lines each of which is commonly connected to control gates of memory cells of the same row in the NAND cells in each block, a first select gate line which is commonly connected to gates of first select transistors in the NAND cells in each block, a second select gate line which is commonly connected to gates of second select transistors in the NAND cells in each block, a second selection circuit configured to select memory cells of a subblock in the block, a plurality of driving lines each of which is arranged for a corresponding one of the plurality of word lines and supplies a voltage to the corresponding word line, a plurality of transfer transistors which act as switches that selectively connect, of the plurality of word lines and the plurality of driving lines, word lines and corresponding driving lines for each block, when the plurality of word lines are divided into word lines connected to memory cells to be erased and those connected to memory cells not to be erased, the plurality of transfer transistors being laid out so that the number of transfer transistors connected to the word lines connected to the memory cells to be erased and arranged on both and opposite sides of a transfer transistor of a word line connected to a memory cell not to be erased becomes not more than two, and an interconnection switching region which is formed between one end of a current path of each of the plurality of transfer transistors and the plurality of word lines and makes word lines on a side of the block and word lines on a side of the transfer transistors cross each other to change at least some layout positions of the word lines.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0023] FIG. 1 is a circuit diagram showing the memory cell array of a NAND flash memory and some of its peripheral circuits so as to explain a conventional nonvolatile semiconductor memory device;
[0024] FIG. 2 is a schematic view for explaining voltage application conditions in an erase mode for one NAND cell in the circuit shown in FIG. 1 ;
[0025] FIG. 3 is a schematic view for explaining voltage application conditions in a subblock erase mode for one NAND cell in the circuit shown in FIG. 1 ;
[0026] FIG. 4 is a plan view showing a conventional pattern layout of word line transfer transistors;
[0027] FIG. 5 is a plan view showing the relationship between the word line transfer transistor pattern layout and the potentials of nodes when the subblock erase is executed to erase cells connected to specific word lines in one NAND cell in the circuit shown in FIG. 1 ;
[0028] FIG. 6 is a block diagram showing the schematic arrangement of a circuit portion related to a subblock erase in a NAND flash memory so as to explain a nonvolatile semiconductor memory device according to the embodiment of the present invention;
[0029] FIG. 7 is a plan view showing the pattern layout of word line transfer transistors in the circuit shown in FIG. 6 so as to explain the nonvolatile semiconductor memory device according to the embodiment of the present invention;
[0030] FIG. 8 is a schematic view showing the pattern of word lines connected to the word line transfer transistors in the pattern layout shown in FIG. 7 ;
[0031] FIG. 9 is a circuit diagram showing an example of the structure of the interconnection switching region between the word lines and the word line driving signal lines in the circuit shown in FIG. 6 ;
[0032] FIG. 10 is a sectional view showing the structure of the interconnection switching region shown in FIGS. 6 and 9 ; and
[0033] FIG. 11 is a plan view corresponding to FIG. 7 , which shows the relationship between the word line transfer transistor pattern layout and the potentials of nodes when the subblock erase is executed.
DETAILED DESCRIPTION OF THE INVENTION
[0034] FIGS. 6 to 11 are views for explaining a nonvolatile semiconductor memory device according to the embodiment of the present invention. A NAND flash memory that executes a subblock erase will be described. FIG. 6 is a block diagram showing the schematic arrangement of a circuit portion related to the subblock erase in the NAND flash memory. FIG. 7 is a plan view showing the pattern layout of word line transfer transistors in the circuit shown in FIG. 6 . FIG. 8 schematically shows the pattern of word lines connected to the word line transfer transistors in the pattern layout shown in FIG. 7 . FIG. 9 shows an example of the structure of the interconnection switching region of the word lines in the circuit shown in FIG. 6 . FIG. 10 shows the sectional structure of the interconnection switching region. FIG. 11 corresponding to FIG. 7 shows the relationship between the word line transfer transistor pattern layout and the potentials of nodes when the subblock erase is executed to erase memory cells connected to word lines WL 8 , WL 9 , WL 10 , and WL 11 in a block 4 shown in FIG. 6 .
[0035] As shown in FIG. 6 , a memory cell array MCA has a plurality of blocks 4 and 4 ′. NAND cells 4 a (a plurality of nonvolatile memory cells capable of electrically rewriting data) are arranged in each of the blocks 4 and 4 ′. One NAND cell 4 a includes two select transistors S 1 and S 2 and memory cells MC 0 to MCi. The gates of the select transistors S 1 and S 2 are connected to select gate lines SGS and SGD, respectively. The current paths of the memory cells MC 0 to MCi are connected in series between the select transistors S 1 and S 2 . The gates of the memory cells MC 0 to MCi are connected to word lines WL 0 to WLi, respectively. One end of the current path of the select transistor S 1 is connected to a source line CELSRC. One end of the current path of the select transistor S 2 is connected to a bit line BL 0 . The control gates of cell transistors acting as the memory cells MC 0 to MCi and the gates of the select transistors S 1 and S 2 are commonly connected to the control gate lines (word lines WL 0 to WLi) and select gate lines SGS and SGD, which are arranged in the row direction of the memory cell array MCA, for each row.
[0036] As in the prior art, an erase unit means a set 4 b of memory cells MC which belong to the NAND cell 4 a and are connected to a predetermined number of word lines WL. A set of the memory cells MC 0 to MCi connected to all the word lines WL 0 to WLi, including the erase units 4 b , and the select transistors S 1 and S 2 will be referred to as the block (NAND cell block) 4 or 4 ′. That is, each block 4 or 4 ′ includes a plurality of erase units 4 b or 4 b′.
[0037] Each of the word lines WL 0 to WLi is connected to one end (drain) of the current path of a corresponding one of word line transfer transistors Tr 0 to Tri through an interconnection switching region 11 . The transfer transistors Tr 0 to Tri act as part of a row decoder (second selection circuit or second selection means) 12 . The other end (source) of the current path of each of the transfer transistors Tr 0 to Tri is connected to a corresponding one of word line driving signal lines (driving lines) CG 0 to CGi. The gates of the transfer transistors Tr 0 to Tri are commonly connected to the output terminal of a booster circuit 13 . The output from a block decoder 14 is supplied to the booster circuit 13 . Booster circuit 13 supplies a voltage to gates of word line select transistors in a selected block. This voltage is the level that a word line select transistors can be transfer the voltage to word lines form word line driving signal lines. In addition, this booster circuit 13 supplies the power supply voltage Vdd to a selected block in an erase (subblock erase) mode, 0V is supplied to a unselected block as well. The block decoder 14 decodes an address signal to select the block 4 or 4 ′ in the memory cell array MCA. The booster circuit 13 and block decoder 14 act as a selection circuit (first selection circuit or first selection means) which selects the block 4 or 4 ′ in the memory cell array MCA and supplies a voltage corresponding to an operation.
[0038] A sense amplifier 15 is connected to the bit lines BL 0 to BLj. Output signals from a column decoder 16 are supplied to the sense amplifier 15 . The sense amplifier 15 amplifies data read out from a selected memory cell or supplies data to be written to the memory cell array MCA. The column decoder 16 decodes a column address signal to designate a column of memory cells in the memory cell array MCA.
[0039] When i=31, the transfer transistors Tr 0 to Tri are divided into a first group GR 1 , second group GR 2 , and third group GR 3 , as shown in FIG. 7 . The first group GR 1 is constituted by the transfer transistors Tr 0 to Tr 9 having first impurity regions formed along a first element isolation insulating film 17 . The second group GR 2 is constituted by the transfer transistors Tr 10 to Tr 20 having first impurity regions opposing those in the first group GR 1 via the first element isolation insulating film 17 . The third group GR 3 is constituted by the transfer transistors Tr 21 to Tr 31 having first impurity regions opposing second impurity regions in the second group GR 2 via a second element isolation insulating film 18 . The first and second element isolation insulating films 17 and 18 are formed along a direction in which gate lines G 1 , G 2 , and G 3 of the transfer transistors Tr 0 to Tr 9 , Tr 10 to Tr 20 , and Tr 21 to Tr 31 run. The second element isolation insulating film 18 is wider than the first element isolation insulating film 17 (Δ2>Δ1).
[0040] The transfer transistors of the first group GR 1 are arranged from the left to the right in an order of Tr 0 , Tr 2 , Tr 4 , Tr 1 , Tr 9 , Tr 3 , Tr 6 , Tr 8 , Tr 5 , and Tr 7 . The word line driving signal lines CG 0 , CG 2 , CG 4 , CG 1 , CG 9 , CG 3 , CG 6 , CG 8 , CG 5 , and CG 7 are connected to the second impurity regions of the transfer transistors Tr 0 , Tr 2 , Tr 4 , Tr 1 , Tr 9 , Tr 3 , Tr 6 , Tr 8 , Tr 5 , and Tr 7 , respectively. The word lines WL 0 , WL 2 , WL 4 , WL 1 , WL 9 , WL 3 , WL 6 , WL 8 , WL 5 , and WL 7 are connected to the first impurity regions.
[0041] The transfer transistors of the second group GR 2 are arranged from the left to the right in an order of Tr 20 , Tr 18 , Tr 16 , Tr 19 , Tr 17 , Tr 15 , Tr 13 , Tr 11 , Tr 14 , Tr 12 , and Tr 10 . The word line driving signal lines CG 20 , CG 18 , CG 16 , CG 19 , CG 17 , CG 15 , CG 13 , CG 11 , CG 14 , CG 12 , and CG 10 are connected to the second impurity regions of the transfer transistors Tr 20 , Tr 18 , Tr 16 , Tr 19 , Tr 17 , Tr 15 , Tr 13 , Tr 11 , Tr 14 , Tr 12 , and Tr 10 , respectively. The word lines WL 20 , WL 18 , WL 16 , WL 19 , WL 17 , WL 15 , WL 13 , WL 11 , WL 14 , WL 12 , and WL 10 are connected to the first impurity regions.
[0042] The transfer transistors of the third group GR 3 are arranged from the left to the right in an order of Tr 31 , Tr 29 , Tr 21 , Tr 30 , Tr 22 , Tr 27 , Tr 25 , Tr 28 , Tr 23 , Tr 26 , and Tr 24 . The word line driving signal lines CG 31 , CG 29 , CG 21 , CG 30 , CG 22 , CG 27 , CG 25 , CG 28 , CG 23 , CG 26 , and CG 24 are connected to the second impurity regions of the transfer transistors Tr 31 , Tr 29 , Tr 21 , Tr 30 , Tr 22 , Tr 27 , Tr 25 , Tr 28 , Tr 23 , Tr 26 , and Tr 24 , respectively. The word lines WL 31 , WL 29 , WL 21 , WL 30 , WL 22 , WL 27 , WL 25 , WL 28 , WL 23 , WL 26 , and WL 24 are connected to the first impurity regions.
[0043] That is, as compared to the conventional pattern layout ( FIGS. 4 and 5 ), the word line transfer transistors Tr 3 and Tr 9 indicated by broken lines, which are connected to the word lines WL 3 and WL 9 , change their places.
[0044] The word lines WL 0 to WL 9 having the pattern layout schematically shown in FIG. 8 are arranged on the transfer transistors Tr 0 to Tr 9 . One end of each of the word lines WL 0 to WL 9 is connected to the first impurity region of a corresponding one of the transfer transistors Tr 0 to Tr 9 . The other end is connected to the interconnection switching region 11 . When this pattern layout is used, the detour of interconnections can be reduced. Since the number of interconnections in the passage region of the word lines WL 0 to WL 9 can be decreased, the interconnection pitch can be relaxed (increased).
[0045] The interconnection switching region 11 has a structure shown in FIGS. 9 and 10 . As shown in FIG. 9 , the word lines WL 1 and WL 2 , the word lines WL 3 and WL 4 , and the word lines WL 5 and WL 6 cross each other. These word lines WL change their places between the NAND cell side and the word line transfer transistor side. Each cross section is implemented by a multilayered interconnection structure. For example, as shown in FIG. 10 , the control gate (word line WL) of the memory cell MC and a first impurity region 19 of the transfer transistor Tr are connected, across the lower interconnection layer, through metal plugs 20 and 21 and an upper metal interconnection layer 22 .
[0046] FIG. 11 is a schematic view for explaining voltage application conditions in the erase operation of the NAND cell 4 a . As shown in FIG. 11 , a power supply voltage Vdd is applied to the first impurity regions of the transfer transistors Tr 0 , Tr 2 , Tr 4 , and Tr 1 . An erase potential of 20V is applied to their second impurity regions. A voltage of 0V is applied to the two ends of the current path of to the transfer transistor Tr 9 . The power supply voltage Vdd is applied to the first impurity regions of the transfer transistors Tr 3 and Tr 6 . The erase potential of 20V is applied to their second impurity regions. The voltage of 0V is applied to the first and second impurity regions of the transfer transistor Tr 8 . The power supply voltage Vdd is applied to the first impurity regions of the transfer transistors Tr 5 and Tr 7 . The erase potential of 20V is applied to their second impurity regions.
[0047] The power supply voltage Vdd is applied to the first impurity regions of the transfer transistors Tr 20 , Tr 18 , Tr 16 , Tr 19 , Tr 17 , Tr 15 , and Tr 13 . The erase potential of 20V is applied to their second impurity regions. The voltage of 0V is applied to the first and second impurity regions of the transfer transistor Tr 11 . The power supply voltage Vdd is applied to the transfer transistors Tr 14 , Tr 12 , and Tr 10 . The erase potential of 20V is applied to their second impurity regions.
[0048] The power supply voltage Vdd is applied to the second impurity regions of the transfer transistors Tr 31 , Tr 29 , Tr 21 , Tr 30 , Tr 22 , Tr 27 , Tr 25 , Tr 28 , Tr 23 , Tr 26 , and Tr 24 . The erase potential of 20V is applied to their first impurity regions.
[0049] When the subblock erase is executed to erase the data in cells connected to the word lines WL 8 , WL 9 , WL 10 , and WL 11 , the leakage current between the junction portions of the transfer transistor Tr 6 connected to the word line WL 6 of the cell not to be erased flows in two directions indicated by arrows.
[0050] More specifically, when the subblock erase is executed every four word lines (WL(4k), WL(4k+1), WL(4k+2), WL(4k+3): k=0, 1, . . . , 7), the leakage current between the junction portions of a transfer transistor flows in two or less directions in X and Y directions independently of the word line set selected for the erase.
[0051] Hence, when the word line transfer transistors Tr 0 to Tr 31 are laid out in the above-described way, the leakage current between junction portions can be reduced, the potential drop in each unselected word line due to the leakage current between junction portions can be suppressed, and the controllability of the subblock erase can be improved. In addition, the element breakdown voltage of the word line transfer transistor can be easily designed, and the area of the row decoder can be reduced.
[0052] In this embodiment, the subblock erase is executed every four word lines (WL(4k), WL(4k+1), WL(4k+2), WL(4k+3): k=0, 1, . . . , 7). However, the number of word lines to be combined for the subblock erase is not limited to four. The same effect as described above can be obtained by appropriately laying out the word line transfer transistors in accordance with the number of word lines selected for the subblock erase.
[0053] As described above, according to one aspect of this invention, when the word line transfer transistors are appropriately laid out, the number of leakage current paths between the junction portions of transfer transistors in the subblock erase mode can be decreased to two or less. Accordingly, the leakage current of a word line connected to a memory cell not to be erased can be reduced. Since the controllability of the subblock erase can be improved, any erase error can be prevented. In addition, the element breakdown voltage design and element isolation breakdown voltage design of the word line transfer transistor can be relaxed. Since the size of the word line transfer transistor can be reduced, and the element isolation insulating film can be made narrow, the area of the row decoder can be reduced.
[0054] Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents. | A semiconductor device includes a memory cell array, first and second selection circuits, and transfer transistors. The first selection circuit selects a block in the memory cell array. The second selection circuit selects several memory cells in the block to erase the memory cells corresponding to word lines in the block. The transfer transistors act as switches that selectively connect, of the word lines and driving lines, word lines and corresponding driving lines for each block. When the word lines are divided into word lines connected to memory cells to be erased and those connected to memory cells not to be erased, the number of transfer transistors connected to the word lines connected to the memory cells to be erased and arranged on both and opposite sides of a transfer transistor of a word line connected to a memory cell not to be erased becomes two or less. | 6 |
RELATED APPLICATIONS
The following applications are being filed concurrently herewith on this 23 rd day of April 1999 and are incorporated herein by reference:
Title
Atty Docket No.
Express Mailing Label Nos.
Cactus Fruit Skin
7537.0029
EL 113 362 519 US
Care Products
Cactus Fruit Drinks
7537.0026
EL 113 362 479 US
and Food Products
Ginseng Berry Drink
7537.0028
EL 113 362 482 US
and Food Compositions
Ginseng Berry Powder
7537.0030
EL 113 362 496 US
Dietary Supplements
Cactus Fruit Powder
7537.0031
EL 113 362 465 US
Dietary Supplements
FIELD OF THE INVENTION
The present invention relates generally to the field of skin care products and more particularly to products and methods which deliver fresh vitamins and other nutrients to the skin by topical application of a novel, vitamin-rich fruit composition. The present invention comprises ginseng berry extract and other skin nutrients and, preferably, other skin nutrients and moisturizers which are beneficial to the skin.
BACKGROUND
Human skin is extremely susceptible to the temperature and humidity extremes of our environment. However, when skin care products are properly used to counteract adverse environmental conditions, skin can remain healthy and beautiful under a variety of extreme environmental conditions. The environmental factors that most often affect the skin adversely are ultraviolet radiation and humidity.
Ultraviolet radiation varies with time of day, from day to night, with seasons of the year and weather conditions. The geographic region where one lives and the climate will also affect the amount of radiation to which one's skin is exposed. The sun's rays can dry skin through direct moisture loss or through the effects of radiation on the skin which may cause tanning and burning as well as moisture loss.
Skin may also face adverse conditions in the workplace where excessive temperatures or low humidity may harm skin. Exposure to chemicals may also remove moisture from the skin causing damage and actual skin chafing and loss if not treated properly.
Consequently, a mild skin moisturizer that nourishes the skin with natural ingredients and that can be repeatedly applied to the skin is beneficial in areas where skin is particularly susceptible to environmental damage.
In addition to environmental factors, skin must also be properly nourished. Maintaining healthy skin requires maintenance of proper moisture in the skin as well as delivery of essential vitamins to the skin. Vitamins may be consumed in the diet or may be applied directly to the skin.
For some people, oral consumption of vitamin C, especially in large doses, can have detrimental side effects ranging from mouth irritation to overdose. Yet large doses are sometimes considered beneficial to provide the skin with an effective amount of vitamin C. Vitamin C promotes collagen synthesis through its free radical scavenging attributes and its enzyme reactions which, in turn, promotes wound healing and skin health. Vitamin C is also toxic to many cancer cells including melanoma and has been found to catalyze the immune reaction to viral and bacterial infections.
Natural skin care products and remedies are popular among health-conscious consumers today. Many people prefer to enhance their appearance and health with vitamins and other nutrients in a “natural” way from naturally occurring sources. “Natural” products including natural vitamins are now in high demand. These are vitamins which are found in a product in its natural state without vitamin supplements or vitamin “fortification.” While fruit and vegetable juices are known to have high concentrations of vitamins in their natural state and are often a preferred source of vitamins for internal consumption, many natural fruit and vegetable products are largely overlooked as a topical skin application.
What is needed is a skin care product and method that delivers natural vitamins, nutrients and other beneficial products to the skin without oral consumption and its adverse side-effects. Also needed is a natural product which can moisturize as well as nourish the skin.
SUMMARY AND OBJECTS OF THE INVENTION
Accordingly, it is an object of the present invention to provide a product and method which can deliver natural vitamins, skin nutrients and skin protectants to the skin in a topical application that nourishes and moisturizes the skin naturally.
The present invention comprises novel compositions of extracts from ginseng berry, herbs and preferably also other skin care ingredients which are mixed to form a topical application.
It is an object of preferred embodiments of the present invention to deliver natural vitamins to the skin.
It is another object of preferred embodiments of the present invention to deliver natural fruit and vegetable extracts to the skin so that the skin may benefit from natural vitamins, emollients and other healthful ingredients.
It is yet another object of preferred embodiments of the present invention to deliver natural and healthful herbs to the skin.
It is a further object of preferred embodiments of the present invention to moisturize the skin.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative, and not restrictive. The scope of the invention is, therefore, indicated by the appended claims, rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
The present invention is directed towards skin care products and topical skin products containing juice from the ginseng berry. Although the ginseng root is sometimes used as an herbal supplement, the ginseng berry has been overlooked due, at least in part, to its high seed content. Ginseng berries contain a large number of seeds which make up a large percentage of the berry's volume. These seeds must be removed in order to make a liquid suitable for use in topical skin applications.
Laboratory analysis of the juice from ginseng berries used for preferred embodiments of the skin care products of the present invention shows a high concentration of essential vitamins. The following Table 1 gives the result of a laboratory analysis of the essential vitamins and ingredients found in ginseng berry juice.
TABLE 1
Riboflavin
171.9 ug/gram of product
Vitamin A
109 IU
Vitamin E
1.5 IU
Beta Carotene
16.9 IU
Advantageously, ginseng berry juice also acts as an anti-oxidant. Laboratory analysis reveals that one gram of ginseng berry contains 1.4 times more antioxidant that 10 mg of Vitamin C.
Modern machinery may be used to produce juice from ginseng berries, however one presently preferred method of the present invention comprises a manual process. In this process, whole ginseng berries are crushed in a press thereby removing the majority of the juice. The seeds are then removed from the juice by filtration through a coarse screen filter. When a solids-free liquid is desired, the juice is further filtered in a 0.2 micron micro-filtration system to remove even finer solids. Some solids content may be acceptable or desired to improve texture or add fiber to the final product. When this is the case, the micro-filtration step may be omitted.
After the juice has been extracted, it is preferably blended with other natural ingredients which may add moisturizing effects, provide UV protection, or provide other physiological benefits.
Application of natural herb products along with the beneficial vitamins contained in ginseng berry juice may also increase health and vitality. The effects of various herbs and plant products are beneficial to the nervous, digestive and circulatory systems as well as other physiological functions. Herbs which, when applied to the skin, are beneficial to one's health and vitality may be considered to be “natural skin supplements.” The combination of herbal ingredients with healthful and rejuvenating ginseng berry juice products offers the health advantages of natural vitamins and herbs in an aromatic, pleasing and healthful skin application.
Ginseng root also has beneficial physiological effects. It is believed to help regulate blood pressure and increase the body's resistance to adverse physical, chemical and biological influences. Ginseng root can stimulate physical and mental activity and protect against the adverse effects of mental and physical stress. It may also improve concentration and stimulate brain cells. Ginseng root may be considered to be an herbal stimulant.
Ginseng root also has beneficial physiological effects. It is believed to help regulate blood pressure and increase the body's resistance to adverse physical, chemical and biological influences. Ginseng root can stimulate physical and mental activity and protect against the adverse effects of mental and physical stress. It may also improve concentration and stimulate brain cells. Ginseng root may be considered to be a natural skin supplement. In the prior art, like some vitamins, ginseng root is often offered in capsules or tablets in a raw form. This can be difficult for some to ingest due to gag reflexes, physical impairment or psychological aversion to tablet or capsule consumption. A topical skin application allows a user to benefit from many of the beneficial effects of ginseng root without the requirement of ingesting the substance.
Preferred embodiments of the present invention combine the juice of ginseng berries with herbal supplements and stimulants and/or other natural skin supplements to create an application that has pleasurable sensory effect on the user and which provides a great variety of ingredients essential to health and vitality.
Other products within the scope of the present invention may be created from ginseng berry juice. Ginseng berry juice may be concentrated by known techniques to form a concentrated extract or syrup. This concentration may be performed on the pure juice of the ginseng berry or it may be performed after mixing the juice with natural skin supplements or other ingredients. The concentrated extract or syrup may then be diluted with water to return it to a juice state as needed. When more fiber or texture is desired, the final filtration step of the juice making process using a 0.2 micron filter may be omitted or replaced with a step which utilizes a coarser filter. Alternatively, fiber and texture producing ingredients may be added as needed.
The novel method and composition of the present invention allows users to apply natural vitamins, anti-oxidants and emollients directly to the skin.
The following tables further illustrate the ingredients currently used in the certain presently preferred embodiments. Ingrdients listed in these tables are given by weight percentage of the total mixture.
EXAMPLE 1
Replenishing Masque for Dry Skin
Ginseng ( Panax Ginseng ) Berry Extract
11%
Water
28.9%
SD Alcohol 40B
10%
Glycerin
7%
Hybrid Sunflower ( Helianthus Annuus ) Oil
6%
Polyacrylamide
5%
C13-14 Isoparaffin
5%
Laureth-7
5%
Cyclomethicone
5%
Grape ( Vitis Vinifera ) Seed Extract
3%
Ginseng ( Panax Ginseng ) Root Extract
2%
Avocado ( Persea Gratissima )
1%
Cucumber ( Cucumis Sativus )
1%
Jasmine ( Jasminum Officinale )
1%
Orange ( Citrus Aurantium Dulcis ) Peel
1%
Flowery Knotweed ( Polygonum Aviculare )
1%
Hibiscus Sabdariff
1%
Mulberry ( Morus Alba ) Leaf
1%
Riboflavin (Vitamin B2)
1%
Tocopheryl Acetate (Vitamin E Acetate)
1%
Niacin (Vitamin B3)
1%
Pantothenic Acid (Provitamin B5)
1%
Disodium Edta
0.1%
Phenoxyethanol
0.2%
Methylparaben
0.2%
Butylparaben
0.2%
Ethylparaben
0.2%
Propylparaben
0.2%
EXAMPLE 2
Intensive Night Repair
Ginseng ( Panax Ginseng ) Berry Extract
12%
Water
33.9%
Shea Butter ( Butyrospermum Parkii )
4.5%
Glycerin
4.5%
Cyclomethicone
4.5%
Isopropyl Palmitate
4%
Glyceryl Stearate
4%
Stearic Acid
4%
Sodium Behenoyl Lactylate
4%
Grape ( Vitis Vinifera ) Seed Extract
4%
Ginseng ( Panax Ginseng ) Root Extract
4%
Avocado ( Persea Gratissima )
2%
Cucumber ( Cucumis Sativus )
2%
Jasmine ( Jasminum Officinale )
2%
Orange ( Citrus Aurantium Dulcis ) Peel
2%
Flowery Knotweed ( Polygonum Aviculare )
1%
Hibiscus Sabdariff
1%
Mulberry ( Morus Alba ) Leaf
1%
Pyridoxine (Vitamin B6)
1%
Riboflavin (Vitamin B2)
1%
Tocopheryl Acetate (Vitamin E Acetate)
1%
Pantothenic Acid (Provitamin B5)
1%
Xanthan Gum
0.2%
Carbomer
0.2%
Disodium Edta
0.2%
Phenoxyethanol
0.2%
Methylparaben
0.2%
Butylparaben
0.2%
Ethylparaben
0.2%
Propylparaben
0.2%
Triethanolamine
0.2%
EXAMPLE 3
Revitalizing Facial Cleanser
Ginseng ( Panax Ginseng ) Berry Extract
9%
Water
54.5%
Sodium Cocoyl Isethionate
5%
Sodium Methyl Cocoyl Taurate
4%
PEG-8
4%
Octyldodecyl Benzoate
3.5%
Myristic Acid
3%
Glyceryl Stearate SE
3%
Ginseng ( Panax Ginseng ) Root Extract
3%
Chrysanthemum Coccineum
1%
Cucumber ( Cucumis Sativus )
1%
Sage ( Salvia Officinalis )
1%
Grapefruit ( Citrus Grandis ) Peel
1%
Kiwi ( Actinidia Chinensis )
1%
Lemon ( Citrus Medica LI )
1%
Algae
1%
White Water Lily ( Nymphaea Alba )
1%
Niacin (Vitamin B3)
1%
Tocopheryl Acetate (Vitamin E Acetate)
1%
Butylene Glycol
0.2%
Phenoxyethanol
0.2%
Methylparaben
0.2%
Butylparaben
0.2%
Ethylparaben
0.2%
Propylparaben
0.2%
EXAMPLE 4
All-Day Hydrating Nourisher
Ginseng ( Panax Ginseng ) Berry Extract
9%
Water
53%
Shea Butter ( Butyrospermum Parkii )
3.5%
Glycerin
3.5%
Cyclomethicone
3.5%
Glyceryl Stearate
3%
Stearic Acid
3%
Sodium Behenoyl Lactylate
3%
Grape ( Vitis Vinifera ) Seed Extract
3%
Ginseng ( Panax Ginseng ) Root Extract
3%
Avocado ( Persea Gratissima )
1%
Cucumber ( Cucumis Sativus )
1%
Jasmine ( Jasminum Officinale )
1%
Orange ( Citrus Aurantium Dulcis ) Peel
1%
Flowery Knotweed ( Polygonum Aviculare )
1%
Hibiscus Sabdariff
1%
Mulberry ( Morus Alba ) Leaf
1%
Pyridoxine (Vitamin B6)
1%
Riboflavin (Vitamin B2)
1%
Tocopheryl Acetate (Vitamin E Acetate)
1%
Pantothenic Acid (Provitamin B5)
1%
Xanthan Gum
0.2%
Carbomer
0.2%
Disodium Edta
0.1%
Phenoxyethanol
0.2%
Methylparaben
0.2%
Butylparaben
0.2%
Ethylparaben
0.2%
Propylparaben
0.2%
Triethanolamine
0.2%
EXAMPLE 5
Time Signature Pure Ginseng Masque
Ginseng ( Panax Ginseng ) Berry Extract
62.9%
Ginseng ( Panax Ginseng ) Root Extract
5%
SD Alcohol 40B
3%
Glycerin
3%
Hybrid Sunflower ( Helianthus Annuus ) Oil
2%
Polyacrylamide
2%
C13-14 Isoparaffin
2%
Laureth-7
2%
Cyclomethicone
2%
Avocado ( Persea Gratissima )
2%
Cucumber ( Cucumis Sativus )
2%
Jasmine ( Jasminum Officinale )
2%
Orange ( Citrus Aurantium Dulcis ) Peel
2%
Flowery Knotweed ( Polygonum Aviculare )
1%
Hibiscus Sabdariff
1%
Mulberry ( Morus Alba ) Leaf
1%
Riboflavin (Vitamin B2)
1%
Tocopheryl Acetate (Vitamin E Acetate)
1%
Niacin (Vitamin B3)
1%
Pantothenic Acid (Provitamin B5)
1%
Disodium Edta
0.1%
Phenoxyethanol
0.2%
Methylparaben
0.2%
Butylparaben
0.2%
Ethylparaben
0.2%
Propylparaben
0.2%
EXAMPLE 6
Replenishing Masque for Normal Skin
Ginseng ( Panax Ginseng ) Berry Extract
10%
Water
39.9%
Glycerin
5%
Cyclomethicone
5%
Polyacrylamide
5%
C13-14 Isoparaffin
5%
Laureth-7
5%
Aluminum Starch Octenylsuccinate
5%
Hybrid Sunflower ( Helianthus Annuus ) Oil
5%
Grape ( Vitis Vinifera ) Seed Extract
2%
Ginseng ( Panax Ginseng ) Root Extract
1%
Avocado ( Persea Gratissima )
1%
Cucumber ( Cucumis Sativus )
1%
Jasmine ( Jasminum Officinale )
1%
Orange ( Citrus Aurantium Dulcis ) Peel
1%
Flowery Knotweed ( Polygonum Aviculare )
1%
Hibiscus Sabdariff
1%
Mulberry ( Morus Alba ) Leaf
1%
Riboflavin (Vitamin B2)
1%
Tocopheryl Acetate (Vitamin E Acetate)
1%
Niacin (Vitamin B3)
1%
Pantothenic Acid (Provitamin B5)
1%
Disodium Edta
0.1%
Phenoxyethanol
0.2%
Methylparaben
0.2%
Butylparaben
0.2%
Ethylparaben
0.2%
Propylparaben
0.2%
EXAMPLE 7
Deep Purifying Clay Masque
Ginseng ( Panax Ginseng ) Berry Extract
6.5%
Water
57.5%
Kaolin
7%
Glycerin
5%
Glyceryl Stearate SE
5%
Bentonite
3%
Ginseng ( Panax Ginseng ) Root Extract
3%
Avocado ( Persea Gratissima )
1%
Cucumber ( Cucumis Sativus )
1%
Jasmine ( Jasminum Officinale )
1%
Orange ( Citrus Aurantium Dulcis ) Peel
1%
Flowery Knotweed ( Polygonum Aviculare )
1%
Hibiscus Sabdariff
1%
Mulberry ( Morus Alba ) Leaf
1%
Riboflavin (Vitamin B2)
1%
Tocopheryl Acetate (Vitamin E Acetate)
1%
Niacin (Vitamin B3)
1%
Pantothenic Acid (Provitamin B5)
1%
Magnesium Aluminum Silicate
1%
Phenoxyethanol
0.2%
Methylparaben
0.2%
Ethylparaben
0.2%
Propylparaben
0.2%
Disodium Edta
0.2%
EXAMPLE 8
Advanced Spot Control
Ginseng ( Panax Ginseng ) Berry Extract
11%
Water
61.4%
SD Alcohol 40B
7%
Glycerin
5%
Grape ( Vitis Vinifera ) Seed Extract
2%
Ginseng ( Panax Ginseng ) Root Extract
2%
Chrysanthemum Coccineum
1%
Cucumber ( Cucumis Sativus )
1%
Sage ( Salvia Officinalis )
1%
Grapefruit ( Citrus Grandis ) Peel
1%
Kiwi ( Actinidia Chinensis )
1%
Lemon ( Citrus Medica Limonum )
1%
Orange ( Citrus Aurantium Dulcis ) Peel
1%
Niacin (Vitamin B3)
1%
Folic Acid
1%
Tocopheryl Acetate (Vitamin E Acetate)
1%
Triclosan
1%
Carbomer
0.3%
Triethanolamine
0.3%
EXAMPLE 9
Intensive Day Defense
Ginseng ( Panax Ginseng ) Berry Extract
5%
Water
40.5%
Octyl Methoxycinnamate
2%
Oxybenzone
2%
Avobenzone
2%
Phenylbenzimidazole Sulfonic Acid
2%
Aloe Barbadensis Gel
4%
Glycerin
4%
Octyl Stearate
3%
C12-15 Alkyl Bezoate
3%
Stearic Acid
3%
Glyceryl Stearate
3%
Isopropyl Palmitate
2.5%
Octocrylene
2%
Sodium Stearoyl Lactylate
2%
Grape ( Vitis Vinifera ) Seed Extract
2%
Ginseng ( Panax Ginseng ) Root Extract
2%
Avocado ( Persea Gratissima )
1%
Cucumber ( Cucumis Sativus )
1%
Jasmine ( Jasminum Officinale )
1%
Pyridoxine (Vitamin B6)
1%
Riboflavin (Vitamin B2)
1%
Tocopheryl Acetate (Vitamin E Acetate)
1%
Ascorbic Acid (Vitamin C)
1%
Niacin (Vitamin B3)
1%
Triethanolamine
1%
Potassium Hydroxide
1%
Phenoxyethanol
0.2%
Methylparaben
0.2%
Butylparaben
0.2%
Ethylparaben
0.2%
Propylparaben
0.2%
EXAMPLE 10
Body Wash
Ginseng ( Panax Ginseng ) Berry Extract
5%
Water
48%
Decyl Glucoside
6%
Aloe Barbadensis Gel
6%
PEG-120 Methyl Glucose Dioleate
6%
Ammonium Laureth Sulfate
5%
Disodium Cocoamphodiacetate
4%
Grape ( Vitis Vinifera ) Seed Extract
1%
Chrysanthemum Coccineum
1%
Cucumber ( Cucumis Sativus ) Sage
1%
Kiwi ( Actinidia Chinensis )
1%
Lemon ( Citrus Medica Limonum )
1%
Rose ( Rosa Damascena )
1%
White Water Lily ( Nymphaea Alba )
1%
Riboflavin (Vitamin B2)
1%
Tocopheryl Acetate (Vitamin E Acetate)
1%
PEG-7 Glyceryl Cocoate
1%
Cocamidopropyl Betaine
1%
Fragrance
0.2%
Phenoxyethanol
0.2%
Methylparaben
0.2%
Butylparaben
0.2%
Ethylparaben
0.2%
Propylparaben
0.2%
EXAMPLE 11
Hydrating Exfoliant
Ginseng ( Panax Ginseng ) Berry Extract
9%
Water
44.5%
Disodium Laureth Sulfosuccinate
6%
Polyethylene
5%
Glycerin
5%
Cocamidopropyl Betaine
4.5%
Peg-120 Methyl Glucose Dioleate
4%
Triethanolamine
4%
Ginseng ( Panax Ginseng ) Root Extract
3%
Grape ( Vitis Vinifera ) Seed Extract
2%
Chrysanthemum Coccineum
1%
Cucumber ( Cucumis Sativus )
1%
Sage ( Salvia Officinalis )
1%
Grapefruit ( Citrus Grandis ) Peel
1%
Kiwi ( Actinidia Chinensis )
1%
Lemon ( Citrus Medica Limonum )
1%
Rose ( Rosa Damascena )
1%
Algae
1%
White Water Lily ( Nymphaea Alba )
1%
Niacin (Vitamin B3)
1%
Tocopheryl Acetate (Vitamin E Acetate)
1%
Polysorbate 20
1%
Benzophenone-4
0.2%
Phenoxyethanol
0.2%
Methylparaben
0.2%
Butylparaben
0.2%
Ethylparaben
0.2%
Propylparaben
0.2%
Carbomer
0.2%
Disodium Edta
0.2%
EXAMPLE 12
Hair Conditioner
Ginseng ( Panax Ginseng ) Berry Extract
9%
Water
47%
Isopropyl Palmitate
6%
Behentrimonium Methosulfate
6%
Grape ( Vitis Vinifera ) Seed Extract
3%
Cactus ( Cereus Gradiflorus ) Stem
2%
Avocado ( Persea Gratissima )
1%
Cucumber ( Cucumis Sativus )
1%
Jasmine ( Jasminum Officinale )
1%
Orange ( Citrus Aurantium Dulcis ) Peel
1%
Chrysanthemum Coccineum
1%
Pantothenic Acid (Provitamin B5)
1%
Phytantriol
1%
Folic Acid
1%
Biotin (Vitamin H)
1%
PG-Hydroxyethylcellulose Cocodimonium Chloride
1%
Tridecyl Stearate
1%
Neopentyl Glycol Disaprylate
1%
Tridecyl Trimellitate
1%
Silk Amino Acids
1%
Phenoxyethanol
0.2%
Methylparaben
0.2%
Butylparaben
0.2%
Ethylparaben
0.2%
Propylparaben
0.2%
EXAMPLE 13
All-Day Hydrating Nourisher for Oily Skin
Ginseng ( Panax Ginseng ) Berry Extract
10%
Water
52.8%
Glycerin
5%
Cyclomethicone
5%
Polyacrylamide
4%
C13-14 Isoparaffin
4%
Laureth-7
4%
Grape ( Vitis Vinifera ) Seed Extract
2%
Ginseng ( Panax Ginseng ) Root Extract
2%
Avocado ( Persea Gratissima )
1%
Cucumber ( Cucumis Sativus )
1%
Jasmine ( Jasminum Officinale )
1%
Orange ( Citrus Aurantium Dulcis ) Peel
1%
Flowery Knotweed ( Polygonum Aviculare )
1%
Hibiscus Sabdariff
1%
Tocopheryl Acetate (Vitamin E Acetate)
1%
Ascorbic Acid (Vitamin C)
1%
Folic Acid
1%
Acrylates Copolymer
0.5%
Isopropyl Palmitate
0.5%
Disodium Edta
0.2%
Phenoxyethanol
0.2%
Methylparaben
0.2%
Butlyparaben
0.2%
Ethylparaben
0.2%
Propylparaben
0.2%
Carbomer
0.2%
Triethanolamine
0.2%
EXAMPLE 14
Time Signature, Ginseng Essence
Ginseng ( Panax Ginseng ) Berry Extract
60.3%
Ginseng ( Panax Ginseng ) Root Extract Extract
8%
Grape ( Vitis Vinifera ) Seed Extract
3%
Shea Butter ( Butyrospermum Parkii )
3%
Glycerin
3%
Cyclomethicone
3%
Isopropyl Palmitate
2%
Glyceryl Stearate
2%
Stearic Acid
2%
Sodium Behenoyl Lactylate
1%
Avocado ( Persea Gratissima )
1%
Cucumber ( Cucumis Sativus )
1%
Jasmine ( Jasminum Officinale )
1%
Orange ( Citrus Aurantium Dulcis ) Peel
1%
Flowery Knotweed ( Polygonum Aviculare )
1%
Hibiscus Sabdariff
1%
Mulberry ( Morus Alba ) Leaf
1%
Pyridoxine (vitamin B6)
1%
Riboflavin (Vitamin B2)
1%
Tocopheryl Acetate (Vitamin E Acetate)
1%
Pantothenic Acid (Provitamin B5)
1%
Xanthan Gum
0.3%
Carbomer
0.3%
Disodium Edta
0.1%
Phenoxyethanol
0.2%
Methylparaben
0.2%
Butlyparaben
0.2%
Ethylparaben
0.2%
Propylparaben
0.2%
Triethanolamine
0.2%
EXAMPLE 15
Tooth Paste:
Ginseng ( Panax Ginseng ) Berry Extract
4%
Stevia
25%
Deionized Water
23.6%
Hydrated Silica
20%
Sorbitol
18%
Ginseng
4%
Sodium Lauroyl Sarcosinate
1.5%
Flavor
1%
PEG-6
0.8%
Tetrasodium Pyrophosphate
0.5%
Cellulose gum
0.5%
Sodium Benzoate
0.5%
Triclosan
0.3%
Hydrogen Peroxide
0.3% of 35% actives
EXAMPLE 16
Revitalizing Facial Cleanser
Ginseng ( Panax Ginseng ) Berry Extract
3%
Cactus ( Cereus Grandiflorus )
3%
Cactus ( Cereus Grandiflorus ) Fruit
3%
Water
54.5%
Sodium Cocoyl Isethionate
5%
Sodium Methyl Cocoyl Taurate
4%
PEG-8
4%
Octyldodecyl Benzoate
3.5%
Myristic Acid
3%
Glyceryl Stearate SE
3%
Ginseng ( Panax Ginseng ) Root Extract
3%
Chrysanthemum Coccineum
1%
Cucumber ( Cucumis Sativus )
1%
Sage ( Salvia Officinalis )
1%
Grapefruit ( Citrus Grandis ) Peel
1%
Kiwi ( Actinidia Chinensis )
1%
Lemon ( Citrus Medica LI )
1%
Algae
1%
White Water Lily ( Nymphaea Alba )
1%
Niacin (Vitamin B3)
1%
Tocopheryl Acetate (Vitamin E Acetate)
1%
Butylene Glycol
0.2%
Phenoxyethanol
0.2%
Methylparaben
0.2%
Butylparaben
0.2%
Ethylparaben
0.2%
Propylparaben
0.2%
EXAMPLE 17
All-Day Hydrating Nourisher
Ginseng ( Panax Ginseng ) Berry Extract
3%
Cactus ( Cereus Grandiflorus ) Extract
3%
Cactus ( Cereus Grandiflorus ) Fruit Extract
3%
Water
53%
Shea Butter ( Butyrospermum Parkii )
3.5%
Glycerin
3.5%
Cyclomethicone
3.5%
Glyceryl Stearate
3%
Stearic Acid
3%
Sodium Behenoyl Lactylate
3%
Grape ( Vitis Vinifera ) Seed Extract
3%
Ginseng ( Panax Ginseng ) Root Extract
3%
Avocado ( Persea Gratissima )
1%
Cucumber ( Cucumis Sativus )
1%
Jasmine ( Jasminum Officinale )
1%
Orange ( Citrus Aurantium Dulcis ) Peel
1%
Flowery Knotweed ( Polygonum Aviculare )
1%
Hibiscus Sabdariff
1%
Mulberry ( Morus Alba ) Leaf
1%
Pyridoxine (Vitamin B6)
1%
Riboflavin (Vitamin B2)
1%
Tocopheryl Acetate (Vitamin E Acetate)
1%
Pantothenic Acid (Provitamin B5)
1%
Xanthan Gum
0.2%
Carbomer
0.2%
Disodium Edta
0.1%
Phenoxyethanol
0.2%
Methylparaben
0.2%
Butylparaben
0.2%
Ethylparaben
0.2%
Propylparaben
0.2%
Triethanolamine
0.2%
EXAMPLE 18
Time Signature Pure Ginseng Cactus Masque
Cactus ( Cereus Grandiflorus ) Fruit Extract
27.9%
Ginseng ( Panax Ginseng ) Berry Extract
20%
Cactus ( Cereus Grandiflorus ) Extract
15%
Ginseng ( Panax Ginseng ) Root Extract Extract
5%
SD Alcohol 40B
3%
Glycerin
3%
Hybrid Sunflower ( Helianthus Annuus ) Oil
2%
Polyacrylamide
2%
C13-14 Isoparaffin
2%
Laureth-7
2%
Cyclomethicone
2%
Avocado ( Persea Gratissima )
2%
Cucumber ( Cucumis Sativus )
2%
Jasmine ( Jasminum Officinale )
2%
Orange ( Citrus Aurantium Dulcis ) Peel
2%
Flowery Knotweed ( Polygonum Aviculare )
1%
Hibiscus Sabdariff
1%
Mulberry ( Morus Alba ) Leaf
1%
Riboflavin (Vitamin B2)
1%
Tocopheryl Acetate (Vitamin E Acetate)
1%
Niacin (Vitamin B3)
1%
Pantothenic Acid (Provitamin B5)
1%
Disodium Edta
0.1%
Phenoxyethanol
0.2%
Methylparaben
0.2%
Butylparaben
0.2%
Ethylparaben
0.2%
Propylparaben
0.2%
EXAMPLE 19
Replenishing Masque for Normal Skin
Ginseng ( Panax Ginseng ) Berry Extract
2%
Cactus ( Cereus Grandiflorus )
3%
Cactus ( Cereus Grandiflorus ) Fruit
5%
Water
39.9%
Glycerin
5%
Cyclomethicone
5%
Polyacrylamide
5%
C13-14 Isoparaffin
5%
Laureth-7
5%
Aluminum Starch Octenylsuccinate
5%
Hybrid Sunflower ( Helianthus Annuus ) Oil
5%
Grape ( Vitis Vinifera ) Seed Extract
2%
Ginseng ( Panax Ginseng ) Root Extract
1%
Avocado ( Persea Gratissima )
1%
Cucumber ( Cucumis Sativus )
1%
Jasmine ( Jasminum Officinale )
1%
Orange ( Citrus Aurantium Dulcis ) Peel
1%
Flowery Knotweed ( Polygonum Aviculare )
1%
Hibiscus Sabdariff
1%
Mulberry (Morus Alba) Leaf
1%
Riboflavin (Vitamin B2)
1%
Tocopheryl Acetate (Vitamin E Acetate)
1%
Niacin (Vitamin B3)
1%
Pantothenic Acid (Provitamin B5)
1%
Disodium Edta
0.1%
Phenoxyethanol
0.2%
Methylparaben
0.2%
Butylparaben
0.2%
Ethylparaben
0.2%
Propylparaben
0.2%
EXAMPLE 20
Deep Purifying Clay Masque
Ginseng ( Panax Ginseng ) Berry Extract
1%
Cactus ( Cereus Grandiflorus )
3%
Cactus ( Cereus Grandiflorus ) Fruit
2.5%
Water
57.5%
Kaolin
7%
Glycerin
5%
Glyceryl Stearate SE
5%
Bentonite
3%
Ginseng ( Panax Ginseng ) Root Extract
3%
Avocado ( Persea Gratissima )
1%
Cucumber ( Cucumis Sativus )
1%
Jasmine ( Jasminum Officinale )
1%
Orange ( Citrus Aurantium Dulcis ) Peel
1%
Flowery Knotweed ( Polygonum Aviculare )
1%
Hibiscus Sabdariff
1%
Mulberry ( Morus Alba ) Leaf
1%
Riboflavin (Vitamin B2)
1%
Tocopheryl Acetate (Vitamin E Acetate)
1%
Niacin (Vitamin B3)
1%
Pantothenic Acid (Provitamin B5)
1%
Magnesium Aluminum Silicate
1%
Phenoxyethanol
0.2%
Methylparaben
0.2%
Ethylparaben
0.2%
Propylparaben
0.2%
Disodium Edta
0.2%
EXAMPLE 21
Advanced Spot Control
Ginseng ( Panax Ginseng ) Berry Extract
5%
Cactus ( Cereus Grandiflorus )
1%
Cactus ( Cereus Grandiflorus ) Fruit
5%
Water
61.4%
SD Alcohol 40B
7%
Glycerin
5%
Grape ( Vitis Vinifera ) Seed Extract
2%
Ginseng ( Panax Ginseng ) Root Extract
2%
Chrysanthemum Coccineum
1%
Cucumber ( Cucumis Sativus )
1%
Sage ( Salvia Officinalis )
1%
Grapefruit ( Citrus Grandis ) Peel
1%
Kiwi ( Actinidia Chinensis )
1%
Lemon ( Citrus Medica Limonum )
1%
Orange ( Citrus Aurantium Dulcis ) Peel
1%
Niacin (Vitamin B3)
1%
Folic Acid
1%
Tocopheryl Acetate (Vitamin E Acetate)
1%
Triclosan
1%
Carbomer
0.3%
Triethanolamine
0.3%
EXAMPLE 22
Intensive Day Defense
Ginseng ( Panax Ginseng ) Berry Extract
2%
Cactus ( Cereus Grandiflorus )
1%
Cactus ( Cereus Grandiflorus ) Fruit
2%
Octyl Methoxycinnamate
2%
Oxybenzone
2%
Avobenzone
2%
Phenylbenzimidazole Sulfonic Acid
2%
Water
45.5%
Aloe Barbadensis Gel
4%
Glycerin
4%
Octyl Stearate
3%
C12-15 Alkyl Bezoate
3%
Stearic Acid
3%
Glyceryl Stearate
3%
Isopropyl Palmitate
2.5%
Octocrylene
2%
Sodium Stearoyl Lactylate
2%
Grape ( Vitis Vinifera ) Seed Extract
2%
Ginseng ( Panax Ginseng ) Root Extract
2%
Avocado ( Persea Gratissima )
1%
Cucumber ( Cucumis Sativus )
1%
Jasmine ( Jasminum Officinale )
1%
Pyridoxine (Vitamin B6)
1%
Riboflavin (Vitamin B2)
1%
Tocopheryl Acetate (Vitamin E Acetate)
1%
Ascorbic Acid (Vitamin C)
1%
Niacin (Vitamin B3)
1%
Triethanolamine
1%
Potassium Hydroxide
1%
Phenoxyethanol
0.2%
Methylparaben
0.2%
Butylparaben
0.2%
Ethylparaben
0.2%
Propylparaben
0.2%
EXAMPLE 23
Body Wash
Ginseng ( Panax Ginseng ) Berry Extract
3%
Cactus ( Cereus Grandiflorus )
3%
Cactus ( Cereus Grandiflorus ) Fruit
3%
Water
52%
Decyl Glucoside
6%
Aloe Barbadensis Gel
6%
PEG-120 Methyl Glucose Dioleate
6%
Ammonium Laureth Sulfate
5%
Disodium Cocoamphodiacetate
4%
Grape ( Vitis Vinifera ) Seed Extract
1%
Chrysanthemum Coccineum
1%
Cucumber ( Cucumis Sativus ) Sage
1%
Kiwi ( Actinidia Chinensis )
1%
Lemon ( Citrus Medica Limonum )
1%
Rose ( Rosa Damascena )
1%
White Water Lily ( Nymphaea Alba )
1%
Riboflavin (Vitamin B2)
1%
Tocopheryl Acetate (Vitamin E Acetate)
1%
PEG-7 Glyceryl Cocoate
1%
Cocamidopropyl Betaine
1%
Fragrance
0.2%
Phenoxyethanol
0.2%
Methylparaben
0.2%
Butylparaben
0.2%
Ethylparaben
0.2%
Propylparaben
0.2%
EXAMPLE 24
Hydrating Exfoliant
Ginseng ( Panax Ginseng ) Berry Extract
2%
Cactus ( Cereus Grandiflorus )
3%
Cactus ( Cereus Grandiflorus ) Fruit
4%
Water
44.5%
Disodium Laureth Sulfosuccinate
6%
Polyethylene
5%
Glycerin
5%
Cocamidopropyl Betaine
4.5%
PEG-120 Methyl Glucose Dioleate
4%
Triethanolamine
4%
Ginseng ( Panax Ginseng ) Root Extract
3%
Grape ( Vitis Vinifera ) Seed Extract
2%
Chrysanthemum Coccineum
1%
Cucumber ( Cucumis Sativus )
1%
Sage ( Salvia Officinalis )
1%
Grapefruit ( Citrus Grandis ) Peel
1%
Kiwi ( Actinidia Chinensis )
1%
Lemon ( Citrus Medica Limonum )
1%
Rose ( Rosa Damascena )
1%
Algae
1%
White Water Lily ( Nymphaea Alba )
1%
Niacin (Vitamin B3)
1%
Tocopheryl Acetate (Vitamin E Acetate)
1%
Polysorbate 20
1%
Benzophenone-4
0.2%
Phenoxyethanol
0.2%
Methylparaben
0.2%
Butylparaben
0.2%
Ethylparaben
0.2%
Propylparaben
0.2%
Carbomer
0.2%
Disodium Edta
0.2%
EXAMPLE 25
Hair Conditioner
Ginseng ( Panax Ginseng ) Berry Extract
6%
Cactus ( Cereus Grandiflorus )
6%
Cactus ( Cereus Grandiflorus ) Fruit
6%
Water
52%
Isopropyl Palmitate
6%
Behentrimonium Methosulfate
6%
Grape ( Vitis Vinifera ) Seed Extract
3%
Avocado ( Persea Gratissima )
1%
Cucumber ( Cucumis Sativus )
1%
Jasmine ( Jasminum Officinale )
1%
Orange ( Citrus Aurantium Dulcis ) Peel
1%
Chrysanthemum Coccineum
1%
Pantothenic Acid (Provitamin B5)
1%
Phytantriol
1%
Folic Acid
1%
Biotin (Vitamin H)
1%
PG-Hydroxyethylcellulose Cocodimonium Chloride
1%
Tridecyl Stearate
1%
Neopentyl Glycol Disaprylate
1%
Tridecyl Trimellitate
1%
Silk Amino Acids
1%
Phenoxyethanol
0.2%
Methylparaben
0.2%
Butylparaben
0.2%
Ethylparaben
0.2%
Propylparaben
0.2%
EXAMPLE 26
All-Day Hydrating Nourisher for Oily Skin
Ginseng ( Panax Ginseng ) Berry Extract
4%
Cactus ( Cereus Grandiflorus )
2%
Cactus ( Cereus Grandiflorus ) Fruit
4%
Water
52.8%
Glycerin
5%
Cyclomethicone
5%
Polyacrylamide
4%
C13-14 Isoparaffin
4%
Laureth-7
4%
Grape ( Vitis Vinifera ) Seed Extract
2%
Ginseng ( Panax Ginseng ) Root Extract
2%
Avocado ( Persea Gratissima )
1%
Cucumber ( Cucumis Sativus )
1%
Jasmine (Jasminum Officinale)
1%
Orange ( Citrus Aurantium Dulcis ) Peel
1%
Flowery Knotweed ( Polygonum Aviculare )
1%
Hibiscus Sabdariff
1%
Tocopheryl Acetate (Vitamin E Acetate)
1%
Ascorbic Acid (Vitamin C)
1%
Folic Acid
1%
Acrylates Copolymer
0.5%
Isopropyl Palmitate
0.5%
Disodium Edta
0.2%
Phenoxyethanol
0.2%
Methylparaben
0.2%
Butlyparaben
0.2%
Ethylparaben
0.2%
Propylparaben
0.2%
Carbomer
0.2%
Triethanolamine
0.2%
EXAMPLE 27
Time Signature, Cactus Ginseng Essence
Cactus ( Cereus Grandiflorus ) Fruit Extract
45.3%
Ginseng ( Panax Ginseng ) Berry Extract
15%
Cactus ( Cereus Grandiflorus ) Extract
5%
Ginseng ( Panax Ginseng ) Root Extract
3%
Grape ( Vitis Vinifera ) Seed Extract
3%
Shea Butter ( Butyrospermum Parkii )
3%
Glycerin
3%
Cyclomethicone
3%
Isopropyl Palmitate
2%
Glyceryl Stearate
2%
Stearic Acid
2%
Sodium Behenoyl Lactylate
1%
Avocado ( Persea Gratissima )
1%
Cucumber ( Cucumis Sativus )
1%
Jasmine ( Jasminum Officinale )
1%
Orange ( Citrus Aurantium Dulcis ) Peel
1%
Flowery Knotweed ( Polygonum Aviculare )
1%
Hibiscus Sabdariff
1%
Mulberry ( Morus Alba) Leaf
1%
Pyridoxine (vitamin B6)
1%
Riboflavin (Vitamin B2)
1%
Tocopheryl Acetate (Vitamin E Acetate)
1%
Pantothenic Acid (Provitamin B5)
1%
Xanthan Gum
0.3%
Carbomer
0.3%
Disodium Edta
0.1%
Phenoxyethanol
0.2%
Methylparaben
0.2%
Butlyparaben
0.2%
Ethylparaben
0.2%
Propylparaben
0.2%
Triethanolamine
0.2%
EXAMPLE 28
Tooth Paste:
Ginseng ( Panax Ginseng ) Berry Extract
3%
Cactus ( Cereus Grandiflorus ) Fruit
3%
Stevia
25%
Deionized Water
21.6%
Hydrated Silica
20%
Sorbitol
18%
Ginseng ( Panax Ginseng ) Root Extract
4%
Sodium Lauroyl Sarcosinate
1.5%
Flavor
1%
PEG-6
0.8%
Tetrasodium Pyrophosphate
0.5%
Cellulose gum
0.5%
Sodium Benzoate
0.5%
Triclosan
0.3%
Hydrogen Peroxide
0.3% of 35% actives | The present invention comprises novel combinations of ginseng berry juice and extracts combined with other skin nutrients and moisturizers which may be used to soften and moisturize the skin while providing essential vitamins and nutrients to the skin in a natural way. | 0 |
BACKGROUND OF THE INVENTION
A spinning machine of the manufacturer, Rieter Ingolstadt Spinnereimaschinenbau AG, 85049 Ingolstadt, namely a stretcher and doubler, is already known in the industry. For the loading of the upper rolls, two pressure means are provided per upper roll, which are arranged on pressure arms. One pressure arm applies the pressure means on one side of the upper roll, the other pressure arm does so on the other side. Both pressure arms are firmly linked to one another so that they swing commonly about one pivoting axis. A pivoting of the pressure arms is then necessary, when access to the rolling section is desired. This access is required, for instance, in order to rethread a broken fiber band into the rolling system or when the rolling section rolls are maintained or replaced. The pivoting axis of the pressure arm lies in the back of the rolling section as viewed in the direction of the running fiber band. The pressure arms are to be interlocked by means of an interlocking apparatus which is installed in the front of the rolling section as seen in the direction of the running band. Thereby, the pressure means are brought into force upon the upper rolls.
The rolling section of the known spinning machines has the disadvantage that the pivoting axis of the pressure arms is located in front of the section as seen along the running direction of the band, whereby upon maintenance to said section, the pressure arm, which is swung overhead, hinders the activity of the service person. In particular, access is made especially difficult to the area in front of the rolling section, as seen in the running direction of the band. In this zone, for instance, upon a break in the fiber band, this band must be reintroduced into the rolling section under the pivoted assembly of said rolling section. A further disadvantage of the known rolling section is, that the upper rolls of the rolling section, as well as the cleaning rods of the upper rolls do not swing away upon the pivoting of the pressure arms. They remain, rather, in the journal blocks of the lower rolls, in which these are embedded.
Another spinning machine is made known from the European patent 0 359 914 B1, wherein each pressure arm of the rolling section of this machine is divided into two parts and the second part is swivelable about an axis, which runs parallel to the first. The proposed achievement was to be able to align all upper rolls with corresponding lower rolls by a rotating motion. This rolling section has the disadvantage that it requires a costly interlocking apparatus.
OBJECTS AND ADVANTAGES OF THE INVENTION
The purpose of the present invention is then, to design a spinning machine in such a manner that it can be more simply and more quickly maintained.
A further purpose of the invention is to so design the rolling section of the spinning machine, that in a simple way and manner, the upper rolls can be lifted from the lower rolls by means of swinging away the pressure arms.
Additional objects and advantages of the invention will be set forth in part in the following description, or will be obvious from the description, or may be learned through practice of the invention.
By means of the fact that the pivoting axis of the pressure arm is disposed behind the rolling section in the present invention, after the upward swinging of the pressure arm, the entire area in front of the rolling section becomes freely accessible. Upon the introduction of a new fiber band, this band need no longer be brought in beneath the pivoting axis of the pressure arm, but now the entire area is free and accessible from above and a new band to be introduced can be led in to the rolling section by a service person simply and quickly. A further advantage is that the pivoting geometry of the pressure arm can be substantially more varied, since the area in which the pivoting axis can be placed is considerably larger. For instance, even the area beneath the plane in which the rolling section is situated can be used. Thereby it is possible to better align the swingable upper rolls in relation to the lower rolls. The swinging away of the upper rolls, when these are secured and guided on the journal blocks of the lower rolls, is thereby made easier. In particular, this is true of the swinging away of the upper roll of the exit rolls and especially of the turn-around roll.
The pressure arm can permit these pivoting actions without an auxiliary articulated link so that simultaneously all upper rolls can be positioned in relation to the corresponding lower rolls in essentially one pivoting motion. The pivoting movement component in this case is sufficiently large, to allow the upper rolls to find place in their receptacles, i.e. their guided seats on the journal blocks of the lower rolls.
It is particularly advantageous if the offset between the pivoting axis and the exit rolls of the rolling section runs in the range of between 130 and 490 mm. In this way it becomes possible to simplify the swinging geometry and therewith the positioning of the upper rolls to the lower rolls. An additional achievement is found therein that not only in the case of a spinning machine can the area of a rolling section be easily supervised and serviced by a maintenance person, but also in the case of the matting funnel and the calender rolls which transport the fiber band to storage in the final container. The entire area in front of the rolling section to the storage of the fiber band in its container is thus freely accessible for the maintenance person. A rethreading of the fiber band into the matting funnel, which becomes necessary, following a band break or new insert, is also considerably simplified. It is particularly advantageous if the pivoting axis is installed beneath the plane of the exit rolls of the rolling section. Thereby the alignment of the upper roll of the exit roll to the lower roll is particularly improved. Beyond this, the turnaround roll, which guides the fiber band to the funnel after the last pair of rolling section rolls, is also swung away and subsequently repositioned in a rotary motion against its corresponding lower roll, for instance the exit roll of the rolling section. Simultaneously achieved is that the remaining upper rolls of the rolling section, in spite of this, can be swung in an advantageous geometric arcing manner onto their corresponding lower rolls. The pivoting geometry of the pressure arm as well as that of the upper rolls are further advantageously influenced when the pivoting axis lies beneath the plane which is formed by the tangents to the upper rolls and the lower rolls at the contact line of upper roll and lower roll of the entry roll pair of the rolling section.
It is particularly favorable, when the pivoting axis lies under the plane, which is formed by means of the tangents of the upper roll and lower roll at the contact line of the upper roll and the lower roll of the exit roll pair. It is especially favorable for all the upper rolls, when the pivoting axis of the loading arm lies above the plane which is formed by the tangents at the touching line of the turn-around roll and the roll which operates in conjunction therewith.
By means of the advantageous formation of the spinning machine, by which the pressure means on the pressure arms are secured, and by means of the pivotability of the pressure arm, whereby the said pressure means may be swung away, that for maintenance , i.e. servicing, of the machine, the pressure means need not be taken out of the rolling section by the servicing personnel. It is particularly favorable if the upper rolls are held on the pressure arms, so that, by means of swinging the pressure arm, they are moveable away from the lower rolls. This permits that through the swinging away of the pressure arm, the access into the area of the rolling section is made available to the maintenance person, whereby the fiber band is freely accessible in the rolling section. The upper rolls are advantageously held on the pressure arms by means of holding elements, wherein they are flexibly secured to the pressure arms and can be more easily withdrawn from the guides in the journal block of the lower rolls. It is particularly favorable if the said holding elements are installed to be swingably and angularly disposed to the axis of the upper rolls, a method which greatly eases the insertion of the upper rolls into their receptacles on the said journal blocks. The holding elements are advantageously flexibly designed, in order to ease the putting in and taking out of the upper rolls. Through the correlation of an adjustment rod on the holding element, the advantage is reached that the rigidity of the flexible elements can be varied. By this means, it becomes possible to guide the upper rolls also axially by means of the holding elements. By the design of the holding elements with a guide running angularly to the axis of the upper rolls, the goal is advantageously achieved that the upper rolls are movably arranged precisely within the holding elements.
In a further advantageous development of the invention, it is provided that an interlock apparatus is coordinated with the pressure arms with one or more interlock components and with an activation element as well as a control. By means of this, it is possible to control the locking of the pressure arm in such a manner that various interlocked positions are possible. Advantageously, the interlock apparatus possesses at least two positions, whereby in the first position the upper rolls are not loaded, so that in the case of a long idle period the surfaces of the upper rolls are not damaged. In a second position, the rolling section is under pressure. It is particularly advantageous if the activation element transfers the interlocking apparatus from the second position into the first position and vice versa. The control element is thereby advantageously designed to be a pneumatic cylinder, a hydraulic cylinder, or an electric motor. It is particularly to be preferred if the spinning machine has an arrangement to which a contactor switch is added which produces a signal for the regulation of the control component. This is especially of value when the contactor is installed on the pressure arm. Even better is a situation where the contactor switch is designed as a sensor, which directly, or indirectly determines the offset of the upper rolls to the lower rolls and in dependency of the value thereof, produces a signal. In this way, upon a wrapping formation on one of the rolls, that is, if the fiber band winds up around a rolling section roll, the machine will be shut down. Further, particularly preferentially, the rolling section is relieved of load, so that the winding does not become hard wound, and is thus easier to remove. In further advantageous developments in accord with the invention, the control of the spinning machine can contain a timer, which, upon still-stand and after a predetermined time takes control of the interlock apparatus, so that the pressure arm is released and the rolling section relieved of load. This has the advantage, that the rolls, particularly the outside surfaces, do not develop any pressure spots and the bearings are relieved of load.
In an advantageous development of invention, it is provided that a cleaning wiper rod be installed on the pressure means guides or holding means. It is especially favorable if holding means are provided on the pressure arms for the fastening of a pressure rod. By means of the pressure rod, in accord with a known method, the quality of the stretched fiber band is improved. It is advantageous in this addition to the pressure arms, that the said pressure rod, upon the swinging away of the pressure arm is carried along out of the rolling section so that the insertion of a fiber band into the spinning machine can be accomplished especially simply and quickly, since the pressure rod cannot interfere.
In the following text, the invention will be described with the aid of drawn example presentations of a spinning machine. The invention can be advantageously installed on other spinning machines, for instance on a ring spinning machine, on a flyer, or also on a combing machine.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1. illustrates a spinning machine in accord with the invention in a schematic presentation;
FIG. 2. is a profile view of a rolling section developed in accord with the invention;
FIG. 3. is a profile view of the fastening means of the upper rolls on the pressure arms; and
FIG. 4. is a sectional drawing of a pressure means with holding elements.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the presently preferred embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, and not meant as a limitation of the invention. For example, features illustrated or described as part of one embodiment can be used on another embodiment to yield still a further embodiment. It is intended that the present invention cover such modifications and variations.
The spinning machine 1 of FIG. 1 is comprised principally of a housing 11 for the reception of the drive and auxiliary components, as well as the rolling section 2 for the stretching and doubling of the fiber bands 3. These said bands are withdrawn from the supply container 31 and run over a lay-out table 32 of the spinning machine and guided to the rolling section 2. After the fiber band 3 has left the rolling section 2, it is conducted over the calender rolls 29 into a repository tube 290, which is a component of a coiler plate which places the fiber band in a discharge receptacle 33. The rolling section 2 is isolated from the ambient room space by an enclosure 12 which is shown in dotted lines in FIG. 1. The enclosure 12 contains particularly a produced vacuum, which carries away the dust-like material which is released by the stretching. The enclosure can be swung away from the rolling section, wherein this swinging away can be effected in the same direction as the pressure arms. The lower rolls of the rolling section 2 are conventionally turned by belt drive.
FIG. 2 shows the rolling section 2 of the spinning machine of FIG. 1. As is evident from FIG. 1, the fiber band 3 is introduced into the rolling section from the left side (of the drawing), where it is seized between the section rolls and is stretched by means of different RPM's of various pairs of rolls. The rolling section of FIG. 2 is comprised of the entry cylinders 21, the middle cylinders 22 and the exit cylinders 23. The lower roll 230 of the exit cylinder 23 operates in conjunction with a turn-around roll 24. The purpose of this reverse roll 24 is to direct the stretched fiber band to the calender rolls 29. Stretching of the fiber band does not, as a rule, occur by means of the return roll 24. The upper roll 211 of the entry cylinder 21, the upper roll 221 of the middle cylinder 22 and the upper roll 231 of the exit cylinder 23, as well as the return roll 24, are all secured in the pressure arm 4. By means of the swinging away of the pressure arm 4 the upper rolls are lifted from the lower rolls. Regarding the pressure arm 4, only the right pressure arm is presented in the profile view of FIG. 2, "right" being as seen in the direction of travel of the fiber band 3. A fiber band held between the upper and lower rolls thus becomes freely accessible. The swinging away of the pressure arms 4 is done by means of a rotary motion of the pressure arms about their pivoting axis 41, upon which they are swingably hinged by a bearing. In FIG. 2, is shown by dotted lines, the position the pressure arms assume along with the thereto affixed upper rolls when they are swung back for maintenance.
The rolling section is loaded during operation. That is to say, the upper and lower rolls and the fiber band in between are in contact under pressure. For this purpose, pressure means 5 are placed on the upper rolls, which pressure means in their turn are affixed to the pressure arm 4. Accordingly, the pressure arms 4 are drawn in the direction of the rolling section 2 by means of an interlocking system 6, so that the upper rolls 211, 221, 231 are pressed against the lower rolls 210, 220, 230. The interlocking apparatus possesses two loading hooks 61, whereby each pressure arm 4 is allotted one loading hook. The loading hooks 61 engage one bolt 62 per pressure arm 4, whereby a tension brought to bear on the loading hook is transferred to the corresponding pressure arm 4. Upon release of the pressure arm 4 by means of the interlocking apparatus 6, the loading hook, since it no longer is under tension, swings away from the bolt 62, so that now the pressure arms may be pivoted away. The pressure arms exert no force on the rolling section rolls anymore. By means of a spring (not shown), the pressure arm 4, for instance, can be preferably so far lifted that the upper and lower rolls no longer touch one another, so that their surfaces are completely relieved of pressure and in the case of a long period of idleness of the machine, the upper rolls need not be removed.
The rolling section 2 of FIG. 2 is so designed in an embodiment in accord with the invention, that the pivoting axes 41 of the pressure arms 4 are installed with an offset of 270 mm below the lower roll 230 of the exit cylinder 23. At a pivoting angle for the pressure arms of less than 70°, the entire area of the rolling section is freely open for the service person. After the pressure arms are swung up, by a similar formation, the area of the calender rolls becomes freely accessible. The pivoting axis 41 is installed below a plane, where lower roll 230 of the exit cylinder 23 is to be found. At the same time, the pivoting axis 41 of the pressure arms 4 finds itself above a plane E4 which is formed by the tangents of the return roll 24 and the lower roll 230 along their mutual touching line. Likewise the pivoting axis E4 is located below a plane E1, which is formed correspondingly by the tangents at the touching line of the lower roll 210 and the upper roll 211 of the entry cylinder 21. For the sake of clear understanding, the planes E1, E2, E3, and E4 are shown in illustrated form in FIG. 3. By means of this advantageous arrangement of the pivoting axis 41 of the pressure arms 4 the achievement is attained in that the accessibility of the rolling section is guaranteed in ample measure and simultaneously the disposition of the upper rollers to the lower rollers comes into such a relationship, that these can be positioned in an advantageous alignment to one another. In particular, it is possible to place the bearings of the upper rolls in the journal block of the lower rolls and to lift said upper rolls from journal block 20 upon the opening and closing of the rolling section. In more detail, to raise said upper rolls out of the recess 201 of said journal block 20 upon opening and upon closing to reinsert said upper rolls in recess 201. It is due to this positioning that the direction of force of the pressure means 5, which is exerted upon the upper rolls, is aimed toward the rotating axes of the corresponding lower rolls. By this means it becomes possible to swing all the upper rolls out of the journal block of the lower rolls and simultaneously guarantee a favorable direction of force from the pressure means 5.
The interlocking apparatus 6, which allows the pressure arms in conjunction with the upper rolls to bring pressure upon the lower rolls and to interlock, is comprised of an interlocking element 60, onto which a control element 63 connects and brings about such an action that the loading hook 61 transfers from its "open" position (which is presented in dotted lines) to its "closed" position (shown in solid lines). During this, the bolt 62 in the closed position of the rolling section remains always positioned at the same place. The result of this is that the pressure means 5 exert a predetermined force by means of a simple adjustment on the rolling section cylinder. The magnitude of the force, which is brought by means of the control element 63 has no influence on the force with which the upper rolls press upon the lower rolls. The position of the loading hook and also that of the pressure arms is always the same in the closed position. The control element 63 is comprised of a pneumatic cylinder, which is connected by a line (not shown) to a control valve. The control valve in turn is controlled by a regulator 64. In FIG. 1 the controller 64 is schematically represented. The controller 64 can be activated by a push button (not shown) which can be pressed by an operator for the purpose of bringing the rolling section into an open or closed position. Moreover, the control 64 is connected with two mutually independently working contactors, which send a signal to the control to transfer the roll section from the closed to the open position. One of the signal emitters is the contactor 641, which advantageously is installed on each of the two pressure means of an upper roll. The contactor 641 is comprised of a signal rod 642 and a contact rail 643 (see FIG. 3 and FIG. 4). Upon disturbance in the roll section, in particular in the case of a so called wind-up in which the fibers wind themselves around a roll thereby increasing the distance of the upper rolls from the lower rolls, the signal rod 642 is pushed in the direction of the contact rail 643.
Upon the contact of the signal rod 642 with the contact rail 643 an electrical signal is produced and sent to the control 64 . By means of the subsequent reaction of the signal 64 the pressure arms are released from the interlock and the offset between the upper roll and the lower rolls can be freely adjusted. This has the positive result that the one or more windings of fibers on the rolls, the so called "Wind-up" is formed more loosely. Thereby its removal from the roll can be substantially made easier.
The previously above mentioned second signal emitter is designed in accord with the invention as a time switch 644, which is presented schematically in FIG. 1. The time switch 644 is so designed, that it is only active when the roll section is at still-stand and the interlock apparatus 6 finds itself in its second position, that is, when the roll section is loaded. The time switch operates in such a manner, that after a predetermined still-stand time lapse, automatically a signal is given to the control 64, which thereupon transfers the interlocking apparatus from the second position to the first position, so that the roll section is relieved of pressure. This is to protect the rolls, since otherwise upon still-stand their surfaces could develop pressure spots. The duration, following which the time switch 644 gives its signal, lies preferably in the range of 0.5 to 1 minute. The time can be advantageously increased on an individual basis by the operator. It is not realistic to release the rolling section too quickly, because the operator then has no opportunity to take action, before possible damage may be done to the band due to the release of pressure. Particularly advantageous would be to adjust the said time-lapse to 1 to 4 minutes.
FIG. 3 shows the principal elements of the rolling section 2 of FIG. 2 in a profile view, whereby some components, for instance the lower rolls, are shown with dotted lines. Likewise the pressure arm 4 is only sketchily depicted, since otherwise the pressure means 5 would be covered (see FIG. 4, pressure arm 4, right side). In accord with the invention, the upper rolls 211, 221, 231 and the return roll 24 are secured in flexible retaining elements 42. The retaining elements 42 are held in place on the pressure means 5 by a securing means 423, normally a screw. The securing means 423 is of such a kind that the retaining elements 42 about said securing means 423 are pivotable (see double arrow P). This mobility allows that the insertion of the upper rolls into the recess 201 of the journal block of the lower rolls can be done easier. The recess 201 for the upper rolls advantageously possesses for this insertion an inclined insertion guide, which additionally aids in easing the insertion of the upper rolls. So that the bearing 203, i.e. the outer ring thereof, is prevented from turning with the shaft, the holding element 42 is embedded in a slot 204 of the said outer ring.
The holding elements 42 are each comprised of a flexible, thin sheet metal part, which possesses an extended long slot 425 for the reception of the upper roll. Into this the upper roll protrudes with a shaft end pin 424 and is secured thereby. By means of the design of the long slot 425, the upper rolls can be so guided, even during the operation, within their holding elements, that changes of the axis-offsets between the upper rolls and the lower rolls cause no problem. The shaft end tip of the upper roll, which on each side penetrates the long slot 425 of the holding element 42, can adjust itself sufficiently in this long slot. The long slot 425 forms a guide for the upper rolls.
In the pressure element 5 is provided at times an adjustment 421, which is slidably mounted on the pressure means 5. The adjustment device 421 is guided by, among other things, the securement means 423. The adjustment means 421 possesses a slot 426, by which it can be moved angularly in the direction of the upper roll through a distance in accord with the length of said slot. The adjustment 421 serves to limit the holding element 42 in its movability in the direction of the axis of the upper roll. This is so that the holding element 42 which carries the upper roll 211 of the entry cylinder 21 is limited by the adjustment 421 when said adjustment is in its lower position. The holding element 42 of the middle cylinder 22, on the other hand, is axially movable in the direction of the upper roll 221, since the adjustment 421 is pushed to the upper position. What is achieved by means of the increase of the movement of the holding elements 42, is that the upper rolls in the case of swung back pressure arms 4 can be more easily removed. This comes about since the flexible holding elements 42 can be shoved in the direction of the axes, whereby the shaft end tip 424 of the upper rolls can be more easily extracted from the long slot of the holding element 42. The limitation of the movement of the holding elements 42 by means of the adjustment 421 has the advantage that the holding elements are then also in a position to guide the upper rolls axially, so that no guide means is necessary on the recess 201 of the journal block 20.
FIG. 4 shows a sectional presentation through a pressure element 5, which is seen in the running direction of the fiber band and on the right side of the roll section 2. The pressure means 5 is installed between the right and left part of the pressure arm 4, which arm is assigned to this side of the roll section. In principle, the entry, middle, and exit cylinders resemble one another, so that this presentation is valid for all, and further also for the reverse roll 24. The upper roll 221 is installed in the recess 201 of the journal block 20 of the lower roll 220 of the middle cylinder 22, which roll is depicted here as an example. The upper roll 221 does not support itself toward the lower roll 220 by its bearing 203, but supports itself solely on the lower roll 220. The pressure means 5 presses by means of a pressure rod 51 on the upper roll 221. The pressure rod 51 is loaded by the spring 52, which in turn is pretensioned by an adjusting screw 53. Penetrating through the adjusting screw 53 is found a signal rod 642 extending to the pressure rod 51 , so that the pressure rod 51 represents the position of the upper roll, and with these data, as explained above, together with the contact rail 643 forms a contact means 641 for the interlocking apparatus 6. Upon the touching of the signal rod 642 against the contact rail 643, the signal for the controller 64 is released.
Moreover, on the pressure means 5, advantageously a holder for a cleaning rod 241 is installed. In this case it is also possible upon change of position of the pressure arm 4, simultaneously also to change the position of the cleaning rod. The cleaning rod is conventionally movably mounted in bearings in its securement 242 and lies by its own weight upon the upper roll, for the purpose of cleaning said roll during operation. Since, the securement 242 of the cleaning rod 241 is attached to the pressure means 5 and not to the pressure arm 4, it becomes an especially advantageous possibility upon the change of position of the pressure means 5 to also simultaneously change the position of the securement of the cleaning rod 241 with it. A change of position of the pressure means is, for instance, required, when the offsets of the cylinders of the rolling section are varied.
FIG. 4 presents, moreover, a sectional drawing of the holding means 42 and the adjustment 421. The adjustment 421 is shown in the lower position in which it limits the axial motion of the flexible holding elements 42. This is the position as it is found during the operation of the rolling section. By means of this embodiment it is advantageously possible to guide the upper rolls with the holding elements 42 simultaneously in an axial direction. If the adjustment 421 is placed in the raised position, (see FIG. 3, middle cylinder 22), then, as already described, the holding element 42 is yieldable in the axial direction, whereby the shaft end tip 424 would come out of the long slot 425 of the holding element 42 and the upper roll 221 can be taken out. The movability of the of the adjustment 421 is limited by the slot 426.
Even in the manner of a cleaning rod 241, also a (not shown) pressure rod can be advantageously affixed to the pressure means 5. In this case, it is not foreseen, contrary to the cleaning rod, that the said pressure rod in its securement is so held, that it can move freely upward, the pressure rod lies much more with pressure on the fiber band. The attachment of said pressure rod directly on the pressure arm is also possible, since the pressure rod need not be, in practice, pushed into the rolling section, since it is installed in the area of the exit cylinder 23, which is not changeable in position.
It should be apparent to those skilled in the art that various modifications and variations can be made in the invention without departing from the scope and spirit of the invention. It is intended that the present invention cover such modifications and variations as come within the scope of the appended claims and their equivalents. | A spinning machine for the doubling or stretching of fiber bands with a rolling section having lower rolls which are secured in journal blocks, and wherein the upper rolls may be also secured on said journal blocks with pressure means for the loading of said upper rolls, it is proposed that the pivoting axis of the pressure arm for the placement of the pressure means to the upper rolls be arranged in such a way that, when observed in the running direction of the fiber band, said axis lies behind the rolling section. Advantageously, what is achieved thereby, is that the spinning machine can be maintained in a considerably simpler and quicker manner. Following the upward pivoting of the pressure arm, the entire area of the rolling section becomes freely accessible. The pivoting geometry of the pressure arm can be so varied, that the upper rolls can be easily restored into the guides on the journal blocks of the lower rolls. | 3 |
This is a division, of application Ser. No. 686,038, filed May 13, 1976 now U.S. Pat. No. 4,047,396.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to universal couplings and more particularly to universal joints and universal joint crosses.
2. Description of the Prior Art
The prior art is replete with various forms and types of universal couplings in which internal passages have been provided for lubrication of their various operational parts. Additionally, such prior art universal joints have included additional mechanisms and devices which attempt to improve the lubrication effectiveness. For example, U.S. Pat. No. 3,070,980 to Slaght, patented Jan. 1, 1963, is representative of the prior art providing for an extremely complex bearing cap to enhance the lubricant flow to the needle bearings. U.S. Pat. No. 3,006,168 to Kayser, patented Oct. 31, 1961, also discloses a highly complex and expensive to manufacture self-lubricating universal joint having a multiplicity of parts which may fail during operation. U.S. Pat. No. 3,353,374 to Buthenhoff, patented Nov. 21, 1967, discloses a further example of a highly complex universal joint utilizing a plurality of moving seal and spring loaded devices. U.S. Pat. No. 3,470,711 to Kayser, patented Oct. 7, 1969, discloses yet another example of a highly complex universal joint and, more particularly, a cross therefor including a number of resilient members which may tend to distort and malfunction during operation. Other examples of representative prior art which attempted to solve the lubrication problem are as follows:
______________________________________United StatesPatent Number Patentee Patented______________________________________1,889,470 F. A. Garrett November 29, 19321,968,787 W. W. Slaght et al July 31, 19341,992,257 H. F. Braun et al March 5, 19352,025,502 W. B. Fageol December 24, 19342,081,505 J. E. Padgett May 25, 19373,087,314 V. E. Jarvis et al April 30, 19633,178,907 J. M. Lyons April 20, 19653,242,695 P. M. Ross, Jr. March 29, 19663,352,127 R. L. Skinner, Sr. November 14, 19673,611,751 Hans-Joachim Kleinschmidt October 12, 19713,721,110 Borneman March 20, 19733,832,865 Lewis September 3, 1974______________________________________
The above-noted voluminous prior art patents all may be generally characterized as highly complex and generally vulnerable to malfunction and expensive to manufacture and none of such prior art devices includes effective means to ensure that each of the critical bearing areas are lubricated during each lubricating cycle. Further, they may be additionally characterized as difficult to maintain in the field, thus, potentially resulting in substantial downtime of the vehicle with which they are operationally associated.
SUMMARY OF THE INVENTION
It is, therefore, a primary object of the present invention to provide a universal joint and, more particularly, a cross therefor which employs a self-contained lubricant control system which is effective, efficient and virtually maintenance free.
Another object of the present invention is to provide a universal joint having a cross including a lubricant metering system which assures the even flow of lubricant to all bearing and operational areas of the cross each time the joint is lubricated.
It is yet another object of the present invention to provide a universal joint having a cross including lubricant reservoirs within the trunions thereof which hold substantially more lubricant to extend the lubrication intervals significantly over the prior art.
It is a still further object of the present invention to provide a filtering means of fine mesh filter screen which will filter the lubricant as it reaches the lubricant reservoir to prevent admission of abrasive particles and dirt into such reservoir and ultimately out into the needle bearings.
It is another object of the present invention to provide a universal joint having a cross in which the metering orifice at the reservoir assures an even distribution of lubricant to the needle bearings and bearing caps at approximately 500 p.s.i. and such metering orifice also prevents the flow-back of heated lubricant from the bearings and reservoir when the vehicle is idle so that the lubricant is always available to assure proper needle bearing lubrication.
It is still a further object of the present invention to provide a universal joint having a cross comprising a body having four trunions extending therefrom along two mutually perpendicular lines, a lubrication network in the body and the trunions to provide lubrication to the cylindrical outer bearing surface of the trunions. The network includes a plurality of branches in communication with and terminating in a counterbore provided internally in each of the trunions. Each counterbore has a cylindrical inner surface coaxial with the cylindrical outer bearing surface of the trunions. The counterbore is open at its end opposite the branches. A flow metering member has at least one metering orifice therethrough fixedly disposed within each of the counterbores to meter lubricant flowing from each of the branches downstream into the counterbore and to the bearing means in bearing engagement with the cylindrical outer bearing surface of the trunions.
It is yet another object of the present invention to provide a universal joint having a cross wherein a filtering means is a screen provided upstream of each of said metering orifices to filter particulate matter from the lubricating grease to avoid clogging of the metering orifice and to ensure the free flow of the grease through said orifice.
It is a further object of the present invention to provide a universal joint having a cross wherein the metering orifice member is a substantially rigid member and is held fixedly in place within the counterbore near the radially extending shoulder by interference fit between its outer surface and the inner cylindrical surface of said counterbore.
It is another object of the present invention to provide a universal joint having a cross wherein a diffusion baffle plate having a plurality of apertures therein is fixedly disposed in each counterbore downstream of and near said metering orifice member to provide a uniform flow of lubricant to the bearing means and to avoid the generation of any air pockets within the lubricant flowing to said bearing means.
It is a further object of the present invention to provide a universal joint having a cross wherein there is one metering orifice in the metering member centrally disposed thereon and there are ten apertures in the baffle plate.
It is a still further object of the present invention to provide a universal joint having a cross wherein the metering member is a steel cupped shaped member whose annular lip is in interference fit relation with the inner surface of the counterbore.
It is yet another object of the present invention to provide a universal joint having a cross wherein the metering member is of substantially rigid plastic material pressfitted within the counterbore.
It is a further object of the present invention to provide a universal joint having a cross wherein the baffle plate is of substantially rigid plastic material pressfitted within the counterbore.
It is another object of the present invention to provide a universal joint having a cross wherein the metering member and the baffle plate are nylon and each are carried by a cylindrical plastic member whose outer cylindrical surface is in interference fit relation with the inner cylindrical surface of the counterbore.
It is yet another object of the present invention to provide a universal joint having a cross wherein the baffle plate is formed integrally with the cylindrical plastic member made of nylon.
It is a still further object of the present invention to provide a universal joint having a cross wherein the metering member is pressfitted with the inner surface of the nylon cylindrical member.
It is yet another object of the present invention to provide a universal joint having a cross wherein the filtering means is a screen disposed across each of the counterbores with the screens being captured between the metering member and the radially extending shoulder at the end of each of the counterbores.
It is another object of the present invention to provide a universal joint having a cross wherein the bearing means are needle bearings enclosed and operably supported within a bearing cup which covers and surrounds the outer bearing surface of the trunions. The needle bearing is in bearing contact with the cylindrical outer bearing surface and the bearing surface provided on the inner cylindrical surface of the bearing cup. A thrust washer is operably disposed between said bearing cup and said trunion and is in bearing engagement with the radially extending circumferential surface at the end of each of the trunions and the radially extending inner surface of the end of the bearing cup.
It is a still further object of the present invention to provide a universal joint having a cross wherein the thrust washer has channels formed thereon to allow for the passage of the lubricant from the counterbore to the needle bearings.
It is another object of the present invention to provide a universal joint having a cross wherein the branches intersect each other within the body of the cross. An external grease fitting is in communication with the branches by means of a supply bore which annularly intersects the branches at the junction thereof. This grease fitting is provided with a protective cover to shield it from the environment.
It is still a further object of the present invention to provide a cross for a universal joint comprising a body having four trunions extending therefrom along two mutually perpendicular lines, a lubrication network in the body and the trunions provides lubrication to the cylindrical outer bearing surface of the trunions, the network includes a branch in each of the trunions and the branches are in communication with each other and each terminates in a counterbore provided internally and at the end of each of the trunions. Each counterbore has a cylindrical inner surface coaxial with the cylindrical outer bearing surface of the trunions with a radially extending surface at the junction of each branch and the counterbore. The counterbore is open at its end opposite the radially extending shoulder. A flowing meter member has at least one metering orifice therethrough fixedly disposed within each counterbore to meter lubricant flowing from each passageway downstream into the counterbore and to the bearing means in bearing engagement with the cylindrical outer bearing surface of the trunions. A filtering means is a screen provided upstream of each of the metering orifices to filter particulate matter from the lubricating grease to avoid clogging of the metering orifice and to ensure the free flow of such grease through the orifice. A diffusion baffle plate has a plurality of apertures therein and is fixedly disposed in each counterbore downstream of and near the metering orifice member to provide a uniform flow of lubricant to the bearing means and to avoid the generation of any air pockets within the lubricant flowing to the bearing means. There is one metering orifice in the metering member centrally disposed thereon.
It is still another object of the present invention to provide a universal joint having a cross wherein the generally radial extending surface is a radially extending conical surface and the filtering screen is conically formed complementary to the conical surface.
It is a further object of the present invention to provide a universal joint having a cross wherein the thrust washer is made of austempered spring steel and is generally compliant to absorb shock loading.
Other objects of the present invention and details of the structure of the universal joint lube structure will appear more fully from the following description and accompanying drawings.
It is yet another object of the present invention to provide a universal joint having a cross wherein there is a substantially small space between the downstream side of the metering member and the upstream side of the baffle plate.
DESCRIPTION OF THE DRAWINGS
The accompanying drawings referred to herein and constitute a part hereof illustrate the embodiments of the invention and together with the description serve to explain the principle of the invention wherein:
FIG. 1 shows a universal joint in elevation partially in phantom with the several operational parts of one of the trunions in an exploded view with certain parts thereof in section; FIG. 1 also shows the top trunion in a sectional view;
FIG. 2 is a side elevational view of the universal joint of FIG. 1;
FIG. 3 is the universal joint cross of the universal joint of FIG. 1 partially in section;
FIG. 4 is the cylindrical insertable plastic member to be inserted in a counterbore in each of the trunions of the universal joint of FIG. 1;
FIG. 5 is the metering member which constitutes a part of the insertable plastic member of FIG. 4;
FIG. 6 is a thrust washer used in the universal joint of FIG. 1; and
FIG. 7 is a partial sectional view of a trunion showing another general form of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and particularly to FIGS. 1-6, there is shown a universal joint 10 employing the concept of the present invention. For the purposes of the description of the present invention, the word "axial" shall be used in reference to the axis of rotation of the universal joint connecting the drive shaft members with which it is operably associated and the word "radial" shall mean the direction extending perpendicular relative to the above-mentioned axis of rotation. Unless otherwise mentioned, the words "radial" and "axial" shall be used and construed in the above manner. The universal joint 10 comprises a number of parts and the basic element of the various parts is the universal joint cross 12. As the name implies, the universal joint cross or cross having two intersecting and perpendicular arms have trunions 14 at each end thereof. The cross of journal cross 12 has a cylindrical bearing raceway surface 16 formed thereon. The bearing surface 16 will be explained in greater detail below.
The journal cross 12 is provided with a lubrication network including a central lubrication area 18. The lubricant, which is typically a high grade lubricant grease, is introduced into the lubrication area by means of grease fitting 20 which is in communication with an intermediate channel 11 which, in turn, is in communication with the central area 18. The grease fitting 20 is provided with a protective cap 24 which maintains the cleanliness of the grease fitting from its hostile environment encountered during operation of the universal joint 10. The central area 18 is provided with a series of branches and, more specifically, with four branches 26 which direct the lubricant toward each of the trunions 14. Each of the branches 26 terminate in a counterbore 28 which is provided internally in each of the trunions 14. The internal counterbores 28 are provided with a cylindrical inner surface 39 coaxial with the cylindrical outer bearing surface 16. A generally radially extending shoulder or surface 32 is provided at the junction of each of the branches 26 and the counterbore 28. The generally radially extending shoulder 32 may be formed in a truncated conical fashion and the purpose of the shoulder 32 will be more fully explained below.
The cross 12 may be characterized, therefore, as a simplistic and rugged structure which is highly adaptable to state-of-the-art forging, machining and grinding techniques. The cross 12 may be manufactured from a range of suitable material as, for example, 8620 steel and may be heat treated after machining and forming typically in a high carbon atmosphere to increase its strength and enhance the lubricity of the bearing surface 16.
The counterbore 28 in each of the trunions 14 is adapted to receive several parts for performing a number of different functions, which functions relate to the filtration, metering, diffusing and ultimate effective delivery of the lubricant to the various critical wear areas of the universal joint 10. As before mentioned, there is provided a generally radially extending shoulder or surface 32 at the junction of the counterbore 28 and each of the branches 26. This frustoconical section acts as a seat for a filtering member or screen 34 which may be shaped in a substantially and complementary conical form. The filtering screen 34 may be generally pressed into place to abut and be seated upon the radially extending surface 32. The filtering screen 34 is held in its operational position by the insertion of a generally cylindrical, substantially rigid cylindrical member 36, i.e., the cylindrical member 36 captures the filtering screen 34 between the radial shoulder 32 and itself. The filtering screen 34 may be manufactured from a wide range of galvanized or stainless steel and has a mesh of approximately 0.022 of an inch. The cylindrical member 36 in its inserted position, as shown in FIG. 3, is in a generally interference fit with the inner cylindrical surface 30 of the counterbore 28. For example, the outer diameter of the cylindrical member 36 may be approximately 0.002 of an inch greater than the inner diameter of the counterbore. The cylindrical member 36 and its various component parts of critical importance in understanding the present invention and comprise a real and substantial advantage over the prior art as typified by the prior art referred to in the Background of the Invention. The cylindrical member 36 may be manufactured from a plastic material, 6/6 nylon as manufactured by DuPont, and may have such a wall thickness as to allow for its insertion with a 2.002 inch interference fit. The cylindrical member 36 is provided with a flow metering member 38.
The metering member 38 or plate is provided with a centrally disposed metering orifice 40 therethrough which meters the lubricant as it leaves the various branches 26, flows through and is filtered by the filtering screen 34 and encounters the metering plate 38. In a typical application the orifice 40 may be approximately 0.032 of an inch in diameter. The metering member or plate 38 may be formed integrally with the cylindrical member 36 or otherwise suitably attached or connected thereto as by a pressfit therein. Obviously, mounting techniques and other economics enter into the specific method and form in which the metering plate 38 is interfitted with the cylindrical member 36.
As the lubricant encounters and is metered by the metering member 38 and flows through the orifice 40 thereof it then encounters a diffusion baffle plate 42. The baffle plate 42 is provided with a plurality of apertures or openings 44 which act to diffuse the lubricant as it flows through the baffle plate 42. It has been found that the action of the baffle plate and, more particularly, the various apertures 44 reduce and substantially eliminate "air locks" or entrapped air within the lubricant stream; thus enhancing the consistency and continuity of flow of the lubricant to the various critical wear areas. As with the metering plate 38, the baffle plate 42 may be formed integrally with or otherwise fixedly attached to the cylindrical member 36. As shown in FIG. 4, the baffle plate 42 is shown formed integrally with the cylindrical member 36 while the metering member is shown pressfitted therein and thereto. The apertures 44 may typically be in a range from 0.040 to 0.050 of an inch. There may be provided in a typical application ten such apertures 44.
The cylindrical member 36 when in its fully inserted position within the counterbore 28 will not protrude beyond the radial extremity of the trunion but may terminate at or below the inner surface of the counterbore 28.
Each trunion 14 is adapted to receive several operational parts. The bearing cup or cap 46 is adapted to be fitted over each of the trunions 14. The cylindrical inner surface 48 of the bearing cap 46 and the outer cylindrical surface 16 of the trunions provide the bearing raceways for the full complement of needle bearings 50. A resilient seal 52 surrounds and is mounted upon a shoulder 54 provided on each of the trunions 14. A spacer piece 56 is provided between the resilient seal 52 and needle bearing 50 to maintain the rotational alignment of the needle bearings 50 as they encircle the bearing surface 16 of the trunions 14.
Another important element of the present invention is found in the thrust washer 58 provided between the inner end 60 of the cap 46. The thrust washer 58 is best shown in its enlarged form in FIG. 6. The thrust washer 58 is provided with a central bore aperture 62 and alternating offset portions 64 which are offset from the original plane of the washer 58. The thrust washer 58 performs a number of functions including the maintenance of the alignment of the needle bearings 50 in a manner similar to the spacer piece 56. Additionally, and more importantly, the thrust washer 58 acts as a thrust bearing between the bearing cap 46 and the journal cross 12, i.e., as a generally radial force is transmitted through the cap to the journal cross it is generally absorbed and mitigated by the thrust washer which is a compliant member. This compliance or resiliency is achieved by the alternating offset portions and by the selection of material as, for example, austempered spring steel. This shock absorbing feature of the thrust washer 58 increases the longevity of the overall universal joint 10 and specifically reduces the galling or wear of the ends of the trunions 14. Each of the bearing caps 46 has a plate 66 attached to the tops thereof to secure them to their respective drive member yokes (not shown).
The yokes may be suitably threaded to receive the threaded bolts 68 which secure the plates 66 to the yokes. Thereafter, the bolts are locked in place by suitable locking means such as locking plates 70 having locking tangs 72 thereon.
It can be seen, therefore, that as the lubricant is introduced under pressure through the fitting 20 the pressure will force the lubricant to flow toward the trunions 14 and the critical wear areas (e.g. bearing surfaces 16, 48 and 60, bearings 50, etc.) under pressure in the range of approximately 500 p.s.i. The flow of the lubricant will be from the central area 18 through the branches 26 to be then filtered by the filtering screen 34, metered by the metering member 38 and diffused by the baffle plate 42 and ultimately to the aforementioned critical wear areas in a consistent and effective rate therefrom. The thrust washer will enhance this flow by channeling the lubricant through the channels 74 intermediate the various alternating offset portions 64.
An additional important feature of the present invention is that once the pressurized introduction of lubricant ceases the lubricant will not flow back to the central area 18 from the trunions when the universal joint is in a stationary position. This is achieved essentially by the metering orifice 40 of the metering member or plate. The surface tension of the lubricant at the metering orifice is of such a magnitude as to overcome the force of the lubricant due to gravity even if one of the trunions stops in a vertical direction. The various apertures 44 of the baffle plate 42 also tend to inhibit the return of the lubricant to the central area 18. This is important for the various critical wear areas must be suitably lubricated as they begin to rotate or serious wear damage will occur.
FIG. 7 shows another general form of the present invention in which the various parts are substantially the same as the above-noted structure except that the metering member 76 is a cup like member in which its outer cylindrical surface 28' is pressfitted within the counterbore in each of the trunions 14'. The metering member 76 is provided with a centrally disposed metering orifice 80 which acts in a fashion similar to the metering orifice 40 of the metering member 38. The metering member 76 may be manufactured of a suitable substantially rigid material such as stainless steel, nylon or the like.
Obviously, the present invention is not limited to the specific details as hereinabove described but is capable of other modifications and changes without departing from the spirit and the scope of the appended claims. | A universal joint includes a cross operably connected therein, the cross comprises a body having four trunions extending therefrom along two mutually perpendicular lines, a lubrication network in the body and the trunions to provide lubrication to the cylindrical outer bearing surface of the trunions, the network includes a plurality of branches in communication with and terminating in a counterbore provided internally in each of the trunions, each counterbore having a cylindrical inner surface coaxial with the cylindrical outer bearing surface of the trunions, the counterbore is open at its end opposite the branches, a flow metering member having at least one metering orifice therethrough fixedly disposed within each of the counterbores to meter lubricant flowing from each of the branches downstream into the counterbore and to the bearing means and various bearing surfaces associated therewith including the cylindrical outer bearing surface of the trunions. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates to a sequence-specific method for amplifying nucleic acids. More particularly, the present invention provides a method for amplifying nucleic acid sequences which enables such sequences to be detected with high precision, rapidity and high specificity as compared with conventional methods. Further, the present invention provides a simple method for cloning nucleic acids, particularly, a rapid and simple method for amplifying alternative splicing forms synthesized by an alternative splicing which is performed in a process of preparing a matured mRNA from a DNA.
BACKGROUND OF THE INVENTION
[0002] In recent years, techniques of detecting nucleic acids such as gene diagnosis, nucleic acid test for agricultural products and infectious disease diagnosis have been widely utilized. Various methods are known as a method for detecting nucleic acids for the purpose of such test and diagnosis. For example, there is a method of performing a polymerase chain reaction (PCR) using a primer containing a nucleic acid sequence to be tested, and investigating the presence or the absence of the amplified product, and a method of using a labeled probe which binds to a nucleic acid sequence to be tested. Further, there is a RT-PCR method and a ligase chain reaction method (LCR method) in addition to PCR which is most frequently utilized as a method for amplifying nucleic acid sequences to be tested. Further, as an isothermal amplification method which does not need complicated temperature adjustment as in PCR, a strand displacement amplification method (SDA method), a self retaining sequence amplification method (3SR method), a Qβ replicase method, a NASBA method, a LAMP method, an ICAN method, and a rolling circle method are known. Detecting techniques using these methods has been developed, and sold as test kits. However, these techniques have a problem in that 1) detection takes time, 2) the detection step is complicated, and 3) precision is low, and practical implementation is difficult in cases where rapidness and simplicity are required, such as infectious disease testing at airports, and testing of agricultural products in the field.
SUMMARY OF THE INVENTION
[0003] An object of the present invention is to, upon amplification of a desired nucleic acid sequence, enhance rate, eliminate amplification of background or non-specific sequences, and enhance specificity of amplification of a desired sequence, and provide a means for detecting whether a desired nucleic acid sequence is contained in a specimen or not rapidly and at a better precision, based on the presence or the absence of an amplification product.
[0004] Accordingly, in one aspect of the present invention, there is provided a method for amplifying a double-stranded nucleic acid, which comprises incubating the double-stranded nucleic acid in a solution containing at least one kind of a primer complementary to a part of one or more loop parts of a stem loop structure, under a condition where the double-stranded nucleic acid has the stem loop structure.
[0005] In other aspect of the present invention, there is provided a method for amplifying a double-stranded nucleic acid, which comprises incubating the double-stranded nucleic acid in a solution containing at least one kind of a first primer and at least one kind of a second primer, under a condition where the double-stranded nucleic acid has a stem loop structure, wherein the first primer has a sequence complementary to a part of one or more loop parts of a stem loop structure and the second primer has a sequence complementary to an amplification product of the first primer.
[0006] In another aspect of the present invention, there is provided a method for amplifying a double-stranded nucleic acid, which comprises steps of:
[0007] ligating a nucleic acid having at least one stem loop structure with the double-stranded nucleic acid; and
[0008] incubating the double-stranded nucleic acid in a solution containing at least one kind of a primer complementary to the part of one or more loop parts of a stem loop structure, under a condition where the double-stranded nucleic acid has the stem loop structure.
[0009] In still another aspect of the present invention, there is provided a method for amplifying a double-stranded nucleic acid, which comprises steps of:
[0010] ligating a nucleic acid having one or more stem loop structures with the double-stranded nucleic acid; and
[0011] incubating the double-stranded nucleic acid in a solution containing at least one kind of a first primer and at least one kind of a second primer, under a condition where the double-stranded nucleic acid has the stem loop structure, wherein the first primer has a sequence complementary to a part of one or more loop parts of a stem loop structure and the second primer has a sequence complementary to an amplification product of the first primer.
[0012] In still another aspect of the present invention, there is provided a method for amplifying a nucleic acid, which comprises steps of:
[0013] ligating an oligonucleotide forming a stem loop structure to one or more terminuses of a double-stranded nucleic acid, wherein the oligonucleotide contains any or both of a sequence complementary to a part of a first strand constituting a double-stranded nucleic acid, and a sequence complementary to a part of a second strand, and wherein the double-stranded nucleic acid can complementarily bind to the oligonucleotide to a part of the first strand, a part of the second strand or both of them, respectively, to form a new stem loop structure specific for a target double-stranded nucleic acid; and
[0014] incubating the nucleic acid in a solution containing at least one kind of a primer complementary to a loop part of the new stem loop structure.
[0015] In still another aspect of the present invention, there is provided a method for amplifying a nucleic acid, which comprises steps of:
[0016] ligating an oligonucleotide forming a stem loop structure to one or more terminuses of a target double-stranded nucleic acid, wherein the oligonucleotide contains either a sequence complementary to a part of a first strand constituting the double-stranded nucleic acid or a sequence complementary to a part of a second strand, or both of them and wherein the double-stranded nucleic acid can complementarily bind to the oligonucleotide to a part of the first strand, a part of the second strand, or both of them, respectively, to form a new stem loop structure specific for the double-stranded nucleic acid; and
[0017] incubating the nucleic acid in a solution containing at least one kind of a first primer and at least one kind of a second primer, wherein the first primer has a sequence complementary to a loop part of the new stem loop structure, and the second primer has a sequence complementary to an amplification product of the first primer.
[0018] In still another aspect of the present invention, there is provided a method for amplifying a nucleic acid, which comprises steps of:
[0019] ligating an oligonucleotide forming a stem loop structure to at least one or more terminuses of a target double-stranded nucleic acid, wherein the oligonucleotide contains either a sequence complementary to a part of a first strand constituting the double-stranded nucleic acid, or a sequence complementary to a part of a second strand, or both of them and wherein the double-stranded nucleic acid can complementarily bind to the oligonucleotide to a part of the first strand, a part of the second strand, or both of them, respectively, to form a new stem loop structure specific for the target double-stranded nucleic acid; and
[0020] incubating the nucleic acid in a solution containing at least one kind of a primer which is complementary to either a part of a first strand or a part of a second strand of the double-stranded nucleic acid constituting the loop part of the new stem loop structure, or both of them.
[0021] In still another aspect of the present invention, there is provided a method for amplifying a nucleic acid, which comprises steps of:
[0022] ligating a second nucleic acid to at least one or more terminuses of a target double-stranded nucleic acid containing one or more places of a single-stranded part forming a loop in a part of the double-stranded nucleic acid to form a hairpin structure or a loop structure; and
[0023] incubating the target double-stranded nucleic acid with the second nucleic acid linked thereto in a solution containing at least one kind of a primer complementary to a single-stranded part forming a loop in the double-stranded nucleic acid, or a part forming a loop at a terminus.
[0024] In still another aspect of the present invention, there is provided a method for amplifying a nucleic acid, which comprises steps of:
[0025] ligating a second nucleic acid to at least one or more terminuses of a double-stranded nucleic acid containing one or more places of a single-stranded part forming a loop in a part of a target double-stranded nucleic acid to form a hairpin structure or a loop structure; and
[0026] incubating the target double-stranded nucleic acid with the second nucleic acid ligated thereto in a solution containing one or more kinds of a first primer and one or more kinds of a second primer, wherein the first primer is complementary to a single-stranded part forming a loop in the target double-stranded nucleic acid or a part forming a terminal loop, and the second primer has a sequence complementary to an amplification product of the first primer.
[0027] Instill another preferable embodiment, the double strand is derived from a double-stranded nucleic acid having a loop formed of complementary strands of two different nucleic acids which result from an alternative splicing. In another preferable embodiment, sequence information of two different nucleic acids which result from an alternative splicing from an amplified nucleic acid can be obtained.
[0028] In still another aspect of the present invention, there is provided an oligonucleotide comprising a sequence complementary to a part of a target nucleic acid, wherein the oligonucleotide can form a secondary structure having one or more stem loop structures with the target nucleic acid, after the oligonucleotide is ligated to a target nucleic acid.
[0029] In still another aspect of the present invention, there is provided an oligonucleotide comprising a sequence complementary to a part of a first strand constituting a target double-stranded nucleic acid, and a sequence complementary to a part of a second strand, wherein a secondary structure having a new stem loop structure can be formed by binding complementarily the oligonucleotide and a part of the first strand or a part of the second strand or both of them, respectively, after the corresponding end of the double-stranded nucleic acid and two end of the oligonucleotide are ligated.
[0030] These oligonucleotides can be preferably used in the method for amplifying a nucleic acid of the present invention.
[0031] Objects, features and advantages of the present invention will become apparent by the following detailed explanation. However, detailed explanation and Examples of the present invention are shown for illustration, and it should be understood that various variations and modifications obvious to a person skilled in the art by this detailed explanation are within the scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] FIG. 1 is a view showing one embodiment of the present invention.
[0033] FIG. 2 is a view showing a cleavage site of a restriction enzyme, of a dumbbell form-type product used in Example 1.
[0034] FIG. 3 is a photograph showing results of Example 1.
[0035] FIG. 4 is a photograph showing results of Example 2.
[0036] FIG. 5 is a conceptional view showing a method of Example 1.
[0037] FIG. 6 is a conceptional view showing a method of Example 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] In the present invention, a sequence forming a stem loop (hereinafter, referred to as “linking oligonucleotide”) is ligated to a target sequence to form a template nucleic acid for amplification. That is, in the present invention, the linking oligonucleotide is ligated to a target sequence and a complementary sequence thereof to form an amplification template of a double-stranded nucleic acid.
[0039] In such a double-stranded nucleic acid, when the double-stranded structure is formed between the target sequence and the complementary sequence thereof, a single-stranded loop is formed at one terminus or two opposite terminuses of a double-stranded part. It is desirable that a loop is formed at the opposite terminuses of the double-stranded part. A structure having one loop at each of the opposite terminuses of the double-stranded part is referred to as dumbbell form.
[0040] Ligating of the linking oligonucleotide and the target double-stranded nucleic acid is chemically or enzymatically performed after mutual overhang terminal parts are hybridized. It is desirable that such ligating step is enzymatically performed by a ligase.
[0041] A primer can be designed so as to anneal to an arbitrary place of a ligated or linked double-stranded nucleic acid. For example, the primer can be designed so as to anneal to a part of the loop part or the stem part of a stem loop structure. From a viewpoint of efficiency of amplification, it is desirable to design the primer so that it anneals to a part of the loop part of the stem loop structure. The number of bases of a primer is not particularly limited as long as the primer anneals to a nucleic acid which is to be a template. As a primer to be annealed, one or more kinds may be used, and plural kinds of primer which anneal to plural sites of a linked double-stranded nucleic acid can be used. Amplification efficiency can be further enhanced by using a second primer having the same sequence as that of a part of a linked double-stranded nucleic acid in addition to a primer complementary to the linked double-stranded nucleic acid. A primer having the same sequence as that of a part of the double-stranded nucleic acid may have the same sequence as an arbitrary sequence of a linked double-stranded nucleic acid and, in terms of amplification efficiency, a primer having the same sequence as that of a part of the loop part of the stem loop structure is desirable.
[0042] A DNA polymerase used in a nucleic acid synthesizing method in accordance with the present invention may be any DNA polymerase as long as it has strand displacement activity (strand displacing ability), and any of normal temperature type, medium temperature type and heat resistant type can be preferably used. In addition, this DNA polymerase may be wild type or a variant to which a mutation is artificially added. Examples of such DNA polymerase include a Phi29 phage DNA polymerase. Other examples include a variant in which 5′→3′ exonuclease activity of a DNA polymerase derived from a thermophilic Bacillus bacterium such as Bacillus stearothermophilus (hereinafter, referred to as “B. st”) and Bacillus caldotenax (hereinafter, referred to as “B. ca”), and a Klenow fragment of a DNA polymerase I derived from E. coli has been deleted. Further examples include a Vent DNA polymerase, a Vent (Exo-) DNA polymerase, a DeepVent DNA polymerase, a DeepVent (Exo-) DNA polymerase, a MS-2 phage DNA polymerase, a Z-Taq DNA polymerase, a Pfu DNA polymerase, a Pfu turbo DNA polymerase, a KOD DNA polymerase, a 9°Nm DNA polymerase, and a Therminator DNA polymerase. In order to improve heat resistance, it is possible to add trehalose or the like, or in order to stabilize an enzyme, it is possible to add glycerol or the like. Further, when the desired nucleic acid is a RNA, it is preferable to use a Bca (exo-) DNA polymerase having strong reverse transcriptase activity. When reverse transcriptase activity is weak, it is desirable to conbine these enzymes and M-MuLV Reverse Transcriptase or the like having reverse transcriptase activity.
[0043] The present invention may be utilized when one wants to detect an arbitrary sequence in a genome. In the present invention, it is possible to remarkably enhance a priming efficiency of a primer and, consequently, increase an amplification rate and enhance specificity. Due to high amplification specificity in accordance with the present invention, SNP (single base polymorphism) can be detected. Further, by adding a second primer having a sequence complementary to this amplified nucleic acid, a target sequence may be amplified exponentially.
[0044] In addition, in the present invention, the linking oligonucleotide is ligated or otherwise linked to the opposite terminuses of a straight chain double-stranded nucleic acid, and may be utilized in amplification. In this case, by performing the amplification reaction using a primer having a sequence complementary to the stem loop part, it becomes possible to enhance the rate of synthesizing a single-stranded long chain nucleic acid in which respective chains of DNAs are alternately bound, and has become possible to simply amplify without thermal denaturation which was necessary in the method described in WO 01/040516.
[0045] Further, in the present invention, the linking oligonucleotide can be designed so that an amplification reaction is commenced only when the linking oligonucleotide is precisely linked to the target sequence. Thereby, only the target nucleic acid can be selectively amplified from a mixture of plural kinds of nucleic acid molecules and, by measuring the presence or the absence of this amplification reaction, it becomes possible to detect the target nucleic acid contained in a sample.
[0046] The specific design of this linking oligonucleotide having enhanced specificity is shown, for example, in FIG. 1 . When the linking oligonucleotide is linked with a molecule other than the target nucleic acid, an erroneously linked molecule is amplified by rolling circle amplification, and specific amplification or detection of the target nucleic acid becomes difficult. In order to prevent such non-specific amplification, the linking oligonucleotide is designed so that the terminal sequence of the target nucleic acid makes up a part of the loop part of the stem loop after a target nucleic acid and the linking oligonucleotide are ligated. Unless a linking oligonucleotide and a target nucleic acid are ligated, a stem loop is not formed. Further utilizes is a primer for amplification having a sequence complementary to the terminal sequence of the target nucleic acid forming the loop part of the stem loop formed after the ligation or, preferably, a part of the loop part.
[0047] In addition, a plurality of primers for amplification may be used, but by utilizing a primer having a sequence complementary to the target sequence, specificity of amplification may be also enhanced. In addition, by incorporating a restriction enzyme recognition sequence into the linking oligonucleotide sequence in advance, a long chain nucleic acid molecule synthesized by the amplification reaction may be cut and degraded into nucleic acid molecules of the same length.
[0048] Further, by applying this method, an alternatively spliced form may be specifically amplified. Alternative splicing is a mechanism for synthesizing a plurality of different proteins from one locus, and it is known that a protein having different physiological activity or a protein which is the cause of a disease is synthesized in many cases. Therefore, alternative splicing is gathering a lot of attention. Several methods are known for collecting two kinds of spliced forms in the form of a double-stranded nucleic acid from a plurality of alternatively spliced forms produced from the same locus. In this double-stranded nucleic acid, an exon, which is a subject of alternative splicing, forms a loop, taking the form of a single strand. When a double-stranded nucleic acid obtained from two kinds of different alternatively spliced forms is amplified using the aforementioned method and using a primer having a sequence complementary to a sequence of the exon forming a loop, it becomes possible to specifically amplify an alternatively spliced form of a desired locus.
[0049] The present invention has been generally explained above and will be more specifically explained below by way of Examples. However, Examples are only for the purpose of explanation, and it is not intended to restrict the scope of the present invention to these Examples.
EXAMPLES
Example 1
Linking of a Loop Cassette, and Amplification Using
[0050] the same as a template By the SURCAS method (Super Rolling Circle Amplification System) shown in FIG. 5 , a mouse musculus achaete-scute complex homolog-like 3 ( Drosophila ) (Ascl3) gene, ID Number: NM — 020051 was amplified using a mouse genome DNA as a template. The sequence of an insert is shown below (SEQ ID NO:1). An underlined part is a sequence which anneals to a 3′ terminal side of a primer, and a restriction enzyme (BamHI) cleaving site is shaded.
[0051] Amplification was performed using primers shown below.
(SEQ ID NO:2) YH-F1: 5′ATGCGCGGAC CCA GATTGC TGG ATGGACACCAGAAGCTACCC (SEQ ID NO:3) YH-R1: 5′GCTGCGGCAC CCA ACAGAA TGG TCAAATGACTCTCAGAGCCG
[0052] In the primer sequences, the underlined sequence is a sequence which anneals to the underlined sequence of the insert. A BstXI restriction enzyme recognition sequence (bold letter part) was added to the 5′ region of each primer. The synthesis of primers for amplification was carried out by Invitrogen Corporation.
[0053] The insert was amplified by PCR using these primers. The PCR reaction solution and the number of cycles are given as follows.
[0054] <Composition of PCR Reaction Solution>
Component Final 10Xbuffer 1X MgCl 2 2.5 mM dNTPs 200 μM Primer F 0.2 μM Primer R 0.2 μM Template 500 ng AmpliTaq 1.25 U H 2 O up to 25 μl
94° C.; 2 minutes, (95° C.; 30 seconds, 65° C.; 1 minute, 72° C.; 1 minute), 35 cycles
[0055] After PCR amplification, unreacted primers were removed by Promega Wizard® RSV Gel and PCR Clean-Up system to purify the desired amplification product.
[0056] The terminus of the purified amplification product (insert part) was subjected to restriction enzyme treatment with BstXI. The composition of a reaction reagent is as follows. Restriction enzyme treatment was performed at 50° C. for 90 minutes.
[0057] <Composition of Reaction Reagent>
BstXI Buffer 5 μl BstXI 1 μl Purified amplification product 10 μl dH 2 O up to 50 μl
[0058] The amplification product whose terminus had been cut with a restriction enzyme was purified using Promega Wizard® SV Gel and PCR Clean-Up system.
[0059] The amplification product after purification was ligated to the loop cassette. The sequence of the loop cassette is shown below. This loop cassette is a 5′ terminal phosphorylated oligonucleotide. The underlined part is a loop part. In the loop cassette, the bold letter sequence in the loop indicated by the underlined part is a sequence which anneals to a loop primer. Each loop cassette was designed so that a 3′ terminus had an overhang by four bases (indicated by bold letter).
[0060] The amplification product and a loop cassette were ligated by treatment with a reaction reagent shown below at 16° C. for 90 minutes. Thereafter, Promega Wizard® SV Gel and PCR Clean-Up system was used to remove an unligated short chain loop cassette, and a dumbbell form-type product with a loop cassette linked thereto was purified.
[0061] <Loop Cassette Sequence>
(SEQ ID NO:4) LOOP-F: 5′GCATCGACGG CAT ATGCCATAGCATTTTTATCC ACGATCAC CCGTCGA TGC ATTG 3′ (SEQ ID NO:5) LOOP-R: 5′GAGCCTAGCG CAGTACT GACGTTAAAGTATAGAGGTA TCC CGCTAGGC TC CAGA 3′
[0062] Ligation Solution>
LOOP-F (10 uM) 1 μl LOOP-R (10 uM) 1 μl BstXI digested sample 10 μl T4 DNA ligase buffer 2 μl T4 DNALigase (NEB) 2 μl dH 2 O up to 20 μl
[0063] Using the resulting dumbbell form-type product as a template, and using the following reagent composition, Rolling Circle Amplification was performed at a room temperature (25° C.) for 4 hours. A primer sequence is shown below. A loop primer set was designed so that it can anneal to a loop sequence, and a stem primer set was designed so that it can anneal to a stem sequence, respectively, and amplification was performed using each primer set.
[0064] <Primer Sequence for RCA>
Loop primer set pBADF: 5′ATGCCATAGCATTTTTATCC 3′ (SEQ ID NO:6) PGAL1: 5′TACCTCTATACTTTAACGTC 3′ (SEQ ID NO:7) Stem primer set SF1: 5′GATCACCCGTCGATGCATTG 3′ (SEQ ID NO:8) SR1: 5′GTATCCCGCTAGGCTCCAGA 3′ (SEQ ID NO:9)
[0065] <Amplification Reagent Composition>
10X buffer 2.5 μl 100XBSA 0.25 μl DMSO 1.25 μl dNTPs (Final 140 μM) 140 μl T4Gene32 (Amersham) 0.5 μl Phi29Pol (NEB) 2.0 μl Template (equivalent to about 10 7 molecules) 6.0 μl Each primer (Final 0.4 μM) 2 μl H 2 O up to 25 μl
[0066] In order to confirm whether a desired sequence was amplified or not, restriction enzyme treatment was performed at 37° C. for 20 hours using a restriction enzyme BamHI. A cleavage site of a restriction enzyme of a dumbbell form-type product used in the present experiment is shown in FIG. 2 .
Amplified product 2 μl BamHI (TAKARA Co., Ltd. 10 unit) 2.5 μl BufferK 1 μl dH 2 O up to 10 μl
[0067] 5 μl of the restriction enzyme-treated reaction solution was electrophoresed at 100 V for 80 minutes on a 1.5% nusieve 3:1 agarose gel (manufactured by TAKARA SHUZO Co., Ltd.). A gel after electrophoresis was stained with ethidium bromide (EtBr) to confirm a nucleic acid. Results are shown in FIG. 3 . A sample of each lane is as follows.
[0000] Lane 1: 20 bp DNA Ladder size marker
[0000] Lane 2: amplification with Loop primer set, and then non-treatment with restriction enzyme
[0000] Lane 3: amplification with Loop primer set, and then treatment with BamHI
[0000] Lane 4: amplification with Stem primer set, and then non-treatment with restriction enzyme
[0000] Lane 5: amplification with Stem primer set, and then treatment with BamHI
[0000] Lane 6: 2-Log DNA Ladder size marker
[0068] After amplification using the loop primer set, lane 2 is non-treatment with a restriction enzyme, and the amplification product which had not been cleaved with a restriction enzyme was confirmed at about 10 Kbp. In lane 3, a nucleic acid was cleaved with BamHI, and a band was confirmed at about 480 bp and about 710 bp. These results were consistent with the size predicted from the restriction enzyme map shown in FIG. 2 . From this, it was confirmed that a nucleic acid was amplified using an insert sequence linked with a loop cassette as a template. However, in the case of amplification with Stem primer set, the amplified product was not obtained and, even when restriction enzyme treatment was performed, a band of a desired size after cleavage was not obtained. In addition, when a dumbbell form-type linked double-stranded DNA was amplified, it was shown that it is not necessary to thermally denature to completely convert a template into a single strand, and the DNA is specifically amplified by using the loop primer set which provides a 3 terminus to a loop part forming a single strand.
Example 2
Clover Leaf Amplification
[0069] A mouse musculus achaete-scute complex homolog-like 3 ( Drosophila ) (Ascl3) gene, ID Number: NM — 020051 was tried to be amplified using a mouse genome DNA as a template by a Clover Leaf method shown in FIG. 6 . A sequence of the insert is shown below (SEQ ID NO: 10). The underlined parts are sequences which anneal to a 3′ terminal side of a primer, and a restriction enzyme (BamHI) cleavage site is shaded. This insert is called template A.
[0070] Amplification was performed using primers shown below. Synthesis of the primers was performed using a DNA synthesizer Model 394 of ABI (Applied Biosystem Inc.).
[0071] <Primer Sequence Used in Amplification of Insert Sequence>
(SEQ ID NO:11) YH-F1 TAACTATAACGGTCCTAAGGTAGCGA ATGGACACCAGAAGCTACCC (SEQ ID NO:12) YH-R1: TAACTATAACGGTCCTAAGGTAGCGA TCAAATGACTCTCAGAGCCG
[0072] In the primer sequences, the underlined sequence is a sequence which anneals to the underlined sequence of the insert. An I-CeuI restriction enzyme recognition sequence (bold letter part) is added to the 5′ terminal region of each primer.
[0073] Using these primers, the insert was amplified by PCR. A PCR reaction solution and the number of cycles are as follows.
[0074] <PCR>
Component Final 10Xbuffer 1X MgCl 2 2.5 mM dNTPs 200 μM Primer F 0.2 μM Primer R 0.2 μM Template 500 ng AmpliTaq 1.25 U H 2 O up to 25 μl
<Reaction Condition>
94° C.; 2 minutes, (95° C.; 30 seconds, 65° C.; 1 minute, 72° C.; 1 minute), 35 cycles
[0075] After PCR amplification, unreacted primers were removed by Promega Wizard® SV Gel and PCR Clean-Up system to purify a desired amplification product.
[0076] Further, in order to demonstrate specificity of the present method, a template DNA (referred to as template B) having a nucleotide sequence, a part of which is different from a base sequence of a template A, was artificially prepared, amplified as in a template A, and an amplification product was purified. The sequence of a template B is shown below (SEQ ID NO: 13). The sequence part which is different from the template A is shown by a bold letter.
[0077] The terminal of each amplification product of template A and template B was subjected to restriction enzyme treatment with I-CeuI. The reaction reagent composition is as follows. Restriction enzyme treatment was performed at 37° C. for 3 hours.
[0078] <Reaction Reagent Composition>
I-CeuI Buffer 5 μl I-CeuI 1 μl Purified amplification product 10 μl dH 2 O up to 50 μl
[0079] Using Promega Wizard® SV Gel and PCR Clean-Up system, an amplification product in which a terminal was cut with a restriction enzyme was purified.
[0080] An amplification product after purification was ligated to a loop cassette. The sequence of a loop cassette is shown below. This loop cassette is a 5′ terminal phosphorylated oligonucleotide. The underlined part is the loop part. Each loop cassette was designed so that a 3′ terminus had an overhang of four bases (shown by bold letter). Further, after the ligation of the loop cassette, the sequence to which an amplification primer annealed is boxed (including a sense strand and an antisense strand). In addition, the sequence corresponding to the aforementioned primer sequence is underlined and, further, the sequence part such that, after amplification including a desired region sequence, the primer binds to the loop cassette and, after thermal denaturation, the linking product can form a different structure (only when a desired nucleic acid is amplified, a region homologous to a sequence in a loop can be produced) is shaded. The reaction reagent composition is as follows, and the ligation reaction was performed at 16° C. for 90 minutes. Thereafter, using Promega Wizard® SV Gel and PCR Clean-Up system, the unligated short chain loop cassette was removed to purify the sequence ligated with the loop cassette.
[0000] <Loop Cassette Sequence>
[0081] Ligation Solution>
LOOP-F2 (10 μM) 1 μl LOOP-R2 (10 μM) 1 μl I-CeuI digested sample 10 μl T4 DNA ligase buffer 2 μl T4 DNALigase (NEB) 2 μl dH 2 O up to 20 μl
[0082] Amplification was performed using the resulting dumbbell form-type product as a template. Template A and template B were thermally denatured at 95° C. for 5 minutes, thereafter, this was allowed to stand at room temperature for 5 minutes, and Rolling Circle Amplification was performed at room temperature (25° C.) for 4 hours using the following reagent composition. The primer sequence is as follows. The loop primer was designed so that it could anneal to a loop sequence, and amplification was performed.
[0083] <Loop Primer: RCA Primer Sequence>
PGAL1: TACCTCTATACTTTAACGTC (SEQ ID NO:16)
[0084] <Amplification Reagent Composition>
10Xbuffer 2.5 μl 100XBSA 0.25 μl DMSO 1.25 μl dNTPs (Final 140 μM) 1.4 μl T4Gene32 (Amersham) 0.5 μl Phi29Pol (NEB) 2.0 μl Template (equivalent to about 10 7 molecules) 6.0 μl Each Primer (Final 0.4 μM) 2 μl H 2 O up to 25 μl
[0085] In order to confirm whether a desired sequence was amplified or not, restriction enzyme treatment was performed at 37° C. for 2 hours using a restriction enzyme BamHI.
Amplification product 2 μl BamHI (TAKARA Co., Ltd. 10 unit) 2.5 μl BufferK 1 μl dH 2 O up to 10 μl
[0086] 5 μl of the restriction enzyme-treated reaction solution was electrophoresed at 100V for 80 minutes on a 1.5% nusieve 3:1 agarose gel (manufactured by TAKARA SHUZO Co., Ltd.). A gel after electrophoresis was stained with ethidium bromide (EtBr) to confirm a nucleic acid. Results are shown in FIG. 4 . Samples of respective lanes are shown in as follows.
[0000] Lane 1: 20 bp DNA Ladder size marker
[0000] Lane 2: amplification using template (A), and then untreatment with restriction enzyme
[0000] Lane 3: amplification using template (A), and then treatment with BamHI
[0000] Lane 4: amplification using template (B) of sequence change, after amplification, and untreatment with restriction enzyme
[0000] Lane 5: 2-Log DNA Ladder size marker
[0087] Lane 2 was untreated with the restriction enzyme, and the amplification product which had not been cut with the restriction enzyme was confirmed at about 10 Kbp. Lane 3 was cut with BamHI, and bands at about 600 bp and about 800 bp were confirmed. These results were consistent with the size predicted from a restriction enzyme map. From this, it was confirmed that amplification was performed using an insert sequence linked to the loop cassette as a template. However, amplification was not confirmed when template B in which a part of a sequence of template A was changed was amplified, and a loop cassette was bound thereto, and this was amplified as a template.
[0088] By the present method, it was found out that, specific amplification occurs only when a desired nucleic acid region (insert) is amplified, a loop cassette was bound thereto and, thereafter, a specific secondary structure can be formed.
REFERENCES
[0000]
Tsugunori Notomi et. al. (2000): Loop-mediated isothermal amplification of DNA. Nucleic Acids Research, Vol. 28, No. 12: e63
Kentaro Ngamine and Tesu Hase, Tsugunori Notomi: Accelerated reaction by loop-mediated isothermal amplification using loop primers. Molecular and Cellular Probes Vol. 16, No. 3, 223-229, 2002. | The invention provides a sequence specific method for amplifying nucleic acids. More particularly, the invention provides a method for amplifying nucleic acid sequences which enables such sequences to be detected with high precision, rapidity and high specificity as compared to conventional methods. The present invention also provides a simple method for cloning nucleic acids, particularly, a rapid and simple method for amplifying alternative splicing forms synthesized by an alternative splicing which is performed in a process of preparing a matured mRNA from a DNA. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to a bladderless pipeliner and method for using same. Prior apparatus and methods for repairing pipelines have included an inversion bladder tube as well as a felt liner tube. The liner tube is positioned inside the bladder tube and the action of the bladder tube during inversion causes the liner and the bladder tube to invert together. Once the inversion is complete the bladder that was originally on the outside of the liner is reversed to be on the inside, and the liner which was originally inside the bladder has been reversed to be outside the bladder. The bladder is then inflated to press the liner against the sewer pipe wall. These two together may be referred to as a liner/bladder assembly.
In these prior art liner/bladder assemblies, the bladder is longer than the liner. The end of the bladder includes a wick and a source of vacuum for facilitating the introduction of resin into the bladder tube to cause impregnation of the liner tube. Since the bladder is longer than the liner, the bladder continues to invert a short distance even when the liner is fully inverted. The bladder portion that extends past the end of the liner keeps the end of the liner open so there is no need to cut the end of the liner.
The bladder material used in the prior art has sometimes been made of reinforced urethane. Urethane withstands heat generated during curing of the resin. Urethane also has an excellent stretch characteristic and that is important for the bladder to be sized somewhat smaller than the host pipe. The bladder and liner then both stretch under pressure leaving a smooth bore interior of the newly cured-in-place liner.
The urethane bladder is very expensive. It represents approximately 60% of the liner/bladder assembly in raw material cost. Bladder material must be slit into the appropriate lay flat size. It is then welded into a tube and air tested for leaks and burst pressure. Then the liner tube is pulled inside of the bladder tube and this can be a difficult task, especially if the lengths are long. The bladder tube must be laid out straight with a rope passing through it so that the liner can be pulled through the bladder. If the liner is 200 feet long the manufacturing facility must have an assembly table that is at least 200 feet long also.
Therefore, a primary object of the present invention is the provision of an improved bladderless pipeliner and method for using same.
A further object of the present invention is the use of a bladderless pipeliner which does not include an inversion bladder.
A further object of the present invention is the provision of an apparatus and method which are economical to use, efficient in operation, and durable after installing.
BRIEF SUMMARY OF THE INVENTION
The foregoing objects may be achieved by an apparatus for repairing a pipeline comprising an elongated liner tube having a liner tube wall comprised of a resin absorbent material. The liner tube includes at least first and second ends. The liner tube wall includes first and second opposite wall surfaces. An uncured and unhardened resin impregnates the resin absorbent material of the liner tube wall. An extension tube is provided having a tube shaped open end and a close end. A sealing member detachably secures the tube shaped open end of the extension tube to the first end of the liner tube and forms a substantially fluid tight seal therebetween. A flexible pulling line is connected to the closed end of the bladder extension.
Inversion means are connected to the second end of the liner tube for inverting the liner tube from an initial position wherein the first wall surface of the liner tube wall is facing in an inward radial direction and the second wall surface of the liner tube is facing in an outward radial direction to an inverted position wherein the first wall surface faces in an outward radial direction and the second wall faces in an inward radial direction.
The term “inversion means” as used herein includes various apparatus shown in the prior art for inverting liner tubes into a pipeline. Examples are shown in U.S. Pat. No. 5,816,293, which shows various embodiments of apparatus for inverting the liner tubes. Another reference, U.S. Pat. No. 6,021,815, shows various types of launcher devices which may be used for repairing a main sewer line or a lateral sewer line, and which will accommodate either elongated cylindrical liner tubes or T-shaped liner tubes. U.S. Pat. Nos. 5,950,682 and 6,039,079 show metal launcher devices which may be used as inversion means. The term inversion means also includes the launcher as shown in FIGS. 1-4 of the present application and the inverter tank shown in FIGS. 10 and 11 . Other apparatus for inverting the liner tube, either into the main line or into the lateral line are included in the term “inversion means”.
According to a further feature of the present invention, a metal launcher is utilized and includes an inflatable cuff between the launcher tube and the main liner member. A second fluid conduit is connected to the inflatable cuff for inflating the cuff and causing the cuff to exert pressure on the main liner member in an outward direction away from the launcher tube. In this configuration a lateral liner tube is connected to the main liner member to create a T-shaped configuration. The lateral liner tube is included inside the launcher tube whereas the main liner member is positioned outside the launcher tube.
According to another feature of the invention, the liner tube wall includes a plastic layer covering the outside of the liner tube when the liner tube is in its initial position and the plastic layer is positioned inside the liner tube after the liner tube is inverted to its inverted position.
The method of the present invention comprises taking the liner tube, attaching an inversion means to the first end of the liner tube, and attaching a tube-shaped end of an extension tube to a second end of the liner tube. The extension tube includes a closed end opposite from its tube shaped end. Next, a liquid uncured resin is impregnated into the absorbent material of the liner tube wall. An inversion means is then used to invert the liner tube in the pipeline from an initial position wherein the first wall surface of the liner tube faces in an inward radial direction and the second wall surface of the liner tube faces in an outer radial direction to an inverted position wherein the first wall surface of the liner faces in an outward radial direction and the second wall surface faces in an inward radial direction. The resin is then permitted to cure and harden. Finally the extension tube is pulled away from the liner tube to detach the extension tube from the liner tube.
According to another feature of the method, the attachment step comprises using a sealing member to attach the liner to the bladder extension. The step of pulling the extension tube away from the liner tube further comprises detaching the sealing member from the liner tube while keeping the sealing member attached to the bladder extension.
The present invention can also be practiced without the use of extension tube. Here, the second end of the liner tube is temporarily closed. When the liner tube is inverted, the means used to close the second end of the liner tube is blown off, leaving the liner tube fully inverted and open at its second end. Next, an inflatable plug is inserted into the open second end of the liner tube, and the plug is inflated so as to seal the second end of the liner tube.
According to another feature of the invention, the pipeline comprises a main pipeline and a lateral pipeline which form a juncture with the main pipeline. The method further comprises a main liner portion outside the launcher device and a lateral liner portion inside the launcher device before the inversion step. The inflation step further comprises inflating the main liner so as to contact the main pipe. The inversion step further comprises inverting the lateral liner portion out of the launcher device through a launcher device opening in the launcher device into the lateral pipeline.
A further feature of the invention includes a tank which is utilized as an inversion means and which contains the liner tube before the inverting step. The tank includes a tank opening and the inverting step comprises inverting the liner tube out of the tank through the tank opening.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of an embodiment of the present invention.
FIG. 1A is an enlarged sectional view taken along line 1 A- 1 A of FIG. 1 .
FIG. 1B is a sectional view taken line 1 B- 1 B of FIG. 1 .
FIG. 2 is a sectional view similar to FIG. 1 , but showing the liner tube in an inverted position.
FIG. 3 is a view similar to FIG. 2 , but showing the initial pulling of the extension tube to remove it from the liner tube.
FIG. 4 is a view similar to FIG. 3 showing the extension tube completely removed from the liner tube.
FIG. 5 is a perspective view of a modified form of the invention.
FIG. 6 is a sectional view showing the modification of FIG. 5 in a main pipeline and lateral pipeline junction.
FIG. 7 is a view similar to FIG. 6 , but showing the inflatable cuff in its inflated position.
FIG. 8 is a view similar to FIGS. 6 and 7 , but showing the lateral pipeliner in its inverted condition.
FIG. 9 is a view similar to FIG. 8 , but showing the extension tube fully removed from the lateral pipe liner.
FIG. 10 is a sectional view similar to FIG. 6 , illustrating an embodiment of the present invention without an extension tube.
FIG. 11 is a sectional view showing the lateral liner tube completely inverted and sealed with an inflatable plug.
FIG. 12 is a sectional view showing a modified form of the inversion means which can be used for the present invention.
FIG. 13 is a sectional view of a manhole and pipeline utilizing the inversion means of FIG. 12 for inverting the pipeliner of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, the numeral 10 generally designates a main pipeline requiring repair. The numeral 12 refers to the apparatus for repairing the main pipeline. Apparatus 12 includes a launcher tube assembly 14 comprising a launcher tube 16 and a launcher end cap 18 . End cap 18 includes a fluid inlet 20 for introducing fluid under pressure and a rope opening 22 for permitting a rope to exit through the launcher end cap. At the forward end of the launcher tube assembly 14 is a launcher collar 24 which is comprised of a rigid material such as metal. The launcher collar 24 defines a launcher tube opening 26 .
A liner tube 28 is comprised of a felt material 30 and a plastic layer 32 ( FIG. 1A ). The felt material is adapted to absorb a liquid resin, and the plastic material is adapted to provide an impervious smooth continuous surface. In the position shown in FIGS. 1 and 1A , the plastic layer 32 is located on the outside of the liner tube 28 and the felt layer 30 is located on the inside. During the inversion process which will be described below, the liner tube is inverted so that the felt layer 30 is on the outside of the liner tube and the smooth plastic layer 32 is on the inside of the liner tube 28 .
Liner tube 28 includes a first end 34 which is folded back on the outer surface of the launcher tube 12 in alignment with the rigid collar 24 . A second end 36 is positioned inside the launcher tube 28 . A pair of launcher flaps 38 are positioned outside the first end 34 of liner tube 28 , and extend forwardly to receive a pulling line 40 through grommets 44 . The pulling line 40 includes a releasable knot 42 which permits the pulling line to be removed from the device after the sewer line repair has been complete.
A clamp 46 surrounds the first end 34 of liner tube 28 , the end of the launcher tube 16 , and the rigid collar 24 so as to clamp those parts together.
Attached to the second end 36 of the liner tube 28 is an extension tube 48 . Extension tube 48 , preferably made from a flexible “lay flat” hose, includes a closed end 50 having a plug 52 therein. A flexible line 54 is attached to the plug 52 and extends through the rope opening 22 in the launcher end cap 18 . The extension tube 48 also includes a tubular open end 56 which surrounds the second end 36 of liner tube 28 . Use of a rigid plug 52 in the end of the extension tube 48 can, in some applications, make it difficult to navigate around bends in the pipeline 10 . An alternative (not shown) is to fanfold the closed end 50 of the extension tube into several layers and put a grommet through the layers with a rope fed through the grommet.
An adhesive material 58 , such as a 2-sided tape (preferably carpet tape or pressure sensitive tape) or a liquid adhesive (preferably Tetrahydrofuran (THF)) is used to attach the open end 56 of the extension tube 48 to the liner tube 28 . The adhesive material 58 provides a sealed connection between the liner tube 28 and the extension tube 48 . Extension tube 48 may be further attached to the liner tube by means of connecting tabs 60 which are welded to the extension tube 48 , and which are attached to the felt surface 30 of the liner tube 28 by means of frangible stitches 62 . The term “frangible stitches” refers to stitches which are connected to the liner tube 28 , but which can be torn away by the pulling of rope 54 . This further means of attaching the extension tube 48 to the liner tube 28 by using connecting tabs 60 is an added feature and is not necessary to perform the invention by using an adhesive to attach the extension tube 48 to the liner tube 28 .
In operation, the liner tube 28 is impregnated with a liquid uncured resin. Resin impregnates the felt material 30 , and remains in an uncured state. The liner tube 28 is then pulled within the launcher tube 12 and is transported to the location of the pipeline requiring repair. FIG. 1 illustrates the apparatus 12 located within a main sewer line 10 which requires repair.
FIG. 2 illustrates the apparatus in its inverted condition. The axial lengths of liner tube 28 and launcher tube 16 are shown shorter than in FIG. 1 so as to show the various layers in enlarged scale. To obtain this inversion, fluid under pressure, preferably air, is introduced through fluid inlet 20 . This causes the liner tube 28 to invert outwardly through the collar 24 to the position shown in FIG. 2 . The extension tube 48 also inverts outwardly, and the line 54 is permitted to extend outwardly with the inversion. In the position shown in FIG. 2 , the adhesive material 58 has reversed its position, and is located inside the liner tube 28 and the extension tube 18 . In FIG. 1 the adhesive material is on the outside of the liner tube 28 and the extension tube 48 .
Similarly the tabs 60 are inverted from a position outside the liner tube 28 and the extension tube 48 ( FIG. 1B ) to an inverted position wherein one of their ends is positioned inside the liner tube 28 and the other of their ends (with stitches 62 thereon) is positioned between adhesive material 58 and liner tube 28 .
After the liner tube 28 has been inverted into the main pipeline, the resin is permitted to cure and harden. The extension tube 48 preferably includes an air exhaust port that for regulating and controlling the pressure and temperature within the line 28 during the curing process. After the resin has cured and hardened, the rope 54 is pulled to cause the extension tube 48 to break away from the liner tube 28 . In this break away action, the tabs 60 , because of their frangible stitching 62 , are easily torn away from the interior of the liner tube 28 . The adhesive material 58 is shown in FIG. 3 to be folded back upon itself during the pulling action. This permits the adhesive material to peel away from the interior surface of the liner tube 28 while at the same time remaining attached to the extension tube 48 .
FIG. 4 illustrates the extension tube, the tabs 60 , and the adhesive material 58 completely removed from the interior of the liner tube 28 .
FIGS. 5-9 illustrate the use of the present bladderless liner in a T-shaped configuration for repairing a main pipeline 72 having a lateral pipeline 74 extending there from. The modified assembly is designated generally by the numeral 70 . It is used for repairing a main pipeline 72 having a lateral pipeline 74 extending therefrom.
Assembly 70 includes a metal launcher tube 76 having closed opposite ends and a launcher tube opening 78 ( FIG. 6 ) intermediate those opposite ends. At one end of the launcher tube 76 is a fluid inlet 80 having a fluid hose 81 connected thereto. A line opening 82 is adapted to receive a flexible line 104 . At the opposite end of the launcher tube 76 is a grommet 84 having a pull line 86 attached thereto.
A T-shaped liner tube 88 includes a main liner member 90 (preferably a flat sheet formed in the shape of a tube) and a lateral liner tube 92 which are joined together forming a liner assembly. The liner assembly is comprised of the resin absorbent material shown in the liner assembly of FIG. 1 . The main liner member 90 is positioned outside the launcher tube 76 and includes its smooth surface 32 directed inwardly towards the interior of the sewer line 72 . The lateral liner tube 92 is inverted inwardly into the interior of the launcher tube 76 . In this position the lateral liner tube has its smooth surface 32 facing radially outwardly and its felt surface 30 facing radially inwardly. The juncture between the main liner member 90 and the lateral liner tube 92 is provided with a main liner member opening 94 .
An extension tube 96 includes a closed end 98 having a plug 100 therein. As described previously, fan folding the closed end 98 of the extension tube 96 and placing a grommet therethrough obviates the need for a plug 100 and in some instances makes it easier to navigate around bends in the pipeline. An open end 102 of the extension tube surrounds the one end of the lateral liner tube 92 . A tape 106 or other adhesive material secures the two together and seals around the periphery of the open end 102 . Tabs 108 are attached to the extension tube 96 and the lateral liner tube 92 in the same manner described for FIG. 1 . Stitches 110 frangibly attach the tabs 108 to the liner tube 92 .
Between the main liner member 90 and the steel launcher tube 76 is an inflatable cuff 112 which includes a first cuff end 114 and a second cuff end 116 which are attached to the outer surface of the metal liner tube 76 . This may be done by vulcanizing, or by adhesive means, or by mechanical means such as clamps or simply friction caused by a tight fit. The cuff 112 has intermediate its opposite ends a cuff opening 118 which is folded over its cuff opening perimeter 120 and which is attached to the launcher tube opening 78 in a manner shown in FIG. 6 . The cuff 112 includes at one end thereof a fluid inlet 122 to which is attached a fluid hose 124 .
In operation the assembly 70 is pulled by means of rope 86 to the appropriate position within the main pipeline 72 so that the launcher tube opening 78 is aligned with the lateral pipeline 74 as shown in FIG. 6 . During this positioning step the inflatable cuff 112 is deflated so as to permit the assembly to move easily within the main pipeline 72 .
Next, the hose 124 is used to introduce fluid such as air into the inflatable cuff 112 so as to cause it to expand radially outwardly and force the main liner member into tight engagement with the interior surface of the main pipeline 72 . This properly positions the main liner member 90 , and it also forms a seal between the main liner member 90 and the main pipeline 72 .
Next, air or other fluid is introduced through fluid conduit 81 into the interior of the steel launcher tube 76 . This causes the lateral liner tube 92 to invert upwardly into the lateral pipeline as shown in FIG. 8 . In this position the main liner member 90 and the lateral liner tube 92 form a T-shaped configuration 88 .
The resin is then permitted to cure and harden, and after the curing, the rope 104 is pulled to remove the extension tube 96 from the lateral liner tube 92 in the same manner as described for the embodiment shown in FIG. 1 . FIG. 9 shows the extension tube 96 completely removed with the inflatable cuff 112 again deflated.
The present invention can also be practiced without an extension bladder. An exemplary embodiment is illustrated in FIGS. 10 and 11 . Here, the end 93 of the lateral liner tube 92 opposite the main liner member 90 is temporarily closed, preferably by tying a rope 105 around the end 93 of the lateral liner tube 92 . This creates a temporary seal at the end 93 of the lateral liner tube 92 during the inversion process. The rope 105 which is tied to the end 93 of the lateral liner tube 92 is also attached to line 104 . The lateral liner tube 92 is pulled into the launcher tube 76 by pulling on the line 104 . Inverting the lateral liner tube 92 causes the rope 105 that is tied to the end 93 of the lateral liner tube 92 to be pushed off by pressure applied within the lateral liner tube 92 . This leaves the end 93 of the lateral liner tube 92 open with the lateral liner tube 92 in the inverted position. As shown in FIG. 11 , the end 93 of the lateral liner tube is at a remote portion of the lateral pipe, such that the end 93 cannot be sealed or closed directly by an operator. To overcome this problem, a plug 115 is inserted (typically through a cleanout 117 ) in the end 93 of the lateral liner tube 92 (see FIG. 11 ). The plug 115 is inflated using a separate air hose 119 to form a seal at the end 93 of the lateral liner tube 92 so as to keep the liner tube 92 under pressure and inflated until the resin has cured. The plug 115 should include an exhaust port (not shown) for regulating the pressure and temperature inside the lateral liner tube 92 . Upon curing of the resin, the plug 115 is deflated and removed. Those skilled in the art having the benefit of this disclosure will appreciate that tape, elastic bands, twine or the like may be substituted for the rope 105 as a means for temporarily closing the end 93 of the lateral liner tube 92 .
FIGS. 12 and 13 illustrate a modified form of inversion means which can be used for inverting the liner tube of the present invention. The inversion means comprises a pressure tank 128 having a boss 130 thereon. A tank wall 132 encloses a tank chamber 134 . A fluid inlet boss 136 is also provided and is connected to a fluid conduit 138 which is capable of introducing fluid under pressure into the tank chamber 134 . A valve 148 is capable of opening and closing to permit the introduction or stopping of the fluid under pressure.
Within the tank chamber 134 is a liner tube coil 140 formed from a liner tube of the configuration shown in FIGS. 1-4 or 5 - 9 . A pivot axle 142 is provided at the center. While shown only in a schematic form, the plug 52 and the extension tube 48 are also wound into the coil and are identified by numerals in FIG. 10 . The flexible line 54 is wound at the center of the coil.
The end 34 of the liner tube 28 is folded over on the outside of the boss 130 so that when air is introduced under pressure into the tank chamber 134 , the liner tube 128 inverts out of the boss 130 in the manner shown in FIG. 11 . FIG. 11 shows a manhole 144 which is in communication with the main sewer line 150 . The extension tube 48 is attached by means of tape 58 to the liner tube 28 , and the line 54 extends outwardly and upwardly to the top of the manhole 144 . After the inversion is complete, the line 54 is pulled to remove the extension tube from the cured liner tube.
In the drawings and specification there has been set forth a preferred embodiment of the invention, and although specific terms are employed, these are used in a generic and descriptive sense only and not for purposes of limitation. Changes in the form and the proportion of parts as well as in the substitution of equivalents are contemplated as circumstances may suggest or render expedient without departing from the spirit or scope of the invention as further defined in the following claims. | A lining apparatus and method is provided that obviates the need for a bladder to press the liner against the host pipe. The lining apparatus may include an extension tube sealed to the liner at one of its ends with an inversion mechanism attached to the other end of the liner for inverting the liner to its desired position within the pipe to be repaired. The lining apparatus can also avoid the use of an extension tube by temporarily closing the liner during the inversion process so that the liner can be inflated when pressurized by a fluid and then sealing an open end of the liner after it has been inverted into the pipe. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates to the field of electrochemical batteries and, more specifically, rechargeable batteries.
BACKGROUND
[0002] Electrochemical batteries (“batteries”), which provide a stable, continuous electrical current to a circuit from a chemical energy source, have been in use at least since the early 1800s, when Allesandro Volta invented the voltaic pile. In a battery, internal chemical reactions (such as an oxidation/reduction reaction) drive electrons (and, therefore, a negative net charge) to an electrical contact called an anode, and a positive charge to another electrical contact called a cathode. By bridging the anode and cathode with an electrical conductor, a circuit is formed, which may include an appliance, and electrical current flows from cathode to the anode, powering such an appliance. As the battery discharges its current, the internal chemical reaction, and the battery itself, is eventually depleted and must be replaced or recharged to maintain delivery of electrical power in the circuit.
[0003] The first rechargeable batteries were lead-acid batteries, originating in the 1850s. By passing an electrical current in the direction opposing its discharge current, some of the chemical reactions are reversed (and the capacity of the battery is restored) in a rechargeable battery. To this day, rechargeable batteries face difficult challenges and are thought by many to be a relatively impractical power source for high-power, high-capacity applications. Among other challenges, each rechargeable battery has its own unique discharge and optimal recharging profile (“curve”), requiring specialized hardware to carefully control, and requiring significant time to accomplish. If sub-optimal discharge takes place, a significant amount of power is lost in waste heat. That waste heat, if mismanaged, can lead to catastrophic events, such as fires that destroy the appliance and injure users. See, e.g., Consumer Product Safety Commission, PC Notebook Computer Batteries Recalled Due to Fire and Burn Hazard , Recalls Release No. 09-035 (Oct. 30, 2008), available at http://www.cpsc.gov/en/Recalls/2009/PC-Notebook-Computer-Batteries-Recalled-Due-to-Fire-and-Burn-Hazard/. Incorrectly applied recharge currents, even in batteries designed to be recharged, may result in catastrophic events—such as explosion due to electrolysis releasing gas. Virtually all mainstream battery labels in everyday households instruct laymen on how to avoid the risks of explosion and leakage from common misuse, such as placing the battery into an appliance backwards. See, e.g., Proctor & Gamble, Duracell Duralock 1.5 Volt AA Alkaline Battery Product Label (EXP 2022).
[0004] Due to environmental concerns about the use of fossil fuels, electric and hybrid vehicles have been developed, using large numbers of rechargeable batteries. Among the unique challenges in this area are carefully pairing batteries in series arrays with similar electrochemical profiles in terms of capacity and resistance, to prevent individual cells from becoming charged and discharged out-of-sync with one another. Charge management structures are generally too expensive to overcome the challenges in this regard.
SUMMARY OF THE INVENTION
[0005] New electrochemical battery recharging, refurbishment and replacement techniques are provided. In some aspects of the invention, small, fungible battery elements may be immersed in a fluid or gel and delivered via a bifurcated pump interface that simultaneously unloads discharged cells and loads new, charged cells, to accomplish rapid cell replacement and recharging. The cells may be magnetically aligned to bring cathode and anode elements together, in series, and bridge contacts within the tank (for power service to an appliance).
[0006] Density or other differentials between charged and discharged elements may aid in placing them in proper series (with similar charge states and capacities) and in separating them from one another for removal during replacement. For example, in some aspects, cells attain a final electrostatic charge differential that may drive compression of the cell, to increase its density upon discharge, or vice versa. In others, a discharged battery may attain an electrochemical state that leads it to bind with denser or lighter materials or materials that are more easily filtered or moved (carriers). Such carrier and filtration methods exploit an existing difference between charged and discharged cells, such as salt content in the electrolyte affecting its diamagnetism and motility in a variable magnetic field.
[0007] In other aspects, cathode and/or anode elements may be rapidly flushed to accomplish rapid recharging, in a staged process. In some embodiments, a buffer solution may be sorted into chambers to apply a more uniform immersion of the solution about an electrode. This may be done by selective weighting of the solution in different chemical states.
[0008] Aspects of the invention also provide for rapid exchange of larger, streamlined battery elements, without the use of an immersive fluid, and the systematic control of recharging balances accomplished by such exchanges.
[0009] Where any term is set forth in a sentence, clause or statement (“statement”), each possible meaning, significance and/or sense of any term used in this application should be read as if separately, conjunctively and/or alternatively set forth in additional statements, as necessary to exhaust the possible meanings of each such term and each such statement.
[0010] It should also be understood that, for convenience and readability, this application may set forth particular pronouns and other linguistic qualifiers of various specific gender and number, but, where this occurs, all other logically possible gender and number alternatives should also be read in as both conjunctive and alternative statements, as if equally, separately set forth therein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a side view of an exemplary battery cell that may be used along with several other such cells, in a charging gel or fluid, in accordance with aspects of the invention.
[0012] FIG. 2 is a side, cross-sectional view of a battery cell fluid tank, including several battery cells such as the example provided in FIG. 1 , above, in accordance with aspects of the present invention.
[0013] FIG. 3 is a perspective illustration of aspects of an exemplary system, including an actuable pump handle 301 and bifurcated nozzle 303 for the simultaneous delivery of freshly-charged battery cells and fluid in which they are immersed and removal of discharged battery cells and fluid in which they are immersed, in accordance with aspects of the present invention.
[0014] FIG. 4 depicts a battery cell 401 with a system enabling specialized electrolyte flushing, which, in effect, allows for rapid recharging in accordance with additional aspects of the invention.
[0015] FIG. 5 depicts a stream-lined cathode element, which may be variably combined, flushed and replaced with other such cathode elements to accomplish rapid recharging of a battery cell in accordance with aspects of the present invention.
[0016] FIG. 6 depicts part of an exemplary flushable cathode and anode and electrolyte containment system, permitting the variable flushing and filling of a cathode and an anode chamber with electrolyte and cathode and anode elements, such as the elements discussed with reference to FIG. 5 .
[0017] FIG. 7 depicts part of the same exemplary flushable cathode and anode and electrolyte containment system as in FIG. 6 , but including a top containment wall, and other additional aspects of the invention.
[0018] FIG. 8 depicts an exemplary battery reloading system in accordance with aspects of the present invention, in the context of restoring or changing power resources for an electric motor vehicle.
[0019] FIG. 9 is a schematic block diagram of some elements of an exemplary hardware and software control system that may be used in accordance with aspects of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0020] FIG. 1 is a side view of an exemplary battery cell 101 that may be used along with several other such cells, in a charging gel or fluid, in accordance with aspects of the invention. Cell 101 is a complete battery, capacitor or other device able to deliver a current for use in an appliance. The precise form of Cell 101 is illustrative only, and many other alternate forms may be used to carry out aspects of the invention.
[0021] Among its capabilities, cell 101 may deliver an electrical current from a cathode 103 , and through a circuit, and receive current to an anode 105 (each an electrode). Electrodes 103 and 105 each have a multi-valent, curved outer contact area, which contribute to the overall curved and generally spherical or otherwise streamlined shape of cell 101 . However, in some embodiments, cell 101 may alter its density, for example, by expanding and/or contracting depending upon its charge condition, as will be discussed in greater detail, below. Electrodes 103 and 105 may make contact with neighboring electrodes (not pictured) with contact areas of a variety shapes and sizes, including, but not limited to, neighboring contacts of other cells similar to cell 101 . However, owing the shapes and locations of electrodes 103 and 105 (and similar, neighboring electrodes) for such contact to occur, generally, a neighboring electrode to the right or left of cell 101 will need to be oriented in a substantially similar way as cell 101 , and substantially to the left or right of it. A wide variety of alignment techniques may be used, including neighboring physical force, gravitational bias (for example, due to bottom weights 107 ) or, in a preferred embodiment, magnetic alignment. To explicate that embodiment, cell 101 may comprise a magnetic dipole (or dipoles) such as that shown as positive magnetic pole(s) 109 , at or about the center of the cathode, and negative magnetic pole(s) 111 , at or about the center of the anode. The magnetic poles 109 and 111 generally lead each such similar cell, with the same components as cell 101 , to mutually align and touch one another's contacts, in series, and, in some embodiments, at least some of them, or some groups of them, may be placed in parallel.
[0022] To alter its density, a cell such as cell 101 may, for example, contract its electrodes inward, toward one another. An at least partially flexible or otherwise collapsible inner container wall 110 holding electrolyte 113 of cell 101 may aid in effectuating that change in density, for example, with the aid of a compressible/expandable interstitial space 112 , confined by overlapping sliding louvers 116 , which are non-conducting and may contain a compressible gas. But a wide variety of alternate means for altering the density of the cell, including, but not limited to, alterations to the electrolytic or other chemical or physical contents, may also be effectuated. In some embodiments, cell 101 depletes its charge, by discharging to provide power to a circuit, it decreases in size and/or increases its density—although the reverse, and other filtration enabling differentials linked to charge condition may, alternative or in addition, be used. For example, near the end of discharge, for example, by a current-triggered switch 114 on part of cathode 103 , may disconnect part of cathode 103 , such as mid-cathode section 115 , from the remainder of the cathode. At that point, a charge-carrying ion, such as the positively-charged Lithium ion pictured, may continue to build without neutralization by incoming electrons from the circuit current. In conjunction with a similarly isolated negatively-charged section of anode 105 , that discharge-dependent negative charge may cause a mutual, inward pulling attraction between the two anodes, which may travel in towards one another on an insulated bridge 117 (e.g., on which at least one of the electrode's middle sections may run, laterally on a rail). Recharging cell 101 may reset switch 114 by the same switch, which may be reversed by reversed current. As will be discussed with reference to further figures, below, the alteration of cell 101 's density may lead it, and other cells with the same structure, to automatically sort themselves by grouping together when in a similar charge condition, for example, in a tank or other container holding such cells. The rounded, spherical or otherwise stream-lined shape of a group of cells such as 101 may facilitate the movement and sorting of cells past one another, for sorting purposes, as will be explained further, below.
[0023] In some embodiments, cell 101 may expand, rather than contract, and decrease in density, rather than increase in density, upon discharge. In such embodiments, a neighboring net positive charge, for example, on bridge 117 may drive cathode section 115 further away, rather than closer, upon section 115 accumulating a net positive charge (for example, from intercalated Lithium ions). This may be preferred in embodiments where the magnetic dipole is on a central element, such as bridge 117 , that becomes too shielded and distant between cells and other neighboring magnetic materials to become effective. This may have a freeing effect, permitting cells such as 201 to move more freely, and separate out, upon discharge, as will be discussed in greater detail below.
[0024] FIG. 2 is a side, cross-sectional view of an exemplary battery cell fluid tank 201 , including several battery cells such as the example provided in FIG. 1 , above, in accordance with aspects of the present invention. A plurality of variable-density battery cells, such as the examples shown as 203 , which may each be similar to or as discussed in reference to FIG. 1 , above, are present in the tank, and aligned in rows by their magnetic dipoles, as also discussed in reference to FIG. 1 . In addition, cells 203 are stratified in layers or rows, such as those examples shown as 205 , according to their relative density (weight per volume) and are so stratified, in part, due to the influence of gravity (producing a force opposite to that shown as the “Up” arrow 207 , or, vertically downward from the perspective of the figure). To ease viewing, only one vertical plane layer of cells 203 are shown, but it should be understood that tank 201 is a three-dimensional volume, and cells 203 would extend in three dimensions, not just two, and include several layers into the page, as well as up and down and left and right, in practice. Because, as discussed above, the density of cells such as 203 may increase with discharge and, in some embodiments, the degree of discharge may lead to a graduated density change, cells 203 occur in several such rows, in which the individual cells are approximately of equal size and charge condition. As mentioned above, in some embodiments, the cells 203 may become less dense with discharge and, if such embodiments are implemented in this figure, the most fully discharged cells will be in the top-most layer(s). As also mentioned above, in some embodiments, those discharged cells may also be more free from magnetic alignment with each other, and easier to pull apart from each other. As such, discharged cells at the top of the tank will be easier to remove, for example, by an upper siphon tube 209 , which may be connected to a pump (not pictured) and lower filling tube 211 (for example, with a variably-sealing nozzle that may variably connect and form a seal with bifurcated nozzle inlet/outlet 213 ). Such a pump may simultaneously load newly-charged, dense and small cells 205 at the bottom of tank 201 via tube 211 and remove discharged cells at the top of the tank via tube 209 . The discharged cells may then be recharged in an off-board facility, according to the optimal recharging regimen for the cells, and the tank exchange for fresh, charged cells is performed more quickly than on-board recharging. An exemplary pump handle and bifurcated nozzle system are shown in greater detail, below, in reference to FIG. 3 .
[0025] To discharge their energy into a circuit delivering power to an appliance, bridging the lead and tail (outer-facing) anodes and cathodes of each cell row, terminal contacts at a super-anode 215 and a super-cathode 217 , at opposite ends of the tank, are provided, with contacts 218 that variably electrically connect with those lead anodes and cathodes in each row 205 of cells 203 . To maintain proper alignment, actuable magnets, such as those shown as positive inward-facing pole 219 and negative inward-facing pole 221 , may aid in maintaining the alignment of the cells 203 and rows 205 , maintaining series of cells for the circuit. To facilitate the resorting, poles 219 and 221 may be alterable, and/or new magnetic fields (for example, caused by actuable/creatable upward-facing magnets near the bottom of the tank 201 ) may be formed by additional magnets to momentarily free up, or even drive downward, the movement of cells 203 until they are properly re-sorted by charge. To maintain power to external circuits during these resorting maneuvers, and to power these maneuvers, capacitors or an auxiliary battery may be used. Also, to aid the free-movement and resorting of cells 203 , an interstitial suction-enabling, lubricant or other interstitial fluid 223 may surround the cells, and aid in their siphoning via tubes 209 and 211 . Preferably, such a fluid is not highly conductive, with few dissolved electrolytes, preventing short-circuiting, but does not form an unbridgeable insulating layer between anodes and cathodes of cells that abut one another. Deionized water, among other liquids, gels and/or fluids, may be used.
[0026] A margin of air or empty space is shown at the top of tank 201 , such that, with the expansion of discharged cells, there will be sufficient room for the cells, and enabling cell movement. A sensor and automatic shut-off mechanism in a pump servicing the tank may aid in accomplishing optimum fill levels for that purpose. Discharge vents, such as that shown 225 may be included to prevent explosion in the event of gas buildup.
[0027] FIG. 3 is a perspective illustration of aspects of an exemplary system, including an actuable pump handle 301 and bifurcated nozzle 303 for the simultaneous delivery of freshly-charged battery cells and fluid in which they are immersed and removal of discharged battery cells and fluid in which they are immersed. Nozzle 303 is bifurcated into a removal inlet 305 and a delivery outlet 307 . Inlet 305 and outlet 307 are exits of an inlet tube and an outflow tube, respectively, comprised in pump service hose 309 . As mentioned above, a pump (not pictured) may drive the flow of both newly charged cells from outlet 307 and discharged cells into inlet 305 , and the suction-enabling, lubricating insulating fluid in which they are immersed. The pump may drive flow from either or both tubes, as pressure from outlet 307 or suction from inlet 305 will drive the other with an fluid-tight seal between nozzle 303 and a tank that it is operating on—for example, a tanks such as that discussed above, with reference to FIG. 2 , with its corresponding nozzle inlet/outlet 213 .
[0028] Such a tank nozzle inlet/outlet is shown as 311 , in connection with a battery tank installed on an electrically-powered motor vehicle. Tank inlet/outlet 311 , as with inlet/outlet 213 , is bifurcated to complement the corresponding inlet 305 and outlet 307 of nozzle 303 , with which it may variably mate, and form a fluid-tight seal. To perform a discharged cell replacement (with fresh cells) a user may press nozzle 303 into tank inlet/outlet 311 and, if a control system connected to sensors detecting proper sealing between the two (for example, in the pump handle 301 or inlet and outlet tubes), the pump may begin to operate, in some embodiments, after a user has actuated a GUI, which may include pump actuation handle 313 . Preferably, a hermetic valve seals both the inlet 305 and outlet 307 , and complementary inlet/outlet 303 , to prevent spillage and the introduction of air into the system.
[0029] FIG. 4 depicts a battery cell 401 with a system enabling specialized electrolyte flushing, which, in effect, allows for rapid recharging in accordance with additional aspects of the invention. Cell 401 comprises an inner cell section 403 , containing some conventional components of a lithium ion battery: folded and/or wound layers of electrodes 404 (anode and cathode layers, with separators) immersed in an electrolyte, such as an organic solvent and Li+ and PF 6 − salt ions dissolved within it. However, unlike conventional cells, section 403 is not fully “starved” with absolutely minimal electrolyte, and a variable valve 405 , along with a variable inlet valve 407 and outlet valve 408 and corresponding flushing nozzles 409 from an external recharging system (not fully pictured), may permit the periodic flushing of specialized electrolyte fluids between the anode and cathode layers, to hasten recharging, clean impurities, and prolong the life of the cell. In addition, reverse-current recharging electrodes 411 , associated with nozzles 409 in a recharging armature 413 , assist in effectuating recharging, along with the flushing techniques, as discussed below, for example, by interfacing and driving current through anode and cathode caps 410 .
[0030] An exemplary recharging process for cell 401 may include the following steps. First, cell 401 is discharged, for example, by powering an appliance until all free lithium ions in the electrolyte have intercalated with material in the cathode (for example, a crystal structure incorporating Li+ ions, driving electron flow into the cathode). Second, recharging armature 411 may extend from a recharging system, engage with valves 407 and 408 , and proceed to drive electrolyte with a high concentration of PF 6 − ions, and no Li+ ions, from the upper outlet nozzle, into valve 407 , and through the pleated electrode material 404 . At the same time, armature 413 , through contacts 411 , begins to drive electrons out of the cathode material with a reverse (charging) current. This charging current may be much higher, and recharging accomplished much faster, than in a comparable non-flushing battery cell. After substantially all of the Li+ ions are stripped from the cathode, and flushed, the recharging system may begin to flush the electrodes with a new electrolyte solution, this time, with a high concentration of Li+ ions, while applying a strong recharging current to drive electrons into the anode and, for example, Li+ ions into the anode, again intercalating them, in this instance, into an anode material, such as graphite. Finally, a balanced electrolyte may be introduced in final steps, with matching, conventional levels of both Li+ and PF 6 −, to again provide a buffer for discharge reactions. To assist in the determination when the relevant ions are flushed and saturated for each stage, a sensor 414 placed at the exit of the inner cell 403 (for example, below valve 405 ) may be provided, along with a local processor 415 , which may be in connection with a control subsystem within the recharging system—such as, but not limited to, the control system discussed with reference to FIG. 9 , below. Sensor 414 is preferably placed directly in the exit path 417 of the flushed fluid exiting valve 405 , and being pulled into the bottom nozzle 409 , to provide information, for example, concerning when all Li+ ions have been stripped from the cathode (and the sensor detects no such ions), in that step, and to provide information concerning when Li+ ions have saturated the anode (and detects too high a concentration of that ion), in that step.
[0031] The type of battery (lithium ion) used in this example is exemplary only, and such a staged ion flushing and saturation technique may be used with virtually any other battery type, and even some capacitors.
[0032] FIG. 5 depicts a stream-lined cathode element 503 , which may be variably combined, flushed and replaced with other such cathode elements to accomplish rapid recharging of a battery cell in accordance with aspects of the present invention. Cathode element 503 may comprise any suitable cathode matter, such as Aluminum, among many other possible elements, alloys and other materials, in a skeleton 505 , which may be comprise multi-valent outer contact surfaces 507 , electrically connected with one another and the remainder of the skeleton 505 , for example, through central bridging 509 , which is also comprised in the skeleton 505 . Skeleton 505 may also comprise crystals 511 , or other cathode materials, for accepting ions (such as Li+ ions) or other electrolytic products or aspects from a surrounding electrolyte(s). Skeleton 505 preferably is ciliated, reticulated or contains other surface-area maximizing features, such as the examples shown as 513 , that are thinly constructed (for example, 7-30 microns in width, to maximize the ion acceptance capacity of cathode element 503 . Crystals 511 preferably coat, impregnate or are otherwise comprised throughout at least the surface of each such surface feature.
[0033] Due to their size and shape, contacts 507 also serve to protect surface features 513 and crystals 511 , while permitting electrolyte to enter and interact with them. As a result, a multitude of cathode elements 503 may be piled or otherwise variably grouped together while maintaining electrical contact with one another, but avoid destroying one another, for example, when variably flushed with a surrounding electrolyte. Protecting contacts 507 may take a wide variety of alternate forms to protect crystals 511 , or other cathode structures, such more completely covering and porous structures, or a single or multiple such contacts 507 , as long as the pores are sufficiently large to allow at least the Lithium ion (or other similar electrolyte) enter. As with battery cell 101 , discussed above, cathode element 503 may contain magnetic dipole(s), or a ferromagnetic material, which may variably react with, and may be used with an external magnetic field, which itself may be variable, to encourage binding and electrical contact between a plurality of such cathode elements in a cathode container, as will be discussed in greater detail, below.
[0034] Similar structures, but using anode materials (such as copper, as a skeleton material, and graphite, as a coating material), may also or alternatively be used in a battery cell system permitting variable, rapid flushing to hasten recharging and allow for the repair of battery cells.
[0035] FIG. 6 depicts part of an exemplary flushable cathode and anode and electrolyte containment system 601 , permitting the variable flushing and filling of a cathode chamber 605 and an anode chamber 603 with cathode and anode elements, respectively, such as element 501 , and such as a similar anode element, discussed above. To ease presentation and understanding by showing the inner components of chambers 603 and 605 , system 601 is shown without a top containment wall. However, it should be understood that, in a preferred embodiment, such a top containment wall is included, along with at least five other, or an otherwise complete, set of containment wall(s). An exemplary embodiment of a top containment wall will be discussed with reference to FIG. 7 , below.
[0036] Cathode chamber 605 and anode chamber 603 may be variably separated by an adjustable dividing wall 607 . Dividing wall 607 comprises variable openings, such as those examples shown as 609 , and may further comprise a slidable side 611 with at least partially variably-overlapping pores. By actuating a handle 613 , which may be actuated by a control system, such as a hardware and software control system described in reference to FIG. 9 , below, the amount of fluid flow may be varied, and even brought to zero, with solid portions of side 613 completely covering each opening 609 , in some configurations variably selectable by the system and/or user. Inlet channel 615 straddles the dividing wall 607 , at the top of containment system 601 , as shown, and itself may be divided into two sections, anode feed section 617 and cathode feed section 619 , each for separately channeling electrolyte fluid and anode and/or cathode elements into anode chamber 603 and cathode chamber 605 , respectively, via distribution tubes 621 and 623 . Distribution tubes 621 and 623 are, likewise, respectively dedicated to supplying gel, liquid or other materials from sections 617 and 619 and into anode section 603 and cathode section 605 , respectively. As will be explained in greater detail, below, with reference to FIG. 7 , inlet channel 615 may be variably sealable by an inlet port, within a top containment wall.
[0037] FIG. 7 depicts part of the same exemplary flushable cathode and anode and electrolyte containment system as in FIG. 6 (now 701 ), but including a top containment wall 700 , and other additional aspects of the invention. Containment wall 700 , when installed onto system 701 , forms an air- and liquid-tight seal, separately closing chambers 603 and 605 , preferably, with the aid of sealing strip 702 and sealing rings (not shown in this figure, but shown as 625 in FIG. 6 ) which preferably comprise an elastomeric material, such as rubber gasket or O-ring material.
[0038] An inlet port 703 is also pictured, which also forms an air- and liquid-tight seal, separately, with each section of inlet channel 615 and, variably, with complementary bifurcated nozzle (not pictured) with separate feeding sections and connected tubes for each section of port 703 and channel 615 and, therefore, is capable of separately feeding anode electrolyte and elements into the anode chamber 603 and cathode electrolyte and elements into the cathode chamber. As in other embodiments and aspects of the invention, a lubricant or other suction-improving fluid may be added to the electrolyte and cathode and anode elements, to ease their transfer into system 701 . An outlet port, for example, at the base of system 701 , may also be provided, to assist in flushing discharged cathode and anode elements from system 701 as new, elements, in a charged and pure condition, are added through port 703 . Both port 703 and the outlet port may be variably valved, to prevent unintended leakage while permitting outflow during such a flushing procedure. To aid in flushing each chamber 603 and 605 , completely, dividing wall 607 may be placed in a condition closing its variable openings 609 prior to flushing with new electrolyte and materials through port 703 , for example, via an actuator moving handle 613 (not pictured) of an external recharging and control system, which may also comprise the bifurcated feed nozzle, discussed above.
[0039] FIG. 8 depicts an exemplary battery reloading system 801 in accordance with aspects of the present invention, in the context of restoring or changing power resources for an electric motor vehicle 800 . Rather than attempt to charge a battery on-board the vehicle 800 , system 801 provides a system for rapidly inserting a freshly charged and/or otherwise restored (“new”) battery 803 , preferably with a streamlined, torpedo structure into a complementarily-shaped battery receiving and mounting bay, 805 , within the motor vehicle 800 . A variable one-way receiving port 806 , which may permit injection of a new battery, but may also prevent its escape through valve louvers 807 , which may rotate about axes at the center of louver joints 808 , inward, to permit the entry of a new battery 803 , but which louvers also collide with one another when encountering reverse force from a battery that has been installed in bay 805 . Once installed within bay 805 , anode and cathode contacts 809 (and optional data delivery contacts, not separately pictured), of battery 803 may permit battery 803 to deliver electrical power to the motor vehicle 800 via a contact harness 810 within bay 805 , unless and until the battery 803 is ejected.
[0040] Preferably, from the same process of the maneuver for loading the new battery, the system 801 may eject another, preferably, more depleted, but similarly-shaped (“old”) battery, if present, via a variable exit or release gate 811 , at a different point in bay 805 than the entrance point of the new battery. Also preferably, the new battery may aid, along with gravity, in pushing the old battery out of the bay, and/or triggering release gate 811 to open (releasing the old battery) and then return to a closed, locked position, as the new battery is loaded and, in the process, electrical contacts on the new and/or old battery linked to control system hardware (such as control system hardware set forth below, with reference to FIG. 9 ) relay information to a control system relating to the final charge states, capacity and other specifications of both the old and new battery. Also preferably, the control system may determine a net amount of additional power, and other quality gains or exchange results, affecting the motor vehicle, and may aid in determining a proper monetary cost to be applied to a user requesting such a reloading maneuver as described herein, via data derived from front and rear contacts (discussed further below). Such information may be ascertained by the system earlier, however and, for example, prior to carrying out the exchange. In some embodiments, a user may request different charge, capacity and other battery characteristics, pay for them in advance, and if payment clears, the system may select a new battery for replacing the user's old battery to accomplish the different qualities requested and/or paid for by the user.
[0041] The battery reloading maneuvers described above may be accomplished, in part, with the aid of a loading rig 813 . Loading rig 813 , as with the motor vehicle 800 , may have its own contact harness 815 , to temporarily electrically connect to contacts 809 of batteries such as 803 , if and when they are held on the rig (as pictured). Actuable gripping arms 817 and pushing arm 819 may aid harness 813 , and the operators and/or system utilizing it to load battery 803 into bay 805 via one-way receiving port 806 . An informational electronic plug or contact set 821 may ascertain information from battery 803 and the replaced battery, via complementary rear contacts 822 , while arm 819 pushes battery 803 into place, and its front contacts 823 communicate with rear contacts from the old battery, with which they touch. In some embodiments, harness 815 may extend to front and rear contacts 823 and 822 , accomplishing both data transfer and power delivery aspects of the invention, and separate contacts 809 may be omitted (or vice versa). Carriage 813 , or another container to which carriage 813 delivers an old battery, for example, captured by bay-drop net or cantilever 825 , may accomplish recharging of an old battery ejected from bay 805 in the exchange process, after bay-drop net or cantilever 825 has caught it.
[0042] FIG. 9 is a schematic block diagram of some elements of an exemplary control system 900 that may be used in accordance with aspects of the present invention, such as, but not limited to, actuating sensors, motors, battery charging operations and station machinery (such as, but not limited to battery-swapping armatures and flushing mechanisms, and determining currents and amounts for recharge and execute transactions with users), other actuators in connection with structural aspects, such as braces and frame pieces, and driving current and current patterns for recharging. The generic and other components and aspects described herein are not exhaustive of the many different systems and variations, including a number of possible hardware aspects and machine-readable media that might be used, in accordance with the present invention. Rather, the system 900 is described to make clear how aspects may be implemented. Among other components, the system 900 includes an input/output device 901 , a memory device 903 , storage media and/or hard disk recorder and/or cloud storage port or connection device 905 , and a processor or processors 907 . The processor(s) 907 is (are) capable of receiving, interpreting, processing and manipulating signals and executing instructions for further processing and for output, pre-output or storage in and outside of the system. The processor(s) 907 may be general or multipurpose, single- or multi-threaded, and may have a single core or several processor cores, including, but not limited to, microprocessors. Among other things, the processor(s) 907 is/are capable of processing signals and instructions for the input/output device 901 , analog receiver/storage/converter device 919 , analog in/out device 921 , and/or analog/digital or other combination apparatus 923 to cause a display, light-affecting apparatus and/or other user interface with active physical controls, such as a charging station pump (any of which may be comprised or partially comprised in a GUI) to be provided for use by a user on hardware, such as a personal computer monitor or PDA (Personal Digital Assistant) screen (including, but not limited to, monitors or touch- and gesture-actuable displays) or terminal monitor with a mouse and keyboard or other input hardware and presentation and input software (as in a software application GUI), and/or other physical controls. Alternatively, or in addition, the system, using processors 907 and input/output devices 919 , 921 and/or 923 , may accept and exert passive and other physical (e.g., tactile) user and environmental input and output.
[0043] For example, and in connection with aspects of the invention discussed in reference to the remaining figures, the system may carry out any aspects of the present invention as necessary with associated hardware and using specialized software, including, but not limited to, controlling the placement of recharging contacts and flushing nozzles on rechargeable, flushable battery sections, actuating magnetic fields to align batteries in a battery tank, controlling the flow and patterns of current, power usage, power and current buffering (for example, using capacitors or a capacitor bank) and using attached sensor/motors and other actuating devices and system-wide interfaces to effect aspects of a recharging system. The system may also, among many other things described for control systems in this application, respond to user, sensor and other input (for example, by a user-actuated GUI controlled by computer hardware and software or by another physical control) to activate/deactivate recharging systems and pumps, store batteries and monitor their status in an inventory, exchange batteries and determine net power, capacity and other exchanges with users, or perform any other aspect of the invention requiring or benefiting from use of a control system. The system 901 may also permit the user and/or system-variation of settings, including but not limited to the affects of user activity on modes of operation of the system, and send external alerts and other communications (for example, to users and administrators) via external communication devices, for any control system aspect that may require or benefit from such external or system-extending communications.
[0044] The processor 907 is capable of processing instructions stored in memory devices 903 and/or 905 (and/or ROM or RAM), and may communicate with any of these, and/or any other connected component, via system buses 975 . Input/output device 901 is capable of input/output operations for the system, and may include/communicate with any number of input and/or output hardware, such as a computer mouse, keyboard, entry pad, actuable display, networked or connected second computer, other GUI aspects, camera(s) or scanner(s), sensor(s), sensor/motor(s), range-finders, GPS systems, receiever(s), transmitter(s), transceiver(s), transflecting transceivers (“transflecters”), antennas, electromagnetic actuator(s), mixing board, reel-to-reel tape recorder, external hard disk recorder (solid state or rotary), additional hardware controls (such as, but not limited to, buttons and switches, and actuators, current or potential applying contacts and other transfer elements, light sources, speakers, additional video and/or sound editing system or gear, filters, computer display screen or touch screen. It is to be understood that the input and output of the system may be in any useable form, including, but not limited to, signals, data, commands/instructions and output for presentation and manipulation by a user in a GUI. Such a GUI hardware unit and other input/output devices could implement a user interface created by machine-readable means, such as software, permitting the user to carry out any of the user settings, commands and input/output discussed above, and elsewhere in this application.
[0045] 901 , 903 , 905 , 907 , 919 , 921 and 923 are connected and able to communicate communications, transmissions and instructions via system busses 975 . Storage media and/or hard disk recorder and/or cloud storage port or connection device 905 is capable of providing mass storage for the system, and may be a computer-readable medium, may be a connected mass storage device (e.g., flash drive or other drive connected to a U.S.B. port or Wi-Fi) may use back-end (with or without middle-ware) or cloud storage over a network (e.g., the internet) as either a memory backup for an internal mass storage device or as a primary memory storage means, or may simply be an internal mass storage device, such as a computer hard drive or optical drive.
[0046] Generally speaking, the system may be implemented as a client/server arrangement, where features of the invention are performed on a remote server, networked to the client and made a client and server by software on both the client computer and server computer. Input and output devices may deliver their input and receive output by any known means of communicating and/or transmitting communications, signals, commands and/or data input/output, including, but not limited to, input through the devices illustrated in examples shown as 917 , such as 909 , 911 , 913 , 915 , and 977 and any other devices, hardware or other input/output generating and receiving aspects. Any phenomenon that may be sensed may be managed, manipulated and distributed and may be taken or converted as input or output through any sensor or carrier known in the art. In addition, directly carried elements (for example a light stream taken by fiber optics from a view of a scene) may be directly managed, manipulated and distributed in whole or in part to enhance output, and whole ambient light or other RF information for an environmental region may be taken by a series of sensors dedicated to angles of detection, or an omnidirectional sensor or series of sensors which record direction as well as the presence of electromagnetic or other radiation. While this example is illustrative, it is understood that any form of electromagnetism, compression wave or other sensory phenomenon may include such sensory directional and 3D locational information, which may also be made possible by multiple locations of sensing, preferably, in a similar, if not identical, time frame. The system may condition, select all or part of, alter and/or generate composites from all or part of such direct or analog image or other sensory transmissions, including physical samples (such as DNA, fingerprints, iris, and other biometric samples or scans) and may combine them with other forms of data, such as image files, dossiers or metadata, if such direct or data encoded sources are used.
[0047] While the illustrated system example 900 may be helpful to understand the implementation of aspects of the invention, it is understood that any form of computer system may be used to implement many control system and other aspects of the invention—for example, a simpler computer system containing just a processor (datapath and control) for executing instructions from a memory or transmission source. The aspects or features set forth may be implemented with, and in any combination of, digital electronic circuitry, hardware, software, firmware, or in analog or direct (such as electromagnetic wave-based, physical wave-based or analog electronic, magnetic or direct transmission, without translation and the attendant degradation, of the medium) systems or circuitry or associational storage and transmission, any of which may be aided with enhancing media from external hardware and software, optionally, by wired or wireless networked connection, such as by LAN, WAN or the many connections forming the internet or local networks. The system can be embodied in a tangibly-stored computer program, as by a machine-readable medium and propagated signal, for execution by a programmable processor. The method steps of the embodiments of the present invention also may be performed by such a programmable processor, executing a program of instructions, operating on input and output, and generating output. A computer program includes instructions for a computer to carry out a particular activity to bring about a particular result, and may be written in any programming language, including compiled and uncompiled, interpreted languages, assembly languages and machine language, and can be deployed in any form, including a complete program, module, component, subroutine, or other suitable routine for a computer program. | New electrochemical battery recharging, refurbishment and replacement techniques are provided. In some aspects of the invention, small, fungible battery elements may be immersed in a fluid and delivered via a bifurcated pump interface that simultaneously unloads discharged cells and loads new, charged cells, to accomplish rapid cell replacement and recharging. The cells may be magnetically aligned to bring cathode and anode elements together, in series, and bridge contacts within a container (powering an appliance). Density differentials between charged and discharged elements may aid in placing them in series (with similar charge states and capacities) and in removing them during replacement.
In other aspects, electrode elements may be rapidly flushed to accomplish rapid recharging, in a staged process. Aspects of the invention also provide for rapid exchange of larger, streamlined battery elements, without the use of an immersive fluid, and systematic control of recharging balances accomplished by such exchanges. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to magnetic resonance (MR) measurement of shear rates of moving materials and more specifically to MR mapping of the velocity of a moving material.
2. Description of Related Art
Shear rate is defined as the change in velocity of a material with respect to position. It is an important parameter in indicating regions of great or little velocity. In flowing materials, such as liquids flowing through metal tubes, shear rate influences the rate of corrosion. By localizing regions of extremely high or low shear rates, portions of a tube wall which may possibly fail could be identified.
Shear rate is also related to the of development of arteriosclerotic disease in mammals. Locations which have low shear rates, are more apt to develop plaque and blockage characteristic of this disease.
A traditional fluid flow analysis method, known as ink streamlining, requires introducing a contrast agent into a flowing fluid and observing the motion of the contrast agent.
Another method of measuring shear rate employs laser Doppler methods. This requires a laser beam to be reflected from particles suspended in the material which is to be measured, and determining the displacement of each particle over a short interval thereby indicating the velocity of the material at the chosen location.
Both of these methods are invasive, or destructive and require direct access to the material being tested. If the material is inside a tube or deep within a living subject, these methods will not be useful. Furthermore, they are not suited for in-vivo, or non-destructive testing applications.
Since velocity is a vector quantity, it can be expressed as the stun of three mutually orthogonal component vectors. Each of these components, in turn, can be measured with respect to three mutually-orthogonal spatial dimensions to give a total of nine different shear rate measurements. Existing techniques can be used to measure some of these shear components, but detection of all components is difficult or impossible in most situations.
SUMMARY OF THE INVENTION
Methods using Magnetic Resonance (MR) pulse sequences for the acquisition of shear rate images are disclosed. These pulse sequences are comprised of a slice-selective rf pulse, conventional phase-encoding and readout gradient pulses for spatial encoding and a bipolar velocity-encoding gradient pulse to encode velocity as a phase shift in the resulting image. The direction of the velocity-encoding gradient determines the component of the velocity which is detected. If desired the procedure can be repeated to obtain images sensitive to orthogonal components of velocity.
Imaging of a selected component of shear rate is performed by repeating the pulse sequence a minimum of four times for each increment of the phase-encoding gradient. In the first acquisition a positive polarity velocity-encoding gradient is applied. In the second acquisition a negative polarity velocity-encoding gradient is applied. During both the first and second acquisition the receiver and transmitter are operated at the same frequency. The third and fourth acquisitions are performed in an identical fashion to the first and second acquisitions, except that the center of the field-of-view is shifted by an amount, D, with respect to the first and second acquisitions.
Data from the first and second acquisitions are used to compute a phase difference data set. The phase of each pixel in the phase difference data set is directly proportional to velocity (assuming no phase wrap). Data from the third and fourth acquisitions are processed in the same way to give a second phase difference data set. Since the third and fourth acquisitions were obtained with an offset field-of-view, however, the second phase difference data set is not exactly registered with the first phase difference data set. Since the first and second phase difference data sets contain velocity information from slightly different points in space a shear rate image can then be computed by taking the phase difference of the first and second phase difference images.
Shear rate images with respect to the three orthogonal spatial dimensions can be made by shifting the third and fourth phase images in the readout, phase-encoding and slice selective directions. Multiplexed detection of velocity components can be used to minimize the amount of data which must be collected.
OBJECTS OF THE INVENTION
It is an object of the present invention to provide a method for the detection and display of a selected component of shear rate within a subject.
It is another object of the present invention to provide a method for the detection and display of all components of shear rate within a subject.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the invention believed to be novel are set forth with particularity in the appended claims. The invention itself, however, both as to organization and method of operation, together with further objects and advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying drawing in which:
FIG. 1 is a simplified block diagram of a magnetic resonance (MR) imaging system suitable for use with the present invention.
FIG. 2 is a more detailed diagram of the magnet assembly of FIG. 1.
FIG. 3a is a graphical illustration of one embodiment of a velocity-encoding magnetic field gradient pulse sequence which is incorporated into a shear rate imaging pulse sequence.
FIG. 3b is a graphical illustration of a second embodiment of a velocity-encoding magnetic field gradient pulse sequence.
FIGS. 4a-4c are vector illustrations of the effect of bipolar magnetic field gradient pulses on stationary spin magnetization.
FIGS. 5a-5c are vector illustrations of the effect of bipolar magnetic field gradient pulses on moving spin magnetization.
FIG. 6 is pulse sequence diagram of a first embodiment of the present invention which can be used to measure the distribution of shear rate within a subject.
FIG. 7 is schematic diagram illustrating the data processing steps required to obtain shear rate images using the pulse sequence shown in FIG. 6.
DETAILED DESCRIPTION OF THE INVENTION
In the present embodiment of the invention, a subject is placed within the magnet of a magnetic resonance imaging system. The region over which a shear rate image is desired is then identified by an operator, perhaps with the assistance of a conventional MR imaging sequence. A pulse sequence is then applied and the data analyzed.
FIG. 1 is a simplified block diagram of the major components of a magnetic resonance (MR) imaging system suitable for use with the invention described herein. The system is comprised of a general purpose mini-computer 2 which is functionally coupled to a disk storage unit 2a and an interface unit 2b. A radiofrequency (RF) transmitter 3, signal averager 4, and gradient power supplies 5a, 5b and 5c, are all coupled to computer 2 through interface unit 2b. Gradient power supplies 5a, 5b and 5c energize gradient coils 12-1, 12-2 and 12-3 to create magnetic field gradients Gx, Gy and Gz, respectively, in the "X", "Y" and "Z" directions respectively, over a subject to be imaged. RF transmitter 3 is gated with pulse envelopes from computer 2 to generate RF pulses having the required modulation to excite an MR response signal from a subject. The RF pulses are amplified in an RF power amplifier 6 to levels varying from 100 watts to several kilowatts, depending on the imaging method, and applied to a transmitter coil 14-1. The higher power levels are necessary for large sample volumes, such as in whole body imaging, and where short duration pulses are required to excite larger NMR frequency bandwidths.
The MR response signal is sensed by a receiver coil 14-2, amplified in a low noise preamplifier 9 and passed to receiver 10 for further amplification, detection, and filtering. The signal is then digitized for averaging by signal averager 4 and for processing by computer 2. Preamplifier 9 and receiver 10 are protected from the RF pulses during transmission by active gating or by passive filtering.
Computer 2 provides gating and envelope modulation for the MR pulses, blanking for the preamplifier and RF power amplifier, and voltage waveforms for the gradient power supplies. The computer also performs data processing such as Fourier transformation, image reconstruction, data filtering, imaging display, and storage functions (all of which are conventional and outside the scope of the present invention).
Transmitter coil 14-1 and receiver RF coil 14-2, if desired, may comprise a single coil. Alternatively, two separate coils that are electrically orthogonal may be used. The latter configuration has the advantage of reduced RF pulse breakthrough into the receiver during pulse transmission. In both cases, the coils are orthogonal to the direction of a static magnetic field B0 produced by a magnet means 11. The coils may be isolated from the remainder of the system by enclosure in an RF shielded cage.
Magnetic field gradient coils 12-1, 12-2 and 12-3 are necessary to provide gradients Gx, Gy and Gz, respectively, that are monotonic and linear over the sample volume. Multi-valued gradient fields cause a degradation in the MR response signal data, known as aliasing, which leads to severe image artifacts. Nonlinear gradients cause geometric distortions of the image.
Magnet assembly 11, shown schematically in FIG. 2, has a central cylindrical bore 11a which generates a static magnetic field B0, typically in the axial, or Z Cartesian coordinate direction. A set of coils 12, such as coils 12-1, 12-2 and 12-3 of FIG. 1, receive electrical signals via input connections 12a, and provide at least one gradient magnetic field within the volume of bore 11a. Also situated within bore 11a is an RF coil 14, which receives RF energy via at least one input cable 14a, to provide an RF magnetic field B1, typically in the X-Y plane.
FIGS. 3a and 3b show two embodiments of velocity-encoding magnetic field gradient pulse sequences. In FIG. 3a the magnetic field gradient has substantially zero intensity until time t=0. Beginning at t=0 and ending at t=a, a first magnetic field gradient pulse 300 is applied. Beginning at t=b and ending at t=c a second magnetic field gradient pulse 310 having substantially the same duration and intensity of the first gradient pulse, but having opposite polarity, is applied. The time interval between the two gradient pulses is T.
An alternative embodiment of this velocity-encoding gradient pulse is shown in FIG. 3b. This embodiment is similar to the embodiment shown in FIG. 3a with the exception of the addition of a refocusing RF pulse 340 placed between the gradient waveforms 320, 330 and the second waveform 330 having a polarity identical to that of the first gradient pulse 320.
The application of magnetic field gradient pulse sequences such as those of FIGS. 3a and 3b results in a phase shift in transverse spin magnetization which is directly proportional to velocity, the area of each lobe of the pulse sequence being Ag, the gyromagnetic ratio of the nuclear species being γ and the time interval between successive gradient lobes being T. This relationship is well known to those skilled in the art and can be expressed as:
Φ=γVTAg (1)
where Φ is the velocity-induced phase shift and V is the velocity component of the nuclear spin parallel to the applied magnetic field gradient.
The effect of a velocity-encoding magnetic field gradient pulse on a body of stationary spin magnetization is shown in FIGS. 4a-4c. For the purpose of illustration, only vectors corresponding to the transverse magnetization of two spins at different positions in the direction of the applied velocity-encoding gradient are shown. After the generation of transverse spin magnetization by an RF pulse, all the spins have the same phase and can be represented as a single vector 400 at time t=0, as shown in FIG. 4a. At time t=a, however, each spin has acquired a phase shift which is directly proportional to its position along the magnetic field gradient, as shown in FIG. 4b. These individual vectors 410, 420 arise from spins which do not change position and thus, when second gradient pulse, 310 of FIG. 3a, is applied the phase shifts generated by first gradient pulse, 300 of FIG. 3a, are exactly cancelled by the second gradient pulse, 310 of FIG. 3a. Consequently, the phase shifts at time t=c for each spin is identical, and the two vectors coincide and are represented as a single vector 430 in FIG. 4c. The phase shift at time t=c is substantially identical to the phase shift found at time t=0.
The effect of a velocity-encoding magnetic field gradient pulse on a body of moving spin magnetization shown in FIGS. 5a-5c differs from that on a body of stationary spin magnetization shown in FIGS. 4a-4c. For the purpose of illustration, only vectors corresponding to the transverse spin magnetization of two spins traveling at the same velocity, but at different positions in the direction of the applied velocity-encoding gradient, are shown. After the generation of transverse spin magnetization by an RF pulse, all the spins have the same phase and can be represented as a single vector 500 at time t=0, as shown in FIG. 5a. At time t=a, however, each spin has acquired a phase shift which is directly proportional to its position along the magnetic field gradient as shown by vectors 510, 520 in FIG. 5b. These individual vectors arise from spins which change position with time and thus, when the second gradient pulse is applied, the phase shifts generated by the first pulse are not entirely cancelled by the second gradient pulse. Consequently, the phase shift at time t=c, represented by the single vector 530 as shown in FIG. 5c, differs from the phase shift found at time t=0 by an amount Φ. This phase shift is directly proportional to velocity V of equation 1.
FIG. 6 is a pulse sequence diagram of radio frequency (RF) pulses and magnetic field gradients employed in a first embodiment of the present invention which may be executed by the MR imaging system of FIGS. 1 and 2. Pulse sequence 600 is comprised of a excitation RF pulse 630 which is applied in the presence of a slice selective magnetic field gradient pulse 640. Excitation pulse 630 nutates spin magnetization in a selected portion of the subject. The amount of nutation can be selected by selecting the duration and amplitude of detection pulse 630. The location and size of the selected portion can be adjusted by appropriate selection of the frequency and bandwidth of RF pulse 630 and the amplitude of slice selective magnetic field gradient pulse 640.
After the excitation RF pulse 630 and slice selective magnetic field gradient pulse 640 are applied, a slice refocusing magnetic field gradient pulse 650 is applied. Slice refocusing gradient pulse 650 has an amplitude and duration which is selected to cause all transverse spin magnetization within the selected portion of the subject to be substantially in phase after the application of slice refocusing gradient pulse 640. In the present embodiment the product of the amplitude and duration of slice refocusing gradient pulse 650 is substantially half that of the negative of the product of the amplitude and duration of slice selective gradient pulse 640 in a manner well known to those skilled in the art.
After excitation RF pulse 630 and slice selection gradient pulse 640 have been applied, a bipolar velocity-encoding magnetic field gradient pulse is applied in a selected direction. The velocity-encoding pulse consists of a first velocity-encoding magnetic field gradient pulse lobe 655a and a second velocity-encoding magnetic field gradient pulse lobe 655b. The product of the pulse duration and amplitude of second velocity-encoding pulse lobe 655b is substantially equal to the negative of the product of the pulse duration and amplitude of the first velocity-encoding pulse lobe 655a as described in FIG. 3.
Successive application of first velocity-encoding pulse lobe 655a and second velocity-encoding pulse lobe 655b to transverse spin magnetization causes a phase shift in the magnetization which is proportional to the velocity component of the magnetization parallel to the direction of the velocity-encoding magnetic field gradient. This phase shift can be used to distinguish moving from stationary transverse spin magnetization.
After excitation RF pulse 630 and slice selection gradient pulse 640 have been applied, a phase encoding magnetic field gradient pulse 660 of a selected amplitude is applied. Phase encoding gradient pulse 660 is applied in a direction substantially orthogonal to slice selective gradient pulse 640 and can be applied simultaneously with slice refocusing pulse 650 if desired. For the sake of clarity, phase encoding pulse 660, velocity-encoding pulses 655a, 655b and slice refocusing pulse 650 are not shown to be simultaneous in FIG. 6, but it is possible to apply combinations of these pulses simultaneously.
After excitation RF pulse 630 and slice selective gradient pulse 640 have been applied, a readout dephasing magnetic field gradient pulse 670 of a selected amplitude is applied. Readout dephasing gradient pulse 670 is applied in a direction substantially orthogonal to both slice selective gradient pulse 640 and phase encoding pulse 660. Readout dephasing pulse 670 can be applied simultaneously with either slice refocusing pulse 650 or phase encoding pulse 660 if desired. Readout dephasing pulse 670 causes transverse magnetization at different positions along the direction of the readout dephasing magnetic field gradient to obtain phase shifts which are proportional to position in the readout direction.
Following the application of slice refocusing pulse 650, phase encoding pulse 660 and readout dephasing pulse 670, a readout magnetic field gradient pulse 680 is applied. Readout pulse 680 is applied in the same direction as readout dephasing pulse 670, but is given the opposite polarity. The amplitude and duration of readout pulse 680 is selected so that substantially all transverse spin magnetization has an identical phase shift at a selected point during readout pulse 680.
Substantially simultaneously with the application of readout pulse 680, a data acquire signal pulse 690 is sent to a data acquisition subsystem which is part of the imaging system. MR response signals are digitized during data acquire pulse 690. Since the MR response signals coming from resonant nuclei within the selected portion of the subject are acquired during readout magnetic field gradient 680, each detected MR response signal will have a frequency which is proportional to the location of the resonant nuclei which generated said signal. The location of each signal source can be determined by applying a Fourier transformation to the acquired signal data in a fashion well known to those skilled in the art.
In the present invention pulse sequence 600 is repeated a plurality, N, times to form a single frame of data which has sufficient information to permit the measurement of at least one component of shear rate. The acquisition of a frame is repeated a plurality, Y, times. In each frame acquisition, phase encoding pulse 660 is given a different amplitude. Phase encoding pulse 660 causes phase shifts in the detected MR signals which are proportional to the position of resonant nuclei giving rise to transverse spin magnetization along the direction of phase encoding magnetic field gradient 660. Data acquired responsive to different amplitudes of phase encoding gradient 660 can be Fourier transformed to give the position (in the direction of phase encoding gradient 660) of the resonant nuclei producing transverse spin magnetization in a manner well known to those skilled in the art.
In a first embodiment of the present invention, each frame consists of N=4 applications of pulse sequence 600. In the first application, velocity-encoding gradient pulses 655a, 655b are applied with a selected polarity. This causes the phase of the transverse spin magnetization to be proportional to velocity. The phase of each portion of transverse spin magnetization, however, will also have contributions from sources other than velocity. These sources may include transmitter offsets, chemical shift effects and eddy currents.
In order to remove contributions from all components other than velocity, pulse sequence 600 is applied a second time and a second set of MR response signals is acquired. The RF and magnetic field gradient pulses of the second application are identical to that of the first with the exception of first velocity-encoding pulse lobe 655a and second velocity-encoding pulse lobe 655b. In their place a third velocity-encoding pulse lobe 655c followed by a fourth velocity-encoding pulse lobe 655d are applied. Third and fourth velocity-encoding pulse lobed 655c, 655d are identical to first and second velocity-encoding pulse lobes 655a, 655b respectively, except that they have opposite polarity. The MR response signal set collected from the first application is then subtracted from MR response signal set collected in the second application to result in a first difference set. Phase shifts induced by the third and fourth velocity-encoding gradient lobes have opposite polarity relative to the phase shifts induced by the first and second velocity-encoding gradient lobes.
When the phase of the MR response signal set acquired from the first application of pulse sequence 600 is subtracted from the phase of the MR response signal set acquired responsive to the second application of pulse sequence 600, phase contributions from all non-velocity sources are substantially canceled, leaving only a phase shift arising from velocity. This phase shift is directly proportional to velocity and can be used to quantify velocity.
A third and fourth application of pulse sequence 600 are then performed in a manner identical to that of the first and second application, respectively, with the exception that the center of the field-of-view is shifted in a selected direction by a selected amount, D, which is described later. A second difference set is generated from a third and fourth application of pulse sequence 600. Shear rate information, which is defined as the changes in velocity with respect to the direction of the field-of-view shift, can be calculated by computing the differences of the phases of the first and second difference sets as illustrated in FIG. 7. It should be noted that the shift in the center of the field-of-view can be less than the size of a single pixel in the final image.
The direction selected for shifting the center of the field-of-view determines how pulse sequence 600 will be modified in the third and fourth applications. If the selected direction is parallel to the direction of the slice selection gradient pulse 640, the field-of-view shift is performed by changing the frequency of both the transmitter 3 and receiver 10 of the MR imaging system of FIG. 1 by an amount F which is determined by the gyromagnetic ratio of the nuclear spins and the strength of slice refocusing gradient pulse 650. If the selected direction is parallel to the direction of the readout gradient pulse 680, the field-of-view shift is performed by changing the frequency of either the receiver 10 or the transmitter 3 by an amount F' which is determined by the gyromagnetic ratio of the nuclear spins desired to be imaged, the data acquisition rate and the strength of the readout gradient pulse 680. If the selected direction is parallel to the direction of the phase encoding gradient pulse 660, a phase shift is added to the phase of the transmitter. This phase shift is incremented by an amount P for each of the Y increments of phase encoding gradient pulse 660. The incremental phase shift P is determined by the gyromagnetic ratio of the nuclear spins, the field-of-view and Y and is directly proportional to the product of the amplitude and duration of phase encoding gradient pulse 660.
The modifications to pulse sequence 600 which are required to perform changes in the center of the field-of-view are summarized in Table 1. Note that shifting the field-of-view center can only be performed in a single desired direction for each frame. Consequently, if all components of shear rate are to be measured, frames for each of three velocity directions must be measured with respect to each of three orthogonal spatial dimensions, for a total of nine measurements. Since each frame in the present embodiment requires four repetitions of pulse sequence 600, a total of 9×4=36 repetitions of pulse sequence 600 are required to measure all components of shear rate.
TABLE 1______________________________________ Flow Slice Select Readout Phase EncodingApplication Encoding Shift Shift Shift______________________________________1 655a, 655b 0 0 02 655c, 655d 0 0 03 655a, 655b F F' P4 655c, 655d F F' P______________________________________
In a second embodiment of the current invention, the detection of orthogonal components of velocity are multiplexed to more efficiently acquire all components of shear rate. Using a Hadamard multiplexing scheme it is possible to obtain quantitative information for all three velocity vector components at a selected field-of-view offset with only four applications of pulse sequence 600. All shear rate components can then be determined by collecting additional MR response signals responsive to field-of-view shifts in the slice select, readout and phase encoding directions. Such a scheme requires only 4×4=16 applications of pulse sequence 600. One embodiment of such a scheme is given in table 2. Here "+" denotes the application of first and second velocity-encoding pulses 655a, 655b and "-" denotes the application of third and fourth velocity-encoding pulses 655c, 655d. In this embodiment applications 1-4 are used to obtain the three-mutually orthogonal velocity vectors for the unshifted field-of-view, applications 5-8 are used to obtain the three-mutually orthogonal velocity vectors for the MR response signal set shifted in the slice select direction, applications 9-12 are used to obtain the three-mutually orthogonal velocity vectors for the MR response signal set shifted in the readout direction, and applications 13-16 are used to obtain the three-mutually orthogonal velocity vectors for the MR response signal set shifted in the phase encoding direction. After Hadamard demultiplexing of individual components of velocity, shear rate images with respect to the slice select direction can be obtained by subtracting the MR response signal set acquired in applications 1-4 from the MR response signal set acquired in applications 5-8. Likewise, shear rate images with respect to the readout direction can be obtained by subtracting the MR response signal set acquired in applications 1-4 from the MR response signal set acquired in applications 9-12 and shear rate images with respect to the phase encoding direction can be obtained by subtracting the MR response signal set acquired in applications 1-4 from the MR response signal set acquired in applications 13-16.
TABLE 2______________________________________ SliceApplica- Flow Encoding Select Readout Phase-tion SS RO PE Shift Shift encoding Shift______________________________________ 1 + + + 0 0 0 2 - - + 0 0 0 3 - + - 0 0 0 4 + - - 0 0 0 5 + + + F 0 0 6 - - + F 0 0 7 - + - F 0 0 8 + - - F 0 0 9 + + + 0 F' 010 - - + 0 F' 011 - + - 0 F' 012 + - - 0 F' 013 + + + 0 0 P14 - - + 0 0 P15 - + - 0 0 P16 + - - 0 0 P______________________________________
While several presently preferred embodiments of the novel MR shear rate imaging method have been described in detail herein, many modifications and variations will now become apparent to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and variations as fall within the true spirit of the invention. | A shear rate imaging method uses magnetic resonance to detect the distribution of velocities within a subject. Distributions are measured responsive to at least two different field-of-views. Differences of the velocity distribution obtained with one field-of-view and the second field-of-view are computed to give a component of shear rate. The method can be used to obtain velocity measurements in any of three mutually orthogonal directions responsive to field-of-view shifts in as many as three mutually orthogonal directions to give a total of nine shear rate components. Data for each component can be acquired independently or data acquisition can be multiplexed to reduce data acquisition requirements. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. provisional application Ser. No. 60/882,275, filed Dec. 28, 2006, which is incorporated herein in its entirety.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to a water dispenser. The water dispenser may be included in a household water faucet or within a household refrigerator. In particular, the water dispenser preferably includes a light source where the light shines into a stream of water or a column which is produced by the water dispenser. In this manner, the water column appears to glow from within.
[0003] Currently, water dispensers for use in common household applications dispense clear or white (aerated) streams of water. Using any of these dispensers at night, or in the dark, could cause unnecessary spills or wasted water. Therefore, it is desirable to provide a water dispenser that illuminates the column or stream of water being dispensed to minimize the amount of wasted water.
[0004] Consumers who have purchased a refrigerator with a built-in water dispenser frequently use the water dispenser. Typically, the water dispenser is provided with a light source above the water dispensing tube that illuminates the entire area where the consumer places a glass to be filled. The general area is illuminated so that the consumer can see where to put the container to be filled with water. The water column itself is not illuminated. Since the typical water column produced by a water dispenser in a refrigerator is not aerated, the water column appears clear. Illuminating the entire area where the consumer typically places the glass makes the clear water column difficult to see. This may have the unfortunate result of causing spills or unnecessarily wasting water. Therefore, it is desirable to illuminate the water column itself instead of the general area of the dispenser and highlight where the consumer should place the glass or container to be filled with water.
[0005] Refrigerators with ice makers and/or water dispensers often have water filters to assist in purifying water. Many household water supply systems have similar filtration systems. The water filters in these systems require periodic replacement. To assist in maintaining the refrigerator, it would be beneficial if the refrigerator could tell the consumer when to replace the water filter. It is therefore desirable to have a system that alerts the consumer to change the water filter at a location frequently used by the consumer.
[0006] Leaks may also occur in water supply systems. Unfortunately, leaks are often difficult to detect. Unless the leak is relatively large, it may go on for some time before being addressed. It is desirable to have a system that can notify a consumer of a leak in their system and to have the notification occur in a location that is convenient for the consumer.
[0007] The water supplied may also vary in temperature. Unfortunately, many of today's faucets have a single lever or knob that is used to control the temperature of the water being dispensed. Because extremely hot water can be dangerous, it would be desirable if a second indicator could be used to tell the consumer whether the water being dispensed is hot or cold.
[0008] What is needed is an improved appliance or faucet for addressing these problems.
BRIEF SUMMARY OF THE INVENTION
[0009] Therefore, it is a primary object, feature or advantage of the present invention to improve upon the state of the art.
[0010] It is a further feature of the present invention to provide a water dispensing nozzle or faucet which illuminates a column of water produced by the nozzle or faucet.
[0011] It is still a further feature of the present invention to provide a nozzle or faucet in which the color of the light illuminating the water column may be changed.
[0012] Another feature of the present invention is to provide a water nozzle or faucet which may change the color of the light illuminating the water column to indicate a change in condition.
[0013] Yet another feature of the present invention is to provide an appliance, such as a household refrigerator, which includes a water dispensing feature wherein the water dispenser illuminates the column of water dispensed.
[0014] A further feature of the present invention is to provide an appliance, such as a household refrigerator, which includes a water dispensing feature wherein the water dispenser illuminates the column of water to be dispensed and may change the color of the column of water to be dispensed.
[0015] A further feature of the present invention is to provide an appliance, such as a household refrigerator, which includes a water dispensing feature wherein the water dispenser illuminates the column of water to be dispensed and may change the color of the column of water to be dispensed to indicate a change in condition.
[0016] One or more of these and/or other objects, features or advantages of the present invention will become apparent from the specification and claims that follow.
[0017] According to one aspect of the present invention, a water dispenser is provided. In one embodiment, the water dispenser is provided as a household faucet. This household faucet includes a nozzle which is in fluid communication with a water supply line. When operated, the nozzle dispenses a column of water. The faucet also includes a light source which is secured within the faucet to illuminate the column of water when dispensed. The light source may be turned on at any time, with or without the water running, to indicate where the water faucet is pointed. Preferably, the light source is located within the faucet so as to shine within the water stream that results in the water column. The light source secured within the faucet is preferably able to change the color of the light emitted.
[0018] A controller or processor is also preferably connected to the light source. The controller or processor indicates when the light source should be operated. Operation of the light source is preferably done only when the faucet is dispensing water, but may be done at any time. The controller or processor may also dictate what color of light is emitted from the light source. This color choice may be selected by the consumer based on the consumer's preference or may be selected by the processor to indicate a change in condition of the faucet or associated systems. This change in condition can be relayed to the processor or controller through one or more sensors.
[0019] Another embodiment of the present invention includes a typical household refrigerator with a built-in water dispenser. A refrigerator cabinet including a door secured to the cabinet is provided. A dispensing unit may be secured either to the door or to the interior of the refrigerator cabinet. The dispenser unit includes a water supply line, a nozzle in fluid communication with the water supply line and a light source secured within the dispenser. When the nozzle dispenses a column of water, the light source secured within the dispenser unit illuminates the column of water. This household appliance may also include a light source that changes color.
[0020] A processor is preferably connected to the light source and the dispenser unit. When the dispenser unit is activated, the processor tells the light source to turn on. Alternatively, the light source may be operated at any time to tell the consumer where to place their glass within the dispenser unit. The processor may also tell the light source to change color. The change in color may be dictated by either the consumer's preference or by a change in condition. For example, when the temperature of the water changes from hot to cold, the processor can control the color of the water column by changing the color of the light source from red to blue. Thus, the change in color indicates the temperature of the water has changed. Other conditions such as the water filter status may also be monitored.
[0021] According to another aspect of the present invention, a method for illuminating a column of water is provided. The method includes running water through a water dispenser including a nozzle. A column of water is formed and a light source in the water dispenser shines into the column of water. By shining the light source into the column of water, the column of water is illuminated. The method may further include changing the color of the illuminated column of water. The change in color of the illuminated column of water can be done to indicate either the consumer's preference or a change in condition.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is front view of an exemplary refrigerator according to one embodiment of the present invention.
[0023] FIG. 2 is a block diagram showing fluid connections in a typical household refrigerator.
[0024] FIG. 3 is a cross sectional view of a water dispenser associated with a household refrigerator according to one embodiment of the present invention wherein the water dispenser is shown in the off position.
[0025] FIG. 4 is a cross sectional view of a water dispenser associated with a household refrigerator according to one embodiment of the present invention wherein the water dispenser is shown in the on position.
[0026] FIG. 5 is a block diagram of electrical connections according to one embodiment of the present invention.
[0027] FIG. 6 is a perspective view of a faucet according to one embodiment of the present invention.
[0028] FIG. 7 is a cross-sectional view of a faucet according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0029] The present invention will now be described as it applies to its preferred embodiment. It is not intended that the present invention be limited to the described invention. It is intended that the invention cover all modifications and alternatives which may be included within the spirit and scope of the invention.
[0030] Now, referring to the drawings, FIG. 1 illustrates a typical household refrigerator 10 . The household refrigerator is shown in a side by side arrangement. This means that the refrigerator compartment 16 is on one side of the refrigerator and the freezer compartment 14 is on the other side of the refrigerator. Other layouts of the freezer compartment 14 and refrigeration compartment 16 may be used. For example, the freezer compartment 14 may be located on the bottom of the cabinet 12 while the refrigeration compartment 16 is located within the upper portion of the cabinet 12 . Alternatively, the refrigerator 10 may consist entirely of one or more refrigerator compartments. The refrigerator 10 may also consist entirely of one or more freezer compartments. Any arrangement is acceptable for the present invention.
[0031] As shown in FIG. 1 , a refrigerator 10 includes a refrigerator compartment door 20 and freezer compartment door 18 , which are secured to the refrigerator cabinet 12 . Typically, an ice and water dispenser unit 22 is included within the freezer compartment door 18 . This is typically done by mounting the dispenser housing 26 on the upper half portion of the freezer compartment door 18 . Alternatively, the ice and water dispenser unit 22 may be located within the refrigerator compartment door 20 . If only a water dispenser unit is employed, the water dispenser unit may be located within the cabinet 12 . A water filter 48 is typically located in a water filter housing 50 which is mounted in a convenient location.
[0032] As shown in FIG. 2 , water is provided to the ice/water dispenser unit 22 through a water supply line 30 . The water supply line 30 preferably sends water to an internal water reservoir 40 that may be located within the refrigerator compartment 16 or in any other desired location within the cabinet 12 . Within the water reservoir 40 , the water may be chilled or heated, depending on the desired use. Preferably, a water filter 48 is also included. The water filter 48 may be located anywhere within the water fluid circuit so long as water is filtered prior to dispensing. For example, the water filter 48 may be located before the water reservoir 40 so that filtered water is stored in the water reservoir 40 .
[0033] As shown in FIG. 2 , unfiltered water is stored in the water reservoir 40 . This unfiltered water then travels through the water filter 48 until it reaches the water valves 38 that control when and where the water dispensed. If an ice maker 24 is included, dual valves 38 may be employed to provide water to the ice maker 24 and also to a water dispenser 25 when necessary. The water dispenser 25 is shown in more detail in FIGS. 3 and 4 .
[0034] As shown in FIGS. 3 and 4 , the dispenser unit 22 includes a dispenser housing 26 that defines a well or cavity into which the consumer places a glass 54 . An actuator or button 28 is typically provided on the interior of the well to allow a consumer to activate the system by pushing their glass against the actuator 28 . Alternatively, and as shown, actuators 28 may be located both on the interior of the well and on the outer surface of the dispenser housing 26 . The actuator 26 turns the system on and a nozzle 32 provides a water column that is directed into the consumer's glass 54 . Such a water dispenser provides a convenient way for consumers to obtain chilled water quickly.
[0035] For example, water from the water reservoir 40 may be chilled within the refrigerator compartment 16 . When the consumer places a glass 54 into the dispenser unit 22 and activates the button 28 , the processor or controller 36 is sent a signal. Operation of the button 28 , which may be a mechanical or electrical switch or another type of sensor, typically completes an electrical circuit between a source of power and a solenoid operated valve 38 connected to the water supply or water reservoir 40 . When the solenoid valve 38 is opened, pressure in the water reservoir 40 forces water through the water supply line 30 and into the nozzle or spout 32 . After traveling to the nozzle 32 , the water is dispensed as a column 52 of water into the consumer's glass 54 .
[0036] Preferably, a light source 34 is also located within the ice/water dispenser unit 22 . The light source 32 is placed within the water dispenser in a manner such that it illuminates the column of water produced by the dispenser nozzle 32 . For example, the light source 32 is placed to shine light in the direction of flow of the column of water. The use of a mirror or other path altering device such as a prism or lens is acceptable. Alternatively, the body of the dispenser nozzle 32 may be made of a transparent or semi-transparent material, such as clear plastic or glass, to allow for some of the light produced by the light source 34 to shine through the dispenser nozzle 32 .
[0037] Preferably, the light source is a super bright light emitting diode “LED”. Other possible light sources include an organic light-emitting diode “OLED,” a polymer light-emitting diode “PLED,” an incandescent light source, a laser light source, a xenon light source, a halogen light source, an electroluminescence panel, or any type of solid state illumination device. An LED typically consumes less energy then some other types of light sources. LEDs also come in multiple colors or color changing varieties.
[0038] The light source 34 is preferably located within the nozzle 32 to shine within the water stream that produces the water column 52 . Alternatively, the light source 34 may also be located outside of the water stream that produces the water column 52 so long as it shines on the column. The water column 52 is produced by allowing the water to flow under pressure in a state of free fall. The light produced by the light source 34 reflects off of the water/air interface causing the light to be partially reflected back into the water column 52 . In this manner, the water column 52 acts as a light pipe and it appears as if the light is coming from the water column 52 .
[0039] Any color of light can be used. An additional feature of the preferred embodiment allows the consumer to select the color of their desired water column 52 . The selection of the color of the water column 52 can be made by the consumer providing their preference by making a selection on the display 46 . The display 46 is preferably a touchscreen display. Alternatively, the display 46 may be a screen that presents options next to buttons external to the display 52 . Once the consumer has made their selection, the choice is sent to the processor or controller 36 . The processor 36 uses the consumer's input to determine which color of light to have the light source 34 provide.
[0040] In the example of an LED light source 34 , the processor 36 sends a signal to a driver or micro controller (which may be incorporated as part of the overall processor or controller 36 ). The driver may control a number of individually colored LEDs or a bi-color or multi-color LED. Alternatively, the color may be changed by shining the light through a colored lens or other colored and transparent material such as a color wheel. When the signal is received, the desired color is produced.
[0041] Alternatively, the color of the light source 34 may be changed to indicate something other than the consumer's preference. For example, the color of the light source 34 may be changed to indicate a change in a condition. In the refrigerator water and ice dispenser, the change in condition can be that a sensor indicates it is time to change the water filter. Many refrigerators include a filter sensor 42 as shown in FIG. 5 . The filter sensor 42 may be a timer or flow rate sensor that provides an indication of the filter's use to the processor 36 . If the filter use has exceeded the set criteria, the processor 36 can send a signal to the driver and change the color of the light source 34 .
[0042] Similarly, the color of the light source 34 can change to indicate a leak in the overall system. Moisture sensors alert the processor when moisture is detected. In this manner leaks can be detected before they have filled a portion of the refrigerator cabinet 12 and progressed onto the floor of the consumer's home. For example, if the moisture sensor (not shown) detects a leak, it sends a signal to the processor 36 which sends a signal to the driver to change the color of the light source 34 from white to red, alerting the consumer to a problem with the system.
[0043] Alternatively, the light source 34 can also indicate the temperature of the water being dispensed. For example, when a temperature sensor 44 is included in the system and a hot water reservoir is included, the color of the light source 34 can be set to red to indicate hot water is being dispensed. When cold water is being dispensed, the color of the light source 34 can be set to blue. These color settings are merely exemplary.
[0044] FIG. 6 shows another embodiment of the present invention. As shown, a faucet 56 is provided with a water supply line 30 , a nozzle 32 , a light source 34 and a processor or controller 36 . Power is supplied to the faucet 56 through either a plug-in cord arrangement or through a battery (not shown). As previously indicated, the light source 34 operates at least when the faucet 56 is dispensing water and illuminates the column of water 52 produced by the nozzle 32 . The light source 34 may change color as previously discussed.
[0045] FIG. 7 shows a cross-sectional view of the faucet 56 discussed above. Preferably, the light source 34 is a 3 mm LED. The nozzle 32 and/or the faucet 56 may be clear or semi-transparent. This allows the faucet 56 to appear to glow when in operation, thus improving the chances that consumers will not inadvertently leave the water running. As shown in FIG. 7 , a lens may be used in between the light source 34 and the column of water 52 produced by the nozzle 32 . The lens 58 may be plastic, glass or any other type of transparent or semi-transparent material. The lens 58 may be colored or clear. The lens 58 may be concave, convex or without any curvature and may be formed as a separate piece or integrally with one or more parts of the faucet 56 . The curvature of the lens 58 will depend on the area in which the light is desired. Preferably, the lens 58 focuses the light from the light source 34 to project a 1-inch diameter spot onto a surface 10 inches from the light source 34 .
[0046] When the water is not running in either the faucet 56 or the ice/water dispenser unit 22 , the light source 34 may still be turned on. This will cause the light source 34 to shine light into an area where water would flow. For example, the context of the ice/water dispenser unit 22 , the light source 34 would shine light into a spot within the ice/water dispenser unit 22 to indicate to the consumer where the glass should be placed prior to turning on the water.
[0047] A general description of the present invention as well as a preferred embodiment of the present invention has been set forth above. Those skilled in the art to which the present invention pertains will recognize and be able to practice additional variations in the methods and systems described which fall within the teachings of this invention. Accordingly, all such modifications and additions are deemed to be within the scope of the invention which is to be limited only by the patent claims. | A water dispenser including a light source that shines into a column of water produced by a nozzle is disclosed. The nozzle may be opaque, clear or semi-transparent. The water dispenser may be located in a household faucet, a refrigerator or any other appliance. The light source may vary in color to indicate either a consumer preference or a change in condition. The color selected may be controlled by a processor that is operatively connected to a display and/or one or more sensors. When in use, water is run through the nozzle to form a column. The light source shines into the column of water and may change color to indicate a preference or a change in condition. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] The present invention refers to a process and a composition, containing latex, for the manufacturing of rubbery tissue sheets. The process of the present invention consists of the following steps: formulation of the composition, consecutive impregnation and smoking cycles; and maturation.
[0003] Also, it is part of the scope of the present invention, a impregnation composition which is essentially an aqueous solution comprising latex, a sulfur source and a vulcanization accelerator.
[0004] The rubbery tissue sheets obtained by the present invention can be submitted to the manufacturing of: suitcases, bags, purses, travelling bags, clothes, diaries, wallets, shoes and other objects usually made of leather.
[0005] 2. Prior Art Description
[0006] The conditioning of the latex extracted from the rubber trees started on the beginning of the last century in Brazil. On 1935, Brazilian Patent Document BR 23.282 described a device and a process for the manufacturing of artificial leather by impregnation of a nucleus of fiber material with liquids containing latex. The nucleus was compressed and decompressed alternatively and constantly during the impregnation, in order to guarantee that the impregnation would be complete on both sides of the fiber material. The device described was able to impregnate the fiber material in its both sides, making an effort of pressure, for the maximum absorption of the latex containing composition by the fiber material.
[0007] The physicochemical properties of rubbery tissue obtained by the above mentioned process were not acceptable, and there were no prior concern regarding the formulation used on the impregnation. The specification only mentions the use of a chemical composition containing latex, coloring agents, coagulation salts, vulcanization accelerators and solid substances, including sulfur. Also, no proportions or concentration ranges were defined. The proportions and amounts of the mentioned components influences on the quality properties of the rubbery tissue, therefore being fundamental for the process.
[0008] The Patent Application U.S. Pat. No. 3,524,792 of Apr. 1, 1963, describes a material similar to leather, with plastic and elastic properties, and the process of manufacturing the same. The material has a practical application on the shoemaking field, for example, where a section inserted on the top of the shoe, with a porosity that makes it permeable to air and humidity, obtaining an appearance similar to leather. The method consists on the impregnation of an interlaced raw rubber tissue with latex from a thermoplastic synthetic resin selected from the acrylic an vinyl polymers, immerging the tissue at room temperature and pressure during 5 to 6 seconds. Therefore, the tissue absorbs the impregnation solution.
[0009] The above mentioned invention is an advance towards the proper formulation of the impregnation composition, although the tissue is still impregnated on both sides and there are no concern regarding the quality of the finished product.
[0010] The Patent Application GB 1,251,829 of Dec. 19, 1968, describes a tissue adequate for use as a substitute for leather comprised by a fiber cloth, wherein most of the fibers are made of synthetic organic polymeric material. Collagen particles, linked to the cloth by synthetic polymeric linking agents or non-interlaced natural rubber, are uniformly spread. The leather is obtained by the impregnation of the cloth containing collagen with a polymeric linking agent, followed by heating of the impregnated cloth until coagulation and vulcanization or cure, if necessary.
[0011] The main concern on the patents filed on the 70s was the formulation used in the rubbery process. The Patent Application GB 1320547 of Jul. 13, 1970 describes a substitute for leather and method for manufacturing thereof. The method comprises the formation of a sheet from a slurry made of cellulose fibers and water. The sheet was saturated with aqueous polyurethane latex, containing anionic groups capable of forming salts and an urea aqueous solution.
[0012] The Patent Application U.S. Pat. No. 3,985,929 of Nov. 1, 1974, describes a tissue for the shoemaking industry. The non interlaced tissue is impregnated with a polymer prepared by the polymerization of acrylic or metacrylic acid with polyethylene oxide to improve the absorption.
[0013] The Patent Application BR 8903532-1 of Jul. 18, 1989 was an advance in the state of the art in that period, teaching a process for the fabrication of rubbery tissue with elastic properties and the resulting product thereof. This process consists of the fabrication of a rubbery tissue characterized by the use of pure natural rubber (latex), mixed with accelerators and chemical products, forming a paste. The paste is left for “rest” and is passed through a mixer, heated and taken to a calender, where it is laminated. The resulting blanket is applied by calendering over a tissue net, which is taken to an autoclave for vulcanization.
[0014] The Patent Application CN 93104820.6 of Apr. 4, 1993 describes a rubbery tissue material used on shoemaking. The process is comprised by 7 steps: (a) injection of raw material; (b) compensation; (c) pressurization; (d) flooding and filter pressing; (e) sulfured drying; (f) rolling, planning and labeling; and (g) rounding. The flooding fluid is a mixture of adhesives and coloring agents on the following proportions: 25% natural latex at 60%, 15% of styrol at 30%, 15% of coloring agent and 55% emollient. One of the steps of the manufacturing is flooding, where the tissue is immersed in a “V” shaped conductor and is submitted to pressure.
[0015] In the same year, The Patent Application BR 9304882-3 of Nov. 30, 1993 had improved the process of manufacturing a rubbery tissue. The tissue was successively impregnated with ammonia or caustic soda treated latex, and mixed with a solution containing a sulfur emulsion, an acrylic linker, a silicon based softener, a carbopol based thickening agent, an emulsifier, antioxidant agent, an anti ultraviolet agent and an anti ozonizating agent; all diluted in 1 L of water. Following the impregnation phase, the tissue is immediately exposed to smoke. These operations are done alternatively and repeatedly 5-10 times. After that, the tissue is exposed to solar light and is left to “rest” in the shadow or in a dry oven for drying, with all the superficial impurities and dirty being removed by the application of colorless liquid wax followed by the application of liquid silicon for polishing the material. After this last step, the material is ready for manufacturing the desired articles. This particular process presented a substantial advance compared to the others mentioned above, specially the BR 8903532-1, as the coagulation of the latex on the tissue happened during the and lamination phases.
[0016] The Patent Application BR 9400148-0 presents a smoking step very similar to the described on the Patent Application BR 9304882-3. This process is comprised of the extensive exposition of rubbery tissue with smoked latex to heat and smoke; conditioning for 24 hours in the oven, followed by heat exposure for 3-24 hours on the oven.
[0017] The Patent Application BR 9402908-3 of Jul. 22, 2001 was an improvement of the Patent Application PI9304882-3, describing a process comprising the following steps: addition of the latex extracted from rubber trees, 10%potassium hydroxide solution, at a proportion of 0.4% solid by the rubber dry weight on latex and a vulcanization solution; homogenization; sieving; heating of the mixture for using in consecutive impregnation applied to the tissue; curing; exposition to oven; and drying of the final product.
[0018] Despite the impregnation formulations had suffered improvements throughout the years, the majority of the above mentioned patent applications did not have a prior concern related to the quality of the rubbery tissue produced, especially regarding esthetic and superficial properties of the material. The rubbery tissue technology was applied for the manufacturing shoes or plastic bags.
[0019] The people skilled in the art knows that the properties of the mentioned rubbery tissue are direct influenced by the process of manufacturing, especially the tissue impregnation with the latex solution or polymeric mixture and, as a consequence, the impregnation solution used.
[0020] As far as, the rubbery tissue is obtained by a specific process, which can be differentiated of the “in natura” known latex bag waterproofing procedure, practiced by the Amazon rubber tree tapers, only by the addition of caustic soda to the latex, after collecting it, followed by addition of a chemical formulation, generally composed by sulfur emulsion in water, acrylic linker, silicon based softener, Carbopol based thickening agent and antioxidant.
[0021] The rubbery tissue obtained presents a variable thickness of the latex sheath, tending to be thinner on the top of the bag and thicker at the opposite edge. The color varies from dark yellow to dark brown. A strong mold odor remains on the polished product, due to the favorable conditions for mold development on the manufacturing process. In addition to that, the rubbery tissue presents several superficial imperfections such as: clot particles, blisters, holes, sheath separation, drippings, etc. Regarding the results on environmental conditions and accelerated artificial aging process such as: heat, light, oxygen and ozone, the product presents: sticking, parching, splitting, etc.
[0022] Due to the negative aspects related to the performance of the rubbery tissue obtained using the prior art, specially for using on the manufacturing of shoes, bags, purses and clothes, caused by the inadequate process of production, the applicant of the present invention has developed a new and surprising improvement on the process, comprising a process as a whole since (a) collecting and preservation of latex or, alternatively the use of synthetic latex or other vulcanization compound; (b) preparation of the impregnation solution with all the necessary elements for curing and protection against rubber degradation; (c) impregnation technique and latex application and coagulation from the curing; (d) previous drying and curing; (e) seepage and final drying; (f) finishing and packaging.
[0023] The present invention provides a solution to the technical problem by means of a process and composition for obtaining a rubbery tissue presenting a constant thickness, homogeneous coloring, and improved chemical and physical properties, providing a superior quality of the final product. The rubbery tissue obtained by the aforesaid process does not present neither superficial imperfections nor instability related to adverse environmental conditions.
[0024] Therefore, the material obtained by the present invention presents superior quality compared to rubbery tissues manufactured by the prior art processes and can be used in broad manufacturing applications, such as: bags, suitcases, diaries, notebooks, clothing, etc.
BRIEF DESCRIPTION OF THE INVENTION
[0025] The present invention is comprised by a process for obtaining a rubbery tissue comprising the following steps:
[0026] (a) fixation of the impregnable material in a support;
[0027] (b) treatment of the external surface of the impregnable material;
[0028] (c) formulation, pH adjustment, homogenization under heating and filtration of the impregnation composition;
[0029] (d) impregnation, using the impregnation composition, of the external surfaces of the impregnable material, assuring that the said material absorbs the said composition;
[0030] (e) smoking of the impregnable material;
[0031] (f) submitting the external surface of the material thereof to successive cycles of impregnation and smoking; and
[0032] (g) maturating the material thereof under temperature range of 50-100° C.
[0033] The extraction and collection of the natural latex from the rubber trees as well as the stabilization, can be done before the above mentioned steps. Alternatively, latex from chemical compound, for example, polymeric or synthetic vulcanization latex can be used, conferring the desirable properties for the final product.
[0034] Also, other steps can be added the present invention, after the maturation, such as: washing, drying and final conditioning of the rubbery tissue sheets.
[0035] It is also part of the scope of the present invention the composition used in the impregnation, which is comprised by a mixture of latex with the chemical compounds for the cure and protection of the obtained rubbery tissue, as well as the preservation and assurance of the high quality of the properties. The impregnation solution, according to the present invention, comprises essentially an aqueous solution containing latex, sulfur source, curing accelerator and optionally, stabilizing agent or agents, one or more dispersing agents, one or more thickening agents, one or more coloring agents, buffers, as needed.
BRIEF DESCRIPTION OF THE DRAWINGS AND PICTURES
[0036] The following drawings and pictures illustrate, in a schematic form, the preferred embodiment of the invention.
[0037] [0037]FIG. 1 shows the extraction and the collection of the natural latex from the rubber trees.
[0038] [0038]FIGS. 2 and 3 shows the latex stabilization using stabilizing agents.
[0039] [0039]FIG. 4 depicts the formulation, pH adjustment and homogenization under heating of the impregnation composition.
[0040] [0040]FIG. 5 shows the filtration of the impregnation composition.
[0041] [0041]FIG. 6 shows the fixation of the impregnable material on a support, such as a mat, for example.
[0042] [0042]FIG. 7 shows the treatment of the external surface of the impregnable material (scraping and brushing).
[0043] [0043]FIG. 8 shows the impregnation of the impregnation composition on the impregnable material.
[0044] [0044]FIG. 9 shows the smoking.
[0045] [0045]FIG. 10 shows the maturation on the oven.
[0046] [0046]FIG. 11 shows the washing
[0047] [0047]FIG. 12 shows the addition of the anti adherent agent on the rubbery tissue sheets.
[0048] [0048]FIG. 13 shows the packaging and distribution of the sheets;
[0049] [0049]FIG. 14 shows some products made from the processing of the rubbery tissue sheets obtained according to the process.
DETAILED DESCRIPTION OF THE INVENTION
[0050] According to the knowledge from the prior art, certain sorts of plants produce a milky substance when their surface is cut or wounded, for instance the Hevea, Manibot glaziiovii, Castilloa elastica, Ficus elastica, Landolphia specimens and others. This milky substance, called latex, presents physicochemical properties that, once processed, gives an industrial application of this natural resource, by a variety of industrial products.
[0051] Depending on the nature of the source and incision done on the plant the rubbery tissue produced from the collected latex will be different in terms of purity, molecular weight related to the amount of hydrocarbons, among other chemical and physical properties. Generally the amount of solids on fresh latex as it flows from an average aged rubber tree is about 32 to 35%. The amount of solids on latex of young rubber trees is sometimes less than 20% and for old trees, or for the ones which had been not cut for a long period, the amount of solids on the latex can reach 45%.
[0052] As mentioned above, there are several rubber trees species, each one produces different types of latex with different properties, such as, elasticity. In addition, the origin of cultivation also interferes on latex properties. Generally the native trees produce more latex than the cultivated ones, e.g., the rubber tree seeds that were grafted. Despite the chosen specimen, the rubber tree should be cut properly, in order to maximize latex extraction and the life of the tree.
[0053] Taking into account these two factors, the assignee identified the best way of making the tree incision and latex assessment. According to the present invention, first it is necessary to mark the area which will be submitted to the incision, which is generally referred to the “flag” of the rubber tree. The flag is fixed in a way that corresponds to a half or a third of the total perimeter of the rubber tree. These procedure is taken, mainly because a rubber tree that has 100% of the perimeter used, tend to have a very limited life cycle, in comparison with the ones that produce latex at one half or one third of the total perimeter per flag.
[0054] Once the flag is fixed, the incision is done in a inclined pattern, so that the latex flows between the channel determined by the incision. The depth of the channel is another important parameter of the incision. A rubber tree presents several superposed layers. The latex is generally located on the first layer, called “crust”. Therefore, the incision should not reach the other tree layers (“skin” and “wood”), otherwise the tissues of the rubber tree will be damaged, compromising the latex production and/or life cycle. The thickness of the crust depends on the type of trees, the trees with thicker crust produces more latex.
[0055] After the incision, a collector is quickly attached to the lower part of the incision on the rubber tree, for collecting and storing the latex during all the flow. Generally, the latex flows during 2-12 hours. After the end of the flowing the collector is taken and a stabilizing agent is added, to avoid coagulation.
[0056] While flowing from the tree, the latex is almost neutral, but due to the bacterial and enzymatic reactions, it becomes acid, tending to coagulation. In order to inhibit the coagulation and maintain the latex in a stable colloidal condition, preservatives and bactericides must be added as soon as the latex is collected from the rubber tree. Possible preservatives are: ammonia, formaldehyde, sodium hydroxide, soap and other chemical bactericides, such as pentachlorophenol salts are used to inhibit the coagulation.
[0057] The usual practice is to use a small amount of ammonia. However, the use of ammonia has some disadvantages such as the high cost, the unpleasant odor, the loss due to volatilization and the ability of some bacteria to develop resistance to this chemical compound. In the preferred embodiment of the present invention, potassium hydroxide is used for latex stabilization, which present some advantages compared with ammonia such as: the use of smaller amounts and the easiness in concentrate solids.
[0058] However, any other sorts of stabilizers or mixtures thereof, can be readily used for the purpose of this invention. Exemption is made for the stabilizers that reacts with the material to be impregnated or with one or more impregnation solution compounds, producing undesirable products.
[0059] The addition of the stabilizing agent is dependant on the climate of the region. In a warm and dry climate, the latex is more susceptible to coagulation. It is necessary to add the stabilizer simultaneously to the collection.
[0060] The extracted latex should be preserved for a short term with a stabilizing agent which, preferably must be added to the latex collection recipient, before the beginning of the process of collection. Generally, 10-100 mL of 10% potassium hydroxide for 1-16 L of latex, preferably 40-60 mL of 10% potassium hydroxide for 6-10 L of latex. On a preferred embodiment of the present invention, 10% of caustic soda solution is added in a proportion of 12 g of solution per Kg of latex containing 30% of total solids.
[0061] The latex solution is essential for the quality and the desired properties of the rubbery tissue, such as, heat, ozone, solar and ultra violet radiation resistance; curing compliance; mold and exudation absence; color and aspect.
[0062] The impregnation composition comprises a mixture of one or more sulfur sources, one or more curing accelerators, forming an aqueous solution containing latex. If desired, other compounds can be added such as protection and stabilization agents, dispersants, thickening agents, solvents, coloring agents, scents, buffers, etc., or mixtures thereof. Exemption is made for the above mentioned compounds and/or mixtures that undesirably reacts resulting a rubbery tissue with inferior properties.
[0063] The latex used in the formulation of the impregnation composition can be natural, e.g., extracted and collected from the rubber trees and stabilized. Alternatively, latex from chemical compounds can be used, such as polymeric or synthetic latex, or any compound that can be vulcanized to achieve the desired properties of the final product.
[0064] Any sulfur source known in the art can be used, pure sulfur or sulfur compounds, salts and solutions containing sulfur. It is still in the scope of the invention the addition of compounds or mixtures thereof that can potentially react, mix or interact, forming potential sulfur sources.
[0065] The same applies to the curing accelerator. Any accelerator or mixtures thereof known in the art can be used. Exemption is made to the particular ones that undesirably reacts interfering on the quality of the final product. The preferred accelerators are the ones suitable for curing at low temperatures.
[0066] The impregnation solution presents a 1:1-1:3 rate between the sulfur source and vulcanization accelerator; preferably the rate is 1:1,5. The impregnation solution is completed with water.
[0067] In the preferred embodiment of the present invention, the impregnation composition comprises: 4-12% of sulfur; 2-8% of zinc oxide; 6-21% of vulcanization accelerator (preferably ZDEC-Akzo NL); 6-21% of protecting and stabilizing agent (preferably Wingstay L-Goodyear EUA); 8-24% of dispersing agent (preferably Faxan 11P 10%-Montanoir F); 2-6% of thickening agent (preferably AlGum HV 3%-Mathon F); and 10-80% of water (all percentages in weight).
[0068] It can be necessary to add compounds in order to adjust the pH of the impregnation composition to a desirable range. The compounds must be added in order to result in a dispersion containing active chemical compounds enough to cure a certain amount of latex with a predetermined rubber amount. The rate between the active chemical compounds and the rubber in the latex is about 1:0.5 to 1:2, preferably 1:1.
[0069] Compared with the patent application BR 9402908-3 of Jul. 22, 1994, the impregnation composition herein described is superior to the composition described in the above mentioned patent application, mainly because of the low amount of sulfur (approximately 0.6%), avoiding the blooming effect (e.g., milky appearance); the use of a accelerator more active than the ZDBC and a protective material that avoids bleaching.
[0070] The finishing of the impregnation solution must be done carefully, by adding the vulcanization and protection elements previously dispersed, separately or in a single mixture to the latex with the amount of solids previously determined, with proper quantities related to the effective concentration of latex. After the addition of all the components, forming an aqueous solution with pH adjusted between 6 and 10, preferably between 7 and 10 and more preferable between 8 and 9, the mixture should be homogenized and filtered.
[0071] After all the components are added, the solution is mixed under moderated heat, between 30-80° C., preferably between 40-70° C., more preferably between 55-60° C. The previously heated composition is better applicable during the impregnation phase, consuming less energy and time for the process during the smoking time. It is important not to let the solution boil, otherwise it will compromise the elasticity of the final product.
[0072] The warm impregnation composition is filtrated, in order to separate the solids and eliminate insoluble impurities, and in case the composition not used immediately, it should be stored in a recipient, standing by for the impregnation of the composition on the impregnable material.
[0073] The material to be impregnated with the impregnation composition containing latex is fixed on supports, which can be made from any material that withstands the temperatures of the process described herein, without causing any impact on the quality and the properties of the rubbery tissue, as well as not reacting in a detrimental manner with the impregnation solution, forming undesirable side products.
[0074] In one of the preferred embodiments, the said impregnable material is cut in appropriate dimensions to be fixed on a vertical rectangular grid, with or without the manipulation rod fixed on the median part of the inferior side of the support. Preferably a 1.2 m×0.8 m grid is used, due to the better usage of the material during the manufacturing of the final product. The 1.2 m measurement was based on the average height of trousers, used by clothes stylists.
[0075] Alternatively, a mat or a mobile or rolling device can be used to sustain the impregnable material in order to have a continues process.
[0076] Regarding the type of impregnable material, any type of fabric can be used in the present invention, except the fabric that undesirably reacts with the impregnation solution, producing side products. Generally, any material, fabric, cloth made of wool, silk, cotton, linen, white cotton cloth, natural fiber artificial or synthetic, among others, can be used. However some synthetic fabrics present low absorption capacity and adherence to the impregnation solution. The preferred embodiment of the invention is to use a 100% cotton fabric.
[0077] After the cutting, the fabric is extended and fixed on the grid. The fixed fabric is then scraped and brushed, to eliminate lumps and wrinkles, softening the fabric and preparing it for a better absorption of the impregnation composition.
[0078] The fixation of the material on a grid or a mat, in case of a continues process, has a fundamental objective in the process claimed herein. Contrary to the processes mentioned on the state of the art, the material is not introduced or submerged in a recipient containing the impregnation solution. The applicant surprisingly found out that, by the direct impregnation in just one of the faces of the material supported on the grid, the rubbery tissue obtained has improved properties, as well as the aspects of quality and processing of the material for the production of manufactured goods with best finishing, such as: coats, wallets, suitcases, etc. So, the internal surface of the material is not directly impregnated with the impregnation solution.
[0079] In a non-theoretical way of thinking, the optimum properties of the rubbery tissue are obtained when the material absorbs partially the impregnation solution. Therefore, the impregnation should be done in a particular way to provide a leather appearance to the material, but not in excess, avoiding the accumulation of the material in the interstices, chemical compound molecules such as oxidants and vulcanization agents, capable of severely compromise the quality of the rubbery tissue in a long term. In a simple way, the impregnation composition must be applied to the external face of the material (between the grids of the fabric, for example), but the composition should not reach its interior face therefrom. Once it happens, the impregnation composition starts to drip on the internal face of the grid, influencing negatively the external face properties, by forming spots or clumps, which interferes on the appearance and on the final quality of the rubbery tissue obtained.
[0080] However, it must be assured that the impregnable material absorbs a sufficient amount of impregnation composition, in order to the latex will be vulcanized on the material, determining the desired leather appearance. For achieving this objective, the impregnation is done on multiple applications, for a gradual absorption of the impregnation composition by the impregnable material.
[0081] The first application is the most important, due to the fact that it is more difficult to apply the impregnation composition avoiding the surpassing of the impregnable material which is still in its natural state, e.g., raw. The subsequent steps present advantages when compared to the first one, because the impregnation is done on a already impregnated material, which means that the material is already coated meanwhile the impregnation composition is applied repeatedly. The vulcanized latex from the repeated applications will provide a protection layer to the material, avoiding the surpassing of the impregnation material.
[0082] In the first application, named “priming”, the impregnation composition should be carefully applied. The simplest form is to manually rub the impregnable material with the impregnation composition, in order to facilitate its adherence to the material, followed by the first longitudinal bath, from top to bottom, on the external face. The impregnation composition has to be spread, and cover the whole external face of the material. Non-manual applications can be also used, such as, by using a hose, spraying, etc., the limitation being that the pressure or flow rate of the impregnation should be optimized in order to avoid that the solution passes to the internal face of the material. Also, the impregnation should assure that the material absorbs the impregnation composition, providing a good adherence between the material and the rubber formed by the vulcanization of the latex on the material surface.
[0083] Therefore, the first application determines the initial absorption of the material in relation to the impregnation composition, specially on the porous and holes closer to the external surface of the material, which is put directly in contact with the solution.
[0084] The applications of the impregnation composition must be done with the grid slightly sloped and from top to bottom, consequently, the said impregnation composition flows on the external surface of the material, in all its extent, avoiding spots and regions with different concentrations as a result of composition reflux.
[0085] After the application of the impregnation composition and subsequent flow of the excess of the said impregnation composition, the impregnated material should be smoked, e.g., the impregnated surfaces of the said material should be exposed to the dense fumes of an oven, preferably a conic oven.
[0086] Generally, the said smoking can be done by the contact of heated vapors, promoting the vulcanization of the latex on the surface of the impregnated material. In a preferred embodiment of the invention, the smoking is done, by the smoke produced by a complete combustion reaction, e.g., composed by oxygen and carbon dioxide. However, any other heating method which promotes, in a satisfactory way, the vulcanization of the latex on the material can be used.
[0087] During the smoking, it is important to maintain, at least initially, the impregnable material slightly sloped in order to avoid the reflux of the composition on the surface. This avoids heterogeneous regions regarding the concentration and absorbed amount of impregnation composition. Generally, the material must be exposed to heat during smoking from 1 to 10 minutes, preferably from 2 to 7 minutes and mostly preferable from 3 to 5 minutes. The necessary exposure time will depend on the smoking method used.
[0088] The level of exposure can be evaluated by the color of material being smoked. When the material pass from a white to a yellowish color, it is a positive indication that the smoking has achieved the desired level. Excessive smoking should be avoided, otherwise ashes will be formed, interfering on the rubbery tissue properties. On the other hand, incomplete smoking can compromise the rubbery tissue properties, once the latex will not be completely vulcanized.
[0089] Another way of verifying the vulcanization of a rubbery tissue sheet, is a quick analysis based on the fact that any type of rubber absorbs test liquids (organic solvents, for example, or any other liquids or mixtures thereof known on the art) in a higher or lower grade. This particular method do not measure the level of vulcanization, only if any vulcanization thereof is present on the rubbery tissue sheets. Therefore, according to the method, the liquid absorption causes a increase on the rubber volume (“swelling”). As a consequence, the physical properties can be determined. The first sheets, of pure latex, are completely soluble in certain liquids, but the vulcanized sheets, as in the form Vulcatex 22.15, are virtually insoluble. Strong chemical bonds, such as the sulfur with the rubber chains, prevents the complete evolvement of the rubber chains by the liquid and restrict the rubber deformation.
[0090] In a practical way, a small sample of the sheet is cut to be analyzed. This sample is put in recipient containing liquid, for example, gasoline, for the test. After 90 minutes of immersion, the sample is removed from the recipient. If the sample is dissolved, this is a proof of the non-vulcanization of the material. For the partially vulcanized sample, it is observed that the rubber separates from the fabric, without dissolution. The totally vulcanized samples swell and twist, without dissolving.
[0091] Once smoked, the rubbery tissue is evaluated. In case of irregularities, such as the presence of granules, blisters or pits on the material surface, it is submitted to pressing only on the deformed areas, saving the properties of the material as a whole.
[0092] Following the above mentioned step, the material is once again submitted to a impregnation solution application, as described above. It is advisable to filtrate and mix the impregnation solution for each step of application.
[0093] From the second step on, the impregnation can be done by any non-manual means known on the art, such as the application of the impregnation composition by using hoses, sprays, etc., the said composition being pumped to be spread on the material surface uniformly.
[0094] The flow rate of the impregnation solution jet should be carefully adjusted, despite of the mechanism of application adopted, to avoid foam generation. The foam generates bubbles that, due to the wind action, can collapse forming “holes” on the external surface of the material and, therefore compromising the properties of the rubbery tissue obtained, specially its superficial and finishing properties. The optimal adjustment can be obtained by the proper dimensioning of the hose diameter or other method adopted.
[0095] In the preferred embodiment of the present invention, a hose application system for the impregnation solution was adopted. For an adequate application, considering the grid dimensions cited above, such device should present a 0.00254-0.0762 m (0.1-3 in) diameter, preferably 0.00762-0.0254 m (0.3-1 in) diameter, most preferably 0.010-0.016 m (0.4-0.6 in) diameter.
[0096] Impregnation and smoking cycles are repeated, according to the industrial process demands and quality standards. In order to reach adequate physicochemical properties, as well as a good leather appearance, and high superficial and finishing qualities for the manufactured products from the rubbery tissue, it is advisable to submit the impregnable material to 1-20 cycles, preferably 4-15 cycles, most preferably 6-12 cycles. The adequate impregnation of the material, as well as the number of cycles necessary to obtain a rubbery tissue with the desirable properties will strongly depend on the specific weight of the material used.
[0097] After various cycles of impregnation and smoking, the rubbery tissue sheets are placed in a oven and let for curing for 1-4 days, preferably 2-3 days. The smoking temperature for the leather sheets is 50-90° C., preferably 60-80° C., most preferably 70° C. It is possible, at the beginning of the maturation process, to establish a relatively high temperature, between 80-100° C., preferably 90-95° C., stabilizing afterwards the temperature to 70° C., during tanning.
[0098] It is also important to take into account the fact that the material, before being tanned, is very sensitive to humidity and other environmental agents. The sheets must not get exposure to hostile environments and weather conditions.
[0099] The tanned vegetal leather sheets can be washed thoroughly with water and/or other types of cleaning agents that do not undesirably reacts with the rubbery tissue, such as powder soap. After cleaning, the sheets are dried at room temperature or in the oven.
[0100] Alternatively, the rubbery tissue sheets can be removed from the oven and placed on a seepage tank, remaining on it for the desired period of time. After being taken out of the water, the sheets must be rubbed with a sponge and water. After washing and/or leaching, the rubbery tissue sheets must be put on the oven again, for final drying.
[0101] Finally, the rubbery tissue sheets submitted to the final drying must be removed, from the oven. The washed and/or leached and dried must be removed from the grid, examined and classified according to the quality standards before packaging.
[0102] The finishing of the rubbery tissue sheets, giving them a smooth touch, must be obtained by the application of the adequate product after the manufacturing of the product, not compromising the assembly with neoprene glue, for instance.
[0103] If desirable, it is possible to coat the rubbery tissue sheets with protecting agents, anti-adherents and mixtures thereof known in the art, however the agents applied cannot react undesirably with the obtained rubber tissue. This procedure is desired when the sheets are boxed in non foldable stacks, in order to avoid sticking among the sheets. An example of anti-adherent used on the preferred embodiment of the present invention is zinc stearate.
[0104] Before the packaging of the sheets, quality tests can be done to evaluate the physicochemical properties presented by the material, as well as the surface and esthetical properties. Therefore, toughness and color measurements, resistance and elasticity tests, degree of vulcanization, surface tests, among others, can be applied to the rubbery tissue sheets obtained by the present invention, according to the convenience of the industrial process used.
[0105] There are protection agents that can be applied to the sheets in other to prevent surface imperfections. By surface imperfections it is understood any irregularities caused by the use of inadequate material, bad latex distribution, scratches, dirty and other visible marks that tend to reduce the area of the sheet suitable for manufacturing. In addition to that, no color variation is allowed on the sheets.
[0106] Irregularities, like pits on the surface of the sheets and trapped on the blisters are from mineral sources (sulfur and silicon) and organic sources (accelerator). The pit formation is mainly due to a bad dispersion when mixing the impregnation solution.
[0107] Also, white lines can appear on the surface of the rubbery tissue sheets, as a result of scratches. Some of them can be more visible, due to the abrasive effect on the surface, for which the silicon oil is insufficient. In order to obtain a more accurate mechanical protection, it is advisable to cover the surface of the sheet with polyurethane resin, which provides a certain mechanical resistance, maintaining the “flexibility”. If the addition of these agents are undesirable for the subsequent manufacturing of the rubbery tissue sheets, the application of these agents should not be done. However, the application of the above mentioned agents on the products manufactured with the rubbery tissue sheet as a stating material is possible.
[0108] Once described the present invention on a general manner, it is important to mention that the examples referred above, specially on the preferred embodiments of the present invention are herein described only for illustrative means and do not have intention to limit the scope of the invention. Technicians specialized on the art will recognize several variants that take part of the scope of the invention and claims herein described. | The present invention refers to a process and a composition, containing latex, for the manufacturing of rubbery tissue sheets. The process of the present invention consists of the following steps: formulation of the composition, consecutive impregnation and smoking cycles; and maturation. Also, it is part of the scope of the present invention, a impregnation composition which is essentially an aqueous solution comprising latex, a sulfur source and a vulcanization accelerator. The rubbery tissue sheets obtained by the present invention can be submitted to the manufacturing of: suitcases, bags, purses, travelling bags, clothes, diaries, wallets, shoes and other objects usually made of leather. | 3 |
This application is a Continuation of U.S. application Ser. No. 10/989,152, filed Nov. 15, 2004, now issued as U.S. Pat. No. 8,225,307, which claims priority to Canadian Patent Application No. 2,449,534, filed Nov. 14, 2003, entitled “ON-DEMAND SOFTWARE MODULE DEPLOYMENT,” the entirety of which is incorporated herein by reference.
FIELD OF THE INVENTION
This present invention relates generally to using software modules in a computer system and more particularly to on-demand deployment of software modules used in a computer system.
BACKGROUND OF THE INVENTION
Typical operation of computerized applications such as those using Java 2 platform Enterprise Edition (J2EE) to incorporate Enterprise Java Beans (EJB) incurs process overhead for each and every EJB included in the application. Overhead is incurred at the start of the application in the form of start-up time delay and later during the life of the application through overall memory footprint. During a typical start-up of the application server the EJB modules contained within the application are typically examined, deployment descriptors typically parsed and home objects are typically instantiated and populated into the name service associated with the corresponding EJB container. As the application uses and finishes with the EJBs they are not released but are maintained. These EJBs are maintained within a pool of previously instantiated EJBs and re-used as required by the application. This subsequent pooling and caching of the already instantiated EJBs provides performance benefits during the processing of the application, avoiding the need to re-instantiate an EJB prior to re-use. This technique of initializing, loading and caching typically works well during the production mode of operation for the application. Performance is however obtained at the cost of resources in the form of initial application load time and ongoing memory footprint. Current techniques such as that just described typically load all the EJBs contained within the application at start-up, thereby increasing application start time and memory requirements.
An EJB container is usually responsible for registering unique look-up names within a Java Naming and Directory Interface (JNDI) namespace when the server starts and binding those names to home objects within the container.
A development environment typically has requirements differing from those of the production environment. In a development environment one needs to typically get a unit of work done as quickly as possible to verify operation of specific code elements of interest within the application. The development environment typically focuses on a smaller number of EJBs relative to the number of EJBs found in the application as a whole. Unfortunately the development environment must usually adhere to the same instantiation and maintenance practices as found in the production environment. Additionally a development environment is usually memory constrained not having access to the same amount of resource afforded the production environment.
Therefore what is required is a more effective way to create and operate a development environment using EJBs that allows for faster start-up while maintaining lower memory requirements as compared to that of a production environment.
SUMMARY OF THE INVENTION
A method, system, program product and signal bearing medium for deploying software modules for software application use in a computer system are provided. Deployment of software modules and associated descriptor information allow for selected requested software modules to be obtained and made available only as needed, resulting in reduced start-up delay and memory consumption as compared to that of a typical production environment.
In one aspect of the present invention, there is provided a method of deploying software modules for software application use in a computer system, said method comprising deploying of a plurality of software modules into a software module depository and deploying deployment descriptors associated with each of the plurality of software modules into a deployment information repository.
In another aspect of the present invention, there is provided a deployment system for deploying software modules for software application use in a computer system, comprising a first deployer for deploying a plurality of software modules into a software module depository and a second deployer for deploying deployment descriptors associated with each of the plurality of software modules into a deployment information repository.
In another aspect of the present invention there is provided a computer program product having a computer readable medium tangibly embodying computer readable program code for instructing a computer to perform the method for deploying of a plurality of software modules into a software module depository and deploying deployment descriptors associated with each of the plurality of software modules into a deployment information repository.
In yet another aspect of the present invention there is provided a signal bearing medium having a computer readable signal tangibly embodying computer readable program code for instructing a computer to perform a method for deploying of a plurality of software modules into a software module depository and deploying deployment descriptors associated with each of the plurality of software modules into a deployment information repository.
In another aspect of the present invention there is provided a computer program product having a computer readable medium tangibly embodying computer readable program code for instructing a computer system to provide the means of a first deployer for deploying a plurality of software modules into a software module depository and a second deployer for deploying deployment descriptors associated with each of the plurality of software modules into a deployment information repository.
In another aspect of the present invention there is provided a signal bearing medium having a computer readable signal tangibly embodying computer readable program code for instructing a computer to provide the means for first deployer for deploying a plurality of software modules into a software module depository and a second deployer for deploying deployment descriptors associated with each of the plurality of software modules into a deployment information repository.
Other aspects and features of the present invention will become apparent to those of ordinary skill in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures. The illustrative embodiments of the present invention incorporate the use of Enterprise Java Beans. Those skilled in the art may appreciate that EJBs are but one form of software module which may be within the scope of the embodiments of the present invention. In the examples which follow one is reminded of the following relationships.
Enterprise Java Beans are but one embodiment of software modules and in general should not be taken as limiting applicability to use of the subject matter to Enterprise Java Beans.
Deployment descriptors associated with the EJBs may also be found in relationship to other implementations of software modules as a means of providing descriptive information regarding attributes of the particular software module type.
A software enabler is discussed within the following examples as a home object associated with an EJB. It is used to instantiate an EJB for software application use and may have a counterpart in other software implementations such as stub code for performing operations.
A name service as in the examples is referred to as a mapper providing mapping between the JNDI name space and home object implementation classes. Other techniques are available for this service as well such as a simple look up table or database table. Any suitable means for quickly resolving an input identifier to an out identifier is useful.
A property file is one form of resource used to provide extrinsic information regarding a software module or EJB. It may be replaced by another technique providing programmatic access to attribute information related to the software module or EJB as in the examples. Functionality could also be provided by way of lists, tables, arrays and objects.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a hardware overview of a computer system, in support of embodiments of the present invention;
FIGS. 2 , 3 and 4 are block diagrams showing typical EJB deployment into a production environment as supported in the computer system of FIG. 1 ;
FIG. 5 is a flow diagram of a typical process of deploying an EJB into a production environment as suggested in FIGS. 2 , 3 and 4 ;
FIGS. 6 , 7 and 8 are block diagrams showing an EJB deployment into a development environment in an embodiment of the present invention;
FIG. 9 is a flow diagram showing a process of an EJB deployment into a development environment in an embodiment of the invention as suggested in FIGS. 6 , 7 and 8 ;
FIG. 10 is a flow diagram showing an embodiment of the present invention as shown in FIG. 9 with designated home objects;
FIG. 11 is a flow diagram showing an embodiment of the present invention as shown in FIG. 10 with prioritized home objects.
Like reference numerals refer to corresponding components and steps throughout the drawings. It is to be expressly understood that the description and the drawings are only for the purpose of illustration and as an aid to understanding, and are not intended as a definition of the limits of the invention.
DETAILED DESCRIPTION
FIG. 1 depicts, in a simplified block diagram, a computer system 100 suitable for implementing embodiments of the present invention. Computer system 100 has processor 110 , which is a programmable processor for executing programmed instructions stored in memory 108 . Memory 108 can also include hard disk, tape or other storage media. While a single CPU is depicted in FIG. 1 , it is understood that other forms of computer systems can be used to implement embodiments of the invention. It is also, appreciated that embodiments of the present invention can be implemented in a distributed computing environment having a plurality of computers communicating via a suitable network 119 .
CPU 110 is connected to memory 108 either through a dedicated system bus 105 and/or a general system bus 106 . Memory 108 can be a random access semiconductor memory for storing application data for processing such as that in a database partition. Memory 108 is depicted conceptually as a single monolithic entity but it is well known that memory 108 can be arranged in a hierarchy of caches and other memory devices. FIG. 1 illustrates that operating system 120 may reside in memory 108 .
Operating system 120 provides functions such as device interfaces, memory management, multiple task management, and the like as known in the art. CPU 110 can be suitably programmed to read, load, and execute instructions of operating system 120 . Computer system 100 has the necessary subsystems and functional components to implement on-demand loading of software modules such as Enterprise Java Beans (EJBs) as will be discussed later. Other programs (not shown) include server software applications in which network adapter 118 interacts with the server software application to enable computer system 100 to function as a network server via network 119 .
General system bus 106 supports transfer of data, commands, and other information between various subsystems of computer system 100 . While shown in simplified form as a single bus, bus 106 can be structured as multiple buses arranged in hierarchical form. Display adapter 114 supports video display device 115 , which is a cathode-ray tube display or a display based upon other suitable display technology. The Input/output adapter 112 supports devices suited for input and output, such as keyboard or mouse device 113 , and a disk drive unit (not shown). Storage adapter 142 supports one or more data storage devices 144 , which could include a magnetic hard disk drive or CD-ROM, although other types of data storage devices can be used, including removable media.
Adapter 117 is used for operationally connecting many types of peripheral computing devices to computer system 100 via bus 106 , such as printers, bus adapters, and other computers using one or more protocols including Token Ring, LAN connections, as known in the art. Network adapter 118 provides a physical interface to a suitable network 119 , such as the Internet. Network adapter 118 includes a modem that can be connected to a telephone line for accessing network 119 . Computer system 100 can be connected to another network server via a local area network using an appropriate network protocol and the network server that can in turn be connected to the Internet. FIG. 1 is intended as an exemplary representation of computer system 100 by which embodiments of the present invention can be implemented. It is understood that in other computer systems, many variations in system configuration are possible in addition to those mentioned here.
FIG. 2 is a simplified view of a typical relationship between pre-deployment software components comprising software modules such as EJB module 200 and deployment descriptor 205 containing attribute information of the associated software module and post deployment software components comprising deployed EJB module 210 , deployed deployment descriptor 215 and deployed code 220 resulting from a deployment operation of EJBs. Deployed deployment descriptor 215 is also kept with deployed EJB module 210 as it will be used later during server initialization. Not all server required information was captured in the deployed EJB module 210 , hence the maintenance of deployed deployment descriptor 215 .
FIG. 3 is a block diagram showing the typical components of deployed EJBs of FIG. 2 after server initialization has completed. Deployed deployment descriptor 215 provides information for the further establishment of name service 230 . All of the EJBs specific to application 240 will be loaded in the form of preloaded home objects 235 and made available for application 240 uses by way of server initialization. Name service 230 provides a lookup service to resolve Java Naming and Directory Interface (JNDI) home object names to the implementation of various classes. Deployed deployment descriptor 215 may be a copy of deployment descriptor 205 in a deployed format.
Referring now to FIG. 4 , EJB container 400 is shown associated with and managing reusable cached and pooled objects 405 . EJBs which have been previously used by application 240 are recycled by means of reusable cached and pooled objects 405 . EJBs once used are not discarded; they are placed in reusable cached and pooled objects 405 to await further use requests.
Referring now to FIG. 5 a typical process inherent in the discussion of FIGS. 2 , 3 and 4 is shown. Beginning with operation 500 the EJB module and its associated descriptor are deployed into a production environment of the previous examples. Having completed deployment, processing moves to operation 505 during which the server is initialized. Having initialized the server processing moves to operation 510 during which the name service to be used for resolving named home object requests is created. The name service is required for object retrieval. During operation 515 all of the EJBs used in the application are found for which are created home objects. All of the home objects created during operation 515 are then used to populate the naming service during operation 520 . Having finished populating the name service, processing moves to operation 525 during which a storage pool is created. The storage pool is used to maintain previously used EJBs pending their further use. During operation 526 a request for a home object is received and the home object requested is then retrieved during operation 530 . A home object acts as a software enabler, making a requested EJB available for use by a requesting software application. If the home object requested was previously used it has an associated EJB that was cached in the pool and that EJB will then be retrieved during operation 545 . If the application has completed use of a home object it will release the EJB associated with the home object during operation 535 . Having released an EJB from the home object during operation 535 , the associated EJB is then moved to the pool during operation 540 where it resides awaiting further use, where it may again be retrieved by way of operation 545 as before.
Having described a typical production view a different environment having been optimized in accordance with embodiments of the present invention will now be discussed. Referring now to FIG. 6 there is shown as before EJB module 200 and deployment descriptor 205 . Deploying EJB module 200 and deployment descriptor 205 causes deployed EJB module 210 , deployed code 220 and deployment information repository 225 to be created. Deployment of EJB module 200 and deployment descriptor 205 may be accomplished using a single deployer combining both capabilities or separate deployers as in a first and second deployer established to handle an EJB module and deployment descriptor respectively as part of a deployment system. Deployment information repository 225 contains all of the necessary information needed by the server during initialization at start-up. Creation of deployment information repository 225 eliminates the need for maintaining the copy of deployment descriptor 205 in a post deployment form. Deployment information repository 225 contains parsed input from deployment descriptor 205 eliminating the need to have deployment descriptor 205 parsed yet again during server initialization. Deployment information repository 225 may be implemented in any suitable form as is known in the art. A suitable implementation may be in the form of a property file mapping JNDI home object names to the implementation classes. In a similar manner lookup tables may be used as well as relational tables, arrays, indexed arrays or other means may be used to provide fast efficient resolution.
This embodiment will delay the loading of EJBs until they are actually requested by the application typically allowing the application to be ready sooner than otherwise possible. Further a reduction in memory allocation at start-up is typically possible due to the reduced number of EJBs to be loaded into storage as well as on an ongoing basis only having those which are used loaded.
FIG. 7 shows in block form a relationship between deployment information repository 225 and name service 245 . Name service 245 is used to resolve the EJB name passed by the application to the proper request-loaded home objects 250 as requested by application 240 . Name service 245 possesses intelligence in order to find the mapping between a requested EJB and on-demand instantiated home object 250 to perform the needed retrieval. On-demand instantiated home objects 250 are created on a call by call basis as EJBs are requested for use by application 240 . No home object is created until a request has been received from application 240 . When application 240 requests name service 245 to find an EJB home object, name service 245 will use information in deployment information repository 225 to locate and instantiate the required home object implementation classes.
Referring now to FIG. 8 EJB container 410 may be seen with application 240 . No additional storage is maintained by EJB container 410 to hold on-demand instantiated home objects 250 as they are released from application 240 after each use. As on-demand instantiated home objects 250 are released they are made available for garbage collection and subsequent disposal.
Referring now to FIG. 9 a typical process of an embodiment of the invention that may be used typically in an environment such as in a development mode using EJBs is shown. Beginning with operation 500 an EJB module and associated deployment descriptor are deployed. As part of the deployment an information repository is created during operation 550 to contain information needed during server initialization. Server initialization is then performed during operation 505 . Processing moves to operation 510 during which a name service is created to resolve mappings between EJBs requested by an application and home objects providing runtime support. During operation 526 a request is received needing a home object. A determination is then made in operation 555 as to whether the home object has been loaded. If the requested home object is found, it is then retrieved during operation 530 , otherwise processing moves to operation 560 . During operation 560 information is retrieved from the deployment information repository for the specific EJB and processing moves to operation 515 , during which the home object is instantiated and made ready for use by the application. Processing moves to operation 530 and as before the home object is retrieved for application use. After application use of the home object, processing moves to operation 535 during which the used home object is discarded as it is no longer required.
Referring now to FIG. 10 a typical process of another embodiment of the invention that may be used typically in an environment such as in a development mode using EJBs is shown. Beginning with operation 500 an EJB module and associated deployment descriptor are deployed. As part of the deployment an information repository is created during operation 550 to contain information needed during server initialization. Server initialization is then performed during operation 505 . Processing moves to operation 510 during which a name service is created to resolve mappings between EJBs requested by an application and home objects providing runtime support. Having completed operation 510 , operation 516 begins during which designated home objects are instantiated. These designated home objects are a number of EJBs which have been determined to be made available prior to execution of the application rather than waiting for eventual requests from the application. Examples of such EJBs may be those dealing typically with housekeeping or security operations or other functions which are commonly used and useful in a variety of environments. Designated home objects may be so chosen for any reason, the reason not being of import rather it is the facility being offered. Locating designated home objects may be performed by way of resource files as used in various programming environments, simple lists, arrays, indexed arrays and tables. Typical numbers of such designated home objects will be small relative to the number available to the related application. Retrieval of such names should be simple and fast to ensure rapid loading of the environment. During operation 526 a request is received having an associated home object. A determination is then made in operation 555 as to whether the home object has been loaded. If the requested home object is found, it is then retrieved during operation 530 , otherwise processing moves to operation 560 . During operation 560 , information is retrieved from the deployment information repository for the specific EJB and processing moves to operation 515 , during which the home object is instantiated and made ready for use by the application. Processing moves to operation 530 and as before the home object is retrieved for application use. After application use of the home object, processing moves to operation 535 during which the used home object is discarded as it is no longer required.
Referring now to FIG. 11 a typical process of yet another embodiment of the invention that may be used typically in an environment such as in a development mode using EJBs is shown. Beginning with operation 500 an EJB module and associated deployment descriptor are deployed. As part of the deployment an information repository is created during operation 550 to contain information needed during server initialization. Server initialization is then performed during operation 505 . Processing moves to operation 510 during which a name service is created to resolve mappings between EJBs requested by an application and home objects providing runtime support. Having completed operation 510 , operation 516 begins during which designated home objects are instantiated. These designated home objects are a number of EJBs which have been determined to be made available prior to execution of the application rather than waiting for eventual requests from the application. Examples of such EJBs may be those dealing typically with housekeeping or security operations or other functions which are commonly used and useful in a variety of environments. Designated home objects may be so chosen for any reason, the reason not being of import rather it is the facility being offered. During operation 526 a request is received having an associated home object. A determination is then made in operation 555 as to whether the home object has been loaded. If the requested home object is found, it is then retrieved during operation 530 , otherwise processing moves to operation 560 . During operation 560 , information is retrieved from the deployment information repository for the specific EJB and processing moves to operation 515 , during which the home object is instantiated and made ready for use by the application. Processing moves to operation 530 and as before the home object is retrieved for application use. After application use of the home object, processing moves to operation 531 during which a determination is made regarding the priority of the used home object. If the home object was required for future processing it would have an entry in a priority list and be retained within the EJB container for subsequent retrieval. On the other hand if it is no longer required it would not be located on a priority list and processing would move to operation 535 during which the home object is discarded. Home objects which would be typical candidates for inclusion on a priority list may be those designated earlier as designated home objects or those which may have been recorded as a result of test conditions. A variety of rationale may be used to determine candidates for prioritization. Prioritized home objects may be so chosen for a number of reasons, the reason not being of import rather it is the facility being offered. Locating designated home objects may be performed by way of resource files as used in various programming environments, simple lists, arrays, indexed arrays and tables. Typically numbers of such prioritized home objects will be small relative to the number available to the related application. Retrieval of such names should be simple and fast to ensure rapid loading of the environment.
Although the invention has been described with reference to illustrative embodiments, it is to be understood that the invention is not limited to these precise embodiments and that various changes and modifications may be effected therein by one skilled in the art. All such changes and modifications are intended to be encompassed in the appended claims. | A method, system, program product and signal bearing medium embodiments of the present invention provide for deploying software modules for software application use in a computer system thereby reducing load time as well as memory requirements. Deployment of a plurality of software modules and associated deployment descriptors into a software module depository and creation of a deployment information repository from the associated deployment descriptors occurs. A name service is initialized with information from the deployment information repository and a requested software module identifier is then mapped to a respective enabler. Having mapped the requested software module to an enabler, the respective software module is enabled for the software application use. On-demand deployment in this manner saves start-up time as well as initial and ongoing memory allocation. | 6 |
TECHNICAL FIELD OF THE INVENTION
This invention relates to a method and system for encrypting and decrypting multi-dimensional information, objects or data with digital holography.
BACKGROUND OF THE INVENTION
The application of optical processing systems to security, verification, and encryption of information has been explored previously (H.-Y. Li, Y. Qiao, and D. Psaltis, “Optical Network For Real-time Face Recognition,” Appl. Opt. 32, 5026–5035 (1993); B. Javidi and J. L. Horner, “Optical Pattern Recognition For Validation and Security Verification,” Opt. Eng. 33, 1752–1756 (1994); Ph. Refrégier and B. Javidi, “Optical Image Encryption Based on Input Plane and Fourier Plane Random Encoding,” Opt. Lett. 20, 767–769 (1995); C. L. Wilson, C. I. Watson, and E. G. Paek, “Combined Optical and Neural Network Fingerprint Matching,” Proc. SPIE 3073, 373–382 (1997); N. Yoshikawa, M. Itoh, and T. Yatagai, “Binary Computer-generated Holograms for Security Applications From A Synthetic Double-exposure Method by Electron-beam Lithography,” Opt. Lett. 23, 1483–1485 (1998) and O. Matoba and B. Javidi, “Encrypted Optical Memory System Using Three-dimensional Keys in the Fresnel Domain,” Opt. Lett. 24, 762–764 (1999); which are incorporated herein by reference).
In one approach, the information to be secured or verified is encoded as a two-dimensional image using amplitude, phase, polarization or wavelength modulation of light and optically processed. In order to encrypt the information, random phase-codes can be used to modify the Fraunhofer or Fresnel diffraction patterns of the input image (B. Javidi and J. L. Horner, “Optical Pattern Recognition For Validation and Security Verification,” Opt. Eng. 33, 1752–1756 (1994); Ph. Refrégier and B. Javidi, “Optical Image Encryption Based on Input Plane and Fourier Plane Random Encoding,” Opt. Lett. 20, 767–769 (1995) and O. Matoba and B. Javidi, “Encrypted Optical Memory System Using Three-dimensional Keys in the Fresnel Domain,” Opt. Lett. 24, 762–764 (1999)) as in methods for securing or multiplexing holographic memories (J. E. Ford, Y. Fainman, and S. H. Lee, “Array Interconnection By Phase-coded Optical Correlation,” Opt. Lett. 15, 1088–1 090 (1990); C. Denz, G. Pauliat, G. Roosen, and T. Tschudi, “Volume Hologram Multiplexing Using A Deterministic Phase Encoding Method,” Opt. Commun. 85, 171–176 (1991); H. Lee and S. K. Jin, “Experimental Study of Volume Holographic Interconnects Using Random Patterns,” Appl. Phys. Lett. 62, 2191–2193 (1993); J. F. Heanue, M. C. Bashaw, and L. Hesselink, “Encrypted Holographic Data Storage Based on Orthogonal-phase-code Multiplexing,” Appl. Opt. 34, 6012–6015 (1995); C. Denz, K. O. Mueller, F. Visinka, and T. I. Tschudi, “Digital Volume Holographic Data Storage Using Phase-coded Multiplexing,” Proc. SPIE. 3802,142–147 (1999) and C. C. Sun, W. C. Su, B. Wang, and Y. Ouyang, “Diffraction Selectivity of Holograms With Random Phase Encoding,” Opt. Commun. 175, 67–74 (2000) which are incorporated herein by reference).
In general, the encrypted image contains both amplitude and phase and thus holographic recording may also be required (J. W. Goodman, Introduction to Fourier Optics , McGraw-Hill, New York, 1996 which is incorporated herein by reference). This necessity makes it difficult to transmit the encrypted information over conventional communication channels.
Several digital holography methods have been applied to solve the previous problem by recording fully complex information with electronic cameras (U. Schnars and W. P. O. Juptner, “Direct Recording of Holograms By A CCD Target and Numerical Reconstruction,” Appl. Opt. 33, 179–18 1 (1994); Y. Takaki, H. Kawai, and H. Ohzu, “Hybrid Holographic Microscopy Free of Conjugate and Zero-order Images,” Appl. Opt. 38, 4990–4996 (1999) and E. Cuche, F. Bevilacqua, and C. Depeursinge, “Digital Holography For Quantitative Phase-contrast Imaging,” Opt. Lett. 24, 291–293 (1999) which are incorporated herein by reference). Among them, digital phase-shifting interferometry stands out as a versatile and efficient technique (J. H. Bruning, D. R. Herriott, J. E. Gallagher, D. P. Rosenfeld, A. D. White, and D. J. Brangaccio, “Digital Wavefront Measuring Interferometer For Testing Optical Surfaces And Lenses,” Appl. Opt. 13, 2693–2703 (1974); J. Schwider, “Advanced Evaluation Techniques In Interferometry,” in: Progress in Optics , Vol. XXVIII, ed. E. Wolf, pp. 271–359 (North-Holland, Amsterdam, 1990) and I. Yamaguchi and T. Zhang, “Phase-shifting Digital Holography,” Opt. Lett. 22, 1268–1270 (1997) which are incorporated herein by reference).
A first attempt to electronically record the holographic information associated with a two-dimensional encrypted image has already been reported by using off-axis digital holography (B. Javidi and T. Nomura, “Securing Information By Means Of Digital Holography,” Opt. Lett. 25, 28–30 (2000) which is incorporated herein by reference) and inline digital holography (E. Tajahuerce, O. Matoba, S. C. Verrall, and B. Javidi, “Optoelectronic Information Encryption With Phase-shifting Interferometry”, Appl. Opt. 39, 23 13–2320 (2000) which is incorporated herein by reference). In this way, advantages of optical encryption such as speed, large number of degrees of freedom and high security, are combined with the usefulness of electronic information transmission.
Optical encryption and security are recent applications of optical information processing. (F, Goudail, F, Bollaro, B. Javidi, and Ph. Refregier, “Influence of A Perturbation In A Double Phase-encoding System,” J. Opt. Soc. Am. A 15, 2629–2638(1998); H. Y. Li, Qiao and D. Psaltis, “Optical Network For Real-time Face Recognition,” Appl. Opt. 32, 5026–5035 (1993); Ph. LaLanne, H, Richard, J. C. Rodier, P. Chavel, J. Taboury, K. Madani, P. Garda and F. Devos, “2D Generation of Random Numbers By Multimode Fiber Speckle for Silicon Arrays of Processing Elements,” Opt. Commun. 76, 387–394 (1990) and J. L. Horner and B. Javidi, eds., Optical Engineering Special Issue on Optical Security (SPIE, Belingham, Wash., 1999), Vol. 38, which are incorporated herein by reference). Optical systems present a good potential for these tasks because, they provide a large degree of freedom to secure data. Several different techniques exist to secure and store data by phase encoding. (T. F. Krile, M. O. Hagler, W. D. Redus and J. F. Walkup, “Multiplex Holography With Chirp-modulated Binary Phase-coded Reference-beam Masks,” Appl. Opt. 18, 52–56 (1979) and Y. H. Kang, K. H. Kim and B. Lee “Volume Hologram Scheme Using Optical Fiber for Spatial Multiplexing,” Opt. Lett. 22, 739–741 (1997) which are incorporated herein by reference) In each case the encrypted data are fully complex and thus may be recorded and stored holographically. (H. J. Caulfield, ed., Handbook of Optical Holography (Academic, London, 1979) which is incorporated herein by reference). A high quality reconstruction can be obtained by use of a high density analog recording medium. However, information recorded in this way is difficult to transmit over digital communication lines. If not digitized, or converted in some way, this information must be reconstructed optically.
One way in which fully complex information may be stored or communicated digitally is to record it with digital holography. (L. Onural and P. D. Scott, “Digital Decoding of In-line Holograms,” Opt. Eng. 26, 1124–1132 (1987); U. Schnarrs, “Direct Phase Determination In Hologram Interferometry With Use of Digitally Recorded Holograms,” J. Opt. Soc. Am . A 11, 2011–2015 (1994); G. Pedrini, Y. L. Zou and H. J. Tiziani, “Digital Double-pulsed Holographic Interferometry for Vibration Analysis,” J. Mod. Opt. 40, 367–374 (1995); J. C. Marron and K. S. Schroeder, “Three-dimensional Lensless Imaging Using Laser Frequency Diversity,” Appl. Opt. 31, 255–262 (1992); U. Schnarrs, T. M. Kreis and W. P. O. Juptner, “Digital Recording and Numerical Reconstruction of Holograms: Reduction of the Spatial Frequency Spectrum,” Opt. Eng. 35, 977–982 (1996) and E. Cuche, F. Bevilaqua and C. Depeursinge, “Digital Holography for Quantitative Phase-contrast Imaging,” Opt. Lett. 24, 291–293 (1993) which are incorporated herein by reference). With this method holograms are captured by an electronic camera and reconstructed by use of a digital computer that approximates a diffraction integral. These digital holograms may also be reconstructed optically, but digital reconstruction allows the focus to be adjusted electronically.
A method for using the CCD capabilities more efficiently is by digital phase-shifting interferometry to record the fully complex information. (K. Creath, “Phase-measurement Interferometry Techniques,” in Progress In Optics , E. Wolf, ed. (North-Holland, Amsterdam, 1990), Vol. XXVI, pp. 349–393 and T. Zhang and I. Yamaguchi, “Three-dimensional Microscopy With Phase-shifting Digital Holography,” Opt. Lett. 23, 1221–1223 (1998) which are incorporated herein by reference). This phase-measurement technique is more precise than that of digitally recording an off-axis hologram. Generally, the system errors decrease with an increase in the number of phase-shift steps used to infer the fully complex information. However, it should be noted that, with currently available technology, the largest sources of system errors are the limited resolution and dynamic range of commercially available CCD arrays.
SUMMARY OF THE INVENTION
A method and system for encrypting and decrypting multi-dimensional information or data by using digital holography is disclosed. A phase-shifting interferometer records the phase and amplitude information generated by an object at a plane located in the Fourier or Fresnel diffraction region in an intensity-recording device. This information is encrypted with the Fourier or Fresnel diffraction pattern generated by a random phase mask and stored electronically. To perform decryption, a key is also electronically recorded by phase-shifting interferometry. The encrypted hologram can be transmitted electronically to remote locations but can only be decoded with the proper keys.
After decryption, images of the object, focused at different planes, can be generated digitally or optically. The method allows for the reconstruction of the object with different perspectives from a single encrypted image. The method does not require sending the key exclusively through a digital communication channel. Instead, a copy of the random phase key itself can be sent to the authorized user.
A method of forming a remote image of an object is disclosed. The method comprises forming a hologram of the object; compressing the hologram of the object; transmitting the compressed hologram of the object to remote locations over a distributed computer network; decompressing the compressed hologram of the object; and reconstructing the object from the decompressed hologram of the object.
EXPLANATION OF THE DRAWINGS
FIG. 1 is a first schematic diagram of a phase-shifting holographic system for encrypting multi-dimensional information.
FIG. 2 is a schematic diagram of the location of the window in the hologram to generate different vertical perspectives.
FIG. 3 is an image of the three-dimensional object to be encrypted obtained by phase-shifting interferometry with the system in FIG. 1 without a reference phase mask.
FIG. 4A is a gray-level representation of the encrypted amplitude of the object of FIG. 3 by using a random phase mask.
FIG. 4B is a gray-level representation of the encrypted phase of the object of FIG. 3 by using a random reference phase mask.
FIG. 5A is a representation of the key amplitude of the random phase mask used to encrypt the information in FIG. 4A .
FIG. 5B is a representation of the key phase of the random phase mask used to encrypt the information in FIG. 4B .
FIG. 6A is the result of the decryption of the encrypted information contained in FIGS. 4A and 4B using the key in FIG. 5 .
FIG. 6B is the result of the incorrect decryption of the encrypted information in FIGS. 4A and 4B using a wrong phase key.
FIG. 7A is a first perspective of the three-dimensional object obtained after decryption at an angle of view of β˜0.7°.
FIG. 7B is a second perspective of the three-dimensional object after decryption at an angle of view of β˜0°.
FIG. 7C is a third perspective of the three-dimensional object after decryption at an angle of view of β˜0.7°.
FIG. 8 is a representation of the four step method of inducing a phase shift in the reference beam.
FIG. 9 is a schematic representation of a distributed computer network connected to the phase-shifting holographic system of FIG. 1 .
FIG. 10 is a second schematic diagram of a phase-shifting holographic system for encrypting multi-dimensional information.
FIG. 11 is a third schematic diagram of a phase-shifting holographic system for encrypting multi-dimensional information.
FIG. 12 is a schematic diagram of a phase-shifting holographic system for recording and reconstructing a multidimensional object.
FIG. 13A is a first schematic representation of an optical reconstruction of an object from a hologram.
FIG. 13B is a second schematic representation of an optical reconstruction of an object from a hologram.
FIG. 14 is a schematic representation of a phase-shifting interferometer configured to perform Fourier encryption of an input object with two random phase masks;
FIG. 15A–15C is a schematic representation of a method of encryption, obtaining a key and decryption of an object;
FIG. 16 is a schematic representation of a phase shifting interferometer configured to perform Fresnel encryption of an input object;
FIG. 17 is a representation of information to be encrypted by Fourier transformation of the input obtained by digital phase-shifting interferometry of FIG. 14 without a reference phase mask;
FIG. 18A–18C is a representation of encrypted images of the input of FIG. 17 wherein FIG. 18A is a gray level representation of the phase distribution obtained by phase shifting interferometry, FIG. 18B is the amplitude distribution and 18 C shows the reconstruction of the input object from the complex amplitude distribution associated with FIGS. 18A and 18C ;
FIG. 19A–19C is a representation of the key and decryption of FIG. 17 wherein FIG. 19A is a gray level representation of the phase distribution of the key at the output plane obtained by phase-shifting interferometry, 19 B is the amplitude distribution and 19 C shows the reconstruction of the input object when the phase and the amplitude distribution in FIG. 18A–18C are corrected with the key;
FIG. 20 is a representation of information to be encrypted by Fresnel propagation of the input signal obtained by digital phase-shifting interferometry with the optical system of FIG. 16 without the reference phase mask;
FIG. 21A–21C is a representation of encrypted images of the information in FIG. 20 obtained by phase-shifting interferometry with the system of FIG. 16 wherein FIG. 21A is a gray level representation of the phase distribution, FIG. 21B is the amplitude distribution and FIG. 21C shows an attempt to reconstruct the input object from the complex amplitude distribution associated with FIGS. 21A and 21B ; and
FIG. 22A–22C is a representation of the key and decryption of the information in FIG. 20 wherein FIG. 22A is a gray-level representation of the phase distribution of the key at the output plane, FIG. 22B is the amplitude distribution of the key and FIG. 22C shows the successful reconstruction of the input object when the phase and amplitude distribution in FIG. 21A–22 c are corrected with the previous key.
DETAILED DESCRIPTION OF THE INVENTION
A system for encrypting multi-dimensional information or data is shown generally at 100 in FIG. 1 . The system 100 is based on an interferometer, such as a Mach-Zehnder interferometer. A first beam splitter 106 divides polarized and collimated light 102 originating from a laser, such as an Argon laser, a Helium-Neon laser an infrared laser or similar laser (not shown) embracing a range of wavelengths, into a reference beam (or reference set of data) 102 a , 102 aa and an object beam 102 b , 102 c 102 e.
With a first diaphragm 116 open, and a second diaphragm 118 closed, the object beam 102 b , 102 c illuminates a moving or still object, such as an opaque three-dimensional object 132 (to be encrypted), after reflecting in a second beam splitter 114 and reflection at mirror 122 . The object 132 may also be, for example, a two-dimensional or three-dimensional phase object, a color object, an original set of data comprising an optical image, a digitized image, a computer generated image, a one dimensional set of data or multi-dimensional set of data, an electrical signal or an optical signal. The object 132 is shown as a three-dimensional object by way of exemplification.
Assuming that the incident light 102 c is diffracted from the object 132 only once, the object 132 can be described at an output plane 130 as a three-dimensional continuum distribution of point sources with relative amplitude U O (x,y,z), were x, and y are transverse coordinates and z is the paraxial distance from the object 132 to the output plane 130 . In this manner, the complex amplitude distribution, U H (x,y), at the output plane 130 , can be evaluated from the following three-dimensional superposition integral:
U H ( x , y ) = A H ( x , y ) exp [ ⅈ ϕ H ( x , y ) ] = 1 ⅈ λ ∫ ∫ - ∞ ∞ ∫ U o ( x ′ , y ′ ; z ) × 1 z exp [ ⅈ 2 π λ z ] exp { ⅈ π λ z [ ( x - x ′ ) 2 + ( y - y ′ ) 2 ] } ⅆ x ′ ⅆ y ′ ⅆ z ( 1 )
where λ is the wavelength of the incident light. In Eq. (1), A H (x,y) and φ H (x,y) are the amplitude and phase, respectively, of the complex amplitude distribution, U H (x,y), at the output plane 130 generated by the object beam 102 e diffracted from the object 132 . In this approximation, neglecting secondary diffraction, the object 132 can be considered also as a continuum of two-dimensional images at different distances z to the output plane 130 .
The reference beam 102 a travels through two phase retarders 108 , 110 and is diffracted by a random phase mask 112 . The light so diffracted 102 aa is reflected by a third beam splitter 126 and interferes, at 102 f , with the light 102 e diffracted by the three-dimensional object 132 . The interference pattern of the object beam 102 e and the diffracted reference beam 102 aa is recorded as a hologram in the output plane 130 of a detector 128 , such as a CCD detector or an optically or electrically addressable spatial light modulator. The phase retarders 108 , 110 are quarterwave (λ/4), and halfwave (λ/2) plates. As seen in FIG. 8 the phase retarders 108 , 110 allow for the modulation or shifting of the phase, φ, of the reference beam 102 a with respect to the object beam 102 b . In this manner, phase shifts, Δφ p , of Δφ 1 =0, Δφ 2 =−π/2, Δφ 3 =−π, and Δφ 4 =−3π/2 are introduced into the reference beam 102 a with respect to the object beam 102 b by the relative positioning of the fast and slow axes of the phase retarders 108 , 110 with the polarization of the incident light 102 a . The aforesaid phase shifts, Δφ p , may also be introduced into the reference beam 102 a with respect to the object beam 102 b by other methods or apparatus, such as the use of a liquid crystal chip in place of the phase retarders 108 , 110 or by the movement of mirror 120 . The phase mask 112 , with a random phase distribution of φ(x,y), and located at a distance L=L 1 +L 2 from the output plane 130 ( FIG. 1 ), generates a complex field, U R (x,y;Δφ p ), for each of the aforesaid phase shifts, Δφ p , given by the following Fresnel integral:
U
R
(
x
,
y
;
Δ
φ
p
)
=
exp
[
ⅈΔ
φ
p
]
exp
[
ⅈ
π
λ
L
(
x
2
+
y
2
)
]
×
∫
-
∞
∞
∫
exp
[
ⅈϕ
(
x
′
,
y
′
)
]
exp
[
ⅈ
π
λ
L
(
x
′2
+
y
′2
)
]
exp
[
-
ⅈ
2
π
λ
L
(
xx
′
+
yy
′
)
]
ⅆ
x
′
ⅆ
y
′
(
2
)
In Eq. 2 constant factors other than Δφ p have been neglected. Equation (2) can be written in the form of a convolution as:
U R ( x , y ; Δ φ p ) = A R ( x , y ) exp [ ⅈ ( φ R ( x , y ) + Δ φ p ) ] = exp ( ⅈ Δ φ p ) exp [ ⅈ Φ ( x , y ) ] ⊗ exp [ ⅈ π λ L ( x 2 + y 2 ) ] ( 3 )
(J. W. Goodman, Introduction to Fourier Optics , McGraw-Hill, New York, (1996)).
In Eq. 3, A R (x,y) and φ R (x, y) are the amplitude and phase, respectively, of the complex amplitude distribution, U R (x,y;Δφ p ) at the output plane 130 generated by the reference beam 102 a when both fast axes of the phase retarders 108 , 110 are aligned with the direction of polarization, i.e., when Δφ p =0. Since Φ(x,y) is a random phase distribution, from Eq. (3) it may be concluded that A R (x,y) and φ R (x,y) are random, noise-like functions.
The interference pattern, I p (x,y), of the combination of U H (x,y) and U R (x,y;Δφ p ) is recorded digitally, or on film, as a hologram at the output plane 130 . Such digital recording may be in the form, for example, of tangible media, such as floppy diskettes, CD-ROMs, hard drives, electrically or optically addressable spatial light modulators, charge coupled devices or any other computer-readable storage medium addressable across a distributed environment such as a computer or communications network system. I p (x,y) is given by the coherent superposition of Eqs. (1) and (3), i.e.
I
p
(
x
,
y
)
=
[
A
H
(
x
,
y
)
]
2
+
[
A
R
(
x
,
y
)
]
2
+
2
A
H
(
x
,
y
)
A
R
(
x
,
y
)
cos
[
ϕ
H
(
x
,
y
)
-
φ
R
(
x
,
y
)
-
Δ
φ
p
]
(
4
)
Recording four interference patterns, I p (x,y), (or holograms) with the phase of the reference beam 102 a shifted by Δφ p , it is possible to obtain the encrypted phase and encrypted amplitude of the object 132 . From Eq. (4) it is straightforward to show that the encrypted phase, φ E (x,y), of the hologram is given by:
ϕ E ( x , y ) = ϕ H ( x , y ) - φ R ( x , y ) = arc tan ( I 4 - I 2 I 1 - I 3 ) ( 5 )
The encrypted amplitude, A E (x,y), of the hologram can be calculated from the following equation:
A E ( x , y ) = A H ( x , y ) A R ( x , y ) = 1 4 [ ( I 1 - I 3 ) 2 + ( I 4 - I 2 ) 2 ] 1 / 2 ( 6 )
For simplicity, the spatial dependence of I p (x,y) has been omitted from Eqs. (5) and (6). The two functions given by Eqs. (5) and (6), i.e., the amplitude A E (x,y) and the phase φ E (x,y), constitute the encrypted image. Without knowledge of the functions A R (x,y) and φ R (x,y), which act as keys for decryption, it is very difficult to recover the amplitude A H (x,y) and phase φ H (x,y) in order to reconstruct images of the three-dimensional object 132 by inverse Fresnel propagation. Alternatively, the random phase mask 112 and its three-dimensional position can also act as the key. In contrast with other phase encryption methods, not only the phase, but also the amplitude, of the diffraction pattern of the object 132 is modified by the introduction of the random phase mask 112 into the reference beam 102 a . Furthermore, instead of a Fraunhofer diffraction pattern, a Fresnel diffraction pattern of the object 132 is used for encryption. Therefore, phase retrieval algorithms are difficult to apply. Still further, by dealing with Fresnel diffraction patterns, the intensity of the output images is properly adapted to the dynamic range of the CCD 128 . As seen in FIG. 10 , it is also possible to effect encryption of the object 132 by utilizing a random phase mask 112 a located a distance L 3 from the output plane 130 within the object beam 102 e and without the random phase mask 112 in the reference beam 102 a . In addition, it will be appreciated that the random phase masks 112 a , 112 of FIGS. 1 and 10 may be utilized in combination to accomplish encryption of the object 132 as shown in FIG. 11 . This improves security, as the number of keys is increased, but it would be necessary to perform two Fresnel propagation steps to reconstruct the object 132 . The following are incorporated herein by reference in their entirety: P. Refregier and B. Javidi, Optical Image Encryption Using Input and Fourier Plane Random Phase Encoding , Journal of Optics Letters, vol. 20, pp. 767–769, Apr. 1, 1995; B. Javidi, Encrypting Information with Optical Technologies , Physics Today, vol. 50, no. 3, March 1997; N. Towghi, B. Javidi, and Z. Luo, Fully Phase Encrypted Image Processor , Journal of the Optical Society of America A (Optics, Image Science and Vision), Vol. 16, No. 8, pp. 1915–1927 (August 1999).
To obtain the functions that can be used as keys for decrypting the encrypted information (or set of data), diaphragm D 3 is open, diaphragm D 2 closed and the object 132 is removed from the interferometer 100 . Item 124 is a mirror. Now the reference beam 102 aa and the object beam 102 d interfere in-line at the output plane 130 . In this way, a second set of four intensity patterns, I′ p (x,y), are recorded by adjusting or shifting the phase of the reference beam 102 a as before. Now, the phase key, φ K (x,y), for decrypting the encrypted object (or set of data) is calculated from:
ϕ K ( x , y ) = ϕ C - φ R ( x , y ) = arc tan ( I 4 ′ - I 2 ′ I 1 ′ - I 3 ′ ) ( 7 )
and the amplitude key, A K (x,y), for decrypting the encrypted object, is calculated from:
A K ( x , y ) = A C A R ( x , y ) = 1 4 [ ( I 1 ′ - I 3 ′ ) 2 + ( I 4 ′ - I 2 ′ ) 2 ] 1 / 2 ( 8 )
The parameters φ C and A C are respectively, the constant phase and amplitude of the object beam 102 d and can be replaced with constant values, such as 0 and 1 respectively.
In a first embodiment decryption is performed by combining A E (x,y) and φ E (x,y) with A K (x,y) and φ K (x,y) in the following way:
ϕ
D
(
x
,
y
)
=
ϕ
E
(
x
,
y
)
-
ϕ
K
(
x
,
y
)
and
(
9
)
A
D
(
x
,
y
)
=
{
A
E
(
x
,
y
)
A
K
(
x
,
y
)
,
if
A
K
(
x
,
y
)
≠
0
0
otherwise
(
10
)
In a second embodiment, decryption can be performed directly form the intensity measurements in the following manner:
ϕ D ( x , y ) = arc tan [ ( I 4 - I 2 ) ( I 1 ′ - I 3 ′ ) - ( I 1 - I 3 ) ( I 4 ′ - I 2 ′ ) ( I 4 - I 2 ) ( I 4 ′ - I 2 ′ ) - ( I 1 - I 3 ) ( I 1 ′ - I 3 ′ ) ]
and ( 11 ) A D ( x , y ) = [ ( I 1 - I 3 ) 2 + ( I 4 - I 2 ) 2 ( I 1 ′ - I 3 ′ ) 2 + ( I 4 ′ - I 2 ′ ) 2 ] 1 / 2 ( 12 )
In Eqns. 11 and 12, the two functions I 13 (x,y)=I 1 (x,y)−I 3 (x,y) and I 42 (x,y)=I 4 (x,y)−I 2 (x,y) constitute the encrypted information, while the functions I′ 13 (x,y)=I′ 1 (x,y)−I′ 3 (x,y) and I′ 42 (x,y)=I′ 4 (x,y)−I′ 2 (x,y) act as the decryption key.
The functions A D (x,y) and φ D (x,y) constitute the amplitude and phase of the decrypted Fresnel hologram which is given by U D (x,y)=A D (x,y) exp[iφ D (x,y)]. Except for constant factors, U D (x,y) reproduces the Fresnel hologram, U H (x,y), of the three-dimensional object 132 as set forth in Eqn. (1). Thus, by the free-space propagation of U D (x,y), the amplitude distribution of the object 132 can be reconstructed.
In FIG. 13A , the reconstruction of the object from encrypted or unencrypted holograms may be performed optically rather than digitally. An electrically addressable spatial light modulator 220 a is interfaced with the detector 128 . The digital holograms 224 a are displayed on the electrically addressable spatial light modulator 220 a . The encrypted or unencrypted hologram 224 a is propagated by a reference wave 102 g . The encrypted hologram is passed through an optical key 222 to reconstruct the original object 132 a in a reconstruction plane 130 a . The optical key 222 is not necessary for the unencrypted hologram. In FIG. 13B , the encrypted or unencrypted hologram 224 b , such as an off-axis hologram, is formed by an optically addressable spatial light modulator 220 b such as a liquid crystal light valve or Ferro-electric spatial light modulator. The encrypted or unencrypted hologram 224 b is read out from the output of the optically addressable spatial light modulator 220 b and propagated by a reference wave 102 g . The encrypted hologram is passed through an optical key 222 to reconstruct the original object 132 a in a reconstruction plane 130 a . The optical key 222 is not necessary for the unencrypted hologram. As best understood from FIGS. 13A and 13B the optical key 222 may be in substantially the same plane as the spatial light modulators 220 a , 220 b and is shown separated for clarity. The following are incorporated herein by reference B. Javidi and J. L. Horner, Real - time Optical Information Processing , Academic Press, 1994, B. Javidi, Optical Information Processing , Encyclopedia of Electrical and Electronic Engineering, Volume on Optics, John Wiley, 1999.
Digital reconstruction of the object 132 is performed by numerically computing a Fresnel integral. Let U D (m,n) be the discrete amplitude distribution of a decrypted digital hologram, where m and n are discrete coordinates in the plane of the digital hologram, along the orthogonal directions x and y, respectively. In this way, x=mΔx and y=nΔy, where Δx and Δy are the resolution of the detector. The discrete complex amplitude distribution, U O (m′,n′), of the reconstructed object, located at a plane orthogonal to the decrypted digital hologram, and at a distance d from the decrypted digital hologram, is given, aside from constant factors, by the following discrete Fresnel transformation:
U
o
(
m
′
,
n
′
)
=
exp
[
-
ⅈ
π
λ
d
(
Δ
x
′2
m
′2
+
Δ
y
′2
n
′2
)
]
∑
m
′
=
0
N
x
-
1
∑
n
′
=
0
N
y
-
1
U
D
(
m
,
n
)
⨯
exp
[
-
ⅈπ
λ
d
(
Δ
x
2
m
2
+
Δ
y
2
n
2
)
]
exp
[
-
ⅈ2π
(
m
′
m
N
x
+
n
′
n
N
y
)
]
(
13
)
In Eq. (13), m′ and n′ are discrete coordinates in the reconstruction plane, Δx′ and Δy′ denote the resolution in that plane, and N x and N y are the number of pixels of the detector along the x and y axis, respectively. It can be shown that the resolutions Δx′ and Δy′ along the horizontal and vertical directions of the reconstruction plane are given by:
Δ x ′ = λ d N x Δ x , and
Δ y ′ = λ d N y Δ y ( 14 )
In this manner, the resolution of the image of the reconstructed object improves as the number of samples in the hologram plane increases.
Referring now to FIG. 2 , a decrypted digital hologram is shown at 206 . Different regions, or windows, of the decrypted digital hologram 206 record light arising from different perspectives, views or segments of the three-dimensional object 132 . Thus, different perspectives, views, or segments, of the three-dimensional object 132 can be reconstructed by defining different windows 206 a within the decrypted digital hologram 206 and illuminating the windows 206 a with plane waves tilted at an angle of β with respect to the optical axis 202 . To this end, assume that the input object 132 to be encrypted is located at a distance d from the CCD 128 . To reconstruct a particular view of the decrypted three-dimensional object 132 , a rectangular window 206 a (or subset) is defined within the decrypted digital hologram 206 and centered at the location, a x ,a y . The information contained within this window 206 a corresponds to a particular direction of observation 208 that subtends angles α and β with respect to the optical axis 202 . These angles are given by:
α = a x Δ x d , and
β = a y Δ y d ( 15 )
In FIG. 2 , a x equals zero.
The decrypted digital hologram 206 is illuminated by a light beam directed towards the window 206 a at angles α and β with respect to the optical axis 202 as given by Eq. (15). In this manner, the perspective of the object 132 will remain centered in the reconstruction of the object 132 . The angular range achieved will be limited only by the size of the detector.
From the above considerations, a partial discrete amplitude distribution, U′ D (m,n;a x ,a y ), is defined over the window 206 a within the decrypted digital hologram 206 , and is used for reconstructing a segment of the object 132 . The partial discrete amplitude distribution is given by:
U D ′ ( m , n ; a x , a y ) = U D ( m , n ) rect ( m - a x b x , n - a y b y ) exp [ ⅈ 2 π ( a x m + a y n ) ] ( 16 )
where rect(g,h) is the so called rectangle function and b x and b y denote the transverse size of the window 206 a . The linear phase factor in Eq. (16) simulates the effect of a tilted plane wave incident upon the decrypted digital hologram 206 . Now, the discrete complex amplitude distribution, U′ O (m′, n′;α,β), of a particular perspective, view or segment of the reconstructed object at a plane located at a distance d from the decrypted digital hologram 206 and tilted by angles α and β with respect to the optical axis 202 can be computed using the following equation:
U o ′ ( m ′ , n ′ ; α , β ) = exp [ - ⅈ π λ d ( Δ x ′2 m ′2 + Δ y ′2 n ′2 ) ] ∑ m ′ = 0 N x - 1 ∑ n ′ = 0 N y - 1 U D ′ ( m , n ; α d Δ x , β d Δ y ) ⨯ exp [ - ⅈ π λ d ( Δ x 2 m 2 + Δ y 2 n 2 ) ] exp [ - ⅈ2 π ( m ′ m N x + n ′ n N y ) ] ( 17 )
The introduction of the linear phase factor in Eq. (16) is equivalent to a tilted plane wave illuminating the hologram in Eq. (17).
The geometry of the configuration for the particular case of a vertical variation in the perspective of the object (e.g., restricted to a x =0) is depicted in FIG. 2 . The maximum angle of view, β max , is a function of the CCD size and the window size, β max =(N y −b y )Δy/d. This range in β can be increased by increasing the size of the CCD or by decreasing the size of the window used for reconstruction. However, as pointed out in Eq. (14), the resolution of the reconstructed object decreases by selecting smaller windows. Nevertheless, the hologram window 206 a does not need to be square. Therefore, when a set of perspectives is obtained in only one direction, it is possible to improve the resolution of the object reconstruction by increasing the size of the hologram window 206 a in the transverse direction, as is shown in FIG. 2 .
Equation (17) can be efficiently computed using a fast Fourier transform algorithm (J. W. Cooley, J. W., Tukey, “An Algorithm For The Machine Calculation Of Complex Fourier Series,” Math. Comput. 19, 297–301 (1965) which is incorporated herein by reference). Thus, different perspectives can be generated at high speed. Points on the surface of the object 132 at distances z from the hologram where z≠d will appear defocused in the image of the reconstructed object. Nevertheless, the planes of reconstruction can also be changed easily in the computer starting from the same digital hologram. The field of focus can be increased by diminishing the size of the hologram window 206 a at the expense of a reduction in resolution.
Encryption of a three-dimensional object was performed with the phase-shifting interferometer 100 depicted in FIG. 1 . A mega-pixel camera 128 with pixel size equal to 9×9 μm was used to record the interference patterns between the object beam 102 c , 102 e and the reference beam 102 aa with a dynamic range equivalent to 256 grey levels. The object 132 was the shape of a cube of about 10 mm lateral size. In FIG. 3 an axial view of the object 132 reconstructed from a non-encrypted digital hologram using Eq. (13) is shown. The object 132 was located at a distance of d equal to about 570 mm from the camera 128 and without a phase mask in the reference beam 102 a . Diaphragm D 2 was open and diaphragm D 3 was closed in order to illuminate the three-dimensional object 132 . The resolution of the re-constructed image was limited by the size of the camera 128 , which acts as an aperture in the reconstruction process, as is shown in Eq. (14). The quality of the image is also affected by speckle. The speckle size is, roughly speaking, equal to 1.2 λ/NA, where NA is the numerical aperture of the system. Thus, the size of the speckle is approximately equal to the resolution of the image of the reconstructed object given by Eq. (14).
FIG. 4A is a gray-level representation of the encrypted amplitude of the object computed from Eqn. (6) using a random phase mask as in FIG. 1 . FIG. 4B is a gray-level representation of the encrypted phase of the object computed from Eqn. (5) using a random phase mask as in FIG. 1 . The random phase mask 112 was a plastic diffuser of randomly varying thickness with a correlation length of about 6 μm in both the x and y directions.
FIG. 5A is a gray-level representation of the amplitude key used to decrypt the information in FIG. 4A . FIG. 5B is a representation of the phase key used to decrypt the information in FIG. 4B . The amplitude and phase keys of FIGS. 5A and 5B were generated at the output plane 130 utilizing the random phase mask 112 and by removing the object 132 , closing diaphragm D 2 and opening diaphragm D 3 . From the encrypted and key interference patterns the decrypted hologram is obtained by using Eqs. (9) and (10) or Eqs. (11) and (12). The decrypted image shown in FIG. 6A was generated using the entire decrypted hologram. By way of comparison, FIG. 6B shows a decryption performed without the correct keys. Noise in the image of the decrypted object arises from errors, generated by the random phase mask 112 , in the evaluation of the Fresnel diffraction pattern in the CCD. These errors are due to the limited size of the detector pixels and the grey-level quantization.
FIG. 7 shows different perspectives of the decrypted three-dimensional object 132 reconstructed from the decrypted digital Fresnel hologram 206 . A rectangular window 206 a was used limited to a vertical size, by, of 256 pixels and horizontal size, b x , equal to the size of the CCD. The size reduction is used to reconstruct different perspectives from different regions 206 a of the decrypted digital hologram 206 . However, this also reduces the resolution and, consequently, the quality of the images with respect to those obtained using the whole decrypted digital hologram 206 . Thus, only the size of the window 206 a in the direction for which different views of the three-dimensional object 132 are need is reduced (e.g. in they direction in the example of FIG. 2 ). In this embodiment, the window 206 a was displaced only in the vertical direction generating an angular difference of about 0.7 degrees between the different perspectives shown in FIGS. 7A , 7 B and 7 C. Any other view angle, limited only by the size of the CCD, can be reconstructed in the same way.
Referring to FIG. 9 , the detector 128 is shown connected to a distributed computer or communications network 400 , such as a local area network (LAN) or a wide area network (WAN) via a computer 402 . The detector 128 may also be connected directly to a liquid crystal display (LCD), liquid crystal television (LCTV) or an electrically or optically addressable spatial light modulator or ferroelectric spatial light modulator 412 a . The computer network 400 includes a plurality of similar client personal computers 404 connected to a server 410 from remote geographical locations by wired or wireless connections, by radio based communications, by telephony based communications, or by other network-based communications. The computer 402 may also be connected directly to another like computer 402 or to a display device 412 , such as a liquid crystal display (LCD), liquid crystal television (LCTV) or an electrically, or optically addressable spatial light modulator (SLM) for optical reconstruction of the 3D object 132 or set of data. The computer network 400 is in turn similarly connected to other computers 502 or networks 504 through the Internet 500 . The computers 402 , 404 , 504 , display devices 412 , 412 a and other devices of the networks 400 , 500 , 504 are configured to execute program software, that allows them to send, receive, record, store and process the encrypted and decrypted holograms, the encrypted sets of data, decryption keys and decrypted sets of data between and amongst themselves via the networks 400 , 504 and the Internet 500 . Such processing includes, for example, various image compression and decompression, filtering, contrast enhancement, image sharpening, noise removal and correlation for image classification. Decompressed images may be displayed on display devices such as liquid crystal displays, liquid crystal TVs or electrically or optically addressable spatial light modulators. This embodiment has applications in the serial three dimensional imaging of moving objects, such as in three dimensional TV, three dimensional video, three dimensional movies as well as three dimensional display and three dimensional visualization and other similar applications. Thus serial images may be formed of moving objects by forming a series of original encrypted holograms of the moving objects; compressing the series of original encrypted holograms of the moving objects to form a series of compressed encrypted holograms; decompressing the series of compressed encrypted holograms to form a series of decompressed encrypted holograms; and reconstructing the moving objects from the series of decompressed encrypted holograms to form a series of multi-dimensional images of the moving objects.
Thus, based upon the foregoing description, an optoelectronic holographic method and system for encrypting and decrypting multi-dimensional information or data, based upon phase-shifting interferometry, has been shown. Such method allows for the securing of three-dimensional scenes or data. The holographically encrypted data can be transmitted through conventional digital communication channels to remote locations and the data decrypted and reconstructed digitally or optically. Different views or segments of the decrypted three-dimensional object can be reconstructed at different axial distances and at different perspectives. Since an optical system is utilized to record the digital hologram, optical encryption with a random phase mask represents a convenient way to secure both two and three-dimensional objects or information. Furthermore, in this manner, to increase security, the method allows for the avoidance of electronic transmission of decryption keys if so desired. Still further, other electronic encryption methods can also be applied to the digital hologram. In the methods of this invention, after electronic transmission of the encrypted information or data, decryption is carried out digitally or optically. Alternatively, decryption can be performed optically by generating the decrypted digital hologram as a computer generated hologram and displaying it, for example, on an electrically addressable spatial light modulator, liquid crystal television or liquid crystal display.
In accordance with a second embodiment of the invention, an optical encryption method based upon digital phase-shifting interferometry may be used to record the fully complex encrypted information. Fourier and Fresnel domain optical encryption is achieved by the use of one or more random phase masks attached to the input in the object beam and another phase mask at a variable position in the reference beam of a Mach-Zehnder phase-shifting interferometer. The fully complex key to be used in the decryption process is also obtained by phase-shifting interferometry. The encrypted information can easily be transmitted over digital communication lines, and the key can be transmitted either electronically or by means of making controlled copies of the reference phase mask used in the encryption procedure. The decryption can thus be performed either electronically or optoelectronically.
The encryption is performed immediately and directly on the fully complex information and that the decryption procedure, if performed electronically, requires no more computation than the usual image reconstruction procedures. Therefore the potential for a significant speed advantage over fully digital encryption techniques is quite apparent. After decryption, electronic reconstruction with a one-step fast Fourier transform (FFT) procedure or optical reconstruction methods can be applied. With optical decryption, the correct phase key must be positioned in three-dimensional space to successfully decrypt the data.
In FIG. 14 , in an interferometer 100 , such as a Mach-Zehnder interferometer, an argon laser beam 102 , is expanded 146 , collimated 148 , and divided by a beam splitter 106 into two plane wave fronts traveling in different directions. These are the object beam 102 b and the reference beam 102 a . After reflecting in a mirror 124 , the object beam 102 b impinges on a multi-dimensional input object or transparency 132 , whose amplitude transmittance, t(x,y), contains the data to be encrypted. A refractive lens 140 forms a representation of the Fourier transform of the input into the output plane 130 of a CCD detector 128 through the second beam splitter 126 . The detector is connected to a distributed computer or communications network 400 as in FIG. 9 . To improve the dynamic range of the Fourier transform in the output plane 130 , and to make it more difficult to obtain the power spectra of the input object 132 , a random phase mask 132 a , with phase φ 1 (x,y) is attached to the input object 132 . Therefore, aside from constant factors, the complex amplitude distribution, U 0 (x,y), of the Fraunhofer diffraction pattern at the output plane 130 is approximated by:
U 0 ( x , y ) = exp [ ⅈ π f ( 1 - d f ) ( x 2 + y 2 ) ] ⨯ ∫ ∫ - ∞ ∞ t ( x ′ , y ′ ) exp [ ⅈ ϕ 1 ( x ′ , y ′ ) ] ⨯ exp [ - ⅈ 2 π λ f ( xx ′ + yy ′ ) ] ⅆ x ′ ⅆ y ′ ( 18 )
where d is the distance between the input and the refractive lens, f is the focal length of the lens, and λ is the wavelength of the laser beam 102 . Aside from the phase factor outside the integral, the complex amplitude distribution is the Fourier transform of the product of the input transmittance and the input phase mask. A Fourier transformation is obtained when d=f. By measuring the amplitude and the phase of, U 0 (x,y), we can recover the amplitude of the input function t(x,y), from the inverse Fourier transform intensity.
The parallel reference beam passes though two phase retarders 108 , 110 , one quarter and one half wave plate; is reflected by a mirror 120 ; and is modified by a second random phase mask 112 . The system is aligned such that, without the phase mask 112 , the reference beam 102 a generates a plane wave 102 f traveling perpendicular to the CCD 128 sensor after reflecting in the second beam splitter 126 . The light provided by the argon laser 142 is linearly polarized. In this way, by suitable orientation of the phase retarders 108 , 110 , the phase of the reference beam 102 a can be changed, as shown in FIGS. 8A–8D . Assume that the phase of the parallel beam 102 a after the second plate 110 is φ o when the fast axes of both plates 108 , 110 are aligned with the direction of polarization of the incident light 102 a . By successively aligning the different slow and fast axes of the phase retarders 108 , 110 with the direction of the polarization, phase values φ o +α with α=−π/2, −π and −3π/2 can be produced with high accuracy, as shown in FIGS. 8A–8D .
The reference phase mask 112 has a random phase distribution φ 2 (x,y) and is placed at a distance z=z 1 +z 2 from the CCD 128 , as shown in FIG. 14 . The complex amplitude distribution of the reference beam as in the output plane 130 can be calculated by use of the Fresnel-Kirchhoff integral with the following expression
U R ( x , y : α ) = exp ( ⅈα ) [ ⅈ π λ z ( x 2 + y 2 ) ] ⨯ ∫ ∫ - ∞ ∞ exp [ ⅈ ϕ 2 ( x ′ , y ′ ) ] exp [ ⅈ π λ z ( x ′2 + y ′2 ) ] ⨯ exp [ - ⅈ 2 π λ z ( xx ′ + yy ′ ) ] ⅆ x ′ ⅆ y ′ ( 19 )
where α denotes the relative phase changes introduced by the retarder plates 108 , 110 on the reference beam 102 a . Constant phase factors are omitted in Eqn. 19.
The intensity pattern recorded by a linear intensity recording device, such as a CCD camera 128 , is then given by
I ( x,y ;α)=| U o ( x,y )+U R ( x,y ;α)| 2 (20)
with U 0 and U R given by Equations 18 and 19, respectively. Since Eqn. 19 provides a random-noise-like phase and amplitude distribution, the image provided by the CCD 128 will also look like a random intensity distribution.
The complex light field at the output plane 130 can be evaluated with digital phase-shifting interferometry when four intensity patterns are recorded with the reference beam 102 a phase shifted by α=0, π/2, π and 3π/2. The phase shifting is accomplished by suitable orientation of the retarder plates 108 , 110 located in the path of the reference beam 102 a (see FIG. 8A–8D ). Denoting the complex amplitude distribution of the object 132 and the reference beams 102 a at the output plane 130 with U 0 =A o (x,y)exp[iφ(x,y)] and U R =A R (x,y)exp{i[φ(x,y)+α]} respectively, Eqn. 20 can be rewritten as
I ( x,y ;α)=[ A o ( x,y )] 2 +[A R ( x,y )] 2 +2 A o ( x,y )× A R ( x,y )cos[φ o ( x,y )−φ( x,y )−α] (21)
In this way it can be shown that the phase φ E (x,y) provided by this phase-shifting interferometric technique is given by
ϕ
E
(
x
,
y
)
=
ϕ
o
(
x
,
y
)
-
φ
(
x
,
y
)
arctan
[
I
(
x
,
y
;
-
3
π
/
2
)
-
I
(
x
,
y
;
-
π
/
2
)
I
(
x
,
y
;
0
)
-
I
(
x
,
y
;
-
π
)
]
(
22
)
The amplitude, A E (x,y), can be calculated from the following equation:
A E ( x , y ) = A o ( x , y ) A R ( x , y ) = 1 4 I ( x , y ; 0 ) - I ( x , y ; - π ) cos [ ϕ o ( x , y ) - φ ( x , y ) ] ( 23 )
where the argument of the cosine function in the denominator is obtained directly from Eq. 22.
It is difficult to recover the complex amplitude distribution, U O (x, y), generated by the object beam 102 b . Since φ(x,y) and A R (x,y) are random functions, the phase φ o (x, y) and the amplitude, A o (x,y) can not be obtained from Eqns. 22 and 23, respectively. Thus, it is difficult to obtain the input function, t(x, y), by an inverse Fourier transformation. The input data are encrypted such that they can be decrypted only with knowledge of the reference complex amplitude distribution U R (x, y;0) or the reference phase mask φ 2 (x, y) and its three-dimensional position, which is acting as a key. The phase and the amplitude given by Eqns. 22 and 23, respectively, can be simply understood as the phase and the amplitude of the product of the Fourier complex amplitude, U O (x, y), with a second random complex amplitude distribution, which is the complex conjugate of U R (x, y;0). When the reference phase mask 112 is imaged over the output detector 128 instead of using Fresnel propagation, the encrypted image is that which is achieved by the double phase method. However, with this new technique we improve on the security extending the encryption to the Fresnel domain, and we can store, process and transmit the encrypted information easily without the help of holographic recording media. In FIG. 15A , a diagram of the encryption procedure is shown.
To decrypt the information and obtain the original complex amplitude distribution U O (x, y), we also use the phase-shifting interferometry technique to achieve the key complex distribution U R (x, y;0). By removing the input transparency 132 , the input phase mask 132 a , and the Fourier transforming lens 140 in the optical system 100 in FIG. 14 , the phase and the amplitude of the Fresnel diffraction pattern generated by the reference phase mask 112 can be measured. In this case, the intensity at the output plane 130 is given by:
I ′( x,y ;α)=| A c exp( i φ c )+ U R ( x,y ;α)| 2 (24)
where A C and φ C are the constant amplitude and phase, respectively, of the object beam at the output plane. The phase, φ K (x, y), and the amplitude, A K (x, y), provided by the phase-shifting interferometry technique are now
ϕ K ( x , y ) = ϕ c - φ ( x , y ) = arctan [ I ′ ( x , y ; - 3 π / 2 ) - I ′ ( x , y ; - π / 2 ) I ′ ( x , y ; 0 ) - I ′ ( x , y ; - π ) ] ( 25 ) A K ( x , y ) = A c A R ( x , y ) = 1 4 I ( x , y ; 0 ) - I ( x , y ; - π ) cos [ ϕ o - φ ( x , y ) ] ( 26 )
respectively.
Parameters φ c and A c in Eqs. 25 and 26 are only constant factors and thus can be simply substituted by 0 and 1, respectively. Thus Eqs. 25 and 26 allow us to obtain directly the key functions φ(x, y) and A R (x, y). The complex amplitude distribution U o (x, y) can be obtained when we combine Eqs. 25 and 26 with Eqs. 22 and 23 in the following way:
ϕ
o
(
x
,
y
)
=
ϕ
E
(
x
,
y
)
-
ϕ
K
(
x
,
y
)
(
27
)
A
o
(
x
,
y
)
=
{
A
E
(
x
,
y
)
A
K
(
x
,
y
)
,
if
A
K
(
x
,
y
)
≠
0
0
otherwise
(
28
)
A diagram of the procedure for obtaining the key is shown in FIG. 15B . By proper propagation of the previously obtained complex amplitude distribution, U 0 (x, y), with the Fresnel-Kirchhoff integral, it is possible to obtain the intensity distribution in any other plane of the incident light beam within the paraxial approximation. In particular, the input object intensity can be recovered by an inverse Fourier transformation. FIG. 15C corresponds to the diagram of the decryption procedure. The reconstruction can be implemented both optical and digitally. For the direct computer reconstruction we perform the following inverse discrete Fourier transformation of the complex amplitude distribution characterized by Eqs. 27 and 28, i.e.,
t ( m , n ) 2 = ∑ m ′ = 0 N - 1 ∑ n ′ = 0 N - 1 U o ( m ′ , n ′ ) exp [ ⅈ 2 π N ( mm ′ + nn ′ ) ] 2 ( 29 )
where m′ and n′ are the discrete spatial coordinates in the CCD plane 130 and m, n are those corresponding to the object plane. If we consider only the horizontal transversal direction, we have x′=m′ Δx′=mΔx′, with Δx′ and Δx as the spatial resolutions in the CCD plane 130 and the input plane 132 , 132 a respectively. In Eq. 29 we assume that the number of pixels in both orthogonal directions of the CCD 128 is the same, denoted by N. Extension to different number of pixels is straightforward. Eqn. 29 can be calculated through a FFT algorithm.
The resolution of the technique can be evaluated taking into account the physical size of the CCD 128 and the configuration of optical system 100 . The scale factor of the optical Fourier transform operation performed by the system in FIG. 14 is x′/u=λf, where u is the spatial frequency in the horizontal direction. However, it can be shown that the scale factor of the computer Fourier transformation in Eqn. 29 is x′/u=NΔx′Δx. By comparing both equations, we have the following resolution in the input plane 132 , 132 a ,
Δ x = λ f N Δ x ′ = λ f T ′ ( 30 )
where T′ is the transversal size of the CCD 128 . We can improve on the resolution by using a shorter wavelength, a longer focal length of the Fourier transforming lens 140 , or by increasing the size of the CCD 128 .
An optical reconstruction will also be possible by simple coding of the phase and the amplitude given by Eqs. 27 and 28, respectively, into two LCD's configured to work in only phase and amplitude, respectively, and by means of performing an optical Fourier transform with a single lens.
The Fourier encryption can be modified in different ways when we change the optical setup in FIG. 14 . For example, the reference random phase mask 112 can either be imaged or Fourier transformed at the output plane 130 instead of free-space propagated. The optical transformation applied to the object beam 102 b can also be similarly modified. This section explains how to modify the previous system into a lensless architecture. This modification allows for a more compact and versatile optical system and improves the security. Now, to decrypt the information, it is necessary to know the position of the input object 132 and the wavelength, λ, of the light beam 102 b.
The optical configuration is depicted in FIG. 16 . The object beam 102 b is still incident on the input transparency 132 , with the input phase mask 132 a bonded, but the diffracted light travels by free-space propagation directly to the CCD camera 128 . In the situation the complex amplitude distribution that is due to the object beam 102 b over the CCD 128 can be evaluated from the following expression:
U
o
(
x
,
y
)
=
exp
[
ⅈ
π
λ
d
(
x
2
+
y
2
)
]
∫
-
∞
∞
∫
t
(
x
′
,
y
′
)
exp
[
ⅈϕ
i
(
x
′
,
y
′
)
]
×
exp
[
ⅈ
π
λ
d
(
x
′2
+
y
′2
)
]
exp
[
-
ⅈ
2
π
λ
d
(
xx
′
+
yy
′
)
]
ⅆ
x
′
ⅆ
y
′
(
31
)
By use of phase-shifting interferometry, Eqs. 22 and 23 provide the encrypted phase and amplitude of the input signal. Both images will look like random distributions, owing to the action of the input and the reference phase masks. The key images are obtained as well from Eqs. 25 and 26 by phase-shifting interferometry after removal of the input function 132 and the input phase mask 132 a from the optical system 100 . With only these key images it is possible to decrypt the stored information by use of Eqs. 27 and 28.
Again, the reconstruction of the encrypted information, t(x, y), can be implemented both optically or by computer. In this case we need information not only about the location of the input image 132 in the optical path of the interferometer 100 but also about the wavelength of the incident light and the pixel size of the CCD 128 . Then, the computer reconstruction can be performed by applying an inverse discrete Fresnel transformation to simulate the free-space propagation. Thus the input information can be retrieved from the following equation,
t ( m , n ) 2 = ∑ m ′ = 0 N - 1 ∑ n ′ = 0 N - 1 U o ( m ′ , n ′ ) exp [ ⅈ π Δ x ′2 λ d ′ ( m ′2 + n ′2 ) ] exp [ ⅈ 2 π N ( mm ′ + nn ′ ) ] 2 ( 32 )
where it is assumed that the size of the pixels in both transversal directions is the same, denoted by Δx′ and d′=−d. The evaluation of the Eq. 32 can be performed in the computer in a short time by use of FFT algorithm.
Now the resolution of the reconstruction depends on the distance d. By applying a reasoning similar to that in the Fourier encryption, it can be proved that the resolution is given by Eq. 30 but substituting f with d. Thus the resolution can be improved again by selection of a shorter wavelength, when the size of the CCD 128 is increased or the distance d is decreased. The Fresnel approximation is Eq. 31 restricts the possible values of d. There is also another limit imposed by the spatial quantization of the quadratic phase factor in Eq. 32. In this way the distance d must be kept greater than Δx′ 2 /λN to obtain a proper sampling of the phase factor.
The optical system 100 in FIG. 14 was experimentally constructed in to verify the performance of our approach. An argon laser 142 was used emitting a vertical polarized light beam with λ=514.5 nm. The retarder plates 108 , 110 were half and quarter-wave plates optimized for the preceding wavelength. They were previously calibrated to find the directions of the fast and the slow axes. The four-step phase shifting was performed manually. However, other phase-shifting methods can be used to optically encrypt data in real time. For example, it is common to shift the mirror 120 of the reference beam 102 a with a piezoelectric translator to obtain high-speed phase shifting.
The Fourier transform lens 140 in the object beam 102 b had an approximate focal length f=200 mm and an approximate numerical aperture of 0.1. The input object 132 , with the input phase mask 132 a bonded, was located at a distanced from the Fourier transform lens 140 . The input information 132 was encoded as a binary image in a black-and-white transparency. The reference phase mask 112 was located at an approximate distance z=300 mm from the CCD plane 130 . The phase mask 112 is commercially available plastic diffuser of randomly varying thickness with a correlation length of 6 mm in both the x and y directions. The different interferograms were registered by a CCD camera 128 , sampled with 480×480 pixels and quantized to 8 bits of gray level with a frame grabber. The size of the pixels in the camera 128 were measured to be Δx′Δy′=10 μm×10 μm.
FIG. 17 shows a computer-reconstructed image of the input to be encrypted. It was obtained by phase-shifting interferometry without use of the reference phase mask. Once the phase and the amplitude at the CCD plane 130 were obtained, an inverse FFT algorithm was applied to recover the input image. The noise in the image is due to the limited space-bandwidth of the optical system 100 . The encrypted phase and amplitude distributions after location of the reference phase mask 112 as indicated in FIG. 14 are shown in FIGS. 18A and 18B , respectively, as gray-level pictures. By inverse Fourier transformation of the complex amplitude distribution associated with these images, the picture in FIG. 18C is obtained. We are able to obtain only a random-like intensity pattern.
To decrypt the previous information the key phase and amplitude functions are measured by using Eqs. 25 and 26. These distributions are shown in FIGS. 19A and 19B as gray-level pictures. By correcting the images in FIGS. 18A and 18B with the key, as is stated in Eqs. 27 and 28, we are able to reconstruct the original image by inverse Fourier transform in a computer 402 . The decrypted image is shown in FIG. 19C . The experimental results prove the feasibility of the proposed technique.
FIGS. 20-22C show the results obtained in the encryption experiment with free-space propagation of the amplitude distribution at the input plane 132 , as shown in FIG. 16 . In FIG. 20 we represent the input image obtained by phase-shifting interferometry without the reference phase mask 112 . FIGS. 21A and 21B show the encrypted phase and amplitude functions, whereas FIG. 21C corresponds to the intensity distribution obtained from these functions by inverse Fresnel propagation in the computer. The key phase and amplitude functions are shown in FIGS. 22A and 22B . Finally, FIG. 22C shows the decrypted image. Note that the quality of the image is almost the same as that in FIG. 20 .
By the foregoing disclosure, a technique has been introduced to combine the high speed and the high security of optical encryption with the advantages of electronic transmission, processing, storage and decryption. Digital phase-shifting interferometry is exploited to use the limited CCD resolution more efficiently than can be done with off-axis digital holography. A three dimensional phase key in the Fresnel domain is used to provide high security. It has been described how this technique can be adapted to encrypt either the Fraunhofer or the Fresnel diffraction pattern of the input signal. Although Fresnel encryption requires a small increment of computation in the decryption process, the compactness, easy configuration of the optical system, and security improvement justify this second approach. Electronic decryption can be performed with a one-step FFT reconstruction procedure.
The proposed system can potentially encrypt and decrypt data at video frame rates. As an initial demonstration of the concept, for the experiments reported herein the four-step method of digital phase-shifting interferometry is implemented manually. However, other phase-shifting methods can be used to optically encrypt data in real time. Also, an opto-acoustic device can be used to perform high-speed phase shifting, and a digital signal processing chip can be used to perform high-speed electronic reconstruction.
In addition to allowing for electronic transmission of the encrypted information, the proposed system provides many degrees of freedom for securing information. It is also a convenient method for encrypting information in the optical domain such as real images and information stored in holographic media. Either optical or computer decryption techniques can be used with the proposed technique depending on the specific application.
In FIG. 12 , an unencrypted hologram of the object 132 , e.g., one formed without the use of random phase masks 112 , 112 a , may be formed at the output plane 130 . Thus, in accordance with a third embodiment of the invention, a three dimensional optical display apparatus and method, based upon digital phase-shifting interferometry, may be used to record the fully complex information of a multi-dimensional object 132 . Fourier and Fresnel domain optical recording is achieved by interfering the input object beam 102 e and the reference beam 102 a in an interferometer, such as a Mach-Zehnder phase-shifting interferometer 100 . The recorded information can be transmitted over a distributed computer or communications network 400 via digital communication lines as in FIG. 9 . However, the computers 402 , 404 , 504 , display devices 412 , 412 a and other devices of the networks 400 , 500 , 504 in FIG. 9 are configured to execute program software, that allows them to send, receive, record, store and process compressed and decompressed holograms or sets of data between and amongst themselves via the networks 400 , 504 and the Internet 500 . Such processing includes, for example, various image compression and decompression methods applied to the recorded interferometric information of the three dimensional object 132 before electronic transmission or storage thereof. Similar methods can be applied to decompressed information before reconstruction of the three dimensional object 132 . The processing also includes filtering, contrast enhancement, image sharpening, noise removal and correlation for image classification. Decompressed images may be displayed on display devices such as liquid crystal displays, liquid crystal TVs, or electrically or optically addressable spatial light modulators for applications in three dimensional TV and three dimensional display. This embodiment has applications in the serial three dimensional imaging of moving objects, such as in three dimensional TV, three dimensional video, three dimensional movies as well as three dimensional display and three dimensional visualization and other similar applications. Thus serial images may be formed of moving objects by forming a series of original holograms of the moving objects; compressing the series of original holograms of the moving objects to form a series of compressed holograms; decompressing the series of compressed holograms to form a series of decompressed holograms; and reconstructing the moving objects from the series of decompressed holograms to form a series of multi-dimensional images of the moving objects.
The reconstruction is performed immediately and directly upon the fully complex information and, if performed electronically, requires no more computation than the usual image reconstruction procedures. After decompression, electronic reconstruction with a one-step fast Fourier transform (FFT) procedure or optical reconstruction methods can be applied. The three dimensional or multi-dimensional reconstruction of the object 132 can be performed either electronically, optically or optoelectronically as in FIGS. 13A and 13B respectively.
Thus, a digital hologram of the object 132 may be formed in the output plane 130 and then compressed by signal compression methods. The compressed digital hologram may then be transmitted to remote locations over digital communications lines whereat the digital hologram is decompressed. The object 132 is then reconstructed from the decompressed digital hologram.
It will be recognized that the holograms formed at the output plane 130 are not limited to the in-line holograms of FIGS. 1 , 10 , 11 and 12 , but may also be formed by off-axis holograms as is well known in the art.
The following are incorporated herein by reference: B. Javidi and E. Tajahuerce, “ Three Dimensional Image Processing And Reconstruction ” International Symposium On Photonics For Aerospace Application Of Optics, SPIE Proceedings Vol. 4043, Orlando Fla., Apr. 24–28, 2000; U.S. patent application Ser. No. 09/493/692, entitled “Optical Security System Using Fourier Plane Encoding” and filed Jan. 28, 2000.
While preferred embodiments have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustration only, and such illustrations and embodiments as have been disclosed herein by reference are not to be construed as limiting the claims. | A method and system for encrypting multi-dimensional information utilizing digital holography is presented. A phase-shifting interferometer records the phase and amplitude information generated by a three-dimensional object at a plane located in the Fresnel diffraction region with an intensity-recording device. Encryption is performed by utilizing the Fresnel diffraction pattern of a random phase mask. Images of different perspectives of the three-dimensional object focused at different planes can be generated digital or optically with the proper key after decryption.
After decryption, images of the object, focused at different planes, can be generated digitally or optically. The method allows for the reconstruction of the object with different perspectives from a single encrypted image. The method does not require sending the key exclusively through a digital communication channel. Instead, a copy of the random phase key itself can be sent to the authorized user.
A method of forming an image of an object is disclosed. The method comprises forming an original hologram of the object; compressing the original hologram of the object to form a compressed hologram; decompressing the compressed hologram of the object to form a decompressed hologram; and reconstructing the object from the decompressed hologram to form a multi-dimensional image of the object. | 6 |
REFERENCE TO RELATED APPLICATION
This application claims priority to provisional patent application filed on Dec. 17, 2003, bearing application Ser. No. 60/531,018, which is hereby incorporated by reference in its entirety for all purposes.
FIELD
This patent relates generally to accessing content over a network. More specifically, this patent relates to minimizing the impact of network latency on the response time to a client's request for a resource from a remote content server.
BACKGROUND
Browser-based applications are deployed and managed centrally, and therefore are inexpensive in comparison to client/server applications. Specifically, in contrast to client/server applications, browser-based applications can be accessed ubiquitously from any web-browser, and therefore do not require the maintenance of specialized software on each user's desktop. On the downside, browser applications suffer from performance issues in that responding to client actions may take several network roundtrips to the server. In contrast, client/server applications carry significant computing intelligence on the client, thereby providing significantly better performance.
Round trips (i.e., multiple communications) on the network can take anywhere from a fraction of a millisecond to more than a second, depending on the type of network and the geographic distance between the client and the server. For example, on a campus Local Area Network (LAN), the latency is typically 0.1 ms. As a second example, the latency on a high-speed land line between New York and Tokyo is ˜400 ms. As a third example, the latency between any two terrestrial points on a satellite link is about 1.5 seconds. In light of this, the performance of browser-based applications depends substantially on the number of network roundtrips required to respond to a typical client action. A response that requires 16 round trips would take well over 7 seconds when the client is in Tokyo and the server is in New York. It is therefore desirable to minimize the number of network roundtrips involved in each response of the application to client action.
In general, application developers tend to focus on providing the best functionality in the application, but pay little attention to performance issues. A market therefore exists for technology to optimize the performance of applications a posteriori by examining the request/response interactions between the client and the server. The situation is similar to that of application development, where application developers write software with a view to richness of functionality, leaving it to compilers and optimizing processors to deliver performance afterwards.
With regard to the impact of network latency on application performance, application developers often construct files (e.g., web pages) that, when displayed, involve multiple objects (e.g., frames). For example, a customer service application at an insurance company may includes files that, when accessed, display web pages having several frames such as an “account information” frame, a “contact information” frame, a “policy claims” frame etc. This organization of the frames is convenient to the application developer because the application modules for different frames can be separately developed then the modules can be reused in multiple pages in any combination. For example, the “account info” frame may occur in every page or just in some of the company's pages. This allows the application developer to rapidly develop complex applications in a modular fashion.
On the downside, requiring the browser to download many independent objects (e.g., frames) to complete a response to a client request can have severe negative impact on performance. In general, each object is requested by the browser independently; therefore, a web page including multiple objects will require several network roundtrips. This causes the impact of network latency to become manifold thereby leading to poor performance.
Other techniques used by application developers can also impact network performance. For example, application developers often implement so-called server-based redirects. A developer may construct an application to comprise several functional modules. When a client requests a URL, a content server may process the URL at a nominal control module which then redirects the client to another module for handling the request. Redirection of client requests can have severe performance impact because each client request must travel the network twice—once to the server's control module and back, and a second time to another (redirected) server module and back.
Network latency can have varying impact on the performance of web and other network applications involving the fetching of an object that in turn requires the fetching of other objects that are external to the originally fetched object. When the latency between the client and the server is small, network latency has limited impact on performance. When the latency is large (e.g., of the order of a second), as is the case when the client and the server are separated by a significant geographic distance, network latency can degrade application performance significantly.
Thus, a market exists for techniques to minimize the impact of network latency on application performance a posteriori to application development. Optimization can be carried out dynamically as a client interacts with an application so that changes to the application (e.g., on the server or client computers) are not required (but may be optional depending on design choice).
SUMMARY
An exemplary method performed by a proxy server located between a content server and a client browser for reducing effects of network latency therebetween comprises intercepting a request from the client browser for a resource at the content server, obtaining a response by the content server to the request, determining that the response would, if unmodified, require a plurality of communications between the content server and the client browser in the absence of the proxy server, modifying the response to reduce a network latency associated with the plurality of communications for accessing information located externally to the response, and transmitting the modified response to the client browser for use thereby.
Other embodiments and implementations are also described below.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 illustrates an exemplary network environment.
FIG. 2 illustrates an exemplary process for reducing network latency caused by server redirects.
FIG. 3 illustrates an exemplary process for reducing network latency when processing requested resources containing embedded objects.
FIG. 4 illustrates another exemplary process for reducing network latency when processing requested resources containing embedded objects.
DETAILED DESCRIPTION
I. Overview
Exemplary techniques for reducing network latency are disclosed herein.
Section II describes an exemplary network environment.
Section III describes an exemplary process for reducing network latency caused by a server redirect.
Section IV describes exemplary processes for reducing network latency when a content server's response is a resource including multiple embedded objects.
Section V describes other aspects and considerations.
II. An Exemplary Network Environment
FIG. 1 illustrates an exemplary environment including a client browser 100 connected over a Wide Area Network (WAN) 110 to, and accessing content from, a content server 300 . In an exemplary embodiment, the proposed system is deployed as a transparent proxy server 200 located on the network immediately in front of the content server 300 , and connected on a high-speed low latency Local Area Network (LAN) 120 to the content server 300 .
When a user using the client browser 100 requests a URL, the proxy server 200 intercepts the request, and forwards the request to the content server 300 . The content server 300 then responds to the proxy server 200 . The proxy server 200 examines and modifies the response in accordance with various embodiments to be described herein then forwards the modified response to the client browser 100 .
Those skilled in the art will realize that the proxy server 200 can be implemented in any combination of software and/or hardware, depending on the technical and financial requirements of the particular implementation. For example, a software implementation could be run on a general purpose computer having a processor, one or more memories or other computer-readable media, and appropriate I/O interfaces for connections to the content server 300 and the client browser 100 , via the LAN 120 or the WAN 100 , respectively. Or, a hardware implementation could be deployed using ASICs, PALs, PLAs, or still other forms of hardware now known or hereafter developed.
Further, the computer-readable media can store data and logic instructions (which, when executed, implement the processes described herein) that are accessible by the computer or the processing logic within the hardware. Such media might include, without limitation, hard disks, flash memory, random access memories (RAMs), read only memories (ROMs), and the like.
III. An Exemplary Process for Reducing Network Latency Caused by Server Redirects
FIG. 2 illustrates an exemplary process for reducing network latency caused by server redirects. Server redirects are instances where a content server's response to a client request is a redirect to another Universal Resource Locator (URL) identifying a unique resource. In general, each URL uniquely identifies a resource. A resource can be any type of data, including, without limitation, a frame, a text file, an image file, a voice file, any other types of data, and/or a combination thereof. For ease of explanation, the terms resource and object may be used interchangeably throughout this patent.
The exemplary process begins at block 10 .
At block 15 , the proxy server 200 obtains a client request for URL 1 . The client request is sent by the client browser 100 via the WAN 110 and destined for the content server 300 . In an exemplary implementation, the proxy server 200 intercepts the client request. The request interception can be transparent to the client browser 100 .
At block 20 , the proxy server 200 forwards the request to the content server 300 via the LAN 120 .
At block 25 , the proxy server 200 receives the content server's 300 response to the request. In an exemplary implementation, the proxy server 200 examines the response after receiving it.
At block 30 , the proxy server 200 determines whether the response is a redirect to another URL (e.g., URL 2 ).
If so, at block 35 , the proxy server 200 requests the redirect URL (e.g., URL 2 ) from a content server. The content server may or may not be the same content server as the one for URL 1 (i.e., content server 300 ). The process returns to block 25 , where the proxy server 200 receives a response to the redirect URL from a content server. If the new response is not yet another redirect to yet another URL (e.g., URL 3 ), then the process continues to block 40 where the new response is forwarded to the client browser 100 .
In this exemplary embodiment, the proxy server 200 intercepts a redirect response from the content server 300 and requests the resource identified by the redirect URL via the high-speed low latency LAN 120 . Therefore, network latency between the client browser 100 and the content server 300 is reduced by eliminating one roundtrip between them over the higher latency WAN 110 to request the resource identified by the redirect URL.
IV. Exemplary Processes for Reducing Network Latency when a Requested Resource Includes Multiple Embedded Objects
Network latency can also occur when a response (e.g., a resource) from the content server 300 to a client request (e.g., made via the client browser 100 ) includes multiple embedded objects. FIGS. 3 and 4 illustrate two exemplary processes for reducing network latency by modifying the response from the content server 300 .
A. Reducing Network Latency by Obtaining and Appending the Embedded Objects to the Response
FIG. 3 illustrates an exemplary process performed by the proxy server 200 that includes the same blocks 10 - 35 of FIG. 2 .
After determining that a response from the content server 300 is not a redirect to another URL, at block 45 , the proxy server 200 determines whether the response includes any embedded objects. For ease of explanation only, this response will be referred to as the original response.
If so, at block 50 , the proxy server 200 requests the embedded objects from the content server 300 via the LAN 120 and appends the objects to the original response to form a modified response. In an exemplary implementation, the embedded objects are separated from the parent resource by a header. In addition, each object is also separated from another object by a header. In an exemplary implementation, a header may identify the resource location of each object appended immediately following the header.
The modified response can be represented in any desired format, subject to the ability of the client browser 100 to recognize such format. For example, a well-known format that could be used is the so-called Multipurpose Internet Mail Extension HTML (a.k.a. MIME HTML, MHTHL or MHT). The MIME HTML format, developed by a committee of the standards setting body known as the Internet Engineering Task Force, is well known to those skilled in the art, and need not be described in greater detail herein. For example, see the specification for this format at www.ietf.org/rfc/rfc2110.txt and www.ietf.org/rfc/rfc2557.txt. Current versions of some popular browsers, including Microsoft's Internet Explorer, are configured to recognize (and some can even write) files in this format.
At block 55 , the proxy server 200 forwards the modified response to the client browser 100 via the WAN 110 . The client browser 100 can render the parent resource as well as the embedded objects by opening the modified response in accordance with the requirements of the implemented format, without having to incur additional roundtrips to request and obtain the objects embedded in the parent resource.
Referring back to block 45 , if the original response from the content server 300 does not include any embedded objects, then at block 55 , the proxy server 200 forwards the original response to the client browser 100 via the WAN 110 .
In this exemplary embodiment, the proxy server 200 intercepts an original response from the content server 300 and directly requests the content server 300 for any objects embedded in the original response via the high-speed low latency LAN 120 . Therefore, network latency between the client browser 100 and the content server 300 is reduced by eliminating additional roundtrips between them over the higher latency WAN 110 for retrieving any embedded objects.
B. Reducing Network Latency by Creating Additional Unique Pseudonyms
Client browsers 100 are typically hard-coded by the manufacturers to automatically open two parallel TCP/IP connections per uniquely named content server. Without proxy server 200 intervention, a resource having multiple embedded objects will be retrieved directly by the client browser 100 via the two connections opened for the content server 300 of the resource. In this example, a first connection will be used to retrieve the parent resource, and a second connection will be used to retrieve any embedded objects one-by-one until either the first connection becomes free or when all embedded objects have been retrieved. In the first scenario, the first connection can be used in parallel with the second connection to retrieve any remaining embedded objects. If more connections could be opened, then network latency can be correspondingly reduced. FIG. 4 illustrates an exemplary process performed by the proxy server 200 to enable the client browser 100 to open additional connections.
FIG. 4 includes the same blocks 10 - 35 of FIG. 2 .
After the proxy server 200 determines that a response from the content server 300 is not a redirect to another URL, at block 60 , the proxy server 200 determines whether the response includes any embedded objects. For ease of explanation only, this response will be referred to as the original response.
If the original response includes embedded objects, at block 65 , the proxy server 200 creates additional unique pseudonyms of the content server 300 and modifies the addresses of the embedded objects in the original response to include the unique pseudonyms (to form a modified response). The impact of this process performed by the proxy server 200 can best be illustrated by example.
Consider a parent resource identified by the URL www.bank.com. The parent resource includes multiple embedded objects identifiable by the following URLs:
<img src = “http://www.bank.com/button1.jpg”>
<img src = “ http://www.bank.com/button2.jpg”>
<img src = “ http://www.bank.com/clock.jpg”>
<img src =” http://www.bank.com/footer.gif “ >
In the absence of the proxy server 200 , when the client browser 100 receives the parent resource, it will attempt to fetch the embedded objects (e.g., image files) using the two connections opened for the content server www.bank.com. Assuming both connections are free (i.e., one of the connections has already finished retrieving the parent resource), the client browser 100 will fetch the first two objects “button1.jpg” and “button2.jpg” followed by the next two, “clock.jpg” and “footer.gif.”
By creating additional unique pseudonyms for the content server 300 , the proxy server 200 can enable the client browser 100 to open more connections (e.g., 4 connections) to be used to retrieve the embedded objects in parallel. For example, the proxy server 200 creates two unique pseudonyms: server1.bank.com and server2.bank.com for the content server www.bank.com, and modifies the addresses of the embedded objects in the parent resource to reference the pseudonyms. Thus, the embedded objects can now be identified by:
<img src = “http://www.server1.bank.com/button1.jpg”>
<img src = “http://www.server1.bank.com/button1.jpg”>
<img src = “http://www.server2.bank.com/clock.jpg”>
<img src = “http://www.server2.bank.com/footer.gif”>
In this example, when the client browser 100 receives the modified response (see block 75 ), it will open two connections for each of the pseudonym servers, i.e., a total of four connections to the content server, and can retrieve all four embedded objects in parallel.
In order for pseudonyms created by the proxy server 200 for a content server to resolve to the content server, at block 70 , the proxy server 200 adds additional entries into a Domain Name Server, one for each pseudonym created by the proxy server 200 so the pseudonym(s) will resolve to the same IP address as the content server (e.g., www.bank.com). In an exemplary implementation, the proxy server 200 may add a single DNS entry having a wildcard character symbol (e.g., an asterisk) preceding (or after) the content server name instead of adding a separate entry per unique pseudonym. In the above example, an entry of the form “*.bank.com” can be added to refer to the content server name of “.bank.com” with any string of wild card characters preceding the name. Alternatively, such DNS entry (i.e., having a wildcard character symbol) can refer to the proxy server 200 which will resolve any address to an appropriate content server.
At block 75 , the modified response is forwarded to the client browser 100 to enable it to open additional connections (i.e., more than 2) to access the content server 300 .
Referring back to block 60 , if the original response does not include any embedded objects, then at block 75 , the original response is forwarded to the client browser 100 unmodified.
One skilled in the art will recognize that, depending on design choice, the number of unique pseudonyms to be created by the proxy server 200 may be a default number or a dynamically determined number (e.g., based on the size of the parent resource, the number of embedded objects, and/or any other factors).
In an exemplary implementation, when a parent resource identifies embedded objects by relative URLs (e.g., of the form “./button.jpg”), the proxy server 200 fills in the complete root path to convert the relative URL to an absolute URL, then introduces a created pseudonym to the absolute URL. To illustrate using the above example, if the parent resource makes a reference to an embedded object by a relative URL “button.jpg,” the proxy server 200 will fill in the complete root path to convert the relative URL to an absolute URL www.bank.com/button.jpg, and then introduce a pseudonym of the content server to modify the absolute URL to a modified URL www.server1.bank.com/button.jpg.
In other exemplary implementations, the proxy server 200 is configured to introduce the same pseudonym for each object if the object is referenced multiple times (e.g., within the same parent resource). This feature can prevent retrieval of the same object multiple times. In one implementation, the absolute URL (or the content) of an object can be hashed to the space of a pseudonym.
In this exemplary embodiment, the proxy server 200 intercepts an original response from the content server 300 , creates additional unique pseudonyms of the content server 300 , modifies the addresses of embedded objects in the response, and sends the modified response to the client browser 100 . The modified response enables the client browser 100 to open additional connections to the content server 300 to thereby retrieve the embedded objects faster. Therefore, network latency between the client browser 100 and the content server 300 is reduced.
V. Other Aspects and Considerations
A. Latency Testing
The process of intercepting a file (e.g., a request from the client browser 100 or a response from the content server 300 ) at the proxy server 200 , appending external objects or otherwise form a modified file (e.g., a modified response), and transmitting that modified file to a client will involve some overhead and therefore, will introduce some latency of its own. Additional latency might be introduced by the overhead associated with reading a modified file (e.g., a MIME HTML file) at the client browser 100 computer. In most cases, the additional latency will be more than offset by the reduction in latency associated with the savings in eliminated round trips (or by opening additional server connections). However, this is not always the case. For example, the overhead may exceed the savings when requesting content from a content server 300 that is very close to the client browser 100 , or when the network is very lightly loaded. As one optional aspect, it may therefore be useful to perform latency testing and condition the operation of the modification (of the original response) on the outcome of such testing. In other situations, the overall effect of differential network speeds between the content-server-to-proxy legs and the proxy-to-client legs might also render the modification operation moot.
B. Client Application Testing
As mentioned above, some response modifications may require the client browser 100 to be able to read a modified response. If a modified response is sent to a client browser that cannot read it, not only will no savings result, but the original response may have to be retransmitted in any case. Thus, in another exemplary embodiment, the proxy server 200 might be configured to interrogate the client browser 100 (e.g., by sending a test message or otherwise) to determine whether the client computer can read a certain file format. If not, the proxy server 200 can either skip the modification, or transmit a supplementary application (via a plug-in, patch, applet, etc.) to invest the client computer with the missing functionality.
C. Caching
Still another optional aspect utilizes caching at the proxy server 200 to further reduce latency. For example, if a commonly requested resource can be found in the proxy server's cache, then one trip back to the content server 300 can be eliminated.
In an optional embodiment, the proxy server 200 could even be equipped with “precomputing” technology to predict that a particular resource will be needed in the future, and to compute that resource ahead of time. This is particularly useful for dynamic content. An exemplary such precomputing technology has been developed by FineGround Networks, Inc. and is described in pending U.S. patent application Ser. No. 10/459,365 filed on Jun. 11, 2003, which application is hereby incorporated by reference in its entirety for all purposes.
VI. Conclusion
As a matter of convenience, the techniques of this patent have been disclosed in the exemplary context of a web-based system in which the user accesses content identified by URLs from a client browser. However, those skilled in the art will readily appreciate that other user access devices, and content identifiers, may also be used. Similarly, it should be appreciated that the proposed techniques will operate on any networked computer, including without limitation, wireless networks, handheld devices, and personal computers. Therefore, exemplary terms such as resource, web, browser, URL and the like should be interpreted broadly to include known substitutes and other equivalents, counterparts, and extensions thereof. Indeed, it should be understood that the technologies disclosed herein are more generally applicable to obtaining virtually any form of resource over a network. Accordingly, the specific exemplary embodiments and aspects disclosed herein are not to be construed as limiting in scope.
Therefore, the inventions should not be limited to the particular embodiments discussed above, but rather are defined by the claims. Furthermore, some of the claims may include alphanumeric identifiers to distinguish the elements thereof. Such identifiers are merely provided for convenience in reading, and should not necessarily be construed as requiring or implying a particular order of elements, or a particular sequential relationship among the claim elements. | An exemplary method performed by a proxy server located between a content server and a client browser for reducing effects of network latency therebetween comprises intercepting a request from the client browser for a resource at the content server, obtaining a response by the content server to the request, determining that the response would, if unmodified, require a plurality of communications between the content server and the client browser in the absence of the proxy server, modifying the response to reduce a network latency associated with the plurality of communications for accessing information located externally to the response, and transmitting the modified response to the client browser for use thereby. | 7 |
FIELD OF THE INVENTION
[0001] The present invention is directed to the manufacture of cellulose ester filaments.
BACKGROUND OF THE INVENTION
[0002] Conventionally, in the manufacture of cellulose esters filaments, the filaments are not lubricated until after they leave the spinning cabinet. One reason for this practice is to avoid the contamination of the solvent used in the extrusion of the cellulose ester filaments with the lubricant.
[0003] Conventionally, in the manufacture of cellulose ester filaments, the cellulose ester polymer is dissolved into a solvent, that solution is known as dope. The dope is pumped to a die (or jet or spinneret) having a plurality of holes therethrough. The die is typically located at the upper end of a spinning cabinet. When the dope exits the die, the solvent flashes from the dope and the filaments begin to solidify. While the filaments travel downwardly through the cabinet, the solvent is captured within the cabinet for reuse. At the bottom of the cabinet, there is an outlet through which the filaments exit the cabinet. Typically, the filaments are guided from their downward (or vertical) travel to a generally horizontal direction (including angles below the horizontal) of travel at the outlet of the cabinet. The guide may be any conventional guide device, but it does not lubricate the filaments as their direction is changed. Thereafter, the filaments exit the cabinet. After exit, the filaments are lubricated by a lubricator, for example, a kiss roll. This lubricator is typically located about 6-12 inches (15-30 cm) from the exit of the cabinet. Then, the filaments are drawn away by a feed roll.
[0004] It is believed that the filaments are damaged as they pass over the non-lubricated guide. This damage causes variability in the filament.
[0005] There is a need to make a more uniform and more robust filament product.
[0006] Japanese Application No. 2003-020952 (Publication No. 2004-232124) discloses a method for manufacturing cellulose acetate tow where finish (oil) is metered on to filaments of the tow band at the point where the various thread lines from the cabinets are converged. The point of convergence is away from the cabinet exit.
[0007] U.S. Publication Nos. 2005/0202179 and 2005/0202993 disclose a finish for improving plug making that is applied, through existing fiber finish applicators, as the filaments exit the spinning cabinet. These publications do not mention the problem solved in the instant application.
SUMMARY OF THE INVENTION
[0008] In the manufacture of cellulose ester fibers, a dope is extruded into filaments. Extrusion occurs in an elongated cabinet having an outlet for the filaments. The filaments are taken up after exiting the outlet. The filaments are lubricated at the outlet of the cabinet.
DESCRIPTION OF THE DRAWINGS
[0009] For the purpose of illustrating the invention, there is shown in the drawings a form that is presently preferred; it being understood, however, that this invention is not limited to the precise arrangements and instrumentalities shown.
[0010] FIG. 1 is a schematic illustration of the present invention.
[0011] FIG. 2 is an isometric illustration of an embodiment of a lubricator.
DETAILED DESCRIPTION OF THE INVENTION
[0012] Cellulose ester filaments, as used herein, refers to, but is not limited to, cellulose acetates, cellulose propionates, cellulose butyrates, cellulose valerates, cellulose formates, and co-polymers thereof. Co-polymers include, but are not limited to, acetates-propionates or butyrates or valerates or formates and the like. Cellulose acetate refers to a cellulose acetate polymer having a typically degree of substitution between 2.1 and 2.7. For the following discussion of the invention, reference will be made to cellulose acetate, but the invention is not so limited.
[0013] Referring to FIG. 1 , there is shown a cellulose acetate spinning operation 10 . For simplicity, only one spinning operation 10 is shown, but the skilled person will understand that there may be a plurality of spinning operations joined together (e.g., a metier). A dope supply 12 is connected to a die 16 , via manifold 14 . Die 16 is located at the upper end of cabinet 18 . Cabinet 18 is an elongated enclosure that is used to capture the solvent (e.g., acetone when forming cellulose acetate filaments) for re-use. Cabinet 18 has an outlet 20 (typically a door or opening through the cabinet wall) through which filaments 22 exit the cabinet. A lubricant applicator 24 is located at the lowermost end of the cabinet. The placement of applicator 24 with relation to outlet 20 will be discussed in greater detail below. Applicator 24 is used to apply lubricant (discussed below) to the filaments and change the direction of travel of the filaments. After lubrication, the filaments exit the cabinet 18 via outlet 20 . Filaments 22 are drawn from the cabinet 18 by feed roll 32 (or take up roll). Between outlet 20 and feed roll 32 , there is a lubricator 30 which is conventional, e.g., a kiss roll. While spinning operation 10 is illustrated with filaments exiting on a side of cabinet 18 , spinning operation 10 may also be a ‘pass through’ spinning operation where filaments exit through the bottom end of the cabinet 18 .
[0014] The applicator 24 is located at the lowermost end of the cabinet and in the vicinity of outlet 20 . ‘In the vicinity of outlet 20 ’ means from about six inches (15.25 cm) before to about six inches (15.25 cm) after the outlet 20 , and before the lubricator 30 . In one embodiment, applicator 24 is located within the cabinet before the outlet or at the outlet but in the cabinet.
[0015] Lubricant, discussed in greater detail below, is supplied to applicator 24 from a lubricant supply 26 via metering pump 28 . In one embodiment, pump 28 is a peristaltic pump.
[0016] Lubricant application rates are less than 40 cc/min (when the filaments number 80-620 filaments per cabinet) to avoid excess lubricant for subsequent processing of the tow. Preferably, the rate is less than 20 cc/min, and most preferably, the rate is 5-10 cc/min.
[0017] Lubricant may be selected from the group consisting of water, oil-in-water emulsions, and oils. Typically, oils are mineral oils, as is well known in the art. The oil-in-water emulsions are well known and may include emulsifiers, anti-stats, and the like.
[0018] The applicator 24 may be any type of applicator including cylindrical applicators, channel applicators, spray applicators, dip tank applicators, or brush applicators. In FIG. 2 , applicator 60 is a channel-type applicator. Applicator 60 may be an inverted U with a flat surface 62 . Flat surface 62 is the filament contact surface. Lubricant is introduced via inlet 64 and wets the filaments on surface 62 .
EXAMPLES
[0019] The foregoing invention is further illustrated in the following non-limiting examples.
[0020] The following examples illustrate the improvement in filament properties obtained by lubrication at the outlet of the cabinet. In each of the examples, the applicator 24 (referred to as the FCPL in the Table) is located at the inside of the outlet 20 . The FCPL applicator was a channel-type applicator (see FIG. 2 ). ‘Control-1’ refers to the use of a non-rotating ceramic roll with a concave surface. ‘Control-2’ refers to the use of a ceramic channel guide with a flat surface (see FIG. 2 ). The ‘kiss roll’ refers to the conventional lubricator 30 . For lubricant, ‘Nothing’ means no lubricant; ‘H2O’ means water; and ‘EMUL’ means an oil-in-water emulsion. Improvement in filament properties is illustrated by the coeffiecent of variation for elongation at break (% Eb CV) and tensile factor (TE 1/2 ). All physical properties set forth in the table below are measured in a conventional manner.
TABLE Elongation Kiss Tenacity at Break % Eb FCPL Roll (g/denier) (Eb %) CV TE½ Control-1 Nothing EMUL 1.03 22.13 7.50 4.83 Control-2 Nothing EMUL 1.03 21.40 4.63 4.79 Invention H20 EMUL 1.07 22.69 5.60 5.09 Invention EMUL EMUL 1.05 22.22 5.09 4.95 Invention EMUL Nothing 1.02 21.06 6.70 4.70 Control-1 Nothing EMUL 1.12 17.57 13.49 4.72 Control-2 Nothing EMUL 1.13 18.15 11.02 4.82 Invention H2O EMUL 1.27 21.86 2.15 5.92 Invention EMUL EMUL 1.26 22.95 4.97 6.04 Invention EMUL Nothing 1.22 22.17 3.88 5.75 Control-1 Nothing EMUL 1.06 16.64 21.54 4.37 Control-2 Nothing EMUL 1.10 17.88 18.35 4.69 Invention H2O EMUL 0.75 24.31 7.08 3.70 Invention EMUL EMUL 1.05 21.17 3.35 4.84 Invention EMUL Nothing 1.03 21.59 5.05 4.77 Control-2 Nothing EMUL 1.11 15.28 16.36 4.35 Invention H20 EMUL 1.15 19.17 5.53 5.02
[0021] The present invention may be embodied in other forms without departing from the spirit and the essential attributes thereof, and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicated the scope of the invention. | In the manufacture of cellulose ester fibers, a dope is extruded into filaments. Extrusion occurs in an elongated cabinet having an outlet for the filaments. The filaments are taken up after exiting the outlet. The filaments are lubricated at the outlet of the cabinet. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority under 35 U.S.C. §119 of German Patent Application DE 20 2009 006 792.0 filed May 12, 2009, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention pertains to a cutter for spine surgery, especially for use in the area of the cervical spine, with a cylindrical cutter shank and cutter teeth formed at the distal end thereof, as well as with a cutter set comprising the aforementioned cutters.
BACKGROUND OF THE INVENTION
[0003] A cutter of this type is known from DE 20 2005 016 763 U1 and describes a facet joint cutter, which is used to cut out vertebral components in the area of the spine. This cutter has a cylindrical shank and sawtooth-like teeth formed at its front-side, distal end. The teeth point forward from the distal end, and said teeth are slightly expanded outwardly. The teeth are directed parallel to the axis, and grooves, which likewise extend parallel to the axis and extend radially from the internal diameter of the cutter wall up to the external diameter, are located between them.
[0004] It was found that the bone material cannot be cut out sufficiently gently, especially from the delicate cervical vertebrae, with the prior-art cutters.
SUMMARY OF THE INVENTION
[0005] The basic object of the present invention is therefore to create improved cutters for endoscopic spine surgery while avoiding the aforementioned drawbacks.
[0006] This object is accomplished with a cutter of the type mentioned in the introduction by the teeth of the cutter at the distal end of the cutter shank being formed by grooves in the wall of the cutter shank, which deepen and expand from the outer radius of the cutter shank towards the distal end such that teeth narrowing towards the distal end with increasing height are formed between them.
[0007] Due to the teeth modified compared to the state of the art, which are formed in a star-shaped pattern on the distal front side of the cutter shank such that the front side of the teeth point from the inner wall side of the shank radially outwardly, and especially with a flat front-side closure, wherein the cutting edges are formed at the edge of the front side, more gentle cutting is achieved along with uniform precision and cutting action. The base of the grooves between the teeth, the groove base, is closed; consequently, no slots extending completely radially through the shank wall are formed between the teeth. The tooth flanks extending in the wall of the cylindrical shank are directed outwardly in a star-shaped pattern on the front side. Great sharpness of the teeth of the individual cutters is nevertheless guaranteed.
[0008] The teeth are separated by grooves, the grooves cut expand parabolically in the axial direction towards a distal end facing the vertebra to be cut and the teeth have a transition edge corresponding to the shape of the groove between the groove and the tooth wall. The groove bases have an angle of at least 13° to 15° in relation to a longitudinal axis of the cutter. Furthermore, the present invention makes provisions for the teeth defined by tooth walls becoming pointed parallel to the axis and/or for the edges of the tooth walls becoming pointed towards the distal end parallel to the axis, and provisions may also be made for the tooth walls becoming pointed towards the distal end beginning from half of their groove length. Outer edges of the tooth walls are extremely preferably located on an external diameter of the cutter shank, and the cutting edges may also be formed on the front side. This makes possible an especially gentle cutting without surrounding delicate tissue being jeopardized. Such a cutter can be used as a cervical spine cutter especially for the cervical spine. Preferred variants of such a cutter make provisions for outer edges of the teeth to be located on an external diameter of the cutter shank and/or for edges of the tooth walls to become pointed towards the distal end parallel to the axis.
[0009] In another preferred embodiment the teeth have bent outer tooth walls, and the tooth walls extend parallel to the axis over up to half the length of the grooves and at an angle of at least 30° in relation to the longitudinal axis of the cutter towards the distal end. Provisions may be made here for the teeth having sharp cutting edges at the obliquely extending transition edges. Thus, sharp cutting edges of the teeth are formed in all embodiments of the cutter at the front-side end or in the obliquely extending area only.
[0010] In a preferred embodiment, the shank has at least one or more colored ceramic rings towards a proximal end for better distinction of cutters of different sizes, the heat-resistant ceramic rings being more durable and resistant than colored rings made of plastic.
[0011] An annular recess, with which the cutter can be clamped in a corresponding handling or rotating device, is formed on the shank of the cutter according to the present invention, and at least two rectangular slots are formed at a proximal end in another embodiment, and a torque can be transmitted to the cutter due to positive-locking connection with the handling or rotating device.
[0012] The cutter preferably has 4 to 8 teeth at an internal diameter of less than 2 mm of its wall, 5 to 10 teeth at an internal diameter of 2 mm to 2.5 mm, 10 to 16 teeth at an internal diameter of 3 mm to 4 mm and 12 to 24 teeth at an internal diameter greater than 5 mm.
[0013] A set of cutters, comprising at least three cutters, is preferably provided, wherein a first cutter has an external diameter that corresponds, possibly taking tolerances into account, at most to an internal diameter of a next larger cutter. The external and internal diameters of the cutters are thus very preferably coordinated such that the cutters can be pushed one into the other. At least one cutter of a set of cutters has an external diameter greater than 5 mm.
[0014] Other advantages and features appear from the claims and from the following description, in which an exemplary embodiment of the present invention is specifically explained with reference to the drawings. 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 preferred embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] In the drawings:
[0016] FIG. 1 is a schematic enlarged view of a first cutter, according to the present invention, with an external diameter of 2 mm;
[0017] FIG. 1 a is a schematic view of the front side of the cutter according to the present invention from FIG. 1 ;
[0018] FIG. 2 is a schematic enlarged view of another cutter according to the present invention with an external diameter of 3.6 mm;
[0019] FIG. 2 a is a schematic view of the front side of the cutter according to the present invention from FIG. 2 ;
[0020] FIG. 3 is a schematic enlarged view of another cutter according to the present invention with an external diameter of 4.7 mm;
[0021] FIG. 3 a is a schematic view of the front side of the cutter according to the present invention from FIG. 3 ;
[0022] FIG. 4 is a schematic sectional view of a cutter according to the present invention in section A-A from FIG. 2 a;
[0023] FIG. 5 is a schematic enlarged view of another cutter according to the present invention with another embodiment of the teeth; and
[0024] FIG. 5 a is a schematic sectional view of a cutter according to the present invention in sectional view C-C from FIG. 5 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] Referring to the drawings in particular, FIGS. 1 , 2 and 3 show a schematic view each of cutters 1 according to the present invention and the cutters 1 together form a set of cutters 1 of different sizes. Serrated lines in the figures indicate a shortening of the length in the drawing for the sake of greater clarity.
[0026] A cutter 1 , as it is shown in the exemplary embodiment according to FIG. 1 or FIG. 1 a , has a cylindrical shank 2 , which is formed from a long steel tube. A front-side, distal end a of cutter 1 is formed as a set of cutter teeth 3 , which comprise teeth 4 and grooves 5 located between them. Grooves 5 are cut in the axial direction parabolically into the wall of shank 2 , and the grooves 5 expand radially as well as axially towards the distal end a. Thus, they show a partly conical incision in the wall of shank 2 . The teeth 4 are formed from the tooth walls 4 a left behind after the grooves 5 have been cut out, the tooth walls 4 a becoming pointed parallel to the axis towards the distal end a. A transition edge 4 b corresponding to the parabolic shape of groove 5 is formed between the tooth wall 4 a and the groove 5 . Transition edge 4 b may have a sharpened edge. Grooves 5 and the adjoining tooth walls 4 a thus show an axial direction of the main course parallel to the axis, so that the teeth 4 formed are located on the external diameter of shank 2 . Cutter 1 has a flat closure on the front side. This flat closure brings about the formation of a sharp cutting edge of the teeth 4 at the front-side, distal end a. As an alternative, a bent closure may also be provided, which will be explained in more detail below in FIGS. 5 and 5 a.
[0027] Furthermore, shank 2 of cutter 1 has a recessed colored ceramic ring 8 with a width of about 2 mm. The cutters 1 in FIGS. 2 and 3 have not only a colored ceramic ring 8 , but correspondingly two or three colored ceramic rings 8 . It is thus possible to distinguish the different cutters by means of the number and color of the ceramic rings 8 . Furthermore, shank 2 has an annular recess 9 , whose center is located at a distance of 13 mm from a proximal end b located opposite the distal end a in the exemplary embodiment according to FIGS. 1-3 and which is used to axially fasten the cutter 1 in a corresponding handling or rotating device.
[0028] The set of cutter teeth 3 are shown, furthermore, in a schematic front view in FIGS. 1 a , 2 a and 3 a for the respective sizes of the cutters 1 , showing that the teeth 4 are shaped radially outwardly, i.e., in a star-shaped pattern, in one plane on the cutter head due to the correspondingly cut grooves 5 and the flat closure at the distal end a. In the front-side view, the grooves 5 cut point-symmetrical as circle segments towards the center of the front-side radial plane have a certain depth 5 , which is defined by a thin wall to an internal diameter 6 . The teeth 4 are arranged each at right angles to the circumference of the cutter head, and their outer edges are located on an external diameter 7 of shank 2 . The outer edges are defined by the pointed transition edge 4 b , as a result of which a sharp outer cutting edge of teeth 4 is obtained at the front-side distal end a.
[0029] FIG. 4 shows a longitudinal section through cutter 1 through the connection A-A in FIG. 2 a . Furthermore, the distal end a with the set of teeth 3 with teeth 4 and grooves 5 is again shown in FIG. 4 in a longitudinal section by a shortening of the drawing, the grooves 5 having a groove base 5 a . Groove base 5 a changes here over the length of the grooves 5 radially with the axial height at a certain angle α towards a longitudinal axis B and ends on the front side at the distal end a. This angle α equals approx. 15° for the cutters 1 from FIGS. 1 and 2 and the angle α equals approx. 13° for cutter 1 from FIG. 3 . It can be clearly recognized here that the teeth 4 are located on the external diameter 7 of shank 2 .
[0030] Furthermore, at least two opposite rectangular slots 10 , by means of which a torque can be transmitted to the cutter 1 by positive-locking connection with a corresponding handling or rotating device, are formed at the proximal end b of shank 2 .
[0031] FIGS. 5 and 5 a show an alternative embodiment of the teeth of cutter 1 according to the present invention with a bent closure at the distal end a. The teeth are again formed by grooves 5 cut parabolically in the wall of cutter 1 in the axial direction, wherein the tooth walls 4 a formed hereby are at first parallel to the axis towards the distal end a. Beginning from half the length of the grooves 5 , the tooth walls 4 a are bent radially inwardly. The groove bases 5 a are made pointed towards the distal end a, and the tooth walls 4 a have a nearly constant width. Due to the flat front-side closure, a sharp cutting edge is obtained directly on the front side. An additional cutting edge may be formed in the obliquely extending area of the tooth walls 4 a.
[0032] FIG. 5 a shows for this a longitudinal section according to section C-C, with shortening of the drawing for the sake of greater clarity, through the cutter 1 in FIG. 5 . For the variant of the teeth 3 being shown here, the groove base 5 a of the grooves 5 likewise varies radially with the axial height with the angle α towards the longitudinal axis B and ends on the front side at the distal end a. As was already described in FIG. 5 , the tooth walls 4 a do not extend parallel to the axis over their entire length, but are bent beginning from half of the length of groove 5 at an angle β towards the longitudinal axis B of cutter 1 and likewise end at the distal end a on the front side. This variant of the teeth 3 has values of α=13°-15° and β=30°.
[0033] In this exemplary embodiment the cutters 1 according to FIGS. 1-3 cover, furthermore, as a set of cutters the following dimensions of the internal diameter 6 , external diameter 7 , number of teeth 4 and overall length of the cutter 1 :
[0000]
Internal
External
Overall length
diameter 6
diameter 7
Number of
of cutter 1
[mm]
[mm]
teeth 4
[mm]
1
2
6
250
2.1
3.6
7
230
3.7
4.7
14
210
[0034] The cutters 1 from FIGS. 1 and 3 have a wall with a thickness of about 0.5 mm. The cutter in FIG. 2 has for this a wall thickness of about 0.75 mm. Besides the dimensions listed here, cutters 1 with an external diameter 7 greater than 5 mm with up to 24 teeth are also provided with the corresponding other dimensions adapted hereto.
[0035] Due to the diameters coordinated with one another, in which the external diameter 7 of a thin cutter 1 fits the internal diameter 6 of the next thicker cutter 1 with a tolerance of 0.1 mm, the cutters 1 as a set of cutters can be optimally pushed one into the other, so that they can be placed for this one over another and/or split up for hollowing out in a vertebra. They can be distinguished in their different sizes not only by the different external diameters 7 , but also by the different number of colored ceramic rings 8 consisting of heat-resistant ceramic. Common to all is the annular recess 9 and the rectangular slot 10 at the proximal end b of shank 2 , which make it possible to firmly clamp the cutters 1 in a corresponding handling or rotating device and to transmit a torque due to positive-locking connection with the handling or rotating device, as a result of which precise operation is made possible in endoscopic spine surgery.
[0036] While specific embodiments of the invention have been 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. | A cutter for spine surgery is provided, especially for use in the area of the delicate cervical spine. The cutter includes a cylindrical cutter shank with cutter teeth formed at the distal end thereof. The cutter teeth at the distal end of the cutter shank are formed by grooves in the wall of the cutter shank. The grooves become deeper and expand from the outer radius of the cutter shank towards the distal end such that teeth narrowing towards the distal end with increasing height are formed between them. This guarantees especially gentle cutting in the area of the cervical spine, without surrounding delicate tissue being additionally jeopardized. | 0 |
CORRESPONDING RELATED APPLICATIONS
The present application is a continuation of U.S. application Ser. No. 11/249,478, filed Oct. 14, 2005 (now U.S. Pat. No. 7,390,154), which is a continuation of application Ser. No. 10/734,678, filed Dec. 15, 2003 (now U.S. Pat. No. 7,175,377), which is incorporated by reference herein in its entirety, which is continuation in part of U.S. application Ser. No. 10/336,033 filed on Jan. 3, 2003 (now U.S. Pat. No. 6,827,531), which is incorporated by reference herein in its entirety. Additionally, the present application is related to U.S. application Ser. No. 09/874,979 filed on Jun. 7, 2001 (now U.S. Pat. No. 6,846,140), and U.S. application Ser. No. 10/109,051 filed on Mar. 29, 2002 (now U.S. Pat. No. 6,712,568) by Mark D. Snyder et al., which are incorporated by reference herein in their entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to fasteners for securing loads to a track, and more particularly, to adjustable fasteners for securing loads to a track mounted in or near a truck bed.
2. Background of the Invention
Fasteners for securing loads to framing, tracks, and channels have been commercially available for some time. Some conventional fasteners used in automotive track applications will be briefly described below.
Conventional track fasteners have been designed to be removable and/or relocateable along a track slot length. Many of these conventional track fasteners employ a rotatable locking base portion that engages locking teeth inside the track slot or on a locking mechanism to securely retain the fastener within the track slot, and to facilitate relocation along the track slot length. These devices, however, can be difficult to install and use, which detracts from their desirability in consumer environments such as original equipment manufactured (OEM) vehicles such as pickup trucks, mini-vans, sport-utility vehicles or other vehicles. Often, conventional track fasteners can only be loaded from an end of the track slot, because their design does not facilitate top down loading, and are thus difficult to replace if broken. Also problematic, many of these fasteners have limited load capacities, such as fasteners available on roof racks, and are thus unsuitable for applications such as truck beds and cargo areas where heavier loads are placed.
Other conventional track fasteners (e.g., U.S. Pat. Nos. 4,410,298, 4,784,552, and Re. 36,681, which are incorporated by reference herein in their entirety) have been designed with a center through bolt to apply pressure between a top plate mounted above the track slot and a base plate mounted within the track slot. The bolt can be tightened to clamp the fastener in place, thereby securely retaining the fastener within the track slot, or loosened to allow relocation along the track slot length. Clamp styled fasteners are often used to temporarily attach rails to the top side of a truck bed for tonneau covers and the like, and generally allow relocation along the length of the track slot. These devices, however, often require a user to have a wrench to loosen or tighten the bolt, which detracts from their ease of use.
Thus, a need exists for an improved track slot fastening device.
SUMMARY OF THE INVENTION
The present invention is directed to overcoming or at least reducing the effects of one or more of the problems set forth above and other problems in the prior art.
According to embodiments of the invention described below, there is provided a fastener assembly for securing loads to a track, the fastener assembly being retainable within a track slot of the track. The fastener assembly may include a retainer adapted to fit at least partly within a track slot and a rotatable handle operating on the retainer, the rotatable handle being rotatable between at least an engagement position and a release position. A pressure applicator is positioned between the track and the rotatable handle, the pressure applicator having a bottom surface for applying a pressure on a top surface of the track in response to the position of the rotatable handle. The pressure applicator includes at least one projection projecting from an interior region of the bottom surface and adapted to engage a positioning scallop of the track.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing advantages and features of the invention will become apparent upon reference to the following detailed description and the accompanying drawings, of which:
FIG. 1 is a perspective view of a fastener assembly according to an embodiment of the present invention;
FIG. 2 is a bottom perspective view of the fastener assembly of FIG. 1 ;
FIG. 3 is a bottom perspective view of the fastener assembly of FIG. 1 mounted on a track slot with the track slot cut in a mid-region to show an interface between the fastener assembly and the track slot;
FIG. 4 is a perspective view of a shaft coupled to a retainer according to an embodiment of the present invention;
FIG. 5 is a top perspective view of a rotatable handle according to an embodiment of the present invention;
FIG. 6 is a bottom perspective view of the rotatable handle of FIG. 5 ;
FIG. 7 is a sectional view of the fastener assembly of FIG. 1 viewed from plane VII-VII;
FIG. 8 is a sectional view of the fastener assembly of FIG. 1 viewed from plane IIX-IIX;
FIG. 9 is a sectional view of a fastener assembly with ramped or angled portions according to another embodiment of the present invention; and
FIG. 10 is a partial sectional view of the fastener assembly of FIG. 9 viewed from plane X-X.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to presently preferred embodiments of the invention. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
The following description of the present invention will describe implementations of the present invention in reference to a track slot used in a truck bed. One such implementation is described in copending U.S. patent application Ser. No. 09/874,979 filed Jun. 7, 2001, by Michael D. Anderson et al., which is incorporated by reference herein in its entirety. Additional improvements and variations are described in the aforementioned corresponding related applications. Other implementations are also contemplated, as would be readily apparent to one of skill in the art after reading this disclosure.
It should be appreciated that the term track slot as used in the present specification refers to the entire internal volume of the track. Hence, track slot includes the space substantially between two upper inwardly protruding portions at the top of the track, and the volume underneath the protruding portions to a bottom surface of the track. It should also be appreciated that the term load as used in the present specification refers to a force applied to a fastener assembly by an object secured thereto. This load may include, for example, a horizontal force acting substantially along a plane of a vehicle body, a vertical force acting upwards and away from the aforementioned plane of the vehicle body, or a combination of the two.
A fastener assembly 1000 retainable within a track slot 605 of a track 600 according to a first embodiment of the present invention is shown in FIGS. 1 through 8 . The fastener assembly 1000 includes a rotatable handle 1010 , such as a thumb-wheel, which is shown best in FIGS. 5 and 6 . The rotatable handle 1010 is disposed within an outer tie down 1011 for securing loads to the fastener assembly 1000 . The rotatable handle 1010 is operably connected to a retainer 1050 by way of a shaft 1020 . Retainer 1050 is configured to function in conjunction with a pressure plate 1040 to apply a mechanical clamping force on the track 600 when in an engaged or locked configuration.
According to the first embodiment of the present invention as shown in FIG. 2 , a plurality of projections 1090 are configured to extend from a bottom surface 1041 of pressure plate 1040 . Preferably, the projections 1090 extend from a region located generally in the interior of the bottom surface 1041 of pressure plate 1040 . In this configuration, the projections 1090 may be spaced from one or both of the ends 1042 and 1044 of pressure plate 1040 and from one or both of sides 1046 and 1048 of pressure plate 1040 , or a plurality of combinations thereof. It can be appreciated that spacing the projections 1090 an approximately equal distance on opposite sides of shaft 1020 will ensure an equal load distribution across the bottom surface of the pressure plate 1040 . Preferably, projections 1090 are positioned in a configuration shown in FIG. 2 .
The projections 1090 may include four periphery portions 1091 formed in a shape conforming to that of scallops 1095 in track 600 to promote engagement therebetween and slot guide portions 1093 to further assist in positioning the fitting in the track. A clearance may also be provided to facilitate ingress and egress of the projections 1090 . In the embodiment of the invention shown in FIGS. 1 to 8 , the scallops are in the shape of a portion of a circle having a radius of about 5 mm (such as 5.37 mm) and thus each of the four periphery portions 1091 are in the shape of a portion of a circle having a radius of about 5 mm. In this particular embodiment, the non-scalloped portion of the top of the track slot is about 21 mm wide (such as 21.45 mm) and thus portions 1093 on each projection 1090 are spaced apart about 21 mm. In this particular embodiment, the centers of curvature of adjacent scallops are about 40 mm apart and thus the centers of curvature of the portions 1091 are about 40 mm apart. Other variations are also plausible, as will be readily apparent to one of ordinary skill in the art after reading this disclosure. For example, the scallops and periphery portions can have other arc-shaped geometries in addition to circular geometries. Projections 1090 are illustrated to project from pressure plate 1040 at an angle of 90° from the bottom surface 1041 . However, it is contemplated that the projections 1090 may extend at a variety of angles to increase engagement with corresponding scallops 1095 .
As shown in FIGS. 5 through 8 , the rotatable handle 1010 may be formed of a multi-piece or multi-section construction. By way of example, the rotatable handle 1010 may include a top 1012 including a threaded nut 1014 , for translating the threaded portion 1025 of shaft 1020 , and a washer 1016 which prevents rotation and rocking of shaft 1020 . This multi-piece or multi-section construction allows the rotatable handle 1010 to be easily assembled and manufactured. Also, shown in FIG. 8 are fasteners 1013 , which hold the tie-down portion 1011 to pressure plate 1040 and a clip 1015 which retains the shaft 1020 to the rest of the fitting.
In order to insert the fastener assembly 1000 in track 600 , the longitudinal axis of the fastener assembly 1000 is initially placed transverse to the longitudinal axis of the track 600 . Next, the retainer 1050 is positioned such that the longer axis is oriented parallel to and above the slot. The retainer 1050 is then placed in the longitudinally extending slot 605 of the track 600 . The fastener assembly 1000 is then rotated 90° in the clockwise or counterclockwise direction, thus aligning with track 600 so that the retainer 1050 is also rotated 90°. In this manner, the fastener assembly 1000 can be inserted in track 600 in a top-down method and easily secured to the track 600 .
To secure fastener assembly 1000 to track 600 , the fastener assembly 1000 is first inserted in the track 600 , as described above. Next, the fastener assembly 1000 is placed along the track 600 such that projections 1090 engage corresponding scallops 1095 formed in the track 600 . The rotatable handle 1010 is then rotated clockwise about a central axis defined by shaft 1020 , which in turn rotates a central threaded portion 1014 of the rotatable handle 1010 . Rotation of the rotatable handle 1010 operates to translate the threaded portion 1025 of shaft 1020 , thereby translating shaft 1020 relative to rotatable handle 1010 . As the shaft 1020 is translated the retainer 1050 , which is coupled to the shaft 1020 , contacts a lower surface 610 of a flange 615 formed on the track 600 . The retainer 1050 and pressure plate 1040 combine to exert a clamping force on the track 600 , thereby retaining the fastener assembly 1000 in a secured position on track 600 . In this manner, the fastener assembly 1000 can be securely coupled to the track 600 in a plurality of locations along the track 600 for fastening loads thereto.
A fastener assembly 400 retainable within a track slot of a track 110 according to a second embodiment of the present invention is shown in FIGS. 9 and 10 . A portion of FIG. 9 viewed from plane X-X is shown in greater detail in FIG. 10 . The fastener assembly 400 according to this embodiment includes a rotatable handle 410 , such as a thumb-wheel, within an outer tie down 411 for securing loads to the fastener assembly 400 . The rotatable handle 410 operates retainer 450 via shaft 420 . A spring 430 is provided in a space between the rotatable handle 410 and a pressure plate 440 , such that the spring 430 applies a vertical force on a pin 443 with respect to the pressure plate 440 . The pressure plate 440 is secured to the tie down 411 by screws 435 .
To operate the fastener assembly 400 , the rotatable handle 410 includes an angled running surface 445 interfacing pin 443 . As the rotatable handle 410 is rotated between a locked position and a released position, the angled running surface 445 vertically displaces the pin 443 which is coupled to the retainer 450 by shaft 420 . The rotatable handle 410 is limited in vertical displacement due to intersecting a portion of the outer tie down 411 .
The interface between the angled running surface 445 and the pin 443 may be formed to prevent overtightening of the fastener assembly 400 and to default to a tightened condition during partial tightening of the rotatable handle 410 . By way of example, the angled running surface 445 may include a notch (not shown) for receiving the pin 443 at a loosened state near the top of the angled running surface 445 . If an operator only partially loosens the fastener assembly 400 , thereby not engaging the notch, the spring 430 forces the pin 443 to slide down the angled running surface 445 into a tightened or engaged position. To prevent overtightening, the spring 430 is configured to apply the maximum retention force on the retainer 450 when the pin 443 is at the bottom of the angled running surface 445 . Therefore, overtightening may be prevented and default engagement may be achieved by the present invention.
The foregoing description of preferred embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention. For example, other types of retainers such as nuts or other fasteners may be used. The embodiments were chosen and described in order to explain the principles of the invention and its practical application to enable one skilled in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined with reference to the claims appended hereto, and their equivalents. | A fastener assembly secures loads to a track in a truck bed and is retainable within a track slot of the track. The fastener assembly may include a retainer adapted to fit at least partly within a track slot and a rotatable handle operating on the retainer, the rotatable handle being rotatable between at least an engagement position and a release position. A pressure applicator is positioned between the track and the rotatable handle, the pressure applicator having a bottom surface for applying a pressure on a top surface of the track in response to the position of the rotatable handle. The pressure applicator includes at least one projection projecting from an interior region of the bottom surface and adapted to engage a positioning scallop of the track. | 1 |
BACKGROUND OF INVENTION
[0001] Current designs for double row or larger polygonal arches present difficulties when applied to structures with spans above 40 feet (12 m) that need to meet public load safety standards, or that need to be dismantled easily and reused, or which are constructed without scaffolding, assembled without heavy equipment, and built with bamboo or other locally-available beam materials, or which need to be safely and reliably assembled by non-professionals.
[0002] What are needed are connectors that enable the construction of arch-shaped structures either individually or as parallel ribs of cylindrically-shaped structures such as supporting arches for bridges, tunnel linings, Quonset hut-type shelters and arbors. The need is for a connector that enables the construction of arches where the stringer beams are arranged in two or more parallel rows so that the ends of the beams in one row are opposite the midsection of the beams in an adjacent row. Arches constructed from straight beams are desirable because they use lower cost standard components but retain the strength, simplicity and extended span of arches constructed of specially engineered curved components.
[0003] The end-to-end alignment of beams in polygonal arches transfers the load placed on the arch to the abutments along the longitudinal axis of each beam. This end-to-end load transfer makes efficient use of the strength of most materials. Although a polygonal arch makes good use of materials, the end-to-end alignment of the beams is unstable. Adding enough bracing to make a single row of beams rigid increases costs and lowers the strength-to-weight ratio. The instability problem is solved by joining at least two parallel, end-to-end aligned rows of beams so that the point where the beams meet in one row is braced by the mid-point of a beam in the adjacent row. The resulting arch is strong, light-weight and uses readily available standard materials.
[0004] For most civil engineering projects, the trusses and curved-component arches that can be made of aluminum or steel are more efficient in their use of materials than the double row polygonal arch. However, for many remote, emergency response, environmentally-sensitive or limited-funding situations, the double row or multi-row polygonal arch would be a superior support structure for bridges and larger shelters due to its simplicity, strength and ability to span greater distances with small, human-portable components assembled by unskilled labor. To meet the requirements of these demanding situations, the structure needs to be improved so it can be built quickly and safely out of standard modules in difficult terrain, be constructed of bamboo or other local materials like small diameter timber, and be easily disassembled, transported and reused.
[0005] Various designs exist for building arches using straight beams both with and without connectors between the beams, e.g., U.S. Pat. No. 4,412,405, J. J. Tucker; U.S. Pat. No. 1,727,022, T. Ahlborn; U.S. Pat. No. 3,004,302, W. W. Nightingale; U.S. Pat. No. 3,091,002, L. E. Nicholson. Historical arch designs also provide examples, e.g., the ‘self-supporting bridge’ of Leonardo Da Vinci, bridges in rural China such as Meichong Bridge, Yunhe County, and Xidong Bridge, Taishun County, both in Zhejiang Province, and the Moon Bridge at Huntington Gardens in Pasadena, Calif. Some designs provide modularity, reusability and safety, but the benefits are limited primarily to one material, or to very small structures. A single design which addresses the combined requirements of cantilevering, allowing a wide range of beam materials, and reducing construction time, which can be scaled up to build structures with spans of 20 meters or more, is lacking.
SUMMARY OF INVENTION
[0006] The present invention is a structural connector for creating a double row or multi-row polygonal arch using straight beams. The connector joins three straight beams in a triangular union that forms one node of the structure. A series of ‘nodes’ creates an arch, or a complete circle if enough ‘nodes’ are added. All the ‘nodes’ of the arch are established by the connector, all connectors in a single arch can be identical connectors of the type described in the invention, and no other types of connectors are required to assemble the beams into an arch structure. The connector according to the present invention is typically made of sheet metal or steel plate.
[0007] The connector is a ‘Y’-shaped device with three brackets that bind the ends or middle of beams to the connector. One bracket is located on each arm of the ‘Y’. The two brackets at the top of the ‘Y’ are on the opposite longitudinal face of the connector from the bracket at the bottom of the ‘Y’ so that the connector joins two beams from one row of beams together end-to-end, and joins the two separate rows of beams in the arch to each other.
[0008] The beams inserted into the two brackets at the top of the ‘Y’-shape must slope downward at an angle of 1 or more degrees from horizontal in a completed arch. To establish the required slope, the top brackets may be fixed in relation to each other and the bottom bracket at the specific angle required, or allowed to swivel through a range of angles so that the final angle is determined by the length of the beams used and the basic rules of geometry. The bottom bracket is aligned at roughly 90 degrees to the vertical centerline of the connector so that the beam in the bottom bracket is the base of the isosceles-triangle-shaped union and the beams in the top brackets are the sides of the union.
[0009] The connector establishes a modular ‘building block’ for double row or multi-row polygonal arches. One beam with one connector attached to the beam's midsection by the bottom bracket of the connector is the basic construction unit. Each of these ‘building blocks’ interlocks with other identical blocks turned in the opposite direction. The ends of the beams in opposite-facing ‘building blocks’ fit into the top brackets of the connectors of its neighboring ‘building blocks’ creating an interlocking structure.
[0010] The connector allows an arch to be assembled in-place, without scaffolding, by creating a series of cantilevers from the arch's abutments to the center of the span. Each ‘building block’ cantilevers from the next lower block by hanging from its own connector and using the connector of the next lower building block as a counter-balance. At the center of the span, the final ‘building block’ acts as a ‘keystone’ joining the two cantilevered half-arches.
[0011] Once an arch is complete, the connectors direct the load forces around the arch to the abutments in the same way as the stones in a keystone arch. Each connector also maintains the alignment of the beams in the double row structure of the arch.
[0012] The brackets of the connector can simply hook over the beams, holding the beams in place by balancing the opposing forces in the top brackets against the bottom bracket. Fasteners holding beams to the brackets are not required but can be used to add convenience during construction, or structural durability. top brackets may be constructed to fully enclose the ends of the beams, allowing the use of beams made of bundles of smaller elements, like bamboo poles and small diameter timber.
[0013] A transverse beam may be added through the optional transverse notch between the top brackets to connect a single arch to other parallel arches in a multi-arch structure.
[0014] The bottom bracket can be configured with a flange, called a “Chaining Hook”, which connects the bracket to the adjacent connector in a structure with multiple, closely adjacent parallel arches.
[0015] Construction-grade connectors are applicable to bridges, shelters, culverts, tunnels and arbor-like structures. Smaller embodiments of the connector made of thin-gauge metal, plastics, fabric or composites can be used in furniture, toys and small devices. The number, type, composition and size of fasteners required used to assemble the connector and attach beams to the brackets of the connector are application-specific.
DRAWINGS
[0016] FIG. 1A is a perspective view of one embodiment of the invention showing ‘U-shape’ type top and bottom brackets.
[0017] FIG. 1B is a perspective view of another embodiment of the invention showing I-shape′ type top and bottom brackets.
[0018] FIG. 1C is a perspective view of another embodiment of the invention showing ‘Fully-enclosed’ type top and bottom brackets.
[0019] FIG. 1D is a perspective view of yet another embodiment of the invention showing ‘Wing’ type′ top brackets with a ‘U-shaped’ type bottom bracket.
[0020] FIG. 1E is a perspective view of an embodiment of the invention showing the connector configured without a transverse notch between the two top brackets. This embodiment is Illustrated with exemplary ‘Wing’ type top brackets and an I-shape′ type bottom bracket.
[0021] FIG. 2 is a perspective view of a single row polygonal arch structure created with the invention constructed using Y-shaped connectors according to the present invention.
[0022] FIG. 3A is a front perspective view of one node of a double row polygonal arch created with the invention which shows the invention with two stringer beams inserted into the top brackets, one stringer beam inserted into the bottom bracket and a transverse beam inserted in the transverse notch.
[0023] FIG. 3B is a front view of one node of a double row polygonal arch showing the use of a triangular shim to allow rectangular-ended beams to be inserted into the top brackets.
[0024] FIG. 4A is a front perspective view of one embodiment of the present invention shown as an assembly of the three primary elements: top brackets, a bottom bracket, and a central structure.
[0025] FIG. 4B is a rear perspective view of the invention shown in FIG. 4A .
[0026] FIG. 5A is a perspective view of one embodiment of the invention with ‘configurable vertical spacing’, showing a central structure that has vertical slots which allow the bottom bracket to be selectively fixed at one of a variety of distances from the top brackets. In this figure, the bottom bracket is shown at the lower end of the range of travel.
[0027] FIG. 5B is a front perspective view of the invention shown in FIG. 5A with the bottom bracket at the middle of the range of travel.
[0028] FIG. 5C is a front perspective view of the invention shown in FIG. 5A with the bottom bracket at the top of the range of travel.
[0029] FIG. 5D is a rear perspective view of the invention shown in FIG. 5A , showing use of bolts to attach the bottom bracket to the central structure through the two slots.
[0030] FIG. 6 is a front view of an embodiment of the present invention illustrating the top brackets connected to the central structure of the Y-connector with hinges.
[0031] FIG. 7A is a perspective view of an embodiment of the invention with the bottom bracket configured with a ‘chaining hook’.
[0032] FIG. 7B is a side view an embodiment of the invention where two Y-shaped connectors with a ‘chaining hooks’ are nested, with the ‘chaining hook’ of one connector resting on the ‘notch floor plate’ of the adjacent connector.
[0033] FIG. 8 is a perspective view of the ‘building block’ established by the invention: a construction module that interlocks with other identical modules to create a double row of polygonal arches. The illustration shows the ‘Side-Braced’ embodiment of the connector configured with the ‘L-shape’ type top brackets and the ‘Fully-enclosed’ type bottom bracket attached to a stringer beam forming a single construction unit.
[0034] FIG. 9 illustrates a front perspective view of an ‘Abutment connection bracket’ according to the present invention, including a stub beam, a ‘locking angle’ and a support brace with a springer ‘building block’.
[0035] FIGS. 10A, 10B, and 10C are side views illustrating a sequence where a springer building block is being lowered onto the abutment. FIG. 10A shows the initial position of the ‘locking angle” when the springer ‘building block’ starts to be lowered onto the abutment. FilG. 10 B shows the rotation of the ‘locking angle’ as the ‘stub beam’ slides into the top bracket of the springer ‘building block’. FIG. 10C shows the final positions of the ‘locking angle’ and springer ‘building block’.
[0036] FIG. 11 is a perspective view of a cantilevered assembly sequence using ‘building block’ modules created with the invention.
[0037] FIG. 12 is a perspective view of a tied arch created according to the invention.
[0038] FIG. 13 is a perspective view showing a two arch structure created using Y-shaped connectors according to the present invention where a transverse beam is used at each node to join the arches together.
[0039] FIG. 14A shows one embodiment of a Y-shaped connector for 3-row polygonal arches. Shown is a Type A connector which has four top brackets and one bottom bracket.
[0040] FIG. 14B shows another embodiment of a Y-shaped connectors for 3-row polygonal arches. Shown is a Type B connector which has two top brackets and two bottom brackets.
DETAILED DESCRIPTION
[0041] Referring to FIG. 1A , one embodiment of the invention is a Y-shaped structural connector 100 having three U-shaped brackets designed to bind three stringer beams to the union created by the connector. One U-shaped bracket is located on each arm of the KY′. Each of the brackets 110 and 112 form the upper arms 1 L, 1 R, respectively, of the ‘Y’ shaped connector 100 . Each of these brackets 110 , 112 binds the end of a stringer beam to the connector 100 . The top brackets are aligned with each other so that they are mirror images of each other relative to the vertical, front-to-back midplane 42 of the connector 100 . The U-shaped bracket 114 forms the bottom arm 2 of connector 100 . Bracket 114 binds the midsection of a third stringer beam to the connector 100 . The bottom bracket 114 is aligned with the top brackets 110 and 112 so that a beam fully inserted into either top bracket 110 , 112 will slope toward the level of the bottom surface 116 of the bottom bracket 114 . Both top brackets extend downward at an angle 40 that is greater than zero from the transverse plane 43 of the connector 100 . The transverse plane 43 of connector 100 is always parallel to the bottom surface 116 on which the beam inserted in the bottom bracket 114 or the tangent to the lowest point of the beam, if the beam is cylindrical.
[0042] In the FIG. 1A embodiment, the two top brackets are separated by a space, a transverse notch 3 , which enables a transverse beam to be inserted into the connector 100 .
[0043] FIGS. 1A-1E illustrate five embodiments of the inventive connector 100 illustrating different types of brackets and transverse notch options. FIG. 1A shows ‘U-shaped’ brackets 110 - 114 , which allow the beams to enter the top brackets from below and to control the lateral movement of the beams without fasteners. FIG. 1B shows ‘L-shaped’ brackets 120 , 122 , and 124 in a connector 100 ′ which allow the beams to enter the top brackets 120 , 122 from the side as required for the top three beams of an arch assembled by cantilevering. The bottom bracket in connector 100 ′ is shown at 124 . Bolts, screws or other fasteners are required to keep the beam in place in ‘L-shaped’ brackets. FIG. 1C shows ‘Fully-enclosed’ brackets 130 , 132 , and 134 in a connector 100 ″ which are used in applications where the ends of the stringer beams require protection from the weather, e.g., with bamboo stringer beams. The top brackets are shown at 130 and 132 , and the bottom bracket is shown at 134 . FIG. 1D shows ‘Wing’ type top brackets 140 and 142 in a connector 100 ′″. In this embodiment, the bottom bracket is selected to be a U-shaped bracket 144 . FIG. 1E shows ‘Wing’ type top brackets 150 and 152 in a connector 100 ″″ configured without a transverse notch. In this embodiment, the bottom bracket in connector 100 ″ is selected to be an L-shaped bracket 154 . The brackets in FIG. 1E are shown with holes 4 for bolts or other fasteners that are to be used to retain the beams in the brackets.
[0044] As shown in FIG. 2 , the purpose of the inventive connector, an example of which is shown at 5 , is to join straight beams 6 , 7 , 8 in a triangular union that forms one node, e.g., node 9 B, of a multi-row polygonal arch structure. FIG. 2 illustrates that, at each node of a double row polygonal arch, two beams 6 , 7 which are adjacent sides of a polygon meet end-to-end at an obtuse angle next to the midsection of a third beam 8 . The beams that meet end-to-end 6 , 7 at the node are in one row A of the arch and the third beam 8 is in the other row B of the arch. A series of these ‘nodes’ 9 ABC creates two polygonal arcs of straight beams which are staggered with respect to each other by one-half the length of a beam. Using the beam numbered 8 as an example, each beam in the structure belongs to three ‘nodes’: one node at each end of the beam 9 A, 9 C, and one node at its midpoint 9 B.
[0045] FIG. 3A gives a detailed view of one node created with a ‘Wing’ type connector 300 showing the stringer beams 6 , 7 , 8 inserted into the two top brackets 1 L and 1 R, and the bottom bracket 2 , respectively. A partial view of a transverse beam 10 is shown with one end inserted into the transverse notch between the ends of beams 6 and 7 . FIG. 3B is a front view of one node of a double row polygonal arch showing the use of a triangular shim 11 to allow rectangular-ended beams to be inserted into the top brackets.
Elements of the Invention
[0046] Top Brackets: Each Y-shaped connector has two top brackets 1 L, 1 R, as illustrated in FIG. 4A . Each top bracket provides a joinery-free connection to a node of a double row polygonal arch for the end of a stringer beam.
[0047] Any method of attaching the end of a stringer beam to a node of a double row polygonal arch that does not require joinery which interlocks or overlaps the beam with either the end of the stringer beam in the opposite top bracket or the transverse beam is considered a top bracket. All top brackets allow disassembly of the attachment between the stringer beam and the top bracket, and reuse of the bracket and beam.
[0048] Each top bracket holds the stringer beam at a downward sloping angle relative to the upper transverse plane 43 of the connector (as seen in FIG. 1A ). The slope of the top bracket establishes the shape of the arch at that ‘node’. The connector can be made with two top brackets that have different downward sloping angles to create non-circular arches.
[0049] Each top bracket can have holes 4 , as shown in FIG. 1E , and one or more flanges or other features for securing the stringer beam in each bracket in a Y-shaped connector according to the present invention. The geometry of the arch and the normal forces produced by the weight of the arch hold the stringer beams in the ‘U-shaped’ and ‘Fully-enclosed’ types of top brackets without fasteners. Fasteners can be added for convenience, safety or durability as required by the application.
[0050] Transverse Notch:
[0051] Referring to FIG. 4A , each connector may have a space between the top brackets termed the transverse notch 3 . The transverse notch can be used for various purposes including: adding a transverse beam to the node, suspending a load from the arch, housing a lifting device for dynamically controlling the curve of the arch, or attaching decorative elements to the ‘nodes’. The transverse notch is created by constructing the central structure 12 of the connector with the required space between the top brackets.
[0052] Bottom Bracket:
[0053] Each connector has one bottom bracket 2 . The bottom bracket is constructed to attach the connector to the midsection of a stringer beam. In operation, bottom bracket applies an upward force on the stringer beam. The upward force is generated by the outward thrust produced by loads on the arch or by the weight of the cantilevered portion of the arch which is transferred to the connector through the top brackets and countered by the stringer beam in the bottom bracket.
[0054] The bottom bracket may be configured as “L-shaped”, “U-shaped”, “Fully-enclosed” or simply as a flat plate of material extending down from the top brackets with one or more bolts used to attach the plate to the stringer beam.
[0055] Central Structure:
[0056] As shown in FIG. 4A , the central structure 12 is the part of the connector which joins the top brackets 1 L and 1 R to the bottom bracket 2 .
[0057] The central structure is a general term for the elements of the connector which are not included in the top brackets or bottom bracket. The central structure:
separates the top brackets to create the transverse notch 3 , when present aligns the top and bottom brackets so the top brackets are centered on the same longitudinal plane 44 and are located on the opposite side of the vertical plane 45 of the connector from the bottom bracket contains braces 13 to make the connector more rigid when needed,
[0061] FIG. 4B shows the rear view of the central structure. Bolts 14 or other suitable fasteners attach the bottom bracket to the central structure when the bottom bracket is a separate part. Likewise, bolts 15 or other suitable fasteners join the top brackets to the central structure when they are separate parts.
[0062] As illustrated in FIG. 5A , the central structure can have vertical slots 16 or tracks which enable the vertical position 17 of the bottom bracket to be adjusted by sliding the bottom bracket up or down along the central structure 12 of the connector. FIGS. 5A, 5B, and 5C show the bottom bracket 2 moving from the end of the range of travel with the greatest separation from the top brackets up to the level of the least separation.
[0063] FIG. 5D shows a typical implementation of the moveable bottom bracket using multiple bolts 14 to keep the bottom bracket aligned with the connector. A single fastener in a single slot can also be used.
[0064] The sliding bottom bracket allows one connector to be used with beams of different lengths creating different spans for the arch.
[0065] The central structure 12 with one or more slots or tracks can be constructed to extend up to the top of the top brackets or beyond, extending both above and below the top brackets. Sliding the bottom bracket from below to above hinged top brackets causes the arch to first collapse to a straight row of beams and then curve up rather than down.
[0066] One or more embodiments of the invention may form the central structure part as part of the top or bottom brackets. In these embodiments, a portion of a top bracket or bottom bracket element performs the function of the central structure. FIG. 1E illustrates a central structure 12 that is an extension of the same piece of material as the bottom bracket,
[0067] Top Bracket Mounting Using Hinges, Pivots or Flexible Material:
[0068] The invention, as illustrated in FIG. 6 , includes the optional attachment of top brackets to the central structure 12 with hinges 18 , pivots or flexible material that have an axis of rotation that is perpendicular the vertical plane of the connector. Mounting the top brackets on hinges or pivots enables a connector to be used with a variety of beam lengths, thereby extending the range of applications in which it can be used. Hinge-mounted top brackets can be used in conjunction with the moveable bottom bracket shown in FIG. 5 or as an alternative top brackets can rotate through a range of angles 19 . The range of angles includes, but is not limited to, the angles required to form a double row or multi-row polygonal arch.
[0069] The pivot can be located anywhere along the top, bottom or transverse-notch-facing end of the top bracket. FIG. 6 illustrates a typical location for the hinge: the point at which transverse-notch-facing end of the top bracket meets the ‘notch floor’.
[0070] Chaining Hook:
[0071] One embodiment of the invention includes a ‘chaining hook’ 20 , as illustrated in FIG. 7A , which is an extension of the ‘outer side wall’ of the bottom bracket 2 that folds outward away from the connector just above the level of the ‘notch floor plate’ 21 . As shown in FIG. 7B , the ‘chaining hook’ fits into the transverse notch of an adjacent connector.
[0072] In structures with two immediately adjacent double-row polygonal arches, the ‘chaining hook’ 20 acts to counteract the torque that can develop at each node under load. Each Y-shaped connector tends to rotate toward the bottom bracket under load as outward thrust in the top bracket 1 R is resisted by the bottom bracket. The ‘chaining hook’ both stops that rotation for its own connector and counters the rotation in the adjacent connector with the force it applies. Braces 13 can increase the value of the ‘chaining hook’ by making the central structure and bottom bracket 2 more rigid.
[0073] The ‘chaining hook’ can also fasten two adjacent double-row arches together by adding holes for fasteners to the ‘chaining hooks’ 20 and ‘notch floor plates’ 21 .
[0074] Building Blocks:
[0075] The invention, as illustrated in FIG. 8 , establishes a ‘building block’ for double row or multi-row polygonal arch structures. The ‘building block’ consists of one connector 5 and one stringer beam 8 attached by the bottom bracket 2 of the connector at the midsection of the beam. Two ‘building blocks’ facing in opposite directions interlock when the ‘building blocks’ are pushed together so that one end of the stringer beam of each block is fully inserted into a top bracket 1 L, 1 R of the other block. This interlocking feature enables the building of a double row polygonal arch from identical modules.
[0076] FIG. 8 shows a building block made with a connector with ‘L-shaped’ top brackets. This type of building block can be added to the arch by sliding it sideways onto other building blocks. ‘L-shaped’ brackets preferably have holes 4 for fasteners to keep the beams in the bracket.
[0077] Additionally, arches can be constructed using non-identical ‘building blocks’ which are designed to interlock with just the adjacent blocks of the structure. Non-identical ‘Building blocks’ can be asymmetrical to create parabolic and non-semi-circular arches. To create a parabolic or other non-circular arch, the length of the beams and the angles of the top brackets can be unique to every ‘building block’. Each ‘building block’ may also be unique with respect to the location at which the bottom bracket is attached to the beam: exactly at the midpoint or offset from the midpoint toward one end of the beam.
[0078] Referring to FIG. 9 , the ends of the arch preferably connect to a foundation or abutment 22 using an ‘abutment connection bracket’. The ‘abutment connection bracket’ has a hinged ‘locking angle’ 23 , a ‘stub-beam’ 24 and, optionally, a ‘cantilever support brace’ 25 fastened to a metal plate 26 which is bolted to the abutment 22 . The ‘locking angle’ 23 is the cantilever anchor during cantilevered construction and the bracket which transfers outward thrust from the arch to the abutment in a completed arch. The ‘stub beam’ fits into the ‘abutment-facing top bracket’ of the ‘building block’ preventing lateral motion at the end of the arch.
[0079] The ‘stub beam’ 24 of the ‘abutment connection bracket’ is a solid or tubular duplicate of the end of a stringer beam. The stub beam is welded or fastened to the ‘abutment connection plate’ 26 at an angle matching the angle of the top bracket of the springer ‘building block’.
[0080] The ‘locking angle’ 23 is attached to the ‘abutment connection plate’ 26 by a hinge 27 with the axis of rotation parallel to the ground. The hinge is mounted such that the lower wall 28 of the ‘locking angle’ is flush with the ‘abutment connection plate’ 26 at one end of the range of travel and at 90 degrees to the plate at the other end of the range of travel. The lower wall of the ‘locking angle’ is as tall as the depth of the springer ‘building block beam’ and at least as wide as the beam.
[0081] The ‘cantilever support brace’ 25 is located immediately below the ‘locking angle’ and extends at 90 degrees from the ‘abutment connection plate’ 26 . The ‘cantilever support brace’ is only used when the arch is constructed by cantilevering. The ‘cantilever support brace’ supports the springer ‘building block’ whose beam is the sole support for the entire cantilevered portion of one side of the arch during cantilevered construction.
[0082] The ‘cantilever support brace’ 25 has a notch 29 in the upper face of the brace to allow room for the ‘bottom wall’ of the bottom bracket of the springer ‘building block’. The length of the ‘cantilever support brace’ is application-specific. The ‘cantilever support brace’ is welded or bolted to the metal plate. The ‘cantilever support brace’ can be removed and reused once the ‘keystone building block’ is in place.
[0083] Referring to FIG. 10A , the springer ‘building block’ 30 is attached to the ‘abutment connection bracket’ 31 by sliding the lop bracket′ 1 R onto the ‘stub beam’ 24 . The ‘locking angle’ 23 is held at the upper extent of the hinge's range of travel until the ‘building block beam’ 32 in the ‘bottom bracket’ touches the lower wall of the ‘locking angle’ initiating the rotation of the ‘locking angle’.
[0084] The abutment-facing end of the beam of each springer ‘building block’ is shortened to fit the ‘abutment connection bracket’. The beam is cutoff at 90 degrees. The position of the cutoff is calculated so that the cutoff face of the beam end will rest squarely on the lower wall of the ‘locking angle’ 28 when the ‘stub beam’ 24 is fully inserted into the ‘top bracket’ of the springer ‘building block’ 30 and the arch is loaded. FIG. 10A shows the point at which the springer ‘building block beam’ 32 first contacts the ‘locking angle’. FIG. 10B shows the locking angle 23 rotating as the stringer beam descends to the abutment connection plate′ 26 guided by the locking angle. FIG. 10C shows the final position of the springer ‘building block’ 30 and the ‘locking angle’ 23 .
[0085] The ‘abutment connection bracket’ may have multiple ‘stub beam’ and a ‘locking angle’ pairs so that multiple parallel arches to be connected to the abutment with one bracket.
Cantilevered Construction:
[0086] The invention enables a double-row polygonal arch to be assembled in its final location and vertical orientation from the abutments without any other scaffolding or support as illustrated in FIG. 11 . FIG. 11 shows a structure consisting of four double-row polygonal arches: A through D, each arch at a different level of completion and all being built by the same method using cantilevering.
[0087] Assembly Procedure:
1. Attach the ‘abutment connection bracket’ 31 to the abutment 22 See Arch A. 2. Cut off one end of the beam of the springer ‘building block’ 30 as specified in the ‘abutment connection bracket’ description. 3. Attach a springer ‘building block’ 30 to the ‘abutment connection bracket’ 31 , as shown in Arch A. 4. At the second and subsequent arches, optionally add a ‘transverse beam’ to the ‘transverse notches’ of adjacent connectors joining neighboring arches at the ‘nodes’ as shown on the left side of Arches A through D. 5. Slide the ‘abutment-facing top bracket’ 35 of a standard ‘building block’ 33 onto the end of the current highest ‘building block’ in the half-arch, as shown in Arch B. 6. Repeat steps 4 and 5 , alternating the direction in which the ‘building blocks’ are facing, until half of the arch is complete, as shown in Arch C. 7. Repeat steps 1 through 5 from the other side of the span. 8. Slide the ‘keystone building block’ 34 onto the voussoir ‘building blocks’ 36 of each side of the span, as shown in Arch D. In arches with an even number of connectors, there are two connectors at the same level at the top of the arch. In these cases, the last ‘building block’ added to the arch is considered the ‘keystone building block’. In cantilevered assembly, the ‘keystone building block’ is added by sliding it into the arch from the side.
[0096] Tied Beam Connection for Tied Arches:
[0097] The connector supports creating a tied arch, as illustrated in FIG. 12 , by connecting the springer ‘building blocks’ 37 to opposite ends of a tie beam 39 : An ‘abutment connection bracket’ without the ‘support brace’ is fastened to the end of the tie beam by a locally engineered solution. The ‘springer building block’ connects to the ‘abutment connection bracket’ as it would with an abutment-mounted bracket.
[0098] Multi-Rib Arch Structures:
[0099] The invention enables multiple double-row polygonal arches to be connected into larger, multi-rib structures by transverse beams 10 inserted in the ‘transverse notch’ 3 of the inventive connectors in each arch, as seen in FIG. 13 . A primary feature of the invention is that the transverse beams at each node are located between the ends of the load-bearing stringer beams 8 , 9 , rather than above or below the beam-to-beam interface through which loads pass to the abutments. When an arch made with the invention is loaded, the transverse beams are held securely by the compression forces transmitted along each row of beams in the arch.
[0100] Symmetrical Connectors:
[0101] A variant of the double-row polygonal arch which has 3 rows of beams can be created by combining two standard connectors into one connector. Two combinations are possible: ‘front-to-front’ and tack-to-back′. ‘Front-to-front’ connectors, as shown in FIG. 14B , have a single common ‘bottom bracket’ 2 and four lop brackets' 1 L, 1 R. Back-to-back, as shown in FIG. 14A , connectors have two ‘top brackets’ 1 L, 1 R in common and two ‘bottom brackets’ 2 . Unlike the standard connectors which are the same at every ‘node’ of an arch, the two types of 3-row connectors must alternate around the arch to produce polygonal rows of beams.
[0102] The 3-row arch has value as a decorative structure. The 3-row arch can be used for structures if the beams in the center row are increased in size to be equal in load-bearing capacity of the two outer rows.
[0103] Hinges and Pivots:
[0104] The hinges and pivots described and illustrated represent generic, off-the-shelf components or application-specific engineered connections that have the axis of rotation indicated and perform the function described. The illustrations are not necessarily drawn to scale. Flexible material such as fabric can serve as a hinge in some applications. Custom engineered solutions and integration of the hinge function into elements of the connector are include as options where hinges or pivots are included in the invention. | The invention is a structural connector used as a component to construct an arch consisting of a plurality of closely adjacent, polygonal rows of stringer beams. The multiple row polygonal arch is a low-cost, general purpose support structure for bridges, shelters and arbors applicable to many cost-, time- or environmentally-sensitive situations. The invention is a Y-shaped connector, typically made of sheet metal, with three brackets, two upper brackets and a lower bracket, which collectively enable a union of three beams forming one node of the multiple row polygonal arch. Using these Y-shaped connectors to join the beams at each node creates the arch structure, and additionally provides the features of cantilevering, modularity, generic component shape, reusability and safety. The invention is applicable to a variety of structures such as: pedestrian and vehicular bridges, shelters, arbors, as well as jewelry, furniture and toys. | 4 |
This application is a divisional of co-pending application Ser. No. 09/456,406, filed on Dec. 8, 1999 now the U.S. Pat. No. 6,454,318, the entire contents of which are hereby incorporated by reference and for which priority is claimed under 35 U.S.C. §120; and this application claims priority of application No. 10-348059 and 11-295422 filed in Japan on Dec. 8, 1998 and Oct. 18, 1999, respectively under 35 U.S.C. §119.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a structure of a connection portion of an exhaust pipe, where the connection portion is connected to an exhaust port of an engine, typically, an engine for a motorcycle.
2. Background Art
An example of a connection portion of an exhaust pipe, where the connection portion is connected to an exhaust port of an engine is disclosed in Japanese Patent Utility Model Laid open No. Sho 61 88021.
The above described related art structure is configured such that a collar is fitted to the outer periphery of an end portion of the exhaust pipe, and the inner peripheral surface of the collar is fixed to the edge of an end portion of the exhaust pipe by welding; and the exhaust pipe is connected to the exhaust port via the collar by means of bolts.
The above described related art structure, however, has the following problems: (1) Since the exhaust pipe is connected to an exhaust port via the collar by means of bolts, stress concentration may occur at a welding portion between the exhaust pipe and the collar, thereby reducing the strength of the connection portion; (2) a clearance between the exhaust pipe and the collar may become larger due to looseness therebetween and the like, thereby causing gas leakage due to occurrence of cracks or the like; and (3) the welding control for preventing a reduction in flow resistance of exhaust gas flowing in the exhaust pipe due to welding beads formed on welding between the exhaust pipe and the collar is complicated.
SUMMARY OF THE INVENTION
In view of the foregoing, the present invention has been made to solve these problems of the related art, and to improve the overall state of the art.
An object of the present invention is to provide a new structure of a connection portion of an exhaust pipe for an engine.
To achieve the above object, there is provided a connection portion of an exhaust pipe, where the connection portion is connectable to an exhaust port side of an engine, the connection portion includes an extension portion extending radially outwardly and integrally formed on an edge of an end portion of the exhaust pipe; and a collar fixed to an outer periphery of the end portion of said exhaust pipe by crimping, wherein the edge of an end portion of said collar is abutted against said extension portion. With this configuration, the exhaust pipe can be rigidly connected to the exhaust port without occurrence of stress concentration therebetween; a clearance between the exhaust pipe and the collar is made as small as possible; since there is no welding bead appeared in the related art structure of a connection portion of an exhaust pipe, the flow resistance of exhaust gas is not increased, and therefore, it is not required to perform mechanical treatment for reducing the flow resistance of exhaust gas; and since the welding means is not required, it is possible to significantly reduce the cost.
In addition, to achieve the above object, there is provided a connection portion of an exhaust pipe, where the connection portion is connectable to an exhaust port side of an engine, the connection portion includes a reinforcing outer pipe fixed on an outer periphery of an end portion of the exhaust pipe by crimping; and a collar fixed on an outer periphery of said outer pipe. With this configuration, the reinforcing outer pipe can be rigidly fixed to the exhaust pipe without welding, to significantly increase the strength of the connection portion of the exhaust pipe, and also a clearance between the exhaust pipe and the outer pipe is made as small as possible.
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:
FIG. 1 is a side view, with a portion broken away, of an exhaust pipe including a connection portion structure of the present invention (first embodiment);
FIG. 2 is a sectional view taken on line 2 — 2 of FIG. 1 (first embodiment);
FIG. 3 is a sectional view taken on line 3 — 3 of FIG. 1 (first embodiment);
FIGS. 4 ( a ) to 4 ( c ) are sectional views showing a process of fixing a collar to an exhaust pipe by crimping (first embodiment);
FIG. 5 is a sectional view showing a state in which the exhaust pipe is assembled in an engine (first embodiment);
FIG. 6 is a side view, with a portion broken away taken along line 6 — 6 of FIG. 7, showing an exhaust pipe including a connection device of the present invention (second embodiment);
FIG. 7 is a sectional view taken on line 7 — 7 of FIG. 6 (second embodiment);
FIG. 8 is a sectional view showing a state in which the exhaust pipe is assembled in the engine (second embodiment); and
FIG. 9 is a sectional view showing a state in which an exhaust pipe in the engine (third embodiment).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
First, a first embodiment of the present invention will be described with reference to FIGS. 1 to 5 .
FIG. 1 is a side view, with a portion broken away taken on line 1 — 1 of FIG. 3, showing an exhaust pipe including a connection portion structure of the present invention; FIG. 2 is a sectional view taken on line 2 — 2 of FIG. 1; FIG. 3 is a sectional view taken on line 3 — 3 of FIG. 1; FIGS. 4 ( a ) to 4 ( c ) are sectional views showing a process of fixing a collar to an exhaust pipe by crimping; and FIG. 5 is a sectional view showing a state in which the exhaust pipe is assembled in an engine.
Referring to FIGS. 1 to 3 , a flange like extension portion 1 a projecting radially outwardly is integrally formed on the edge of a connection side end portion, to be connected to an exhaust port Pe of an engine E (see FIGS. 5, 8 & 9 ), of a stainless steel made cylindrical exhaust pipe 1 . The base end of the extension portion 1 a is formed into a rounded plane.
A carbon steel short sized cylindrical collar 2 is rigidly fixed, by a crimp Ck, on the outer periphery of a connection side end portion, to be connected to the exhaust pipe Pe of the engine E, of the exhaust pipe 1 by means of a crimping means to be described later. The edge of the outer end of the collar 2 abuts against the inner end surface of the extension portion 1 a.
A carbon steel rhombic joint 3 is slidably fitted on the outer periphery of the end portion of the exhaust pipe 1 at a position offset inwardly from the collar 2 . One end surface of the joint 3 is abutted against the inner end surface of the collar 2 . The joint 3 is used for connecting the exhaust pipe 1 to the opening end of the exhaust port Pe of the engine E in co-operation with stud bolts 4 (see FIGS. 5, 8 & 9 ) planted by screwing in the surface portion of the opening end of the exhaust port Pe of the engine E. A pair of bolt holes 5 for allowing the stud bolts 4 to pass therethrough are provided in the outer end portion, opposed to the opening end of the exhaust port Pe, of the joint 3 .
Referring to FIGS. 4 ( a ) to 4 ( c ), a process of fixing the collar 2 to the end portion of the exhaust pipe 1 by crimping is shown. The entire outer periphery of the collar 2 is crimped from outside to the outer periphery of the exhaust pipe 1 . As shown in FIG. 4 ( a ), the collar 2 is set on the outer periphery of the end portion of the exhaust pipe 1 , and the edge of the outer end of the collar 2 is abutted against the extension portion 1 a at the edge of the end portion of the exhaust pipe 1 . Then, as shown in FIGS. 4 ( b ) and 4 ( c ), a portion of the collar 2 is crimped in the vertical direction by the crimping means, wherein shown as upper and lower crimping dies 8 and 9 , with a result that the outer peripheries of the exhaust pipe 1 and the portion of the collar 2 are crimped together to be integrated with each other. The collar 2 is thus rigidly fixed to the exhaust pipe 1 by the crimp Ck. It is readily obvious to those of ordinary skill in the art that the crimping means is not limited to the upper and lower crimping dies 8 and 9 . For example, the crimping means may be dies operable to crimp collar 2 at locations around the periphery thereof, not along the entire periphery as shown. Moreover, the position of the dies 8 and 9 are not limited to the width or style shown. Furthermore, the dies 8 and 9 are not limited to the width and position shown in the Figures.
The structure of mounting the exhaust pipe 1 , on which the collar 2 has been fixed by the crimp Ck as described above, to the exhaust port Pe of the engine E will be described below with reference to FIG. 5 . An annular fitting groove 11 is formed in the opening end portion of the exhaust port Pe. The end portion of the exhaust pipe 1 , on which the collar 2 has been fixed by crimping, is fitted in the fitting groove 11 . Two stud bolts 4 are planted by screwing in the opening end portion of the exhaust port Pe. The exhaust pipe 1 is set to the exhaust port Pe such that the two stud bolts 4 are allowed to pass through the bolt holes 5 and fastened with nuts 6 , to thus rigidly hold the collar 2 together with the extension portion 1 a of the exhaust pipe 1 between the end surface of the exhaust port Pe and the joint 3 . In this way, the exhaust pipe 1 can be integrally connected to the exhaust port Pe of the engine E.
According to the connection portion structure of the exhaust pipe 1 in the first embodiment, it is possible to rigidly connect the exhaust pipe 1 to the exhaust port Pe without occurrence of any stress concentration therebetween, and to make a clearance between the exhaust pipe 1 and the collar 2 as small as possible. Also since welding beads which appeared in the above described related art structure are not present, the flow resistance of exhaust gas is not increased, and thereby it is not required to perform mechanical treatment for reducing the flow resistance of exhaust gas. Further, since the welding means is not required to implement the present invention, it is possible to significantly reduce the cost of the exhaust structure and the manufacturing cost thereof.
A second embodiment of the present invention will be described below with reference to FIGS. 6 to 8 .
FIG. 6 is a side view, with an essential portion broken away taken along line 6 — 6 of FIG. 7, showing an exhaust pipe including a connection device of the present invention; FIG. 7 is a sectional view taken on line 7 — 7 of FIG. 6; and FIG. 8 is a sectional view showing a state in which the exhaust pipe is assembled in an engine. In these figures, parts corresponding to those in the first embodiment are designated by the same characters.
In the second embodiment, a positioning means Fi is provided between a collar 102 , fixed at an end portion of the exhaust pipe 1 by crimping, and a joint 103 fitted to the exhaust pipe 1 . A pair of positioning projections 102 a , spaced at a phase difference of approximately 180°, are formed on the inner end surface, to be abutted against the joint 103 , of the cylindrical collar 102 in such a manner as to project therefrom in the axial direction. Meanwhile, a pair of positioning recessed grooves 103 a corresponding to the pair of positioning projections 102 a , which are similarly spaced at a phase difference of approximately 180°, are formed on the inner peripheral surface of the joint 103 formed into a rhombic shape and having a pair of bolt holes 105 in such a manner as to be each located at an intermediate portion between the pair of bolt holes 105 . The projections 102 a and the recessed grooves 103 a constitute the positioning means Fi. It is readily apparent to those of ordinary skill in the art that the positioning means Fi is not limited to the projection pairs 102 a and the recessed grooves 103 a . For example , the positioning means Fi may be any means capable of aligning the exhaust pipe 1 with the exhaust port Pe.
Like the first embodiment, the collar 102 is fixed using a crimp Ck on the outer periphery of the end portion, on the connection side to the exhaust pipe Pe, of the exhaust pipe 1 , and the joint 103 is slidably fitted on the outer periphery of the end portion, positioned inwardly from the collar 102 , of the exhaust pipe 1 . The inner end surface of the collar 102 is abutted against one end surface of the joint 103 . At this time, the peripheral positioning between the collar 102 and the joint 103 is performed by fitting the pair of projections 102 a of the collar 102 in the pair of the recessed grooves 103 a of the joint 103 .
The pair of bolt holes 105 of the joint 103 are allowed to pass through the stud bolts 4 planted by screwing in an opening end surface of the exhaust port Pe, and the stud bolts 4 are screwed with nuts 6 . In this way, the collar 102 is forcibly held between the end surface of the exhaust port Pe and the joint 103 , so that the exhaust pipe 1 is integrally connected to the exhaust port Pe.
According to the second embodiment, in addition to the same function and effect as those of the first embodiment, the peripheral positioning between the collar 102 and the joint 103 can be simply performed by the positioning means Fi, with a result that the exhaust pipe 1 is easily connected to the exhaust port Pe.
A third embodiment of the present invention will be described with reference to FIG. 9 .
FIG. 9 is a sectional view showing a state in which an exhaust pipe is assembled in the engine. In the Figure, parts corresponding to those described in the first and second embodiments are designated by the same characters.
The third embodiment is characterized by additionally providing a reinforcing outer pipe 20 on the exhaust pipe 1 . A cylindrical outer pipe 20 having a specific length is fitted on a connection side end portion, to be connected to the exhaust port Pe side of the engine E, of the exhaust pipe 1 . A collar 2 is fitted on the outer periphery of the outer pipe 20 . The inner peripheral surface of the collar 2 is fixed to both of the edges of the end portions of the exhaust pipe 1 and the outer pipe 20 by a fixing means 21 such as welding. Alternatively, the fixing means may be bonding using an epoxy, or the collar 2 and the reinforcing outer pipe 20 may be formed integrally together.
A portion, positioned inwardly from the collar 2 , of the outer pipe 20 is fixed, using a crimp Ck, on the exhaust pipe 1 . To be more specific, like the first embodiment, the entire periphery of the outer pipe 20 is crimped on the entire periphery of a portion of the exhaust pipe 1 in the vertical direction by means dies 8 and 9 . Therefore, the entire peripheries of the outer pipe 20 and the portion the exhaust pipe 1 are crimped together. In this way, the outer pipe 20 is fixed on the exhaust pipe 1 by crimping.
The joint 3 is slidably fitted on the outer periphery of the outer pipe 20 , and one end of the joint 3 is abutted against the inner surface of the collar 2 .
Like the first embodiment, the exhaust pipe 1 is integrally connected to the opening end of the exhaust port Pe by means of stud bolts 4 and nuts 6 while holding the collar 2 between the opening end of the exhaust port Pe and the joint 3 .
In the third embodiment, since the reinforcing outer pipe 20 can be rigidly fixed to the exhaust pipe 1 without use of welding, that is, by crimping, it is possible to significantly increase the strength of the connection portion of the exhaust pipe 1 , and to make a clearance between the exhaust pipe 1 and the outer pipe 20 as small as possible.
While the first, second and third embodiments of the present invention have been described, such description is for illustrative purpose only, and it is to be understood that many variations may be made without departing from the scope of the present invention. For example, although the entire periphery of the collar or the outer pipe is crimped to the exhaust pipe in the above described embodiments, part of the collar or the outer pipe may be crimped to the exhaust pipe as an alternative.
While the collar or outer pipe is crimped from outside to the exhaust pipe in the above described embodiments, the exhaust pipe may be crimped from inside, that is, from the inner side of the exhaust pipe, to the collar or the outer pipe.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims. | An extension portion extending outwardly is integrally formed on the edge of an end portion of an exhaust pipe; a collar is fixed on the outer periphery of the end portion of the exhaust pipe by caulking; and the edge of the outer end of the collar is abutted against the extension portion. The aforementioned arrangement provides a connection portion of an exhaust pipe for an engine which is intended to rigidly connect the exhaust pipe to an exhaust port of the engine, to prevent gas leakage by eliminating the occurrence of clearance at the connecting portion, to reduce the flow resistance of exhaust gas in the exhaust pipe, and to reduce the production cost of the connection portion. | 5 |
BACKGROUND OF THE INVENTION
This is a Continuation of application Ser. No. 08/290,444 filed Aug. 15, 1994, now abandoned, which is a continuation of Ser. No. 08/044,137 filed Apr. 8, 1993, now abandoned, which is a continuation-in-part of U.S. application Ser. No. 07/755,267 filed Sep. 5, 1991, now abandoned, which is a continuation-in-part of U.S. Ser. No. 07/734,829, filed Jul. 24, 1991, now abandoned, which is a continuation-in-part of U.S. Ser. No. 07/685,329, filed Apr. 15, 1991, now U.S. Pat. No. 5,258,408, which is a continuation of U.S. Ser. No. 07/612,747 filed Nov. 13, 1990, now U.S. Pat. No. 5,182,304, which is a continuation of U.S. Ser. No. 07/267,141, filed Nov. 4, 1988, now U.S. Pat. No. 5,006,562, which is a continuation-in-part of U.S. patent application Ser. No. 06/894,985, filed Aug. 8, 1986, now abandoned, and Ser. No. 07/071,305, filed Jul. 16, 1987, now U.S. Pat. No. 4,804,683, the disclosures of which are incorporated herein by reference.
This invention relates to liquid detergent compositions suitable for cleaning hard surfaces and which impart insect repelling properties. More particularly, this invention relates to liquid all purpose detergent compositions containing an insect repellent material, and to a process for cleaning and repelling insects from surfaces and articles to which such detergent compositions are applied.
Many types of insects common in households, such as German (Blattela germanica) or house cockroaches, are classified as pests, and much effort has been made to eradicate or at least to control them. Mosquito repellents have long been marketed and various chemicals that are effective in repelling roaches have been discovered. Typically, these chemicals and repellents are used in the household by applying or spraying them to surfaces of walls, floors, cabinets, drawers, packages, containers, rugs, upholstery and carpeting, and in potential nesting places for insects, such as inside walls and between floors. However, heretofore insect repellents have not been generally used in conjunction with hard surface cleaners so as to effectively clean a hard household surface, such as a kitchen wall, oven top, bathroom floor or the like, while at the same time applying a film of insect repellent material which is sufficiently substantive to the surface to which the composition is applied to repel insects therefrom.
The incorporation of an insect repellent into a polishing product for household floors is known in the art. U.S. Pat. No. 3,018,217 to Bruce discloses floor wax coating compositions containing dibutyl succinate as an insect repellent. U.S. Pat. No. 3,034,950 to Goodhue et al, discloses a class of insect repellent compounds which may be applied to surfaces dispersed in a wax. In U.S. Pat. No. 4,455,308 to Smolanoff, there are described insect repellent formulations containing a liquid carrier such as liquid aliphatic or aromatic hydrocarbons. An emulsifying agent such as a nonionic surfactant may be added to the liquid hydrocarbon to permit the composition to be dispersed in water for end use application. U.S. Pat. No. 4,822,614 to Rodero, discloses an insect-repellent ingredient in a hydrocarbon-based solvent such as isoparaffinic hydrocarbons.
SUMMARY OF THE INVENTION
The present invention provides an aqueous liquid detergent composition capable of cleaning a hard surface and repelling insects therefrom comprising (i) a detersive proportion of a surface active detergent compound selected from the group consisting of anionic, nonionic, cationic and amphoteric detergent compounds; (ii) at least about 50%, by weight, water; and (iii) an effective amount of an insect repellent material which is sufficient to repel insects from such hard surface after application of the detergent composition thereto. The liquid detergent composition is free of an insecticide.
The present invention is predicated on the discovery that the insect repellent properties of a repellent material is enhanced with regard to a specific area or location when such area or location is cleaned with a detergent composition as herein described. This effect may be attributed to the natural tendency of insects to preferentially congregate in soiled areas rather than upon a cleaned surface as well as the increased substantivity of the insect repellent material to such washed or cleaned surfaces.
The term "insect" is used herein in its broad sense and, is intended to encompass cockroaches, such as the German (Blattela germanica) and American (Periplaneta americana) roach, as well as mosquitoes moths, flies, fleas, ants, lice and arachnids, such as spiders, ticks and mites.
The term "insect repellent material" is intended to encompass a wide variety of materials having insect repellent properties which are compatible with the type of detergent composition described herein and which manifest a sufficient substantivity to the hard surface to which the detergent composition is applied to be efficacious as a repellent.
Included among the insect repellent materials useful for the present invention are the following compounds which may be used individually or in combination with other repellent materials, the designation in parenthesis following certain compound names referring to its commercial or common designation:
N-alkyl neoalkanamides wherein the alkyl is of 1 to 4 carbon atoms, and the neoalkanoyl moiety is of 7 to 14 carbon atoms:
N,N-diethyl-meta-toluamide (DEET);
2-Hydroxyethyl-n-octyl sulfide (MGK 874); 1
N-Octyl bicycloheptene dicarboximide (MGK 264);
A preferred mixture of the above two materials comprising 66% MGK 264 and 33% MGK 874;
Hexahydrodibenzofuran carboxaldehyde (MGK 11);
Di-n-propyl isocinchomerate (MGK 326);
2-Ethyl-1,3-hexanediol (Rutgers 612);
2-(n-butyl)-2-ethyl-1,3-propanediol;
Dimethyl phthalate;
Dibutyl succinate (Tabutrex);
Piperonyl butoxide; and
Pyrethrum
Although the above-mentioned insect repellent materials are longer lasting and are preferred for purposes of the present invention, other useful repellent materials include essential oils such as Mentha arvensis (Cornmint); Mentha piperita (Peppermint); Mentha spicata (American Spearmint); Mentha cardica (Scotch Spearmint); Lemongrass East Indian Oil; Lemon Oil; Citronella; Cedarwood (Juniperus virginiana L.); and Pine Oil. Terpenoids are another class of material having insect repellent properties, the most useful being (-)-Limonene; (+)-Limonene; (-)-Carvone; Cineole (Eucalyptol); Linalool; Gum Camphor; Citronellial; Alpha and Beta-Terpineol; Fencholic acid; Borneol iso Borneol, Bornyl acetate and iso Bornyl acetate.
Among the non-commercial repellent materials useful for the invention are the following:
N,N-Diethyl cyclohexylacetamide (DECA)
1,2,3,6-Tetrahydro-1-(2-methyl-1-oxopentyl) piperidine
N,N-Diethyl-3-cyclohexyl propionamide (DCP)
2-Ethyl-1-(2-methyl-1-oxo-2-butenyl) piperidine
N,N-diethyl nonanamide, and
N,N-Diethyl Phenylacetamide.
With regard to the aforementioned N-alkyl neoalkanamides, the alkyl group is preferably methyl or ethyl, and most preferably is methyl. The neoalkanoyl moiety is preferably neodecanoyl or neotridecanoyl.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a graph showing the number of days with 90% repellency as a function of the percent of MNDA in the test composition.
DETAILED DESCRIPTION OF THE INVENTION
The detergent compositions of the invention contain a detersive proportion of one or more surface active detergent compounds from among anionic, nonionic, cationic and amphoteric detergents, which generally will be in the range of from about 1 to about 30%, by weight, of the composition, preferably from about 2 to about 20%, by weight. The detergent is preferably a synthetic organic detergent of the anionic or nonionic type and often a combination of anionic and nonionic detergents will be most preferred. Descriptions of many such detergents are found in the text Surface Active Agents and Detergents, Vol, II, pages 25-138, by Schwarz, Perry and Berch, published in 1958 by Interscience Publishers, Inc. Such compounds are also described in a 1973 publication by John W. McCutcheon, entitled Detergents and Emulsifiers. Both such publications are incorporated herein by reference.
The anionic detergents employed will normally be salts of alkali metals, such as sodium or potassium or ammonium or lower alkanolammonium salts, e.g., triethanolamine salts. The anionic detergent may be a sulfate, sulfonate, phosphate or phosphonate or salt of other suitable acid but usually will be a sulfate or sulfonate. The anionic detergents include a lipophilic group, which will normally have from 10 to 18 carbon atoms, preferably in linear higher alkyl arrangement, but other lipophilic groups may be present instead, preferably including 12 to 16 carbon atoms, such as branched chain alkyl benzene. Examples of suitable anionic detergents include higher fatty alcohol sulfonates, such as sodium tridecylbenzene sulfonate; sodium linear alkyl benzene sulfonates, e.g., sodium linear dodecylbenzene sulfonate; olefin sulfonates; and paraffin sulfonates. The anionic detergents are preferably sodium salts but potassium, ammonium and triethanolammonium salts are often more desirable for some liquid compositions.
The suitable nonionic detergents will normally be condensation products of lipophilic compounds or moieties and lower alkylene oxides or polyalkoxy moieties. Highly preferable lipophiles are higher fatty alcohols of 10 to 18 carbon atoms but alkyl phenols, such as octyl and nonyl phenols, may also be used. The alkylene oxide of preference is ethylene oxide and normally from 3 to 30 moles of ethylene oxide will be present per mole of lipophile. Preferably such ethoxylate content will be 3 to 10 moles per mole of higher fatty alcohol and more preferably it will be 6 to 7 moles, e.g., 6.5 or 7 moles per mole of higher fatty alcohol (and per mole of nonionic detergent). Both broad ranges ethoxylates and narrow range ethoxylate (BRE's and NRE's) may be employed, with the difference between them being in the "spread" of number of ethoxylate groups present, which average within the ranges given. For example, NRE's which average 5 to 10 EtO groups per mole in the nonionic detergent will have at least 70% of the EtO content in polyethoxy groups of 4 to 12 moles of EtO and will preferably have over 85% of the EtO content in such range. BRE nonionic detergents have a broader range of ethoxy contents than NRE's, often with a spread from 1 to 15 moles of EtO when the EtO chain is in the 5 to 10 EtO range (average). Examples of the BRE nonionic detergents include those sold by Shell Chemical Company under the trademark Neodol R , including Neodol 25-7, Neodol 23-6.5 and Neodol 25-3. Supplies of NRE nonionic detergents have been obtained from Shell Development Company, which identifies such materials as 23-7P and 23-7Z.
Cationic surface active compounds may also be employed. They comprise surface active detergent compounds which contain an organic hydrophobic group which forms part of a cation when the compound is dissolved in water, and an anionic group. Typical cationic detergents are amine and quaternary ammonium compounds.
The quaternary ammonium compounds useful herein are known materials and are of the high-softening type. Included are the N 1 N-di(higher) C 14 -C 24 , N 1 N-di(lower C 1 -C 4 alkyl quaternary ammonium salts with water solubilizing anions such as halide, e.g. chloride, bromide and iodide; sulfate, methosulfate and the like and the heterocyclic amides such as imidazolinium.
For convenience, the aliphatic quaternary ammonium salts may be structurally defined as follows: ##STR1## wherein R and R 1 represent alkyl of 14 to 24 and preferably 14to 22 carbon atoms; R 2 and R 3 represent lower alkyl of 1 to 4 and preferably 1 to 3 carbon atoms, X represents an anion capable of imparting water solubility or dispersibility including the aforementioned chloride, bromide, iodide, sulfate and methosulfate. Particularly preferred species of aliphatic quats include:
distearyl dimethylammonium chloride
di-hydrogenated tallow dimethyl ammonium chloride
di tallow dimethyl ammonium chloride
distearyl dimethyl ammonium methyl sulfate
di-hydrogenated tallow dimethyl ammonium methyl sulfate.
Amphoteric detergents are also suitable for the invention. This class of detergents is well known in the art and many operable detergents are disclosed by Schwartz, Perry and Berch in "Surface Active Agents and Detergents", Vol. II, Interscience Publishers, Inc., New York (1958) in Chapter 4 thereof. Examples of suitable amphoteric detergents include: alkyl betaiminodipropionates, RN(C 2 H 4 COOM) 2 ; and alkyl beta-amino propionates, RN(H)C 2 H 4 COOM.
Builders may be present in the liquid detergent composition in an amount of from about 1 to 20% to improve the detergency of the synthetic organic detergents. Such builders may be inorganic or organic, water soluble or water insoluble. Included among such builders are polyphosphates, e.g., sodium tripolyphosphate; carbonates, e.g., sodium carbonate; bicarbonates, e.g., sodium bicarbonate; borates, e.g., borax; and silicates, e.g., sodium silicate; water insoluble inorganic builders, including zeolites, e.g., hydrated Zeolite 4A; and water soluble organic builders, including citrates, gluconates, NTA, and polyacetal carboxylates.
Various adjuvants may be present in the detergent compositions such as fluorescent brighteners, antistatic agents, antibacterial agents, fungicides, foaming agents, anti-foams, flow promoters, suspending agents, antioxidants, anti-gelling agents, soil release promoting agents, and enzymes.
The liquid detergent compositions of the invention will generally comprise from about 2 to 20% of surface active detergent compounds which are preferably anionic and/or nonionic, from about 1 to 20%, by weight, of builder salts for such detergents and from about 0.2 to 20%, preferably 0.5 to 10%, by weight, of the insect repellent material, the balance being predominantly water, adjuvants and optionally an emulsifying agent, or hydrotrope such as sodium toluene sulfonate or a solvent suitable for the insect repellent material such as isopropyl alcohol or acetone. To facilitate the incorporation of a fragrance or perfume into the aqueous liquid detergent composition, it is often advantageous to formulate the liquid detergent composition in microemulsion form with water as the continuous phase and oil or hydrocarbon as the dispersed phase.
In practical tests, on actual kitchen floors, counters, drainboards and walls, and in kitchen cabinets and under refrigerators, in roach-infested apartments, significantly fewer roaches will be observed on surfaces to which or near which the invented liquid detergent compositions are applied than on control surfaces, and fewer roaches are found on the bottoms and shelves of cabinets and pantries when walls thereof are treated with the invented detergent compositions. When floors, walls, counters, sinks, cabinets and doors in a house or apartment are treated with the liquid detergent compositions of the invention, the incidence of cockroach infestation is reduced, compared to control apartments where no repellent is applied.
EXAMPLE 1
A single composition in accordance with the invention formulated as shown below was used as the starting material to prepare by dilution six liquid compositions of varying degrees of dilution containing six correspondingly different levels of N-methyl neodecanamide (MNDA) insect repellent material.
______________________________________LIQUID HARD SURFACE CLEANER WEIGHTCOMPONENT PERCENTAGE______________________________________Sodium linear dodecylbenzene sulfonate 4Nonionic detergent.sup.(1) 2MNDA 2.0Coconut fatty acid 0.5Soda ash 2Sodium bicarbonate 1Isopropyl alcohol 4Water BalanceFragrance 1______________________________________ .sup.(1) Condensation product of one mole of a mixture of fatty alcohols of 9-11 carbon atoms with 6 moles of ethylene oxide.
The percentage of MNDA in each of the six tested detergent compositions varied, respectively, as follows: 0.12, 0.20, 0.22, 0.29, 0.4 and 2.0%
The insect repellency of each of these six hard surface cleaning detergent compositions was tested by the procedure described below and compared with the repellency imparted by three repellent-containing comparative compositions, i.e. three solutions of acetone containing 0.25, 0.5 and 1.0%, by weight, respectively, of MNDA.
TEST PROCEDURE
Insects--German and American cockroaches were from established colonies maintained at 27° C. Carpenter ant workers were collected from a log containing a queenright colony and were kept in the same conditions as the cockroaches.
Bioassay--Forty-eight hours prior to initiation of an assay, 50 male German cockroaches were allowed to acclimate to the plastic test cages (51×28×20 cm) with food and water available in the center. A thin film of teflon emulsion (Fluon AD-1, Northern products, Woonsocket, R.I.) on the sides of the cages restricted the insects to the floor of the cage. The assays used either 50 female German cockroaches, 20 males American Cockroaches, or 50 carpenter ant workers.
The repellency of the various compositions to be tested were evaluated over time. The procedure consisted of arranging five 3×3 inch asphalt tiles into a cubic shelter ("cup") and treating the tiles with the various test compositions. The treated sides faced inward. The method relies on the light avoidance response of the cockroaches. Two milliliters of a test composition was applied to the entire inside surface of the cup. Control cups were treated with acetone or water only. The cups were allowed to dry for 1 hr and then a control and a treated cup were inverted into each of the test cages. Food and water were provided in the center of each cage, outside of the cups. The number of insects resting on the inner walls of each cup were recorded in the middle of the photophase daily for 25 days or until equal numbers were found in treated and untreated cups. After each count the insects were disturbed and the positions of the treated and control cups were reversed. Accordingly, the distribution of cockroaches for any given day is considered independent of the previous days distribution.
Repellency was defined as the percentage of insects that avoided the treated surfaces and was calculated as ##EQU1## where N t is the number of insects on the treated surface and N c is the number on the acetone treated control surfaces. The repellency of compounds was evaluated on the basis of the number of days of 90% repellency which is based on (i) the number of days of complete (100%) repellency and (ii) a maximum likelihood probit analysis of time/repellency (SAS User's Guide, SAS Institute 1985) from which a measure was calculated of the number of days of 90% repellency (RT 90 --10% of the insects on the treated surface, 90% on the control surface).
The results of the repellency tests are indicated in FIG. 1 which is a graph showing the number of days with 90% repellency as a function of the percent of MNDA in the test composition.
As noted in the Figure, the comparative compositions not in accordance with the invention were unable to achieve 90% repellency at a level of MNDA repellent of 0.25%. In contrast thereto, the compositions of the invention were able to provide almost 3 days of 90% repellency at a 0.2% level of MNDA. | An aqueous liquid detergent composition is provided for cleaning a hard surface and for repelling insects therefrom comprising a detersive proportion of a surface active detergent compound, an effective amount of at least one of certain defined insect repellent materials which is sufficient to repel insect from the hard surface after application of the detergent composition thereto, the liquid detergent composition being substantially free of a liquid hydrocarbon. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates to an under dispenser containment system (“UDC”) for use under a fuel dispenser such as the kind used to dispense gasoline, diesel or aviation fuel. The system includes quasi-integral penetration fittings and a shear valve support structure separate from the sump portion of the UDC. The UDC is double-walled and made of polyethylene.
BACKGROUND OF THE INVENTION
[0002] Fuel such as gasoline, diesel and aviation fuel is typically stored in large underground storage tanks (“USTs”) and transported by a pump through underground piping to the area below above-ground fuel dispensers. At that point, the underground piping makes a turn to run vertically upward toward the fuel dispenser. Typically, a shear valve is located near the base of the dispenser. The shear valve closes off the fuel pipe to prevent massive fuel leaks in the event that the fuel pipe above the shear valve is broken which can occur, for example, if the fuel dispenser is hit by a car.
[0003] Many jurisdictions, require the fuel to be secondarily contained to reduce the possibility of fuel leaking from the fuel handling equipment into the environment. Thus, UST's are typically double-walled with an inner wall that contains the fuel and an outer wall intended to contain any fuel that may leak through openings in the inner wall. Underground piping also is typically double-walled with an inner pipe that contains the fuel and an outer pipe intended to contain any fuel that may leak from the inner pipe. The interstitial space between the inner and outer wall of the UST and the underground piping may be monitored to detect leaks in either the inner or outer wall. Such monitoring may be accomplished by placing the interstitial space under vacuum and monitoring the vacuum pressure or filling the interstitial space with inert fluid and monitoring the level of the inert fluid. The underground piping typically is constructed from either fiberglass or polyethylene (“PE”). PE piping offers certain advantages over fiberglass piping in that PE is more flexible while fiberglass is more brittle. Fiberglass, however, is easier to bond with other materials making it easier to obtain solid connections that do not leak.
[0004] Under the fuel dispenser, the secondary containment is typically provided by an under dispenser containment (“UDC”) system. The shear valves are typically located within the sump portion of the UDC. The internal piping of the dispenser is located above the sump such that any leaks from the internal piping will fall into and be contained within the sump. Examples of UDCs are shown in U.S. Pat. Nos. 4,842,163, 5,246,044 and 5,301,722.
[0005] Historically, UDCs have presented several challenges. The piping that carries the fuel must pass through the UDC. In most UDC systems, the penetration apertures in the sump are cut at the installation site to allow the apertures to be placed in the proper locations with respect to the underground pipes. Cutting the apertures at the installation site increases the time and complexity of the installation. In addition, such penetrations are difficult to seal against leaks. Thus, the penetrations are usually located on the side of the sump rather than the bottom so that if the penetration is not sealed properly, no liquid fuel will leak through the penetration unless the liquid fuel fills the sump to at or above the level of the penetrations. If the underground piping in a fuel facility is made from fiberglass, many jurisdictions require a four-foot run of pipe from the exterior of the sump before a fitting may be placed on the pipe. Examples of such fittings might include an angled fitting to change the direction of the pipe or a straight connection to connect to a second length of underground pipe. If a four-foot run is required, the penetration is typically made in the side of the sump to avoid having to excavate to a depth of four feet below the bottom of the sump and run the fuel piping connecting to the USTs at an excessive depth.
[0006] One example of an attempt to deal with the propensity of such penetrations to leak is found in U.S. Pat. No. 5,246,044 (“Robertson”). Robertson discloses a fiberglass UDC with integral fiberglass couplings that penetrate the bottom of the UDC. The most common method of sealing a penetration fitting is a bulkhead style penetration fitting. One example of such a fitting is disclosed in U.S. Pat. No. 5,285,829. Use of bulkhead style fittings requires the UDC to be relatively large to allow the installer easy access to the interior of the UDC to install the portion of the bulkhead fitting located inside the UDC. With such larger UDCs, PE's flexibility presents a problem. If a relatively larger UDC is made of PE, the pressure from the surrounding dirt and concrete once the UDC is installed can cause the UDC to bend, buckle or collapse.
[0007] A second function of the UDC is to assist with providing support and bracing for the shear valves and internal piping of the dispenser. Typically, the support for the shear valves is connected to the sump portion of the UDC. For example, U.S. Pat. No. 4,842,163 discloses a “U” shaped brace that connects the shear valve to the side of the UDC. Robertson discloses shear valve support members connected to brackets attached to the UDC. One disadvantage of a connection between the shear valve and the UDC is that damage to the shear valve or internal piping, such as an impact by a car, usually results in damage to the UDC. That problem is particularly prevalent if the UDC is made of fiberglass because of its rigid properties. Thus, after such damage the entire UDC has to be replaced. Such replacement usually requires excavation, usually including breaking and re-pouring concrete surrounding the UDC.
SUMMARY OF THE INVENTION
[0008] The present invention presents a UDC system that overcomes many of problems addressed above. The sump portion of the UDC is double-walled and made of PE. The penetration apertures are pre-molded in the inner and outer walls at the bottom of the sump portion of the UDC. Lips are provided around the edge of the apertures in both the internal wall and the external wall. In the preferred embodiment, double-walled PE pipes are placed in the penetration apertures and fittings are applied that fuse the outer wall of the pipe to the lips around the aperture providing what is essentially an integral penetration fitting. In addition, the lip around the penetration aperture in the internal wall reduces the chance that liquid fuel will leak out of the interior of the UDC in the event of a fuel spill and a failure of the fusion fitting.
[0009] The exterior end of the penetration pipe is connected to the underground fuel piping. The interior end of the penetration fitting is connected to a shear valve. The provision of the penetration pipes already installed in the sump portion of the UDC means that the total size of the sump can be smaller than those currently in use as there is no need to have easy access to the interior of the UDC to install bulkhead style fittings. The smaller size allows the UDC to maintain structural integrity even though it is made from PE. The provision of the penetration pipes and smaller size also allows the sump portion of the UDC to be replaced without the need to break and repour concrete.
[0010] The UDC system also is provided with a support rack for the shear valves and internal piping that is independent from sump portion of the UDC system. Anchors for the support rack are embedded in the concrete next to the upper lip of the UDC. A collar is connected to the anchors. The shear valves are held by the collar. The combination of a PE sump and a shear valve support rack independent from the sump in the disclosed system provides important advantages over the current state of the art. In the event of trauma to the dispenser, such as the dispenser being struck by a car, the internal piping of the dispenser will likely be damaged along with the mechanism providing support for the shear valves. In the current state of the art, the shear valve support structures are integral with the sump portion of the UDC. Thus, damage to the shear valve support structure frequently causes damage to the sump requiring replacement of both the sump and the support structure. Sumps in current use typically have a relatively narrow opening in the top and a wider body to allow room for workmen to work inside the sump. That structure results in the sump having “shoulders” that are typically covered with concrete. Thus, replacement of the sump usually requires excavation including breaking and re-pouring concrete.
[0011] In contrast to the current state of the art, the support structure for the shear valves of the disclosed UDC system is completely independent from the sump portion of the UDC. In addition, the sump portion of the UDC is made of PE which is flexible. Thus, in the event of trauma to the dispenser and damage to the shear valve support structure, the support structure usually can be removed and replaced without the need to break and re-pour concrete. In addition, the flexible properties of the PE sump portion typically allow the sump to absorb any trauma by flexing and springing back into position without any damage to the sump. Finally, the disclosed sump has no “shoulders” but rather straight sides and a lip that is intended to be located at ground level. Thus, should the sump portion need to be replaced, the sump can be lifted out after cutting the bottom of the sump around the penetration pipes. A new sump with openings appropriately sized to accommodate the existing penetration pipes and attached portions of the previous sump may be lowered into the existing hole and the joints sealed by hand welding or other known method. Such replacement may be done without the need to break and re-pour the surrounding concrete.
[0012] The present UDC system presents an additional advantage over the state of the art. As discussed, conventional practice when installing a UDC is to drill the penetration apertures at the location of installation and to install penetration fittings, such as bulkhead fittings, to seal the penetration points. In the preferred embodiment of the present UDC system, the penetrations are pre-installed with PE double-walled pipes extending through the sump and downward from the bottom of the sump portion. The UDC systems may be delivered in a frame that may be buried. Thus, installation may involve simply excavating a hole of an appropriate size and dropping the UDC system including the support structure into the hole. The underground piping is connected to the double-walled penetration pipes of the disclosed UDC system with conventional fittings that are used to connect one piece of underground pipe to another such as elbow or angle fittings. Thus, the disclosed UDC system greatly simplifies the installation process and reduces the chances of human error during the installation resulting in savings of time and money. The double-walled PE pipes of the present UDC system are easily attached to underground piping made of PE. The flexible properties of PE make it a preferable material for underground piping as compared with fiberglass underground piping.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a front view of a fuel dispenser and a cut-away front view of one embodiment of the UDC system installed beneath the fuel dispenser;
[0014] FIG. 2 is a front view of one embodiment of the UDC system;
[0015] FIG. 3 is a side cut-away view of one embodiment of the UDC system along line 3 - 3 of FIG. 2 ;
[0016] FIG. 4 is a plan view of one embodiment of the UDC system;
[0017] FIG. 5 is a side cut-away view of one embodiment of the UDC system along line 5 - 5 of FIG. 4 ;
[0018] FIG. 6 is an enlarged detailed view of one embodiment of the penetration fitting as indicated in FIG. 5 ;
[0019] FIG. 7 is a perspective view showing one embodiment of the UDC system including the support structure installed in earth and concrete; and
[0020] FIG. 8 is a front view of a fuel dispenser and a cut-away front view of a prior art sump installed beneath the fuel dispenser.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] In accordance with the preferred embodiment of the present invention, as shown in FIG. 1 , the UDC system, indicated generally as 10 , is shown installed beneath fuel dispenser 12 . Support rack 14 is connected to anchors 16 by bolts 18 . Anchors 16 are embedded in concrete 20 poured on top of earth 22 . Sump, indicated generally as 24 , rests on earth 22 and is encased in concrete 20 . UDC 10 is installed so that lip 60 of sump 24 is approximately level with the top of concrete 20 . Fuel pipes 26 connect to penetration pipes 28 that pass through penetration fittings 30 . Shear valves 32 are connected to the upper end of penetration pipes 28 and connected to rack 14 by brackets 34 . Additional views of the foregoing components of the UDC system are shown in FIGS. 2 and 3 .
[0022] As shown in FIGS. 3 and 5 , sump portion 24 has an outer wall 36 and an inner wall 38 creating an interstitial space 40 that may be monitored for leaks in walls 36 and 38 .
[0023] As shown in FIGS. 3 , 4 and 5 , support rack 14 may comprise two main L-shaped beams running either side of shear valves 32 . Support rack 14 is connected to anchors 16 by bolts 18 . Shear valves 32 are connected to support rack 14 by brackets 34 . In the event of damage to support rack 14 , such as might occur should dispenser 12 be hit by a car, bolts 18 may be removed, brackets 34 disconnected and rack 14 replaced without the need to remove and replace sump 24 .
[0024] FIG. 6 shows a detail view of a penetration fitting 30 . Penetration pipe, designated generally as 28 , has an inner wall 42 and an outer wall 44 defining an interstitial space 46 that may be monitored for leaks in walls 42 or 44 . The outer wall 36 of sump 24 is formed into an annular lip 48 that surrounds an aperture in outer wall 36 through which penetration pipe 28 passes. Similarly, inner wall 38 of sump 24 is formed into an annular lip 50 that surrounds an aperture in inner wall 38 .
[0025] Cuff 52 is placed over and contains lip 48 and penetration pipe 28 where penetration pipe 28 passes through the aperture formed by lip 48 . Cuff 52 contains internal heating elements that, when activated, partially melt those portions of cuff 52 that contact the outer wall 44 of penetration pipe 28 and lip 48 forming a permanent sealed bond with outer wall 44 and lip 48 . Similarly, cuff 54 is placed over and contains lip 50 and penetration pipe 28 where penetration pipe 28 passes through the aperture formed by lip 50 . Cuff 54 contains internal heating elements that, when activated, partially melt those portions of cuff 54 that contact the outer wall 44 of penetration pipe 28 and lip 50 forming a permanent sealed bond with outer wall 44 and lip 50 . The bonding of lip 50 , cuff 54 and outer wall 44 provides a sealed interior bottom surface of sump 24 that will catch and hold any fuel that may escape from the shear valves 32 or internal piping of the dispenser. Furthermore, in the event cuff 54 fails to bond completely to lip 50 and outer wall 44 or such bond fails at some point in time, lip 50 provides some protection against leaks as any fluid would need to build up in the bottom of sump 24 to a height above lip 50 before such fluid could leak through the aperture defined by lip 50 . In such an event, the fluid would still be contained within sump 24 in the interstitial space 40 . Monitoring of interstitial space 40 by known means would alert interested parties to any failure at any point in penetration 30 .
[0026] FIG. 7 shows the UDC system 10 installed in a typical fueling station environment and illustrates the convenient installation of the UDC system. Anchors 16 are partially embedded in concrete 20 . Support rack 14 is connected to anchors 16 by bolts 18 . Sump 24 is supported by support frame 56 and, after concrete 20 is poured, lip 60 . To install UDC system 10 , a hole is dug in earth 22 that is large enough and deep enough to accommodate sump 24 , support frame 56 and the portion of penetration pipes 28 that extend below sump 24 . Before and during installation, anchors 16 and connected support rack 14 may be held in place at the appropriate level with respect to sump 24 by bands 58 that connect anchors 16 to support frame 56 . UDC system 10 and support frame 56 are lowered into the hole and penetration pipes 28 are connected to fuel pipes 26 by conventional means. The hole is then backfilled and concrete 20 is poured.
[0027] Should it become necessary to replace support rack 14 , support rack 14 may be disconnected from anchors 16 by removing bolts 18 . Shear valves 32 are disconnected from brackets 34 and support rack 14 may be removed and replaced.
[0028] With reference to FIG. 6 , should it become necessary to replace sump 24 , support rack 14 is removed as described above, an annular cut may be made in inner wall 38 around each penetration pipe 28 . A second annular cut may be made in outer wall 36 around each penetration pipe 28 . Once the penetration pipes 28 have been separated from the walls of sump 24 , sump 24 may be lifted out. A new sump 24 with holes in its inner wall 38 and outer wall 36 sized appropriately to accommodate penetration pipes 28 may be dropped into the hole. Penetration pipes 28 may be connected to outer wall 36 and inner wall 38 with annular patches and hand welding.
[0029] As shown in FIG. 8 , typical prior art sumps such as sump 64 have shoulders 62 that are covered with concrete 20 which must be removed and repoured if the sump 64 is to be replaced. The replacement of sump 24 and support rack 14 in the disclosed UDC system 10 may be accomplished without the need to break and re-pour the concrete 20 surrounding UDC system 10 which greatly simplifies the replacement process saving both time and money and allowing the dispenser 12 to be put back into service much more quickly than is possible in the case of prior art UDC systems. | An under dispenser containment system with integral penetration fitting and a fitting support structure separate from the sump. The containment system is adapted for use under fuel dispensers. The containment system comprises a double-walled sump with apertures and lips surrounding the apertures molded into the inner and outer walls. The containment system also comprises a fitting support structure that is not attached to the sump to allow replacement of the support structure without having to replace the sump. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation in part of my prior application filed Apr. 11, 1975, Ser. No. 567,096 now abandoned.
In my applications for letters patent for Tubular Article and Method of Making Same, filed Oct. 1, 1973, Ser. No. 402,131, and Tubular Article and Method of Making Same, filed Mar. 25, 1974, Ser. No. 454,302, there are disclosed improvements to tubular articles formed in a mold with an inflatable mandrel carrying a continuous, surrounding knitted fabric resin distribution component with an exterior lamina or skin and an interior lamina or lining, respectively.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to tubular articles and methods of making the same and more particularly to such articles suited for air, gas or liquid flow and/or storage. It also relates to the art of compression molding reinforced thermosets and more particularly to directing resin flow by controlled air displacement during the molding process.
2. Description of the Prior Art
It has heretofore been proposed in the Sipler U.S. Pat. Nos., 2,990,855 and 2,995,781 to provide tubular conduits and methods of making the same which utilize the mechanical interactions between an inflatable mandrel and a surrounding knitted fabric resin carrying component to produce monolithic permanently shaped strong non-porous tube-like objects by a low pressure molding operation self-stopped by setting of the resin, the fabric being retained in the body of the finished article to contribute to the performance of the finished conduit. Such conduits have been extensively used in the automotive field on trucks for connecting air cleaners to carburetors and for other purposes and are tailored by choice of resin, filler and continuous, surrounding reinforcement so that each unit volume of the tubular articles produced described by the aforesaid one-shot, self-stopped molding operation can contribute substantially equally to the performance of the whole. The premolding reinforcement assembly and immersion resination operation essentially distribute these materials with circumferential symmetry and lengthwise uniformity thus primarily require the otherwise unaided directional stretch and incompressibility of rib-knit reinforcement to determine resulting wall thickness, wall thickness uniformity and strength throughout the overall tortuous conformations of such articles and their local changes in shape.
Each of the three steps of the Sipler method is both essential for the operation of the method and critical to the characteristics and uses of its products as conduits. Trapped air weakens such products. Continuous bubble paths can cause leaks. In this particular method as in all related methods for producing fiber reinforced thermosets without vacuum assistance, resin is caused to flow by directed compression pressure. Liquid resins are essentially incompressible and can only flow by their displacement of other resin or air. The Sipler method has neither external nor internally localized means for controlling these key flows and its self-controlled patterns of compression pressure distribution are complex. Consequently, considerable resin losses are accepted in order to insure the satisfactory quality of its tortuously shaped products.
None of several other methods now known for producing fiber reinforced thermosets can produce tortuous conduits. Each is characterized by a relatively simple pattern of compression pressure distribution and provides for its essential air displacements in ways which are not only relatively simple but also can remain quite inconspicuous until they cause production problems and product deficiencies of the same kinds as have long plagued the fiber reinforcement of thermosetting resins by hand lay-up or any of its more sophisticated filament and/or tape winding analogs. In all of these latter methods, proper management of air displacement is well known to be critical.
In order to better recognize the peculiarities of this common problem in the Sipler method and perceive the ways the present invention handles them in this special case, it will be helpful to summarize the related teachings of others in the following ways.
Chant, in British Pat. No. 1,266,097, uses a complete, resin-carrying, open cell foam layer as the key, integrated device of a new method for producing sheet laminates. Functionally, the Chant method is a geometrical simplification of the Sipler method. Chant replaces the complete outer Sipler fabric tube with a complete foam layer. All resin is uniformly introduced and provided by that layer. Solid platen compression is applied uniformly. Thermosetting heat is uniformly contacted by resin flow. Resin flow patterns are simplified by air displacement from all open edges of the sandwich laminate. Product shapes are flat and simple. Sheet thickness is determined by mold stops. A subsequent modification of this method shown in U.S. Pat. No. 3,867,221, to produce lower density sheets requires a complete layer of high rebound foam, a controlled decompression step and the uniform, partial reexpansion of this resin containing foam layer to trap a layer of foam-reinforced void space.
Neither Chant method provides any localized means for controlling air displacement. In effect, Chant's low density modification recognizes trapped void problems encountered in the operation of its precursor.
The low density Chant method does demonstrate that the viscosity gradient of a solidifying thermosetting resin system from a hot surface through a layer of resin-impregnated reinforcement is sharp. In no way does it or can it use its complete foam component, dry, as either a local heat insulator an temporary air valve or, wet, as a means for immobilizing its load of resin sufficiently to create a local source of pressure directable fluid flow and/or flow stoppage by thermoset skin formation against a hot mold surface. In short, Chant's simplification of the Sipler method is not operable for the far more complex process of producing tortuous, tubular shapes in an unstopped hot mold by single inflation of an expansible internal mandrel. Reinforced shroud laminates produced by obvious hot press adaptations of the Sipler method of the production of flat shapes have been available on the commercial market for several years and are not the subject of the present invention.
The pervading problem of air displacement is effectively handled by the Wiltshire method in U.S. Pat. No. 3,177,105, for producing reinforced tanks by the expansion of a supported, inflatable bag against a rigid pre-loaded unsplit outer mold. In a key, preliminary and in situ step heavy liquid resin is slowly pumped up into the confined and preassembled reinforcement layer to force and displace all of the lighter air upwards where it is vented from the top of the molding apparatus. Then the bag is inflated to form this air-freed and incompressible liquid-solid layer into its tank shape.
Both the Sipler method and all of the preferred embodiments of present improvements of it accomplish both the air displacement step and the product shaping step by one single, very rapid inflation of a pressurizing mandrel against a resinated assembly laid into a horizontally split mold. At the moment of mandrel inflation, Sipler's split, confining outer mold contains a considerably larger volume of air than of incompressible liquid resin and solid reinforcement. Air is free to exit along lengthwise mold lands and at the ends of the mold. In this particular setting, no adaptation of the single-direction, forced-gravity preliminary air displacement operations taught by Wiltshire is possible.
In a negligible pressure, ultraviolet activated method for molding a pre-wound load of thermoplastic tape to form a leg cast, Asbelle et al., in U.S. Pat. No. 3,823,208, use specially placed felt patches to provide the localized comfort of felt-air cushions. Specifically, no resin flows into, out of or through these patches. Always positioned within the multiple layer sock and tape assembly, they are precemented in place, integrated only by being surrounded and in no way participate in any resin flow control. For the entirely different purposes of the present invention, supplemental localized foam, felt and/or fabric components always participate in fluid flows and finally are integrated by impregnating resin.
In the Sipler method, all reinforcing components are loaded onto an inner tube mandrel, the assembly is trough coated with catalyzed thermosetting resin and this resinated assembly is placed into a simple split and rigid hot metal mold for single inflation forming. The surrounding hot mold determines the outer shape of the product. The inner shape of the product and thus both its wall thickness and its cross section for conduit use are determined by the local expansion of the mandrel against the constraints of its uniformly continuous load of expansible reinforcement and rapidly reacting resin matrix. There are no mold stops in this method. Wall thickness is entirely determined by the stretching and flowing interactions of its integrated components with an expandable mandrel which distorts locally when inflated so as to shape itself to the fixed shape complexities of the surrounding, rigid mold.
In the few seconds required for the mandrel to attain its final molding pressure, two major and critical fluid flows take place within the stretching, resinated reinforcement assembly. Air is displaced from the mold and liquid resin follows the air it is pressed against the flow through and fully impregnate the reinforcement and form the conduit product. The air which surrounded the resinated assembly when it was placed into the mold is mainly forced out through the parting lines of the mold and the air not previously displaced by resin within the resinated reinforcement assembly mainly exhausts along the expanding mandrel and out the open ends of the mold. The now relatively continuous layer of incompressible liquid resin follows both air flows until it is either trapped in the pressure packed reinforcement or stopped by the rapid increasing of its own viscosity by the heat of the surrounding mold or is wasted from the mold parting lines and its open ends.
Although the external operations of the Sipler method are simple, its internal performance is complex and becomes increasingly so as the necessary shapes of its products become more tortuous lengthwise and involve sharp changes in cross section size and/or shape. Increasing the sufficient excesses of resin is not always the most practical solution. Localized internal control of its air and resin flows is possible and practical and is accomplished by the instant invention. With minimum other operating changes, the primary air displacement patterns of the Sipler method are modified so as to utilize resin more efficiently.
As in all thermoset molding and, in part, because set resin is neither recoverable nor reworkable, the major wastes of resin are in rejected products and in resin distribution in acceptable products which are less than optimum for meeting the performance requirements of the product. In the first instance, all of the material, labor and time are lost. In the second, the high setting shrinkage of thermoset resins makes the shrink crackage of thick resin-rich pools a special problem to the Sipler method because its inflated mandrel expands its uniformly surrounding load of fabric and resin with considerable local variation in rates and extents to obtain tortuous and complexly shaped conduits. In service, the inner surfaces of conduits are highly important. In production, these surfaces are the most difficult to inspect.
Some resin must be wasted through outer mold lands in order to insure sufficient and satisfactory amounts are everywhere retained in product walls. With the uniformities of sock loading and resination peculiar to the Sipler method, minor amounts of such land flashing are, at present, the best insurance of satisfactory overall completion of each conduit by the molding process. In large measure and in the absence of any external mold stops in this self-stopped method, it is the packing of stretching fabric which determines local wall thickness as the mandrel expands and shapes itself and its surrounding fabric-resin load to the contours of the outer mold. During the very brief period when resin is sufficiently liquid to flow and accomplish the full impregnation of all fabric components, it is the only incompressible fluid in this solid-liquid-air system. Thus it flows when the system is compressed and stretched and always flows to follow the air it displaces.
The primary purpose of the present invention is to more favorably control those air displacement flows, locally, so as to permit safe and satisfactory decreases in the total amount of resin required to make each particular conduit. In effect, the air closed into the Sipler mold is not only at the same time both the cheapest and most costly raw material acted on by the method but also the most manageable one. Properly chosen and pre-filled with air (dry) or resin (wet), relatively small pieces of compressible open porous foam, felt and/or fabric are localized in main air displacement routes so as locally to optimize following flows of liquid resin when the mandrel expands. Primarily, the improvement taught here improves upon the peculiarities of the Sipler method. More generally, it is useful to other methods of thermoset molding by expansible mandrels.
SUMMARY OF THE INVENTION
In accordance with the invention, previously available tubular articles which can be of tortuous conformation, with high curvature, sharp transitions in cross section size and/or shape, and ends conforming to close tolerances, and which are free from porosity, light in weight, inert to many fluids, and resistant to high and low temperatures are improved by the more efficient distribution of resin accomplished internally by localized devices for directing air displacement and controlling resin flow. The improvements of the articles as to their production, utility and performance is effected by inclusion, in the unitary construction, of additional molding and/or reinforcing devices locally placed so as to additionally control the flow of resin matrix during the molding process and contribute to the satisfactory performance of the article. These devices advantageously include mats and unskinned foams of open cell, and partially open and closed cell structure, felts and fabrics.
It is the principal object of the invention to provide an improved unitary, permanently shaped, strong, rigid, knitted fabric reinforced tubular article with key complexities of shape more effectively formed by the inclusion of additional localized resin flow control devices which are incorporated in the article by the molding process.
It is a further object of the invention to provide improved methods of making tubular objects of the aforesaid character utilizing the mechanical interactions between an inflatable mandrel and resin distributing combinations of continuous surrounding knit fabric and localized foam, felt and/or fabric devices in a one-shot self-stopped low pressure compression molding operation.
It is a further object of the invention to provide simple and handy internal means for conserving resinous raw materials in the operation of the above highly specialized method.
It is a further object of the invention through its aforesaid typical applications to demonstrate the general utility of providing means for locally and internally modifying the patterns of air displacement and resin flow in the inflatable mandrel compression molding of reinforced thermosetting resin systems.
Other objects and advantageous features of the invention will be apparent from the description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The nature and characteristic features of the invention will be more readily understood from the following description, taken in connection with the accompanying drawings forming part hereof, in which:
FIG. 1 is a diagrammatic vertical sectional view showing the action of a solid platen compressive pressure on a small sheet of compressible, air-surrounded, resin-filled porous material to create a localizable source of directed fluid flow;
FIG. 1A is a transverse sectional view taken approximately on line 1A--1A of FIG. 1;
FIG. 2 is a diagrammatic vertical sectional view showing the action of compressive pressure of an inflatable mandrel against a line vent which is partly covered by a small piece of compressible, air-surrounded and air-filled porous material to create a variable air displacement valve;
FIG. 2A is a transverse sectional view taken approximately on the line 2A--2A of FIG. 2;
FIG. 3 is a diagrammatic vertical cross sectional view showing the action of the compressive pressure of a liquid covered inflated mandrel against a mold land line vent which is partly covered by a small piece of compressible, air-surrounded and air-filled porous material to vent air locally and absorb impregnating resin following the air;
FIG. 3A is a transverse vertical sectional view taken approximately on the line 3A--3A of FIG. 3;
FIG. 4 is a diagrammatic horizontal sectional view taken at the mold line with a component assembly in place in the mold illustrating the included air and its exits;
FIG. 5 is a fragmentary view partly in elevation and partly in section of a simple compressible resin filled sheet localizable fluid flow control component employed in connection with the invention;
FIG. 6 is a fragmentary view partly in elevation and partly in section of a simple, compressible air-filled sheet localizable fluid flow control component employed in connection with the invention;
FIG. 7 is a perspective view of a cylindrical compressible resin absorbent localizable fluid flow control component used in connection with the invention;
FIG. 8 is a perspective view of a cylindrically overlapped compressible resin absorbent localizable fluid flow control component used in connection with the invention;
FIG. 9 is a view partly in elevation and partly in longitudinal central section of one of the continuous tubular stretchable knitted fabric components employed in connection with the invention;
FIG. 10 is a transverse sectional view of a tubular construction showing one location of the fluid flow control component;
FIG. 11 is a transverse sectional view of a tubular construction showing another location of the flow controlling component;
FIG. 12 is a transverse sectional view of a tubular construction showing still another location of the flow controlling component;
FIG. 13 is a transverse sectional view of a tubular construction showing still another location of the flow controlling component;
FIG. 14 is a transverse sectional view of a mold for making articles in accordance with the invention, taken approximately on the line 14--14 of FIG. 15;
FIG. 15 is a plan view of one part of a mold shown in FIG. 14;
FIG. 16 is a view partly in elevation and partly in section of a portion of a wall at a curve of a tubular article made in accordance with the invention and having a resin control sheet component localized at an outer corner;
FIG. 17 is a fragmentary view partly in elevation and partly in section of a box shaped wall of a tubular object formed in accordance with the invention and employing a localized resin control sheet component;
FIG. 18 is a view in longitudinal section of the inflatable mandrel with the knitted fabric assembly and localized resin control components therein employed in connection with the invention; and
FIG. 19 is a vertical view partly in section and partly in elevation showing a wipe up resination step in the formation of the tubular article.
It should, of course, be understood that the description and drawings herein are illustrative merely and that various modifications and changes can be made in the structure disclosed without departing from the spirit of the invention.
Like numerals refer to like parts throughout the several views.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now more particularly to FIGS. 1 through 4, inclusive, of the drawings, the two main modes of fluid flow control action of the porous, compressive devices of the invention will be made clear.
In FIGS. 1 and 1A the small piece of openly porous compressible sheet 20 is prefilled with liquid resin indicated by a plurality of small x symbols. Solid platen pressure between plates P1 and P2 squeezes the incompressible resin outward in all free directions displacing surrounding air in a continuous manner as compressive pressure is increased. The new component assembly shown in FIGS. 4 and 18 directly adapts this advantageous fluid flow pattern to the other operations of the earlier Sipler method to accomplish what will herein be subsequently referred to as insideout molding. From a central inside location directly against the inflatable mandrel 21 a continuous front of flowing resin displaces air outwardly through and from the dry textile tube 22 to accomplish full impregnation of this reinforcement before resin reaches surrounding hot mold surfaces of mold 25, 25a . Other embodiments of this invention minimize air entrapment by locally retaining delayed air exits in hot split mold surfaces.
In FIGS. 2, 2A and 3, 3A the openly porous partially compressed devices 20a are initially dry, i.e. filled with air indicated by a plurality of small o symbols and are shown placed so as to partly cover line vents 25b of the type left by the closure of simply split metal molds 25, 25a. FIGS. 2, 2A show that such devices allow air to pass through locally at rates variably lower than free line vents. FIGS. 3, 3A carry this simplified illustration of local air valving one step further to show how air-folliwng resin is impeded by such devices so as to fully impregnate them with liquid resin after the uncovered parts of a mold land vent 25b of molds 25, 25a has been stopped off by rapid thermosetting of resin forced into them.
Air-filled foams, felts, mats and fabrics are also well known heat insulators. Placed or by mandrel expansion forced directly against hot mold surfaces of molds 25, 25a they provide local means for timing rapid viscosity increases so as to allow the expanding mandrel to move air-following liquid resin away from corner pools in box shapes such as shown in FIG. 17, for instance, and more generally, are particularly useful in similarly thickening the outer peripheries of curves where continuous knitted sock components are most stretched and are least able to retain satisfactory wall thickness packing as shown in FIG. 16.
Whereas high resin capacity, high compressibility, stretchable foam devices are most useful in inside-out molding, the relatively low resin capacity-low compressibility combinations afforded by felts and mats and woven fabrics are more useful in external locations on the knitted sock load where they need only to be shaped and integrated by mandrel compression.
Inside-out molding and local air valving are operable in combination and are not restricted with respect to the type of thermosetting resin system employed. Newer chemically thickened polyester systems much as Marco's GR 14021 available from the Marco Division of W. R. Grace & Co. afford appreciable no-drip handling conveniences for inside-out molding but, otherwise, are operated by the present invention in the same ways which will now be described in greater detail for use with common liquid resin systems in which proportionating of resin, styrene and filler tailor operating viscosities as described in the Sipler U.S. Pat. Nos. 2,990,855 and 2,995,781.
FIG. 4 illustrates a portion of a simply split mold 25 with its mating component 25a removed and opened up so as to locate the non-mandrel air included when a component assembly readied for inside-out molding is laid into the hot mold. The centrally located, resin filled boot is air free. The surrounding dry knitted sock components are air filled. The whole assembly occupies only a small part of a full mold volume which is otherwise filled with air. All of this air must be displaced by mandrel expansion during the conduit forming process and can only exit through mold land line vents and/or out the open ends of the mold. Only the flow of liquid resin is available to cause these air displacements. The compressed packing of stretched knitted sock components 25 is the primary mold stop. Air-following resin solidifies rapidly when it touches hot mold surfaces.
Through FIG. 4, it can be most directly appreciated that the complete assembly to be molded is in gravity contact with the hot mold surfaces it rests on during the time when it is being properly positioned before mold closure and mandrel inflation. The remaining circumference of the assembly is not in such contact. Liquid resins tend to flow downward and to be significantly advanced in their critical viscosity increases by this thermosetting heat. Conduits made by the older Sipler method consistently have wall thicknesses which 20-30% greater on such bottom sides than on their opposite top halves. All parts of the product perform equally in most uses. In effect, prior practice preceding the present invention requires considerable internal distributive wastage of resin in over-thickened bottom halves in order to insure satisfactory wall thicknesses in top halves. Both the inside-out and air valving modes of the present invention take advantage of the fact that air-filled porous materials are efficient heat insulators and thus accomplish useful control of thermosetting heat.
The additional and supplemental localized devices of the instant invention do not have to be both highly stretchable by mandrel expansion and also major contributions of solid reinforcement bulk to self-stop the forming process. They need be only openly porous, resin absorbent, compressible and readily bendable by mandrel pressure. Pieces of reticulated foam, felts and mats and fabric meet this minimum set of requirements with a sufficiently wide spread of performance combinations to handle most problems caused by local variations in mandrel expansion.
Liquid thermosetting resin which is immobilized against the surrounding hot mold surface very rapdily sets to solid. Therefore, local rates of mandrel expansion are as important as are final extents of expansion in determining the in-process distribution and final disposition of impregnating resin.
Because mandrel expansion of mandrel 21 is necessary to operate all of the supplemental devices of this invention and integrate them into conduit walls, the devices also locally modify the expansion of the mandrel 21. This interaction situation significantly differentiates inflatable mandrel molding from solid platen molding. Primarily as in the earlier Sipler method the shape of the mold and the constraints of the expanding fabric tubes both prevent local mandrel blowouts and modify local rates and extents of mandrel expansion to fit outer molding shapes. All preferred embodiments of the present invention primarily aim to use those mandrel expansion non-uniformities characteristic of each mold shape to more effectively direct the air displacements required to form a tortuous conduit of that shape.
Localized pieces 20 of foam sheet, felt and/or mat patches and woven fabric flats are the preferred supplemental devices. For handling convenience, such discontinuous devices may be overlapped circumferentially to form body boots and/or end cuffs. FIGS. 5 and 6 show the most useful shapes. FIGS. 10 and 11 detail the positioning of resin filled shapes in interior air displacement paths while FIGS. 12 and 13 show the positioning of air filled shapes in exterior air displacement paths.
Referring now more particularly to FIGS. 14 and 15 of the drawings, a continuous integral rigid hollow tubular article 30 in accordance with the invention is there illustrated and includes an end section 30a, a curved intermediate section 30b, a support attachment section 30c, a box section 30d, with its axis curved or angled and in a plurality of planes, from which an end section 30e extends preferably relatively straight and open ended if desired. While the sections 30a, 30b, 30c and 30e are generally circular cylindrical and of varying transverse cross section as required for a particular end use the longitudinal axis is usually a tortuous line in a multiplicity of planes. The box section 30d is rectangular in transverse cross section.
The complex interior mold shape of the molds 25, 25a, controls the simple one piece initially cylindrical tubular mandrel 21 to the shape which the outer surface of the assembly thereon must finally attain along its exterior and with the mandrel shaped in a detailed manner to force each part of the assembly to its final position in the mold. Obviously the local rates at which the mandrel expands must be variable and critically determines the flow of the rapidly solidifying liquid resin. The deformation of the mandrel 21 to the shape for sock loading takes place during the very short time required for the mandrel 21 to attain full molding pressure on single inflation.
The shape shown in FIGS. 14 and 15 is merely illustrative of various complexly curved and shaped tubular objects and other objects which can be made in the practice of the invention.
There are several ways in which local controls of resin flow might be provided.
This invention details a practical way to accomplish this by controlling air displacement.
The mode of making the tubular article 30 will now be pointed out.
Referring now to FIG. 9 of the drawings, one of the components of the invention is illustrated at 22, referred to as a knitted sock and preferably consists of a continuous seamless knitted tubular fabric, closed ended if desired, preferably rib-knit, so as to be circumferentially expansible and upon such expansion being free from any tendency to thin out appreciably. While the extent of circumferential expansibility of the knitted tube 22 can be varied, the expansibility is preferably of an order up to about 800%. Any suitable materials for this purpose can be employed, dependent on the degree of heat resistance required. For normal low temperature ranges of the order of 250° F., and suitable for many automotive conduits, cotton or rayon, and nylon, Dacron, or other thermoplastic yarns can be employed for the making of the knitted tube 22.
If a higher order of temperature resistance is required, say up to 500° F., it is preferred that the knitted tube 22 be made of yarns of glass fibers or asbestos.
It is also feasible to use yarns having mixtures of the filamentary materials referred to, or strands of different materials can be employed on different carriers, or needles, in knitting the fabric.
For certain purposes, also a plurality of knitted tubes 22 each with the yarns of different materials can be employed. The texture of such knitted tubes 22 can be varied, if desired.
An inflatable cylindrical mandrel or core tube 21 is provided, closed at one end 21a (see FIGS. 18 and 19) and at the other end has a valved inlet connection 21b. The core tube 21 is preferably of rubber, natural or synthetic, and of a thickness of the type ordinarily used for inner tubes for tires for automotive vehicles.
The additional fluid flow controlling component of the most generally useful mode of operating the present invention to obtain inside-out molding is an overlapped sheet (FIG. 8) or pre-formed boot (FIG. 7) of reticulated polyurethane foam illustrated generally in FIG. 5 filled with resin and placed directly against the expansible mandrel 21 in the component assembly step of the method as shown in FIGS. 4 and 8 and operated as hereinafter explained.
The foam sheet 20 (FIG. 6) which may have a thickness of the order of one quarter of an inch to one half of an inch depending upon particular requirements and is both highly resin absorbent and highly compressible and sufficiently strong and stretchable to contribute relatively little additional constraint to mandrel expansion is handily prefilled with liquid resin in a pan or trough, then positioned centrally around the partially inflated mandrel 21, (FIGS. 10 and 11). Dry sock reinforcement layers 25 are most handily rolled onto the mandrel 21 and over the localized resin-filled device 20. The completed component assembly can then be used to wipe up any excess or additionally needed resin remaining in the trough 29 as shown in FIG. 19. It is placed into the mold 25, 25a and shaped by mandrel expansion.
This compression forces resin out from the foam 20 in a continuous outward front which displaces air through the fabric layers 22 as they are being continuously impregnated with resin and out the mold lands 25b before following resin flows contact hot mold surfaces and are rapidly congealed to form very little flash waste.
For most conduit shapes a small amount of wiped up resin does not at all interfere with the primary outward air displacement patterns created by mandrel compression of the primary inside resin source. In fact, new chemically thickened polyester resin systems can be utilized in inside-out molding directly as cast sheets without the necessity of foam carriers by their proper formulation to also obtain satisfactory and versatile stretching properties in addition to no-drip handling convenience recommends that a foam carrier be used to provide the most versatile mechanical systems through choice of particular foams from many readily available on the open market. Fully reticulated powderpuff polyurethane foam having hundreds of tiny completely open pores per inch are less than 10% solid and highly resin absorbent, highly compressible and remarkably strong. This combination of properties best suits them for use as inside-out molding devices.
Inside-out molding obtains consistent wall thickness and thus reduces resin requirements for conduit sections which are relatively round and straight but frequently can be improved upon by combination with air valving devices placed across mold lands directly against hot mold surfaces external to the main assembly at points where local combinations of locked-in sock restraint and extreme mandrel expansion primarily determine local resin distribution. At the outer peripheries of sharp curves, for example, limited lengths of both mandrel and fabric layers are stretched highly by mandrel expansion and less fabric is available to self-stop the forming process to satisfactory wall thickness. At corners of box-shaped transitions resin pools accummulate and crack with the high solidification volume shrinkage which is characteristic of most common thermosetting resin systems. Supplementary air valving devices are particularly useful in these locations. Their choice, positioning and operation are hereinafter detailed.
At the outer peripheries of sharp curves, the need is more than just to obtain sufficient wall thickness. The obvious expedient of simply patching on more resin-loaded reinforcement does not best solve the air displacement part of the problem. In such areas and even highly constrained by stretching fabric, the mandrel performs much like a toy balloon does, stretching a relatively small local area very rapidly as pressure is increased to forming limits and thus causing resin to flow so rapidly locally that its congealing by the hot mold lands tends to leave air pinholes for the last remaining air to escape through. Relatively incompressible, openly porous sheets of dry felt placed across line mold vents provide local heat insulation, local packing, means for locally delaying following resin flow and immobilizing it to be more uniformly congealed by thermosetting heat and thus prevent pinholing.
In part, the pooling of resin in the corners of box transitions is caused by the same pair of local extremes of mandrel expansion and fabric thinning encountered at outer curves and again delaying the impregnating flow by resin following the escaping air. In this special case it is important to provide sufficient open volume in the device similarly placed across mold land line vents and acting similarly, to valve air out of the mold so that the last shaping of the mandrel to fit such corners will have enough contigously available free volume to flow into and be utilized rather than wasted. Pieces of dry Fiberglas mat such as are readily available from the Owens-Corning Company in a considerable spread of properties have turned out to be most satisfactory for solving corner pooling problems. Dry pads of steel wool placed as shown in FIG. 16 are also useful. The high heat conductivity of their metal composition is more than overriden by the high insulating properties of the air they contain initially and they are readily impregnated with integrating resin pushed into them following the air they locally vent from box corners which, otherwise have no access to mold lands.
A considerable variety of openly porous, compressible, resin absorbent materials besides those particularly preferred for the reasons described here are useful to accomplish inside-out molding and land vent air valving in this improvement upon the Sipler method and there are useful placements of them within the assembly of fabric components rather than directly against the inflatable mandrel, wet, and directly against the hot mold and locally across its line vents, dry, which operate to provide some of the advantages shown here and to obtain some increases in the efficiency of resin utilization. They also operate the principles of the invention.
The preferred embodiments detailed here are illustrative, not limiting, to the invention. They may be used in conjunction with and to supplement the immersion resination step of the prior assembly-resination-molding art. Most effectively, they are employed to solely or majorly supply and control fluid flow in a new resination-assembly-molding method. A typical sequence of operations will now be outlined.
A sufficient number of knit sock layers 22 to stretch-pack to the desired wall thickness is pre-cut to the length of the duct and 4 to 6 times their total weight of precatalyzed resin is taken up from an open trough or pan into a high resin capacity, high compressibility polyurethane foam sheet or preformed boot 20 placed directly around the partially inflated mandrel in lengthwise central location. The continuous sock tubes 22 are then rolled down over the resin-loaded mandrel. The completed assembly may then be used to wipe up any excess resin in the pan and is placed into the open, preheated split mold. Small patches of dry low resin capacity, low compressibility felt or mat are placed against hot mold surfaces and across mold land joints at the outer peripheries of sharp curves and/or box transitions. The mold 25a, 25 is closed and clamped closed in a mechanical press and the mandrel 26 is immediately and rapidly inflated to a sufficiently high pressure to obtain complete impregnation and permanent integration of all of the fabric tubes 22 into conduit walls in cure times of 1 to 5 minutes at mold temperatures high enough to trigger the thermosetting exotherm of the resin. The liquid resin which is rapidly squeezed outward in all free directions from its central location displaces air outward circumferentially and lengthwise through the fabric layers 22 as it impregnates them, is congealed by contact with hot mold surfaces and integrates air valving devices with final, slowed, air-following resin flows. After, and only after complete mandrel pressure release, the mold 25a, 25 is opened, its formed duct is removed for inspection and its forming mandrel 21 is pulled out for reloading to repeat the above resination-assembly-molding sequence. | Method for making tubular articles of tortuous configuration and of resin impregnated material. The method is intended to avoid resin-starved areas in the product. Specifically, tubular articles having high curvature, sharp transitions in cross section size and/or shape and close tolerance ends are provided these being made by applying and incorporating selectively placed porous components.
The article is formed in a mold by an inflatable mandrel which carries a continuous, surrounding knitted fabric component and one or more localized foam, felt and/or fabric devices of porous nature which control the supply, flow and/or final disposition of resin matrix in the molding process. | 1 |
This application claims benefit of Provisional Appl. 60/046,026 filed May 9, 1997.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a heterojunction bipolar transistor (HBT) and method of manufacturing an HBT, and more particularly to an HBT formed by organometallic vapor phase epitaxy (OMVPE) using zinc as the base dopant.
2. Discussion of the Background
A considerable amount of testing (qualification) with respect to, for example, the reliability and performance of heterojunction bipolar transistor (HBT) structures is needed prior to the device entering the manufacturing stage.
Some of the methods used relating to the growth of HBT structures include molecular beam epitaxy (MBE) and organometallic vapor phase epitaxy (OMVPE).
FIG. 1 illustrates a background HBT epitaxy device structure grown by MBE or OMVPE. In FIG. 1, layer 1 is an n-type (n+) doped GaAs collector contact with a doping concentration between 2×10 18 -1×10 19 cm -3 and a thickness between 4,000-7,000 Å grown on a GaAs substrate S, layer 2 is an n-type (n-) doped GaAs collector transit layer with a doping concentration between 7×10 15 -5×10 16 cm -3 and a thickness between 4,000-15,000 Å, and layer 3 is a p-type (p+) doped GaAs base with a doping concentration between 1×10 19 -1×10 20 cm -3 and a thickness between 500-1,000 Å. In addition, layer 4 is an n-type (n) doped Al x Ga.sub.(1-x) As emitter (0.2<x<0.4) with a doping concentration between 1×10 17 -1×10 18 cm -3 and a thickness between 300-2,000 Å, layer 5 is an n-type (n+) doped Al x Ga.sub.(1-x) As graded (0.2<x<0.4 linearly graded to 0.0) layer with a doping concentration between 1×10 18 -1×10 19 cm -3 and a thickness between 200-500 Å, and layer 6 is an n-type (n+) doped emitter contact with a doping concentration between 1×10 18 -1×10 19 cm -3 and a thickness between 500-3,000 Å.
Many modifications of this structure are possible, such as the emitter contact layer 6 including combinations of GaAs and In y Ga.sub.(1-y) As. For example, the emitter contact may include In y Ga.sub.(1-y) As (0.4<y<0.6) with a doping concentration between 5×10 18 -1×10 19 cm -3 and a thickness between 500-1,000 Å or the emitter contact may include n+ GaAs with a doping concentration between 1×10 18 -1×10 19 cm -3 and a thickness between 500-2,000 Å. In addition, an n+ In y Ga.sub.(1-y) As graded region (0.4<y<0.6 linearly graded to 0.0) with a doping concentration between 5×10 18 -1×10 19 cm -3 and a thickness between 500-1,000 Å may be used. A further modification is that the AlGaAs emitter (layer 4) may be replaced with GaInP or an n-type (n) doped AlGaAs graded layer may be used between the emitter and base to reduce the turn-on voltage. Still further, the p+ GaAs base (layer 3) may include AlGaAs and/or an InGaAs graded region to accelerate electrons across the base, and a variety of other modifications may be used to optimize various aspects of performance. However, each of the modifications listed above include a p+ base (layer 3).
During the growth of HBT structures with MBE or OVMPE, the five most likely p-type dopants used are cadmium (Cd), magnesium (Mg), carbon (C), Be and Zn. Be is the preferred choice as the p-type dopant for growing HBTs with MBE, primarily due to its high solubility, good minority carrier lifetime, and low diffusion coefficient under optimized growth conditions. However, Be is not a useful dopant for growing HBT structures with OMVPE because BeO is extremely toxic. For example, the use of diethylberyllium (DEBe) as a p-type dopant for OMVPE GaAs leaves deposits in the reaction cell and exhaust of OMVPE reactors, which must be routinely cleaned. Another reason Be is not useful as a p-type dopant is that the availability of DEBe is currently limited.
The major problem with using Cd as a base dopant is the difficulty of obtaining carrier concentrations above 1×10 18 cm -3 . Mg has the advantage of a low diffusion coefficient; however, the use of bismethylcyclopentadienylmagnesium (MCp 2 Mg) as a Mg source has not resulted in abrupt dopant profiles.
The aforementioned problems leave the dopants of Zn and carbon as the primary candidates for OVMPE growth of HBT structures.
To date, the qualification of HBT structures grown with OVMPE has focused primarily on carbon as the base dopant. This is primarily due to the lower diffusion coefficient of carbon compared to Zn and the commonly held belief that this lower diffusion coefficient will yield improved reliability. However, the demonstrated reliability of HBT structures grown with OVMPE using carbon as the base dopant has been significantly worse than those grown with MBE using Be as the base dopant. Thus, the qualification of HBT structures grown with OMVPE using carbon as the base dopant has not been as successful as that grown with MBE using Be as the base dopant.
Furthermore, the use of carbon doping in OMVPE HBT structures causes additional reliability problems and reduced performance (e.g., reduced minority carrier lifetime and accelerated current gain degradation). Research has been performed showing that the lifetime, carrier concentration, and mobility of GaAs HBT structures grown with OVMPE using carbon as an acceptor dopant degrade with post growth annealing. These effects may be due to one or a combination of hydrogen passivation, dopant precipitation, and/or lattice relaxation. Although excessive doping concentrations with carbon does not result in significantly enhanced diffusion, it may result in precipitation. These observations are consistent with the inferior reliability in carbon doped OMVPE HBT structures compared to that observed with Be doped MBE HBT structures.
SUMMARY OF THE INVENTION
Accordingly, one object of the invention is to provide a heterojunction bipolar transistor (HBT) structure grown with OMVPE using Zn as the base dopant.
Another object of the present invention is to use Zn as a base dopant to produce reliable HET structures grown with OMVPE which will facilitate their qualification for manufacturing.
A further object of the present invention is to control the diffusion coefficient of the Zn dopant of HBT structures to increase its performance and reliability.
A still further object of the present invention is to control the diffusion coefficient of Zn by reducing the emitter and/or collector contact regions to a thickness of approximately the depletion region, thus minimizing n+ type doping regions which tend to create gallium interstitials and increase Zn diffusion.
Yet another object of the present invention is to control the diffusion of Zn by annealing during growth of the structure to suppress the substitutional-interstitial diffusion mechanism. In particular, the annealing process is most useful after growth of some or all of the collector but before growth of the base.
Another object of the present invention is to prevent the diffusion of Zn by using high V/III ratios in any of the base, collector, and emitter layers to increase gallium vacancies which reduce the diffusion of Zn.
These and other objects are achieved by providing an HBT structure which suppresses the diffusion of Zn by inhibiting the substitional-interstitial diffusion mechanism. In particular, any combination of the methods of a) separating the emitter and/or collector contact regions into a thicker, moderately doped portion and a thinner, higher doped portion, b) using high V/III ratios, and c) annealing the structure during growth can be used to inhibit the substitutional-interstitial diffusion mechanism which causes the diffusion of Zn from the base toward the collector and/or emitter. The emitter and collector thinner contact layers can be reduced to a thickness of approximately the depletion region. The thinner contact layers reduce the amount of crystal defects which can then diffuse to the base and cause Zn to diffuse. The use of high V/III ratios increases the amount of gallium vacancies. This increase of gallium vacancies retards the diffusion of Zn. The use of high V/III layers can be used in any of the layers of an HBT structure to retard the diffusion of Zn. The annealing process is used to allow problematic crystal defects to diffuse to the surface and out of the material. The annealing process is most useful during growth of some or all of the collector but before growth of the base.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
FIG. 1 illustrates a background HBT structure grown using MBE or OVMPE;
FIG. 2 illustrates an example according to the present invention of an HBT structure grown with OVMPE in which the emitter and collector contact regions are separated into a thick, moderately doped layer and a thinner, higher doped layer; and
FIG. 3 illustrates another example according to the present invention of an HBT structure including eight layers of varying thicknesses and doping concentrations which are grown on a substrate with OVMPE.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, a preferred embodiment of the present invention will now be discussed.
Zn is a column II acceptor dopant in the periodic table which on a group III site in a III/V semiconductor behaves as an acceptor. The diffusion characteristics of Zn is accurately described by the substitutional-interstitial diffusion mechanism which can lead to very high diffusion rates under certain conditions.
According to the present invention, a combination of techniques are employed in the growth of GaAs doped with Zn in HBT structures to inhibit the substitutional-interstitial diffusion mechanism, thus improving the reliability of the HBT structures. The combination of techniques include, for example,
a) suppressing the creation of gallium interstitials which can activate the zinc substitutional-interstitial diffusion mechanism by, for example, minimizing n+ doping regions (e.g., to a thickness of the depletion region) to minimize zinc diffusion,
b) increasing the gallium vacancy concentration in the material to suppress interstitial diffusion by, for example, the use of high V/III ratios, and
c) suppressing the substitutional-interstitial diffusion mechanism by, for example, annealing during the growth of the structure to allow equilibrium concentrations of defects in the epitaxial material to be reached, thereby suppressing the substitutional-interstitial diffusion mechanism which can be driven by nonequilibrium defect concentrations.
Suppressing the creation of gallium interstitials
The creation of gallium interstitials is suppressed because they can activate the zinc substitutional-interstitial diffusing mechanism and increase the diffusion of Zn. One method to suppress the creation of gallium interstitials is, for example, minimizing the degenerate n+ doping regions.
The main purpose of the n+ doping region in HBT structures is to reduce resistance, most notably contact resistance. Degenerate n-type regions are typically used at the contact regions in the emitter and collector. The HBT structure shown in FIG. 1 has a collector contact layer 1 with a thickness of 4,000-7,000 Å and an emitter contact layer 6 with a thickness of 500-3,000 Å. However, a thickness on the order of the depletion region is all that is required to obtain low contact resistance. Thus, GaAs contact layers can be reduced to a thickness on the order of the depletion thickness.
FIG. 2 illustrates an embodiment of the present invention where the emitter and collector contact regions are separated into a thinner, higher doped layer and a thicker, moderately doped layer. Layer 9 is a p-type (p+) base doped with Zn. Layers 10 and 11 are the emitter contact layers and layers 7 and 8 are the collector contact layers. The degenerate n-type doping layers 8 and 11 can be reduced to a thickness "x" and "y", respectively, which is on the order of the depletion region. The thickness "x" can be reduced to a thickness comparable to the depletion region thickness of layer 8. The thickness "y" can be reduced to a thickness comparable to the depletion region thickness of layer 11.
When the thickness of the GaAs contact layers exceeds the depletion thickness, Ga interstitials can be created because the degenerate n-type doping can drive the Fermi level or chemical potential of the material into the conduction band. Degenerate doping can be considered as a doping concentration which is high enough (e.g., an n-type doping concentration above 6×10 17 cm -3 for GaAs) so that the Fermi level or chemical potential of the material is driven into the conduction band. Crystal defects which are created by the degenerate n-type doping regions can then rapidly diffuse to the base layer 9 and instigate Zn diffusion via a kick-out mechanism which is a variant of the substitutional-interstitial diffusion mechanism. In other words, the crystal defects cause an exchange reaction where gallium on an interstitial site and Zn on a substitutional site switch sites, resulting in the Zn being on an interstitial site and diffusing. Since degenerate n-type regions can initiate the diffusion, their use needs to be limited.
Thus, according to the present invention, the emitter and collector contact layer can be separated into a thicker, moderately doped layer and a thinner, higher doped layer. The layers are grown in order to simultaneously obtain a low contact resistance and to minimize n+ doping regions, thereby minimizing the diffusion of Zn. Note, that reducing the thickness of the emitter contact layer 11 to a thickness comparable to the depletion thickness of this layer does not cause a significant degradation in the emitter resistance of the emitter contact metalization to the emitter contact layer. Since this resistance is more of a function of the contact resistance to the emitter contact layer 11 (which is decreased with increased doping) than the thickness of the thicker emitter contact layer 10, the resistance is not significantly degraded.
In more detail, in FIG. 2 the collector contact maybe separated into a thicker, moderately doped layer 7 with a doping concentration between 2×10 18 -5×10 18 cm -3 and a thickness between 4,000-7,000 Å and a thinner, higher doped layer 8 with a doping concentration between 5×10 18 -1×10 19 cm -3 and a thickness between 200-500 Å. Likewise, the emitter contact may be separated into a thicker moderately doped layer 10 with a doping concentration between 1×10 18 -5×10 18 cm -3 and a thickness between 500-3,000 Å and a thinner, higher doped layer 11 with a doping concentration between 5×10 18 -1×10 19 cm -3 and a thickness between 200-500 Å. The emitter contact layer 11 may be approximately 0.1-0.5 microns from the base layer 9 and the collector contact layer 8 may be approximately 0.3-1.5 microns from the base layer 9.
FIG. 3 illustrates another example of an HBT structure according to the present invention in which an HBT structure is separated into eight layers grown on a substrate. The collector and emitter contact regions are separated into a thicker, moderately doped layer and a thinner, higher doped layer as shown in FIG. 2. That is, the thicker collector contact layer 12 has a doping concentration between 2×10 18 -5×10 18 cm -3 and a thickness between 4,000-7,000 Å and the thinner collector contact layer 13 has a doping concentration between 5×10 18 -1×10 19 cm -3 and a thickness between 200-500 Å. The thicker emitter contact layer 18 has a doping concentration between 1×10 18 -5×10 18 cm -3 and a thickness between 500-3,000 Å and the thinner emitter contact layer 19 has a doping concentration between 5×10 18 -1×10 19 cm -3 and a thickness between 200-500 Å. The emitter contact layer 11 may be 0.1-0.5 microns from the base layer 9 and the collector contact layer 8 may be approximately 0.3-1.5 microns from the base layer 9. Layer 14 is an n-type (n-) doped collector transit layer, layer 15 is a p-type (p+) base, layer 16 is an n-type doped emitter, and layer 17 is an n-type (n+) doped graded layer. Layers (14), (15), (16), and (17) have similar doping concentrations and thicknesses as that of the layers (2), (3), (4), and (5) in FIG. 1, respectively. The emitter contact layer 19 may be approximately 0.1-0.5 microns from the base layer 15 and the collector contact layer 13 may be approximately 0.3-1.5 microns from the base layer 15.
Increasing vacancies
Increasing vacancies in an HBT structure suppresses interstitial diffusion and thus, reduces the diffusion of Zn. An example of increasing the concentration of vacancies is to use high V/III ratios during the growth of an HBT structure.
A higher V/III ratio increases the group III vacancy concentration which retards the diffusion of Zn. The group III vacancy concentration can be thought of as locations where diffusing interstitial Zn can transfer to a substitutional site and stop diffusing. The definition of a high V/III ratio, according to the present invention, is a high partial pressure of an group V growth precursor relative to a group III growth precursor (i.e., arsine or tertiarybutylarsenic, and trimethylgallium for a GaAs compound) used with the OMVPE growth process. In an MBE growth process, a V/III ratio is defined as the partial pressure of the group V elemental beam to the group III elemental beam. A high V/III ratio is achieved by increasing the flow rate on the flow controller used during the growth process to dispense the group V precursor. Thus, there is greater percentage of the group V precursor than the group III precursor which increases the group III vacancies. A high V/III ratio according to the present invention is between approximately 10-100, although this depends on the situation and the particular reactor configuration.
According to the present invention and referring to the GaAs HBT of FIG. 3, high V/III ratios can be used in any one or a combination of the following layers:
in the collector transit layer 14 to prevent the diffusion of Zn from the base layer 15 towards the substrate S, and within the collector transit layer itself.
in the base layer 15 to prevent the diffusion of Zn within the base layer itself, and
in the emitter layer 16 to prevent the diffusion of Zn towards the emitter layer 16 and within the emitter layer 16.
In addition, a high V/III ratio can be used each or any of the other layers to mitigate the negative effects of gallium interstitial and prevent the diffusion of Zn.
The example referring to FIG. 3 is used to clarify a method of the present invention to increase the gallium vacancy concentration to suppress the diffusion of Zn. However, the HBT structure may be separated into any number of layers containing high V/III ratios in order to increase the gallium vacancy concentration. Therefore, the present invention is not limited to an HBT structure separated into eight layers.
Suppressing the substitutional-interstitial diffusion mechanism
According to the present invention, suppressing the substitutional-interstitial diffusion mechanism reduces the diffusion of Zn. An example of suppressing the substitutional-interstitial diffusion mechanism is to use an annealing process to minimize the concentrations of gallium interstitials which can initiate Zn diffusion. As discussed above, the gallium interstitials can diffuse to a region containing Zn and cause an exchange reaction between gallium on an interstitial site and Zn on a substitutional site. That is, the Zn and gallium will switch sites causing Zn to be on an interstitial site, where the Zn can then rapidly diffuse and degrade reliability. In addition, as stated previously, the concentration of gallium interstitials increases when the Fermi level rises into the conduction band if high concentrations of n-type doping are used.
Thus, according to the present invention and referring to FIG. 3, annealing can be performed after growth of the n-type collector layers 12 and 13 or after growth of some or all of the collector transit layer 14, but before growth of the base layer 15. However, the annealing process is not appropriate after growth of the emitter layers because this may cause some gallium interstitials to diffuse towards the base and instigate Zn diffusion. For this reason, the preferred approach to dealing with gallium interstitials generated in the emitter is to minimize the n-type doping regions as discussed above.
The growth of the structure is stopped to anneal the material and allow crystal defects created in the n-type collector contact to diffuse to the surface and/or regions of lower concentrations and out of the material. This will reduce the defects which can subsequently diffuse to the base and kick-out Zn once the base is subsequently grown. During the annealing process the crystal defects caused by gallium interstitials will diffuse into the substrate and/or surface where they can annihilate or otherwise effectively leave the structure before the growth of the base. The annealing is performed for a predetermined time and at a predetermined temperature to allow an equilibrium state to be reached or to allow a non-equilibrium state to become an equilibrium state. For example, an equilibrium state could be considered as the state when the gallium interstitials have completed transferring to the substrate and/or surface.
The time required to obtain for the desired equilibrium state to be reached is dependent on the temperature used. The temperature used to anneal the material is generally higher than the temperature used for growing the HBT structure. For example, if an HBT structure is grown at a temperature of 700° C., the annealing temperature may be 800° C. The time required to anneal may be from 1 minute to 1 hour. However, production costs are increased due a longer annealing period (i.e., the number of HBT structures made per hour decreases with a longer annealing period) and therefore, it is preferably to decrease the amount of annealing time needed, if possible.
Therefore, according to the present invention, an HBT structure with Zn base doping is grown with OMVPE using a combination of techniques to control the diffusion characteristics of Zn and which will exhibit superior performance and reliability than that compared to a HBT structure using carbon as the p-type base doping material. In particular, the present invention is applicable to GaAs-based HBT structures but it may also be used for InP-based HBT structures.
Obviously, numerous modifications and variations of the present invention, including variations of doping thicknesses and doping concentrations, are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. | A heterojunction bipolar transistor structure grown with organometallic vapor phase epitaxy (OVMPE) which uses zinc as the base dopant. The HBT structure has eight layers grown on a substrate, including n-type doped first, second, third, fifth, sixth, seventh, and eighth layers and a p-type zinc doped fourth layer. The first layer is a thicker, moderately doped n-type layer compared to the thinner, higher doped n-type second layer. The seventh layer is a thicker, moderately doped n-type layer compared to the thinner, higher doped n-type eighth layer. In addition, some or perhaps all of the layers have a high V/III ratio of 10-100 used to increase the gallium vacancies and reduce the diffusion of zinc from the base layer. Further, annealing of the structure is performed during growth to minimize gallium interstitials and to inhibit the diffusion of zinc. | 7 |
PRIORITY CLAIM
[0001] This application claims the benefit of the filing date of Brazilian Patent Application Serial No. BR 10 2015 025882 8, filed Oct. 9, 2015, for “Wireless Particulate Solid Material Flow Sensor With Internal Battery,” the disclosure of which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] This invention refers to a robust low-cost wireless sensor with an internal battery that permits operation for extended periods without the necessity of maintenance, for monitoring the flow of particulate solid material such as chemical fertilizers, small seeds, granulated foodstuffs, and others, where such flow is generated by mechanical action, gravity or by pneumatic pressure, as used in equipment or machines found in various sectors such as agriculture and livestock, foodstuffs, civil construction, plastics, etc., although mainly in agricultural machinery, the main purpose of which is to monitor flow within the conduits that conduct particulate material during the operation of equipment and/or machines, and to alert the operator where the flow is irregular or interrupted.
BACKGROUND
[0003] Flow sensors are widely used devices in various sectors of industry used for many purposes. Various types of sensors exist, such as air flow sensors, water flow sensors and particulate material flow sensors, etc.
[0004] Particularly in the agricultural sector with the growing need to produce increasingly higher grain yields, various methods and devices have come to be developed in order to improve the efficiency and accuracy of the application of seeds and inputs in the field. Due to this, flow sensors are one of the devices used in agricultural machinery with the objective of monitoring the flow of seed and/or inputs that are applied in the planting area.
[0005] One of the disadvantages presented by such flow sensors is related to the fact that they are sensitive to the accumulation of dust due to the downward movement of seeds and/or inputs in the conduits of agricultural machines, which leads to sensors functioning incorrectly.
[0006] Another apparent disadvantage is the fact that sensors send data to operator control interfaces, whether monitors or on-board computers, by means of wires routed through agricultural machinery, which are a constant source of faults and failures.
[0007] Furthermore, another apparent drawback is the fact that sensors require a level of power that makes it necessary for the power supply to be fed by means of wires connected to batteries or generators, which are also a source of faults and failures.
[0008] Listed below are some state-of-the-art technical documents and their disadvantages.
[0009] Patent document BR PI0301241-7 concerns an intelligent seed and fertilizer sensor, in particular, a current and voltage sensor, used to “detect” demand for seeds and fertilizer in mechanized distribution units, making it possible to determine whether or not the product is coming out of each containment vessel, as used in multi-line distribution machines, in order to avoid non-homogeneous distribution in a particular line, compromising the quality of planting.
[0010] One of the disadvantages presented by the system described above resides in the fact that the optical sensor exhibits reading failures due to the volume of dust generated by the flow of seeds and/or fertilizer within the conduit.
[0011] Patent document BR PI0704828-9 concerns an optical and/or ultrasonic reading system applied in planters for monitoring the outflow of seeds and fertilizers in which an optical or ultrasonic sensor is positioned between a semiconductor and the seed conductor within the main body and next to the individual reservoir, featuring an optical or ultrasonic sensor close to the blade or double plough disc of fertilizers and between the fertilizer conductor and the sleeve, in which the sensors have signal transmitters and receptors placed within a housing and protected by transparent plaques configured in such a way as to emit rays and occupy the entire space of the section for the passage of products.
[0012] The optical and/or ultrasonic reading system described in the above document diverges frontally from that as recommended by the sensor subject to the present invention due to the use of an optical and/or ultrasonic sensor. In addition, such detection technologies are also greatly affected by the layers of material deposited above the sensors within the conduit.
[0013] Patent document BR PI0923975-8 describes a microprocessor-controlled method and system used to detect the presence of solid inputs, basically comprised of a main capacitive sensor, microcontrollers and other devices whereas the system processes the data measured and emits signals to various external devices, such as light-emitting diodes (LEDs), sirens, on-board computers, machine control panels and wireless signal receptors. This system uses specific methods to create detection parameters that, in addition to detecting solid inputs, also eliminates the possibility of false alarms that arise from the presence of small layers of dirt, such as dust or fertilizer crusts that eventually may come to be deposited on the sensors and that are normally detected by the sensors as an input stream and not as dirt deposited on the sensor.
[0014] The system and method used for the detection of solid inputs by way of capacitive sensors, as described in the aforementioned document, presents some drawbacks, among which are highlighted the requirement for wires to supply the sensors with a power feed, due to their high energy consumption.
[0015] Patent document BR PI0201720-2 describes a solid mass flow sensor that provides for the perfect monitoring of solid mass flows and even indicates when the system is clogged up. Its application is for the monitoring of any solid mass flow, independent of granulation or texture, and for any solid mass applicator equipment. Its use is particularly for, although not limited to, the monitoring of fertilizer solid flows being provided with a transducer, which may be a microphone, buzzer or any type of vibration or sound pick-up. This transducer can directly intercept the mass flow, be coupled externally or internally to the conduit that carries the mass flow, can be simply close to the mass flow or can be laid alongside or close to cords that intercept the mass flow and transmit vibrations or sound to the transducer. The transducer then captures the vibrations or sounds and transforms them into electrical signals that are amplified and filtered and turned into electronic signals, such are then conducted to a control panel, which includes a calibrator button via that the operator will control the ideal conditions for the mass flow and that may also contain LEDs or displays to inform the operator about the conditions of the mass flow.
[0016] The flow sensor described in the above document presents some drawbacks among which are highlighted the absence of a resonate element installed in the conduit that guides the particulate material, to enhance the pick-up of mechanical vibrations due to collisions between particles within the flow and the conduit. Another deficiency in the technique as described in the above document resides in the fact that the transducer is not provided with a shield so as to impede incidences of external vibrations, which can result in malfunctioning of the transducer.
[0017] The initial proposal for a solid fertilizer flow sensor, such as described in the patent document PI0201720-2, resulted in the development of a wireless particulate solid materials flow sensor, the subject of this invention, the main purpose of which is to monitor the flow of particulate material within a tubular conduit during operation of equipment and/or machinery and that alerts the operator when the flow is irregular or interrupted.
[0018] Patent documents U.S. Pat. No. 5,831,539 and U.S. Pat. No. 5,831,542 describe a specialized sensor for the flow of seeds, provided with a passive piezoelectric type transducer inserted at an angle within a tubular conduit for seeds, in such a way that seeds collide directly with the transducer at an angle that captures the vibrations of such collisions.
[0019] Patent document U.S. Pat. No. 4,441,101 describes a specialized sensor for the flow of seeds that consists of a pin with one end coupled to a piezoelectric transducer. The other end of the pin is positioned internally to the seed flow conduit in such a way that vibrations that originate from collisions between the pin and seeds are captured by the piezoelectric transducer.
[0020] Patent document U.S. Pat. No. 4,079,362 describes a specialized sensor for the flow of seeds and fertilizers fed by gravity in which a piezoelectric transducer is positioned in the path of the falling particulate material, in such a way that the particulate material directly impacts the transducer, thereby generating an electrical signal in response to collisions between the material and the transducer.
[0021] The flow sensors described in the aforementioned documents present some drawbacks, among which are highlighted the fact that such sensing methods are done in an invasive manner, that is to say, the transducer itself interrupts the flow of seeds, thereby causing disturbance within the flow and mechanical damage to the seeds. This effect is more pronounced in systems that generate flow by way of air pressure where the material travels through conduits at high speed.
[0022] Additionally, invasive flow sensing is handicapped due to the fact that dirt, dust and chemical treatments present among seeds are deposited on the transducers or on the walls that support such, reducing efficiency and reliability. This disadvantage compromises the sensing of fertilizer solid flows even more, given that in the presence of humidity, the particulate material may be deposited and adhere to the transducer or on the walls that support such, a phenomenon known as crusting, which prejudices their function.
[0023] Patent document US 07450019B1 describes a flow sensor for material transported by pneumatic pressure, provided with a piezoelectric transducer coupled to a flow deflector that captures vibrations that originated from the collision between particulate material and the deflector.
[0024] The flow sensor described in the aforementioned document presents some drawbacks, among which we highlight the fact that the sensor is applied to a specific material dosing system supplied with a deflector. Additionally, deposition of material on the deflector can prejudice the detection of vibrations. In addition, there is the further disadvantage of not having any type of protection or isolation for the transducer-deflector assembly which is subject to the erroneous capture of vibrations that arise from the structure of the machine and from external impacts.
[0025] Patent document US 08950260B2 describes a flow sensor for seeds fed by pneumatic pressure. The sensor is provided with a curved conduit in which an acoustic transducer is coupled which generates sound waves in response to collisions from seeds with the transducer, whereas these sonic waves are transported via a duct to an electromechanical transducer which transforms sound into electrical signals for later processing.
[0026] The flow sensor described in the aforementioned document presents some drawbacks, among which we highlight the fact that the sensor imposes an abrupt change in the direction of flow which generates pressure drops in the pneumatic system and thereby leads to damage to seeds and any treatments applied to them. Furthermore, the geometry of the system favors the deposition of material in front of the acoustic transducer, such as dust, dirt, and chemical treatments among others which prejudices its function. Additionally, it contains a series of rubber tubes placed in each sensor which burdens the product making it difficult to install and which can lead to the need for maintenance. Another drawback is the need for an external energy supply for the system to function which in itself leads to the need to accommodate cables for agricultural equipment with all the known problems associated with this type of solution.
[0027] Patent document US 04057709 describes a flow sensor for seeds transported by pneumatic pressure or by gravity, provided with an angled tubular conduit in which a piezoelectric transducer is glued or cemented which further possesses coupled rubber impact absorbers at the extremities of the tubular conduit. The angulation of the tubular conduit means that the flow is predominately incident on the area where the transducer is positioned, in order that electrical signals may be generated by it in response to the impact of particulate material.
[0028] The flow sensor described in the aforementioned document presents some drawbacks, among which we highlight the fact that the transducer is fixed solidly (glued or cemented) to the tubular conduit without any rear support in such a way that it vibrates together with the tubular conduit whereby it has a substantially reduced detection capacity. Such a deficiency requires that for satisfactory detection, it is necessary for the conduit to be angled so that the flow of seeds focuses predominately in the area of the transducer. However, such angulation has the disadvantage of leading to a loss of pneumatic pressure in the system, as well as favoring the deposition of material alongside the detection area of the sensor itself. These problems prejudice its function of flow detection in the presence of dust which is characteristic in the dosage of solid fertilizer or with dirt or chemical treatment commonly present in seeds. Furthermore, it comprises of only one transducer within the tube and therefore its isolation is a deficiency as it comprises only rubberized material without counting on a more specific format for more efficient noise isolation.
[0029] A simplified summary of the method described for the present invention will appear below, whereas this summary does not provide an extensive overview of all the methods contemplated herein. Furthermore, it is not intended to identify key or critical elements, nor outline the scope of the method. Its sole purpose is to present some of the concepts for the method described in a simplified manner, in such a way as to act as an introduction to the more detailed description that will be presented subsequently.
BRIEF SUMMARY
[0030] This invention refers to a robust low cost wireless sensor with an internal battery that permits operation for extended periods without the necessity of maintenance, for monitoring the flow of particulate solid material such as chemical fertilizers, small seeds, granulated foodstuffs, and others, used in equipment and/or machines of various sectors such as agriculture and livestock, foodstuffs, civil construction, plastics, etc., although mainly used to monitor the flow of fertilizers and seeds in agricultural machinery and that comprises of at least one electromechanical transducer placed against the face of a rigid resonant conductor.
[0031] The rigid conductor is connected to a sleeve of a conduit on an agricultural machine which guides the particulate material, whereas the sensor additionally comprises a protective coating which houses a circular support which fits to supports that secure the transducer to the external face of a rigid conductor, an electronic circuit board, and batteries which supply power to the flow sensor.
[0032] Optionally the rigid resonant conductor can be provided with vanes in order to maximize vibration that arises from collisions within the flow of material, further increasing sensitivity of the sensor.
[0033] A further option, for sensing flow generated by gravity, is that the sensor that is the subject of this invention can be installed with a flow diverter screen fixed externally to the conduit sleeve that conducts the fertilizer from the meter in order to bend the sleeve thereby causing a disturbance in the flow in such a way as to maximize the frequency and intensity of collisions between the flow of particulates and the wall of the rigid resonant conductor.
[0034] The main advantage of this invention is the use of passive electromechanical transducers which drastically minimize energy consumption which permits the sensor to be powered by smaller batteries installed within the sensor for long periods of time without requiring a recharge. As such wires are not required in order to provide a power supply to the sensor.
[0035] Another advantage of this invention is that the sensor sends its data by radiofrequency to a remote monitor to interface with the operator which completely eliminates the need for wires in the device, also eliminating installation difficulties and defects that arise from the routing of wires on apparatus.
[0036] Another advantage due to the use of an internal battery and as a consequence of being wireless is that the sensor does not need to be provided with cables and connectors with a high degree of protection which increases robustness and reduces the total cost of the product.
[0037] Another advantage due to the use of an internal battery is that the sensor does not need to be opened throughout its working life. This enables the use of simpler construction methods for closing-off such as ultrasonic welding thereby avoiding the use of screws and seals which increases robustness and reduces the total cost of the product.
[0038] Another advantage due to the use of an internal battery and as a consequence of the absence of wires is that of the freedom of positioning of the sensor on apparatus. For example, in pneumatic seeders, it is possible to install the sensor close to the soil increasing the speed in which clogging is sensed.
[0039] Another advantage of this invention is that of capturing the flow rate in a non-invasive manner, for instance, without interference, interruption or alteration in the direction of the flow of solid material.
[0040] Another advantage of this invention is to effect sensing without bias or the imposition of any tendency to effect the flow in any specific area of the conduit, in such a way as to minimize the deposition and/or crusting of particulate materials within the rigid conduit thereby increasing the efficiency of the flow sensor and reducing the need for cleaning and maintenance.
[0041] Another advantage of this invention is the ability to activate the flow sensor only when the agricultural machinery is being used in the field, thereby significantly reducing the consumption of energy, and, as a consequence, increasing the self-sufficiency of the sensor's battery.
[0042] Another advantage of this invention is that of isolating the rigid conductor from external vibrations caused by the apparatus, thereby avoiding any incorrect interpretation in relation to the flow of particulate material.
[0043] In order to achieve the preceding objectives and others, one or more methods comprise the aspects which will be described below and specifically defined in the claims. The following descriptions and designs as attached present certain illustrative details for aspects of the methods described. However, these aspects indicate only some of the various ways in which the principals of the various methods may be used. Besides which it is intended that the methods so described include all such aspects and their equivalents.
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] The characteristics, nature and advantages of this invention will become more apparent from the detailed description as set out below when read together with the drawings where the same references refer to the same elements, in which:
[0045] FIG. 1 —Shows a view of the particulate solid material flow sensor, the subject of this invention;
[0046] FIG. 2 —Shows a view of the sensor from FIG. 1 , without the protective coating;
[0047] FIG. 3 —Shows an exploded view of the particulate solid material flow sensor;
[0048] FIG. 4 —Shows a side view in section of the particulate solid material flow sensor;
[0049] FIG. 5 —Shows a top view of the particulate solid material flow sensor with optional vanes for the rigid conductor;
[0050] FIG. 6 —Shows a view of the flow sensor connected to a sleeve of an agricultural machine conduit;
[0051] FIG. 7 —Shows a top view in section of the particulate solid material flow sensor;
[0052] FIG. 8 —Shows a detailed view of the electronic circuit board for the sensor with its respective components;
[0053] FIG. 9 —Shows a sensor assembly with folding couplings;
[0054] FIG. 10 —Shows a block diagram of data flow involved in the functioning of the sensor;
[0055] FIG. 11 —Shows a flowchart for the operating modes of the sensor and the transitions between the modes of operation; and
[0056] FIG. 12 —Shows a perspective view of the remote wireless monitor.
DETAILED DESCRIPTION
[0057] This invention refers to a WIRELESS PARTICULATE SOLID MATERIAL FLOW SENSOR WITH INTERNAL BATTERY, that was specifically developed to monitor the flow of fertilizers and small seeds in agricultural machinery whereas the sensor for this invention may also be used in machines and/or equipment from various sectors of industry, such as for example, that of foodstuffs, civil construction, plastics, etc., for monitoring the flow of any particulate material.
[0058] Refer to FIG. 1 that shows the particulate solid material flow sensor which comprises of a rigid resonance conductor ( 1 ) covered by a circular protective shield ( 2 ).
[0059] Refer to FIGS. 2, 3 and 7 that show the flow sensor for this invention in which the rigid resonance conductor ( 1 ) comprises of a circular support ( 3 ) which fits to supports ( 4 ) that secure the transducers ( 5 ) to the external face of a rigid conductor ( 1 ), which is further provided with an electronic circuit board ( 6 ), and batteries ( 7 ), enclosed in the circular support ( 3 ), all covered by a protective circular shield ( 2 ). Optionally the rigid conductor ( 1 ) can be covered by a rubber protective cover ( 8 ) with the function of isolating the rigid conductor ( 1 ) from external impacts and vibrations which may prejudice its proper functioning.
[0060] Refer to FIG. 8 that shows the electronic circuit board ( 6 ) where the radio frequency transceiver components are located ( 11 ), external impact sensor ( 17 ), microprocessor ( 16 ), maintenance indicator ( 13 ), power indicator ( 12 ) and the analogue adder circuit ( 15 ).
[0061] The rigid resonance conductor ( 1 ) has the ability to resonate, that is to say, vibrate mechanically in its natural frequency due to collisions of particulate material against its internal walls. The internal diameter of the rigid resonance conductor ( 1 ) is equal to the rest of the flow route, avoiding bottlenecks that interfere with the direction of flow. The conductor is straight, without curves, such that on its internal surface there is no area with a greater contact tendency with the particulate material, or by which incidence of the same would predominate, thus avoiding deposition of material, or that which affects the direction of flow. The length of the conductor should be sufficient so that collisions which occur over the length of its internal surface which result in vibrations at minimum amplitudes can be detected by the electromechanical transducers ( 5 ). The wall of the rigid resonance conductor ( 1 ) can be modified in accordance with its intended use and may receive a polish and/or specific treatment in order to minimize crusting of material in the form of dust which may be present, for example, in some types of fertilizers, or can be provided with the addition of vanes ( 9 ), as shown in FIG. 5 , in order to maximize the incidence of collisions, increasing sensitivity of the flow sensor, where such interference with the flow is permissible.
[0062] Along the wall of the rigid resonance conductor are placed one or more electromechanical transducers ( 5 ). An equally spaced number of the transducers can be set-up for any diameter of the resonance conductor ( 1 ) in sufficient quantity to detect vibration about the transducer or even its entire external area. In the proposed constructive arrangement 4 (four) transducers have been illustrated ( 5 ) arranged perpendicularly to one another in order to form a “transduction belt”, in order to provide high sensitivity for any operating position of the flow sensor. These transducers have the ability to capture vibrations or mechanical deformation of the rigid resonance conductor ( 1 ), and transform such into an electrical analogue signal proportional to the vibration or deformation captured, demanding little or no external power in order to function.
[0063] The transducer can be either active or passive and can include a piezoelectric, magnetic, electromagnetic, microphone, strain gauge, or electroactive polymer element or any similar device with the capacity to effect electromechanical transduction with low energy consumption. Preferably the transducers ( 5 ) should have good directionality which results in increased sensitivity along the length of the conductor and reduced sensitivity to external vibration or even noise. Its placement along the rigid resonance conductor ( 1 ) can be achieved via the use of adhesive, fitting or by means of supports ( 4 ). In the proposed constructive arrangement passive piezoelectric transducers are shown which do not need external power in order to function and that are also immune to external sound vibrations. Its positioning along the conductor was achieved by means of supports ( 4 ), described as follows.
[0064] Supports ( 4 ) position the transducers ( 5 ) along the external wall of the rigid resonance conductor ( 1 ), and have the purpose of applying sufficient and necessary force to the transducer in order to maximize the capture of vibrations. They can be made of metallic wire springs or flat plates, plastic springs, or any plastic, metal or rubber device that achieves the same function. Excessive force from the support ( 4 ) applied to the transducer ( 5 ) results in the dampening of vibration for the system and too weak a force results in low mechanical power transmission. In the proposed constructive arrangement metallic wire springs have been used the force of which was empirically determined due to increased sensitivity achieved throughout the tests. The use of supports ( 4 ) significantly increases the sensitivity of the transducer ( 5 ) which enables the use of a smooth and straight resonance conductor ( 1 ).
[0065] The electronic circuit board ( 6 ) comprises an electronic adder circuit ( 15 ), a microprocessor ( 16 ), radiofrequency transceiver ( 11 ), an external impact sensor ( 17 ), a maintenance indicator ( 13 ), and a power indicator ( 12 ).
[0066] The radiofrequency transceiver ( 11 ) effects wireless communication between the flow sensor and the remote monitor ( 18 ) which displays to the operator of the agricultural equipment the flow rate of particulate material within the rigid resonance conductor ( 1 ).
[0067] The electronic adder circuit ( 15 ) has the purpose of summating the analogue signal generated by the transducers ( 5 ) and sends the resultant signal to the microprocessor ( 16 ).
[0068] The external impact sensor ( 17 ) has the ability to detect external impacts and vibrations that could contaminate flow detection. This sensor may be digital, microelectromechanical (MEMs) or electromagnetic; and of the accelerometer, force sensor, pressure sensor or any other type which has a similar function. In the proposed constructive arrangement a low power consumption SMD (surface mounted device) digital accelerometer was used which immediately sends a digital signal to the microprocessor ( 16 ) each time that an impact of high frequency and amplitude is detected.
[0069] The power indicator ( 12 ) has the ability to tell the microprocessor ( 16 ) when the sensor is potentially in use. Various known components exist that have the ability to execute this function, such as mechanical “tilt sensors”, magnetic sensors, accelerometers, MEMs type integrated circuits for the measurement of inclination or acceleration, RTC (real time clock) components, and other timers that are able to set periods, dates and times of function, switches and buttons triggered by the user, or even flow detection transducers that tell the microprocessor ( 16 ) when there is a flow passing through the sensor. In the proposed constructive arrangement a mechanical “tilt sensor” was used which creates a disturbance at the processor input point whenever movement is detected. In this manner the processor is always notified when the apparatus is set in motion, as such is a potential sensor use situation.
[0070] The maintenance indicator ( 13 ) has the ability to tell the microprocessor ( 16 ) that the sensor should switch into maintenance mode. In this event the microprocessor will configure the radiofrequency transceiver on a pre-determined channel set for communication with maintenance equipment. Subsequently such equipment can then alter the network address of the sensor, its sensitivity, or any other relevant functional parameter. Various known components exist that have the ability to execute this function, such as mechanical “tilt sensors”, magnetic sensors, accelerometers, or even switches and buttons triggered by the user. In the proposed constructive arrangement a “reed switch” type magnetic sensor was used in order that the sensor may enter into maintenance mode whenever a magnet approaches a specific area of the sensor.
[0071] The microprocessor ( 16 ) is of the “ultra-low power” type with power saving functions which is freely available on the market from various manufacturers for the sector. It receives signals sent by the transducers ( 5 ) by way of the adder circuit ( 15 ) and is provided with bundled software for signal processing and as a consequence able to evaluate the presence, absence and amount of flow within the rigid resonance conductor ( 1 ), also taking into account the signal generated by the external impact sensor ( 17 ) in order to avoid contamination in evaluation of the flow signal.
[0072] The microprocessor ( 16 ) also has the role of implementing the various functional modes as shown in FIG. 11 , thereby effecting transitions between the modes in accordance with information received by the processor. For the majority of time the sensor will be in “SLEEP” mode where its power consumption will be extremely low, as a consequence it will turn off unnecessary electronic circuits and the microprocessor ( 16 ) will operate in power saving mode. In the event that a signal is emitted by the maintenance indicator ( 13 ) the sensor enters into maintenance mode (MANUT) as described above and returns to “SLEEP” mode after a pre-determined interval. In the event that, in “SLEEP” mode, a signal is emitted from the power indicator ( 12 ), the sensor enters into “RF” mode elevating power consumption due to the sensor trying to communicate with the remote monitor ( 18 ). In the event that the monitor is turned on which indicates that the operator is present, the sensor receives a response and enters into full operation mode (FUNC) with an intermediate level of power consumption. Where no return signal is received the sensor returns to “SLEEP” mode. When in full operation mode (FUNC), the sensor will switch over to “RF” mode for pre-determined periods of time, just to confirm its presence within the apparatus, and in case of a change in flow, when it will communicate the new reading to the remote monitor. While still in “FUNC” mode the sensor will switch to “SLEEP” mode in the event that no flow is detected for a long period of time meaning that, even with the operator present, the machine is not in full operation.
[0073] These different modes of operation and their switching mechanisms ensure that the sensor will be in a state of extremely low power consumption most of the time—which would mean the majority of the year in the case of agricultural equipment—and that it would therefore consume power for communications only when strictly necessary. As such, it achieves an energy reduction to the lowest possible level for battery consumption, increasing its working life.
[0074] The batteries ( 7 ) are meant to supply power to the flow sensor and may be of the primary type with enough power to supply the flow sensor throughout its working life or of the rechargeable type which receives an external charge for a determined period of use. Various manufacturing technologies and chemical elements both current and future can be used to reduce the size of batteries, as well as to augment their volumetric energy density. In the proposed constructive arrangement 2 (two) primary Lithium Cylindrical batteries have been used.
[0075] Refer to FIG. 6 that shows a view of the flow sensor connected to the sleeve (M) of a conduit from an agricultural machine that guides particulate material. As illustrated a flow diverter screen ( 10 ) is installed externally to a sleeve (M) of the conduit together with a rigid connector ( 1 ). This assembly ensures that the particulate material always collides with the sleeve and is dispersed in various directions thereby guaranteeing higher frequency and intensity collisions between the particles in flow and the wall of the rigid resonance conductor ( 1 ). This type of set-up was shown to be extremely efficient in gravity flow equipment where flow velocity is low in the proximity of the particulate material meter which could reduce sensitivity of the sensor. Such an assembly has the advantage of producing the desired flow diversion without causing deposition of material and crusting since its own folding movement (stretching and relaxing) of the sleeve is responsible for expelling any material deposited on the sensor.
[0076] The rubber protective cover ( 8 ) has the ability to protect the sensor against impacts and external vibration. It is made from rubber of sufficient durability to provide strength for the assembly whilst maintaining a degree of softness to isolate and absorb external vibrations and impacts. Additionally, the rubber cap ( 8 ) is provided with internal ridges that form pockets of air and reduce the contact area between the cap and the sensor in such a manner that maximizes protection and provides acoustic isolation.
[0077] FIG. 9 shows the sensor mounted with a pair of folding couplings ( 14 ) at its extremity. These couplings have the purpose of isolating vibrations when the sensor is mounted on rigid tubes. As such, it impedes structural vibrations from equipment reaching the rigid resonance conductor ( 1 ) which otherwise may compromise flow readings. These couplings may be used with any type of equipment with good acoustic isolation, such as rubber, cork, cardboard and others.
[0078] Refer to FIG. 12 that shows the wireless remote monitor ( 18 ) which provides information to the operator from one or more sensors present in the machine and/or equipment which emits an audio and/or visual alarm whenever an abnormality is detected. The remote monitor is provided with a high power radiofrequency transceiver in order to ensure increased strength for the wireless communication link.
[0079] Additionally, the remote monitor ( 18 ) has the ability to infer that an agricultural machine is in motion when there are no seeds or other inputs in flow which avoids unnecessary alarms that may cause discomfort for the operator during maneuvering. The alteration or inhibiting of alarms occurs when a configurable number of sensors notify an absence of flow. For improved performance this information can also be allied to velocity information for the equipment supplied via GPS or any other displacement sensor, such as wheel sensors, encoders, radar and others.
[0080] It should be emphasized that operation of the sensor described for this invention is suitable for any type of particulate material flow generation whether by mechanical action, gravity, pneumatic pressure, or any other type which enables the collision of solid particles with the walls of the sensor.
[0081] It will be easily understood by those versed in the technique that modifications can be made to the invention without such moving away from the concepts set out in the foregoing description. Such modifications should be considered to fall within the scope of the invention. Consequently the particular methods described in detail above are merely illustrative and are not limitative as to the scope of the invention to which should be given full extent under the claims appended and any and all equivalents to the same. | A robust low-cost wireless sensor with an internal battery, which permits operation for extended periods without the necessity of maintenance, for monitoring the flow of particulate solid material such as chemical fertilizers, small seeds, granulated foodstuffs, and others. | 6 |
BACKGROUND OF THE INVENTION
As shown in FIGS. 1 and 2, in the conventional gill C and bobinoir D, a sliver 12 is controlled by needles 10a of a follower 10 or needles 11a of a porcupine roller 11 to impart a draft to the sliver 12.
In a recently developed draft apparatus in which high drafting is made possible while increasing the drafting speed, for example, as shown in FIG. 3, an intermediate roller 13 comprising a balloon rollers 13a and a lower apron 13b is arranged, or as shown in FIG. 4, an intermediate roller 14 comprising double aprons 14a and 14b is arranged as a substitute for the follower or porcupine roller. These high drafting operations are performed without using needles, whereby the draft ratio and drafting speed can be increased.
However, these high draft apparatuses are defective in the following points as compared with the draft apparatus comprising a follower or porcupine roller.
(1) The evenness of a sliver is low and yarn breakages are readily caused in a spinning frame.
(2) Defects of a sliver caused at the preceding steps are not substantially eliminated but are sometimes worsened.
(3) Occurence of unevenness by joining of slivers in not prevented at all.
Each of the recently developed high draft apparatuses is of an apron type or similar type as shown in FIGS. 3 or 4, and it is an indispensable requirement that an ideal and good sliver should be supplied. However, incorporation of a defective sliver or a sliver having defects cannot practically be avoided, and the above-mentioned defects (1) and (2) are caused in the practical operation. Namely, when such defective sliver is supplied, abnormal expansion of the sliver is more prominent than in the conventional low draft apparatus, and yarn breakages are frequently caused in a spinning frame, resulting in reduction of the yarn quality.
The defect (3) will now be described. As shown in FIG. 5, before a sliver 12 supplied from a can 15 is completely consumed, the top end 212a of a sliver 212 taken out from a full can 215 which is let to stand by for the subsequent supply is partially lapped on the rear end 12a of the sliver 12 of the can 15 and joining is performed. Since needles are not nused in the high draft apparatus as pointed out herein-before, the formed joint is not normally drafted but a defect of unevenness appears on the joint, and this uneven portion should be removed afterwards. Because of this operation loss, the effects of increasing the operation speed and the productivity cannot satisfactorily be attained, and this disadvantage is especially serious when an automatic doffing apparatus is arranged.
Unevenness of sliver of this type cannot be checked by the naked eye and the sliver is directly forwarded to a spinning frame, and when an uneven yarn is spun and a fabric is formed by knitting or weaving, this defect is first found out and the poor quality becomes a problem. One of the reasons why adoption of a high draft bobinoir is hesitated is a risk of this poor quality.
SUMMARY OF THE INVENTION
The present invention relates to a high draft apparatus disposed at the gilling or bobinoir step broadly adopted in the worsted spinning process.
An object of the present invention is to provide a high draft apparatus, in which a uniform sliver can be formed by high drafting and occurrence of unevenness is prevented at the time of joining slivers.
In the present invention both the needles and aprons are applied for drafting slivers so that merits of both the needles and aprons are utilized while their demerits are eliminated. More specifically, according to the present invention, there is provided a novel draft apparatus, in which massive migration of fibers at the operation of joining slivers is controlled by the action of the needles and simultaneously, the aprons are driven and rotated by the forefront roller in such a manner as if the aprons are moved to draw in the sliver, whereby the action of holding and delivering a sliver by the aprons can be performed very smoothly and the drafting operation can be accomplished precisely with certainty, with the result that the evenness of the sliver can be improved and a sliver free of unevenness due to joining can be obtained.
BRIEF DESCRIPTION OF DRAWINGS
FIGS. 1 through 5 are schematic side views showing conventional draft apparatuses.
FIG. 1 shows a gill comprising a follower.
FIG. 2 shows a bobinoir comprising a porcupine roller.
FIG. 3 shows a high draft bobinoir comprising a balloon roller and an apron.
FIG. 4 shows a high draft bobinoir comprising double aprons.
FIG. 5 illustrates the operation of joining slivers in the high draft bobinoir shown in FIG. 4.
FIG. 6 is a schematic side view illustrating one embodiment of the high draft apparatus according to the present invention.
FIG. 7 is a schematic side view illustrating another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The structure of the present invention will now be described in detail with reference to embodiments illustrated in the accompanying drawings.
FIGS. 6 and 7 show embodiments of the draft apparatus of the present invention, and in each of FIGS. 6 and 7, reference numerals 1, 101 and 5, 105 represent a front roller and a back roller, respectively. In the draft apparatus A shown in FIG. 6, a porucpine roller 2 and an intermediate roller 3 comprising a balloon roller 3a and an apron 3b are arranged in this order between both the front and back rollers 1 and 5, and in the draft apparatus B shown in FIG. 7, an intermediate roller 104 comprising upper and lower double aprons 104a and 104b is arranged instead of the intermediate roller 3 comprising the balloon roller 3a and the apron 3b, which is arranged in the apparatus A. The lower apron 3b or 104b is driven and rotated by the forefront roller 6 or 106 of a plurality of rollers supporting the apron 3b or 104b, that is, a roller 6 or 106 on the side of the porcupine roller 2 or 102. For this purpose, a saw teeth-like shape is given to the surface of the roller 6 or 106, or the surface of the roller 6 or 106 is roughened, and by the frictional force, the apron 3b or 104b is positively driven and rotated. In the intermediate roller comprising the apron and balloon roller or the intermediate roller comprising the double rollers, the lower apron 3b or 104b is taken out and driven by the forefront roller 6 or 106. Accordingly, sagging of the sliver-holding surface which is caused by feed-out driving by the rear roller 7 or 107 in the conventional apparatus is not caused at all. Furthermore, the intermediate roller is always rotated under tension and therefore, the sliver 12 or 112 can be smoothly fed to this intermediate roller from the back roller. This effect by the apron-driving system is especially prominent when the drafting rate is increased.
The porcupine roller 2 or 102 is arranged between the front roller 1 or 101 and the intermediate roller 3 or 104 and is rotated in the same direction as the sliver delivery direction while parts of needle points 2a or 102a are intruded into the sliver 12 or 112. Accordingly, the sliver 12 or 112 delivered between the front roller 1 or 101 and the intermediate roller 3 or 104 undergoes a final draft and is stretched at this porcupine roller 2 or 102 so that the sliver 12 or 112 is delivered out from the front roller 1 or 101 while having a predetermined thickness. Simultaneously, massive migration of fibers because of unevenness or irregular parallelism is prevented by intrusion fof needle points 2a or 102a into the sliver 12 or 112 and by this control action of the porcupine roller 2 or 102, the sliver is guided into the front roller 1 or 101 as a uniform fiber assembly. The draft is hardly given between the back roller and the intermediate roller but a predetermined quantity of the draft is given between the intermediate roller and the front roller. In the present invention, for example, the draft quantities are adjusted to 1.00 between the back roller and the intermediate roller (the apron) and to 0.90 in the zone of the porcupine roller, and the draft quantity is adjusted to 12.0 in the zone of the front roller. In this high draft zone, the sliver receives the control action of needles in the sufficiently stretched state. Accordingly, unevenness is remarkably reduced. Especially, massive migration of lapped fibers at the time of ending of slivers is effectively controlled by this porcupine roller, and a sliver having a very good evenness can be manufactured.
As will be apparent from the foregoing description, according to the present invention, between a front roller and a back roller at the gilling or bobinoir step of the worsted spinning process, a porcupine roller is arranged on the side of the front roller and an intermediate roller comprising double aprons or a balloon roller and an apron is arranged on the side of the back roller to construct a series of a draft apparatus, and the apron is driven and rotated by the forefront roller of rollers supporting said apron. By virtue of such characteristic features, the spron of the intermediate roller is rotated in the state where the sliver-holding surface is kept under tension, and therefore, the sliver supplied from the back roller is smoothly held and delivered out under tension without being bent. Accordingly, a high draft can always be given to the sliver precisely, and by the combing action of the porcupine roller, fibers of the sliver are sufficiently controlled and uneveness due to the joining operation is not caused to occur at all. Therefore, a sliver having a good uniformity and being free of unevenness can always be spun out. Furthermore in the present invention, the porcupine roller and the intermediate roller comprising a lower apron and an upper balloon roller or double roller 3, which is positively driven and rotated by the forefront roller, can easily be constructed by modifying and remodeling the conventional gill or bobinoir. Moreover, by such arrangement of the porcupine roller and such driving of the apron, high draft is made possible and the effects of stabilizing the quality, preventing formation of a defective joint, eliminating the operation loss and improving the operation efficiency can be attained. | A high draft apparatus for use in the worsted spinning process. At the gilling or bobinoir step of the worsted spinning process, a porcupine roller and a middle roller are disposed between a front roller and a back roller to prevent an occurrence of unevenness and to obtain a uniform sliver. | 3 |
FIELD OF INVENTION
The invention relates to head covers and particularly to a head cover in the form of a cap. More specifically, the invention is directed to a cap fabricated in such a manner that when worn on a person's head, the head is shielded from selected forms of radiation.
BACKGROUND OF INVENTION
Caps, hats and other forms of head covers, are typically made of some kind of fabric selected primarily for its ability to shield the wearer's head from the rays of the sun, from cold weather or from moisture. A very popular kind of cap is referred to by many as a "baseball" cap irrespective of whether it is being used in some kind of sport, for hunting, for work or other application. Such a cap typically comprises a flexible portion which covers the head and an outer relatively stiff panel portion which provides shade for the eyes. The head cover portion is called the crown and the shade portion is referred to as the bill.
A typical method of fabricating a baseball cap of the type referred to is to precut a selected number of panels from a sheet of fabric and seam these together to form the crown to which the bill is attached. For purposes of adjustment to different head sizes, the cap is typically fitted with an adjustable strap at the rear of the cap and a somewhat inverted U-shape opening is left in the crown portion above the location of the strap. In some types of caps of the kind being described, a large portion and sometimes the entire portion of the crown, is formed of a porous net material. In some instances, the fabric composite from which the crown panels are cut comprises an outer cloth layer which may be either natural or synthetic and a thin inner layer which also may be either natural or synthetic and which is bonded to the outer layer to form an inner lining for the cap.
So far as is known, the popular type of cap described has never been fabricated in a form suited to the purpose of shielding the head from radiation such as emitted by television sets, microwave ovens, citizens-band (CB) radios, cordless telephones and the like. Yet, there is increasing concern and numerous studies and research articles indicate there is cause for concern when a person for whatever reason is continuously exposed to certain frequencies. This concern centers to a great concern on potential damage to the brain.
The technology for making surface metallized fabrics suited for use as personal protective clothing is described in U.S. Pat. Nos. 3,164,840; 4,420,757; 4,278,435; 4,439,768; and 4,572,960 the teachings of which are incorporated herein by reference.
A radiation protective garment having a head covering formed of a metallized fabric is described in U.S. Pat. Nos. 3,164,840; 4,338,686; and 4,572,960 and more recently in U.S. Pat. No. 5,073,984, the teachings of which patents are incorporated herein by reference.
The fabrics, referred to above as surface metallized fabrics, are now being produced and sold so far as applicant is aware, primarily for industrial applications as for example, being applied somewhat like wallpaper to shield a room from electric field, electromagnetic field, and other radio frequency interference. One such fabric is sold under the trademark "Flectron" by Monsanto Chemical Company of St. Louis, Mo. So far as is known, no one has heretofore recognized either the possibility or suitability of applying such shielding material to the manufacture of the popular and widely used baseball-type cap so as to make the cap a selective frequency shielding device for the head without impairing the ability of the cap to be a baseball-type cap bead cover.
SUMMARY OF INVENTION
The present invention recognizes that the type of metallized fabric presently being produced for radiation shielding in industrial applications exhibits characteristics suitable for fabrication of caps of the type described above in that such fabrics are light weight, drapable, easily cut, easily sewn and of attractive appearance. Thus, the present invention is directed to providing a baseball-type cap which can serve both as a head cover and as a shield for shielding the brain of the wearer by attenuating certain frequencies determined by the nature of the fabric.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a somewhat schematic view illustrating the cap of the invention in use in an environment in which, by way of example, undesired radiation is emitted by a computer screen.
FIG. 2 illustrates in reduced size the cap of the invention in use with an auxiliary radiation shielding drape covering the back of the user's head and releasably attached to the crown of the cap.
FIG. 3 is a top view of the cap of the invention.
FIG. 4 is a bottom view of the cap of the invention.
FIG. 5 is an enlarged outside view of the drape shown in FIG. 2 but detached from the crown of the cap.
FIG. 6 is an enlarged inside view of the drape.
DESCRIPTION OF THE INVENTION
The cap 10 of the invention has the important advantage that it can be manufactured by conventional cut and sew and other practices known in the art of manufacturing baseball caps. In this regard, as an initial step of manufacture, a metallized textile fabric is selected according to the desired frequencies to be shielded, the weight, drapability and appearance of the fabric. The term "metallized textile fabric" is intended to include any of the numerous types of available metallized fabrics suited to the invention herein described for shielding electromagnetic field, radio frequency and microwave frequencies. Such metallized fabrics are available in woven, knitted and non-woven form and according to the invention, can also be produced in a form in which the metallized fabric is laminated to a suitable non-metallized liner fabric which may be of either a thin, natural or synthetic material. The metallized fabric can also be selected with regard to the plating being, for example, of copper, nickel, nickel on copper with the thickness of the plating will, in general, determine both the range of the frequencies that are shielded and the degree of attenuation all of which is known from the cited prior art and readily available trade literature.
In the embodiment being described, a woven "Flectron" copper/polyester so-called Ripstop type metallized fabric available from the Monsanto Chemical Company was laminated to a thin, non-woven synthetic, polyester liner so as to provide a composite sheet fabric having an electrically conducting surface on one side and a substantially non-electrically conducting surface on the opposite side. The "Flectron"fabric had a thickness of about 5 to 6 mils and a weight of about 2 to 2.5 oz/sq. yd. and had the frequency shielding characteristics associated with this type fabric. The referred to "Flectron" type fabric, typically woven or non-woven, is made up of individual metallized fibers which in the example being used for reference was a woven fabric made up of individual polyester fibers having a layer of copper, copper being a highly electrically conductive metal. With this type "Flectron" fabric, an attenuation effectiveness of up to about 90 Db is obtained in the 6 MHz to 10 GHz range.
Once the frequencies desired to be shielded are known and the particular metallized fabric has been selected and then bonded to the liner material as described above, a suitable number of panels 11 are cut from the fabric and are joined by sewn seams 24 reinforced by interior stitched tapes 15. The seams 24 at each join preferably join the edges of the panels in both physical and electrical contact. However, it has been found that even though complete electrical contact between the panel edges is not achieved substantial shielding may still be obtained. Six such panels are illustrated by way of example. The electrically conducting somewhat hemispherically-shaped thin surface formed by the thin metallized fabric is exposed on the outer surface of the crown of the cap and the electrically non-conducting thin liner material 17 is exposed on the interior of the crown. Thus, the crown of the cap in the illustrative embodiment has outwardly a unique and attractive copper appearance. A bill 13, in the form of a stiff panel, is attached to the crown of the cap 10 by conventional procedures and in the illustrative embodiment, is preferably of an extended length L of about five inches and has a width W at its trailing end of about eight inches. The metallized fabric 12 covers the outer surface of bill 13 and the metallized fabric 12' also preferably covers the inner surface of the bill 13. The bill 13 is preferably thin, relatively rigid and self-supporting and may comprise a rigid, fabric-covered panel. A metallized fabric-covered button 19, 19' enhances the overall copper-like, external appearance and strengthens the central join of the panels.
The previously mentioned somewhat inverted U-shaped opening U found in the conventional baseball cap also appears in the illustrative cap 10 of the invention and below which is mounted a conventional head size adjusting strap 22. Within the peripheral base portion of the crown of the cap, a strap 18 is sewn and has a fur-like surface suited to releasably engaging the mating "Velcro" type straps 16 fixed to the interior of a drape 14 which can be detachably secured to cap 10 as best seen in FIG. 2. Drape 14 is made of the same fabric as that employed for making the panels 11 and thus presents a continuing, attractive copper-metallized fabric appearance on its outer surface 14' and the appearance of the liner on its inner surface.
In use as illustrated in FIG. 1, the cap 10 of the invention finds application when an operator 0 is seated facing a computer having a screen 20 whose display is controlled by a keyboard 20' and which for purposes of describing the invention is treated as being an illustrative source of radiation depicted schematically by the arrows in FIG. 1. Thus, in this environment, it can be seen that cap 10 provides protection and attenuation of the radiation emitted by computer 20 both by reason of the crown portion of the cap 10 as well as by reason of the protruding, substantially large metallized surface of bill 12. In an alternative work environment as depicted in FIG. 2 where the operator 0 is concerned both about direct or reflected radiation aimed at the rear of the operator's head, additional protection is provided by installing the detachable cape 14 utilizing the "Velcro" straps 16 attached to the strap 18.
Utilizing the test described on Page 282 of the book "Cross Currents" by Robert O. Becker (1990), a small, portable AM radio was tuned to a spot on the dial where a station could not be heard and was adjusted to maximum volume. The radio in this condition was held about a foot away from both an operating television set and an operating microwave oven and in both instances, a radio frequency induced "noise" was heard on the radio. The same experiment was repeated with the radio wrapped within the cap 10 of the invention and no "noise" was heard thus illustrating that in these examples, the cap 10 of the invention can serve as a practical device for shielding both the head and brain and attenuating such undesired radiation.
As is amply illustrated by readily available and voluminous technical and medical literature, there is ample and growing concern about the effect on the body of electric, electromagnetic, and radio frequency fields. Thus, the cap 10 of the invention contributes to alleviating this concern.
In summary, the cap 10 of the invention as represented in the described illustrative embodiment, offers at least these advantages:
(1) The cap can be fabricated using existing cut and sew and other known fabrication techniques and thus does not require training in new manufacturing procedures.
(2) The individual panels making up the crown of the cap can be both physically and electrically joined by conventional sewing techniques.
(3) The available metallizing frequency shielding fabrics from which the cap can be fabricated are recognized as being suitable to existing and known cut and sew production and other established production procedures by being pliable, drapable, light weight and sewable.
(4) The cap, depending on the choice of fabric, can be tailored to fit the attenuation of selected frequencies deemed to be of the greatest concern.
(5) Both the cap and the drape in their appearance when worn provides a unique and distinctive copper-like metallized appearance.
(6) The cap, while serving the new and novel purpose of shielding the head and in particular the brain, remains equally serviceable as a baseball-type cap for use in activities not concerned with radiation shielding.
While an illustrative embodiment was used for purposes of illustration, it is to be recognized that other forms of caps and head covers may be devised to employ and benefit from the teachings of the invention. Accordingly, all such variations, modifications and embodiments are to be regarded as being within the spirit and scope of the invention. | A cap is formed of a metallized fabric capable of being fabricated with conventional cut and sew techniques into a baseball style cap and serviceable both as a head covering and as a means for shielding the head of the wearer and attenuating selected electric field, electromagnetic field or other radio frequencies which, unless shielded and attenuated, would pass through the cap and provide a cause of concern for the wearer of the cap. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation, under 35 U.S.C. §120, of copending International Application No. PCT/EP2012/070634, filed Oct. 18, 2012, which designated the United States; this application also claims the priority, under 35 U.S.C. §119, of European Patent Application No. 11 290 489.1, filed Oct. 21, 2011; the prior applications are herewith incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a method for operating a feed pump which operates in a pulsating manner. Such feed pumps are used, for example, in feed units for feeding liquid operating substances in motor vehicles. Liquid operating substances in motor vehicles are, inter alia, fuels for internal combustion engines, fluids used with windshield wipers for cleaning windows of motor vehicles, cooling fluids or lubricating fluids for internal combustion engines and reducing agents for cleaning exhaust gases of internal combustion engines.
In particular, reducing agents for cleaning the exhaust gases of internal combustion engines have been recently used to a greater extent. Such reducing agents are required in exhaust gas treatment devices in order to convert the noxious components in the exhaust gas together with the reducing agent. Such an exhaust gas treatment method is the method of selective catalytic reduction [SCR=selective catalytic reduction]. In that method, a reducing agent which contains or makes available ammonia is fed to the exhaust gas of the internal combustion engine. The ammonia in the reducing agent is then converted in the exhaust gas together with the nitrogen oxide compounds. In that context, non-damaging reaction products such as water, carbon dioxide and nitrogen are produced. Ammonia is normally not stored directly itself in motor vehicles but rather in the form of a reducing agent precursor. A frequently used precursor is aqueous urea solution. The term “reducing agent” is also used below for reducing agent precursor.
In exhaust gas treatment devices, relatively small quantities of reducing agent are required. The consumption of reducing agent is normally between 2% and 10% of the consumption of fuel by the internal combustion engine. For that reason, feed pumps which operate in a pulsating fashion (in an intermittent or reciprocating fashion) have proven particularly valuable for feeding reducing agents. Feed pumps which operate in a pulsating fashion are particularly cost effective and allow precise adjustment of the feed quantity.
A disadvantage of feed pumps which operate in a pulsating fashion is, in particular, the efficiency and the generation of noise of the feed pump due to the feed stroke and high power losses which lead to considerable generation of heat in the feed pump. In particular, the generation of heat can lead to problems when feeding thermally sensitive liquids (such as, for example, a urea/water solution).
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a method for operating a feed pump operating in a pulsating manner and a motor vehicle having a feed pump, which overcome the hereinafore-mentioned disadvantages and at least alleviate the highlighted technical problems of the heretofore-known methods and vehicles of this general type. The intention is, in particular, to disclose a method for operating a feed pump which operates in a pulsating fashion and by which the feed pump can be operated in a particularly economical fashion in terms of energy and with low noise.
With the foregoing and other objects in view there is provided, in accordance with the invention, a method for operating a feed pump operating in a pulsating manner, wherein the feed pump has a feed piston and a drive coil for driving the feed piston, a feed unit has a pressure sensor downstream of the feed pump in the feeding direction, and the method comprises at least the following steps:
a) applying a voltage profile to the drive coil; b) carrying out a feed stroke of the feed piston in accordance with the voltage profile; c) monitoring a pressure profile in the feeding direction downstream of the feed pump; d) evaluating the pressure profile; and e) adapting the voltage profile as a function of at least one characteristic property of the pressure profile.
The method according to the invention is based on the concept of adapting the voltage profile for driving the feed pump in such a way that a pressure profile in the feed line is particularly advantageous, for example by virtue of the fact that it corresponds to a predefined set point pressure profile. A pressure profile in a feed line is, in particular, a chronological pressure profile which occurs in the feed line due to a stroke of the feed pump which operates in a pulsating fashion. In the simplest case, the voltage profile for driving the drive current is a simple square wave signal which is defined by the absolute value of an applied voltage and duration of the applied voltage. Any desired voltage profiles with a relatively complex structure are conceivable.
Consequently, a control method is also proposed herein in which the pressure profile of a feed stroke from step b) is evaluated which occurs in accordance with a predefined voltage profile (step a)) in step d) and an adapted voltage profile is predefined in step a) for a following step b). This control process can be carried out often enough until the evaluated pressure profile in step d) corresponds to a predefined set point pressure profile. The “adaptation” of the voltage profile includes, in particular, one of the following measures: changing of the voltage amplitude, changing of the duration of the voltage, changing of the chronological voltage profile (increase/decrease; holding times etc.).
The feed pump is preferably a component of a feed unit feeding a liquid operating material for a motor vehicle with a predefined feeding direction, in particular for feeding liquid reducing agents such as urea/water solution. It is also preferred that the pressure sensor be a component of the feed unit so that in this case, in particular, the monitoring of pressure also takes place within the feed unit.
In accordance with another particularly advantageous mode of the method of the invention, the voltage profile has an overall duration and a first voltage, and at least the overall duration or the first voltage is adapted in step d). The overall duration relates in this case to the time period from a starting value of the voltage (for example zero volts) to the start of the feed stroke up to an end value of the voltage (for example zero volts again) at the end of the same feed stroke. The “first voltage” constitutes in this case, in particular, a first (predefined) voltage amplitude, in particular at the end of the overall duration of the voltage profile or during the feed stroke itself. Consequently, in the method at least one of these characteristic variables of the voltage profile in step e) is adapted for the next feed stroke.
In accordance with a further advantageous mode of the method of the invention, the voltage profile starts with an activation interval with an activation voltage, wherein the activation voltage is increased over the first voltage. The increased activation voltage serves firstly to set the feed piston of the feed pump in motion. For this purpose, an increased voltage is necessary. When the piston has been set in motion, all that is necessary is to move the piston on within the feed pump. It is therefore possible to operate with a relatively low first voltage. Accordingly, the timing of the activation voltage of the first voltage mentioned above is moved forward in a voltage profile.
In accordance with an added particularly advantageous mode of the method of the invention, a first time of a pressure peak is determined as a characteristic property of the pressure profile, and at least one of the following variables of the voltage profile is adapted as a function of the first point in time:
overall duration; first voltage; activation interval; or activation voltage.
The generation of noise and the efficiency of the feed pump can be improved in this way. It is possible, for example, to ensure that the feed piston strikes less hard or even not at all against a stop within the feed pump (if appropriate this is, in fact, the cause of the measured, undesirably high pressure peak) by virtue of the fact that the voltage profile is correspondingly changed. For example, the overall duration of the voltage profile can be selected in such a way that the feed piston is not accelerated further when a pressure peak is reached.
In accordance with an additional mode of the method of the invention, at least a second time at which a pump valve opens or a third point in time in which a pump valve closes is determined as a characteristic property of the pressure profile, and in addition at least one of the following variables of the voltage profile is adapted as a function of at least the second point in time or of the third point in time:
overall duration; first voltage; activation interval; or activation voltage.
This also includes the fact that the pressure values of the pressure profile are determined both at the second point in time and at the third point in time, and the voltage profile and its parameters are adapted to the second point in time and to the third point in time.
The valve opening times of the feed pump and the valve closing times of the feed pump can be detected in the pressure profile which the pressure sensor measures. The valve opening can be detected, for example, when the pressure profile first rises. The closing process of the valve can be detected, for example, from a drop in pressure. Lag times, which last until a valve movement has an effect on the pressure sensor, could also be taken into account.
If appropriate, a further pressure sensor can be disposed within the feed pump, and a comparison of the pressure measured there with the pressure in the feed line can take place, as a result of which certain times or properties of the pressure profile can then be detected particularly precisely by using a measurement of a pressure difference.
In accordance with yet another advantageous mode of the method of the invention, the voltage profile is generated from a supply voltage using pulse width modulation. The supply voltage is in this case the voltage made available by a voltage source (constant) for the operation of the feed pump.
In accordance with yet a further mode of the method of the invention, a current profile in the drive coil is monitored in parallel with step c) and is used at least during the evaluation of the pressure profile in step d) or during the adaptation of the voltage profile in step e). It is possible to provide additional monitoring measures or monitoring devices for the parallel (simultaneous) monitoring of the current profile. In addition it is also possible for knowledge from this current profile to be used both for step d) and for step e).
In accordance with yet an added advantageous mode of the method of the invention, at least one parameter from the following group of further parameters is used at least during the evaluation of the pressure profile in step d) or during the adaptation of the voltage profile in step e):
energy consumption of the drive coil during a feed stroke; outputting of energy by the feed pump to the liquid operating substance; or a return flow of energy from the drive coil after termination of a feed stroke.
The pump can also be considered energetically within the scope of the method. The energy consumption of the feed pump through the drive coil during a feed stroke can be determined by using the current flowing through the coil and the applied voltage profile. The outputting of energy of the feed pump to the liquid operating substance can be determined, for example, by using the volume flow of the feed pump in combination with the feed pressure of the feed pump and/or the increase in pressure caused by the feed pump. If appropriate, measurement is possible by using a second pressure sensor. It would therefore be possible to determine a volume flow by measuring a pressure difference. The return flow of energy from the drive coil after the end of a feed stroke can be measured with a corresponding synchronously operating diode.
An efficiency level of the feed pump and/or a power loss of the feed pump can be calculated with a comparison of the outputting of energy of the feed pump to the liquid operating substance with the energy consumption of the feed pump through the drive coil during a feed stroke. The voltage profile which is predefined to the feed pump can therefore be adapted in such a way that the efficiency level is particularly high or that the predefined quantity of energy is not sufficient for the feed piston to move against a stop with a high impetus. Particularly advantageous operation of the feed pump in the partial stroke can therefore be implemented.
In accordance with yet an additional advantageous mode of the method of the invention, the feed pump can be operated with a frequency of more than 10 feed strokes per second, and more than 20 feed strokes occur before a feed stroke is carried out with an adapted voltage profile.
The feed pump is frequently monitored in the engine control or controller of a motor vehicle. The controller is disposed at a large spatial distance from the feed pump. Moreover, the computing capacities which are available in the engine controller are not (always) sufficient to permit adaptation of the voltage profile for carrying out a feed stroke within a few milliseconds. For this reason it is advantageous if an adapted voltage profile does not have an effect until more than 20 feed strokes after the measurement of a pressure profile. An adapted voltage profile preferably no longer has an effect after 50 feed strokes and, in particular, after 100 feed strokes after the measurement of a pressure profile. A long lag time or delay is therefore produced in the adaptation control loop which is formed by the method according to the invention. It is also possible for a lag time of at least 1 second, preferably at least 5 s [seconds] and particularly preferably at least 10 s to occur between step a) and step e). However, this makes it possible for the calculations which are necessary for the method according to the invention to be carried out in a remote control unit with a comparatively small computing power.
If appropriate, correspondingly adapted voltage profiles (set point voltage profiles) can also be stored for specific pressure pulse patterns (characteristic profiles of the actual pressure profile) of the feed pump. These stored predefined voltage profiles can then be used to operate the feed pump if corresponding conditions are present in the feed unit. The conditions in the feed pump can be defined, for example, on the basis of the temperature in the feed unit and/or the present consumption of liquid operating substance.
If a (separate) control unit which can carry out the method according to the invention is provided within the feed unit for feeding the liquid operating substance itself, it is also possible to carry out the method during a substantially lower number of feed strokes, with the result that the lag time (or delay) of the method is significantly shorter.
With the objects of the invention in view, there is also provided a method for operating a feed pump operating in a pulsating manner, wherein the feed pump has a feed piston and a drive coil for driving the feed piston, and the method comprises at least the following steps:
i. applying a voltage profile to the drive coil; ii. carrying out a feed stroke of the feed piston in accordance with the voltage profile; iii. monitoring of a temperature at the feed unit; and iv. adapting the voltage profile as a function of at least the temperature.
The particular advantages and configuration features which are illustrated for the method for adapting the voltage profile as a function of the pressure can be applied and transferred in an analogous fashion to the method illustrated herein for adapting the voltage profile as a function of the temperature. The same applies to the special advantages and configuration features which are described below for the method for adapting the voltage profile as a function of the temperature and which can be applied and transferred in an analogous fashion to the method for adapting the voltage profile as a function of the pressure.
In particular, both methods can also be combined with one another, with the result that the adaptation of the voltage profile takes place as a function of at least the temperature or the pressure/pressure profile. In summary, the voltage profile can accordingly be adapted as a function of a (current) measure of the operating state of the feed pump.
This applies specifically to the configuration of the feed pump, of the feed piston and of the drive coil as well as of the feed device and of the pressure sensor. This also applies specifically to the individual properties of the voltage profile, which can be adapted within the scope of the adaptation.
The temperature can be monitored with a temperature sensor which can be disposed at a location in the surroundings of the feed unit and/or in direct contact with the feed unit. The temperature sensor can, for example, be mounted on a base plate in the feed unit, at which base plate the feed pump is also mounted. It is also possible for the temperature sensor to be disposed directly on the feed pump. In a further embodiment variant, the temperature is measured by using the drive coil of the feed pump. The drive coil typically has a temperature dependent electrical resistance. The electrical resistance of the drive coil can be inferred from the voltage profile and from the current flow through the drive coil which occurs as a result of the voltage profile. Given a known temperature dependence of the electrical resistance, the temperature of the drive coil can be calculated from this electrical resistance.
In feed units with feed pumps which operate in a pulsating fashion, very high energy losses regularly occur during the conversion of the electrical energy which is introduced into the drive coil for the purpose of feeding the volume and increasing the pressure. These energy losses have already been described in detail above. In addition to the high power consumption, the energy losses also lead to strong heating of the feed pump. This heating can in some cases be desired, for example if the feed pump is used at the same time to heat the feed unit through its power loss. This may be advantageous in order to melt reducing agent which is frozen in the feed unit and/or to avoid the freezing of reducing agent in the feed unit. However, if the temperature of the feed unit or of the feed pump exceeds a limiting temperature (which is, for example, between 80° C. and 120° C.), further heating by the power loss is undesired in this case. At raised temperatures, it is possible, in particular when the feed pump feeds urea/water solution as a reducing agent, for deposits to form, which can lead to significant damage to the pump. The deposits can act like sandpaper particles which can damage the pump. The feeding accuracy and/or the efficiency level of the feed pump can be reduced in this way. It is therefore advantageous to avoid high temperatures in the feed pump. This may be achieved, in particular, by adapting the voltage profile as a function of the temperature.
The voltage profile is preferably adapted in such a way that the temperature in the feed pump or the temperature in the feed unit does not exceed a defined limiting temperature. The (maximum) limiting temperature is, for example, 120° C., 100° C. or even only 80° C. Furthermore, intermediate temperatures which are lower than the predefined limiting temperature can be predetermined. Therefore, if the limiting temperature and/or the predefined intermediate temperature/temperatures is/are reached, the voltage profile which has applied until then is changed.
In one preferred embodiment variant, the two methods for adapting to the pressure and for adapting to the temperature are both carried out in combination. The voltage profile is then adapted both to the temperature and to characteristic properties of a pressure profile. The adaptation of the voltage profile to the properties of a pressure profile also serves, inter alia, to reduce the power loss which occurs during operation of the feed pump. If the temperature in the feed pump or in the feed unit is as far as possible no longer to be increased, the feed pump should be operated with a lower power loss. In this case, in order to reduce the temperature, the voltage profile can be adapted, on the basis of the pressure profile as described further above.
In order to start a pump stroke, a particularly high activation voltage can be used in order to set the feed piston in motion as quickly as possible. If the activation voltage is particularly large, the necessary current or the necessary current strength to set the feed piston in motion is reached particularly quickly. As a result, the energy loss is particularly reduced because this current flow only then occurs for a shortened time interval due to the necessary current strength being reached more quickly. Furthermore, an activation interval, for which the activation voltage is present at the drive coil, can also be adapted. With respect to the adaptation of the activation voltage and/or the activation interval, explicit reference will be made once more to the explanations given above with respect to the adaptation of the activation voltage and of the activation interval within the context of the adaptation to the pressure, which explanations are incorporated herein by reference in their full scope.
The maximum current which flows through the coil during a pump stroke can be reduced. The maximum current can be reduced by virtue of the fact that a first voltage for generating the current flow during the motion of the piston is reduced to such an extent that the maximum current is reduced to the necessary current or the necessary current strength (for the, in particular, continuous or constant motion). The necessary current is, in other words, also that current which is necessary to place the feed piston (just) in motion. In order to ensure that the feed piston is reliably set in motion (and moves at a sufficient speed), the maximum current should be predetermined and increased by an interval (for example a value between 1 percent and 10 percent, preferably between 2 percent and 5 percent) above the necessary current or the necessary current strength. With respect to the adaptation of the first voltage, explicit reference will be made once more to the explanations given further above with respect to the adaptation of the first voltage within the scope of the adaptation to the pressure, which are incorporated by reference herein to their full scope.
Furthermore, the overall duration of a current pulse or of the current pulse which is provided for placing the feed piston in motion can be reduced. If the feed piston has reached its ultimate position (if appropriate against a stop in the feed pump) and the current pulse or the current flow continues, the entire current flow constitutes a power loss. For this reason, it is advantageous to adapt the overall duration of the current pulse or of the current pulse which is provided for a specific motion of the feed piston, in such a way that this overall duration corresponds to the time interval of the motion of the feed piston. The overall duration of the current pulse or of the current flow preferably ends when the feed motion of the feed piston ends. It is also possible for the overall duration of the current flow to end a short time period before or after the end of the feed motion. Premature ending of the current flow before the end of the feed motion permits strong impacting of the feed piston against a stop to be reduced. A subsequent end of the current flow after the end of the feed motion makes it possible to ensure that the feed motion is carried out completely in every case. With respect to the adaptation of the overall duration, explicit reference is made once more to the explanations given further above with respect to the adaptation of the overall duration within the scope of the adaptation to the pressure, which are incorporated herein by reference to their full scope.
As a result of the fact that the current profile of the current pulse or of the current flow for activating the feed piston or the voltage which is made available and by using which the current profile is produced, is generated by using pulse width modulation, it is possible to make the current profile independent of the on board power system of a motor vehicle and, in particular, independent of the voltage made available by the on board power system. The voltage of the on board power system fluctuates, for example, as a function of to what extent a battery in the motor vehicle is charged, to what extent current is fed into the on board power system through a generator and/or how many loads are connected to the battery. The on board power system of a motor vehicle with 12 volts sometimes makes available, for example, only between 9 volts and 12 volts for a feed unit in the starting phase of the motor vehicle, while in the regular operation of the feed unit, for example, between 13 and 14 volts are made available. It is proposed that a current profile, which is (largely) independent of the voltage which is made available, is generated for the feed pump by using pulse width modulation from the voltage which is made available by the on board power system.
If a relatively low voltage is made available to the drive coil in order to move the feed piston, the current flow for moving the feed piston is established more slowly and the motion of the feed piston lasts longer. As a result, the power losses due to the current in the coil (that is to say the energy which is converted directly into heat by the resistance of the coil and does not lead to a motion of the feed piston) become larger. In particular, during the starting phase of a motor vehicle it is possible, as explained further above, for only a relatively low voltage to be regularly made available. In the starting phase, the feed pump is, however, still cold, with the result that the produced heat which is increased due to the low voltage is not so problematic in this case. During the operation after the termination of a starting phase of a motor vehicle, the on board power system can regularly make available relatively high voltages again. The heat which is produced by the drive coil can be reduced with the methods proposed herein.
With the objects of the invention in view, there is concomitantly provided a motor vehicle, comprising a tank for a liquid operating substance and a feed unit with a feed pump which operates in a pulsating fashion and has the purpose of feeding the operating substance out of the tank, as well as a control unit which is configured to operate a feed pump with a method according to the invention. The control unit, controller or computer can, for this purpose, be equipped with a suitable data processing program, characteristic diagrams, sensors, signal lines, etc. In this context, reference is also made, in particular, to the following description of the figures.
Other features which are considered as characteristic for the invention are set forth in the appended claims, noting that the features which are specified individually in the claims can be combined with one another in any desired technically appropriate way and can be supplemented by explanatory contents from the description, in which further embodiment variants of the invention are indicated.
Although the invention is illustrated and described herein as embodied in a method for operating a feed pump operating in a pulsating manner and a motor vehicle having a feed pump, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 is a diagrammatic, partly-sectional view of a feed unit which is configured and constructed for a method according to the invention;
FIG. 2 is a block diagram of a motor vehicle having a feed unit for a method according to the invention;
FIG. 3 is a diagram showing pressure profiles;
FIG. 4 is a diagram showing an example of pulse width modulation;
FIG. 5 is a diagram showing a current profile in a coil;
FIG. 6 is a further diagram showing a current profile in a coil; and
FIG. 7 is a flow chart of an embodiment variant of a method according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now in detail to the figures of the drawing for explaining the invention and the technical field in more detail by showing particularly preferred structural variants to which the invention is not restricted and in which size ratios are diagrammatic, and first, particularly, to FIG. 1 thereof, there is seen a feed pump 1 which can feed a liquid operating substance 3 (in particular a urea/water solution) through a line 48 , illustrated in certain sections, in a feeding direction 5 . A pressure sensor 8 is provided downstream of the feed pump 1 in the feeding direction 5 . A control unit 25 receives signals from the pressure sensor 8 for controlling the feed pump 1 . The feed pump 1 is a feed pump which operates in a pulsating fashion or manner and is driven by a drive coil 7 . The drive coil 7 drives a feed piston 6 . The feed piston 6 can be moved back and forth by the drive coil 7 and a restoring spring 44 . The force of the feed piston 6 is transmitted to a diaphragm 30 through a transmission fluid 29 . The diaphragm 30 then transmits the force of the feed piston 6 to the operating substance 3 . The feeding direction 5 through the line 48 is predefined by pump valves 20 , which preferably open and/or close passively. A so-called free-wheeling diode 46 , which is connected parallel to the drive coil 7 of the feed pump 1 , absorbs a current which is induced in the drive coil 7 by the restoring spring 44 when the feed piston 6 moves back. Furthermore, a temperature sensor 52 is provided on the feed pump 1 .
FIG. 2 shows a motor vehicle 4 having an internal combustion engine 23 and an exhaust gas treatment device 26 into which an operating substance can be fed through an injector 27 (in droplet form). The injector 27 is supplied with an operating substance 3 from a tank 24 by a feed unit 2 having a feed pump 1 . The operating substance 3 is preferably a reducing agent (in particular a urea/water solution) for cleaning the exhaust gases of the internal combustion engine 23 . A pressure sensor 8 and a control unit 25 for controlling the feed pump 1 are illustrated within the feed unit 2 . The operating substance 3 flows from the tank 24 to the injector 27 in a predefined feeding direction 5 .
FIG. 3 shows pressure profiles plotted on a pressure axis 42 against a time axis 34 , in a feed unit. A pre-pumping pressure 43 , that is to say a pressure upstream of the feed pump, is illustrated by a dotted line. A thick line shows a pressure profile 11 which has been determined at a pressure sensor disposed downstream of the feed pump in the feeding direction. The pressure profile 11 is intermittent on the basis of the pulsating feed motion of the feed pump. A pump chamber pressure 41 , that is to say a pressure in the feed pump, is plotted in dashed lines. The pump chamber pressure 41 varies between the pressure profile and the pre-pumping pressure 43 . A first point of time 16 of a pressure peak 17 in the pressure profile 11 can be also be seen in FIG. 3 . Furthermore, a second point of time 18 of a valve opening of the feed pump and a third point of time 19 of a valve closure of the feed pump can be seen. The valve opening of the feed pump occurs whenever the pump chamber pressure 41 reaches the pressure profile 11 which is present downstream of the feed pump in the feeding direction. The valve closes when the pump chamber pressure 41 drops below the pressure profile 11 .
FIG. 4 shows an example of a voltage profile 9 which is produced by using pulse width modulation. The voltage profile 9 is plotted on a voltage axis 35 against a time axis 34 . The voltage profile 9 starts with an activation voltage 15 which is present for a chronological activation interval 14 . The voltage profile 9 then drops to a first voltage 13 . Overall, the voltage profile 9 has an overall duration 12 . The activation voltage 15 and the first voltage 13 are generated from a supply voltage 21 using pulse width modulation. During pulse width modulation, a fixed clock length 32 is predefined. A pulse width 33 of this supply voltage 21 is varied within the clock length 32 . The voltage profile 9 arises from the pulsed supply voltage 21 by using a corresponding damping circuit.
FIG. 5 is a diagram of a current profile 22 during a pump pulse. The current profile 22 is plotted on a current axis 37 against a time axis 34 . The pressure profile 11 in the feed unit is illustrated diagrammatically (in the background). The voltage profile 9 is also illustrated diagrammatically in the background. The chronological reference of the current profile 22 with respect to the voltage profile 9 and with respect to the pressure profile 11 will now be explained. The voltage profile 9 is a square main voltage in this case for the sake of simplicity. Furthermore, an idealized current profile 49 is illustrated diagrammatically in the background. This idealized current profile 49 shows how the current in the drive coil would be if the feed piston of the feed pump were not to carry out a feeding motion.
The idealized current profile 49 and the current profile 22 both start with an initial gradient 39 at the beginning of the voltage profile. This initial gradient 39 is predefined by the resistance of the drive coil and the inductance of the drive coil.
As soon as the feed piston of the feed pump starts to move at a second time 18 , the voltage profile 22 and the idealized voltage profile 49 move away from one another differently. The idealized voltage profile 49 continues to increase, while the voltage profile 22 remains approximately level at a fourth point of time, in the case of an operating current 45 , for a time interval up to a stop of the feed piston. This is due to the fact that the motion of the feed piston induces an opposing voltage in the drive coil 7 which leads to a slowing down of the increase in the voltage profile 22 . Approximately a plateau is therefore produced during the motion of the feed piston. The level of the plateau or the size of the operating current 45 are approximately proportional to the force generated by the feed piston, or to the increase in pressure brought about by the feed pump.
As soon as the feed piston has come to a stop at a fourth point of time 28 , the current profile 22 continues to rise in accordance with the idealized current profile 49 . The profile of the current profile 22 is offset only in a chronologically following fashion compared to the idealized current profile 49 . The idealized current profile 49 and the current profile 22 both increase up to a maximum current 40 . This maximum current 40 is defined by the electrical resistance of the drive coil. The inductance of the drive coil plays no role in this case because the magnetic field of the drive coil is completely built up at this time.
The relationship of the operating current 45 to the maximum current 40 is informative for the efficiency level of the feed pump: the higher the operating current 45 in relationship to the maximum current 40 , the greater the amount of electrical energy which cannot be used to move the feed piston but is instead converted into thermal energy by the electrical resistance of the drive coil. The operating current 45 is preferably less than 30%, in particular less than 15% and particularly preferably less than 5% of the maximum current 40 .
As soon as the voltage profile 9 has ended after the expiration of the overall duration 12 , the current drops away with a current drop profile 50 . Due to the magnetic energy which is stored by the drive coil, the current does not drop away in an immediately abrupt fashion. The dissipation of the energy stored in the form of a magnetic field by the drive coil leads to an induced negative voltage 51 . A return flow 36 of energy from the drive coil 7 is therefore produced. This return flow of energy can, for example, be consumed in a freewheeling diode so that the induced negative voltage 51 does not lead to a destruction of electrical components.
After the fourth point of time 28 , when the feed piston has reached its stop, the electrical energy which continues to be introduced into the drive coil by the voltage profile 9 and the current profile 22 is converted directly into heat on the basis of the electrical resistance of the drive coil and therefore merely generates an energy loss 38 . This no longer results in a feeding effect. The energy loss 38 , which is shown in FIG. 5 , is illustrated in exaggerated form for the sake of illustration. The energy loss 38 is relatively large because the current profile 22 is continued so far that it almost reaches the maximum voltage 45 . Such conditions normally do not occur in real use of a feed pump.
FIG. 6 shows the diagram of FIG. 5 , in which the voltage profile 9 has been adapted by the method according to the invention. The voltage profile 9 is, for the sake of simplicity, a square wave voltage in this case which has only been shortened in its duration 12 . The voltage profile 9 then already ends before the fourth time 28 at which the feed piston reaches its stop. This can ensure that, on one hand, the energy loss 38 is completely avoided. Furthermore, when the feed piston is actuated with the voltage profile 9 according to FIG. 6 , the feed piston does not reach the stop or has already been at least partially slowed down because acceleration of the feed piston already stops occurring before the stop is reached at the fourth time 28 .
FIG. 7 illustrates the method according to the invention in a one flow chart. It is apparent that the method steps a), b), c), d) and e) are carried out in a regular repeated fashion in a chronologically successive fashion in the manner of a loop. This takes place until an abort condition is met. After this, the method can be initiated again as required by regular monitoring of the pressure profile and/or of other characteristic values of the operation of the feed pump and/or of the motor vehicle. | A method for operating a feed pump operating in a pulsating manner in a feed unit to feed a liquid operating substance in a feeding direction, is used in a motor vehicle. The feed pump has a feed piston and a drive coil for driving the feed piston. The feed unit has a pressure sensor downstream of the feed pump in the feeding direction. A voltage profile is firstly applied to the drive coil. A feed stroke of the feed piston is subsequently carried out in accordance with the voltage profile. In this context, a pressure profile in the feed unit downstream of the feed pump in the feeding direction is monitored. This pressure profile is subsequently evaluated. The voltage profile is subsequently adapted as a function of at least one characteristic property of the pressure profile. A motor vehicle having a feed pump is also provided. | 5 |
FIELD OF INVENTION
This invention relates to improving yarns, particularly their cut-resistance, and more particularly to a process for achieving this.
BACKGROUND OF THE INVENTION
Some industrial articles of clothing, such as protective gloves, are designed with an objective of protecting the wearer's skin. This has been difficult to achieve, consistent with providing garments that are comfortable to wear. Ideally, certain such articles should be made from yarns that have themselves superior cut-resistance, so that the gloves or other garments or articles themselves resist cutting by sharp instruments, edges or other hazards in the workplace. There is a need for an improved yarn of such cut-resistance.
Many synthetic fibers provide superior industrial yarns. For instance, the strength, heat resistance and other useful properties of aramid fibers, such as PPDT, poly (p-phenylene terephthalamide), sold commercially by Du Pont under the tradename "KEVLAR" is well known in this respect. It would be desirable, however, to provide yarns having improved cut-resistance, and with a soft covering, such as to enable industrial work garments, for instance, including protective gloves, to be made in a form that is comfortable to wear and yet can protect the wearer against cuts and like hazards.
The problem has been solved by the present invention, which provides a way to incorporate a continuous wire in the core of a wrapped yarn of the type disclosed (in the decade of the sixties) by Field in U.S. Pat. Nos. 3,365,872 and 3,367,095, the disclosures of which are hereby incorporated herein by reference. Briefly, Field taught a wrapped yarn of a core of at least two continuous integral core elements of relatively straight textile fibers (for instance continuous filament yarn bundles or spun yarns from staple fibers) and surface wrappings of discontinuous textile fibers (for instance natural or synthetic staple) tightly twisted about the core and with portions locked into the core, and a false twisting process for combining the two types of textile fibers to form his wrapped yarns. Field discloses "all synthetic and natural fibers and filaments, and combinations thereof" as being suitable raw materials for making his yarns (col. 3, line 21 et seq of U.S. Pat. No. 3,365,872) and lists several compositions that include metal fibers, glass fibers, and asbestos fibers (lines 50-51). Field did not, however, suggest incorporating a continuous metal wire into the core of his yarns, and when attempts were made, according to the invention, to try and incorporated a continuous metal wire into wrapped yarns of the types specifically disclosed by Field, several practical problems were encountered, and products resulting from
such attempts were unsuitable for various reasons.
SUMMARY OF THE INVENTION
The problem has been solved according to the present invention by modifying the process taught by Field and succeeding in incorporating into certain of his wrapped yarns a continuous annealed metal wire of thickness about 1 to 8 mils, especially of stainless steel, as disclosed hereinafter.
According to the present invention, there is provided a twist-transference, false-twisting process for producing an intertwined yarn comprising (1) a core of a continuous annealed metal wire of thickness about 1 to 8 mils and of at least two continuous integral core elements of textile fibers and (2) surface wrappings of discontinuous fibers, which comprises continuously feeding loose discontinuous fibers, forwarding and supporting the fibers in a compressible fluid stream, continuously feeding separately said continuous multifilamentary core elements to converge with each other and the stream-supported discontinuous fibers and then passing through false-twisting means, false-twisting the core elements together to cause twist to back up and combine the discontinuous fibers with the core elements, and subsequently removing the twist from the core elements and reverse-twisting the discontinuous fibers tightly about and between the core elements by false twisting means to produce an intertwining of discontinuous fibers helically twisted about substantially straight core elements with portions of discontinuous fibers locked into place between the core elements, wherein said wire is fed into the process together with at least one of said core elements.
One of these fiber core elements preferably acts as a carrier for each such wire in the process, so the wire and this core element travel together from their sources of supply. If desired, more than one such wire may be incorporated in the core by such means.
As suggested by Field, the false twisting is preferably accomplished by applying a torque with a fluid jet to produce a yarn having fibers helically twisted about the core at a relatively constant twist level along the yarn.
As may be seen hereinafter, the process of the invention may be operated at speeds of over 200 mpm, and even above 300 mpm, and yet provide a satisfactory product.
This process accordingly provides an intertwined yarn comprising a core, composed of a wire and at least two continuous integral core elements of textile fibers, and intertwining fibers, composed of discontinuous textile fibers, the discontinuous fibers being tightly twisted about the core with portions of fibers locked into place in the core, and the core fibers being relatively straight and held together as a compact bundle by the discontinuous fibers, the wire being a continuous annealed wire of thickness about 1 to 8 mils in close proximity to and preferably surrounded by the continuous integral core elements of textile fibers. The thickness of the wire is preferably at least about 3 mils and preferably up to about 5 mils, and the wire is preferably of stainless steel. The total denier of the yarn may range from somewhat less than 1000 denier (say 800 denier) up to about 70,000 denier. For instance a 3 mil wire of stainless steel is equivalent to about 400 denier, and could be incorporated in a core of as little as about 600 denier (of suitable textile filaments) with about 120 denier of staple fibers to make a total of slightly more than 1100 denier for the composite yarn.
The intertwining fibers are preferably staple fibers helically twisted about the core at a relatively constant twist level along the yarn. The core elements are preferably bundles of continuous filaments that are preferably substantially free from twist, but may also include at least one core element that is a spun yarn composed of discontinuous fibers and at least one core element that is a continuous filament yarn, there being substantially no twist of such core elements about each other. The discontinuous fibers are preferably held in position by portions of such fibers being locked into place between core elements. The discontinuous fibers preferably comprise about 2% to 50% of the total weight of the yarn, especially about 10 to 40% of such total weight. Suitable discontinuous fibers generally have a length of 1 to 20 inches, and preferably a length of 2-4 inches. Preferred core elements are bundles of continuous filaments of p-aramid polymer, especially bundles of 200 denier or more, but may be other strong synthetic fibers, such as highly oriented polyolefin continuous filaments, and especially of 600 denier or more.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic representation of a specific embodiment of the process and apparatus for producing the yarns of this invention.
FIG. 2 is a photomicrograph of a yarn produced according to this invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention solves the problem that has existed for many years by making use of the process taught in the nineteen sixties by Field, by incorporating selected metal wires into selected composite yarns of the general type taught by Field, and by solving the several problems posed by incorporating such a large and different continuous element into the core of such composite yarns. It would be superfluous to repeat the disclosures of the Field patents. Attention should be drawn, however, to Field's FIG. 3, which shows an artistic representation of a greatly enlarged cross-sectional view of his wrapped yarns.
In contrast, examination of FIG. 2 of the present application shows an actual photomicrograph, i.e. a greatly enlarged (50×magnification) photograph in contrast to Field's artistic representation. The actual bundles of filaments (in this instance continuous filaments) of the core elements can be seen, as well as the surface wrapping of discontinuous fibers. FIG. 2 shows a single metal wire, the large size of which contrasts with the much smaller sizes of the textile fibers. Also the centered location of the wire surrounded by the textile fibers is clearly shown in this cross-sectional view in FIG. 2 of the present application. This is highly desirable. It was surprising that the process of the present invention would give such a desirable result, and it is possible only in hindsight to speculate why this should occur. It is also evident from this photomicrograph that the binding action of the surface fibers is important, so long as it confines the reinforcing metal wire in the core. The aesthetics of the surface discontinuous fibers in terms of a softer hand may also be important for some applications, but not as important as the binding function, for other end-uses.
Field disclosed that continuous core elements may be comprised of virtually any fiber including polyester, nylon, polyolefin, and glass. Such elements may be continuous filament or spun yarns, or combinations of these. The continuous filament yarns may contain interlace or twist, or neither. If a spun yarn is used as a core element, it should preferably be accompanied by a continuous filament yarn to insure core integrity. The preferred core elements are p-aramid yarns and highly-oriented polyolefin yarns, and combinations thereof; an example of the former is PPDT poly (p-phenylene terephthalamide), while an example of the latter is used in some Examples. The term "highly-oriented polyolefin yarns" refers to yarns having tenacities of at least 15 gpd. It is also preferred that a sufficient number of the continuous (textile) core elements be used to cover, and preferably surround, the wire in the core.
The intertwining component is comprised of short fibers, desirably 1" to 20" in length, of almost any type of fiber, including polyester, nylon, polyolefin, stainless steel, aramid, including p-aramid, cotton, wool, etc.. The dpf (denier per filament) of these fibers should be sufficiently fine so that the fibers wrap around the core components. Typically, dpf's of 1 to 30 have been found to be useful; 2 to 4 dpf fibers are preferable.
The continuous metal wire may be made from essentially any metal which is formable into wire, has sufficient stability under use conditions of textiles, and is sufficiently bendable and twistable to withstand the rigors of the fiber-intertwining process. Thus, iron, steel, stainless steel, copper, brass, bronze, silver, tantalum, platinum, and such like metals are all potentially useful. Steel wire, particularly stainless steel wire, has been found to be particularly useful because of availability, cost and performance. Stainless steel wire in the range of about 1 mil to about 8 mils is useful, preferably 3 to 5 mils. "Annealed" rather than "hard" stainless steel wire should be used because the former has the resilience and twistability needed for the process of this invention. Below 1 mil, the wire has been difficult to see and work with, and has had very low strength; we prefer to use a wire of strength at least 0.2 gpd. Above 8 mils, the wire has resisted adopting the twist needed during processing and process continuity has not been maintained.
The yarns produced according to this invention are useful for a wide range of fabrics and end-use applications where cut-resistance is desired. The yarns can be woven or knit or used in so-called "non-woven" fabrics. The fabrics so produced can be fashioned into end-use articles to provide cut-resistance protection to persons or things. For example, knit fabrics might be used to make cut-resistant gloves for butchers or other food processors. Similarly, woven or knit fabrics can be used for cut-resistant clothing, aprons, chaps, etc.. Examples of utility in non-apparel applications are in cut-resistant tarpaulins, cut-resistant bags, fabric coverings for furniture or valuable artifacts, etc.
The invention is further described in the following Examples, with reference to a preferred apparatus, as illustrated schematically in FIG. 1. It will be noted that FIG. 1 herein is similar in many important respects to the illustration in FIG. 1 of the Field references, mentioned hereinabove, except as regards matters that may be different from Field's process. It would be superfluous to repeat herein what is similar and already described in the art. All parts and percentages herein are by weight, unless otherwise indicated.
EXAMPLES
A series of Examples of intertwined yarn, most having excellent cut-resistance, were prepared by the process of this invention. Five Comparatives were prepared by a similar process, without the wire, by way of contrast, and are included in the Table, for convenience, along with the Examples of the invention.
The equipment is illustrated in FIG. 1. At least two continuous core elements (in all Examples and Comparatives these were continuous multifilament yarns) were fed from supply packages (such as yarns 1, 2, 3 or 4 from supply packages 11, 12, 13 and 14, in FIG. 1) past guide 8 to a pair of feed rolls (6 and 7; 7 is a driven roll, 6 is a nip roll) operating at a speed of 365 yards per minute, and then through separate openings (38) in a collector plate (39) and into a convergence tube (33) to form the desired yarn (40) at convergence point (41). For the Examples of the invention, at least one stainless steel wire is simultaneously fed to the collector plate and convergence tube in the same manner as the core elements. Each end of wire was processed together with one core element. This is desirable so that the core element "carries" or supports the wire and avoids abrasion and breakage of the wire. This is illustrated in FIG. 1 where core element 4 supports wire 5, being passed together around guide 9. The stainless steel wires were all annealed; we found that unannealed ("hard") wires could not be processed. This may have been because such wires were not flexible enough. In addition, we found that 1.6 and 3 mils stainless steel wires had to be supported or "carried" through the process by a core element to avoid overly frequent process interruptions; these thinner wires were quite weak and had tenacities of only about 0.3 and 1.25 grams per denier, respectively. The thicker 4.5 & 8 mil wires were processable without a "carrier" textile element, but should be fed together with such a textile core element to the convergence point 41.
A variety of core element yarns were used including PPDT poly (p-phenylene terephthalamide) yarns (200, 400 and 1000 denier yarns with 134, 267 and 660 filaments, respectively), HOPE highly-oriented polyethylene yarn (each of 650 denier, 60 filaments) and 2G-T poly(ethylene terephthalate) yarn (each of 220 denier, 50 filaments). The actual number of PPDT core element yarns used, their type and denier in each Example is shown in the Table. For example; under PPDT yarn in Example 1, 5×400 means 5 yarns of 400 denier each were simultaneously fed into the process. This Table also gives the number of HOPE yarns (of 650 denier) or of 2G-T yarns (of 220 denier), and , in the case of annealed stainless steel wires, the number used and wire thickness in mils; for example, 1×3 means 1 end of wire of 3 mils thickness. The discontinuous fibers used to intertwine the product were 2 inch, 2.25 dpf poly(ethylene terephthalate) fibers, gotten from drafting of 75 grain sliver; the weight % of such fibers in each Example and Comparative is given in Table 1. The 2G-T and PPDT yarns are commercially available from E. I. du Pont de Nemours and Company, of Wilmington, Del. The HOPE yarns are commercially available from Allied Chemical Corp. The sliver (31) was drafted 20-100X through a drafting section (not shown in FIG. 1). The fibers were picked up from final drafting rolls (24 and 26) at transfer box (32) via a vacuum line (34) and brought into contact with the core elements and wire(s) at the convergence point (41) in the convergence tube (33). The amount of discontinuous fiber introduced is controlled by the roll speeds in the drafting zone.
As false twisting device (44), a fluid jet of the type shown in FIG. 4 of U.S. Pat. No. 3,079,746 was operated with compressed air at about 185 psig at room temperature. The intertwined yarns exit the false twisting device, pass through let-down rolls (43, 45) and are wound upon a surface driven wind-up (48). The let-down rolls were run at about 3% less speed (at 354 yards per minute) than the feed rolls 6 and 7. The wind-up package (46) was operated at about 354 yards per minute for all Examples and Comparatives, but its precise speed was adjusted to keep adequate tension of the yarn during wind up.
To assess their cut-resistance, the intertwined yarns prepared above were knit into fabrics with weights ranging from about 10 to about 31 oz. per sq. yd., using a Shimaseiki glove knitting machine. Those fabrics which are double asterisked in Table 1 were prepared with two ends of intertwined yarn per feed to the knitting machine. All others were prepared with one end of yarn per feed. The fabrics so prepared were cut and sewn into gloves. The fingers of the gloves were cut off, mounted and tested for cut-resistance on a Betatec testing machine using a jumping cam with a 180 g. weight, as described herein. Table 1 gives the fabric weights and cut resistances of each Example and Comparative.
When annealed wire is incorporated according to the present invention, cut resistance is remarkably improved over the similar Comparative yarn by a factor from about 4 to about 24. Intertwined yarns with "Kevlar" aramid core elements yarns, or combinations of "Kevlar" yarns and highly oriented polyethylene yarns, give excellent cut-resistance when combined with only one wire. Intertwined yarns with polyester yarn core elements and an end of wire give good cut-resistance; these can be further enhanced by going to heavier fabrics. The addition of more wires (e.g., 2 or 3 or more) to the intertwined Examples of this invention further improve their cut resistance.
Cut-Resistance Test
Cut resistance tests were conducted using a modified "Betatec" (Registered trademark by Allied-Signal Inc.) procedure. The Betatec Testor was developed to evaluate cut-resistance of protective apparel by measuring the number of cycles required for a static razor blade under load to cut through a test fabric. The Testor used in these tests was modified to impart a lateral motion on the blade during cutting; to allow for the entire blade edge to be used during the cutting action. This reduces blade wear, permits use of a blade standardization step and, under the test conditions used, improved reproducibility of the obtained data.
TABLE__________________________________________________________________________Core Elements (Yarns) Glove PPDT 2G-T Wire Fabric Cut ResistItem # × Denier HOPE 2G-T Sliver (# × Mils) oz/sq. yd (Ave. Cycles)__________________________________________________________________________Ex. 1 5 × 400 20% 1 × 3 16.1 268Ex. 2 2 × 1000 19% 1 × 3 16.1 219Ex. 3 5 × 400 11% 1 × 3 14.0 179A 5 × 400 21% -- 15.3 11Ex. 4 2 × 400 2 19% 1 × 3 16.6 132Ex. 5 1 × 1000 2 17% 1 × 3 17.5 224Ex. 6 3 14% 1 × 3 15.5 76B 2 × 400 2 22% -- 15.5 12Ex. 7 2 × 400 2 10% 1 × 3 15.5 137Ex. 8 2 × 400 2 15% 1 × 3 15.6 171Ex. 9 2 × 400 2 30% 1 × 3 18.1 174C 3 × 200 20% -- 10.5** 15Ex. 10 3 × 200 20% 1 × 3 14.4** 60Ex. 11 3 × 200 20% 3 × 3 17.9** 125D 4 × 400 20% -- 12.3 20Ex. 12 4 × 400 20% 1 × 1.6 12.4 120Ex. 13 4 × 400 20% 1 × 3 14.0 123Ex. 14 4 × 400 20% 1 × 4.5 15.5 110Ex. 15 4 × 400 20% 1 × 8 274E 6 16% -- 19.7** 4Ex. 16 6 11% 1 × 3 20.7** 20Ex. 17 6 10% 1 × 1.6 23.7** 57Ex. 18 6 10% 2 × 3 27.8** 137Ex. 19 6 10% 3 × 3 31.3** 224__________________________________________________________________________ **Two yarns were combined and knit together as a single feed | A false-twisting, intertwining and wrapping process can combine continuous metal wire into the core of a composite structure comprising also continuous textile fiber core elements in the core, interlocking discontinuous textile fibers within the core and with such discontinuous fibers as surface wrappings. | 3 |
FIELD OF THE INVENTION
The invention relates to antivibratory supports to be placed, for support and damping purposes, between two rigid elements individually subjected to certain oscillations and/or vibrations, the damping, at least under certain operating conditions, comprising the driving of a liquid through a restricted passage.
By way of non limitative example, such supports may be mounted between a vehicle chassis and the internal combustion engine of this vehicle for damping not only the "hash" oscillations imposed on the chassis by the unevennesss and gradient variations of the ground when the vehicle is travelling over such ground, but also vibrations due to the operation of the engine, particularly when idling or else when shocks are applied to this engine during starting up and stopping by respectively the first and last explosions.
SUMMARY OF THE INVENTION
The invention relates more particularly, among the supports of the kind in question, to those which are formed by a sealed case interposed between the two rigid elements. The case comprises a rigid base fixable to one of the two rigid elements, a rigid ring fixable to the other rigid element, a resilient annular support wall sealingly connecting the base to the ring and a flexible membrane connected sealingly to the ring. The inside of this case is divided by a tight dividing wall connected to the ring between the annular wall and the membrane, into two chambers, namely a work chamber on the annular wall side and a compensation chamber on the membrane side. These two chambers communicate together permanently through the above restricted passage, which is advantageously formed by a curved channel situated in the connection zone between the annular wall and the ring. A liquid mass fills the two chambers as well as the restricted passage.
The invention relates more particularly still to the case where the intermediate sealed dividing wall comprises a deformable or mobile portion forming a floating "valve" and two mechanical stops surrounding this valve axially so as to limit the amplitude of its free movements to a low value, preferably less than 0.5 mm.
With such a support, the oscillations or vibrations created between the two rigid elements result in moving these two elements towards or away from each other axially in turn.
Those of these oscillations, called "hash" or "chopping" motions, which have a relatively low frequency (less than 20 Hz) and a relatively high amplitude (greater than 0.5 mm) result in driving the liquid from one of the two chambers into the other through the restricted passage and conversely. For a given value of said frequency depending essentially on the dimensions of said passage, high damping of the oscillations considered can be observed due to a resonating effect of the liquid mass flowing through this passage.
Those of said oscillations which have a relatively high frequency (greater than 20 Hz) and a relatively low amplitude (less than 0.5 mm) cause corresponding oscillations of the valve without there being a true transfer of liquid through the restricted passage, which results in filtering the transmission of the oscillations considered of the rigid element where they are generated to the other rigid element.
The role which has just been mentioned of the valve is dangerous for certain situations, but it may happen that under other circumstances this valve is the seat of undesirable transient vibrations.
This is the case for example during starting or stopping of the engine of some vehicles, in which there is a danger of "clacking" of the value. This is a sudden movement with the production of an intense sound, if it is not blocked.
To overcome or at least to attenuate such undesirable vibrations, it has already been proposed to temporarily limit the amplitude of the free movement of the valve by adjusting the axial position of one of the two stops which surround it axially and against which it abuts during each alteration of its free movements.
These adjustments are generally controlled by means of electromagnets which involves a construction, at least partial, from magnetic material of the stop to be moved.
A mechanical solution has also been suggested, the adjustment then being carried out on a cylindrical body fast with the stop to be moved and passing axially through the membrane. This solution is difficult to put into practice for the adjustments require axial movements of the membrane; in addition, the cylindrical body divides the compensation chamber into two separate coaxial compartments which behave differently during operation of the support.
The purpose of the invention is, among other things, to overcome these drawbacks.
For this, the supports of the kind in question in accordance with the invention further include mechanical means for adjusting the amplitude of the range of movement of the valve and these means are essentially characterized in that they comprise:
a rotary cam immersed in one of the two chambers of the support and forming by itself one of the two stops which define the range of movement of the valve, the amplitudes of these movements varying then from a maximum value to a minimum value, possibly zero, as a function of the angular positions of the cam about its offcentered rotational axis, which axis is oriented in a direction perpendicular to the direction of movement of the valve,
a rod fast with the cam and passing through the wall of said chamber through a seal,
and means external to the support for controlling the rotation of the rod.
In advantageous embodiments, recourse is further had to one and/or other of the following arrangements:
the chamber in which the cam is immersed is the work chamber of the support,
the cam has the external form of a cylinder offcentered with respect to its axis of rotation,
the support comprises a second restricted passage joining the two chambers together and preferably formed in the rigid seat of the valve and a rotary member adapted for adjustably closing this second passage and coupled to the above rotary cam so that maximum blocking of the valve corresponds to opening of the second passage and so that maximum unblocking of this valve corresponds to closure of this second passage.
Apart from these main arrangements the invention comprises certain other arrangements which are preferably used at the same time and which will be more explicitly discussed hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
In what follows, a preferred embodiment of the invention will be described with reference to the accompanying drawings in a way which is of course in no wise limitative.
FIGS. 1 and 2 of these drawings show in axial section an antivibratory support constructed in accordance with the invention, in its two conditions corresponding respectively to maximum blocking and unblocking of the valve.
FIG. 3 is a partial section on a larger scale of the rotary cam of support.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The support considered is intended to be interposed vertically or in a direction slightly slanted from the vertical between a rigid carrier member formed by a vehicle chassis and a rigid supported member formed by an internal combustion engine.
The terms "top, bottom, upper, lower, dish" are used in the following description by way of non-limitative example, for the support described may be perfectly well used upside down with respect to the direction adopted for this description.
The support has the general form of a sealed case of revolution about an axis X comprising:
a rigid ring 1 extending horizontally and outwardly the edge of an upturned metal dish 2, itself capable of supporting the engine of a vehicle by means of a stud bolt 3 whose threaded shank, extending upwardly, passes through the center of said dish,
a lower base 4 formed by blind threaded holes 5 opening downwardly and adapted for receiving bolts for fixing this base to the chassis of the vehicle,
a sufficiently thick resilient annular wall 6 for transmitting the loads of the engine to the chassis, which wall is defined essentially by two upwardly widening truncated cone shaped surfaces whose small base, disposed at the bottom, is adhered to base 4, its large base being connected sealingly to the ring 1,
and an upper tight and flexible membrane 7 contained inside dish 2, the edge of this membrane being sealingly fixed to ring 1.
An intermediate dividing wall 8 divides the inside of the case thus formed into two chambers, namely a lower work chamber A and an upper compensation or balancing chamber B.
The periphery of the dividing wall 8 is for this purpose sealingly connected to ring 1, between the thick wall 6 and membrane 7.
A restricted passage 9 causes the two chambers A and B to communicate permanently together.
This passage 9 is here formed by at least one curved channel extending along an arc of a circle about axis X, which channel is formed in the periphery of the dividing wall 8.
The central portion of the intermediate dividing wall 8 is formed by a rigid valve-forming disk 10.
This valve is mounted "floating" so as to be able to move in the direction of axis X between two rigid stops one of which is formed by a blocking washer 11 housed in a complementary groove of dividing wall 8.
A liquid mass 12 fills the chambers A and B as well as channel 9 and valve 10 is immersed in this liquid mass.
As is well known, the existence of this valve 10 damps the transmission of certain undesirable vibrations from one of the rigid elements to the other, because of the range of movement then imposed on said valve of these undesirable vibrations.
The invention proposes reducing, even cancelling out, the amplitude of the range of movement of this valve in certain other situations in which these movements are themselves undesirable.
For this, a rotary eccentric cam 13 is immersed in the support, preferably in its chamber A. The fixed axis of rotation Y of this cam intersects axis X and extends perpendicularly to this axis in a diametrical direction of the support.
Said cam 13 is adapted so that:
for one of its angular positions (shown in FIG. 1 and with continuous lines in FIG. 3), cam 13 comes into contact with the valve 10 all along one of the diameters of valve 10 while the periphery of valve 10 is axially applied against washer 11,
and, for another angular position offset by 90° from the preceding one (position shown in FIG. 2 and with broken lines in FIG. 3), it comes into contact with the valve at most at the times when this latter is subjected to its movements of maximum amplitude.
Cam 13 is secured to a rod 14 with axis Y which passes through ring 1 through a seal 15. Rod 14 ends, externally of the support, in a head 16 adapted for being driven in rotation.
In the drawings, this head 16 is a bolt head formed with a diametrical slit 17.
But it may also be formed by an element coupled to an appropriate drive member such as a small electric motor or similar whose energization is itself made dependent on the appearance of a phenomenon making blocking of the valve desirable or not.
Thus, in an advantageous embodiment, and so as to avoid "clacking" of the valve during stopping and starting of the engine, means may be provided for blocking the valve on the one hand for a time T 0 following each start up of the engine and, on the other, for a T 1 preceding each stopping of this engine. These times T 1 and T 0 for example of the order of a second.
It should be further noted that between the two endmost angular positions of cam 13 corresponding respectively to total blocking and maximum unblocking of valve 10, there exists an indefinite number of intermediate positions corresponding to different values for the allowed amplitudes of the movements of the valve.
In the preferred embodiment illustrated, a second restricted passage 18 has been provided in parallel with the first one 9. Passage 18 is formed by a short rectilinear channel of relatively large section in the dividing wall 8 parallel to axis X.
More precisely, channel 18 is formed in a rotary cylindrical member 19 itself placed in a complementary housing member 19 forms a "valve body" provided in dividing wall 8 and this member is secured to rod 14.
The result of such securing is that the rotary controls of cam 13 and those of member 19 are simultaneous, thus, the assembly is provided so that total blocking of valve 8 corresponds to total opening of channel 18, and maximum unblocking of valve 10 corresponds on the contrary to total closure of channel 18.
For the angular positions of this rotary assembly between these two endmost positions, partial opening only of channel 18 can be observed, combined with only partial blocking of the valve, i.e. a simple limitation of the amplitude of free movement of the latter.
This progressivity makes it possible to move continuously the value of said frequency, which corresponds to maximum damping, within the range of frequencies of the oscillations imposed on the support considered.
Thus, said value may be very small and of the order of 5 Hz only, when the second column 18 is totally closed and relatively high, namely of the order of 25 to 30 Hz, when this second column is totally freed.
An advantageous application of such coupling is the one, mentioned above, in which the valve must be blocked for a time T 0 after each beginning of starting the engine and for a time T 1 before each stopping of this engine.
In fact, during the periods considered, it is advisable for the support to be adapted so as to damp the vibrations which are generated by the engine of the idling vehicle, on stopping of this vehicle. It is precisely to such a speed that, in the above numerical example, total opening of the second channel corresponds, synchronized with blocking of the valve.
Following which and whatever the embodiment adopted, an antivibratory support is finally obtained whose construction, operation and advantages follow sufficiently from the foregoing.
As is evident and as it follows moreover already from what has gone before, the invention is in no wise limited to those of its modes of application and embodiments which have been more especially considered; it embraces, on the contrary, all variants thereof, particularly those in which the above valve is replaced by the central portion of a deformable membrane connected sealingly to the rigid remainder of the intermediate dividing wall 8. | In an antivibratory support interposed between two rigid elements (1-3 and 4-5) and comprising a work chamber (A) and a compensation chamber (B) separated by a dividing wall (8) with a mobile valve (10) and connected together by a restricted passage (9), a rotary cam (13) is provided immersed in the work chamber and serving as end of travel stop for the valve, the rotational movements of this cam being controllable from outside the support by means of a rod (14) passing sealingly through the dividing wall of the chamber. The cam is coupled to a a member (19) for controlling the opening of a second restricted passage (18). | 5 |
RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/857,810, filed on Nov. 8, 2006. The entire teachings of the above applications are incorporated herein by reference.
GOVERNMENT SUPPORT
The invention was supported, in whole or in part, by a grant N00014-03-1-0489 from the Office Of Naval Research. The Government has certain rights in the invention.
BACKGROUND OF THE INVENTION
There has been considerable interest in the use of ultrawide bandwidth (UWB) systems for both commercial and military applications. UWB may be used to refer to any radio technology having bandwidth exceeding the lesser of 500 MHz or 20% of the arithmetic center frequency, according to Federal Communications Commission (FCC). The use of large transmission bandwidth translates to many advantages over the conventional narrowband systems. To realize these advantages, however, the receiver may need to perform signal acquisition.
Signal acquisition may involve detecting timing delay. To perform signal acquisition, the receiver quantizes signal as a function of uncertainty range into several small ranges, referred to as bins or cells. Signal acquisition is completed when a receiver detects an in-phase bin, which is defined as a bin that corresponds to a timing delay or phase of a propagation path. In general, the receiver performs best if it completes the signal acquisition as fast as possible. A few prior art methods of signal acquisition employ accelerators, whose cost of processing is proportional to time used to test a particular bin or location.
SUMMARY OF THE INVENTION
Acquisition of wide or ultra bandwidth signals is a challenging task. The use of a wide transmission bandwidth typically translates into a large mean acquisition time (MAT). A large MAT may increase design and processing costs associated with the acquisition. There are two major approaches to improve the MAT. The first approach improves the MAT at a detection layer. For example, a receiver may dedicate more resources, such as correlators, to form a decision variable. The second approach is to improve the MAT at a search layer. For example, a receiver may use a search pattern, such as an expanding zigzag window, a non-consecutive or consecutive serial search (CSS), a fixed-step serial search (FSS), or a bit-reversal search. However, these searching methods still yield high design and processing costs.
In an example embodiment of the present invention, a searching apparatus and corresponding method for use that may reduce the MAT, and, therefore, reduce design and processing costs, is presented. The apparatus may include a selecting unit configured to select a first bin within a range of bins characterizing an uncertainty region, each bin corresponding to a phase of a transmitted signal, and a comparing unit configured to compare a local signal, which may have a phase corresponding to the first bin, with a received signal, that may be received via a transmission medium. The searching apparatus may also include a reporting unit that may be configured to report whether the local signal matches the received signal and an assigning unit that may be configured to assign weightings to the bins if the local signal and the received signal do not match. The selecting unit may further be configured to select a next bin according to the weightings, and the comparing unit may further be configured to compare subsequent bins at least until the local signal, having a phase corresponding to the next bin, matches the received signal.
The selection of the next bin may be based on the transmission medium. The selection of the next bin may be based on selecting randomly and uniformly from the range of bins while excluding the previously selected bin. The selection of the next bin may also be based on a posteriori probability. The posteriori probability of a random event or an uncertain proposition is the conditional probability that is assigned when the relevant evidence is taken into account. The selection of the next bin may be based on a serial search. The weightings may also be updated according to the posteriori probability. The weightings may be updated except when a previous bin is assigned a weighting of zero. At least one preliminary comparison between the local signal and the received signal may be performed.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing will be apparent from the following more particular descriptions of example embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating embodiments of the present invention.
FIG. 1A is a diagram of an example of a wireless communications system employing phase/bin selection;
FIG. 1B is a graphical depiction of received signals and a depiction of a vector of phase bins;
FIGS. 2A and 2B are block diagrams of a searching apparatus according to example embodiments of the present invention;
FIGS. 2C-2G are bin diagrams illustrating methods of bin selection according to example embodiments of the present invention;
FIG. 3 is a flow diagram of operations performed by the searching apparatus of FIGS. 2A and 2B according to example embodiments of the present invention;
FIG. 4A is a block diagram of a comparing unit according to example embodiments of the present invention;
FIG. 4B is a block diagram of a quick test component according to example embodiments of the present invention;
FIG. 4C is pseudo code of software instructions for updating/assigning probability/weightings of bins according to example embodiments of the present invention; and
FIG. 5 is another block diagram of a comparing unit according to example embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
A description of example embodiments of the invention follows.
In example embodiments of the present invention, techniques for searching for one or more targets are presented. In terms of wireless communications, the target may be a received signal, and the description below is presented in that example context. However, it should be understood that the example embodiments may be applied to technologies other than wireless communications.
FIG. 1A illustrates an example of a wireless communications system 103 . A periodic signal 105 may be sent to a receiver with the use of a transmitter. In the present example, the receiver is a cell phone 108 , and the transmitter is a base station 107 . Due to noise, dispersion, and/or interference, for example, the receiver 108 may receive multiple reflected copies of the transmitted signal 109 due to multi-path, for example, with each copy being an attenuated version of the original transmitted signal shifted in time or phase. Therefore, the receiver may perform operations, such as frame synchronization and decoding of a received message, after signal acquisition. Upon initial processing, the processed signal 111 may be used by the receiver for the evaluation of the received bits of data. Signal acquisition may be used to determine the bit boundaries of the processed signal. Since the receiver may have received an attenuated version of the transmitted signal, it is useful to determine the bit boundaries so that each bit may be read at its starting point. Without determining bit boundaries, a bit may be read, for example, at its mid-point, resulting in a loss of information.
FIG. 1B provides another illustrative example of signals that may be received by a receiver 100 . As shown, the receiver may receive multiple attenuated versions of the transmitted signal. During the signal acquisition stage, a search may be performed to identify the phase of the received signal in relation to the transmitted signal. In processing the received signals for the purpose of signal acquisition, each received signal may be evaluated against a series of bins in a vector of bins 101 . Each bin may correspond to an individual phase included in the observation under evaluation. As an initial search, the receiver may choose the bins denoted with an ‘*’ symbol, which may represent an estimation of the correct phase. For example, if a known pattern or signal includes seven bits of ‘1010110,’ the received signal may be the string ‘10110 . . . 1010110.’ Therefore, the received signal has a phase of two with respect to the known pattern or transmitted signal (i.e., the received signal begins with the second bit in the known pattern). In this example, a phase of zero refers to the original pattern or transmitted signal with zero phase offset.
FIG. 2A illustrates a searching apparatus 200 that may be employed in the signal acquisition stage, according to example embodiments of the present invention. The searching apparatus 200 may be configured to receive any number of transmitted signals 201 with the use of one or more antenna(s) 203 . The searching apparatus 200 may include a phase determiner 205 that may be configured to identify the received signal having a phase equal to the phase of the original transmitted signal. The phase determiner may thereafter report the signal with the correct matching phase 207 , or report the matching phase for use by another system, such as feedback to the transmitter or offset by another receiver (not shown) receiving the same signal, possibly at the same phase or known phase offset from the phase received by the phase determiner 205 .
FIG. 2B illustrates the various components that may be included in a phase determiner 205 , and FIG. 3 illustrates example operations of the phase determiner of FIG. 2B , according to example embodiments of the present invention. During an initial pass, the searching apparatus/phase determiner 205 may include a selecting unit 209 that may be configured to select a phase/bin 211 , from a vector of bins associated with a received signal, of a corresponding phase value ( 301 ). The selected phase/bin 211 may be sent to a comparing unit 213 that may be configured to generate a local reference signal having the same phase as the phase associated with the selected bin ( 303 ). The comparing unit 213 may also compare the generated local signal to the measured received signal ( 305 ) in order to determine if a match exists ( 307 ). The comparing unit 213 may send the results of the comparison 217 to a reporting unit 219 . If a positive match is detected, the reporting unit 219 may send a positive match signal 221 , to the receiver instructing the searching apparatus to end the signal acquisition stage ( 309 ). If a negative match is detected, the reporting unit 219 may send a negative match signal 223 to an assigning unit 225 . The assigning unit 225 may assign a weight, or update a current weight 227 , to all, or a subset of, the bins of the vector ( 311 ). Upon assigning or updating the weights of the bins, the assigning unit 225 may send the updated weightings 227 to the selecting unit 209 . It should be appreciated that in place of, or in addition to, the assigning unit, an assessment unit may be used. The assessment unit may determine environment of channel conditions, which may be sent to the selecting unit. The selecting unit 209 may then select a new bin for comparison based on the updated weightings or channel conditions ( 313 ). It should be appreciated that the assigning unit 225 may also update or assign probability values to the bins if a negative match is reported by the reporting unit 219 . The assessment unit may be configured to continuously, or continually, monitor the channel conditions during each selecting cycle or during a pre-determined time period.
A number of methods may be employed in selecting, by the selecting unit 209 , the next phase/bin for comparison, according to example embodiments of the present invention. One such method may include bin selection based on probabilities. Initially, the vector of bins may have a uniform probability distribution, indicating that each bin in the vector of bins is equally likely to have a phase that is correctly matched to the phase of the receiving signal. Thus, each bin in the vector may have an equal weighting. The assigning unit 225 may continuously, or continually, update a probability distribution of the vector of bins, based on a posteriori probability. Updating the probability distribution may be done by assigning the bins updated weightings or probabilities. In subsequent comparisons, the selecting unit 209 may select the phase/bin that has the highest weighting or the phase/bin associated with the highest posteriori probability value.
FIG. 2C provides an illustrative example of a selection for a subsequent comparison. Each bin in the bin vector 235 may be evaluated with regard to its corresponding probability/weightings 237 . A bin 239 corresponding to the highest probability/weighting 241 may thereafter be selected.
FIG. 2D illustrates a second method of selection, according to an embodiment of the present invention, may include a random selection of a next phase/bin with memory. As shown in FIG. 2D , in a bin vector 243 , a first bin 247 may be selected randomly. Subsequently a second and third bin 251 and 249 , respectively, may be chosen. A memory unit 245 may be used to record the bins that have been selected. Thus, after it has been determined that a specific bin does not provide a matching local reference signal, that bin may be excluded from subsequent bin selections. Therefore, a phase/bin may be randomly selected, but once a phase/bin has been selected and tested, the searching apparatus may take note that the phase/bin has been selected and therefore not select the same phase/bin twice in subsequent comparisons.
It should also be appreciated that the selecting unit 209 may include a random number generator 253 that may be configured to select a bin number 255 randomly. The selected number may be mapped to the number of possible phase selections. For example, if a random number generator, implemented, for example, using software, generates a random number in the number range 1 . . . M, inclusively, and there are ‘n’ phases, each of the ‘n’ phases may be associated with a portion of the M numbers. Assuming M is equally divisible by ‘n’ in this example, the portion associated with each of the ‘n’ phases may include a contiguous range of ‘M/n’ numbers so that the first phase may be selected if the random number is in the range 1 . . . M/n, the second phase may be selected if the random number is in the range M/n+1 . . . 2*M/n, and so on.
FIG. 2E illustrates another method for searching, according to an embodiment of the present invention, which may include cluster searching. As shown in FIG. 2E , in cluster searching a group of adjacent phases/bins 259 , included in the bin vector 257 , may be selected by the selecting unit 209 at the same time. The comparison unit 213 may be configured to process or compare the received measured signal to each of the cluster bins in a parallel fashion. It should be appreciated that each phase/bin in the selected cluster may also be compared in a serially or random fashion. Subsequent clusters, such as cluster 261 , may be selected with or without memory of previously selected clusters. In example embodiments, the memory aided selection may be performed with a memory unit 263 . A random number generator 265 may also be employed to provide a cluster number 267 in the random selection of subsequent clusters.
FIG. 2F illustrates that the clusters may also be chosen based on a probability or weighting. As shown in FIG. 2F , each cluster in the bin vector 269 may be evaluated with regards to its corresponding probability/weightings 271 . A cluster 273 corresponding to the highest probability/weighting 275 may thereafter be selected. It should also be appreciated that the size of the cluster may be dynamic and may depend on environment and/or channel conditions. It should also be appreciated that not all the clusters included in the bin vector need be the same size.
FIG. 2G illustrates yet another method of selecting a next phase/bin which may include fixed serial searching (FSS). In fixed serial search, the phases/bins may generally be selected in order. As shown in FIG. 2G , a first bin 279 included in bin vector 277 may be chosen. The subsequent bin chosen 281 may be the immediately next bin, in terms of phase. Following the same logic, a third bin 283 and so on may be chosen until a match is obtained. It should be appreciated that in example embodiments, portions of the vector may employ a FSS method of selection based on environment or channel conditions.
It should be appreciated that in an embodiment of the present invention, any of the above mentioned searching methods may be used in combination. For example, the cluster searching method may be performed randomly with or without memory. The cluster searching method may also be performed in conjunction with the probability method, where a probability distribution, or weighting, of each cluster may be updated as a function of previously compared clusters.
It should also be appreciated that any method of phase/bin selection may be chosen based on characteristics of the transmission medium or channel condition. In the example of wireless communications, the transmission medium may be air. The channel condition may be determined by analyzing the received measured signal for characteristics, such as, but not limited to, signal strength and signal-to-noise ratio (SNR). Characteristics of the transmission medium may be determined by analyzing the environment of the transmission medium. The method of selecting a next bin may also change during the signal acquisition stage. For example, if the measured signal is characterized as having a low SNR, a method of random bin selection with memory may be employed. If during the signal acquisition stage the measured signals are characterized as having a high or medium SNR, a method of cluster without memory or with memory may be employed.
The methods of bin selection discussed above may reduce the mean acquisition time (MAT). In an embodiment of the present invention, employing a quick test on the selected bin may also aid in the reduction of the MAT.
FIG. 4A illustrates a comparing unit 213 featuring a quick test component 401 and a verification component 403 . In operation, according to example embodiments, a signal 201 received via an antenna 203 may be directed to the comparing unit 213 . The selected phase/bin 405 may be used to generate a local reference signal 402 having a phase corresponding the to the selected phase/bin. The quick test component 401 may perform an initial determination or test as to whether the received signal 201 matches the local reference signal 402 having a phase corresponding to the selected phase/bin 405 . The quick test 401 may act as a preliminary comparison, where only a portion of the received signal 201 and local reference signal 402 are compared.
Upon performing the preliminary comparison, the quick test component 401 may send a signal 409 to the reporting unit 219 if a negative match is determined to exist between the received signal 201 and the local reference signal 402 . Thereafter, the selecting unit 209 may proceed with selecting a new phase/bin.
The quick test component 401 may also send a signal 407 to the verification component 403 indicating that a positive match between the received signal 201 and the local reference signal 402 has been obtained. Thereafter, the verification component 403 may perform verification processing on the received signal 210 and the local reference signal 402 in order to verify that the two signals do indeed match. Thus, the verification component 403 may perform a more in-depth comparison (e.g., a comparison involving a slower integration) than the preliminary comparison performed by the quick test component 401 (e.g., a comparison involving a faster integration). Upon the comparison, the verification component 403 may send a signal 411 to the reporting unit 219 indicating whether or not a match between the received signal 201 and the local reference signal 402 has been found.
It should also be appreciated that the comparing unit 213 may also be employed in document searches, where the received signal may be electronic data (e.g., a webpage or text document) or a document included, for example, in a database. Therefore, the quick test component 401 may be configured to evaluate only a portion of the electronic data or document in order to determine if the received electronic data or document matches a selected phrase or document 405 for which a user or system intends to search. Similar to the example using received wireless signals, if the quick test component 401 detects a positive match, the verification component may be employed to compare the received electronic data 201 with the selected phrase or document 405 .
FIG. 4B shows a schematic of elements that may be included in a quick test component 401 , according to example embodiments of the present invention. The quick test component 401 may include a number of quick test sub-components, for example, sub-components Q T1 , Q T2 , . . . and Q TN , 413 , 415 , and 417 , respectively. It should be appreciated that although FIG. 4B only illustrates three quick test sub-components, any number of sub-components may be employed 429 . Each of the quick test sub-components may perform a different quick test. For example, each quick test sub-component may compare different portions of the received signal 201 and the local reference signal 402 . Each quick test sub-component may also employ a different method of comparing the measured signal 201 and the local reference signal 402 . In addition, the quick test sub-component 413 may compare the received signal 201 and the local reference signal 402 over a small portion, while subsequent quick test sub-components 415 . . . 417 may compare the received signal 201 and the local reference signal 402 over larger portions. Furthermore, quick test sub-component 413 may make the decision based on a single comparison of the received signal 201 and the local reference signal 402 over the fixed portion, while subsequent quick test sub-components 415 . . . 417 may make the decision based on several comparisons of the received signal 201 and the local reference signal 402 over the disjoint portions.
If any of the three quick test sub-components 413 , 415 , or 417 detect that a match does not exist between the measured signal 201 and the local reference signal 402 , signals 421 , 425 , and 427 , respectively, may be sent to a sub-component processor 427 . In example embodiments of the present invention, the sub-component processor may include an OR gate, where if a signal from any of the sub-components 413 , 415 , or 417 indicates a negative match, the sub-component processor may be configured to send a matching phase signal 409 indicating the negative match result to the reporting unit 219 .
In the case that any of the quick test sub-components 413 , 415 , or 417 detect a positive match between the measured signal 201 and the local reference signal 402 , the sub-components may send signals 419 , 423 , and 407 , respectively, indicating a positive match has been detected. In example embodiments, the sub-components 413 , 415 , or 417 may compare the measured signal 201 and the local reference signal 402 sequentially or in parallel. Once the sub-component processor 431 has determined that all the quick test sub-components have registered a positive match, the quick test component 401 may be configured to send a matching phase signal 407 indicting the positive match to the verification component 403 .
In example embodiments of the present invention, the various quick test sub-components may be ordered from least to most costly, determined in accordance with one or more criteria for the particular application. The quick test sub-components may also be utilized in order from least to most expensive (e.g., in terms of processing costs) so that the most expensive or costly quick test sub-component is utilized only after one or more lesser costly sub-components have determined the selected phase/bin provides a generated local reference signal 402 matching the received signal 201 . It should be appreciated that any other ordering of sub-components may be employed.
It should also be appreciated that the quick test component 401 may also be employed in document searches, where the received signal may be electronic data (e.g., a webpage or text document) or a document included, for example, in a database. Therefore, the various quick test sub-components 413 , 415 , 417 , and 429 may be configured to evaluate portions of the electronic data or document in order to determine if the received electronic data or document matches a selected phrase or document 405 for which a user or system intends to search. Similarly to the example using received wireless signals, if all of the sub-components detect a positive match, the verification component may be employed to compare the received electronic data 201 with the selected phrase or document 405 .
It should further be appreciated that each quick test sub-component may have an associated degree of certainty. The more costly the quick test evaluation (e.g., the more number of quick test sub-components included in the searching apparatus), the higher the degree of certainty that may be associated with a negative match decision. In other words, there may be a higher confidence that the resulting match decision or determination has made by the particular quick test sub-component is correct as the design cost of the searching apparatus increases.
As such, the probability of a selected phase (S) which has just caused a quick test sub-component (Q Tx ) to yield a negative match result may have its associated probability adjusted in accordance with a degree of certainty (DC) associated with the quick test sub-component Q Tx . The DC for each Q Tx may describe a degree of confidence or reliability of the test, and may also be manually or otherwise assigned or may be empirically determined based on the knowledge of the designer. Other example embodiments may initially select DCs using other manual and/or automated techniques.
In example embodiments of the present invention, at initialization, all phases/bins may have an equal probability of being the correct phase/bin. On subsequent iterations selecting a phase/bin, a selected phase S determined not to be a match by a Q Tx component having an associated degree of certainty DC x may cause an adjustment of the probability associated with the selected phase/bin S x , and an adjustment of probability associated with each other phase/bin in the vector ‘s,’ where ‘s’ does not equal ‘S.’
FIG. 4C is a listing of example pseudo code of software instructions for the probability/weighting assigning/updating process for the above mentioned example when a previously selected phase/bin has been determined to not be equivalent to the phase associated with the received signal. Pnew(S) may be defined as the new probability of the selected phase S after adjustment, and Pnew(s) may be defined as the new probability of each remaining phase s, other than the selected phase S. The DC value may be a real numbered value in the range of 0 . . . 1, inclusively, with a higher DC value representing a greater degree of certainty. In [line 1] of the code, the value of the probability of a previously selected phase S and associated DC x is evaluated. If the evaluated value DC x has a value less than one, the previous quick test may not be 100% reliable, therefore the probability of the previously selected phase is updated according to the equation described in [line 2] of the code. The probability of all the other phases/bins may be updated according to the equation described in [line 3] of the code.
In the case that the probability of the previously selected phase/bin S and the associated degree of certainty DC x both have a value of one, the previous quick test may be deemed as reliable, and therefore the probability associated with the previously selected phase/bin may be set to zero as described in [line 6] of the code. The probability of all the other phases/bins may be updated according to the equation described in [line 7]. It should be appreciated that the code of FIG. 4C is merely an example and that any other form of instructions may be employed.
FIG. 5 illustrates another example configuration of the comparing unit 213 according to example embodiments of the present invention. In the comparing unit 213 of FIG. 5 , a threshold-based quick test component 502 may be employed to perform a comparison of a portion of the received signal 201 with a portion of the local reference signal 402 . In a threshold-based test, a portion of the received signal 201 and a portion of the local reference signal 402 may be correlated with one another. If the threshold-based quick test component 502 determines a match, the component may send a signal 514 to a phase locked loop (PLL) component 504 indicating a positive match has been found. The PLL component 504 may perform verification processing in order to examine the additional portions of the received signal 201 .
In the case that the threshold-based quick test component 502 and/or the PLL component 504 detects a negative match between the received signal 201 and the local reference signal 402 , the components may send signals 510 and 513 , respectively, to a comparison processor 531 . Similar, to the sub-component processor 431 of FIG. 4B , the comparison processor 531 may be configured to send a signal 409 to the reporting unit 403 indicating a negative match result has been obtained. In example embodiments of the present invention, the comparison processor 531 may include an OR gate configured to send the signal 409 indicating the negative match result if either one of the signals 510 or 513 , from components 502 and 504 , respectively, indicates a negative match. It should be appreciated that any form of quick test known in the art may be employed. For example, a bit-wise quick test may be employed with binary forms of the received signal 201 and the local reference signal 402 may be digitally compared.
It should also be appreciated that the comparing unit 213 of FIG. 5 may also be employed in document searches, where the received signal may be electronic data (e.g., a webpage or text document) or a document included, for example, in a database. Therefore, the threshold-based test component 502 may be configured to evaluate only a portion of the electronic data or document in order to determine if the received electronic data or document matches a selected phrase or document 405 for which a user or system intends to search. Similarly to the example using received wireless signals, if the threshold-based test component 502 detects a positive match, the PLL component may be employed to compare the received electronic data 201 with the selected phrase or document 405 .
It should be appreciated that in example embodiments of the present invention, the comparison unit may employ N c correlators to combine signals and may have two modes of operation, search and verification. In the search mode, a portion of the received signal may be correlated with the local reference signal using a bank of correlators. In the verification mode, a number of independent tests, which may be similar to that of the search mode, may be performed.
It should be appreciated that the comparison units described above may also be configured to perform processing which may take into account the presence of transmission errors included in the received signal. For example, the received signal may have been affected by noise or attenuation, therefore, the received signal may include erroneous bit values. The comparison units may perform processing which allows or accepts some degree of noise or attention to be present in the received signal, and may therefore determine a match between the selected phase or bin of the received signal in the presence of errors.
It should also be appreciated that the above embodiments may also be employed in other search applications including, but not limited to, drilling for a desired element such as oil, database queries, and searching for objects, such as celestial stars, underwater artifacts, or persons in connection with a wreckage at sea. It should also be appreciated that the techniques presented may also be used in connection with a variety of different search spaces in which there may be one or more correct matches or targets. For example, in connection with the wireless communications example of signal acquisition, there may be a single correct or matching phase for additive white Gaussian noise channels, and multiple correct or matching phases/bins for multi-path channels.
In example embodiments where a selection of oil drilling locations may be made, there may be more than one matching target. Each potential candidate location may be associated with a ‘phase’ or possible selection number. One or more quick tests may be used, for example, which are based on soil samples, seismic analysis, profiles of the layers underlying the surface based on any one of a variety of different techniques described herein, and the like. Rather than use a PLL technique for verification processing, verification may be performed by actually drilling for oil. Such processing may take place after one or more quick tests have determined that the selected location has oil located therein.
In connection with astronomy, a search may be performed looking for a particular star or other element having specified properties. There may be one or more elements which match the specified properties. For example, when looking for a particular type of star. A panoramic view of the sky or portion thereof may be partitioned into grid sections, each grid being assigned a coordinate. Therefore, there may be more than one in a grid section of the sky. On the other hand, the search criteria may specify a particular element for which there can be only one possible match, such as a known named planet. In example embodiments involving astronomy, quick tests may be performed, for example, using a low resolution telescope to determine if there are existing conditions associated with any celestial bodies matching those of a particular type of star. If so, that particular grid section may then be examined with a high resolution telescope as part of verification processing.
Example embodiments may also be used in connection with rescue operations and retrieval of an object. For example, when searching for an object under water or survivors in a wreckage at sea, a portion of the body of water or other area defining the search region may be partitioned into grid sections. Each of the grid sections may correspond to phase/bin, where the goal is to find a grid section where the object or person is located. A first quick test may be, for example, executing a low resolution SONAR on the area. A second quick test may include deploying an underwater camera. The verification mode may include sending a diver to a particular area corresponding to a grid section.
In applications directed to database or archival inquiry, example embodiments of the present invention may be used to search for documents that satisfy some specified criteria. Examples of specified criteria may be, for example, documents including one or more words in a search query. The documents may be included in one or more data stores or the same or different types. In some data stores including the documents to be searched, there may be no indexing of words included in the documents, and all such documents in the data stores may be searched. In one example application, the embodiments of the present invention discussed herein may be used to locate the first one of more matches, for example to display a result such as in connection with an Internet search. Each file in the one or more data stores may correspond to a phase/bin. A first quick test may be to read a portion of a file and decide based on a heuristic method whether the document is likely to be a match. For example, a document that is determined to be related to a painting or art based on examination of the portion of the document may include the search term of an artist such as ‘Van Gogh.’ A second quick test may be to read a second portion of the file and make a determination in accordance with the heuristic method. Verification may be accomplished by reading the entire file and determining if there is a match to the search term included therein.
It should also be appreciated that the example embodiments of the present invention described herein may be used in connection with criteria that vary in accordance with knowledge of a target. In other words, the example embodiments may be configured for use in connection with a variety of applications and may not require a specified amount of knowledge about the target for use.
As will be appreciated by those skilled in the art, the components and units herein may be implemented in a variety of different ways using a variety of different hardware and/or software components or units. The components and units may be implemented using hardware and/or software.
Components and units implemented using software may be, for example, source code written in a programming language which may be processed by one or more subsequent software components or units to produce machine executable code for execution on a processor such as any computer system known in the art. If implemented in software, in operation, a general purpose or application specific processor loads and executes the software or a derivative thereof (e.g., machine code) in a manner well understood in the art. The software may be stored on any form of computer readable medium, such as random access memory (RAM), read only memory (ROM), compact disk read only memory (CD-ROM), and so forth. The examples provided herein are for the purposes of illustration and should not be construed as a limitation of the techniques herein.
While this invention has been particularly shown and described with references to example embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims. | A method and corresponding apparatus for searching for a signal is presented. The apparatus may be configured to select a first bin within a range of bins characterizing an uncertainty region. The bins may represent a phase within a bandwidth of interest. The apparatus may also be configured to compare a local signal, having a phase corresponding to the first bin, with a received signal, the received signal being received via a transmission medium. The apparatus may report whether the local signal matches the received signal. The apparatus may assign weightings to the bins if the local signal does not match the received signal. If a match is not found, the apparatus may select a next bin according to the weightings or according to characteristic of the transmission medium until a matching bin is obtained. One benefit of the search is reduced search time to allow, for example, a cell phone to synchronize the phase of a received signal more quickly than is currently done. | 7 |
DEDICATORY CLAUSE
The invention described herein may be manufactured, used, and licensed by or for the Government for governmental purposes without payment to me of any royalties thereon.
BACKGROUND OF THE INVENTION
Trainers of the general type with which the invention is concerned are the type which use interconnecting wires and discrete components. Examples of this type are those made by ADD Corporation, Digiac, Inc. of New York, and Health Corporation of Benton Harbor, Michigan. A wireless type of trainer presently on the market is the Broder Logic Trainer. Although the Broder Unit is wireless, this present invention is dissimilar. The Broder unit uses a programable logic array, is not programable by the user, does not use edge encoded cards, and can not change computer function upon card insertion.
SUMMARY OF THE INVENTION
The present invention relates to vocational training in the field of computers and logic. The device imitates any logic device and any logic family presently used in computers, as well as many other electronic citcuits. Expansion capabilities are virtually limitless. Simulation of a central processing unit can demonstrate computer actions. In an effort to minimize required training time, the wireless approach; i.e., inserting a program lesson card, greatly reduces the time necessary to set up the circuit. Since the present invention is software controlled in a committted application, very little effort by the student is required to begin the training sequence. The inclusion of a software test probe and test points can be used to simulate any logic family (TTL, DTL, RTL, etc.) characteristics, including malfunctions such as undefined open wire levels. The test probe data can also be used to determine which graphic display may be output to a CRT when teaching analog type circuits.
In direct contrast to the Broder unit, the present invention is capable of simulating any single logic device and allow signal tracing through complex circuits by use of test points in the program lesson card. Timed or clocked circuits are simulated with a selection of fast, slow, or single step clock action. In simulating clocked circuits, ring counters, BCD counters, serial adders, multipliers, and dividers may be taught. By use of software expansion, any complex computer circuit may be simulated as well as many analog circuits such as amplifiers, power supplies and oscillators if a graphic display is added to the trainer.
Under software guidance, the various logic circuits and the complex circuitry involved in a computer as well as most analog circuits are presented to the student. Each program lesson card, by use of its encoded edge, establishes which section of preprogramed memory is used to simulate the subject displayed on the card. Lamp displays give the result of student actions using data switches, step switches, or an automatic clock. The test probe can indicate logic states or determine analog graphics displays for electronic circuits if a graphics unit is added to the trainer.
To use, a student turns on the trainer, inserts a program lesson card, on which a schematic or circuit diagram is displayed, presses reset, and then maneuvers switches. A lamp display shows the result of switch movement, according to the placement of data switches, as established by the program lesson card. A logic test probe is utilized to reinforce signal tracing skills by use of: simulation, a seven segment readout, and test points (holes) in the program lesson card. Using a graphics display, analog circuits can be simulated by showing analog signals corresponding to the point of contact on the test plane.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic drawing of a preferred embodiment of the wireless training device.
FIG. 2 is a drawing of an example training card.
FIG. 3 is a block diagram of a preferred embodiment of the wireless training device.
FIG. 4 is a schematic diagram of a preferred method of creating input/output strobes for obtaining and dispensing data to the slope panel display.
FIG. 5 is a timing diagram illustrating the necessary signals to input and output data to the computer.
FIG. 6 is a block diagram of the card edge identifying input circuit.
FIG. 7 is a block diagram of the data switch and clock switch input circuit.
FIG. 8 is a block diagram and drawing of the test plane and the test plane input circuit.
FIG. 9 is block diagram of the seven segment logic probe output display circuit.
FIG. 10 is a block diagram of the indicator lamp output circuit.
FIG. 11 is a drawing illustrating the slope panel display with a logic AND gate training card thereon.
FIG. 12 is a flow chart illustrating the simulation of a logic AND gate with test points.
FIG. 13 is a flow chart illustrating subroutines used by the AND gate simulation program.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1 the wireless trainer is built having a slope panel which serves as a test panel board 1. A portion of the panel contains metal strips or fingers 16 over which a program lesson card is inserted during operation. These metal strips are utilized by grounding a strip with a logic probe lead 2. When a strip is grounded, the resultant byte of information is transferred to a computer where the value is determined and the seven segment display 3 is manipulated or selectively activated to show proper output according to the program for the lesson card inserted.
A lamp display 4 across the top of the panel operates as a memory location. Data stored in the lamp display location is the result of program action dependent on input variables. Data switches 5 are used to manually change the contents of a memory location. This input memory location when read, establishes specific program action to take place, thus affecting the output lamp display 3.
A clock speed selector switch 6 determines whether clocking inputs are fast, slow, or stepped by a step switch 7. The clock speed switch is a simulated function and has no bearing on the operation of the computer clock. The trainer is automatically reset by the initial application of power or by depressing a reset switch 8.
FIG. 2 discloses a typical program lesson card 9 which is edge encoded 10 to establish an area in memory to be used as a starting address for the circuit shown on the card. The edge encoded data actually occupies addressable memory locations in the computer used as a branch command operand, thus establishing a starting address for a specific program application.
The card edge 10 is encoded with hole/no hole patterns for photo-cell detection of light passing therethrough. The data derived from these patterns is used by the computer to identify a software program which will simulate the particular circuit drawn on the card 9.
The drawing on the training card has specifically designated holes 42, 44, and 46 through which test probe 2 can contact the metal fingers 16 of the test plane board 1. The test plane is thus programed for use by software and the physical location of the test point holes on the training card 9. Any digital circuit and most analog circuits can thus be taught using particular schematic, wiring diagram, block diagram or other similar circuits placed on training cards 9 and writing software programs to achieve proper output functions for the circuit presently pictured.
FIG. 3 is a block diagram of a preferred embodiment of the electronic circuit of the present invention. The controlling programs are stored in the digital computer 11. Computer 11 coordinates output indications by lighting lamps in the logic level display 4, lighting segments of the test probe display 3, or outputting waveforms as graphics for analog simulations to a graphic display 14. Inputs to digital computer 11 come from photo electric identification of edge encoded 10 data, mechanical data from switches 5 and clock status switch 6, and from the test plane fingers or strips 16. The input and output data from the computer is placed on the appropriate data bus by the addressable strobe unit 17, shown in further detail in FIG. 4.
FIG. 4 is a schematic diagram which illustrates a preferred method of obtaining addressable strobes from the digital computer 11. An address decoder 18 of strobe unit 17 will only produce an active (high) output when that output is addressed. The output of gate G1 becomes active when the write signal from the digital computer 11 and the computer system clock are both active. The output pulse from gate G1 is applied to gates G2, G3, and G4. When enabled by the address decoder 18 and the pulse from gate G1 is applied, gate G2 outputs a pulse which will strobe the display 4A output device. The display 4A strobe is therefore a result of a selected address, computer write, and clock pulse, all active conditions existing in the trainer.
In a similar manner gate G3 outputs a pulse to strobe display 4B when selected by the address decoder 18 and enabled by gate G1. Gate G4 operates similarly by producing a strobe pulse for the seven segment probe display 3 when selected by the address decoder 18 and enabled by the pulse from gate G1.
Input strobes are also used to place input data on the data bus to be read by the computer 11. AND gate G5 has a constant or fixed input voltage V supplied to one input thereof. Gate G5 produces an active output only when an active read signal is applied from the computer 11 to the other input. The output of gate G5 is applied to gates G6, G7, G8, G9, G10, and G11.
Gate G6 will produce an active strobe, placing the data from the mechanical data switches 5 onto the data bus to be read by the computer 11, only when selected by the address decoder 18 and if the output of gate G5 is active.
When selected by the address decoder 18 gate G7, upon receiving an active input from gate G5, will issue an active strobe placing the clock switch 6 status data to be placed on the data bus and read by the computer 11.
Gates G8 and G9 work in a similar manner to gates G6 and G7. Gate G8 will enable the data from the test plane 16C to be read by the computer when selected by the address decoder 18 and the read signal from gate G5. Gate G9, when selected by the address decoder 18 and upon receipt of an active input from gate G5, will place data from test plane 16D on the data bus to be read by the computer 11.
The edge encoded data 10 on training card 9 is strobed onto the data bus by gates G10 and G11. An IDA strobe is the first byte of information from a card identifier circuit, and an IDB strobe is the second byte of information from a card identifier circuit. When enabled by the address decoder 18 and upon receipt of an active input from gate G5, gate G10 will issue the IDA strobe thus allowing the data read from the training card encoded edge 10 to go to the computer 11. When selected by a different address, gate G11 will issue the IDB strobe upon receipt of an active input from gate G5. The IDB strobe will allow further information from the encoded edge 10 of the training card 9 to pass to computer 11.
FIG. 5 illustrates the timing chain developed by the addressable strobe unit in FIG. 4. FIG. 5A illustrates the system clock pulse 19 and the valid or stable address bus lines 20 which are common for development of both the output strobes and input strobes.
FIG. 5B in conjunction with FIG. 5A illustrates how the write signal 21 from the computer 11 relates to the system clock 19 and address bus valid signals 20. The data bus 22 is in an output condition, meaning data from the computer 11 is on the data bus. The output strobe 23 is the result of an AND operation of the write signal 21, the system clock signal 19, and the selected address from the valid address bus 20. The output strobe 23 occurs at a time when the data output from the computer 11 is available and settled on the data bus 22. The output strobe 23, which would appear as display strobes 4A, 4B, or probe display, can therefore be used to trigger a latch circuit thus capturing the output data.
FIG. 5C in conjunction with FIG. 5A illustrates how the strobes used for data input is derived. The address bus 20 must be in its valid address condition. The data bus 24 is made active by the read signal 25 enabling the computer 11 to take in data on the bus. The input strobe 26 is used to place the addressed data onto the bus to be sampled or read by the computer 11. The input strobe signal 26 is the result of an ANDing operation which ANDs the selected address 20 and the read signal 25. Data buses 22 and 24 may be separate or may be combined into one bi-directional bus, depending on the computer used.
FIG. 6 is a block diagram of the card edge identifier circuit to digital computer 11 interface. When, due to the operating program, the digital computer 11 places a selected address on the address bus lines, the addressable strobe unit 17 will create a logic level which activates the IDA strobe line. The IDA strobe takes the tri-state driver 27 out of its open circuit output condition and allows the data from the card edge identifier circuit A 28 to pass through and be present on the data bus, ready for input to the digital computer 11. The tri-state driver is a circuit which is capable of passing signals when enabled and exhibiting a high impedance (open) output characteristic when not enabled.
In a similar manner, a different address when received by the addressable strobe unit 17 will cause the IDB strobe to be issued. This IDB strobe takes the tri-state driver 29 out of its open circuit output condition and allows data from the card edge identifier circuit B 30 to be input to the computer 11.
The card edge identifier circuits 28 and 30 (standard transmit/receive photocell modules) are photo sensor arrays which read the data on the card edge 10 in the form of holes and no holes much like a Hollerith code. The information found on the encoded card edge 10 is used to establish the starting address of the software program for that particular training card 9. Although photo sensors are used to obtain the edge encoded data 10, it can also be done using mechanical switches and notches or magnetic strip readers such as found on small calculators.
FIG. 7 is a block diagram illustrating the data switch 5 input and clock speed status 6 switch inputs. When the digital computer 11 addresses the selected address, the addressable strobe unit 17 will activate the clock status strobe line. The active clock status strobe from G7 (FIG. 4) will take the tri-state driver 31 out of its open circuit condition thus placing the data from the clock speed and clock step switches 6 on the data bus to be read by the computer 11. In the software treatment of this data, the condition of the clock step switch is only considered when the clock speed switch is in the step position. In the step position the programer may incorporate programing which would look at the status of the pushbutton switch 7. In this manner, the trainer can discern whether or not a student is pressing the step (push button) switch expecting to see a change in output. The inputs to the tri-state driver 31 must be pulled up, insuring a known voltage level on a point that would otherwise be floating, such that an open switch line is at a logic high level. A logic low is established when a switch is closed thus making connection to ground.
In a similar manner, when properly addressed by the computer 11, the addressable strobe unit 17 will establish an active data switch strobe. The data switch strobe from G6 takes the tri-state driver 32 out of its open circuit condition thus allowing the data from the data switches to be input to the digital computer 11. Pull up resistors on the inputs of the tri-state driver 32 will ensure the presence of the proper logic levels to indicate which switch is closed or open.
FIG. 8 is a combination drawing of the printed circuit test plane and input circuit. Metal fingers 16 of the test plane are connected through tri-state drivers to the computer. When properly addressed by digital computer 11, the addressable strobe unit 17 will produce a test plane C strobe. The test plane C strobe from G8 takes tri-state driver 33 out of its open circuit condition allowing data from part of the metal fingers 16 to be input to the digital computer.
In a like manner, when the computer properly addresses the addressable strobe unit 17, a test plane D strobe is activated. The test plane D strobe from gate G9 takes the tri-state driver 34 out of its open circuit condition to allow data from the next set of metal fingers to be input to the computer. Typically, sixteen metal fingers are shown with 8 fingers being accessed through each driver. Additional addressable strobes, drivers, and fingers can be incorporated in a like manner for as many test strips 16 as desired. The input from each finger 16 to the respective tri-state driver 33 or 34 is pulled up through resistors. All inputs to the drivers are at the power supply level if the test probe 2 is not touching any metal fingers 16. When touching a strip 16 with the test probe 2, only that input line will become a ground potential line while the probe is contacting the finger. The software in the computer 11 can thus identify when and where a point is tested.
FIG. 9 is a block diagram which illustrates how data is sent to the seven segment probe display 3. When properly addressed by the computer 11, the addressable strobe unit 17 issues a probe display strobe. The probe display strobe from gate G4 causes the data on the data bus to be caught and held by latch 35. The output of latch 35 will determine which segments of the probe display 3 will be illuminated. Individually operated flip-flops provide the latching action for each segment of the display.
The segments annunciate or indicate "O" for open, "L" for low, "H" for high, and "P" for pulse. A flashing decimal point can be used to indicate that no training card is inserted. All of these functions are controlled by the software program in the digital computer 11.
FIG. 10 is a block diagram which illustrates how data is output to the indicator lamps 4 from the computer 11. When properly addressed by the computer 11, the addressable strobe unit 17 will issue a display A strobe. The display A strobe from gate G2 toggles latch 36 thus capturing and storing the data from the computer 11 in the latch. The output of latch 36 determines which of indicator lamps 4A are lit or unlit.
In a like manner, the computer 11 may also address the display B strobe through the addressable strobe unit 17. The display B strobe from G3 toggles latch 37 thus capturing the data on the data bus and storing it. The output of latch 37 determines which indicator lamps 4B are lit and unlit. As many indicator lamps as desired may be added using a similar arrangement of addressable strobes and latches.
FIG. 11 is a drawing of the slope display panel with an example training card 9 inserted. The encoded card edge 10 (not shown) establishes which program the computer 11 will run when the reset 8 button is pressed. The training card 9 has an AND gate 40 drawn on it. The inputs to the AND gate are drawn so they will align with particular switches 52 and 54 of data switches 5 selected by the programmer. Test point 42 and test point 44 are punched holes in the card which allow access to programmer selected test plane fingers 16 by test probe 2. The output line from the AND gate is drawn to align with a selected lamp 48 of indicator lamps 4. Test point 46 is a hole punched through training card 9 which allows a selected test plane finger 16 to be accessed by the test probe 2. The test point holes coincide with a portion of the drawing representative of a circuit element that would contain or have a signal passing therethrough. Thus test points 42, 44, and 46 represent respective AND gate inputs and output leads.
In operation, the logic probe display 3 indicates a "O" (for open) condition when test probe 2 is not touching a selected test plane finger 16. If both AND gate input switches 5 are in their low position, the indicator lamp 48 remains unlit. Touching test probe 2 to test point 42, 44, or 46 results in the logic probe display 3 indicating an "L" (for low). Moving the data switch 52 associated with test point 42 to the high position will not cause any change in the status of the unlit selected indicator lamp 48. Touching test probe 2 to test point 42 will now indicate an "H" (for high) on the probe display 3. Test points 44 and 46 will indicate an "L" when tested.
If both data switches 52 and 54 are in their high positions, the selected indicator lamp 48 will light showing a high output from the drawn AND gate. Furthermore, logic probe display 3 will indicate an "H" when test points 42, 44, and 46 are tested with test probe 2.
Although not used in this example, clock speed switch 6 and the clock step switch 7 are utilized in much the same way as the data switches 5. For circuits using a clock, a drawn line (shown dashed in) to point 50 would lead a student to this switch, the line indicating that the switch position affects the circuit operation. The programmer can make whatever use of this switch he desires to simulate conditions on the drawn circuit being taught. For example, the programmer can simulate a triggered flip-flop circuit utilizing switches 6 and 7 in such a manner that the student can see automatic fast and slow operation or put it in the step position and trigger the circuit at his own speed manually. An on/off switch 58 is used to turn the trainer power on and off.
FIG. 12 is an example flow chart for the simulation of the AND training card 9 in FIG. 11. The start 60 of the program performs any necessary housekeeping steps such as zeroing data locations, and specifying key values. This occurs anytime reset switch 8 or power switch 58 is operated. The address of the desired program 62 must be established by reading the training card edge encoded 10 area. When the program address is established, the program then proceeds through connector 164 to a subroutine 66 which inputs the data from the data switches 5 into the computer 11.
After the read data switch subroutine 66, the program goes to a subroutine 68 which reads the data from the test plane fingers 16. From the input data a decision 70 must be made as to whether or not test point 42 was touched. If test point 42 was not touched, a decision 72 must be made as to whether or not test point 44 was touched. If test point 44 was not touched, a decision 74 must be made as to whether or not test point 46 was touched. If test point 46 was not touched, then the seven segment display 3 must display 76 an "O" (for open). The program then proceeds through connector 2 78 to a decision 80 which determines whether or not all the input data switches 5 are in a high position. If all selected input data switches are not in their high positions, the program goes through connector 3 81 and displays 82 the selected logic level indicator lamp 4 in an unlit condition. The program then repeats itself by going to connector 1 64 and continuing. If at decision 80 all selected input switches had been in their high position, then the program goes through connector 4 88 and displays 90 the selected indicator lamp 4 in a lit condition. Now the program repeats itself by going to connector 64 and continuing.
If test point 42 had been touched at decision 70, the program would have gone through connector 5 84 to a decision 85 concerning the status of the data switch 52 associated with test point 42. If the data switch 52 was not in its high position, the program would go through connector 6 86 and display 87 an "L" (for low) on the seven segment logic probe display 3. The program then proceeds to connector 2 78 and the decision 80 concerning the status of the selected data switches 5. Since switch 52 was not in its high position, the program goes through connector 3 81 and displays 82 the selected indicator lamp 4 in an unlit condition. The program then repeats itself by going to connector 1 64 and continuing. If the selected data switch 52 had been in its high position the program would have gone from decision 85 through connector 7 98 and display 99 an "H" on logic display 3. The program would then go to connector 2 78 and decision 80 concerning the status of all data switches as has been previously noted. The program would then repeat itself by going to connector 1 64 and continuing.
If test point 42 had not been touched but point 44 had been touched at decision 72, the program would have gone through connector 8 92 to decision 93. The decision 93 checks the status of the data switch 5 associated with test point 44 on the training card 9. If the test point 44 data switch 54 is not in its high position, the program goes to connector 6 86 and then displays 87 an "L" (for low) on the seven segment display 3. The program then goes to connector 2 78 where a decision 80 is made whether all selected data switches 5 are in a high position or not. Since the concerned data switches are not all high, the program goes through connector 3 81 and displays 82 the selected indicator lamp 4 in an unlit condition. The program then repeats itself by going to connector 1 64 and continuing. If switch 54 had been in its high position the program would have gone from decision 93 through connector 7 and display 99 an "H" on logic display 3. The program would then go to connector 2 and decision 80 concerning the status of the data switches as previously noted. The program then repeats itself by going to connector 1 and continuing.
If only test point 46 had been touched at decision 74, the program would go to connector 9 95 to perform the decision 96. The decision 96 checks the status of the data switch 52 associated with test point 42 on the training card 9. If the data switch 52 is not in a high position, the program goes to connector 6 86 and then displays 87 an "L" (for low) on the seven segment probe display 3. The program then proceeds to connector 2 78 and the decision 80 which checks the status of the selected data switches 52 and 54. At decision 80, since point 42 was "low", the concerned data switches are not all in their high condition, the program goes through connector 3 81 to display 82 the selected indicator lamp 4 in an unlit condition. The program then repeats itself by going to connector 1 64 and continuing. If at decision 96 the data switch 52 had been in a high position, the program would go to connector 8 92 and then make a decision 93 about the status of the other selected data switch 54. If data switch 54 is not in its high condition, the output of the simulated AND gate would be low so the program goes through connector 6 86 to display 87 and "L" (for low) on the seven segment probe display 3. The program then goes to connector 2 78 and decision 80. At decision 80 the program again takes the "No" route, going through connector 3 81 to display 82 the selected indicator lamp 4 in an unlit condition. The program then repeats itself by going to connector 1 64. If at decision 93 the concerned data switch 54 was in the high position, then the program would have gone to connector 7 98 and then display 99 an "H" on the seven segment probe display 3. The program then goes to connector 2 78 where it must take the "yes" branch to connector 4 88 since all concerned data switches 5 are in the high position. Connector 4 88 leads to display 90 which displays the selected indicator lamp 4 in the lit condition. The program then repeats itself by going to connector 1 64.
The repetition of program runs results in instantaneous changes due to changing real world conditions. This means any changes made in the monitored inputs will be reflected immediately by the proper output indication. The program repeats itself until the training card is removed or power is turned off, thereby allowing the operator to operate the device at his own speed.
The clock status switch 6 is used as a real world input for those circuits which have toggled or timed functions. The program involving the clock status switch 6 would require a reading subroutine and the proper decisions in order to be incorporated. Reading the clock switch 6 status would take a subroutine similar to the read data switch subroutine 66.
FIG. 13 contains flow chart diagrams for the subroutines 66 and 68 called for in FIG. 12. The read data switches 5 subroutine 66 starts by reading the input data and storing it as "Read A" 101. Decision 102 is a time delay decision. The time out decision 102 allows for mechanical switch or contact debouncing without hardware circuits by waiting a given period of time before reading the data switch 5 input operation 103. Decision 104 compares the data from the two read operations 101 and 103. If Read A and Read B are equal, the operation 105 takes Read A and moves it to a location selected to hold the valid data switch 5 input data. The subroutine then returns to the main program subroutine 66 block from which it was called. If at decision 104 Read A and Read B did not match, the subroutine would simply go back to the main program subroutine 66 from which it was called. This results in the main program using the same data switch 5 data as it used in the previous run. Only when the data is the same after a read-delay-read sequence will the data supplied to the main program change.
The subroutine 68 for reading test planes 16 is based on the same principle as the read data switch 5 subroutine 66. The main difference is that there are more test planes 16 than there are data switches 5. The read test plane 16 subroutine 68 therefore incorporates an indexed loop.
The subroutine 68 starts by performing housekeeping chores, such as clearing the index register operation 107. Next, the data on the first test plane is read and stored as T1+ the contents of the index register by operation 108. The time out decision 110 delays a suitable length of time to allow setting of any bouncing switch contacts. When time is out the program takes the decision 110 "yes" route to perform another read operation 112 called T2+ the contents of the index register. T1+X and T2+X are compared by decision 113. If they are equal, the data is moved from T1+X to a location selected as the "Test Plane Input" location 1+X by operation 114. If T1+X did not equal T2+X in decision 113, the operation 114 would be bypassed, thus leaving the data supplied to the main program as "Test Plane Input" 1+X unchanged from its previous value. Whether coming from the decision 113 or the operation 114, the program will come to the loop decision 115. If all planes have not been read, an increment operation 116 will occur adding one to the contents of the index register and the program will once again start through the subroutine at operation 108. When all test planes 16 have been read, the decision 115 will cause the program to take the "yes" route thus returning to the subroutine 68 in the main program from which it had been called.
The wireless logic trainer can be operated with substantially all of the components being off the shelf items. For example:
Address decoder 18--SN74154 Decoder Chip
Tri-state driver--SN74126 or SN74125
Probe display 3--MAN-3
Computer 11--MOS Technology-KIM I (or other similar computer)
While the invention has been described in connection with certain specific embodiments thereof, it will be understood that other modifications will support themselves to those skilled in the art and that it is intended to cover such modifications that fall within the scope of the claims appended hereto. | A wireless training device is disclosed which uses a digital computer to simulate or imitate electronic circuits, especially logic or computer circuits. Basically, a control program is selected by insertion of an edge encoded card. This card has on it a drawing of the circuit being taught as well as addressing information for use by the digital computer. Test points on the training card are holes, through which the test probe can contact the metal fingers of a test plane. The information derived from the test plane, as well as inputs from the various test switches, are operated on by the computer and control program to give output indications, usually in the form of lights. By putting the control programs in permanent memory (i.e. ROM or PROM) the student will be required to perform few preparatory steps. The unit is expandable by simply adding more programing to the memory chips and by drawing suitable training cards. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to subscription management in messaging systems.
Publish/Subscribe (or Event Notification) is a well-known messaging pattern where clients interested in information available from a source “subscribe” to the source. When information is available the source then “publishes” the information to the client (which is commonly and hereafter referred to as the “sink”).
There are two common variants of this pattern:
a) The “direct” case, where the sink is registered directly with the source. In this pattern the subscriber identifies each source it is interested in, and then registers a separate subscription with each. It only receives messages from sources with which it has registered.
b) The “brokered” case, where the sink is registered with an intermediary “broker”, not with the true source. The true source publishes information to the broker, which then forwards the information to the sink.
In the brokered case (b) the subscriber does not have to be aware of the identity or location of the true source (publisher), since it never interacts with it directly. The brokered case also has the characteristic that a sink registered against the broker will receive messages from any source (publisher) which is sending relevant messages to the broker. In some situations, this may be exactly what is wanted. However, in some applications (e.g., systems management) the sink might only be interested in messages from a particular set of sources. For example, the sink might be a monitoring application that only wants to monitor 3 out of a set of 60 similar resources.
The direct case (a) allows the sink to control exactly which source(s) it gets messages from. However it can result in a lot of logical connections (if there are m sources and n sinks, we have a total of n*m connections), and it requires each source to maintain a list of subscriptions and each source to distribute messages to multiple recipients.
A need therefore exists for a system and method for subscription management in a messaging system wherein the above mentioned disadvantage(s) may be alleviated.
SUMMARY OF THE INVENTION
Briefly, the invention includes a computer implementable method including sending a subscription request from a first subscriber to a first publisher, intercepting the subscription request from the first subscriber and redirecting the subscription request to a broker, forwarding the subscription request from the broker to the first publisher, sending a first event message from the first publisher to the broker, and forwarding the first event message from the broker to the first subscriber.
BRIEF DESCRIPTION OF THE DRAWINGS
Three systems and methods for subscription management in a messaging system incorporating the present invention will now be described, by way of example only, with reference to the accompanying drawing(s), in which:
FIG. 1 shows a schematic illustration of a prior art ‘direct’ messaging system;
FIG. 2 shows a schematic illustration of a prior art ‘brokered’ messaging system;
FIG. 3 shows a schematic illustration of a simple embodiment of a messaging system employing the present invention;
FIG. 4 shows a schematic illustration of a first preferred embodiment of a messaging system incorporating the present invention; and
FIG. 5 shows a schematic illustration of a second preferred embodiment of a messaging system incorporating the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
It will be appreciated that it is common practice to use a set of broker nodes configured to act as a single publish subscribe broker mechanism. Herein the term ‘broker’ is used to cover either a single broker or a set of broker nodes acting as a single broker.
Additionally, it is common in publish/subscribe systems (whether brokered or not) for a subscriber to subscribe on its own behalf, so that the subscriber is also the recipient (sink) for appropriate matching messages. However, it is also known for a subscriber to subscribe on behalf of a separate sink; the subscriber issuing the subscriptions but the sink receiving resulting matching messages. The following embodiments are described assuming the common form, but it will be appreciated that the subscriber and sink may be separate.
FIG. 1 illustrates a prior art ‘direct’ messaging system ( 10 ), as discussed above, including a subscriber/client/sink ( 12 ) and a publisher/source ( 14 ). In the messaging system 10 , the subscriber/client/sink ( 12 ) initially performs a subscribe action ( 16 ) in which it sends a subscription request to the publisher/source ( 14 ) and receives therefrom a subscription id. The publisher/source ( 14 ) subsequently generates an event ( 16 ), performs selector filtering matching ( 18 ), and sends ( 20 ) an event message directly to any matching subscriber/client/sink ( 12 ).
As mentioned above, the ‘direct’ messaging system 10 allows the sink to control exactly which source(s) it gets messages from; however, it can result in a lot of logical connections (if there are m sources and n sinks, we have a total of n*m connections), and it requires each source to maintain a list of subscriptions and each source to distribute messages to multiple recipients.
In FIG. 1 and all subsequent figures, we have assumed the common case where the subscriber and sink are identical. It will be understood that all the patterns, both of the prior art and of the present invention, can be modified for the case where the subscriber and sink are different. It will further be understood that such modification does not materially affect the present invention.
FIG. 2 illustrates a prior art ‘brokered’ messaging system ( 50 ), as discussed above, including a subscriber/client/sink ( 52 ), a broker ( 54 ), and a publisher/source ( 56 ). In the messaging system ( 50 ), the subscriber/client/sink ( 52 ) initially performs a subscribe action ( 58 ) in which it sends a subscription request to the broker ( 54 ) and receives therefrom a subscription id; the broker ( 54 ) remembers the subscription ( 60 ). The publisher/source ( 56 ) subsequently generates an event ( 62 ), and sends ( 64 ) an event message to the broker ( 54 ). The broker 54 receives ( 66 ) the event, performs ( 68 ) selector filtering, and sends ( 70 ) the event message to any matching subscriber/client/sink such as 52 .
As mentioned above, in the brokered messaging system 50 , the subscriber does not have to be aware of the identity or location of the true source (publisher), since it never interacts with it directly. The brokered case also has the characteristic that a sink registered against the broker will receive messages from any source (publisher) that is sending relevant (e.g., matching) messages to the broker. In some situations, this may be exactly what is wanted. However in some applications (e.g., systems management) the sink might only be interested in messages from a particular set of sources.
FIG. 3 illustrates a simple system 100 , for messaging between a subscriber ( 110 ), a source ( 115 ) and a broker ( 120 ), in which disadvantages of the prior art systems 10 and 50 can be reduced. The system 100 operates under the following scheme:
i. The subscriber ( 110 ) issues a subscribe ( 125 ) against the real source ( 115 ). This includes a reference to the broker ( 120 ).
ii. The real source ( 115 ) re-issues the subscribe ( 130 ) against the broker ( 120 ), using the original sink object ( 110 ) reference.
iii. The broker ( 120 ) returns a subscription ID ( 135 ) to the real source ( 115 ), and the real source ( 115 ) takes the subscription ID returned by the broker and passes this back ( 140 ) to the subscriber ( 110 ).
iv. When the real source ( 115 ) detects an event, it sends an event message ( 145 ) to the broker ( 120 ). The broker ( 120 ) then applies its selector filters in the usual way and distributes the message ( 150 ) to the relevant sink(s) such as the subscriber ( 110 ).
The system of FIG. 3 can be used in one of two modes. In a first mode, there is a single broker for all publishers. Setting up subscriptions requires n*m connections; however, only m+n connections are needed for the flow of events. Also, the subscriber does not need to be aware of the existence of the broker. However, with this mode, the sinks receive events from all publishers.
A second mode requires each source to have a separate instance of the broker service, used exclusively by that source. This offloads work from the source and also hides the existence of the brokers from the subscriber/sink. However, it still results in n*m connections.
As discussed above, in the scheme of FIG. 3 , a sink registered against the broker will receive messages from any source (publisher) that is sending relevant messages to the broker. In some situations, this may be exactly what is wanted. However, in some applications (e.g., systems management) the sink might only be interested in messages from a particular set of sources. For example, the sink might be a monitoring application that only wants to monitor 3 out of a set of 60 similar resources. This can be resolved by having a separate broker service for each publisher.
Although, as also discussed above, if the sink is registered directly with the source, it can control exactly which source(s) it receives messages from, it can result in a lot of logical connections (if there are m sources and n sinks, this results in a total of n*m connections), it requires each source to maintain a list of subscriptions, and it requires each source to distribute messages to multiple recipients.
As discussed above, the two modes of operation of FIG. 3 both achieve some benefits over prior art, but neither gives all the combined effects of m+n connections at event time and of sinks receiving messages from only selected publishers.
Referring now to FIG. 4 , a system 200 , in accordance with a first preferred embodiment of this invention, allows messaging between a subscriber ( 210 ), a source ( 215 ) and a broker ( 220 ) and implements the following operating scheme:
i. The subscriber ( 210 ) issues a subscribe ( 225 ) against the real source ( 215 ). This includes a reference to the broker ( 220 ).
ii. The real source ( 215 ) re-issues the subscribe ( 230 ) against the broker ( 220 ), using the original sink object ( 210 ) reference. However, in distinction to the earlier scheme of FIG. 3 , the real source ( 215 ) identifies itself to the broker as part of the subscription. This identification may be
[a] by modification of the selector (filter) supplied by the original subscriber (as shown schematically at 227 ) so that it additionally filters out any messages not originating from the real source, or
[b] by explicit inclusion of an identifier of the real source in the subscription request, (“subscriptionTargetID”), or
[c] by implicit inclusion of such an identifier, for example where the TCP protocol is used the broker may identify the forwarding real source from the TCP protocol wrappers of the TCP conversation.
iii. The broker ( 220 ) returns a subscription ID ( 235 ) to the real source ( 215 ), and the real source ( 215 ) takes the subscription ID returned by the broker and passes this back ( 240 ) to the subscriber.
iv. When the real source ( 215 ) detects an event, it sends an event message ( 245 ) to the broker ( 220 ). It includes in the message ( 245 ) a “message source ID” field ( 247 ), which uniquely identifies the source ( 215 ) with respect to this particular broker. When the broker ( 220 ) receives this message, it applies its selector filters in the usual way and distributes the message ( 250 ) to the relevant sink(s) such as the subscriber ( 210 ). Where the filter has not been explicitly modified as in ii[a] above, the application of the filter will include the additional step of comparing the “message source ID” with the “subscription target ID”, and only forwarding messages to subscribers where these match.
The “message source ID” may be included explicitly in the message, or the inclusion may be implicit in the protocol in a similar manner to ii[c] above.
It will be understood that in the scheme of FIG. 4 the selectors are modified (step ii.) so that they are additionally filtering using the source's unique ID. In this way, the event message is only delivered to sinks that thought they were registering with the particular source in question.
Thus, it will be understood that compared to the FIG. 3 's second mode requirement for n*m connections discussed above, the number of connections required for the sending of events in the system of FIG. 4 is reduced to n+m. However, up to n*m connections are still required for establishing subscriptions. At the same time, this scheme 4 eliminates the problem of FIG. 3 's first mode that sinks cannot discriminate messages based on selected publishers.
Referring now to FIG. 5 , a system 300 , in accordance with a second preferred embodiment of this invention, allows messaging between a subscriber ( 310 ), a source ( 315 ) and a broker ( 320 ) and implements the following operating scheme:
i. An application program at the subscriber ( 310 ) is unaware of the broker ( 320 ), and makes a subscription apparently directly to the real source ( 315 ). This subscription is intercepted by infrastructure ( 312 ) at the subscriber, which is aware of the broker. This subscriber infrastructure optionally adds to the subscription filter a clause that filters only on messages from the real source, and sends the filtered subscription ( 325 ) to the broker ( 320 ). The broker ( 320 ) then issues a subscribe ( 330 ) against the real source ( 315 ).
ii. When the real source ( 315 ) detects an event, it sends an event message ( 335 ) to the broker ( 320 ). When the broker ( 320 ) receives this message, it applies its selector filters in the usual way and distributes the message ( 340 ) to the relevant sink(s) such as the subscriber ( 310 ). The filtering at the broker may or may not be configured to include matching the message source with the subscription target: with this matching the system will behave as in the second mode of FIG. 3 , or FIG. 4 . Without this matching, it will behave as the second mode of FIG. 3 .
It will be appreciated that the system 300 of FIG. 5 is very similar to that of the system 200 of FIG. 4 , and it is often preferable thereto because:
1. It is simpler.
2. It will work where the publisher is not aware of the broker. This is a common situation, where the subscriber is a (well informed) administration monitor, and the publisher is an (ill informed) ‘standard’ resource (application program, middleware, etc).
3. For n publishers and m subscribers, it only requires a maximum of n+m connections for establishing publications. (the system 200 of FIG. 4 requires up to n*m connections for establishing publications—both require n+m connections for the message traffic itself).
4. Where the subscriber is the same as the sink (a very common case), the same connection can be used for making the subscription and for receiving messages.
It will be understood that the scheme of FIG. 5 will not work where the subscriber infrastructure is unaware of the broker, in which case (and where the publishers are aware of the broker) the scheme of FIG. 4 remains the best solution. | A system and method for messaging subscription management by subscribing a subscriber to a publisher, providing a broker brokering message flow between the publisher and the subscriber whereby the publisher publishes information to the broker which then forwards the information to the subscriber, and filtering messages whereby any messages not originating from the publisher are filtered out. The filtering may comprise modifying at the publisher a filter supplied by the subscriber and sending the modified filter to the broker, or may comprise modifying at the subscriber a filter and sending the modified filter to the broker. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention relates to improvements in telescopic gun sights and, more particularly, to an improved windage correction system for a telescopic gun sight which includes a generally horizontal windage correction scale operative to provide instant windage correction target alignment and including instant windage correction target alignment values positioned at point-specific spaced-apart locations on the generally horizontal scale with specific instant windage correction target alignment values corresponding to selected distance amounts calculated for a selected bullet type and weight.
[0003] 2. Description of the Prior Art
[0004] Present telescopic sites used on rifles and other firearms, generally comprise a cross-hair reticule positioned within the scope for referencing the hunter's vision with respect to a target. A hunter “sights in” or “zeros” the scope by firing bullets in a trial-by-error method and repetitively adjusts the reticule in the scope until the center of the cross-hair of the reticule aligns with the impact position of the bullet on the target. Such a method of zeroing a rifle requires considerable time and the costly firing of bullets.
[0005] U.S. Pat. No. 2,094,623 issued to F. E. Stokey in 1937, discloses a telescopic sight in which two reticules are utilized to enable the rifle to be zeroed in with a single shot. The Stokey device, however, was quite expensive and complicated. Also, because the hunter always views two reticules within his field of vision through the scope, it was quite possible that the hunter would inadvertently sight on the incorrect reticle. Also, the reticule which was sited in on target, could be off center from the field of vision through the scope causing further confusion and irritation to the hunter. Further, the hunter was shooting upside down with the Stokey scope, because the image through the scope was inverted due to the use of an objective and an ocular lens.
[0006] While the Stokey scope of 1937 suggested one-shot sighting, the inherent disadvantages, expense and complication of the system voided its general use. Since 1937, the prior art has suggested the use of an inverting tube to erect the object to be viewed through the scope by the hunter thus, eliminating upside down shooting by the hunter. The use of an inverting tube further establishes the center of the cross-hair wires at the center of the scope's field of vision despite adjustment of the cross-hair reticule relative to the image being viewed. The advent of the inverting tube was thus well received by the hunter.
[0007] When using an inverting tube within a scope, the reticule is positioned at the eye piece end of the tube. This is because the positioning of the reticule at the object end of the inverting tube causes the magnification of the cross-hairs of the reticule at high powers of the scope, particularly where the scope has zoom capabilities for changing the object's magnification. Such magnification of the cross-hair wires is annoying to the hunter, blocking portions of his view. Thus, present day scope manufacturers utilize an inverting tube with cross hair wires positioned at the eye piece end of the inverting tube.
[0008] Besides the problem of multiple firings to sight-in present day scopes, a problem of parallax exists when using the scope to shoot at close range. Parallax is caused by the cross-hair wires lying outside the image plane in conjunction with the hunter varying the position of his eye relative to the scope as he does not each time look across the cross-hairs at the same visual angle.
[0009] Further problems with such conventional scopes include the addition of devices which serve to approximate range and determine the “hold over” or aiming point in view of the range of the target. Particularly, the rifleman must judge the distance of the object and then compensate for the drop of the bullet in view of the weight and velocity of the bullet. Thus, the hunter must point the scope above the target in order for the bullet to drop onto the target. All of these range finding devices, however, add clutter to the hunter's field of vision and are particularly annoying when the hunter is shooting at close range and thus not using the range finding devices.
[0010] Such range finding devices include, for example, the use of a transparent reticule disc at one end of an inverter tube, which bears separate circles for denoting range and drop of the bullet, see for example U.S. Pat. No. 3,392,450 issued to G. L. Herter et al. on Jul. 16, 1968 or Shepherd, U.S. Pat. No. 4,403,421, issued on Sep. 13, 1983. Other such range defining devices include stadia lines which take the form of two parallely disposed horizontal lines positioned across the field of view of the hunter for his use to determine whether the object fits within the lines in order to gauge distance of a targeted object. However, despite the various types of range finding indicia used with scopes of the prior art, there has been precious little development or improvement in the methods and devices available to hunters and shooters to correct for wind, and as wind correction is at least as critical to a successful shot as finding the range to the target, there is a need for significant improvement in this area.
[0011] There are several simple formulas available to calculate the deflection due to a crosswind. One which is used in the art is as follows: z=w*(t−X/v 0 ) where z is the deflection, w is the wind speed, t is the flight time of the bullet to the target, x is the distance to target and v 0 is the muzzle velocity. This formula is most commonly used with metric units, with velocities in meters per second, time in seconds and distances in meters. The only unknown parameter in the above formula is the bullet flight time (which generally may be found in manufacturers' tables).
[0012] Another widely used formula is the United States Marine Corps formula, which is used as follows: After determining wind direction and speed, the following formula is applied: Range in 100 Yds.×Speed in MPH/15 (math constant)=MOA Windage. For instance, if your target is 300 yards away, and there's a 10 MPH wind, you would plug the numbers into the formula like this: 3×10=30/15=2 MOA. Click-in the two minutes of angle into the scope in the direction of the wind and aim dead-on. It should be noted, however, that one additional concern with the Marine formula is that it is only accurate at 500 yards or less. With a target that is farther away, the mathematical constant must change, as shown here: 600 Yards: Divide by 14, 700 Yards: Divide by 13, 800 Yards: Divide by 13, 900 Yards: Divide by 12 and 1,000 Yards: Divide by 11.
[0013] To perform all these calculations immediately prior to taking the shot is a difficult task to say the least, and therefore there is a need to improve and streamline the task of determining appropriate windage corrections. It is, therefore, an object of the present invention to provide an improved telescopic sight which adds the advantages of the prior art without their attending disadvantages.
[0014] It is yet another object of the invention to provide a telescopic sight which includes an easily used windage correction system and method by which windage corrections for shots may be quickly and accurately determined.
[0015] It is yet another object of the present invention to provide a telescopic sight for use with a firearm which includes a secondary reticule having a windage correction scale imprinted thereon which is removed from the field of view in the scope when the magnification of the scope approaches its maximum magnification setting.
[0016] It is yet another object of the present invention to provide a telescopic sight having a generally horizontal windage correction scale imprinted on either the primary or secondary reticule, the scale operative to provide instant windage correction target alignment and including instant windage correction target alignment values positioned at point-specific spaced-apart locations on the generally horizontal scale with specific instant windage correction target alignment values corresponding to selected distance amounts calculated for a selected bullet type and weight.
[0017] It is yet another object of the present invention to provide a telescopic gun sight with a windage correction scale which requires only minimal computation prior to use, and will not substantially slow or retard the aiming and shooting process.
[0018] Finally, an object of the present invention is to provide an improved telescopic sight having a windage correction scale which is relatively simple and durable in construction and is safe, efficient and effective in use.
SUMMARY OF THE INVENTION
[0019] The present invention provides a windage correction system for a telescopic gun sight which includes a telescopic gun sight at least including an adjustable lens configuration for adjustably magnifying an external object to form an object image, an inverting tube for inverting the object image, an ocular lens array for presenting the object image for viewing, a primary reticule positioned generally adjacent the ocular lens array rearwards of the inverting tube and including sighting insignia imprinted thereon and a secondary reticule being movable both horizontally and vertically in the image plane independent of the inverting tube and positioned forward of the adjustable lens configuration. The secondary reticule further includes a generally horizontal windage correction scale operative to provide instant windage correction target alignment. It includes instant windage correction target alignment values positioned at point-specific spaced-apart locations on the generally horizontal scale with specific instant windage correction target alignment values corresponding to selected distance amounts calculated for a selected bullet type and weight.
[0020] The present invention as thus described provides substantial advantages over those windage correction devices and systems found in the prior art. For example, the windage scale allows a user to quickly and accurately determine the appropriate windage correction value which should be used for the shot. Moreover, this is done without requiring the user to undertake extensive calculations to determine the appropriate windage correction, as the present scale generally eliminates the necessity for such calculations. Finally, although minute of angle windage correction scales have been used for a long time in connection with telescopic gun sights, use of such MOA scales still require substantial calculations to enable them to be used for windage correction, whereas the present invention requires almost no detailed calculations prior to use of the scale. It is therefore seen that the present invention provides a substantial improvement over those methods, systems and devices found in the prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a perspective view of the improved telescopic gun sight of the present invention;
[0022] FIG. 2 is a detailed view of the view through the scope showing the indicia imprinted on the primary and secondary reticules;
[0023] FIG. 3 is a detailed view of the view through the scope at a higher magnification power showing how the indicia are shifted out of the line of sight of fire of the rifle as the magnification is increased;
[0024] FIGS. 4 , 5 and 6 are detailed scope views showing usage of the scope during windage correction; and
[0025] FIGS. 7 , 8 and 9 are detailed scope views showing the windage correction scale of the present invention being used for windage correction.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0026] Referring to FIG. 1 , the improved telescopic gun sight 10 is shown as including a pair of reticule adjustment knobs 40 and 42 disposed along the outside of the tubular housing 12 of the scope 10 , for permitting the hunter to selectively adjust the effective position of a pair of sighting reticules disposed within the scope 10 , in order to properly sight-in the rifle and correct for bullet drop and any crosswind.
[0027] The scope includes an eyepiece end 14 comprising an ocular lens system 20 through which the hunter views during siting of a target upon which he wishes to fire. The other end of the scope is the objective end 16 and includes an objective lens 22 which is directed toward the object to be viewed. The light rays coming from the object pass through objective lens 22 and converge to form an image on an image plane within the tubular housing and generally defined by reference numeral 26 . Because the image appearing in the image plane will be the inverted image of the viewed object, an inverter tube 28 is disposed between the image plane 26 and the ocular lens 20 for erecting the image for upright presentation as a second intermediate image in a second image plane generally defined by reference numeral 30 . The second image plane lies at the focus of the ocular lens 20 for presenting the erected image to the eye of the hunter, as understood.
[0028] The inverter tube 28 includes standard erecting lenses positioned in a conventional fashion for erecting the image received by the inverting tube 28 , with the erecting lenses being adjustably mounted relative to one another and are movable via rotational movement of adjustment ring 36 . As the adjustment ring 36 is rotated, the erecting lenses are moved in a predetermined relationship in order to vary the magnification of the object image appearing in image plane 30 , as understood.
[0029] A primary reticule 44 comprising a pair of cross-hair wires is fixed with respect to housing 12 at the ocular end of inverter tube 28 . The cross-hair wires of reticule 44 serve as reference lines for siting the weapon by the hunter, and the primary reticle 44 functions as per standard siting reticles currently used in the prior art.
[0030] The inverter tube 28 is secured in a substantially fixed relationship with respect to housing 12 at the ocular end of the inverting tube, while the objective end of the inverting tube is movable relative to the walls of tubular housing 12 . The inverting tube 28 may be adjusted by any appropriate adjusting device, and such adjustment devices are understood by those skilled in the art of telescopic gun sights. Movement of the objective end of the inverting tube 28 serves to position primary reticule 44 relative to the image plane 26 for positioning the image with respect to the primary reticule as viewed by the hunter. Such inverter tubes have been used previously in scope sights; see for example U.S. Pat. No. 2,995,512 issued to Kollmorgen et al on Oct. 11, 1960.
[0031] The use of the inverting tube permits the primary reticule 44 to have the center of the cross-hair wires always in the center of the field of vision of the hunter through scope 10 . This is most preferable to the hunter and avoids any confusion caused by the cross hairs being positioned off-centered due to adjustment by the hunter to indicate the center of the scope with respect to the gun barrel. Thus, the line of site of scope 10 is along an optical axis which passes through the eye piece lens system, the inverting tube and the objective lens, and has the center of the cross-hair reticule at the center of the field of vision of the hunter.
[0032] A secondary reticule 48 is positionable in image plane 26 for movement therewithin independently of the movement of inverter tube 28 . As shown in more detail in FIGS. 2 and 3 , secondary reticule 48 is adjustably mounted within the tubular housing 12 such that the secondary reticule depends from a mounting structure into the image plane 26 . Reticule adjustment knobs 40 and 42 control the movement of secondary reticule 48 in the horizontal and vertical planes, and in the preferred embodiment, the reticule adjustment knobs 40 and 42 are designed to adjust the position of the secondary reticule 48 through a “click” type of adjustment where each rotational “click” of the reticule adjustment knobs 40 and 42 equates to an adjustment of ¼ MOA (minutes of angle). Of course, it may be preferable to utilize a different adjustment system, but it has been found that the well-known and currently available “click” adjustment system works perfectly well with the present invention and therefore its use herewith is preferred.
[0033] At this point, the invention is similar to at least one prior art gunsight, specifically Shepherd, U.S. Pat. No. 4,403,421. However, the significant inventive aspects of the present invention will now be exposed, particularly as they relate to indicia inscribed on or formed on the secondary reticule 48 which, as was discussed previously, would preferably be a generally circular glass or transparent plastic plate. Specifically, the indicia imprinted on the secondary reticule 48 is an improved windage scale 70 which is operative to provide instant windage correction target alignment for a user of the improved telescopic gunsight 10 of the present invention without requiring significant mathematical equation solving as is currently required by windage correction systems and methods found in the prior art.
[0034] As was discussed previously, one of the most common wind correction methods currently used in the United States Marine Corps windage correction formula which requires the shooter to determine the range in one hundred yard increments from the shooter and then multiply that number by the wind speed in miles per hour, and then divide the resulting figure by fifteen, which serves as the math constant, to determine the minutes of angle which should be used to correct for the wind value. While this formula is not exceedingly difficult to apply, it has several significant drawbacks, the first being that even after the entire formula is computed, the user must then “click in” the resulting minutes of angle into the scope in order to correct for the wind, and the shooter must be sure that the clicks have been applied in the correct direction, namely in the direction of the wind. Furthermore, the USMC formula is only accurate at five hundred yards or less and, when the target is farther away, the mathematical constant must be changed, as was described previously. The shooter must be aware of all of these variations and calculations, compute all of them to a sufficient degree of accuracy, apply the resulting minutes of angle to the scope, ensure that the scope is being adjusted in the correct direction, and then and only then may he or she commence with the shot. In field operations, the maximum amount of time permitted by armed forces regulations to complete the computations and correctly adjust the scope for range and windage is four minutes, and it is clear that in that time period, many other events may have occurred, and in fact the opportunity to take the shot may have been lost forever.
[0035] The improved windage scale 70 of the present invention seeks to avoid all of those computations by providing a simple to use and direct windage correction scale which does not require the user to undertake significant mathematical operations to determine the correct windage adjustment. In the present invention, the improved windage scale 70 would include instant windage correction target alignment values 72 which would be printed above the standard minutes of angle scale 66 , as shown best in FIGS. 2 and 3 . In the preferred embodiment, the instant windage correction target alignment values 72 would consist of a series of integer values beginning with the number three and proceeding up to the number ten, with each numerical integer value being associated with a point-specific location signified by a dot 74 , with one set of instant windage correction target alignment values 72 positioned on each side of the secondary reticule 48 to provide correction for winds blowing from either direction across the shooter's line of fire. As each of the instant windage correction target alignment values 72 are identical, the following description of the left set should be understood to apply equally to the right set of values.
[0036] The positions of the dots 74 are determined by selecting corresponding distance amounts to correspond with the integer values positioned above the dot 74 . In the preferred embodiment, the integer values would correspond with the hundred yard range of the shot to be taken, with the first integer value being three thus corresponding to three hundred yards and the last integer value being ten and corresponding to the thousand yard windage correction location. Each of the dots 74 are positioned at the correct minutes of angle locations to indicate where a fifty-five gram HORNADY®, VMAX bullet propelled at a muzzle velocity of 3240 FPS would be pushed by a full value ten mile per hour wind blowing directly from left to right across the shooter's line of fire. To clarify, a full value wind is from the nine o'clock or three o'clock direction which corresponds to a ninety degree angle from the shooter's line of fire toward the target, which is always considered twelve o'clock. A wind from a direction of one-thirty, four-thirty, seven-thirty, or ten-thirty would be a half value wind, which would move the bullet off course approximately half as much as the same wind would if it were a full value. Likewise, a one-third value wind will move it one-third of the amount and a two-thirds value wind will push it two-thirds and so on and so forth. Winds blowing directly towards or directly away from the shooter have no crosswind value and correction for these types of winds is not necessary using the improved windage scale 70 of the present invention.
[0037] Returning to the improved windage scale 70 of the present invention, it should be noted that the ten mile per hour figure used to design the improved windage scale 70 is a very versatile choice in that it is easy to convert this scale to other wind speeds regardless of the value of those wind speeds. For example, if the shooter were to encounter a five mile per hour wind, the improved windage scale 70 would be used with half the values in the scale, and likewise for a fifteen mile per hour wind, a shooter would use one point five times the value shown on the scale. The main problem in correctly determining the appropriate wind correction factor, however, is to obtain an accurate determination of the speed and direction of the wind, and therefore it is generally recommended to use a portable, hand-held anemometer to make such determinations. However, the benefit of the present invention is that once the wind speed and direction are determined, the user of the present invention will need to make only minor calculations and adjustments to properly institute the windage correction using the improved telescopic gunsight 10 of the present invention.
[0038] For example, say the user determines that a twenty mile per hour wind was blowing from the one-thirty direction during preparation for the shot. As was discussed previously, the one-thirty wind would be a half value wind and when multiplied by the twenty mile per hour wind speed, the resulting affecting speed of the wind is ten miles per hour. This is exactly the scale at which the improved windage scale 70 of the present invention is set, and so once the shooter has determined the distance of the shot, for example four hundred fifty yards. as shown in FIG. 7 , he or she would then “click in” the adjustment by rotating reticule adjustment knob 40 to move the windage scale 70 to the right until the windage adjustment line 76 is positioned in alignment with the dot 74 corresponding to the value halfway between the four and five on the improved windage scale 72 . The shooter would then merely line up the cross hairs on the target and take the shot when ready knowing that the appropriate correction for windage has already been programmed into the improved telescopic gunsight 10 of the present invention. The same procedure may be used with any wind direction and wind speed, such as the five mile per hour wind as shown in FIG. 8 , and the need to determine the minutes of angle which need to be set in the scope is eliminated by the improved windage scale 70 of the present invention.
[0039] It is also a relatively simple matter to prepare an alternative windage scale by using a different bullet as the basis for the windage correction target alignment values 72 to be inserted into the improved windage scale 70 of the present invention. This would involve repositioning of the dots 74 once those computations had been completed, but once the dots 74 are positioned in correct association with the instant windage correction target alignment values 72 as reprogrammed and redetermined in connection with a newly-selected bullet type and weight, the user of the improved telescopic gunsight 10 of the present invention may undertake the same quick and simple to perform steps described previously which are now used with the newly-selected bullet type and weight.
[0040] One of the true benefits of the improved windage scale 70 of the present invention is shown best in FIGS. 2 and 3 in that as the magnification of the target is increased, the viewing field of the gunsight correspondingly grows smaller. Because the improved windage scale 70 is positioned on the secondary reticule 48 , this means that as the power of the scope is increased by rotation of the ring 43 , the improved windage scale 70 is slowly removed from the field of view, as shown in FIG. 3 , and as the magnification of the scope increases towards maximum power, the improved windage scale 70 is no longer visible nor viewable through the improved telescopic gunsight 10 . It should be noted that the improved windage scale 70 is of course still imprinted on the secondary reticule 48 but since the viewing field has decreased as the magnification of the scope has been increased, the portion of the secondary reticule 48 which is viewable through the scope no longer includes the improved windage scale 70 , and thus the viewing field of the scope is less cluttered which will likely improve the usability of the gunsight 10 with the improved visual field available to the shooter.
[0041] Of course, it is not strictly necessary to position the improved windage scale 70 on the secondary reticule 48 in such a manner as to preclude viewing of the improved windage scale 70 as the scope approaches maximum power, but it has been found that the less cluttered the view field of the scope, the greater chance that the shooter will not be distracted in attempting to hit the target. It is only because the improved windage scale 70 is imprinted on the secondary reticule 48 that the above-described feature is even available, and the combination of the features of the improved windage scale 70 as described previously with the removal of the improved windage scale 70 from the viewing field at maximum power renders the present invention a substantial improvement over those windage correction systems and methods found in the prior art.
[0042] It is to be understood that numerous additions, substitutions and modifications may be made to the improved telescopic gunsight 10 and improved windage scale 70 of the present invention which fall within the intended broad scope of the appended claims. For example, although the improved windage scale 70 has been described as being imprinted on the secondary reticule 48 , it may be entirely possible to print the improved windage scale 70 on a primary reticule which is found in numerous gun sights and gun scopes presently available in the prior art, and although the loss of the above-describe feature of having the improved windage scale 70 be removed from view at higher magnifications would be lost when the present invention is used in connection with single reticule scope, the instant windage adjustment features previously described will still be available and these are believed to be extremely valuable and deserving of protection regardless of the positioning of the improved windage scale 70 on any particular primary or secondary reticule. Furthermore, although the improved windage scale 70 has been described as being used with particular integer values to represent yardage of the shot, adjustment or modification of the integer or numeric values may be easily done by substituting any particular alphanumeric or symbolic value for the instant windage correction target alignment values 72 used in connection with the positioning dots 74 as described previously. For example, a shooter who consistently shoots at one particular type of target positioned a specific distance away, such as a biathelete or target shooting participant, could place a positioning dot 74 at the appropriate distance and label that particular location with a selected alphanumeric value which has significance to that particular person. Modification and substitution of such alphanumeric values is therefore understood to be a part of this disclosure. Finally, it should be noted that although use of the improved windage scale 70 has been described as including the step of clicking the scope adjustment device to move the secondary reticule 48 to the appropriate alignment with the windage adjustment line 76 , with practice it may be more efficient for the user to simply offset the shot alignment to move the target into line with the appropriate windage correction target alignment value 72 instead of adjusting the secondary reticule 48 , which takes longer to institute, as shown in FIG. 9 . It is expected that with sufficient practice, such offset aiming will likely be as accurate as adjustment of the scope, but it has been found that adjustment of the scope by use of the improved windage scale 70 of the present invention results in the most accurate and most dependable windage adjustment currently available, and therefore it is preferred that each of the steps described previously be performed in sequence to correct for wind by use of the improved windage scale 70 of the present invention.
[0043] There has therefore been shown and described an improved telescopic gunsight 10 and improved windage scale 70 which accomplish at least all of their intended objectives. | A improved telescopic gun sight includes a telescopic gun sight at least including an adjustable lens configuration for adjustably magnifying an external object to form an object image, an inverting tube for inverting the object image, an ocular lens array for presenting the object image for viewing, a primary reticule including sighting insignia imprinted thereon and a secondary reticule being movable both horizontally and vertically in the image plane. The secondary reticule includes a generally horizontal windage correction scale operative to provide instant windage correction target alignment. It includes instant windage correction target alignment values positioned at point-specific spaced-apart locations with specific instant windage correction target alignment values corresponding to selected distance amounts calculated for a selected bullet type and weight. | 5 |
RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application 60/730,604, entitled “Systems And Methods For Building Construction” by Robert Olvera and George Stevenson, filed Oct. 27, 2005, which is incorporated by reference as if set forth herein in its entirety.
BACKGROUND
Field of the Invention
[0002] This disclosure relates generally to building construction and more particularly to systems and methods for constructing buildings using a frame structure that facilitates installation of wall panels to form the building enclosure.
SUMMARY OF THE INVENTION
[0003] This disclosure is directed to systems and methods that are used in the construction of residential, commercial or other types of buildings. One embodiment of the invention comprises a system in which a prefabricated construction panels are attached to a frame assembly to form a building. In this embodiment, a metal frame is constructed from prefabricated components, such as wall base tracks, “I” stud assemblies, and top beam assemblies. Building panels are then attached to the frame to form walls and complete the building enclosure.
[0004] One embodiment comprises a component for a use in a building system. The frame member is a substantially rigid, elongated member such as a stud. The frame member has an attachment portion extending outward so that construction panels can be secured to it. In a particular embodiment, the stud is designed to be used in a frame system to support vertical wall panels. The stud consists of a pair of metal C-channel studs that are oriented back-to-back with a stiffener plate between them. The stiffener plate extends outward from the stud so that it can be used to secure the wall panels against the stud. More specifically, the stiffener plate has slots through it that allow biscuits to be placed through the stiffener plate and into the edges of the wall panels that abut the stiffener plate. The biscuits hold the edges of the wall panels in alignment with each other and, because the biscuits extend through the slots in the stiffener plate, the wall panels are held against the stud, thereby stiffening the wall formed by the panels.
[0005] An alternative embodiment comprises a building system that incorporates frame members having an attachment portion such as that described above. The building system includes a frame consisting of a base track, a top beam, and one or more studs. The studs are vertically oriented with their lower ends connected to the base track and their upper ends connected to the top beam. The building system also includes a set of construction panels that are secured to the frame. Each construction panel has slots in its edges to accept biscuits which maintain alignment of the panel edges. The attachment portion of each stud has slots through which the biscuits are inserted so that the construction panels are held against the studs. Channels may be provided in the base track and/or top beam to receive the construction panels. The channel in the base track may include supports configured to elevate the construction panels above the bottom of the base track. The top beam may include tabs for attachment of trusses or other support members to the top beam.
[0006] Numerous other alternative embodiments are also possible.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Other objects and advantages of the invention may become apparent upon reading the following detailed description and upon reference to the accompanying drawings.
[0008] FIG. 1 is a set of illustrations showing the general structure of the assembled frame and panels in accordance with one embodiment.
[0009] FIG. 2 is a set of more detailed views of a wall base track in accordance with one embodiment.
[0010] FIG. 3 is a set of more detailed views of an “I” stud assembly in accordance with one embodiment.
[0011] FIG. 4 is a diagram illustrating the manner in which the wall panels, stiffener plate and biscuit fit together in accordance with one embodiment.
[0012] FIG. 5 is a set of more detailed views of a top beam in accordance with one embodiment.
[0013] While the subject matter of the present disclosure is subject to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and the accompanying detailed description. It should be understood, however, that the drawings and detailed description are not intended to limit the subject matter to the particular embodiment which is described. This disclosure is instead intended to cover many modifications, equivalents and alternatives.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0014] One or more embodiments of the system are described below. It should be noted that these and any other embodiments described below are exemplary and are intended to be illustrative rather than limiting.
[0015] The present disclosure describes various systems and methods that are used in the construction of buildings. The buildings may be residential, commercial or other types of buildings.
[0016] The features described herein are part of an overall system in which a prefabricated construction panels are assembled to form a wall. In one embodiment, a frame is first constructed, and then the building panels are assembled to complete the building enclosure. The features described in this disclosure relate to the mechanisms employed in the frame to facilitate assembly of the panels or provide improvements in the resulting structure.
[0017] Referring to FIG. 1 , a set of illustrations showing the general structure of the assembled frame and panels in accordance with one embodiment are provided. FIG. 1A shows the frame structure without the panels, and FIG. 1B shows the structure with the panels.
[0018] Referring to FIG. 1A , the frame consists generally of a wall base track 110 , a series of “I” stud assemblies 120 , and a top beam assembly 130 . Base track 110 is described in detail below in connection with FIG. 2 , while “I” studs 120 are described in detail in connection with FIG. 3 , and top beam 130 is described in detail in connection with FIG. 5 .
[0019] Wall base track 110 is normally fastened to the foundation of the building or, in the case of multi-floor construction, to the structure of the floor below. “I” studs 120 are positioned in a space in the center of wall base track 110 and are fastened to the track. Top beam assembly 130 is then positioned on top of the “I” studs and is fastened to the “I” studs to complete the frame. After the frame is assembled, wall panels 140 can be attached to the frame to form the walls of the building as shown in FIG. 1B .
[0020] Referring to FIG. 2 , more detailed views of wall base track 110 are shown. At the top of the figure is a top view of the track, at the bottom is a side view, and at the left side of the figure is an end view of the track. Wall base track 110 has a pair of tracks or u-shaped channels 210 . The bottom of each construction panel 140 fits into one of these tracks. In this embodiment, the panels in one of the tracks form an interior wall, while the panels in the other track form an exterior wall. Once a panel is properly positioned (i.e., at the correct location with its bottom edge in the track,) the panel may be securely fastened to the track (e.g., by inserting a screw through the track and into the panel.)
[0021] In the embodiment of FIG. 2 , tracks 210 are each spot welded to a bottom plate 220 . Each of tracks 210 in this embodiment has a one side that extends higher than the other. The tracks therefore have more of a “J” shape than a “U” shape. The higher side of the track is positioned toward the center of base track assembly 110 (toward the other track 210 .) This facilitates positioning of the panel in the track, as the panel can be lifted to clear the shorter, outer side of the track without clearing the higher, inner side of the track.
[0022] It can be seen in FIG. 2 that each of tracks 210 includes multiple panel supports 230 . Panel supports 230 are positioned inside tracks 210 so that, when a panel is placed in one of the tracks, the lower edge of the panel will rest on the panel supports instead of the bottom of the track. In other words, the panel supports lift the panel off the bottom of the track.
[0023] Keeping the panel above the bottom of the track serves several purposes. For instance, elevating the panel above the bottom of the track eliminates the need to provide waterproofing where the panel would otherwise come into contact with the foundation. This waterproofing would be necessary to prevent water damage to the panels if they were simply sitting on the bottom of the track. Additionally, by elevating the panel, a gap is provided between the panel and the bottom of the track so that the track can be bolted to the foundation on which it is installed. Since it is preferable to secure the track at its outer edge, providing the gap between the panel and the bottom of the track allows the bolt and the corresponding nut to be positioned in the gap under the panel and to thereby secure the edge of the track.
[0024] It can also be seen in FIG. 2 that tracks 210 are positioned on bottom plate 220 so that there is a space between the tracks. In this embodiment, the spacing is sufficient to allow the “I” stud to be placed between the tracks. In particular, the spacing is just large enough for the “I” studs, and when the panels are installed, the “I” studs contact the back sides of the panels.
[0025] Referring to FIG. 3 , more detailed views of “I” stud assembly 120 are shown. At the top of the figure is a side view of the track, at the bottom is a front view, and at the left side of the figure is a top view of the track. The side and front views of the “I” stud are rotated 90 degrees from the installed, vertical position.
[0026] It can be seen from the front and top views in FIG. 3 that the “I” stud consists of three main components: two conventional C-channel studs ( 310 and 311 ); and a stiffener plate 320 . These three components are spot welded together as illustrated in the side view at the top of the figure. Each of C-channel studs 310 and 311 serves to provide vertical support for the top of the frame structure in the same manner as conventional studs. Obviously, however, the two C-channel studs provide additional support in comparison to a single C-channel stud.
[0027] Stiffener plate 320 is used between C-channel studs 310 and 311 to provide additional stiffness to the assembled wall panels. The additional stiffness is provided by configuring stiffener plate 320 so that a portion 321 of the plate extends forward from between C-channel studs 310 and 311 , as can be seen in the side view of the “I” stud. Portion 321 of the stiffener plate extends forward by an amount that is just less than the thickness of the wall panels with which it is used. It can also be seen in the figure that portion 321 of the stiffener plate does not extend the full length of the “I” stud, as the ends of the “I” stud must fit between the tracks of wall base track assembly 110 and within the top track of top beam 130 .
[0028] This portion of stiffener plate 320 that extends outward from the C-channel studs has several slots 322 that are sized to accommodate disks or “biscuits.” Each of wall panels 140 has slots in its sides to accommodate these biscuits. The biscuits are used to maintain alignment of adjoining ones of the wall panels in essentially the same way wood biscuits are used in the joining of boards to form larger wooden panels. In the case of wall panels 140 , the biscuits extend from a slot in the edge of one panel, through one of the slots 322 in the stiffener plate, and into a slot in the edge of an adjacent panel.
[0029] The manner in which the wall panels, stiffener plate and biscuit fit together is shown in FIG. 4 . In this figure, biscuit 410 is fully inserted into a slot in panel 440 . Biscuit 410 fits within a slot (indicated by the dotted lines) in stiffener plate 420 . Biscuit 410 is shown partially inserted into the slot in the edge of panel 441 . In the absence of stiffener plate 420 , biscuit 410 would keep panels 440 and 441 in alignment with each other, but the panels would both be allowed to flex away from the C-channel studs of the frame. Stiffener plate 420 ties wall panels 440 and 441 to the “I” stud so that they cannot flex away from the “I” stud.
[0030] Referring to FIG. 5 , more detailed views of top beam 130 are shown. At the top of the figure is a top view of the beam, at the bottom is a side view, and at the left side of the figure is an end view of the track.
[0031] Referring to the end view, in can be seen that the body 510 of the beam consists of sheet metal that is formed into a deep U-channel. a set of indentations 540 are made in the sides of beam body 510 in order to strengthen the beam. A top plate 520 is spot welded to the top of the beam (the open end of the U-channel.) A wall top track 530 is spot welded to the bottom of the beam.
[0032] Wall top track 530 is configured to fit over the tops of the “I” studs, as well as the tops of the installed wall panels. Top plate 520 includes several tabs 550 that extend upward from the beam. Tabs 550 may be formed, for example, by cutting three sides of each tab from the top plate and then bending the tabs upward, leaving corresponding holes in top plate 520 . Tabs 550 are used to attach support members such as trusses to the top of the beam. These trusses may be roof trusses if the frame is for the uppermost floor of the building (or a single-story building,) or they may be floor trusses if additional floors will be built above the frame structure.
[0033] The components of the building system described above can be installed in various ways. Typically, at least a portion of the frame (wall base track, “I” studs and top beam) are assembled, and then the wall panels are installed in/on the frame. In one embodiment, the base track is installed, and then the “I” studs and wall panels are installed sequentially. In other words, a first “I” stud is installed, and an adjoining wall panel is installed with one or more biscuits extending from a groove in the edge of the panel through corresponding slots in the stiffener plate of the “I” stud. Then, Another “I” stud is installed at the opposite edge of the installed wall panel. Biscuits are placed through the slots in the stiffener plate of the second “I” stud and into grooves in the edge of the installed wall panel. Then a second wall panel is installed so that the biscuits are positioned in grooves in the edge of the panel. This process is repeated for additional wall panels and “I” studs.
[0034] Because it may be necessary in the sequential installation of alternating “I” studs and wall panels to plumb each additional panel, it may be more efficient to install a more complete frame before installing the wall panels. In one embodiment, a portion of the frame for an entire wall may be assembled and then raised and made plumb. Partial frames for the adjoining walls may be assembled and joined together to form the frame for a room, or even an entire building. Having ensured that these wall frames are square and plumb, no additional labor is necessary for this purpose. The panels can simply be installed in/on the frame, knowing that the walls will be square and plumb.
[0035] In this second method of assembly, the initial wall frame may include only a portion of the studs that will ultimately be needed. After the initial frame is up, additional studs (e.g., “I” studs) can be installed, along with the adjoining wall panels, as described above. Alternatively, the initial frame may include incomplete studs (i.e., studs that do not yet have a stiffener plate.) In this case, the stiffener plate for a stud may be attached to the stud after the wall is erected, and the wall panels can be attached to the studs, stiffener plates and each other essentially as described above. There may, of course, be other ways in which the components of the present building system may be installed.
[0036] As noted above, the foregoing disclosure describes only exemplary embodiments of the systems and corresponding methods. There may be many alternative embodiments that are within the scope of this disclosure, such as the use of a base wall track that includes only a single U/J-channel track or has a different configuration than shown above, the use of a top beam that has no tabs or no strengthening indentations or has other configurations than shown above, the use of a stud that has only a single C-channel stud with the stiffener plate or has a different configuration, or other similar variations on the above system. | Systems and methods for building construction that utilize frame members (e.g., studs) having attachment portions to which construction panels can be secured. In one embodiment, a stud designed to support vertical wall panels consists of a pair of metal C-channel studs that are oriented back-to-back with a stiffener plate between them. The stiffener plate extends outward from the stud so that it can be used to secure the wall panels against the stud. The stiffener plate has slots through it that allow biscuits to be placed through the stiffener plate and into the edges of the wall panels that abut the stiffener plate. The biscuits hold the edges of the wall panels in alignment with each other and, because the biscuits extend through the slots in the stiffener plate, the wall panels are held against the stud, thereby stiffening the wall formed by the panels. | 4 |
This invention pertains generally to a method of treatment for carpal tunnel syndrome and, more specifically, to a non-surgical method and apparatus for such treatment the use of which permits therapeutic agents to be delivered directly into the carpal tunnel.
BACKGROUND OF THE INVENTION
Carpal tunnel syndrome is among the most frequently encountered neuro-musculoskeletal disorders. Initially described by Sir James Paget in 1853, the syndrome of median nerve entrapment has been recognized traditionally as primarily a disease of middle life. Recently however, its incidence and prevalence have been increasing among both younger persons and those beyond middle life.
The increase in occurrence of carpal tunnel syndrome has been coincident with a number of factors including lengthening life expectancy. However, a particularly significant factor appears to be the ubiquity of the computer keyboard in both the home and the office. Indeed, because of the wide spread use of the computer in the home and in clerical and office employment, the incidence of carpal tunnel syndrome has increased dramatically. Moreover, it is estimated that afflicted females out number males at a ratio of from 3:1 to 5:1.
The carpal tunnel is a semi-nondistensible, open-ended and approximately cylindrical anatomical compartment bounded by the carpal bones and the flexor retinaculum, a.k.a. the flexor carpal ligament. The carpal tunnel is situated beneath the soft tissues at and just proximal to the wrist, with its long axis parallel with the axial plane of the arm. The carpal tunnel is traversed by the flexor tendons of the hand, the vascular supply of the median nerve and the median nerve itself. The median nerve supplies sensory and motor functional innervations to a substantial and rather distinct portion of the human hand. In the transverse plain, at the level of the distal forearm, the median nerve lies immediately beneath the flexor retinaculum; the flexor tendons to the hand lie deep to the median nerve.
The median nerve is the softest structure within the carpal tunnel, and when intraluminal pressure becomes augmented or increased, the vectors of force are exerted upon and against the median nerve and its blood supply. Patients with carpal tunnel syndrome suffer from elevated intraluminal pressure, such as that resulting from inflammation due to a myriad of potential underlying pathophysiological etiologies, or all too often, without any apparently identifiable reason. Specifically, where intraluminal pressure within the carpal tunnel increases, the consequential impingement of the median nerve and its blood supply leads to circulatory compromise in the median nerve. This compromise in blood flow in turn, slows the rate of median neural conduction which is manifested by an objective functional impairment of the hand. This impairment may be acutely exacerbated by certain mechanical stresses.
The most frequent complaints of carpal tunnel syndrome are hand pain and a numbness characterized by the classic "text book description" of carpal tunnel syndrome which includes: burning, nocturnal hand pain, which generally is sufficient to awaken the patient from sleep, and which may be temporarily relieved by shaking or suspending the hand and forearm in a dependent position. This pain may also radiate proximally to the forearm or elbow, and, at times, even as far as the shoulder. Numbness occurs along the distribution of the median nerve, which includes the anterior surfaces of the thumb, index finger, middle finger, and the radial half of the ring finger, as well as the distal palm. Loss of tactile sensation or thenar muscle atrophy often results in patient complaints of clumsiness or incoordination of the affected hand(s). Muscular wasting is a relatively late phenomenon in the development of the carpal tunnel syndrome disease process.
Traditionally, treatments employed for carpal tunnel syndrome have been classified as either curative or palliative. Of the curative treatments, surgical release and decompression is considered the only viable and therefore accepted method. One example of a recent development in the surgical treatment of carpal tunnel syndrome is disclosed in U.S. Pat. No. 5,089,000 to Agee et. al. However, even an intervention so seemingly definitive as surgery does not enjoy unequivocal success as propitious therapy for carpal tunnel syndrome. Although conventional operative release and decompression of the carpal tunnel has been deemed the only curative modality available, it appears that surgical success, as that term is used in authoritative text in professional journals describe operative results or outcomes which fall short of permanent abatement of all clinical manifestations of carpal tunnel syndrome. It is estimated that as many as approximately 30% of the cases treated via surgery have failed that modality. In other words, surgical success and operative cure are not synonymous terms in the applicable literature.
Even in those published reports which fail to specifically delineate qualifications for successful surgical treatment, a low threshold for categorization of a surgical result as successful may be inferred from the usual very narrow definition of a surgical failure. Most often a case is considered to have failed surgically where no identifiable improvement occurs immediately after surgery, or where symptoms recur during the proximate post-operative convalescent period.
Moreover, because the surgical methods used to treat carpal tunnel syndrome necessarily give rise to some tissue damage and scarring in or about the carpal tunnel, the resultant inflammatory response increases intraluminal pressure post-surgically. This increase in some individuals is permanent, thereby exacerbating this condition in a number of patients.
In sum, surgical treatment for carpal tunnel syndrome, although potentially curative in some cases, is probably more often in reality, a palliative technique which is ineffective in a large fraction (up to 30%, or more over time) of patients. Clearly, operative management of carpal tunnel syndrome has a number of inevitable and potential drawbacks all of which are self-evident.
Carpal tunnel syndrome has recently become the second leading cause of time lost from work due to disability. Employment-related carpal tunnel syndrome presents a number of heretofore unresolved problems relating to a number of factors. Central among these factors is that no known therapeutic modality adequately treats the problem. Specifically, for example, following surgery for employment-associated carpal tunnel syndrome, the patient-employee suffers early reoccurrence of his/her symptoms, even where the work load and duration of work stress have been dramatically reduced. The relevant medical literature has not offered any substantial explanation or recommendation therefore directly. However, two relatively contemporaneous reports, do explain the situation. For example, computerized axial tomography (CAT) scans of the carpal tunnel were obtained before and after surgery for work-related carpal tunnel syndrome. The CAT scans demonstrated that, following division of the flexor retinaculum, the contents of the carpal tunnel subluxed distally and palmarly. Considering this displacement in light of the poor results following carpal tunnel syndrome surgery, in work-related cases, it can reasonably be inferred that such surgery, in fact, places the median nerve and other carpal tunnel contents in a position more vulnerable to the forces causing the malady in the first place, yet without the buffering protection of the intact flexor-retinaculum.
Although a number of palliative measures have been advanced as alternatives to surgical intervention, these measures provide very limited, if any, therapeutic benefits. Palliative therapies include for example, volar, i.e., palmar or anterior, splinting, short-arm and transversing the wrist joint; elevation of the wrist; administration of non-steroidal anti-inflammatory drugs, e.g., aspirin, indomethacin and ibuprofen and their progeny; diuretic agents which may be prescribed intermittently; and administration of corticosteroid drugs. Any limited benefits that palliative therapies can provide are provided only very early on in the course of carpal tunnel syndrome or where carpal tunnel syndrome is present in its mildest form. Thus, the effectiveness of palliative therapy is at best, inconsistent, transient or equivocal, and at worst, may be harmful to the patient.
Corticosteroid administration is perhaps the most interventional and controversial among the various palliative measures traditionally employed in the treatment of carpal tunnel syndrome. Towards this end, investigators and clinicians have administered corticosteroid agents both systemically, by mouth or parenterally, and locally, by injection. Regardless of the route or cite of steroid administration employed in the therapeutic endeavor, authoritative texts which speak to this matter have generally been uniformly unenthusiastic in describing the efficacy of corticosteroid drugs in the management of carpal tunnel syndrome.
Since the time corticosteroid injection therapy was first employed in the management of carpal tunnel syndrome over three decades ago, virtually the identical methodology and location of that technique has been repeatedly adopted, without any material change or refinement. Technically, the traditional injection technique as recorded in the medical literature is neither a site specific injection nor a treatment of carpal tunnel syndrome, but merely a local injection at the wrist utilized as a palliative measure in the presence of median nerve entrapment. As shown in photographs and drawings contained within reported medical literature, the traditional mode of injection deposits medication approximate to the median nerve at a point near, at, or beyond the entrapped nerve's exit from the distal canal.
Review of the particular corticosteroid agents and their dosages employed in traditional corticosteroid injections for carpal tunnel syndrome reveals that these drugs are generally short-acting, often of only mild-to-moderate potency, or are administered in inadequate doses. Significantly however is that the direction of conventional injections is the same as the direction of the flow of the blood and synovial fluid. This not only carries the instillant away from the carpal tunnel, but also, since it is proximate to a rich vascular arcade, this type of injection hastens its removal from the site of its local injection into the systemic circulation. This, in no small way, contributes to the transient nature of whatever benefits might be conferred.
Finally, traditional corticosteroid injections are performed only by a limited number of medical specialists, most of whom are the same physicians who perform the carpal tunnel release surgery. A number of potential complications of corticosteroid injection have been advanced; the most serious of which are impalement of the median nerve and chemical neuritis.
It can be seen from the foregoing that it is desirable to have nonoperative techniques and instrumentalities for the treatment of carpal tunnel syndrome which are substantially more effective to those methods of treatment currently used.
It is an object of the present invention to provide techniques and devices for the treatment of carpal tunnel syndrome which are viable alternatives to surgical treatment methods and eliminate the risk and complications associated with carpal tunnel syndrome surgery, in appropriate patients (which includes the majority).
It is also an object of the present invention to provide patients with greater accessibility to effective therapy for the treatment of carpal tunnel syndrome.
Yet another object of the present invention is to provide a method of treatment for carpal tunnel syndrome which significantly reduces the cost of healthcare associated with its treatment.
Still another object of the present invention is to provide a treatment method for carpal tunnel syndrome which eliminates the peri-operative patient pain, inconvenience, and prolonged recuperation associated with traditional treatment methods.
Another object of the present invention is to provide a treatment modality which is effective in cases considered to be prognostically poor for or which have failed surgery.
Yet another object of the present invention is to provide an effective non-surgical treatment method for carpal tunnel syndrome which may be performed by a variety of medical specialists.
These and other objects of the present invention are fulfilled by the novel technique and instrumentality set forth herein.
BRIEF SUMMARY OF THE INVENTION
The novel technique employed in the instant invention entails the use of an apparatus specifically designed to permit delivery of a sustained release, depot form of a corticosteroid agent at an adequate therapeutic dosage, directly into the center of the carpal tunnel. The corticosteroid is delivered by a needle installation directly into the anatomic center of the carpal tunnel in order to produce the desired pharmacological effects associated with the use of corticosteroids. These pharmacological effects include both the early anti-inflammatory effects caused by corticosteroid agents, as well as delayed benefits derived from inhibition of scar formation and fibrinogenesis which are seen as latter positive pharmacotherapeutic manifestations with sustained corticosteroid activity after injection of one of the newer synthetic, long-acting agents. The apparatus for the novel technique herein makes treatment of carpal tunnel syndrome a procedure that can be performed by virtually by any physician. In addition, among the other advantages, the novel technique entails injection at and into a site which is not in proximity to the median nerve itself thereby removing the risk of impalement and chemical neuritis.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view of an embodiment of the armboard of the instant invention.
FIG. 2 is a side cross-sectional view of the apparatus of FIG. 1 at line 2a-2b.
FIG. 3 is a top plan view of the apparatus of FIG. 1, shown with a representation of a human forearm and hand.
FIG. 4 is a cross-sectional schematic view of the apparatus shown in FIG. 3, taken along the lines 4a-4b.
FIG. 5 is a top plan view of the wrist bracket and central needle guide portion of the apparatus shown in FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1, there is shown one embodiment of the limb-restraint, injection support armboard 1, of the present invention. As depicted in the embodiment shown, armboard 1 is a generally flat, rectangular shape having a proximal end 2, a distal end 4, two side ends 6, an upper planar surface 8, and a lower planar surface 10, separated by wrist flexion curb 12. Upper planar surface 8 and lower planar surface 10 include an arm support member 14, which is preferably a depression or channel, and which may be more preferably, a generally "u-shaped" channel. Arm support member 14 may also be preferably located generally centrally within the body of the armboard. Arm support member 14 is formed so as to receive and generally support the human forearm on upper planar surface 8, and to receive and generally support the hand on lower planar surface 10, of the armboard.
Situated at or near flexion curb 12, preferably on upper planar surface 8 are a pair of adjustable side brackets 16, each having side bracket adjustment slots 18 and side bracket set screws 20. Side bracket set screws 20 permit side brackets 16 to be mounted on armboard 1 and facilitate the adjustment and securing of a human forearm, preferably anchoring the forearm and wrist within arm support member 14, at or near the ulnar and radial styloid processes. In the embodiment depicted, side bracket set screws are wing-nuts; however, other similar mated-thread assemblies and other alternative mounting and securing means may be used including, for example, compression fittings, sliding fasteners, or ratcheted post and guides.
Preferably, side brackets 16 are located directly opposite each other and are moveable in an inward-outward direction relative to each other, as well as in planar arcuate directions. Side brackets 16 include forearm positioning surfaces 22, which may be contoured, cushioned or otherwise molded to firmly secure a forearm in place with minimum discomfort to the patient. In other, alternate embodiments of the armboard of the present invention, one of the side brackets may be fixed in-place with the other being adjustable in the manner described above, so as to allow adjustment of the forearm to occur at one side of the forearm with the opposite side bracket being essentially stationary. In other embodiments of the armboard of the instant invention, alternative securing means for securing the forearm and wrist may be used, including, for example, clamps or straps which may include hook and pile, velcro-type fasteners.
When in use, a patient's forearm and hand is placed in the armboard, palmar side-up and is positioned in arm support member 14 so that the wrist will lie approximately at or near wrist flexion curb 12. Wrist flexion curb 12 facilitates proper flexion of a patient's wrist to generally expose and provide access to the carpal tunnel. Proper placement will put the patient's hand in a range of approximately 10 to 30 degrees of dorsi-flexion, with the preferred degree of dorsi-flexion of approximately 20 degrees. Wrist flexion curb 12 may be incorporated in the armboard as a slope or ramp with the appropriate angular orientation or it may be an angular 90 degree drop-off or ledge of not more than roughly 3 inches between the upper and lower planar surfaces. Wrist placement may also be further facilitated by the use of positioning blocks, wedges or other shapes including those dictated by patient comfort considerations, which may be placed under the hand and/or forearm.
Positioned at or near flexion curb 12 and preferably above the plane of side brackets 16, is wrist bracket 24. Wrist bracket 24 includes a pair of wrist bracket adjustment slots 26, and may also include central needle guide 30 which may be mounted directly to armboard 1, via wrist bracket adjustment screws 28. In alternate preferred embodiments, wrist bracket 24 may be offset and mounted above side brackets via side bracket adjustment screws 28. In other alternative embodiments, wrist bracket 24 may have only a single adjustment slot for mounting and adjustment. In these embodiments, the wrist bracket remains essentially adjustable in the manner described above. Still, in other alternative embodiments, needle guide 30 may be mounted onto the armboard, separately and apart from wrist bracket 24.
Located generally centrally within wrist bracket 24 is needle guide 30. Guide 30 includes at its proximal side edge centering pointer 32, needle entrance 34, needle channel 36 (shown in outline detail) and needle exit 38. Needle channel 36 lies between needle entrance 34 and needle exit 38. Centering pointer 32 also includes viewing aperture 40 for viewing needle insertion between the two central tendons of a patient's forearm. In one preferred embodiment of the present invention, viewing aperture 40 is simply a opening or void in the centering pointer. In other preferred embodiments, viewing aperture 40 may include a magnifying lens and/or lighting means to facilitate viewing of a needle injection site prior to the needle's insertion into a patient's forearm. Needle entrance 34 is preferably constructed so as to permit insertion there through a flexible sterile needle and through which a drug delivery canula, also preferably flexible, may be passed into the needle interior and ultimately to the carpal tunnel. Upon insertion of the flexible sterile needle into the needle entrance, through the channel and out of the needle exit, a medication delivery tube will typically be inserted therein with the needle being then withdrawn from the injection site. A preferred medication dosage formula may then be infused directly into the injection site. In one preferred embodiment, needle entrance 34 may also include at the end opposite the needle channel, needle hub 42 and syringe adapter 44. Needle hub 42 facilitates attachment of syringe adapter 44 to a cannula or conduit which may be used to infuse an injection site. Syringe adapter 44 is a multi-way valve, such as a three-way stopcock valve, which permits infusion of medication from syringes 46 and 48. In other preferred embodiments, a single needle and syringe may be used to deliver medication to the carpal tunnel.
Armboard 1, and its major component structural parts are preferably made of rigid or semi-rigid materials from which the apparatus made be easily and economically fabricated. Suitable materials for the construction of the apparatus or its component parts include, for example, nylon, ABS, or other light-weight durable plastics or may be made of metal, including aluminum, stainless steel or other materials, including reinforced fiberglass, ceramic composites, or combinations of these materials which are capable of withstanding both repeated use and sterilization processes whether by heat or chemicals. Moreover, the various component parts, such as side brackets, forearm positioning surfaces, wrist brackets and needle guides may also be made in different sizes to accommodate the forearm sizes of a variety of patients, for example, as between younger and older patients or between male and female patients.
Finally, in other preferred embodiments of the armboard of the instant invention, the forearm bearing surface of armboard 1 may be constructed so to form a pair of opposed inclines or ramps, with the wrist flexion curb forming the apex of the two inclines. The incline forming the upper planar surface will support the forearm proper and the incline forming the lower planar surface will support the hand. In these embodiments, the wrist will be placed at the wrist flexion curb with the forearm and hand resting on the arm support member in the manner described above.
In FIG. 2 is shown a side cross-sectional view of the armboard of FIG. 1 at line 2a-2b. The portion of armboard 1 including proximal end 2, generally carries upper planar surface 8, whereas the portion designated distal end 4, includes lower planar surface 10. Shown in partial outline is arm support member 14, depicted as a generally "u-shaped" channel defined at its upper surface edge by upper planar surface 8. Arm support member 14 is preferably of sufficient depth to permit a patient's forearm to rest securely therein. Separating upper and lower planar surfaces is wrist flexion curb 12, generally shown as a slope having an angle of between 10 to 30 degrees, and preferably, having a slope of approximately 20 degrees.
Positioned at or near flexion curb 12, is adjustable side bracket 16. In the embodiment shown in FIG. 2, side bracket 16 is moveable in an inward-outward direction relative to the plane of the drawing, as well as being moveable in an arcuate direction across the drawing plane. Side bracket 16 includes forearm positioning surface 22, which may be contoured, cushioned or otherwise adapted to firmly secure a forearm in place, preferably anchoring the forearm at the ulnar and radial styloid portions. Side bracket 16 is adjustable via bracket adjustment slots 18 (not shown) and side bracket set screws 20 (shown in phantom detail). In alternate embodiments, one side bracket may be non-moveable, so as to allow securing and adjustment of the forearm to occur only on one side of the forearm with the member of the opposite side bracket pair being adjustable.
Positioned at or near flexion curb 12 and at the terminus of arm support member 14 is wrist bracket 24. Wrist bracket 24 includes central needle guide 30. In the embodiment shown, wrist bracket 24 is mounted to armboard 1, via a pair of wrist bracket adjustment screws 28. In alternate embodiments, wrist bracket 24 may have only a single adjustment slot and screw for mounting and adjustment. Guide 30 includes at its proximal side edge centering pointer 32, needle entrance 34, needle channel 36 (shown in phantom detail) and needle exit 38. Needle channel 36 lies between needle entrance 34 and needle exit 38.
FIG. 3 shows a top plan view of the apparatus of FIG. 1, shown with a representation of a human forearm and hand. When the armboard is in use, the forearm and hand may be placed in the centrally located arm support member 14, with the elbow portion of the forearm situated at or near proximal end 2. The forearm and hand are positioned palmar side-up and are advanced towards distal end 4 of armboard 1, until the point of transition occurring at wrist flexion curb 12. By placing the flexor-palmar crease of the wrist portion of the forearm at wrist flexion curb 12, the wrist will be in approximately 20 degrees of dorsi-flexion, thereby providing access to the carpal tunnel from between the two central tendons, designated CT-1 and CT-2. After the wrist is in proper placement at wrist flexion curb 12, side brackets 16 are moved inwardly to bring forearm positioning surfaces 22 in contact with the lateral surfaces of the forearm, preferably at the ulnar and radial styloids. The forearm is then secured in place by side brackets 16 via side bracket adjustment screws 18.
After securing the forearm in place, wrist bracket 24, carrying central needle guide 30 is brought into position over the forearm. Typically the patient's forearm may then be prepared for sterile technique as is well-known in the art. Wrist bracket 24 further secures the forearm at the palmar surface of the wrist by providing downward force on that surface which may be adjusted by wrist adjustment screws 28. As part of securement of the wrist, centering pointer 32 is brought into position between the two central tendons of the forearm. Centering pointer 32 includes viewing window 40 for visual inspection of the injection site on the forearm above the carpal tunnel. After proper placement of centering pointer 32 and after wrist bracket 24 is secured in place, a flexible needle is advanced into needle entrance 34, through needle channel 36 and out of needle exit 38. Preferably, the flexible needle used will be of sufficient length to traverse the entire length of the needle guide without requiring excessive compression of the forearm by wrist bracket 24 in order to reach the carpal tunnel. Typically, the needle used will be from 20 to 26 gauge and will be from 1 to 3 inches in length, preferably 1.5 to 2 inches, depending on the size of the patient's forearm, the configuration of the wrist bracket assembly and the placement of the forearm within the forearm channel. It is important however, to bear in mind that the needle need only be of sufficient length to permit the needle tip to enter into the midpoint of the carpal tunnel without proceeding at all into the median nerve. After the injection site is identified, the site may be prepared with a topical anesthetic spray or subcutaneous injection of a small dose of local anesthetic, prior to infusion of other medications.
In one preferred embodiment of the method of use of the instant invention, after the needle is properly placed into the carpal tunnel of the afflicted extremity, a sterile, flexible plastic conduit or cannula 50 (not shown) may be introduced into the interior of the flexible needle and then passed through to the terminus of the injection site. The needle tip may then be withdrawn while leaving the flexible cannula 50 in place in the carpal tunnel. The cannula end opposite the injection site end may then be fitted with a needle-hub and connected to a syringe or other delivery means for providing appropriate medication directly to the carpal tunnel.
In a preferred embodiment of the method herein, syringe adapter 44 may be connected to the conduit end opposite the injection site end of flexible cannula 50. Preferably this will be a multi-way valve, and more preferably, a three-way valve connected at one port to cannula 50 and at each of the remaining two ports to syringes 46 and 48, one of which contains a local, moderate to long duration injectable anesthetic and the other of which contains a corticosteriodal preparation, respectively.
In this preferred embodiment, syringe 46 is a 5 cc. syringe containing roughly 3 to 5 cc. of a long-acting, local anesthetic agent. Suitable anesthetic agents include those which are non-irritating to the tissue to which they are applied and which do not cause any permanent damage to the nerve structures, such as for example, Lidocaine, mepivacaine or bupivacaine. One preferred agent is a long duration Mepivacaine 5% solution. Syringe 48 is also a 5 cc. syringe containing a long-acting depot form of a synthetic corticosteroid ester. Suitable corticosteroids are those which possess high anti-inflammatory relative potencies such as, for example, prednisolone, methyl-prednisolone, triamcinolone and dexamethasone, marketed under the trade names Hydeltrasol, Hydelta-T.B.A., Depo-Medrol, Medrol Acetate, Aristocort Diacetate and Decadron L.A. One preferred corticosteroid is methyl-prednisolone administered at a dosage range of approximately 1 to 2 milligrams per kilogram of body weight of the patient, preferably at 1.4 to 1.6 milligrams per kilogram per injection.
Following insertion of the cannula and attachment of multi-way valve syringe adapter 44 and syringes 46 and 48, the lever on the valve is set to permit introduction of the long-acting anesthetic from syringe 46 into the injection site. After supplying sufficient local anesthetic into the carpal tunnel, the lever is then moved to permit introduction of the corticosteroid dosage from syringe 48 into the carpal tunnel. After supplying the corticosteroid, the cannula is withdrawn, the needle guide is removed and the forearm is removed from the armboard. In conformity with sterile technique, it is also desirable to apply a topical antibiotic and bandage to the injection site. In some instances, it may also be desirable to apply a volar splint to immobilize the hand and forearm for an eight to twelve hour period before resuming normal activities with the afflicted extremity. The procedure may also be repeated on the opposite extremity where bi-lateral symptomatology is present.
FIG. 4 shows a cross-sectional schematic view of the apparatus shown in FIG. 3, taken along the lines 4a-4b. By placing the flexor-palmar crease of the wrist portion of the forearm at wrist flexion curb 12, the wrist is in approximately 20 degrees of dorsi-flexion. Side brackets 16 have been moved inwardly to bring forearm positioning surfaces 22 in contact with the lateral surfaces of the forearm, preferably at the ulnar and radial styloids. Wrist bracket 24, carrying central needle guide 30 is positioned over the forearm, thereby providing a visual cue as to the location of the carpal tunnel from between the two central tendons, indicated by the designations CT-1 and CT-2. Wrist bracket 24 rests on the forearm on the palmar surface of the wrist and provides downward force on that surface to partially immobilize the wrist. After proper placement of centering pointer of wrist bracket 24, a flexible needle is advanced into needle entrance 34, through needle channel 36 (shown in phantom detail) and out of needle exit 38. A flexible needle of sufficient length to traverse the entire length of the needle guide and permit the needle tip to enter into the carpal tunnel without proceeding into the median nerve is used in needle guide 30. Syringe adapter 44 and syringes 46 and 48 are shown at needle entrance 34. Cannula 50 having cannula terminus end 52 is shown located in the carpal tunnel at a point cephalad to the median nerve (MN).
In FIG. 5 there is shown a top plan view of the wrist bracket and needle guide portion of the apparatus of FIG. 1. Wrist bracket 24, includes central needle guide 30 and a pair of wrist bracket adjustment slots 26 for mounting the bracket to armboard 1 and for lateral adjustment of the needle guide. Central needle guide 30 includes centering pointer 32, needle entrance 34, needle channel 36 (shown in phantom detail) and needle exit 38. Centering pointer 32 includes viewing aperture 40 for visual inspection of the injection site on the forearm anterior to the carpal tunnel. As can be seen, needle exit 38 is located at or within viewing aperture 40 and is situated at or near the proximal side end of wrist bracket 24. Needle channel 36 is of sufficient length to allow an associated flexible needle to traverse the entire length of the needle guide, exiting at needle exit 38, and to permit the needle tip to reach the midpoint of the carpal tunnel. Channel needle 36 is also of sufficient bore to accommodate from 20 to 26 gauge needles and is preferably from 0.75 to 2.5 inches in length, from its starting point at needle entrance 34 to needle exit 38. In one preferred embodiment, needle channel 36 is also curved downwardly, so that needle exit 38 is generally perpendicular to a proposed injection site. In other preferred embodiments, needle exit 38 may also be from approximately 20 to 80 degrees off perpendicular, depending on, for example, the configuration of the wrist bracket itself, the angle of the slope or ledge of the wrist flexion curb and the location of the forearm and hand within the armboard. In other preferred embodiments, the needle guide 30 may be made removable from wrist bracket 24. After the forearm and wrist are properly positioned by the wrist bracket, the needle guide may be placed in an opening adapted to receive the needle guide, within the wrist bracket.
The foregoing descriptions are illustrative of the preferred embodiments shown. The descriptions are not intended to limit the present invention to the specific apparatuses and techniques shown and described, but instead it will be appreciated that adaptations and modifications will become apparent from the present disclosure which are intended to be within the scope of the claims as set forth below. | An apparatus and method of use for treating carpal tunnel syndrome designed to permit delivery of a sustained release, depot form of a corticosteroid agent at an adequate therapeutic dosage, directly into the center of the carpal tunnel. The apparatus consists of an armboard adapted for receiving and securing a human forearm and hand. In a preferred embodiment, the armboard also includes at least one forearm bracket and at least one wrist bracket having an integrally formed centering pointer and needle guide for delivery of medication into the carpal tunnel. In one embodiment of the method of use, an anesthetic agent and a corticosteroid are delivered by a needle installation directly into the anatomic center of the carpal tunnel in order to produce the desired pharmacological effects. | 8 |
This is a division of prior application Ser. No. 09/901,277 filed Jul. 9, 2001.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a recording medium on which a plurality of programs are collected in a plurality of groups and supervised in this grouped state, and an editing method and apparatus for editing, such as dividing/linking/erasing the predetermined programs or groups, recorded on the recording medium.
2. Description of Related Art
An optical disc can be larger in recording capacity than a magnetic disc by two to three order of magnitudes and can be accessed at a higher speed than a tape-shaped recording medium. In addition, the optical disc has merits such as non-contact recording and/or reproduction for a medium and high durability and, for this reason, has recently come to be used extensively.
Among known optical discs, there are, for example, a replay-only optical disc, conforming, as a standard, to the CD-DA (Digital Audio) format, for a standard CD (Compact Disc) having a replay-only area having data recorded in the form of pits, a magneto-optical disc, formed by a magneto-optical recording medium, conforming, as a standard, to the CD-MO (Magneto-Optical) format, as an extension format of the CD-DA format, having a recording and/or reproducing area, and a hybrid disc, including both a replay-only area, having data recorded thereon as pits, and a recording and/or reproducing area for data recording and/or reproduction.
Heretofore, in a disc recording and/or reproducing apparatus for recording data on a disc-shaped recording medium, such as a magneto-optical disc or a hybrid disc, recording is halted by a manual operation whenever the recording data has become useless data in the course of recording. For example, in recording a music air from a compact disc to a magneto-optical disc, recording by a magneto-optical disc recorder is halted by a manual operation after the end of the reproduction by a CD player.
Meanwhile, in a disc-shaped recording medium, such as an optical disc or a magneto-optical disc, there are provided a main data recording area for recording the main data, and a management data area for recording the management data, and the main data recording area is supervised as to a recorded area and a recordable area by management data recorded in the management data area. For example, the optical disc conforming to the CD format includes a data area, having program data, such as performance data, recorded thereon, and a lead-in area provided on its inner rim side. As the table-of-contents (TOC) data, showing the sites of recording and recording contents of the data area, the recorded start address information and the recording end address information for the entire program data are recorded in order in the lead-in area.
The present Assignee has already proposed an MD system for digitally recording and/or reproducing e.g., music signals, using a Mini-Disc (MD, a registered trademark) comprised of an optical disc 64 mm in diameter accommodated in a cartridge. There are three sorts of the Mini-Disc, namely a replay-only optical disc, a recordable optical disc and a hybrid disc comprised of a replay-only area and a recordable area. In an MD system capable of recording main data, a program area and UTOC (User TOC) area are provided in the recordable area of the Mini-Disc and the table of contents data indicating the recording positions and contents of the program arera are recorded in the UTOC area. That is, in the case of the Mini-Disc system, there is recorded the management data, termed UTOC, apart from the main data, such as music data, for supervising the recorded data area, in which the user has made recording on the disc, and a non-recorded area, that is a recordable area. The recording apparatus discriminates an area in which to make recording, as it references this UTOC, whilst the reproducing apparatus discriminates an area to be reproduced as it references the UTOC.
That is, programs etc as each music air recorded are managed in the UTOC in terms of tracks as data units, and the start and end addresses thereof are recorded therein. In a free area in the UTOC, where no recording has been made, there are recorded start and end addresses, as an area in which to record data as from the current time.
In the Mini-Disc system, a disc name, capable of indicating e.g., the disc title as a part of the editing function, and a track name, capable of indicating the title of e.g., a program, recorded in terms of a track or a program as a unit, can be input and registered by a user in accordance with a predetermined operating method. In the Mini-Disc system, the letter information registered as the disc or track name, is stored in a predetermined area on the UTOC, such that, in e.g., reproduction, the letter information stored can be displayed and output by referencing the disc name and the track name of the desired track stored in the UTOC. In the following, the disc name and the track name are collectively referenced as a “name”.
By exploiting these functions, the user may register disc or track names and subsequently confirm the registration as the name of the disc loaded in the reproducing apparatus or the name of the track-based music air is demonstrated on a display unit. Meanwhile, in the Mini-Disc system, recording up to the maximum of 80 minutes (160 minutes for monaural recording) is possible by data compression employing the ATRAC (acoustic transferred adapted coding system). Even the recording of the maximum 320 minutes in a LP4 (long playing) mode by employing the ATRAC3 compression system.
In the conventional Mini-Disc system, there is only a concept of managing the entire disc and the music airs, as a recorded management method, so that, if an album of three CDs is recorded in accordance with ATRAC 3, it has not been possible to perform album-based management.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a recording medium in which plural programs are collectively recorded and managed in plural groups and in which the management data can be edited in case editing commands, such as splitting/linking/erasure for the programs or the groups of programs are issued.
In one aspect, the present invention provides a recording medium in which a plurality of programs are collected into a plurality of groups and are managed and recorded in this form, in which the recording medium includes a program recording area in which the programs are recorded, a first management data recording area in which the first management data for supervising the program names of the plural programs is recorded and a second management data recording area in which the names of the programs collected in the plural groups and the names of the groups are correlated and are recorded as the second management data along with the separating information for separating the program names and the group names.
In another aspect, the present invention provides an editing apparatus for editing a program recorded on a recording medium including a program area for recording a plurality of programs for recording a plurality of programs, and a management area, having recorded therein the first management data for managing the program names for respective programs recorded in the program area, and the second management data, made up of the range information of program numbers making up each of a plurality of groups into which the plural programs recorded in the program area are collected, special codes partitioning the groups from one another, and group names, in which the apparatus includes operating means for commanding changes in the sequence of predetermined ones of the plural groups and editing means which, in case changes in the sequence of predetermined ones of the plural groups are commanded by the operating means, edits the correlation of the range information of program numbers making up each of a plurality of groups in the second management data and the group names to cause block movement of the predetermined groups.
In still another aspect, the present invention provides an editing apparatus for editing a program recorded on a recording medium including a program area for recording a plurality of programs for recording a plurality of programs, and a management area, having recorded therein the first management data for managing the program names for respective programs recorded in the program area, and the second management data, made up of the range information of program numbers making up each of a plurality of groups into which the plural programs recorded in the program area are collected, special codes partitioning the groups from one another, and group names, in which the apparatus includes operating means for commanding division of a predetermined program of predetermined ones of the plural groups, and editing means which, in case division of a predetermined program of predetermined ones of the plural groups is commanded by the operating means, edits the correlation of the range information of program numbers making up each of a plurality of groups in the second management data and the group names.
In still another aspect, the present invention provides an editing apparatus for editing a program recorded on a recording medium including a program area for recording a plurality of programs for recording a plurality of programs, and a management area, having recorded therein the first management data for managing the program names for respective programs recorded in the program area, and the second management data, made up of the range information of program numbers making up each of a plurality of groups into which the plural programs recorded in the program area are collected, special codes partitioning the groups from one another, and group names, in which the apparatus includes operating means for commanding linking of two of the programs making up a predetermined group of the plural groups, and editing means which, in case linking of two of the programs making up a predetermined group of the plural groups is commanded by the operating means, edits the correlation of the range information of program numbers making up each of a plurality of groups in the second management data and the group names.
In another aspect, the present invention provides an editing apparatus for editing a program recorded on a recording medium including a program area for recording a plurality of programs for recording a plurality of programs, and a management area, having recorded therein the first management data for managing the program names for respective programs recorded in the program area, and the second management data, made up of the range information of program numbers making up each of a plurality of groups into which the plural programs recorded in the program area are collected, special codes partitioning the groups from one another, and group names, in which the apparatus includes operating means for commanding division of a predetermined group of the plural groups into two, and editing means which, in case division of the predetermined group is commanded by the operating means, edits the correlation of the range information of program numbers making up each of a plurality of groups in the second management data and the group names.
In still another aspect, the present invention provides an editing apparatus for editing a program recorded on a recording medium including a program area for recording a plurality of programs for recording a plurality of programs, and a management area, having recorded therein the first management data for managing the program names for respective programs recorded in the program area, and the second management data, made up of the range information of program numbers making up each of a plurality of groups into which the plural programs recorded in the program area are collected, special codes partitioning the groups from one another, and group names, in which the apparatus includes operating means for commanding linking of predetermined ones of the plural groups, and editing means which, in case linking of predetermined ones of the plural groups is commanded by the operating means, edits the correlation of the range information of program numbers making up each of a plurality of groups in the second management data and the group names to cause block movement of the predetermined groups.
In still another aspect, the present invention provides an editing apparatus for editing a program recorded on a recording medium including a program area for recording a plurality of programs for recording a plurality of programs, and a management area, having recorded therein the first management data for managing the program names for respective programs recorded in the program area, and the second management data, made up of the range information of program numbers making up each of a plurality of groups into which the plural programs recorded in the program area are collected, special codes partitioning the groups from one another, and group names, in which the apparatus includes operating means for commanding block erasure of predetermined ones of the plural groups, and editing means which, in case block erasure of predetermined ones of the plural groups is commanded by the operating means, edits the correlation of the range information of program numbers making up each of a plurality of groups in the second management data and the group.
In still another aspect, the present invention provides an editing method for editing a program recorded on a recording medium including a program area for recording a plurality of programs for recording a plurality of programs, and a management area, having recorded therein the first management data for managing the program names for respective programs recorded in the program area, and the second management data, made up of the range information of program numbers making up each of a plurality of groups into which the plural programs recorded in the program area are collected, special codes partitioning the groups from one another, and group names, in which the method includes an operating step for commanding changes in the sequence of predetermined ones of the plural group, and an editing step which, in case changes in the sequence of predetermined ones of the plural groups are commanded by the operating step, edits the correlation of the range information of program numbers making up each of a plurality of groups in the second management data and the group names to cause block movement of the predetermined groups.
In still another aspect, the present invention provides an editing method for editing a program recorded on a recording medium including a program area for recording a plurality of programs for recording a plurality of programs, and a management area, having recorded therein the first management data for managing the program names for respective programs recorded in the program area, and the second management data, made up of the range information of program numbers making up each of a plurality of groups into which the plural programs recorded in the program area are collected, special codes partitioning the groups from one another, and group names, in which the method includes an operating step for commanding division of a predetermined program of predetermined ones of the plural groups, and an editing step which, in case division of a predetermined program of predetermined ones of the plural groups is commanded by the operating step, edits the correlation of the range information of program numbers making up each of a plurality of groups in the second management data and the group names.
In still another aspect, the present invention provides an editing method for editing a program recorded on a recording medium including a program area for recording a plurality of programs for recording a plurality of programs, and a management area, having recorded therein the first management data for managing the program names for respective programs recorded in the program area, and the second management data, made up of the range information of program numbers making up each of a plurality of groups into which the plural programs recorded in the program area are collected, special codes partitioning the groups from one another, and group names, in which the method includes an operating step for commanding linking of two of the programs making up a predetermined group of the plural groups, and an editing step which, in case linking of two of the programs making up a predetermined group of the plural groups is commanded by the operating step, edits the correlation of the range information of program numbers making up each of a plurality of groups in the second management data and the group names.
In still another aspect, the present invention provides an editing method for editing a program recorded on a recording medium including a program area for recording a plurality of programs for recording a plurality of programs, and a management area, having recorded therein the first management data for managing the program names for respective programs recorded in the program area, and the second management data, made up of the range information of program numbers making up each of a plurality of groups into which the plural programs recorded in the program area are collected, special codes partitioning the groups from one another, and group names, in which the method includes an operating step for commanding division of a predetermined group of the plural groups into two and an editing step which, in case division of the predetermined group is commanded by the operating step, edits the correlation of the range information of program numbers making up each of a plurality of groups in the second management data and the group names.
In still another aspect, the present invention provides an editing method for editing a program recorded on a recording medium including a program area for recording a plurality of programs for recording a plurality of programs, and a management area, having recorded therein the first management data for managing the program names for respective programs recorded in the program area, and the second management data, made up of the range information of program numbers making up each of a plurality of groups into which the plural programs recorded in the program area are collected, special codes partitioning the groups from one another, and group names, in which the method includes an operating step for commanding linking of predetermined ones of the plural groups, and an editing step which, in case linking of predetermined ones of the plural groups is commanded by the operating step, edits the correlation of the range information of program numbers making up each of a plurality of groups in the second management data and the group names to cause block movement of the predetermined groups.
In yet another aspect, the present invention provides an editing method for editing a program recorded on a recording medium including a program area for recording a plurality of programs for recording a plurality of programs, and a management area, having recorded therein the first management data for managing the program names for respective programs recorded in the program area, and the second management data, made up of the range information of program numbers making up each of a plurality of groups into which the plural programs recorded in the program area are collected, special codes partitioning the groups from one another, and group names, in which the method includes an operating step for commanding block erasure of predetermined ones of the plural groups, and an editing step which, in case block erasure of predetermined ones of the plural groups is commanded by the operating step, edits the correlation of the range information of program numbers making up each of a plurality of groups in the second management data and the group.
According to the present invention, as described above, a recording medium is provided which includes a program area in which to record plural programs, and a management area in which to record the second management data for supervising the group name associated with each group into which the plural programs recorded in the program area is collected. The second management data, recorded in the management area, is made up of the range information of the program numbers making up the group, special codes partitioning the respective group names, and the group names, so that the programs recorded in the recording medium can be supervised as plural groups.
According to the present invention, if, in editing a program recorded on a recording medium including a program area for recording a plurality of programs, and a management area, having recorded therein the first management data for managing the program names for respective programs recorded in the program area, and the second management data, made up of the range information of program numbers making up each of a plurality of groups into which the plural programs recorded in the program area are collected, special codes partitioning the groups from one another, and group names, a change in the sequence is commanded to predetermined groups in the plural groups, the correlation between the range information of the program numbers making up the groups in the second management data and the group names is edited to effect block movement of the predetermined groups to supervise the programs recorded in the recording medium to effect group-based movement.
According to the present invention, if, in editing a program recorded on a recording medium including a program area for recording a plurality of programs, and a management area, having recorded therein the first management data for managing the program names for respective programs recorded in the program area, and the second management data, made up of the range information of program numbers making up each of a plurality of groups into which the plural programs recorded in the program area are collected, special codes partitioning the groups from one another, and group names, a predetermined program forming the predetermined groups in the plural groups is commanded to be split, the correlation between the range information of the program numbers making up the groups in the second management data and the group names is edited to supervise the programs recorded in the recording medium as plural groups to effect the editing of dividing the program in the group.
According to the present invention, if, in editing a program recorded on a recording medium including a program area for recording a plurality of programs for recording a plurality of programs, and a management area, having recorded therein the first management data for managing the program names for respective programs recorded in the program area, and the second management data, made up of the range information of program numbers making up each of a plurality of groups into which the plural programs recorded in the program area are collected, special codes partitioning the groups from one another, and group names, two of the programs forming the predetermined groups in the plural groups are linked, the correlation between the range information of the program numbers making up the groups in the second management data and the group names is edited to supervise the programs recorded in the recording medium as plural groups to effect the editing of linking the two programs in the group.
According to the present invention, if, in editing a program recorded on a recording medium including a program area for recording a plurality of programs for recording a plurality of programs, and a management area, having recorded therein the first management data for managing the program names for respective programs recorded in the program area, and the second management data, made up of the range information of program numbers making up each of a plurality of groups into which the plural programs recorded in the program area are collected, special codes partitioning the groups from one another, and group names, a predetermined group is commanded to be split into two, the correlation between the range information of the program numbers making up the group in the second management data and the group name is edited to supervise the programs recorded in the recording medium as plural groups to effect the editing of dividing the group into two portions.
According to the present invention, if, in editing a program recorded on a recording medium including a program area for recording a plurality of programs for recording a plurality of programs, and a management area, having recorded therein the first management data for managing the program names for respective programs recorded in the program area, and the second management data, made up of the range information of program numbers making up each of a plurality of groups into which the plural programs recorded in the program area are collected, special codes partitioning the groups from one another, and group names, predetermined groups are commanded to be linked together, the correlation between the range information of the program numbers making up the groups in the second management data and the group names is edited to supervise the programs recorded in the recording medium as plural groups to effect the editing of linking the groups together.
According to the present invention, if, in editing a program recorded on a recording medium including a program area for recording a plurality of programs for recording a plurality of programs, and a management area, having recorded therein the first management data for managing the program names for respective programs recorded in the program area, and the second management data,
made up of the range information of program numbers making up each of a plurality of groups into which the plural programs recorded in the program area are collected, special codes partitioning the groups from one another, and group names, predetermined groups are commanded to be erased in a block, the correlation between the range information of the program numbers making up the groups in the second management data and the group names is edited to supervise the programs recorded in the recording medium as plural groups to effect the editing of block group-based erasure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing the structure of an MD player embodying the present invention.
FIG. 2 illustrates a cluster format of a Mini-Disc.
FIG. 3 illustrates a UTOC sector 0 of the Mini-Disc.
FIG. 4 illustrates a link configuration of UTOC sector 0 of the Mini-Disc.
FIG. 5 illustrates a UTOC sector 1 of the Mini-Disc
FIG. 6 illustrates a data allocation structure of RAM provided in a system controller and a buffer memory in the MD recorder.
FIG. 7 shows the contents of a menu display in the MD recorder.
FIG. 8 is a flowchart showing the processing sequence in the album title input mode in the MD recorder.
FIG. 9 is a flowchart showing the processing for registration in a disc name area in the album title input mode.
FIG. 10 is a schematic view showing a typical example of registration contents of a disc name area in case the registration processing in the disc name area in case of performing registration processing in the disc name area.
FIG. 11 is a schematic view showing another typical example of registration contents of a disc name area in case the registration processing in the disc name area in case of performing registration processing in the disc name area.
FIG. 12 is a schematic view showing still another typical example of registration contents of a disc name area in case the registration processing in the disc name area in case of performing registration processing in the disc name area.
FIG. 13 is a flowchart showing the processing sequence of the album title display mode in the MD recorder.
FIG. 14 is a flowchart showing the processing sequence of the album erasure mode in the MD recorder.
FIG. 15 schematically shows a typical example of registration contents of the disc name area in case of performing the processing of album erasure mode.
FIG. 16 is a flowchart showing the continuous track erasure processing in the album erasure mode.
FIG. 17 is a flowchart showing the single music air erasure processing in the album erasure mode.
FIG. 18 is a flowchart showing the album title erasure processing in the album erasure mode.
FIG. 19 is a flowchart showing the album movement mode in the MD recorder.
FIG. 20 schematically shows a typical example of registration contents of the disc name area in case of performing the processing of album movement mode.
FIG. 21 is a flowchart showing the processing sequence of the album AMS mode in the MD recorder.
FIG. 22 is a flowchart showing the processing sequence of the album repeat mode in the MD recorder.
FIG. 23 schematically shows a typical example of the registration contents of the disc name area in case of performing editing processing by album linking.
FIG. 24 schematically shows a typical example of the registration contents of the disc name area in case of performing editing processing by album splitting.
FIG. 25 schematically shows a typical example of the registration contents of the disc name area in case of performing editing processing by erasing tracks in an album.
FIG. 26 schematically shows a typical example of the registration contents of the disc name area in case of performing editing processing by linking tracks in an album.
FIG. 27 schematically shows a typical example of the registration contents of the disc name area in case of performing editing processing by splitting tracks in an album.
FIG. 28 schematically shows registration contents in case of write-once recording plural music airs.
FIG. 29 schematically shows registration contents in case of overwrite recording plural music airs.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings, preferred embodiments of the present invention will be explained in detail.
The present invention is applied to an MD recorder 1 shown for example in the block diagram of FIG. 1 .
The MD recorder 1 is capable of recording and/or reproducing speech data on or from a magneto-optical disc (MD; Mini-Disc, a registered trademark) 90 .
A magneto-optical disc 90 , housed in a cartridge, is configured for being irradiated with the light from an optical head 3 as an optical pickup or applying a magnetic field from a magnetic head by opening/closing a shutter mechanism provided in the cartridge in recording and/or reproduction.
The magneto-optical disc 90 is run in rotation at a CLV (constant linear velocity) by a spindle motor 2 .
In the present embodiment, a disc detection unit 30 is provided for detecting the loading/unloading state of the magneto-optical disc 90 with respect to the loading position of the magneto-optical disc 90 in the MD recorder 1 . It is sufficient if the disc detection unit 30 is able to detect the possible loading of the magneto-optical disc 90 .
There is no particular limitation to the specified structure of the disc detection unit 30 . For example, the disc detection unit 30 may be a mechanical switch thrust or opened by the cartridge of the magneto-optical disc 90 as the magneto-optical disc 90 is in the loaded state, or may be a photo-interrupter that is able to detect the possible presence of the magneto-optical disc 90 .
It is also possible to detect the possible loading of the disc based on a signal derived from the reflection of the laser light radiated from the optical head 3 as now explained.
The optical head 3 is mounted in a facing relation to a magnetic head 6 a with the loaded magneto-optical disc 90 in-between. The optical head 3 is made up of an objective lens 3 a, a bi-axial mechanism 4 , a semiconductor laser, not shown, and a light reception unit for receiving the light radiated by the semiconductor laser and reflected by the magneto-optical disc surface.
The bi-axial mechanism 4 includes a focusing coil for driving the objective lens 3 a in a direction towards and away from the magneto-optical disc 90 and a tracking coil for driving the objective lens 3 a radially of the magneto-optical disc.
There is also provided a sled mechanism 5 for causing marked movement of the optical head 3 in its entirety along the radial direction of the magneto-optical disc 90 .
The reflected light information, detected by the light receiving section in the optical head 3 , is sent to an RF amplifier 7 . Following current/voltage conversion, the matrix processing is executed to generate focusing error signals FE and tracking error signals TE as well as RF signals.
When the light is illuminated on the magneto-optical disc 90 at a laser power lower than that in recording, the magnetic field vector is detected by exploiting the magnetic Kerr effect of the reflected light to generate the RF signals, as replay signals, based on the detected magnetic field vector.
The focusing error signals FE and the tracking error signals Te, generated by the RF amplifier 7 , are processed by a servo circuit 9 with phase adjustment or gain adjustment, and subsequently applied to the focusing coil and to the tracking coil of the bi-axial mechanism 4 via a driving amplifier, not shown.
From the tracking error signals TE, sled error signals are generated in the sled mechanism 5 in the servo circuit 9 so as to be applied via a sled drive amplifier to the sled mechanism 5 .
The RF signals, generated by the RF amplifier 7 , are binary-coded by an EFM/CIRC encoder/decoder 8 and demodulated for EFM (eight-to-fourteen modulation) while being corrected for errors with CIRC (cross-interleave read-Solomon coding) so as to be supplied to a memory controller 12 .
On the magneto-optical disc 90 are tormed grooves with a meandering at a predetermined frequency to record address data by frequency modulation. The predetermined meandering frequency of the grooves is 22.05 kHz.
These address data may be extracted by frequency demodulation via a band-pass filter in an address decoder 10 adapted for passing only the predetermined frequency.
The EFM/CIRC encoder/decoder 8 generates binary-coded EFM signals or spindle error signals for rotationally controlling the disc based on an address decoder, as extracted from the address decoder, to apply the so-generated spindle error signals through the servo circuit 9 to the spindle motor 2 .
Moreover, the EFM/CIRC encoder/decoder 8 controls the pull-in operation of the phase-locked loop, based on the binary-coded EFM signals, to generate spindle error signals for rotationally controlling the disc to apply the so-generated spindle error signals on the spindle motor 2 .
The error-corrected binary-coded data is written by the memory controlling 12 in a buffer memory 13 .
When more than a predetermined amount of data stored in the buffer memory 13 , memory controller 12 reads out data from the buffer memory 13 at a transfer rate sufficiently slower than the write transfer rate and outputs data as audio data.
The data is stored first in the buffer memory 13 and subsequently output as audio data, so that, if unnecessary track jumps occur against disturbances, such as vibrations, such that continuous data read-out from the optical head 3 is interrupted, data corresponding to the data for the time necessary for re-arrangement of the optical head 3 to an address where the track jump has occurred is pre-stored in the buffer memory 13 , thus realizing the continuous audio signal outputting without sound interruptions.
In the present embodiment, if a 4-Mbyte RAM is used as the buffer memory 13 , audio data continuing for about 10 seconds can be stored in the state of the buffer memory 13 fully charged with data.
Meanwhile, the operation of the memory controller 12 is controlled by a system controller 11 .
The data read-out from the magneto-optical disc 90 has been compressed in recording in accordance with a predetermined compression method, herein the ATRAC (Acoustic Transferred Adapted Coding) system. The data read out from the buffer memory 13 under control by the memory controller 12 is decompressed by an audio compression encoder—expansion decoder 14 into decompressed digital data which then is applied to a D/A converter 15 .
The D/A converter 15 converts the digital data, decompressed by the audio compression encoder—expansion decoder 14 , into analog audio signals, which are sent at an output terminal 16 to a replay output system, such as amplifier, loudspeaker and a headphone, not shown, so as to be output as replay audio signals.
In the above-described replay operation, the system controller 11 is responsive to the operation by an operating unit 19 to transfer various servo commands to the servo circuit 9 , command the memory controller 12 to control the buffer memory 13 , perform control to cause a display unit 20 , display the letter information, such as the play time elapsed or the title of the program being reproduced, or to perform control such as spindle servo or decoding processing control in the EFM/CIRC encoder/decoder 8 .
There is also provided a remote commander 29 for outputting commands responsive to the user operations as e.g., the IR modulation signals. This command, that is the operating information, is converted by an IR receiving unit 23 into electrical signals, which are routed to the system controller 11 . The system controller then performs necessary control processing responsive to the operational information from the IR receiving unit 23 .
If, in this MD recorder 1 , audio data, such as music air, is to be recorded on the magneto-optical disc 90 , the audio signals are supplied to an input terminal 17 .
The analog audio signals, output from an analog output terminal of the reproducing apparatus, such as a CD player, are input to the input terminal 17 , and converted by an A/D converter 18 into digital signals, which are sent to the audio compression encoder—expansion decoder 14 .
The digital audio signals, input to the audio compression encoder—expansion decoder 14 , are compression-coded in accordance with the ATRAC (Acoustic Transferred Adapted Coding) 3 system. The compressed digital audio signals are temporarily stored via memory controller 12 in the buffer memory 13 .
The memory controller 12 detects that a predetermined amount of the compressed data have been stored in the buffer memory 13 and permits the data to be read out from the buffer memory 13 .
The compressed data read out from the buffer memory 13 are processed by the EFM/CIRC encoder/decoder 8 with e.g., error code appendage or EFM and thence supplied to a magnetic head driving circuit 6 .
The magnetic head driving circuit 6 is responsive to the data supplied thereto to apply a magnetic field of N or S poles of the magnetic head 6 a.
In recording for applying the magnetic field in this manner, the system controller 11 controls the radiating power of the semiconductor laser, not shown, of the optical head 3 , to heat the magneto-optical disc surface up to the Curie temperature. This attaches the magnetic field information applied from the magnetic head 6 a to the disc recording surface to record data as the magnetic field information.
In recording, the system controller 11 transfers various servo commands to the servo circuit 9 , issues control commands to the buffer memory 13 to the memory controller 12 , performs control to cause the display unit 20 to demonstrate e.g., the track number of the program being recorded or the elapsed recording time, or performs encoding or servo control in the EFM/CIRC encoder/decoder 8 .
This MD recorder 1 is able to record music air or track as program as audio data, the letter information, such as letter information for the entire disc, such as the letter information, e.g., the track name or disc name, in addition to the audio data.
In order for the user to input the letter information by way of name registration, the operating unit 19 includes a letter selection unit, such as an operating dial, and a decision key for determining the input letter string to terminate the letter inputting operation.
The remote commander 29 is provided with alphabet keys from A to Z, space key -, symbol keys such as ? or // and ten keys for inputting numerical figures, in order to enable letter inputting with the aid of the remote commander 29 . The remote commander 29 is also provided with a decision key for determining the input letter string, using these keys, or to terminate the letter inputting.
The system controller 11 holds letters input from the operating unit 19 or the remote commander 29 on the RAM 24 . When the letter string is determined by the decision operation, the system controller 11 registers the letter string in a state matched to the program selected for the time being.
The program selected for the time being is the program being then reproduced, recorded or paused. If such state is not prevalent, with the program not being selected, the input letter string is handled as being the letter information for the entire disc.
The letter information registered is written on the magneto-optical disc 90 as data of the UTOC sector 1 , as later explained, so as to be finalized on the magneto-optical disc 90 . The UTOC data is updated at a predetermined timing following the recording operation or the letter inputting operation.
However, in recording and/or reproducing the magneto-optical disc 90 , it is necessary to read out the management data recorded on the magneto-optical disc 90 , that is, the PTOC (pre-mastered TOC) or the UTOC (user TOC). The system controller 11 then discriminates an address for an area for recording or and an address of an area to be reproduced.
This management data is held in the buffer memory 13 . To this end, the buffer memory 13 is partitioned into a buffer area used as a data area for recording and/or reproducing data and a TOC area for holding the management data.
The system controller 11 reads out the management data by the operation of reproducing the innermost rim of the disc carrying the recorded management data on loading the magneto-optical disc 90 to store the read-out information in the buffer memory 13 so as to be referenced in the course of the recording/reproducing/editing of the magneto-optical disc 90 .
Meanwhile, the UTOC is rewritten for data recording or a variety of editing operations. In each recording/editing operation, the system controller 11 performs UTOC updating processing on the UTOC information stored in the buffer memory 13 and, responsive to the rewriting operation, rewrites the UTOC area of the magneto-optical disc 90 at a predetermined timing.
That is, when the user has input the letter information for name registration, the input letter information as the disc name or the track name is held on the RAM 24 . When the letter input has become finalized, the management data in the buffer memory 13 is updated by exploiting the letter information in the RAM 24 . This management data is written at a predetermined timing in the UTOC area of the magneto-optical disc 90 to update the UTOC contents of the magneto-optical disc 90 .
In the present embodiment, since the letter information as the name is obtained by the editing operation performed by the user, as the letter inputting operation for name registration, it may be said to be the editing information in the management data.
Moreover, in the present embodiment, in which the TOC letter information area is set in the RAM 24 based on the above structure, name letter inputting and editing may be carried out not only on the magneto-optical disc 90 loaded on the MD recorder 1 but also on the magneto-optical disc 90 not loaded on the MD recorder 1 , as will be explained subsequently in detail.
A cluster format of the recording data track on the magneto-optical disc 90 is now explained.
The recording operation in the Mini-Disc system is performed in terms of a cluster as unit. The format for the cluster is shown in FIGS. 2A, 2 B, 2 C, 2 D and 2 E.
As the recording track in the Mini-Disc system, plural clusters CL are formed contiguously, as shown in FIG. 2A, with one cluster being the minimum recording unit. Each cluster corresponds to two to three cycles of tracks.
Referring to FIG. 2B, each cluster CL is made up of a sub-data area of four sectors SFC to SFF and the main data area of 32 sectors S 00 to S 1 F. In audio data, the main data is audio data compressed by ATRAC processing.
One sector is a data unit made up of 2352 bytes.
The 4-sector sub-data area is used for sub-data or as a linking area, while the 32-sector main data area is used for recording TOC and audio data. The sectors of the linking area are throw-out sectors for matching the longer interleaving length, used herein, of the CIRC to the sector length of 13.3 msec as used for error correction in e.g., a CD, and basically represent a reserve area. However, these sectors may also be used for some processing or other or for recording some control data or other.
Meanwhile, addresses are recorded on the sector basis.
Each sector is subdivided into sound groups, as shown in FIG. 2C, while two sectors are subdivided into 11 sound groups, as shown in FIG. 2 D.
That is, as shown in FIGS. 2A, 2 B, 2 C and 2 D, the sound groups SG 00 to SG 0 A are comprised in two consecutive sectors, made up of an even sector, such as sector S 00 , and an odd sector, such as sector S 01 . Each sound group is made up of 424 bytes, and corresponds to the sound data volume corresponding to 11.61 msec.
Referring to FIG. 2E, data are recorded in L and R channels within one sound group SG, as shown in FIG. 2 E. For example, the sound group SG 00 is made up of L-channel data L 0 and R-channel data R 0 , whilst the sound group SG 01 is made up of L-channel data L 1 and R-channel data R 1 .
Meanwhile, 212 bytes which become the data area of the L-R channel are called a sound trame.
The cluster format, explained in FIGS. 2A, 2 B, 2 C and 2 D, is formed in the entire area of the magneto-optical disc 90 , which is divided in the radial direction into a radially inner area as a management area and into a program area contiguous to the management area.
In the radially inner disc area, there is provided a replay-only area in which replay-only data are recorded in the form of phase pits. Next to the replay-only area, there is recorded the photo-magnetically recordable and/or reproducible area. The management area is provided on the innermost areas of the replay-only area and the photomagnetic area.
In the program area, formed consecutively to the management area of the photomagnetic area, audio data are recorded in each sector of the main data area of the program area shown in FIGS. 2A to 2 D.
As the management area, a PTOC (pre-mastered TOC) for area management of the entire disc is provided in the replay-only area. In the management area in the photomagnetic area contiguous to the replay-only area, there is recorded the UTOC (user table-of-contents) information used for supervising the respective programs as audio data of e.g., music airs recorded in the program area.
A UTOC sector, as the management data for supervising the recording and/or reproducing operation of a track corresponding to the program of e.g., the music airs in the magneto-optical disc 90 , is now explained.
FIG. 3 shows the format of for UTOC sector 0 .
As the UTOC sectors, sectors from sector 0 up to sector 31 may be provided. That is, each of the sectors S 00 to S 1 F of one cluster in the management area may be used. The sectors 1 , 4 are the areas for the letter information, whilst the sector 2 is an area for recording the recording date and time.
The UTOC sector 0 is mainly the data management area where there is recorded the management data on the free area in which the user has made recording and in which a program can be newly recorded. That is, in the sector 0 , a start address as a start point or an end address as an end point of each program recorded in the program area, the copying protection information as a track mode representing the properties of each program, and the emphasis information, are supervised.
For example, if a music air is to be recorded on the disc 1 , the system controller 11 finds out the free area on the disc, from the UTOC sector 0 , to record the audio data therein. In replay, the area in which the music air to be reproduced has been recorded is discriminated from the UTOC sector 0 , and is accessed for reproduction.
Referring to FIG. 3, there are recorded in the UTOC sector 0 , in continuation to the header portion forming a sync pattern with 12 bytes, “cluster H”, “cluster L” and “sector”, as three byte data representing the address of the sector, a maker code “maker code” representing the disc producer, a model code “model code”, a first program number “first TNO”, the last program number “last TNO”, the sector using state, the disc serial number “disc serial No.” and the disc ID, by way of an example.
There are also recorded a pointer P-DFA (pointer for defective area) indicating the leading position of the slot in which to store the defect position produced on the disc, the pointer-EMPTY (pointer for EMPTY slot), indicating the slot using state, pointer P-ERA (pointer for free area), indicating the leading position of the slot supervising the recordable area and accommodating table indicating data made up of pointer P-TNO 1 , P-TNO 2 , . . . , P-TNO 255 indicating the leading position of the slot associated with the respective program numbers.
Next, a management table having 255 of 8-byte slots is provided. In each slot, the start address, end address, track mode and the link information are supervised.
In the present magneto-optical disc 90 , it is unnecessary to record the data consecutively but sequential data strings may be recorded discretely, that is as plural parts, on the recording medium. Meanwhile, the parts denote temporally consecutive data recorded in physically consecutive clusters.
That is, the reproducing apparatus, adapted for coping with the magneto-optical disc 90 , is designed so that the data are transiently recorded in the buffer memory 13 , and so that the write rate and the readout rate to or from the buffer memory 13 are varied, in a manner as described above. Thus, the optical head 3 may be caused to sequentially access data discretely recorded on the magneto-optical disc 90 to memorize the data in the buffer memory 13 to restore the stored data into the sequential data string on the buffer memory 13 .
With this structure, continuous speech reproduction is not obstructed because the write rate is faster than the readout rate in the buffer memory 13 during reproduction.
Moreover, if the program shorter than the recorded program is overwritten on the pre-recorded program, any redundant portion may be specified as a recordable area managed from the pointer P-FRA without being erased to utilize the recording capacity efficiently.
Using the case of the pointer P-FRA supervising the recordable area, the method for linking the discrete areas is explained with reference to FIGS. 4A to 4 F.
Referring to FIG. 4A, if a value such as 03 h (hexa-decimal) is recorded in a pointer P-FRA indicating the leading position of the slot supervising the recordable area, the slot corresponding to this “03 h” is accessed. That is, the data of the slot 03 h in the management table is read.
Referring to FIG. 4B, the start and end addresses, recorded in the slot 03 h, indicate the beginning and end points of a part recorded on the disc.
The link information recorded in the slot 03 h indicates an address of the slot which is to come next. In this case, 18 h is recorded.
Referring to FIG. 4C, the link information recorded in the slot 18 h is traced to access the slot 2 Bh shown in FIG. 4E to grasp the starting and end points of a part of the disc as the start and end addresses recorded in the slot 2 Bh.
In similar manner, the link information is traced until appearance of data “00 h” shown in FIG. 4F to grasp the addresses of the entire parts managed from the pointer P-FRA.
Thus, the slots are traced until the link information is 00 h indicating null, with the slot indicated by the pointer P-FRA as a starting point, whereby the parts discretely recorded on the disc can be linked on the memory. In such case, the totality of parts as the recordable area on the magneto-optical disc 90 can be grasped.
In the present embodiment, the pointer P-FRA is taken as an example. In similar manner, the pointers P-DFA, P-EMPTY, P-TNO 1 , P-TNO 2 , . . . , P-TNO 255 , may also be supervised by linking discrete parts.
FIG. 5 shows the format of the UTOC sector 1 .
In the UTOC sector 1 , the disc title, for example, is managed as the letter information associated with respective programs recorded in the program area and as the letter information associated with the entire magneto-optical disc.
If the program recorded is audio data, the disc title is the information such as the album title or the performer's name, while the letter information associated with each program is the information such as the name of the music air. For registering the letter information, the user optionally sets and inputs a letter.
The letter information for each program is recorded in a slot in a letter table specified by a pointer P-TNA(x) of the accommodating table indicating data within a range from 1 to 255. Although the 7-byte letter information can be recorded in one slot, plural slots may be linked in recording, using the link information, if there are many letters.
In the UTOC sector 2 , the recording time and date for each program, recorded in the program area, is managed in similar manner.
In the UTOC sector 4 , katakana and kanji are managed as in FIG. 5 so that these characters can be used as the fonts of the letter information, such as titles of the programs recorded in the program area or the title of the entire magneto-optical disc.
The illustrative structures of the buffer memory 13 and the RAM 24 provided in the MD recorder 1 of the present embodiment are hereinafter explained.
Referring to FIG. 6A, there are separately set in the buffer memory 13 a data area A 1 , where the recording data/replay data are stored, and a TOC area A 2 , where the management data on the recording data/replay data are stored.
As aforesaid, the TOC area A 1 is an area in which PTOC and UTOC as management data read out from the magneto-optical disc 90 , loaded on the MD recorder 1 , is stored, and in which the management data is sequentially updated in accordance with the editing operations, such as recording operation or name registration.
Referring to FIG. 6B, the RAM 24 is split into three areas of a system controller control area A 11 , a letter information control area A 12 , and a TOC letter information area A 13 .
The system controller control area A 11 is an area in which the information such as program data used when the system controller 11 executes a variety of control processing operations or the results of calculations obtained by the control processing operations executed are sequentially stored.
The letter information control area A 12 is an area se as a working area used in case of performing an editing operation of creating or changing the name by the input letter information in accordance with the operation of inputting the letter information for name editing executed by the user.
The TOC letter information area A 13 is an area in which to store the letter information as the track or disc name as finalized by the processing for name registration.
Although there is no particular limitation to the memory device forming the buffer memory 13 and the RAM 24 , the buffer memory 13 , for example, may be formed by a DRAM (dynamic random access memory) for cost saving in view that a larger volume of the recording data/replay data are stored in the buffer memory 13 .
On the other hand, the RAM 24 is not in need of a larger capacity and hence may be formed by an SRAM (static random access memory) without being conscious of expenses.
In the present MD recorder 1 , album names are stated in the disc name areas of the UTOC sector 1 , for supervising the music airs recorded on the disc 90 in plural groups, in accordance with the following principles (A), (B) and (C):
(A) The first and last program numbers “First TNO” and “Last TNO” in an album are stated with a special code “-” in-between, or the program numbers are stated by partitioning with a numbers “First TNO” and “Last TNO” in an album are stated with a special code “;” in-between. Meanwhile, the style of stating the program numbers with the special code “-” may co-exist with the style of stating the program numbers with a special code “;”.
(B) The program number and the album name are separated from each other with the special code “;” in-between.
(C) The different albums are partitioned from each other by a special code “//”, while the same special code “//” is placed at back of the last album name.
If three albums, namely a program number (n1-n2), an album name 1 , a program number (n2-n4), an album name 2 , a program number (n5-n6) and an album name 3 are recorded, “n1-n2; album name 1//n2-n4; album name 2//n5-n6; album name 3 ” is stated as an album name in the disc name area of the UTOC sector 1 .
The album-based program number TNO belongs to the range from First TNO to Last TNO and, although lacking numbers are tolerated, the program number must increase incessantly.
For example, if a program number (n1-n2), an album name 1 , a program number (n3, n5, n10), album name 2 , program numbers (n12-n15) and the album name 3 are recorded, “n1-n2; album name 1//3, n5, n10; album name 2//n12-n15, n17; album name 3//” is stated as an album name. In this case, there is recorded the program in the range from n1 to n2 in the album name 1 , while there is recorded in the album name 2 the program for n3, n5 and n20, such that the program in the range from album names n12 to n15 and the program n17 are recorded in the album name 2 .
Allowance is made for tracks not belonging to any tracks.
It is also possible that one track be registered in plural albums. In this case, only one track is recorded, only the registration in the album is overlapping. By so doing, unneeded tracks are not recorded such that the recording capacity in the recording medium is saved to enable recording of a larger number of tracks.
In an album formed by a sole track, the special code “-” between the program numbers TNOs may be omitted.
When stating the disc name inclusive of the entire albums and the track-name, TNO=0 is stated first at a leading end.
Allowance is made for a blank album name null.
Allowance is also made for the use of “-” and “/”.
Overlapped album names in one disc is allowed.
It is possible to simplify the processing by providing the following limitations.
It is noted that a sole album is formed only by a set of tracks indicated by consecutive program numbers.
A given one of the tracks is registered only in one album.
If the above conditions are used, and if, in a disc bearing the disc name “collections”, an album with an album name “Ted Zeppelin_Presence” is recorded in the track numbers TR 1 to 7 , an album with an album name “Dream Come True” is recorded in the track numbers TR 8 to 17 , an album with an album name “Hikaru Utade/Automatic” is recorded in the track numbers TR 18 to 24 , track numbers TR 25 , TR 26 are unrecorded, an album with an album name “null-unnamed” is recorded in the track numbers TR 27 to 30 , an album with an album name “1999-2000; My Favorites” is recorded in the track numbers TR 31 to 38 , an album with an album name “Love is Over” is recorded in the track number TR 39 , track number TR 40 is unrecorded, and an album with an album name “Love is Over” is recorded in the track number TR 41 , the following description is made in the disc name area of the UTOC sector 1 :
0; collections //1-7; Ted Zeppelin “Presence”//8-17; Dream Come True//18-24; Hikaru Utade/Automatic//27-30; //31-38; 1999-2000; My Favorites//39; Love is Over//41—41; Love is Over.
That is, the magneto-optical disc 90 , the information for which is recorded and/or reproduced by this MD recorder 1 , includes a management area utilized as a disc name area of the UTOC sector 1 in which are recorded the first management data and the second management data. The first management data supervises the program area for recording plural programs and the program name associated with each program recorded in the program area, and the second management data collects the plural programs recorded in the program area in plural groups corresponding to the album to supervise the group name corresponding to the name of the grouped albums. The second management data recorded in the management area of the magneto-optical disc 90 , the information for which is recorded and/or reproduced by the MD recorder 1 , is made up of “n1-n2” as the range information for the program numbers making up the group, a special code “//” separating the group names corresponding to the plural album names and the group name corresponding to the album name. The second management data includes a disc name as the label name of the recording medium itself of the magneto-optical disc 90 .
Stated differently, the management data supervising one or more groups demarcates the first management area supervising respective groups by separating symbols “//”. In each first management data, the second management data supervising the program forming each group is demarcated from the third management data supervising the name of each group by separating symbols “;” for management.
In this MD recorder 1 , the second management data formed by the range information “n1-n2” of the program numbers forming the group corresponding to the album, the special code “//” demarcating the plural group names corresponding to the album names and the group names is recorded in the disc name area of the UTOC sector 1 of the magneto-optical disc 90 to supervise the programs recorded in the program area to supervise the plural programs recorded in the program area as plural groups to perform editing processing.
That is, the system controller 11 in this MD recorder 1 has the following functions based on the group information corresponding to the so-supervised album name. The system controller 11 displays the menu, shown in FIG. 7, in the display unit 20 and, responsive to the input from the operating unit 19 or the remote commander 29 , executes various processing such as the album title input mode, album title display mode, album erasure mode, album movement mode, album AMS mode or the album repeat mode.
The album title input mode is such a mode established on pushing an edit button as an album button is pushed. In this album title input mode, the title of the album being played can be input. The “album title” is selected from the edit menu and the leading and last music airs are selected by range designation to input the album title.
The album title inputting mode is carried out in accordance with a sequence shown in the flowchart of FIG. 8 .
For facilitating the processing and the description, it is assumed that a musical air in an album is designated by specifying the number of the music air by a special code “-”. It is noted that the music air designation by a special code “,” is performed by processing similar to that for the special code “-” and can be coped with by changing the condition for decision. For further simplifying the explanation, it is also assumed that plural albums are not registered in an overlapping fashion on one track.
In the album title inputting mode, the inputting of the leading music air number is accepted and captured into a register (step S 1 ) and subsequently the inputting of the last music air number is accepted and captured into a register (step S 2 ).
It is then checked whether or not A=B, that is whether or not the leading music air number of the album is the same as the last music air number (step S 3 ). If the result of decision at this step S 3 is YES, that is if the leading music air number of the album is the same as the last music air number, the leading music air number of the album is rendered into an ASCII code and “a;” is stored in the buffer (step S 4 ). If the result of decision at step S 3 is NO, that is if the leading music air number of the album differs from the last music air number, the leading music air number of the album A is rendered into an ASCII code a, while the last leading music air number of the album A is rendered into an ASCII code b, and “a-b” is stored in the buffer (step S 5 ).
The inputting of the album title then is accepted (step S 6 ) and the input album title is stored in the buffer (step S 7 ).
The contents thus stored in the buffer [a or a-b; (album title)] is registered in the disc name area (step S 8 ) to finish the album title inputting mode.
The processing of registration of the buffer contents in the disc name area at step S 8 is performed in accordance with, for example, the sequence shown in the flowchart of FIG. 9 .
That is, in the processing for registration in the disc name area, it is first verified whether or not the disc name area is null (step S 801 ). The disc name area being null indicates that the disc name is null, that is blank. If the result of decision at step S 801 indicates null, that is if the disc name area is null, the contents of the buffer [a or a-b; (album title)] is registered in the disc name area (step S 802 ) to finish the registration processing in the disc name area. Thus, if the album title “ 8 - 10 ; GA” is input in the disc name area=null, the contents shown in FIG. 10 are registered in the disc name area.
If the result of decision at step S 801 is_null, that is if the disc name area is not null, the form of “n1-m1;” or “n1;” is retrieved from the leading end (step S 803 ) to check whether or not the form is coincident (step S 804 ), where n1 and m1 are numerical figures in the ASCII code.
If the result of decision at step S 804 is NO, that is if the form is not coincident, “0;” is inserted at the leading end of the disc name area (step S 805 ). The pointer indicating the inside of the disc name area is moved to the trailing end (step S 806 ). Next to the “//”, the buffer contents [a or a-b; (album title)] is added to the disc name area (step S 807 ) to finish the registration processing in the disc name area. By so doing, if there is the disc name “MiniDisc//” from the outset, as shown for example in FIG. 11A, an album name “1-7; SONY” is added, “0; MiniDisc//1-7; SONY” is registered in the disc name area, as shown in FIG. 11 B.
On the other hand, if the result of decision at step S 804 is YES, that is if the form coincides, the form of “n2-m2” or “n2;” is retrieved in succession (step S 808 ) to check whether or not the form coincides (step S 809 ). It is noted that n1 and m1 are numerical figures in the ASCII code.
If the result of decision at step S 809 is NO, that is if the form fails to coincide, the program moves to step S 806 to move the pointer indicating the inside of the disc name area to the trailing end to add the buffer contents next to “//” in the disc name area (step S 807 ) to finish the registration processing in the disc name area. If the result of decision at step S 809 is YES that is if the form coincides, it is checked whether or not the numerical figure a in the ASCII code indicating the musical air number in the album A is larger than n1 and smaller than n2 (step S 810 ).
If the result of decision at step S 810 is NO, that is if the numerical figure is not intermediate between n1 and n2, n2 and m2 are set to n1 and m1, respectively (step S 811 ). The processing then reverts to step S 808 to repeat the processing of steps S 808 to S 811 . If the result of check at step S 810 is YES, that is if the above numerical figure a is intermediate between n1 and n2, “//” is added to the leading end of the buffer contents [a or a-b; (album title)] (step S 812 ).
The buffer contents [//a or a-b; (album title)] is inserted directly before “//n2” (step S 813 ) to finish the registration processing in the disc name area. In this case, if the album title “8-10; GA” shown in FIG. 10 is registered from the outset and an album title “1-7; SONY” is added, the contents shown in FIG. 12 are registered in the disc name area.
The album title display mode is set on pushing e.g., a display mode button or on selection of an album title from the display menu title. The processing of this album title display mode is carried out in accordance with the procedure shown for example in FIG. 13 .
In this album title display mode, the track number currently being displayed or at a standstill is captured into the register TNO (step S 11 ).
Then, from the leading end of the disc name area, the form “n-m;” is retrieved (step S 12 ) to check whether or not the value of the register TNO is larger than n and smaller than m as retrieved (step S 13 ).
If the result of decision at step S 13 is NO, that is if the value of the register TNO is not intermediate between n and m as retrieved, setting is made for the next retrieving (step S 14 ) to revert to step S 12 to repeat the processing of from step S 12 to step S 14 . If the result of decision at step S 13 is YES, that is if the value of the register TNO is intermediate between n and m as retrieved, it is checked whether or not there is “//” back of “n-m;” (step S 15 ).
If the result of decision at this step S 15 is YES, that is if there is “//” back of “n-m;”, the letters from the letter next following “n-m;” up to “//” are extracted and stored in the buffer (step S 16 ). If the result of decision at this step S 15 is NO, that is if there is no “//” in back of “n-m;”, the letters up to the last one of “n-m;” is extracted and stored in the buffer (step S 17 ).
The buffer contents are displayed (step S 18 ) to finish the present album title display mode.
The album erasure mode is set by pushing an album button and simultaneously pushing an erasure button. In this mode, the album being played can be erased in its entirety. This album erasure mode is executed by selecting an album erasure from the edit menu and selecting the group desired to be erased from the album name.
The processing of this album erasure mode is carried out in accordance with e.g., the procedure shown in the flowchart of FIG. 14 .
In the processing of this album erasure mode, the track number currently being reproduced or at a standstill is captured into the register TNO (step S 21 ).
Then, from the leading end of the disc name area, the form “n1-n2” is retrieved (step S 22 ) to check whether or not the value of the register TNO is larger than n1 and smaller than n2 as retrieved (step S 23 ).
If the result of decision at step S 23 is NO, that is if the value of the register TNO is not intermediate between n1 and n2 as retrieved, the next retrieval is set (step S 24 ). Then, processing reverts to step S 22 to repeat the processing of steps S 22 to S 24 . If the result of decision at step S 23 is YES, that is if the value of the register TNO is intermediate between n1 and n2 as retrieved, the tracks contained in the album are continuously erased (step S 25 ) and the album title is erased from the disc name area (step S 26 ) to complete the processing of the album erasure mode.
If, from the disc name area in which “1-7; SONY//8-10;GA//11-20; MiniDisc” has been registered, the album “8-10; GA” has been erased by this album erasure mode processing, as shown in FIG. 15A, the registered contents of the disc name area are “1-7; SONY//8-17; MiniDisc”, as shown in FIG. 15 B.
The continuous track erasure at step S 25 is carried out in accordance with the sequence shown e.g., in the flowchart of FIG. 16 .
That is, in the continuous track erasure, the number of albums recorded is calculated by the operation of i=n2−n1+1 (step S 251 ).
Then, p=n1 is set to set a pointer p of the music air to be erased (step S 252 ).
Then, one air erasure processing for erasing one music air for which the pointer p has been set (step S 253 ).
For verifying whether or not the music airs recorded in the album have been processed repeatedly, it is checked whether or not the number of recorded music airs in the album is larger than 0 (step S 254 ). If the result of decision is YES, that is if the number of recorded music airs in the album is larger than 0, the number of recorded music airs is decremented by 1 (step S 255 ) to revert to step S 252 . The processing of steps S 252 to 255 is repeated until the number of recorded airs is 0 to finish the continuous track erasure processing.
It is noted that the music air erasure processing at step S 253 is carried out in accordance with the procedure shown in the flowchart of FIG. 17 .
That is, in the one-air erasure processing, the music air, for which the pointer p has been set, is erased (step S 2531 ).
It is then verified whether or not there is the music air number (n1+1) (step S 2532 ). If the result of decision is NO, that is if there is no music air number (n1+1), the continuous track erasure processing is terminated.
If the result of decision at step S 2532 is YES, that is if there is the music air number (n1+1), the music air number as from (n1+1) is incremented by one (step S 2533 ).
Next, it is checked whether or not the music air number is the last number (step S 2534 ). If the result of check is NO, that if the music air number is not the last one, processing reverts to step S 252 to repeat the processing from steps S 2533 and S 2534 until the result of decision at step S 256 is YES to complete the one-air erasure processing.
The album title erasure processing at the above step S 26 is carried out in accordance with e.g., the procedure shown in the flowchart of FIG. 18 .
In this album title erasure processing, it is first checked whether or not there is “//” directly ahead of “n1-n2” (step S 261 ).
If the result of decision at this step S 261 is YES, that is if there is “//” directly ahead of “n1-n2”, “//” directly ahead of “n1-n2” is deleted at step S 262 to then transfer to step S 263 . If the result of decision at this step S 261 is NO, that is if there is no “//” directly ahead of “n1-n2”, processing directly transfers to step S 263 .
At step S 263 , it is checked whether or not there is “//n3” (n3=n2+1) at back of “n1-n2”. If the result of decision at this step S 263 is NO, that is if there is no “//n3” at back of “n1-n2”, the letter string downstream of “n1-n2” is deleted (step S 264 ) to terminate the album title erasure processing. If the result of decision at this step S 263 is YES, that is if there is “//n3” at back of “n1-n2”, the letter string up to the letter directly ahead of “//n3” is erased (step S 265 ). Then, processing transfers to step S 266 .
At step S 266 , it is verified whether or not the form is “//n3-n4”. If the result of check at this step S 266 is NO, that is if the form is not “//n3-n4”, processing transfers to step S 268 . If the result of check at this step S 266 is YES, that is if the form is “//n3-n4”, n4−(n2-n1+1) is set to new n4 to correct the last music air number of the next album (step S 267 ). The processing then transfers to step S 268 .
At step S 268 , n3−(n2-n1+1) is set to new n3 to correct the leading music air number of the next album.
It is then checked whether or not there is the form of “//n5” further backwards (step S 269 ). If the result of check is YES, that is if there is the form “//n5” backwards, processing reverts to step S 267 to repeat the processing of from step S 267 to step S 269 until the result of decision at this step S 256 is NO, that is if the form “//nx” ceases to exit backwards (step S 267 to step S 269 ) to correct the music air number in succession to terminate the album title erasure processing operation.
Thus, in this MD recorder 1 , if a predetermined group or a predetermined album in the plural groups or albums are commanded to be erased in a block, the correlation among the range information of the program numbers forming the group(s) or album(s) in the second management data is edited to manage the program(s) recorded in the music air 90 as plural groups or albums to perform editing by group- or album-based block erasure.
The processing of the album movement mode is carried out in accordance with the processing shown in the flowchart of FIG. 19 .
In this album movement mode, the track number, the track number currently being reproduced or at a standstill is captured into the register TNO (step S 31 ).
Then, from the leading end of the disc name area, the form “n1-n2”is retrieved (step S 32 ) to check whether or not the value of the register TNO is larger than n1 and smaller than n2 (step S 33 ).
If the result of decision at step S 33 is NO, that is if the value of the register TNO is not intermediate between n1 and n2 as retrieved, the next retrieval is set (step S 34 ). Then, processing reverts to step S 32 to repeat the processing of steps S 32 to S 34 . If the result of decision at step S 33 is YES, that is if the value of the register TNO is intermediate between n1 and n2 as retrieved, the tracks contained in the album are continuously moved (step S 35 ) and the album title is changed from the disc name area (step S 36 ) to complete the processing of the album movement mode.
If, from the disc name area in which “1-7; SONY//8-10;GA//11-20; MiniDisc” have been registered, the album “8-10; GA” has been moved to backwardly of the album “11-20; MiniDisc”, as shown in FIG. 20, the registered contents of the disc name area are “1-7; SONY//8-17; MiniDisc//18-20; GA”, as shown in FIG. 20 .
In this MD recorder 1 , if the sequence change is commanded on a predetermined group in the plural groups or predetermined group in the album, the correlation between the range information of the program numbers making up the groups or albums in the second management data and the group or album names is edited and the predetermined groups or albums are moved in a block, whereby the programs recorded in the magneto-optical disc can be supervised as plural groups or albums to cause movement on the group or album basis.
The album AMS mode is set by pushing an album button and simultaneously pushing an FF/FR button. In this mode, the album next to the album containing the musical air being played can be accessed. The processing in this album AMS mode is carried out by a procedure shown for example in the flowchart of FIG. 21 .
In this album AMS mode, the track number, the track number currently being reproduced or the track number at a standstill is captured into the register TNO (step S 41 ).
Then, from the leading end of the disc name area, the form “n1-n2” is retrieved (step S 42 ) to check whether or not the value of the register TNO is larger than n1 and smaller than n2 (step S 43 ).
If the result of decision at step S 43 is NO, that is if the value of the register TNO is not intermediate between n1 and n2 as retrieved, the next retrieval is set (step S 44 ). Then, processing reverts to step S 42 to repeat the processing of steps S 42 to S 44 . If the result of decision at step S 43 is YES, that is if the value of the register TNO is intermediate between n1 and n2 as retrieved, “//n3” at back of “n1-n2” is retrieved (step S 45 ).
At the next step S 46 , it is checked whether or not “//n3” is present backwardly of “n1-n2”. If the result of check at this step is NO, that is if there is no “//n3” backwardly of “n1-n2”, the processing of the album AMS mode is terminated. If the result of check at this step is YES, that is if there is “//n3” backwardly of “n1-n2”, the corresponding album name and the music air name are demonstrated in the track number n3 (step S 47 ) to access the track number n3 (step S 48 ) to terminate the processing of the album AMS mode.
The album repeat mode processing is performed in accordance with the processing shown in the flowchart of FIG. 22 .
In this album repeat mode, the track number, the track number currently being reproduced or the track number at a standstill is captured into the register TNO (step S 51 ).
Then, from the leading end of the disc name area, the form “n1-n2” is retrieved (step S 52 ) to check whether or not the value of the register TNO is larger than n1 and smaller than n2 (step S 53 ).
If the result of decision at step S 53 is NO, that is if the value of the register TNO is not intermediate between n1 and n2 as retrieved, the next retrieval is set (step S 54 ). Then, processing reverts to step S 52 to repeat the processing of steps S 52 to S 54 . If the result of decision at step S 53 is YES, that if the value of the register TNO is intermediate between n1 and n2 as retrieved, it is checked whether or not the value of TNO+1 is smaller than n2 (step S 55 ).
If the result of decision at this step S 55 is YES, that is if the value of TNO+1 is smaller than n2, the next track is set to TNO+1 (step S 56 ). If the result of decision at this step S 55 is NO, that is if the value of TNO+1 is smaller than n2, n1 is set a the track number (step S 57 ) to terminate the processing at this album repeat mode.
The system controller 11 in this MD recorder 1 has a variety of processing functions, such as linking or splitting of albums or erasure, linking and splitting of tracks in an-album.
That is, in this MD recorder 1 , if it is commanded to link the predetermined groups or albums, the correlation between the range information of the program numbers forming the above groups or albums in the second management data and the group or album names is edited to supervise the programs recorded in the magneto-optical disc 90 as plural groups or albums to perform the editing of linking the groups or albums. In the editing processing by album linking, as shown in FIG. 23A, if, in a disc in the disc name area of which “1-7; SONY//8-10;GA//11-20; MiniDisc” is registered, the album “1-7; SONY” is linked to the album “8-10;GA”, the album “GA” vanishes, with the registered contents in the disc name area being “1-10; SONY//11-20; MiniDisc”, as shown in FIG. 23 B.
Moreover, if, in this MD recorder 1 , the predetermined group or album name is commanded to be divided in two portions, the correlation between the range information of the program numbers making up the predetermined group or album name in the second management data and the group or album name can be edited to supervise the programs recorded on the magneto-optical disc 90 as plural groups or album names to divide the group or the album name in two. In this editing processing by album division, as shown in FIG. 24A, if, in a disc in a disc name area of which has been recorded “1-10; SONY//11-20; MiniDisc”, an album has been divided between the fifth and the sixth music airs, the registration contents of the disc name area is “1-5; SONY//6-10; 11-20; MiniDisc”, as shown in FIG. 24 B. At a time point this processing is finished, the album name for 6 - 10 is not afforded so that the album name is blank, or null. Meanwhile, the album name, which is blank, may be assigned by another processing not shown in the present invention.
Moreover, if, in this MD recorder 1 , the programs making up the predetermined group or album in the plural groups or albums are erased, the correlation between the range information of the program numbers making up the group or the album in the second management data and the group name or album can be edited to supervise the programs recorded on the magneto-optical disc 90 as plural groups to erase the programs in the group or album by way of editing. In the editing processing by erasure of the tracks in an album, if, in a disc in the disc name area of which “1-7; SONY//8-10; GA//11-20; MiniDisc” has been registered, as shown for example in FIG. 25A, the third music air is erased, the former fourth air is re-defined to be the new third air, with the original fifth air being re-defined to be the new fourth air, whereby the registration contents in the disc name area is “1-6; SONY//7-9; GA//10-19; MiniDisc”, as shown in FIG. 25 B.
Moreover, if, in this MD recorder 1 , two programs making up a predetermined group or album of the plural groups or albums are linked together, the correlation between the range information of the program numbers making up the group or the album in the second management data and the group name or album can be edited to supervise the programs recorded on the magneto-optical disc 90 as plural groups to link two programs recorded in the group or album. In the editing processing by track linking in an album, if, in a disc in the disc name area of which “1-7; SONY//8-10; GA//11-20; MiniDisc” has been registered, as shown for example in FIG. 26A, the first and second music airs are linked, the former first and second music airs are shifted to be the new first air, with the original third air being shifted to be the new second air, whereby the registration contents in the disc name area is “1-6; SONY//7-9; GA//10-19; MiniDisc”, as shown in FIG. 26 B.
Moreover, if, in this MD recorder 1 , predetermined programs making up a predetermined group or album of the plural groups or albums are linked together, the correlation between the range information of the program numbers making up the group or the album in the second management data and the group name or album can be edited to supervise the programs recorded on the magneto-optical disc 90 as plural groups to split the program recorded in the group or album. In the editing processing by track splitting in an album, if, in a disc in the disc name area of which “1-7; SONY//8-10; GA//11-20; MiniDisc” has been registered, as shown for example in FIG. 27A, the fifth music air is split, the former fifth music air is rearwardly shifted to be the new fifth and sixth music airs, with the original sixth air being rearwardly shifted to be the new seventh air, whereby the registration contents in the disc name area is “1-8; SONY//9-11; GA//12-21; MiniDisc”, as shown in FIG. 27 B.
Moreover, this system controller 11 in the MD recorder 1 performs the processing of reflecting a series of recordings as being the recordings by an album by pushing an album button and simultaneously scanning a recording button.
For example, if, ten airs are newly recorded on a disc, in the disc name area of which “1-7; SONY//8-10; GA” has been registered, as shown in FIG. 28A, the registration contents in the disc name area are “1-7; SONY//8-10; GA//11-20”, as shown in FIG. 28 B. That is, “//11-20” has been newly recorded next to the disc name area in which has been recorded “1-7; SONY//8-10; GA”.
For example, if five airs are overwrite-recorded as an album in a mid portion of the third air of the disc in the disc name area of which has been recorded “1-7; SONY//8-10; GA”, as shown in FIG. 29A, the unity as an album of “1-7; SONY” is fractionated into “1-3; SONY” and into “9-10”, and an album “4-8” is overwritten in the former half from the latter half of the third air to a mid portion of the sixth air, so that the registration contents of the disc name area are “1-3; SONY//4-8; //9-10;//11-13; GA”, as shown in FIG. 29 B. Since the air comes to a close before the tenth air prior to the tenth air before overwrite-recording of the recorded portion as shown in FIG. 29B on the disc recorded as in FIG. 29A, there is produced no change in the total recording capacity. | A recording medium on which a plurality of programs are collected in a plurality of groups and supervised in this grouped state, wherein when an editing command such as dividing, linking, and erasing the predetermined programs or groups recorded on the recording medium is executed, management data is edited to perform the editing command. The invention provides a solution to meet this request by a recording medium, an editing method and an editing apparatus. | 8 |
BACKGROUND OF THE INVENTION
This invention relates generally to waste disposal and more particularly to an improved system for sterilizing infectious waste.
As is known in the art, waste disposal is an issue of growing public concern. Increasing quantities of waste are causing landfills to reach maximum capacity sooner than anticipated. As a result, municipalities are being forced to transport waste to remote processing facilities at considerable cost.
As is also known in the art, the disposal of infectious, or pathogenic waste presents a variety of concerns. In particular, the AIDS epidemic has heightened awareness of the risks involved with handling pathogenic waste materials. Additionally, recent incidents of medical waste appearing along coastal waterways has prompted government regulations regarding the disposal of medical refuse.
Various techniques are currently utilized for the disposal of infectious waste material. The most common method for processing infectious waste is incineration. A hospital may have an incinerator located at the facility or, alternatively, may transport its waste to an incinerator at an off-site location. Shipping the waste to an off-site incinerator is, generally, less expensive since the cost of the incinerator, as well as its maintenance is avoided. On the other hand, having an incinerator located at the hospital may reduce the risk of infection to the individuals who transport the refuse due to the fact that the waste is carried a shorter distance. However, while the risk of infection to the waste handler is reduced as the distance that the waste is transported is reduced, the risk still exists when any transport of infectious material is required. For example, the individual carrying a bag of contaminated material may inadvertently hit the bag against a wall or drop the container causing it to tear and waste to leak out. Also, sharp objects, such as hypodermic syringes or broken glass from items used for cultures or tissue specimens, may puncture the bag as well as the individual transporting it.
An equally serious concern regarding the use of incinerators is that certain materials yield ash which may contain carcinogenic or other hazardous materials. Relatively costly precautions are generally required to ensure that the emissions are non-toxic. Furthermore, the certification required to operate an incinerator may be difficult to obtain.
More recently, microwave energy has been investigated as an alternative means for sterilizing contaminated waste. Microwave energy may be used to heat the medical waste to a suitable disinfecting temperature or, alternatively, to a temperature which will incinerate the waste. However, the cost of microwave energy generally exceeds that of conventional energy sources and, thus, microwave energy may be an unnecessarily expensive alternative.
Alternatively, infectious waste may be processed in an autoclave in which sterilization results from exposure to steam. Generally, this technique is utilized with re-usable instruments and containers. While autoclaving may be suitable to render infectious materials sterile for re-use, non-sterilized items can be easily mistaken for ones which have been processed in the autoclave. Thus, a serious risk of exposure to infected re-usable materials exists.
Autoclaving may also be used to disinfect disposable items prior to depositing such items in a landfill. However, as a result of the growing public concern regarding pathogenic waste, an emerging requirement has been that the waste not only be rendered harmless but also unrecognizable as medical refuse prior to being deposited in a landfill. Since, during autoclaving the medical containers and instruments are left intact after being disinfected, autoclaving does not render the medical waste unrecognizable as such.
As is also known in the art, another method of infectious waste disposal includes autoclaving in conjunction with exposure to air heated to temperatures high enough to melt the plastic waste. This method is suitable since today, medical instruments and containers are predominantly made of plastic. An example of this type of waste disposal unit is described in U.S. Pat. No. 3,958,936. In this unit, air is heated to a temperature of at least 450° F. and is directed to a melting chamber in which the infectious waste is disposed. The heated air melts the plastic waste material to a flowable state. An afterburner exhaust arrangement is used to incinerate the vapors evolved during the melting process. When the heating and melting cycle is completed, the chamber is allowed to cool. Upon cooling, the melted material solidifies into a block which can be easily removed and disposed of. Thus, this arrangement renders the pathogenic material harmless and unrecognizable as medical waste. Also, generally, items such as needles and surgical blades will become embedded in the resulting solid block thereby reducing the likelihood of such needles injuring the waste handler. Additionally, the volume of the waste is reduced by the melting process.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a an improved system for sterilizing infectious waste.
A further object of the present invention is to provide a safe method for disposing of infectious waste at the location where the waste is generated.
Another object of the invention is to provide apparatus for reducing the volume of the infectious waste and for rendering the disinfected material unrecognizable as medical waste.
A yet further object is to monitor the sterilization process to provide a record of the sterilization.
A further object of the invention is to provide a waste disposal system operable either on a continuous basis or in a batch mode.
A still further object of the present invention is to provide an infectious waste sterilization system having a simple and effective exhaust arrangement.
Yet another object is to provide a sterilization system having semi-forced cooling.
These and other objects of the present invention are provided by sterilization apparatus including a cabinet having a melting chamber disposed therein. The melting chamber has an aperture through which waste material is deposited and a cover disposed over the aperture. An air circulation system includes a first air circulation chamber disposed on a first side of the melting chamber and communicating therewith, a second air circulation chamber disposed on a second side of the melting chamber and communicating therewith, and a heating element disposed in the first air circulation chamber. The air circulation system further includes a first blower for directing air into the first air circulation chamber, past the heating element, through the melting chamber, and into the second air circulation chamber. An exhaust duct is coupled to the first air circulation chamber and directs air out of such chamber. A second blower is coupled to the exhaust duct and directs air through the exhaust duct to mix with the air directed out of the first air circulation chamber.
With such an arrangement, apparatus for sterilizing infectious waste material is provided with a simple, inexpensive, and effective exhaust arrangement, as contrasted to the afterburner arrangement described in the above-reference U.S. Pat. No. 3,958,936. More particularly, plastic waste material is melted in the melting chamber and the vapors evolving from the melting process are directed therefrom through the exhaust duct. In the exhaust duct, vapors from the melting chamber mix with air directed by the second blower before being directed out of the sterilization apparatus.
In accordance with a further feature of the present invention, the cabinet has an inlet and the air circulation system further includes an inlet duct coupled to the second air circulation chamber for directing air from the cabinet inlet into the second air circulation chamber. A valve is coupled to the inlet duct for opening and closing the duct, and a controller is provided for de-activating the heating element and activating the blower when the inlet duct is open.
This arrangement provides semi-forced cooling to the sterilization apparatus and to the melted waste material disposed therein once the sterilization process is completed. More particularly, when the sterilization, or melting process is completed, the valve is opened, the heating element is shut off, and the blower remains activated. Thus, air is directed from outside of the cabinet, through the cabinet inlet, through the inlet duct, and into the second air circulation chamber. From the second air circulation chamber, the air is directed by the blower into the first air circulation chamber and through the melting chamber. Since the heating element is shut off when the valve is opened, the air entering the melting chamber through the inlet duct is circulated without being heated. In other words, the same blower that circulates the heated air during the melting process, circulates the cooler air entering the cabinet through the inlet after such process is completed and during a cooling period. In this way, the added cost and space requirements associated with additional cooling apparatus is eliminated. Furthermore, the semi-forced cooling thus provided decreases the total sterilization time, as contrasted to the apparatus of the above-referenced U.S. Pat. No. 3,958,936, thereby increasing the waste throughput.
In accordance with another feature of the invention, apparatus for sterilizing waste material includes a cabinet, a melting chamber disposed within the cabinet and having an aperture through which waste material is deposited, and an air circulation system comprising a heating element and a blower. The apparatus further includes a drawer for loading waste material into the melting chamber through the aperture. The drawer is movable between a first loading position and a second position in which the drawer is disposed substantially above the aperture. Preferably, the apparatus further includes a cover disposed over the aperture and having the drawer coupled thereto.
With such a cover arrangement, the sterilization apparatus may be operated in either a continuous mode or a batch mode. Specifically, waste material may be deposited in the drawer on a continuous basis. The drawer may then be moved over the aperture of the melting chamber causing the waste material to drop into the chamber. Continuous mode operation may be desirable when the apparatus is disposed in operating environments in which infectious waste material is continuously generated. Alternatively, waste material may be accumulated and then deposited directly into the melting chamber through the aperture therein by opening the cover. Such batch mode operation may be desirable in applications where the sterilizer is disposed at a distance from the location where the waste is generated.
In accordance with a further feature of the invention, the apparatus includes a temperature sensor disposed within the cabinet for continuously sensing temperature and means coupled to the temperature sensor for providing a record of a plurality of sensed temperatures. With this arrangement, the temperature within the cabinet, and more particularly, that of the waste material disposed therein, is measured to provide a record of sensed temperatures. In this way, assurance is provided that the waste material was in fact exposed to suitable bacteria sterilizing temperatures for a suitable duration and thus, that the apparatus is functioning properly.
Another feature of the present invention provides a method for sterilizing waste material in a cabinet comprising the steps of providing a melting chamber in the cabinet, providing a first air circulation chamber on a first side of the melting chamber in communication therewith, and providing a second air circulation chamber on a second side of the melting chamber also in communication therewith. A heating element is provided in the first air circulation chamber. The air is directed into the first air circulation chamber, past the heating element, and into the second air circulation chamber. Additional steps include sensing temperature within the cabinet and recording a plurality of sensed temperatures.
As with the preceding feature, the above-described sterilization method provides a record of sensed temperatures. Such a record is desirable for verifying the sterilization process.
In accordance with a still further feature of the present invention, sterilization apparatus includes a cabinet and a melting chamber disposed within the cabinet. The chamber has an aperture through which waste material is deposited to a predetermined height. An air circulation system includes a heating element and a blower, with the blower directing air past the heating element and into the melting chamber. A cover is disposed over the aperture and a sonic device is disposed over the melting chamber and in alignment with the aperture. The sonic device provides a control signal corresponding to the height of the waste material disposed in the chamber. The apparatus further includes means responsive to the control signal for de-activating the heating element.
With this arrangement, the melting cycle duration may be extended beyond the time required to sterilize the waste in order to provide maximum, or a desired volume reduction of the waste. In other words, once the sterilization process is completed, the heating element remains activated and the height of the waste is monitored to determine when no further volume reduction is occurring or, alternatively, when a predetermined desired volume reduction has been achieved. The heating element is de-activated in response to such determination.
The above described apparatus may further include a drawer coupled to the cover for loading waste material into the melting chamber through the aperture and a lock mechanism. The drawer is moveable between a first loading position and a second position in which the drawer is disposed substantially above the aperture. The lock mechanism locks the drawer in the first loading position in response to the control signal provided by the sonic means. More particularly, the drawer is locked in the first loading position when the control signal indicates that the height of the waste disposed in the melting chamber has reached a predetermined level. This arrangement prevents an operator of the sterilizer from attempting to load waste material into the melting chamber once such chamber is filled to capacity.
The apparatus may additionally include a lid disposed over the drawer when the drawer is disposed in the first loading position and a lock mechanism responsive to the control signal provided by the sonic means for locking the lid in a closed position. As above, this feature prevents an operator of the sterilizer from attempting to load waste material into the melting chamber via the drawer once such chamber is filled to capacity.
An additional feature of the invention provides a method for sterilizing waste material in a cabinet and includes the steps of providing a melting chamber in the cabinet in which the waste material is deposited, providing a first air circulation chamber on a first side of the melting chamber and in communication therewith, and providing a second air circulation chamber on a second side of the melting chamber and in communication therewith. A heating element is provided in the first air circulation chamber. Additional steps include sensing the height of the waste material deposited in the chamber. The method may further comprise the step of de-activating the heating element in response to the sensed height.
With the above-described method of sterilizing waste material, maximum, or a desirable amount of volume reduction of the waste is achieved. Such is achieved by sensing the height of the waste material and de-activating the heating element in response to such height. In this way, the process time may be extended beyond the necessary bacteria sterilization time to provide a further reduction in the volume of the waste.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing features of this invention, as well as the invention itself may be more fully understood from the detailed description of the drawings, in which:
FIG. 1 is a side elevational view partly in section of a waste disposal system in accordance with the present invention;
FIG. 2 is a cross-sectional view of the waste disposal system taken along lines 2--2 of FIG. 1;
FIG. 3 is a somewhat simplified isometric view of a portion of the waste disposal system of FIG. 1;
FIG. 4 is a side elevational view partly in section of a waste disposed system in accordance with an alternate embodiment of the present invention; and
FIGS. 5A and B show a flow diagram of the operation of the waste disposal system of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, an infectious waste sterilizer 10 includes a base 12 and an outer cabinet 11. Here, cabinet 11 is made of stainless steel; however, alternatively such cabinet 11 may be made of any material having suitable rigidity and strength. Cabinet 11 has a front wall 11a, a rear wall 11b, and sidewalls (not labelled) attached together by any suitable means such as welding. Cabinet 11 includes inlets 13 disposed through front wall 11a and rear wall 11b of outer cabinet 11, as shown, which provide a path for air from outside cabinet 11 to enter cabinet 11, as will be described hereinafter.
An inner housing 15 is disposed inside cabinet 11 and is shaped to provide a melting chamber 16. More particularly, housing 15 is defined by a front wall 30, a rear wall 31, a bottom wall 32, and side walls (not labelled). Here, housing 15 further includes flanges 17a and 17b which are bent over a top portion of front wall 11a and rear wall 11b, respectively, and are suitably attached thereto. Melting chamber 16 is disposed within inner housing 15 and further includes a front chamber wall 18, a rear chamber wall 19, a bottom chamber wall, or floor 20, and chamber side walls (not shown). Melting chamber 16 has an aperture 21 disposed in a top portion thereof through which waste material 25 is deposited. Here, such waste material 25 is disposed in a bag, or pouch 26 within melting chamber 16. The use of bag 26 facilitates the handling of the waste material 25 prior to its disposal in sterilizer 10 and may also aid in the removal of the safe, sterilized waste, as will be further described below. The bag 26 is, here, made of a plastic material which is capable of withstanding temperatures in excess of approximately 450° F. An example of a suitable material for bag 26 is IPPLON WN1500 manufactured by International Plastic Products, Inc., of Carson, Calif. However, bags or containers made of metal such as aluminum foil may be used. Furthermore, it may be desirable to provide handles, either integrally formed with and extending vertically from such a pan or adapted for attaching to such pan, in order to further facilitate removal of the sterilized waste. Alternatively, re-usable pans made of a suitable material having a release coating such as Teflon may be used. Alternatively, infectious waste material 25 may be deposited directly into melting chamber 16 without the use of a bag 26. Note however that it may be desirable to coat the interior of melting chamber 16 with a material such as Teflon, in order to prevent waste material 25 deposited directly therein (i.e. without a bag 26) from sticking to melting chamber 16. Here, melting chamber 16 has a capacity of approximately one thousand cubic inches.
Melting chamber 16 has an insulating material with suitable thermal insulation properties disposed therein. Here, front chamber wall 18, rear chamber wall 19, and chamber side walls (not shown) have an approximately one inch thick layer of "Lo-Con Felt Carborundum Fiberfrax" disposed thereover, such material being manufactured by Standard Oil's Fibers Division of Niagara Falls, N.Y. This material assists in retaining heat within melting chamber 16, as well as keeping the cabinet 11 at a safe temperature for contact by operating personnel. Insulation 56 is disposed around the exterior of housing 15, as shown, to further aid in retaining heat within chamber 16.
Disposed externally to melting chamber 16 and within inner housing 15 are a front air circulation chamber 22 and a rear air circulation chamber 23. Chambers 22 and 23 are separated by a divider 33 disposed between, and attached to, front wall 30 of inner housing 15 and bottom chamber wall 20, as shown. Thus, while the cross-section of FIG. 1 shows chambers 22 and 23 adjacent to front wall 11a and rear wall 11b of cabinet 11, respectively, it should be appreciated that such chambers 22 and 23 extend somewhat along the side walls of cabinet 11. Front chamber wall 18 has an aperture 36 disposed therethrough so that front air circulation chamber 22 communicates with melting chamber 16. Similarly, rear chamber wall 19 has an aperture 37 disposed therethrough so that rear air circulation chamber 23 also communicates with melting chamber 16.
A blower 45 disposed below melting chamber 16 includes a motor 46, a drive shaft 47, and two impellers 48 and 49. Impeller 48 is disposed in the rear air circulation chamber 23. An aperture 38 is disposed through divider 33. In this way, front air circulation chamber 22 communicates with rear air circulation chamber 23, or more particularly, with impeller 48. A blower chamber 42 is, here, disposed below rear air circulation chamber 23 and has impeller 49 disposed therein.
An outlet arrangement 43 is coupled between rear air circulation chamber 23 and blower chamber 42 and directs air out of cabinet 11. More particularly, an exhaust duct 52 extends between outlet arrangement 43 and an aperture 50 disposed through bottom wall 32 of housing 15. In this way, the exhaust arrangement 43 communicates with rear air circulation chamber 23. A valve 51 is coupled to exhaust duct 52 and regulates the air flow through aperture 50, as will be described hereinafter. Suffice it here to say that air is directed out of rear air circulation chamber 23, through duct 52 and, further, through outlet arrangement 43. An outlet aperture 44, here disposed through rear wall 11b of cabinet 11, is coupled to outlet arrangement 43 and is further adapted for coupling to a suitable fume hood arrangement, or a venting duct (not shown). Thus, the air directed through outlet arrangement 43 exits cabinet 11 through outlet aperture 44.
An inlet duct 55 extends from divider 33 to the bottom wall 32 of housing 15 and directs air from outside of cabinet 11 through inlets 13 and into front air circulation chamber 22. More particularly, an aperture 53 is disposed through divider 33 and is coupled to inlet duct 55. A valve 54 is coupled to inlet duct 55 to control the flow of air therethrough as will be described.
An electrical heating element 60 is disposed inside rear air circulation chamber 23 and is controlled by conventional means disposed within a control compartment 61. Here, heating element 60 is a "Calrod" device manufactured by Chromalox of Pittsburgh, Pa. A power cord and plug arrangement 59 is adapted for coupling to a standard 120 volt alternating current source which provides power for, inter alia, heating element 60. Additionally, a conventional alternating current (AC) to direct current (DC) converter 58 (shown schematically) is disposed in control compartment 61 and provides a DC power source for electronics such as a microprocessor 101 also disposed in the control compartment 61. The function of microprocessor 101 will be described hereinafter.
An air flow indicator 57 is disposed in rear air circulation chamber 23 and includes a switch 65 and a paddle 67. Paddle 67 is rigidly attached to rear wall 31 of housing 15 by any suitable means, but is flexible in that paddle 67 sways toward switch 65 in response to a flow of air thereby in the direction indicated by arrow 131. Thus, when blower 45 is activated, thereby activating impeller 48 (as well as impeller 49), the airflow, as shown by arrow 131, forces paddle 67 to sway and contact switch 65. When paddle 67 contacts switch 65, switch 65 is activated. Switch 65 is coupled to microprocessor 101 and, when activated, provides an indication that air is flowing inside sterilizer 10 (i.e. that blower 45 is operating properly).
Temperature sensing devices 62-64 are used to measure the temperature at various locations within the sterilization apparatus 10. More particularly, disposed in rear air circulation chamber 23 and adjacent to heating element 60 is temperature sensing device 62. Temperature sensing device 62 provides continuous temperature sensing in order to modulate the "on" and "off" time of heating element 60. Temperature sensing device 63 is, here, a switch and is disposed in front air circulation chamber 22 to provide an indication of whether the air inside sterilizer 10 is at a temperature which is safe for contact by the operator of sterilizer 10. In other words, temperature switch 63 operates as an over temperature indicator. When the temperature inside sterilizer 10 is greater than approximately 525° F., switch 63 is activated and causes the heating element 60 to be shut off and an audio indicator to be activated, as will be described in conjunction with FIGS. 5A and 5B. A third temperature sensing device 64 is, here, disposed inside melting chamber 16 near the center of the floor 20 thereof, as shown. Temperature sensor 64 provides an indication of the temperature of the waste material 25 due to its placement proximate to, and here under, such waste 25. Here, temperature sensing devices 62 and 64 are conventional thermocouple devices and sensing device 63 is a thermally activated switch; however, alternatively, it is noted that either fewer or more temperature sensing devices may be utilized, and such devices may be of any suitable type. Although not shown, temperature sensing devices 62-64 are coupled to microprocessor 101.
The indication of the temperature of waste material 25 here, provided by temperature sensor 64, may be stored and accessed by the operator of sterilizer 10. For example, microprocessor 101 has the capability of storing a plurality of sensed temperature values. Alternatively, additional memory capability may be provided with a conventional memory device. The temperature values thus stored may be accessed by the operator of sterilizer 10 in various ways. A printer (not shown) may be provided on the sterilizer 10, such printer communicating with microprocessor 101 to provide a printout of successive temperature measurements automatically and continuously during the sterilization process. Alternatively, such a printout may be provided only on demand by the operator. The printer may be part of sterilizer 10 or may be provided as a separate device adapted for coupling to an appropriate connector or jack (not shown) on sterilizer 10, thereby communicating with microprocessor 101. Another alternative is to provide a connector or jack compatible with a computer, such as an RS232 connector, so that the temperature information may be accessed by such computer. In each of the above-described arrangements, the operator of sterilizer 10 is provided with a record of a plurality of sensed temperatures within the cabinet. Stated differently, the temperature within the cabinet (corresponding to the temperature of waste 25) is continuously sensed during the sterilization process and a record of such sensed temperatures provided. In this way, the operation of sterilizer 10 and the fact that the waste 25 has been sterilized may be verified.
Referring now to FIGS. 1 and 2, a cover 66 is disposed over the aperture 21 of melting chamber 16. Here, cover 66 is made of stainless steel and is attached to rear wall 11b of cabinet 11 by a hinge 68. However, it is noted that cover 66 may alternatively be made of other materials having suitable strength and rigidity. Cover 66 includes an outer frame 70 defined by a front wall 70a, a rear wall 70b, side walls 70c and 70d (FIG. 2), a top wall 70e and a partial bottom wall 70f. An inner frame 72 of cover 66 is attached to outer frame 70 by any suitable means such as welding and has insulation 73 attached externally thereto, as shown. Inner frame 72 is defined by a rear wall 72b, side walls 72c and 72d (FIG. 2), and a top wall 72e (FIG. 1). Disposed between insulation 73 and outer frame 70 is a vacant area, or air gap 71. Air enters air gap 71 through openings (not shown) in outer cover frame 70 and flows therethrough by natural convection. Such air flow cools the cover 66 which may become warm during the sterilization process.
Disposed on the front wall 70a of outer frame 70 is a handle 75 with which cover 66 may be lifted to an open position to expose melting chamber 16. Alternatively, cover 66 may be lowered over cabinet 11 to a closed position, as shown, to conceal melting chamber 16. A seal 76, here made of silicone rubber, is disposed around the entire perimeter of aperture 21 (i.e. on flanges 17a and 17b) so that, when cover 66 is lowered over cabinet 11, seal 76 is compressed and effectively isolates the atmosphere inside melting chamber 16 from the atmosphere external to such chamber 16. It is desirable to seal melting chamber 16 so that fumes, evolving from the melting process, do not escape into the atmosphere external to the sterilizer 10.
An interlock mechanism 78 (FIG. 1) allows cover 66 to be locked when such cover 66 is lowered over cabinet 11. Locking the cover 66 in a lowered, or closed position is desirable to ensure that operators of the sterilizer 10 do not raise the cover 66 during the sterilization process or shortly thereafter, when the contents of melting chamber 16 and the chamber 16 itself may be dangerously hot. Here, an extending rod 80 is attached, by any suitable means such as welding, to the bottom wall 70f of outer cover frame 70. Rod 80 has an aperture, or eyelet (not labelled), disposed therethrough. When cover 66 is lowered over cabinet 11, rod 80 is aligned with an aperture (not labelled) in cabinet 11, or more particularly, in flange 17a. Thus, when cover 66 is in its lowered position, as shown in FIG. 1, rod 80 extends down into cabinet 11. In this position, a pin 79 can be moved horizontally into the eyelet of rod 80 thereby locking the cover 66 in a closed position. Here, an interlock lever 81, disposed on front wall 11a, is turned to move the pin 79 through the eyelet to lock cover 66. A solenoid which, upon activation, moves the pin 79 through the eyelet of rod 80, as well as other suitable interlock mechanisms, may alternatively be used.
Disposed within cover 66 is a drawer 82 into which medical waste 25 may be deposited and subsequently transferred to melting chamber 16, as described below. Drawer 82 is defined by a front wall 83, a rear wall 84, side walls 85 and 86 (FIG. 2), and a bottom wall, or floor 87 and has a capacity of approximately one hundred cubic inches. Front wall 83 and bottom wall 87 are attached together by a hinge 89, as shown in FIGS. 1 and 3. Drawer 82 has an aperture 90 disposed in a top portion thereof. Disposed over aperture 90 and aligned therewith, is an aperture 91 disposed through the top wall 70e of outer cover frame 70. A lid 92 is disposed over aperture 91 and is attached to the top wall 70e by a hinge 94. Lid 92 has a knob 96 disposed thereon with which lid 92 may be raised. When lid 92 is in a raised, or open position, drawer 82 is exposed and accessible. A seal 98, here made of silicone rubber, is disposed between cover 66 and lid 92 when lid 92 is in the closed position, as shown. More particularly, here, seal 98 is attached to the bottom surface of lid 92 such that when lid 92 is lowered over aperture 91 in a closed position, seal 98 is compressed and effectively isolates the interior atmosphere of melting chamber 16 from the exterior thereof. An interlock mechanism 100 is provided to allow lid 92 to be locked in the closed position. Such interlock mechanism 100 may be of the type described above in conjunction with cover interlock mechanism 78, or any other suitable device for ensuring that lid 92 will not be opened when the temperature inside sterilizer 10 is so hot as to be dangerous to operating personnel.
A portion of lid 92 may be comprised of an ultraviolet transmissive material, or window 113 and an ultraviolet lamp 114 with a suitable cover 99 disposed thereover may be disposed external to drawer 82, as shown. When ultraviolet lamp 114 is activated, window 113 permits transmission of ultraviolet radiation therefrom to be directed into drawer 82. An example of a material for window 113 having suitable ultraviolet transmissivity is sold under the trade name of Lexan by General Electric of Pittsfield, Mass. When activated, ultraviolet lamp 114 directs ultraviolet radiation into drawer 82 to sterilize any bacteria contained therein. This feature may be desirable in cases where there is concern that infectious waste remaining in drawer 82 during the sterilization process may not be rendered harmless, as will be described.
Cover 66 has an aperture 102 disposed in the bottom wall 70f thereof and aligned with aperture 21 of melting chamber 16 when such cover 66 is in the lowered position, as shown in FIG. 1. A deflector 104, here made of stainless steel, is attached to the bottom wall 70f of cover 66 by a hinge 106. Deflector 104 extends down into melting chamber 16 to direct waste material 25 from drawer 82 into melting chamber 16, as will be described hereinafter. It is noted that deflector 104 may, alternatively, be integrally formed with the bottom wall 70f of cover 66 rather than being hingedly coupled thereto, as shown.
Referring now to FIGS. 1 to 3, a flange 108 is disposed adjacent rear wall 84 of drawer 82. More particularly, here, the side walls 85 and 86 of drawer 82 are attached to flange 108 by any suitable means such as by bolting or welding. A cable 110 is coupled to flange 108 by any suitable means and extends back toward rear wall 72b of inner cover frame 72. More particularly, cable 110 engages with two pulleys 111 and 112 which guide the cable 110 from flange 108 to a knob 88 disposed externally to front wall 70a, as shown in FIG. 2. Pulleys 111 and 112 are mounted to rear wall 72b of inner cover frame 72 by pulley supports 116 and 117, respectively.
A pair of support walls 118, 119 are attached to side walls 72c and 72d of inner cover frame 72, respectively (FIG. 2). A corresponding pair of brackets 120 and 121 are attached to the support walls 118 and 119, respectively. Springs 95 and 97 are disposed, here, above brackets 120 and 121, respectively, and are attached between flange 108 and front wall 70a by any suitable means.
In operation, drawer 82 slides along brackets 120 and 121 toward the rear wall 72b in response to knob 88 being pulled outward, or away from cabinet 11, as will be described below. Drawer 82 is moveable between a first loading position (i.e. the forward position) in which waste material may be deposited therein and a second position in which the drawer is disposed substantially above aperture 21 of melting chamber 16 to transfer waste 25 from drawer 82 into melting chamber 16, as will be described. More particularly, conventional brackets 120 and 121 extend backwards to support drawer 82 as such drawer 82 slides backwards. Springs 95 and 97, bias drawer 82 to the forward position, as shown in FIG. 1. When drawer 82 is in the forward position, a seal 93 is disposed between flange 108 and adjacent portions of cover 66, as shown. More particularly, here, seal 93 is made of silicone rubber and is attached to flange 108 such that when drawer 82 is in the forward position, seal 93 is compressed. In its compressed position, seal 93 effectively isolates drawer 82 from melting chamber 16.
Referring now specifically to FIG. 3, an interlock mechanism 124 is disposed below drawer 82 and permits such drawer 82 to be locked in the forward position. Interlock mechanism 124 is desirable for several reasons. First, by locking drawer 82 in its forward position during the melting cycle, an operator of sterilizer 10 is prevented from pulling handle 88 to slide drawer 82 over melting chamber 16, thereby transferring waste from drawer 82 to melting chamber 16, during such melting cycle. In other words, the possibility of infectious waste 25 being introduced from drawer 82 into the melting chamber 16 at a stage of the melting cycle when it will not be sufficiently heated in order to render it harmless is avoided. Secondly, the drawer interlock mechanism 124 provides an additional level of protection in the event that the lid interlock mechanism 100, which generally would lock the lid 92 closed during the melting cycle, were to fail. In other words, even if an operator had access to the drawer 82 during the melting cycle, the interlock mechanism 124 would prevent the drawer 82 from being moved backward over the melting chamber 16 during such cycle. In this way, the seal 93 is maintained in a compressed position during the melting cycle to prevent the dangerously hot air inside chamber 16 from escaping.
Here, drawer interlock mechanism 124 is comprised of a sliding latch portion 126 and a projecting portion 128. More particularly, the bottom wall 87 of drawer 82 has a projecting porting 128 extending downward therefrom. The sliding latch portion 126 is disposed on the bottom wall 70f of outer cover frame 70 and, in an unlocked position 126a, allows drawer 82 to slide backwards (as shown by arrow 125) along brackets 120 and 121 without interference. A solenoid 127 is disposed adjacent to sliding latch portion 126 and, upon activation, moves such portion 126 to a locked position 126b. In the locked position 126b, drawer 82 is prevented from sliding backwards (as shown by arrow 125) since sliding latch portion 126 interferes with such motion. In other words, when sliding latch portion 126 is in the locked position 126b, projecting portion 128 contacts latch portion 126 if the operator of the sterilizer 10 tries to move drawer 82 backwards by pulling knob 88. In this way, the backward sliding of drawer 82 is prevented when sliding latch portion 126 is in locked position 126b.
In operation, infectious waste material 25 may be deposited into drawer 82 by opening lid 92, or, alternatively, may be deposited directly into melting chamber 16 by raising cover 66. For example, in applications where relatively small amounts of infectious waste 25 are generated on a continuous basis, it may be desirable to utilize the drawer 82 to dispose of such waste 25. Thus, the use of drawer 82 would tend to be convenient when sterilizer 10 is located, for example, in a physician's office or a medical laboratory environment at the location where relatively small amounts of waste are continuously generated. However, if sterilizer 10 is disposed some distance away from the source of the medical waste 25, for example in the basement of a hospital rather than in individual medical laboratories therein, it may be desirable to collect the medical waste 25 in a bag 26 and dispose of such bag 26 periodically rather than continuously. Also, if relatively large amounts of waste 25 are being generated, it may be preferable to deposit such waste 25 directly into melting chamber 16 rather than utilizing drawer 82.
Consider first the use of drawer 82 for the disposal of medical waste 25. The operator of sterilizer 10 opens lid 92 by pulling up on knob 96 to access drawer 82. With drawer 82 exposed, waste material 25 may be deposited directly therein. Once the waste 25 is deposited into drawer 82, the operator of sterilizer 10 closes lid 92. Thereafter, knob 88 is pulled outward from cabinet 11. Note that drawer interlock 124 may be activated to prevent the drawer 82 from sliding backwards until the lid 92 is closed and locked if so desired. As knob 88 is manually pulled outward, the cable 110 attached thereto is pulled accordingly. Thus, pulling knob 88 causes flange 108, to which cable 110 is attached, to slide backwards toward rear wall 72b. As flange 108 and, thus, drawer 82 slides backwards, bottom wall 87 of drawer 82 becomes aligned with the aperture 102 in cover 66. Since bottom wall 87 is not attached to rear wall 84, and is hingedly attached to front wall 83, when such bottom wall 87 moves over aperture 102, the end thereof distal from hinge 89 tilts downward. The downward tilting of bottom wall 87 causes the waste material 25 disposed thereon to drop out of drawer 82 and into melting chamber 16. Furthermore, deflector 104 is disposed such that when the medical waste 25 drops from downward tilted floor 87, deflector 104 directs such waste 25 downward toward the floor 20 of melting chamber 16. In this way, deflector 104 insures that the medical waste 25 will not enter aperture 37 in the rear chamber wall 19, thereby potentially contacting heating element 60. Although not shown, it may also be desirable to taper melting chamber 16 so that the walls thereof slope inward (i.e. so that floor 20 of chamber 16 is smaller in area than aperture 21 of chamber 16). Such tapering may assist in guiding the waste 25 to the floor 20 of chamber 16. Once the knob 88 has been pulled outward and the knob 88 is released, springs 95 and 97 contract to return drawer 82 to its forward position.
It is noted that, as an alternative to knob 88, the sliding of drawer 82 may be achieved by activating a button (not shown) disposed on front wall 11a of cabinet 11. In other words, when the drawer 82 is judged full by the operator, a "load" button may be activated. This action would automatically cause lid 92 to be locked in the closed position and drawer 82 to slide backwards over melting chamber 16, thereby transferring the waste 25 from the drawer 82 to the chamber 16.
It may be desirable to lock the lid 92 shut and/or the drawer 82 in the forward position when the melting chamber 16 has been filled with waste 25 to its maximum capacity. One way of determining when the melting chamber 16 has been filled with waste 25 is to use an ultrasonic sensor 180 (shown schematically in FIG. 1). More particularly, an ultrasonic transducer 180 may be disposed above melting chamber 16 and aligned with aperture 21. Ultrasonic transducer 180 is coupled to microprocessor 101 and provides a control signal corresponding to the duration between transmission of a sonic signal downward toward waste 25 and receipt of a reflection of such signal from waste 25. Such control signal is thus indicative of the height of such waste 25. The drawer interlock mechanism 124 and/or lid interlock mechanism 100 can be activated in response to the control signal to ensure that an operator of sterilizer 10 is prevented from attempting to deposit waste therein one chamber 16 is filled to capacity. A convenient location for such an ultrasonic sensor 180 is shown in FIG. 1. More particularly, the ultrasonic sensor 180 may be embedded in insulation 73 of cover 66, above melting chamber 16. Note that the excessive temperatures to which the inside of melting chamber 16 will be exposed during the melting cycle may require the ultrasonic sensor 180 to be shielded, for example by a sliding cover 182, to protect it from such temperatures. Such an arrangement may be realized by providing an aperture (not labelled) in the top wall 72e of inner cover frame 72, above which such sensor 180 is embedded in insulation 73, and also providing a sliding cover 182 (shown schematically in FIG. 1) thereover. With this arrangement, the sliding cover 182 may be automatically moved under the control of microprocessor 101 to expose the ultrasonic transducer 180 at appropriate times during the melting cycle, when the height of waste 25 is to be measured.
In accordance with an alternate mode of loading waste material 25 into chamber 16, cover 66 may be lifted by handle 75 to expose melting chamber 16. In this way, the operator of sterilizer 10 can deposit medical waste 25 directly into melting chamber 16 either with or without such waste 25 being contained in a bag 26. Medical waste 25 may thus be deposited in melting chamber 16 either via drawer 82, in what may be referred to as a continuous mode of operation, or by raising cover 66 and depositing the waste 25 directly into chamber 16, in what may be referred to as a batch mode operation.
Referring now to FIG. 4, an alternate embodiment 10' of sterilizer 10 includes cabinet 11 and identical parts associated therewith as described above in conjunction with FIG. 1. However, in place of cover 66 (i.e. having drawer 82 disposed therein, FIG. 1), sterilizer 10' includes a simple cover arrangement 184. Cover 184 includes a frame 186, here, comprised of stainless steel and coupled to cabinet 11 by hinge 68. Outer frame 186 has a front wall 186a, rear wall 186b, side walls 186c and 186d (not shown), a top wall 186e, and a bottom wall 186f, as shown. A layer of insulation 188 is coupled to bottom wall 186f as shown to assist in retaining heat within sterilizer 10'. A vacant area, or air gap 190 is disposed between insulation 188 and cover frame 186. Air from outside of sterilizer 10' enters air gap 190 through openings in frame 184 (not shown) and flows therethrough by natural convection. Such air flow assists in keeping cover 184 at a safe temperature for contact during the sterilization process. Waste 25 is loaded into melting chamber 16 of sterilizer 10, by lifting cover 184 via a handle 192, as shown. The ultrasonic sensor 180 may be used in conjunction with cover 184 in a manner similar to that described above in conjunction with FIG. 1. Note that although the embodiment of FIG. 4 does not provide the operational flexibility provided by that of FIG. 1 (i.e. sterilizer 10' is operable in batch mode only), such sterilizer 10' may be desirable due to its manufacturing simplicity and thus, cost savings.
Once the medical waste 25 is deposited in melting chamber 16 of either the sterilizer embodiment of FIG. 1 or FIG. 4, the operator may commence the sterilization process. Here, disposed on the front wall 11a of cabinet 11 are three controls (not shown) adapted for actuation by the operator of sterilizer 10 (or 10'). These controls or, switches, include a power switch, a melting switch used to commence the melting process, and a cooling switch used to commence the cooling process. Each of the three switches has a corresponding indicator light which indicates whether power is on in the case of the power indicator light or whether the sterilizer 10 (or 10') is in the melting or cooling cycle in the case of the melting and cooling indicator lights, respectively. Also disposed on front wall 11a, is an additional indicator light which is lit when the sterilizer 10 is ready to receive waste material 25 and initiate the melting process, and thus such light may be referred to as a "ready" indicator light. The sterilization process is commenced by depressing the power switch. Here, this action causes heating element 60, blower motor 46, and interlocking mechanisms 78, 100, and 124 (i.e. for the sterilizer 10 of FIG. 1, or alternatively, interlocking mechanism 78 only for the sterilizer 10' of FIG. 4) to be activated. In other words, lid 92 and cover 66 (i.e. cover 184 for the sterilizer 10' of FIG. 4) will be locked in their closed positions during the sterilization process, as well as drawer 82 being locked in its forward position. With blower motor 46 activated, impeller 48 draws air in through aperture 38 from front air circulation chamber 22, as indicated by arrow 130. The air is expelled into rear air circulation chamber 23, as indicated by arrow 131. The air is further directed past activated heating element 60 and into melting chamber 16 through aperture 37, as shown by arrow 132. As indicated by arrows 133, the air entering melting chamber 16 interacts with the waste material 25 to heat such material 25. The heated air is then drawn out of melting chamber 16 through aperture 36 and into front air circulation chamber 22, as shown by arrow 134. The above described air circulation flow pattern is continuous while blower motor 46 is activated.
During an initial stage of the sterilization process, the heated air entering melting chamber 16 volatilizes the water content of the waste material 25 into steam. When the air inside chamber 16 reaches a temperature of approximately 212° F., valve 51 coupled to exhaust duct 52 is opened. The steam generated in melting chamber 16 is thus directed through aperture 50, valve 51, exhaust duct 52, and exhaust arrangement 43, as shown by arrow 103. With blower motor 46 activated, impeller 49 draws air into blower chamber 42, as indicated by arrows 105. The air thus directed comes from outside of cabinet 11 and enters cabinet 11 through inlets 13. Impeller 49 expels air through exhaust arrangement 43, as indicated by arrow 107. Here, microprocessor 101 controls the opening of valve 51 to yield a mixing ratio of air drawn through impeller 49 to air directed from rear air circulation chamber 23 of approximately 100:1.
Once the water content of the waste material 25 has been driven off, or vaporized, the temperature within chamber 16 rises to approximately 450° F. By exposing infectious waste material 25 to such a high temperature of approximately 450° F. for a duration of approximately fifteen minutes, the complete destruction of any infectious organisms is ensured. At 450° F., the bacteria is rendered harmless, the waste 25 is liquified, and its volume reduced. However, this temperature is significantly lower than the temperatures at which the plastic is molded and, as a result, the likelihood of toxic fumes evolving is minimized. Note that this duration corresponds to the time required to render the maximum volume of infectious waste harmless once the waste has reached a temperature of approximately 450° F. Furthermore, this high temperature melts the infectious waste 25, thus converting such waste 25 to a liquid state. The melting of waste material 25 provides a volume reduction of the waste material 25 of between approximately seventy and ninety percent. Thus, the plastic waste material 25 is rendered harmless, as well as unrecognizable as medical waste. Once the melting chamber 16 has been maintained at a temperature of approximately 450° F. for a sufficient length of time to ensure that all infectious waste has been sterilized, heating element 60 is de-activated, or shut off.
As mentioned above, when sterilizer 10 (FIG. 1) is operated in the continuous mode (i.e. by loading waste 25 into chamber 16 via drawer 82) ultraviolet lamp 114 may be used to assure that any waste 25 remaining in drawer 82 will be rendered harmless. In other words, it is possible, for example, that infectious fluids may leak out of plastic containers and onto the walls of drawer 82. While the waste 25 transferred from drawer 82 to chamber 16 will be exposed to bacteria killing temperatures (as verified by temperature sensing device 64), there may be concern that any waste remaining in drawer 82 may not be exposed to such temperatures. Thus, ultraviolet lamp 114 may be activated during and/or after the melting process, and before mechanisms 100 and 124 are unlocked, in order to sterilize any bacteria present in drawer 82. Alternatively, a lock mechanism (not shown) may be provided to lock the drawer 82 in the second position in which drawer 82 is disposed substantially above aperture 21 of melting chamber 16 during the sterilization process. In this way, the temperature to which drawer 82 is subjected during the sterilization process will be closer to the bacteria killing temperatures within the melting chamber 16.
In certain cases, the length of time during which infectious waste 25 is exposed to high temperatures in order to render such waste 25 harmless is shorter than the duration necessary to provide maximum volume reduction to the waste 25. In such cases, it may be desirable to expand the processing time beyond that required to sterilize the waste 25 in order to achieve maximum volume reduction. A convenient way of determining whether the volume of the waste has been maximally reduced is to utilize the ultrasonic sensor 180 referred to above. In other words, the heating element 60 can remain activated after the fifteen minute high temperature period has lapsed and for as long as a height reduction is sensed. More particularly, the sonic transducer 180 provides the control signal at the beginning of the melting cycle to indicate the initial height of the waste 25. The transducer 180 then, periodically provides such control signal until microprocessor 101 detects a constant height over a number of samples (i.e. indicating maximum volume reduction) at which time heating element 60 is de-activated. Alternatively, heating element 60 may be de-activated once microprocessor 101 detects a predetermined volume reduction of the plastic waste 25, for example a volume reduction of approximately 8:1. In other words, rather than exposing the waste 25 to high temperatures for a time period corresponding to the time required to sterilize the waste 25, such waste 25 is exposed to high temperatures for an additional period of time required to further reduce the volume of the waste 25.
Note that with the above-described melting process, the waste 25 will be exposed to a temperature in excess of 450° F. for at least approximately fifteen minutes, regardless of the volume of such waste 25. However, the total processing time will vary as a function of the water content of the waste 25 since the duration of the initial stage of the sterilization process (i.e. the stage during which the water content of the waste 25 is volitized) varies with such water content. In certain applications, it may be desirable to provide an indication for example, via an LCD display (not shown), of the duration of the sterilization process. This feature may be realized with the use of ultrasonic sensor 180 in cases where known waste material is to be sterilized. Consider, for example, the case where petri dishes with agar disposed therein are to be sterilized. By sensing the height of such waste, an approximation of the number of petri dishes and, thus, the total ratio of solid material to liquid (based on a predetermined amount of agar per petri dish) may be obtained. With such water content information, the amount of time necessary to vaporize the water content may be estimated based on the heat of vaporization of water and added to the fifteen minute bacteria sterilization time to estimate the total processing time.
After the melting cycle, microprocessor 101 controlled valve 54 coupled to inlet duct 55 is opened and heating element 60 is de-activated. Opening valve 54 causes air from outside cabinet 11 to be directed through inlets 13, inlet duct 55, and into front air circulation chamber 22. This relatively cool external air is drawn into impeller 48 through aperture 38, as shown by arrow 130. Thus, the air is directed through rear air circulation chamber 23, melting chamber 16, and front air circulation chamber 22; however, such air is not heated by heating element 60 since such element 60 is now shut off. In this way, the chamber 16, and more particularly, the molten medical waste 25 is cooled. The flow of cool air further causes the molten waste 25 to harden and solidify yielding an easily handled block of sterilized waste. Once the temperature inside chamber 16 decreases to a level which is safe for contact by operating personnel, the interlock mechanisms 78, 100, and 124 (i.e. in the case of sterilizer 10 of FIG. 1 and mechanism 78 only in the case of sterilizer 10' of FIG. 4) are released thereby enabling such personnel to raise cover 66 (or cover 184 for sterilizer 10' of FIG. 4) and remove the solidified block of sterilized waste material for further disposal in a landfill, if so desired.
As mentioned, the control of the sterilization process, described generally above, is achieved with the use of microprocessor 101. Referring now to FIGS. 5A and 5B, the operation of sterilizer 10 (i.e. like that of sterilizer 10' of FIG. 4 except that cover 66 of sterilizer 10 corresponds to cover 184 of sterilizer 10' and lid 92 and drawer 82 are not present in sterilizer 10') will be described in detail in conjunction with a flow diagram of the operation of microprocessor 101. In step 136, the power switch is operator activated, thereby initiating step 138 in which microprocessor 101 is initialized. More particularly, in step 138, the internal registers of microprocessor 101 are cleared and the code with which the following steps are executed is loaded into random access memory (RAM) as is conventional. After initialization step 138, microprocessor step 140 is executed in which the indicator light corresponding to the cooling switch, or the cooling indicator light, is activated. With the cooling indicator light on, the operator of sterilizer 10 is notified that the apparatus 10 is disposed at a temperature sufficiently low to be safe for contact. Subsequently, in step 142, microprocessor 101 determines whether the temperature inside sterilizer 10 is greater than approximately 225° F. (by monitoring temperature sensing device 62) or whether the over temperature switch 63 has been activated. If the outcome of either of these determinations is true, or affirmative, microprocessor 101 executes step 144 in which it is determined whether the power switch has been activated. If the power switch has not been activated, microprocessor 101 next executes step 146; whereas, if the power switch has been activated, the process is done, as indicated by step 148 and power is shut off. With this arrangement, an operator of sterilizer 10 is permitted to shut off power, in step 144, during the cooling cycle.
As mentioned, if the power switch is not activated in step 144, step 146 is executed in which it is determined whether the melting switch is activated and whether the melting cycle has been interrupted. If both of these conditions are true, step 164 is next executed as will be described below. However, if the outcome of step 146 is false, or negative, as is the case during a cooling cycle which follows an uninterrupted melting cycle, microprocessor 101 will re-execute step 140 and will again indicate that the sterilizer 10 is in the cooling cycle via the cooling indicator light.
Consider now the case in which the outcome of step 142 is negative. In other words, the temperature, as monitored by temperature sensor 62, is less than approximately 225° F. and over temperature switch 63 has not been activated. In this case, microprocessor 101 executes step 150 in which the ready indicator light is activated, or lit thereby notifying the operator of sterilizer 10 that the apparatus is ready to process waste. Subsequently, step 152 is executed in which it is determined whether the melting cycle has been interrupted. If the melting cycle has been interrupted, microprocessor step 154 is executed.
Microprocessor step 154 includes several steps described hereinafter and simplified to "melt error" step 154 for improved clarity of FIG. 4. In step 154, the operator of sterilizer 10 is notified of a melting error. More particularly, both the melting indicator light and the cooling indicator light will flash on and off continuously to indicate an interrupt in the melting process. Such indication to the operator is particularly important so that infectious waste 25 is not mistaken for harmless waste having undergone a full melting cycle. In response to the flashing light indication corresponding to a melting error, the operator of sterilizer 10 may activate the melting switch which causes microprocessor 101 to execute step 166, as will be discussed below. The operator may alternatively depress the cooling switch in response to the flashing light indication of a melting error. Such action by the operator provides a reset mechanism which has the effect of returning microprocessor 101 to step 140.
In the case where it is determined, in step 152, that the melting cycle has not been interrupted, step 156 is executed subsequent to step 152. In step 156, the cover interlock 78 is released thereby permitting access to melting chamber 16. A predetermined length of time is then allowed to lapse, after which power is shut off to the sterilizer 10. More particularly, in step 158, it is determined whether the predetermined time duration has lapsed. In the case where such time lapse has occurred, microprocessor 101 executes step 148 in which power is shut off to sterilizer 10 and the process is done. However, until such time has lapsed, microprocessor 101 subsequently executes step 160, in which the power switch is monitored. If such power switch is activated during this time duration, again microprocessor 101 executes step 148 to shut off power to sterilizer 10. However, in the case where the power switch is not activated during the predetermined time, step 162 is executed in which the melting switch is monitored. If the melting switch is activated in step 162, microprocessor 101 executes step 164.
In step 164, the cover interlock 78 is monitored. More particularly, monitoring of cover interlock 78 in step 164 occurs either in response to the condition mentioned above, where such melting switch is activated prior to the predetermined time duration lapsing or, alternatively, in response to the melting switch being activated and the melting cycle having been interrupted, as described above in conjunction with step 146. If, however, the melting switch 162 is not activated in step 162, microprocessor 101 re-executes the sequence of steps described above, beginning with step 158, as shown.
Microprocessor step 164 includes several steps as described hereinafter. First, microprocessor 101 determines whether cover 66 and lid 92 are in their closed, or lowered positions and locked via interlock mechanisms 78 and 100, respectively (FIG. 1). In the case where the cover 66 and lid 92 are closed and locked, microprocessor 101 then determines whether there is air flow in sterilizer 10 by monitoring air flow switch 65 (FIG. 1), as described above. In the case where there is air flow in sterilizer 10, microprocessor 101 next executes the step 166. However, if there is no air flow or if interlock mechanisms 78 and 100 are not in their locked positions, heating element 60 is shut off and the melting indicator light is flashed on and off to indicate to the operator of sterilizer 10 that either the blower 45 is not operating or that cover 66 and/or lid 92 are not closed and locked. In response to such an indication, the operator may reset the sterilizer 10 by depressing the cooling switch. In this case, microprocessor 101 next re-executes step 150 and resumes operation from such step 150.
In step 166, the waste material 25 is melted. More particularly, step 166 includes a series of steps, the first of which is to determine whether the over temperature switch 63 has been activated. If such switch 63 has been activated, heating element 60 is shut off and an audio indicator is activated to alert the operator of sterilizer 10 of the over temperature condition. The audio indication continues until the over temperature switch 63 is de-activated (i.e. when the temperature goes below the set point thereof; here, approximately 525° F.) or until a predetermined time period has lapsed. Once the predetermined time period has lapsed, power is shut off to sterilizer 10.
Consider next the case where the over temperature switch 63 is de-activated. In this case, temperature sensor 64 is monitored to determine whether the temperature inside chamber 16 is greater than approximately 250° F. If such temperature is above approximately 250° F., an error flag is set so that any interruption of the melting process will be determined in step 152. Once the temperature, as monitored by sensor 64, is greater than approximately 450° F., a timer is incremented. Such timer is then monitored to determine whether a predetermined time, corresponding to the time required to render infectious waste 25 harmless, has lapsed. Once the temperature inside melting chamber 16 has been maintained above approximately 450° F. for a suitable length of time, for example fifteen minutes, the melt error flag is cleared.
Microprocessor step 168 follows the melting step 166, and in such step 168 it is determined whether the temperature inside sterilizer 10 as measured by temperature sensor 62 is greater than approximately 250° F. In the case where such temperature is above 250° F., exhaust valve 51 is opened and air is thus directed out of rear air circulation chamber 23, as described above in conjunction with FIG. 1. Once the temperature is less than approximately 250° F., step 172 is executed and valve 51 is closed. Microprocessor 101 then monitors the cooling switch in step 174 to determine whether it has been activated. In the case where such switch has been activated, microprocessor 101 returns to step 140 to re-execute the series of steps described above. If, however, the cooling switch has not been activated, microprocessor 101 monitors the power switch in step 176. If such power switch is activated, step 178 is executed and power is shut off to the sterilizer 10. If, however, such switch is not activated, microprocessor 101 returns to step 164 and re-executes the sequence of steps thereafter, as described above.
Having described preferred embodiments of the invention, it will now become apparent to one of skill in the art that other embodiments incorporating their concepts may be used. For example, it should be appreciated that significant variations to the flow diagram described above in conjunction with FIGS. 5A and 5B may be realized without departing from the concept of the invention. For example, in step 164, drawer interlock mechanism 124 may additionally be monitored ensure that the drawer 82 is locked in the forward position during the melting process. Moreover, it may be desirable to activate the ultraviolet lamp 114 during microprocessor step 166 for example. It is felt, therefore, that these embodiments should not be limited to disclosed embodiments but rather should be limited only by the spirit and scope of the appended claims. | A system for safely disposing of pathogenic waste materials. The waste material is disposed in a chamber and heated by forced hot air to temperatures above approximately 450° F. to destroy harmful bacteria within several minutes. The high temperatures melt plastic waste materials. The harmless waste is cooled providing a solid block in which syringes and other sharp items are generally encased. The temperature within the chamber is continuously sensed and the operation of the apparatus is microprocessor controlled to adjust the process time in accordance with the load size. The microprocessor further stores the sensed temperature to provide verification that the waste has been exposed to sufficient temperatures and for a sufficient time to render such waste harmless. | 0 |
FIELD OF THE INVENTION
The present invention relates to a process for the local passivation of a substrate by a thin amorphous hydrogenated carbon layer or film. It is used in microelectronics and in particular in producing control circuits for flat-face liquid crystal screens.
The invention more specifically makes it possible to produce thin film transistors based on hydrogenated amorphous silicons used in active matrix display screens. The invention also makes it possible to produce a thin film transistor having a "planar" structure in a so-called "stacked with gate on top" configuration like that used in active matrixes for flat-faced liquid crystal screens. In general terms, the invention relates to a process for the local passivation of a substrate by a thin amorphous hydrogenated carbon film.
BACKGROUND OF THE INVENTION
It is known to deposit thin amorphous hydrogenated carbon films, designated a-C:H, or of a polycrystalline nature on glass or silicon substrates using plasma-assisted chemical vapour phase deposition (PECVD). The gas used for carbon deposition is essentially a mixture of methane and hydrogen. In this connection reference is made to the following articles:
"Electrical and chemical characterization of a-C:H prepared by RF glow discharge", W. J. Varhue et al--J. Appl. Phys. 67(88)--15 Apr. 1990, pp 3835-3841;
"Diamond and diamond-like films: Deposition processes and properties", C. V. Deshpandey et al, J. Vac. Sci. Technol. A7(3), May/June 1989, pp 2294-2302.
As a result of its mechanical characteristics, amorphous hydrogenated carbon, designated a-C:H, is at present mainly used as a protection material (optical components, tools, etc.), but its electrical properties also make it possible to consider its used as a dielectric.
The aforementioned document by Warhue teaches (FIGS. 2 and 11) the obtaining of a-C:H films with high resistivities (10 12 to 13 13 ohms.cm) by using very low gas pressures of ≦4 Pa (30 mTorrs) and radio-frequency power levels of 10 W. Under these experimental conditions, the a-C:H films are highly stressed and adhere badly to the substrate. There is a risk of the separation of 150 to 200 nm films.
The production of an active matrix for a flat-faced liquid crystal screen having two masking levels, as described in French patent FR-A-2 533 072, makes it necessary to etch a thin metal oxide film supported by a glass substrate in order to reveal the columns of the matrix. This oxide is indium-tin oxide (ITO). This metal oxide etching takes place by the wet route using a solution containing hydrochloric acid and iron perchloride.
The wet route etching speeds are generally considered as very short distance isotropic. However, on large substrates (>1 dm 2 ), there is a gradient of the etching speed between the peripheral zones and the centre of the substrate. The highest etching speeds are observed on the edges of the substrate. As a result of this phenomenon, in order to obtain a complete etching of the thin metal oxide film, it is necessary to overexpose the peripheral zones to the etching bath.
There can then be a partial etching of the glass and the diffusion of chlorine ions into its volume. Therefore there is a deterioration in the quality of the thus exposed glass surface.
The thin film transistors used in flat-faced screens use as the semiconductor material amorphous hydrogenated silicon, designated a-Si:H. The structure of these transistors leads to the deposition of said silicon directly on the glass. There is then a migration of the chlorine ions diffused in the glass. This chlorine ion migration and the quality of the amorphous silicon-glass interface modify the semiconducting properties of the silicon, leading to a deterioration of the electrical properties and a limited life for the said transistors.
The first problem which the present invention seeks to solve is the reproducible control of the quality of the amorphous silicon-glass interface by proposing a process for the local passivation of the glass substrate. This problem has long existed and has not hitherto been satisfactorily solved.
Problems of the control of the quality of the semiconductor-substrate interface also exist for substrate types other than glass and for semiconductor materials other than amorphous hydrogenated silicon. The invention relates to any local passivation of a random substrate.
EP-A-377 365 describes a local passivation of a substrate by a polymer deposited simultaneously with the erosion of metal oxide patterns using a particular mixture of three gases. This erosion/deposition method leads to thickness inhomogeneities and to a lack of uniformity of the mechanical and electrical characteristics in the polymer layer for substrate surfaces of ≧1 dm. Thus, said method is not usable for producing large flat-faced display screens.
SUMMARY OF THE INVENTION
According to an essential feature of the invention, the local passivation process for a substrate comprises the following stages:
A) producing photosensitive resin patterns on the substrate outside the areas to be passivated,
B) subjecting the structure obtained in A) to the action of a radio-frequency plasma essentially constituted by hydrocarbon and thus deposit an amorphous hydrogenated carbon layer on said structure and
C) dissolving the resin patterns in order to eliminate the amorphous carbon deposited on the resin, the amorphous carbon deposited on said areas constituting the said passivation.
The invention makes use of a lift-off method, whose principle is known in connection with thin films and microelectronics. Reference is made in this connection to:
Handbook of thin film technology by Leon I. Maissel and Reinhard Glang, McGraw-Hill Book Company, chapter 7, pp 48-49. "Special pattern-formation techniques".
The use of this method, unlike the prior art, makes it possible to obtain an amorphous hydrogenated carbon passivation layer or film having a thickness and mechanical and electrical characteristics which are constant over a large surface (>1 dm 2 ). Thus, the invention is perfectly suitable for producing large flat-faced screens. The inventive process makes it possible to obtain an amorphous hydrogenated carbon layer with a resistivity between 10 12 and 10 14 ohms/cm, which ensures a good electrical insulation. In particular, this local amorphous hydrogenated carbon deposit can be interposed between the sources and drains of thin film transistors having the "stacked with gate on top" configuration. This passivation process is particularly well suited to producing a thin film transistor with the "stacked with gate on top" configuration.
The invention therefore relates to a process for the production of a thin film transistor comprising:
a) depositing on an electrically insulating substrate a layer of a first conductive material,
b) producing photosensitive resin patterns on the layer of the first conductive material defining the patterns to be etched in said layer,
c) eliminating the areas of the first conductive material layer not covered with resin,
d) depositing an amorphous hydrogenated carbon layer on the structure obtained in c),
e) dissolving the resin patterns in order to eliminate the amorphous carbon deposited on the resin,
f) depositing a layer of a semiconductor on the structure obtained in e),
g) depositing a layer of a first electrical insulant on the semiconductor layer,
h) depositing a layer of a second conductive material on the layer of the first insulant,
i) photoengraving the stack of layers of the second conductive material, the first electrical insulant and the semiconductor in order to fix the dimensions of the transistor and
j) passivating the structure obtained in i) with a second electrical insulant.
Therefore the process according to the invention can be used for the production of flat-faced screens having an active matrix according to the two masking level method and as a result of the a-C:H deposition procedure used, there is no supplementary masking stage.
In a gate on top structure, the layer of the first conductive material is etched in order to form the transistor source and drain, whilst the layer of the second conductive material is etched to form the transistor gate. In a gate on the bottom structure, the layer of the first conductive material is etched to form the gate of the transistor, whereas the layer of the second conductive material is etched to form the transistor source and drain.
As a function of the chosen structure and the illumination method selected, the first and second conductive materials can be transparent or reflecting.
Advantageously, the second electrical insulant is amorphous hydrogenated carbon.
As described hereinbefore, a-C:H layers are obtained from a radio-frequency plasma essentially constituted by hydrocarbon. The term hydrocarbon is understood to mean organic compounds essentially constituted by carbon and hydrogen.
The hydrocarbons usable in the invention are those from the group of alkanes, alkenes and alkynes provided by all gas producers for the microelectronics industry. In particular, they are hydrocarbons having 1 to 6 carbon atoms and can be saturated, unsaturated or aromatic.
Hydrocarbons usable in the invention are acetylene, propane diene, ethylene, butene, propylene, methane, ethane, butane and propane. Preference is given to the use of methane.
According to the invention, it is possible to use a hydrocarbon or a mixture of hydrocarbons.
The amorphous hydrogenated carbon deposits according to the invention have the advantage of being produced at ambient temperature, which makes it unnecessary to excessively raise the temperature of the resin used for the lift-off, so that there is no deterioration thereof.
In order to obtain a planar transistor structure, the thickness of the amorphous hydrogenated carbon layer deposited during stage d) is equal to that of the layer of the first conductive material. This is of particular interest when the first conductive material layer is used for producing the source and drain contacts of the transistor.
By adjusting the self-bias conditions of the substrate, as well as the pressure and gas flow rate, the inventors have demonstrated that it was possible to vary the hydrocarbon dissociation rate and particularly that of methane in the plasma. As a function of the hydrocarbon dissociation rate, the polymer films obtained are more or less hydrogenated, which gives them very different physical properties, particularly with regards to their resistivity. It is therefore possible to modify the properties of the deposited carbon layer as a function of the envisaged application.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the invention can be gathered from the following illustrative and non-limitative description. This description relates to the production of a gate on top thin film transistor, but obviously the invention has a more general application, as has been shown hereinbefore. The description relates to the following drawings, wherein show:
FIGS. 1a to 1f Diagrammatically the different stages of producing a thin film transistor according to the invention.
FIG. 2 Variations of the drain current Id, in amperes, as a function of the gate voltage Vg, in volts, for a non-passivated control transistor (curve a) and for a passivated transistor according to the invention (curve b).
DETAILED DESCRIPTION
The deposition of amorphous hydrogenated carbon films according to the invention takes place with the aid of a RIE reactor conventionally used in microelectronics. The substrate for receiving the deposit is consequently placed on an electrode connected to a radio-frequency generator, so that the deposit is of the ionic type. In general, use is made of a frequency of 13.56 MHz.
In all the experimental tests carried out, pure methane was used for creating the plasma. In addition, the deposits were made at ambient temperature.
Different experimental conditions were studied for the deposition of the thin amorphous hydrogenated carbon films and are as follows:
methane pressure: 1.33 to 20 Pa (10 to 150 mTorrs)
methane flow rate: 5 to 50 cm 3 /min
self-bias of substrate: 10 to 300 V
RF power: 10 to 280 W.
Under these conditions, the films obtained make it possible to carry out the passivation functions of a substrate and the "planarization" of transistors according to the invention.
More specifically, the carbon films obtained have the following characteristics:
1) thickness ≦200 nm
2) high resistivity
3) perfect surface state
4) low mechanical stress
5) homogeneous properties on large surfaces (>1 dm 2 ).
1) Thickness
With a view to bringing about a simple passivation of a glass substrate, a few nm polymer deposit is sufficient.
However, to carry out a perfect "planarization" of the transistor, particularly between the source and drain, it is necessary to deposit a 200 nm thick film corresponding to the thickness of the conductive layer used for the source and drain. These two types of deposit were successfully obtained at deposition speeds between 1.5 and 20 nm/minute.
2) Resistivity
In order to avoid any short-circuit risks, particularly between the transistor source and drain (or between the gates of an array of transistors with the gate on the bottom), the deposited polymer must have a high resistivity. The amorphous hydrogenated carbon films produced all have a resistivity between 10 12 and 10 14 ohms.cm. The inventors have demonstrated that these values are sufficiently high to avoid any short-circuit risk between the source and drain (or gates).
3) Stress
The films must naturally have a good adhesion to the generally glass substrate, but also must be subject to low stress in order to avoid a "flaking off" on the surface of the resin and a separation of the stack of layers forming the transistor.
The measurements carried out (sag of a thin substrate) demonstrate that the films are compressively stressed to values comparable to those conventionally measured for other materials deposited in thin film form. The lowest stress values for a given a-C:H film thickness are obtained for the lowest RF power levels and for the highest gas pressures, as can be clearly gathered from the following table I.
Table I relates to 90 nm films deposited with pure CH 4 at a flow rate of 20 cm 3 /min. The stress values are given in 10 9 Pa (i.e. 10 10 dyne/cm 2 ).
TABLE I______________________________________Pressure/power 10 W 50 W 200 W______________________________________1.33 Pa (10 mT) -- 34 --7.7 Pa (58 mT) -- 13 --13.3 Pa (100 mT) <9 9 20______________________________________
The following table II gives the thickness limits for a-C:H films prior to their separation from a glass substrate. These films are deposited with pure CH 4 at a flow rate of 20 cm 3 /min and a pressure of 13.3 Pa (100 mT).
TABLE II______________________________________Thickness limit (nm) 420 320 170 130 100Power (W) 20 50 200 400 600______________________________________
It can be seen that the thickness limit of the films decreases when the RF power increases, everything else being equal. In addition, the thickness limits of the films are always below 100 nm for pressures of 2.66 to 4 Pa (20 to 30 mT).
The optimum a-C:H deposition conditions for a low stress and high resistivity are as follows:
pressure: 6.6 to 20 Pa (50 to 150 mT) and typically 13.3 Pa (100 mT),
methane flow rate: 10 to 50 cm 3 /min and typically 20 cm 3 /min,
RF power: 10 to 100 W and typically 50 W,
self-bias: 10 to 300 V and typically 10 to 55 V.
4) Surface state
In the reactor used, the substrate is kept at ambient temperature in order to obtain the deposition of perfectly amorphous films (the amorphous state of the films having been determined by X-ray diffraction). A topographical analysis of the surface of the films under a scanning electron microscope up to magnifications of 30,000 reveal no intrinsic surface defect in the deposited material.
The quality of the interface between the amorphous hydrogenated carbon and the films forming the transistor can consequently not undergo any deterioration for roughness reasons.
5) Large surface
The homogeneity of the properties of the deposited films was checked on square substrates having a side length of 20 cm. The substrates on which the local deposition of amorphous hydrogenated carbon takes place can be of glass, quartz, silica, silicon or plastics. Moreover, the passivation of these substrates makes it possible to use mediocre quality glass substrates, e.g. of the soda-lime glass type and therefore having a low cost, thereby reducing the cost of manufacture of flat-faced screens.
With reference to FIGS. 1a to 1f a description will now be given of the main production stages of a thin film transistor with the gate on top according to the invention.
The first production stage for said transistor comprises, as shown in FIG. 1a, the deposition on a glass substrate 1 of a 25 to 225 nm thick transparent metal oxide film or layer 2. The latter is of indium-tin oxide (ITO) deposited by vacuum magnetron sputtering.
On said ITO film is formed a first photosensitive resin mask 3 defining the location of the source and drain of the transistor to be produced according to conventional photolithography processes.
As shown in FIG. 1b, this is followed by the etching of the metal oxide film 2 by spray or in a hydrochloric acid bath. The etching process is checked with regards to the etching agent concentration, the temperature and the etching time, so as to obtain ITO patterns 4 having inclined flanks 4a. In particular, said etching is carried out in a bath containing 37% hydrochloric acid diluted to 50% in water and heated to a temperature of approximately 55° C. The inclined flanks 4a of the patterns 4 make it possible to free a resin border 5 at the ITO-resin interface. The patterns 4 obtained constitute the transistor source and drain.
As shown in FIG. 1c, this is followed by an isotropic deposition at ambient temperature of an amorphous hydrogenated carbon film or layer 6 on the complete structure. This film 6 has a thickness of 10 to 150 nm. It is formed under the optimum conditions described hereinbefore using a radio-frequency CH 4 plasma.
The isotropy of the deposit leads to the formation of a discontinuous carbon film 6. Thus, a visible border 5 is retained below the resin patterns 3.
The lift-off of the carbon film takes place without difficulty by dissolving the resin 3, from the border 5 and using acetone or a solvent conventionally used in microelectronics and known as "posistrip".
Only the carbon 6 deposited on the glass 1 is retained, as shown in FIG. 1d. This gives a local passivation of the glass substrate 1, which serves as a barrier to the diffusion of the impurities contained in the glass towards the semiconductor film of the transistor, which will now be deposited. These impurities more particularly result from ITO etching.
The manufacture of the transistor continues, as shown in FIG. 1e, by the deposition on the complete structure of an amorphous hydrogenated silicon film 8, a silicon nitride film 9 and then an aluminium silicide or alminium film 10.
Films 8 and 9 are deposited by plasma assisted chemical vapour deposition and the metal film by sputtering or evaporation. These films 8, 9 and 10 have respective thicknesses of 20, 300 and 200 nm.
This is followed by the definition of the dimensions of the transistor using a second resin photomask 11 produced by known photolithographic processes.
This is followed by a wet route etching of the film 10 and then a dry route anisotropic etching of the films 9 and 8. The etching agents are respectively a SF 6 plasma for films 8 and 9 and an orthophosphoric acid bath for film 10.
Following the wet route elimination of the resin photomask 11, it is optionally possible to form another, not shown photomask, defining the dimensions of the transistor gate in the film 10. With the aid of said photomask, there is a further wet etching of the conductive film 10 to form the transistor gate. Following the elimination of this photomask, the complete structure is passivated by depositing a new amorphous hydrogenated carbon film or silicon nitride film 12. The structure obtained is shown in FIG. 1f.
The carbon film 12 is deposited using a CH 4 RF plasma and the silicon nitride film by plasma assisted chemical vapour deposition.
It can be seen that this process of passivating the substrate and "planarizing" the transistor source and drain requires no supplementary masking level compared with known transistor production processes.
The process described relative to FIGS. 1a to 1f is compatible with the process for the production of an active matrix display screen described in FR-A-2 571 893.
The process of depositing a thin amorphous hydrogenated carbon film and its lift-off was applied to the production of field effect transistors for the control of flat-faced liquid crystal screens.
Different passivation and planarization tests were performed as a function of the hydrogen quantity contained in the carbon films. The hydrogen concentration contained in the films is not known in absolute value terms, but can be modified in a simple manner by adjusting the methane dissociation rate by checking the self-bias of the substrate.
In particular, the inventors have demonstrated by measuring the resistivity, optical absorption and SIMS analysis, that carbon films deposited with the lowest self-bias values contain the most hydrogen.
The following table III clearly shows the effectiveness of the passivation of the glass substrate, as well as the influence of the quality of the passivation film on the electrical characteristics of the transistors.
The carbon deposits were made under a pressure of 13.3 Pa (100 mTorr) and for a CH 4 flow rate of 20 cm 3 /min. The RF power was 50 W. The drain voltage was 0.1 V and the gate voltage 8 V.
The table more particularly shows the evolution of the ratio of the drain currents in the conductive state (I on ) and the blocked state (I off ) as a function of the nature of the passivation films deposited at different self-bias voltages.
This table shows that the ratio of the currents I on /I off increases rapidly with the hydrogen concentration in the passivation films. The ratio of these currents is 25 times greater in the case of a transistor obtained with passivation deposited with a self-bias of 10 V compared with a transistor produced directly on the glass substrate.
The Expert knows that the main properties required by the control transistor of each image element of a flat screen are, in the addressing phase, a current I on between the source and drain which must be as high as possible, so as to charge the liquid crystal capacitor as rapidly as possible at the video voltage and, in the information maintaining phase, a current I off which is as low as possible, so that the capacitor remains charged between two successive addressing operations.
The I on /I off ratio must be at least equal to 10 5 in order to bring about the operation of a flat-faced screen having a few hundred lines. This objective is achieved for locally passivated amorphous hydrogenated carbon films deposited at self-bias voltages below 55 V.
FIG. 2 gives the transfer characteristics Id=f(Vg) for a non-passivated control transistor (curve a) and for a transistor (curve b) passivated between the source and drain by an amorphous hydrogenated carbon film, deposited with a self-bias of 40 V under the aforementioned optimum conditions. Id is the drain current in amperes and Vg the voltage in volts applied to the transistor gate. These curves are obtained for a drain voltage of 4 V, a channel width of 10 μm and a channel length of 40 μm.
Apart from the advantages described hereinbefore, the amorphous hydrogenated carbon deposited between the transistor source and drain serves as an optical mask, thus limiting the prejudicial effects of the ambient observation light of the screen on the amorphous hydrogenated silicon.
FIGS. 1c to 1f show an amorphous hydrogenated carbon film 6 with a thickness slightly below that of the patterns 4 of the transistor source and drain. As stated hereinbefore, it is still possible to deposit a film 6 with a thickness strictly equal to that of the source and drain patterns 4, in order to obtain a perfectly planar structure prior to the deposition of the semiconducting film 8.
TABLE III______________________________________ I.sub.onSelf-bias I.sub.on (μA) I.sub.off (pA) I.sub.off Hydrogen concentration______________________________________ 10 55 90 160 290 Control 1.6 2.6 3.4 3.1 3.7 2.6 1.6 12 39 39 79 73 10.sup.6 2 · 10.sup.5 9 · 10.sup.4 8 · 10.sup.4 5 · 10.sup.4 4 · 10.sup.4 ##STR1##______________________________________ | Process for the local passivation of a substrate by a hydrogenated amorphous carbon layer and process for producing thin film transistors on said passivated substrate. The local passivation process consists of producing photosensitive resin patterns (3) on the substrate (1), subjecting the structure obtained to a radio-frequency plasma essentially constituted by a hydrocarbon for thus depositing a hydrogenated amorphous carbon layer (6) on the structure and dissolving the resin patterns (3) in order to eliminate the amorphous carbon deposited on the resin, the amorphous carbon deposited on the substrate constituting the said passivation. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a buttonhole sewing machine for forming a cutout through a work fabric by means of a cutting mechanism and forming a zigzag stitch around the periphery of the cutout.
2. Description of Related Art
Referring to FIG. 7, a conventional buttonhole sewing machine for forming an eyelet type buttonhole forms a cutout 2 through a work fabric 1. The cutout 2 consists of an eyelet portion 2a and a straight portion 2b. Hereinafter, this type of cutout 2 is referred to as an eyelet hole 2. After forming eyelet hole 2, the buttonhole sewing machine automatically forms a continuous zigzag stitch 3 around the periphery of the eyelet hole 2 in the order shown by arrows A, B, and C in FIG. 7, that is, firstly on the right side of the straight portion 2b, secondly around the eyelet portion 2a, and finally on the left side of the straight portion 2b.
The buttonhole sewing machine has an arm and a bed. The arm is provided with a needle bar that is moved vertically and swung side to side by a driving mechanism.
The bed is provided with a looper driven in synchronization with the needle bar by a driving mechanism. On the bed, there is provided a feed table on which the work fabric 1 is set. The feed table is moved by a feeding mechanism.
The bed is further provided with a cutting mechanism for forming the eyelet hole 2. The cutting mechanism includes a lower knife and a hammer. The lower knife is fixed at a position spaced apart from the looper and has a cutting blade corresponding to the shape of the eyelet hole 2. The hammer is driven toward the lower knife by an air cylinder.
The buttonhole sewing machine is controlled by a control device including a microcomputer. Under the control of the control device, the buttonhole sewing machine forms the eyelet hole 2, shown in FIG. 7, through the work fabric 1 set on the feed table by means of the cutting mechanism.
Further, as shown in FIG. 8A, the buttonhole sewing machine moves the feed table, on which the work fabric 1 is set, by the feeding mechanism in such a manner that a center of swing of the needle bar moves, relative to the feed table, along a two-dot chain line a (which will be hereinafter referred to as a zero bight line a), and simultaneously drives the needle bar and the looper by the driving mechanisms. As a result, the zigzag stitch 3 is formed around the periphery of the eyelet hole 2 thus forming the eyelet type buttonhole. In forming the zigzag stitch 3 around the semi-circular portion corresponding to an upper half of the eyelet portion 2a, as shown in FIG. 8A, the looper and the needle bar are integrally inverted in a counterclockwise direction as viewed in top plan.
In carrying out the buttonhole sewing as mentioned above, a pre-cutting mode is generally adopted wherein the eyelet hole 2 is formed before formation of the zigzag stitch 3. In the pre-cutting mode, as shown in FIG. 8A, a needle bar swing width or zigzag width L1 is preliminarily set so that left needle location points b of the zigzag stitch 3 formed on the right side of the straight portion 2b of the eyelet hole 2 may substantially coincide with right needle location points b of the zigzag stitch 3 formed on the left side of the straight portion 2b. Further, in the pre-cutting mode, inside needle location points b of the zigzag stitch 3 formed around the periphery of the eyelet portion 2a fall inside the eyelet portion 2a. According to the pre-cutting mode, a peripheral edge of the eyelet hole 2 is covered with the zigzag stitch 3 to thereby obtain a buttonhole having a good appearance.
The pre-cutting mode as mentioned above is adopted for the formation of a buttonhole in the case where the work fabric is formed of a normal fabric material. However, when the work fabric 1 is formed of a fabric material such as a knit which is liable to ravel, it is desirable to adopt an after-cutting mode wherein the eyelet hole 2 is formed after the formation of the zigzag stitch 3.
In the after-cutting mode, the zigzag stitch 3 must be formed so that it is not cut by the cutting mechanism when the eyelet hole 2 is formed. Accordingly, as shown in FIG. 8B, a space must be defined between the left needle location points b of the zigzag stitch 3 formed on the right side of the straight portion 2b of the eyelet hole 2 and the right needle location points b of the zigzag stitch 3 formed on the left side of the straight portion 2b. Further, the inside needle location points b of the zigzag stitch 3 formed in the periphery of the eyelet portion 2a of the eyelet hole 2 must fall outside the eyelet portion 2a. To this end, in the after-cutting mode, the zigzag width is changed into a value L2 smaller than the zigzag stitch L1 in the pre-cutting mode with the feeding operation of the feed table along the zero bight line a being identical to that of the pre-cutting mode. Further, as shown in FIGS. 8A and 8B, the forming position of the eyelet hole 2 for the after-cutting mode deviates a distance ΔY from that used in the pre-cutting mode. Therefore, it is necessary to adjust the position of the lower knife by the distance ΔY prior to cutting.
However, in such a buttonhole sewing machine, the driving mechanism for the needle bar is such that rotation of a main shaft is converted into swinging of the needle bar through a needle swinging cam, a cam follower, a driving lever, and a link mechanism. Accordingly, in changing the zigzag width, an operator must operate a zigzag width adjusting mechanism, provided in a portion of the link mechanism, to carry out the fine adjustment of the zigzag width. This fine adjustment is very troublesome and requires much time. The result is a major inconvenience when selecting the pre-cutting mode or the after-cutting mode.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a buttonhole sewing machine which can easily carry out the selection of the pre-cutting mode or the after-cutting mode without the inconvenience and consumption of time.
To achieve the object, a bottonhole sewing machine according to the present invention comprises: a feeding means for moving a feed table on which a work fabric is set; a needle bar driving means for both vertically moving and horizontally swinging a needle bar having a needle at a lower end thereof; a looper driving means for driving a looper in synchronization with the needle bar; a cutting means for forming a cutout through the work fabric set on the feed table; select means for selecting one of a pre-cutting mode where the cutout is formed before formation of a zigzag stitch and an after-cutting mode where the cutout is formed after formation of the zigzag stitch; control means for controlling the cutting means to form the cutout through the work fabric and thereafter controlling the feeding means, the needle bar driving means and the looper driving means to form the zigzag stitch having a predetermined width on opposite sides of the cutout when the pre-cutting mode is selected by the select means, while controlling the feeding means, the needle bar driving means and the looper driving means to form the zigzag stitch having the predetermined width on opposite sides of a position where the cutout is to be formed and therafter controlling the cutting means to form the cutout through the work fabric at the position when the after-cutting mode is selected by the select means; and offset means for offsetting the feed table in such a direction that stitches to be formed on the opposite sides of the position where the cutout is to be formed are spaced apart from each other, before the zigzag stitch is formed, when the after-cutting mode is selected by the select means.
In the buttonhole sewing machine of the present invention, when the pre-cutting mode is selected by the select means, a cutout is first formed through a work fabric, and thereafter a zigzag stitch having a predetermined width is formed on opposite sides of the cutout. In contrast, when the after-cutting mode is selected by the select means, a zigzag stitch having the predetermined width is first formed on opposite sides of a position where the cutout is to be formed through the work fabric, and thereafter the cutout is formed through the work fabric at this position. In the after-cutting mode, the feed table is offset by the offset means in such a direction that the stitches are formed on the opposite sides of the position where the cutout is to be formed. Accordingly, a non-sewn portion permitting the formation of the cutout can be formed between the stitches on the opposite sides of the position where the cutout is to be formed without changing a needle bar swinging width or zigzag width.
As described above, according to the buttonhole sewing machine of the present invention, the selection from the pre-cutting mode to the after-cutting mode is automatically followed by the offsetting of the feed table to be effected by the offset means. Accordingly, the zigzag width need not be changed in selecting one of the modes. Thus, the selection of the pre-cutting mode or the after-cutting mode can be carried out easily without the inconvenience and time consuming adjustment of stitch width.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the present invention will be described in detail with reference to the following figures wherein:
FIG. 1 is a perspective view of the buttonhole sewing machine according to a preferred embodiment of the invention;
FIG. 2 is a side view of the buttonhole sewing machine;
FIG. 3A is a plan view of the feed table of the buttonhole sewing machine in the buttonhole cutting position;
FIG. 3B is a plan view of the feed table of the buttonhole sewing machine in the buttonhole sewing position;
FIG. 4 is a block diagram illustrating the electrical structure of the buttonhole sewing machine;
FIG. 5 is a flowchart illustrating the operation of the buttonhole sewing machine;
FIG. 6A is a view illustrating a relationship between a forming position of an eyelet hole through a work fabric and a position of needle location points in the case of the pre-cutting mode;
FIG. 6B is a view similar to FIG. 6A, in the case of the after-cutting mode;
FIG. 7 is a plan view of the work fabric to which the buttonhole sewing has been applied;
FIG. 8A is a view similar to FIG. 6A showing the prior art; and
FIG. 8B is a view similar to FIG. 6B showing the prior art.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
There will now be described a preferred embodiment of the invention applied to an eyelet type buttonhole sewing machine, with reference to FIGS. 1 to 7. In this preferred embodiment, a work fabric 1, an eyelet hole 2 and a zigzag stitch 3 as shown in FIG. 7, are similar to those previously mentioned in "Description of Related Art". It is therefore omitted to newly illustrate these elements, and reference numerals designating these elements will be used commonly in the following description.
First, the structure of the eyelet type buttonhole sewing machine will be described with reference to FIGS. 1 and 2. A machine body 4 has a bed 5 configured in a substantially rectangular box-like shape and an arm 6 integrally provided on the bed 5. The machine body 4 is placed on a machine table 7. The machine table 7 is provided with a machine motor 8, an operation panel having a select switch 9, a foot-operated start/stop switch 10, and a control device 14, the last three of which will be hereinafter described with reference to FIG. 4.
As shown in FIGS. 1 and 2, a needle bar 16, provided at its lower end with a needle 15 is vertically movable and horizontally swingable, is provided at a free end portion of the arm 6. Provided in the bed 5 is a looper base 17 having a looper for forming stitches in cooperation with the needle 15. A driving mechanism is provided in the machine body 4 for vertically moving and horizontally swinging the needle bar 16 and also driving the looper in synchronization with the needle bar 16.
The driving mechanism will now be described. Rotation of the machine motor 8 is transmitted through a belt 35 and a pulley 18 to a main shaft 19. The main shaft 19 is provided with three cams, i.e., a needle bar vertically moving cam, a needle bar horizontally swinging cam, and a looper driving cam. Rotation of the main shaft 19 is converted into a vertical swing motion of a needle bar vertically driving lever (not shown) supported in the arm 6. As a result, the needle bar 16, connected to the needle bar vertically driving lever, is vertically driven. The rotation of the main shaft 19 is also converted into a vertical swing motion of a needle bar driving lever supported in the arm 6. As a result, a needle bar guiding member 20, connected to the needle bar swing driving lever, is vertically moved.
The needle bar guiding member 20 is loosely engaged with the needle bar 16 in such a manner as to be vertically movable and rotatable. The needle bar guiding member 20 is supported by a needle bar rotating bracket 21 rotatably supported to the free end portion of the arm 6. More specifically, a pair of side surfaces of the needle bar guiding member 20 are formed with obliquely extending grooves. On the other hand, guide pins for sliding in the grooves formed on the needle bar guiding member 20 are fixed to a pair of leg portions 21a of the needle bar rotating bracket 21. Accordingly, vertical movement of the needle bar guiding member 20 results in relative sliding of the guide pins of the leg portions 21a of the needle bar rotating bracket 21, thereby displacing the needle bar guiding member 20 sidewise relatively to the needle bar rotating bracket 21. As a result, the vertical movement of the needle bar guiding member 20 is converted into a horizontal swinging motion of the needle bar 16. On the other hand, the rotation of the main shaft 19 is also converted into a swing motion of a looper driving lever 28 provided in the bed 5. As a result, the looper connected to the looper driving lever 28 is driven so as to be synchronized with the needle bar 16.
The needle bar rotating bracket 21 and the looper base 17 are integrally rotated by an inverting motor 22 (FIG. 4) provided in the bed 5 and an inverting gear mechanism 23 partially shown in FIGS. 1 and 2. Integral rotation of the needle bar rotating bracket 21 and the looper base 17 causes a change in the swing direction of the needle bar 16 and a displacement of the looper such that it follows the needle bar 16. Accordingly, as shown in FIG. 7, the zigzag stitch 3 can be formed around the eyelet portion 2a of the eyelet hole 2.
As shown in FIGS. 1 to 3B, a feed table 24 for setting the work fabric 1 thereon is provided on an upper surface of the bed 5. A pair of fabric pressers 25, for pressing the work fabric to the feed table 24, are provided on an upper surface of the feed table 24. The work fabric is accordingly held between the pair of fabric pressers 25 and the upper surface of the feed table 24. The feed table 24 has a rectangular, shallow box-like shape generally open on the lower side. The upper surface of the feed table 24 is formed with a transversely elongated opening 24a positioned between the pair of foot pressers 25. The feed table 24 is horizontally moved in an X direction (lateral direction) and a Y direction (transverse direction) by a feeding mechanism having an X-axis pulse motor 26 and a Y-axis pulse motor 27 (FIG. 4) provided in the bed 5.
Further, the bed 5 is provided with a cutting mechanism 32 having a lower knife 29, a hammer 30, and an air cylinder 31. The lower knife 29 is fixed to the bed 5 at a position on the right side of the looper base 17 as viewed in FIG. 2. The hammer 30 is provided over the lower knife 29 so as to be able to come into contact with and retract from the lower knife 29. The hammer 30 is driven by the air cylinder 31 (FIG. 4) provided in the bed 5. The hammer 30 cooperates with the lower knife 29 to form the eyelet hole 2 as a cutout through the work fabric 1 as shown in FIGS. 6A, 6B, and 7. The eyelet hole 2 consists of an eyelet portion 2a and a straight portion 2b continuing to the eyelet portion 2a. The eyelet hole 2 is so formed as to extend in the Y direction (transverse direction). The formation of the eyelet hole 2 is carried out when the feed table 24 is brought into a knife operating position as shown in FIG. 3A. That is, when the feed table 24 is moved downwardly in the Y direction to bring the opening 24a of the feed table 24 into a position just over the lower knife 29, the hammer 30 is driven against the lower knife 29. The above-mentioned structure of the buttonhole sewing machine may be similar to the construction disclosed in U.S. Pat. No. 4,501,207. U.S. Pat. No. 4,501,207 is incorporated by reference.
Next, the electrical structure of the buttonhole sewing machine according to the preferred embodiment will be described with reference to FIG. 4. The start/stop switch 10, the select switch 9, and a needle position sensor 33 are connected to the control device 14. The start/stop switch 10 supplies a start or stop signal, to the control device 14, for starting or stopping the buttonhole sewing machine. The select switch 9 supplies a select signal to the control device 14, the select signal indicating a pre-cutting mode or an after-cutting mode as selected by the operator. The needle position sensor 33 supplies a needle position signal, to the control device 14, indicating a vertical position of the needle bar 16 according to a rotational position of the main shaft 19. The control device 14 is further connected to the machine motor 8 for driving the needle bar 16 and the looper, the X-axis pulse motor 26 and the Y-axis pulse motor 27 for driving the feed table 24, the inverting motor 22 for inverting the needle rotating bracket 21 and the looper base 17, and the air cylinder 31 for driving the hammer 30.
The control device 14 includes a CPU 11, a ROM 12, and a RAM 13. The ROM 12 preliminarily stores a program for executing the operation shown by the flowchart in FIG. 5 and various data such as feed pattern data, sewing start position data, offset data, and knife operating position data. The RAM 13 temporarily stores necessary data when the CPU 11 executes the operation shown by the flowchart in FIG. 6. The CPU 11 controls the machine motor 8, the X-axis pulse motor 26, the Y-axis pulse motor 27, the inverting motor 22, and the air cylinder 31 according to the program, the feed pattern data, which are stored in the ROM 12, and the signals supplied from the start/stop switch 10, the select switch 9, and the needle position sensor 33.
When control by the CPU 11 is executed, the eyelet hole 2, consisting of the eyelet portion 2a and the straight portion 2b continuing to the eyelet portion 2a, is formed through the work fabric 1, set on the feed table 24 and retained by the fabric pressers 25 (FIG. 7), by the cutting mechanism 32. Further, the zigzag stitch 3 is continuously formed in the periphery of the eyelet hole 2, shown by arrows A, B, and C in FIG. 7, in order, that is, firstly on the right side of the straight portion 2b, secondly around the eyelet portion 2a, and finally on the left side of the straight portion 2b.
The formation of the continuous zigzag stitch 3 on the work fabric 1 is effected by simultaneously carrying out the swinging of the needle bar 16 with a predetermined zigzag width L1, the vertical movement of the needle bar 16 and the driving of the looper by the driving mechanism, and the movement of the feed table 24 along arrows A', B', and C' (see FIG. 3A) in this order by the feeding mechanism. In sewing a semi-circular portion in the periphery of an upper half of the eyelet portion 2a, the looper base 17 and the needle bar rotating bracket 21 are integrally inverted by the inverting motor 22 in a counterclockwise direction as viewed in top plan.
The feed pattern data stored in the ROM 12 consists of a straight portion data for sewing opposed straight portions (including a semi-circular portion in the periphery of a lower half of the eyelet portion 2a) on the right and left sides of the straight portion 2b and an eyelet portion data for sewing the semi-circular portion in the periphery of the upper half of the eyelet portion 2a. The straight portion data is a set of unit data indicating an X-directional feed quantity and a Y-directional feed quantity of the feed table 24 for every stitch (one stitch being formed by twice locating the needle at right and left points). The eyelet portion data is a set of unit data indicating the X-directional feed quantity and the Y-directional feed quantity of the feed table 24 for every stitch and also indicating a rotational angle of the looper base 17 and the needle bar rotating bracket 21 for every stitch.
In carrying out the sewing work, the CPU 11 first moves the feed table 24 to the sewing start position. In the preferred embodiment that is the right side at the end of the straight portion away from the eye 6, as viewed in FIGS. 6A and 6B. Then, the CPU 11 reads from the ROM 12 the feed pattern data, unit by unit, in the order of the right straight portion data, the eyelet portion data, and the left straight portion data. Thereafter, the CPU 11 controls driving quantities and driving timings of the X-axis pulse motor 26, the Y-axis pulse motor 27, and the inverting motor 22 according to the unit data read above and the needle position signal from the needle position sensor 33.
Before carrying out the sewing work, the operator operates the select switch 9 according to the kind of material of the work fabric for example, thereby selecting either the pre-cutting mode wherein the eyelet hole 2 is formed before formation of the zigzag stitch or the after-cutting mode wherein the eyelet hole 2 is formed after formation of the zigzag stitch.
In the case where the pre-cutting mode is selected, the zigzag stitch 3, as shown in FIG. 6A, is formed. That is, left needle location points b of the zigzag stitch 3 formed on the right side of the straight portion 2b of the eyelet hole 2 substantially coincide with right needle location points b of the zigzag stitch 3 formed on the left side of the straight portion 2b. Further, inside needle location points b of the zigzag stitch 3 formed in the periphery of the eyelet portion 2a fall inside the eyelet portion 2a. Accordingly, the zigzag stitch 3 formed as a whole covers a peripheral edge of the eyelet hole 2 formed through the work fabric 1.
On the other hand, in the case where the after-cutting mode is selected, the zigzag stitch 3, as shown in FIG. 6B, is formed. That is, the left needle location points b of the zigzag stitch 3 formed on the right side of the straight portion 2b of the eyelet hole 2 are deviated by a distance ΔX to the right side from a position where the eyelet hole 2 is to be formed later. Similarly, the right needle location points b of the zigzag stitch 3 formed on the left side of the straight portion 2b are deviated by the same distance ΔX to the left side from the forming position of the eyelet hole 2. Further, the inside needle location points b of the zigzag stitch 3 formed in the periphery of the eyelet portion 2a fall outside the eyelet portion 2a.
The width of the zigzag stitch 3 in both the modes, that is, the zigzag width L1 is mechanically determined by the driving mechanism. The ROM 12 preliminarily stores two kinds of eyelet portion data, that is, eyelet portion data for the pre-cutting mode and eyelet portion data for the after-cutting mode. Accordingly, the feed table 24 is moved according to each eyelet portion data. On the other hand, as to the sewing start position data and the straight portion data, the ROM 12 preliminarily stores such data for the pre-cutting mode only. Accordingly, when the pre-cutting mode is selected, the feed table 24 is moved according to the sewing start position data for the pre-cutting mode and the straight portion data for the pre-cutting mode. In contrast, when the after-cutting mode is selected, the feed table 24 is first offset by the distance ΔX leftwardly in the X direction as viewed in FIG. 3B from the sewing start position for the pre-cutting mode according to the sewing start position data for the pre-cutting mode and the offset data representing the distance ΔX, and the feed table 24 is then moved according to the straight portion data for the pre-cutting mode.
Now, there will be described the operation of the buttonhole sewing machine according to the present invention. Before starting the sewing work, the select switch 9 provided on the operation panel is operated by the operator to select either the pre-cutting mode or the after-cutting mode. Further, the work fabric 1 is set on the feed table 24 by the operator and the work fabric 1 is held on the feed table 24 by the pair of fabric pressers 25. Thereafter, when the start/stop switch 10 is turned on by the operator, a start signal is supplied from the start/stop switch 10 to the control device 14. When receiving the start signal, the CPU of the control device 14 starts to execute the buttonhole processing according to the program stored in the ROM 12. The processing to be executed by the CPU 11 will be described with reference to FIG. 5.
In step S1, the select signal from the select switch 9 is read. In step S2, it is determined which of the pre-cutting mode and the after-cutting mode has been selected. If the pre-cutting mode is selected (YES), the program proceeds to step S3. In step S3, the X-axis pulse motor 26 and the Y-axis pulse motor 27 are driven according to the knife operating position data indicating the knife operating position, thereby moving the feed table 24 to place the work fabric 1 buttonhole position over the knife operating position as shown in FIG. 3A. Then, the air cylinder 31 is driven to operate the hammer 30. As a result, the eyelet hole 2 is formed through the work fabric 1 by the cooperation of the hammer 30 and the lower knife 29. In step S4, the feed pattern data is set by combining the straight portion data and the eyelet portion data for the pre-cutting mode.
In step S5, the machine motor 8, the X-axis pulse motor 26, the Y-axis pulse motor 27, and the inverting motor 22 are driven to execute the sewing operation. In the sewing operation, the X-axis pulse motor 26 and the Y-axis pulse motor 27 are first driven according to the sewing start position data, with the result that the feed table 24, with work fabric 1, is moved from the knife operating position to the sewing start position as shown in FIG. 3B. Then, the machine motor 8, the X-axis pulse motor 26, and the Y-axis pulse motor 27 are driven to perform the sewing operation. As a result, while the needle bar 16 and the looper are being driven by the driving mechanism, the feed table 24 is moved in the order of the arrows A', B', and C', shown in FIG. 4, with the predetermined feed quantities specified by the feed pattern data. When the feed table 24 is moved according to the eyelet portion data of the feed pattern data, that is, when the feed table 24 is moved in the direction of the arrow B, shown in FIG. 4, the inverting motor 22 is also driven in addition to the machine motor 8, the X-axis pulse motor 26, and the Y-axis pulse motor 27. Accordingly, the zigzag stitch 3 with the zigzag width L1 is automatically formed on the work fabric in the periphery of the eyelet hole 2 in the order of the right side of the straight portion 2b, the periphery of the eyelet portion 2a, and the left side of the straight portion 2b as shown by the arrows A, B, and C in FIG. 7.
As shown in FIG. 6A, a center of swing of the needle bar 16 moves along a zero bight line a relative to the work fabric 1 set on the feed table 24. The left, or inside, needle location points b of the zigzag stitch 3 formed on the right side of the straight portion 2b of the eyelet hole 2 substantially coincide with the right or inside needle location points b of the zigzag stitch 3 formed on the left side of the straight portion 2b. Further, the inside needle location points b of the zigzag stitch 3 formed in the periphery of the eyelet portion 2a fall inside the eyelet portion 2a. Accordingly, the peripheral edge of the cutout, constituting the eyelet hole 2 formed through the work fabric 1, is covered with the zigzag stitch to obtain an eyelet type buttonhole with a good appearance. At the end of the movement of the feed table 24 according to the feed pattern data, the machine motor 8, the X-axis pulse motor 26, and the Y-axis pulse motor 27 are stopped to end the sewing operation and the program proceeds to step S6. In step S6, as the pre-cutting mode is selected, the answer is NO, and the processing is ended.
On the other hand, when the after-cutting mode is selected by the operator because the work fabric 1 is of a fabric material, such as a knit, which is liable to ravel, the decision in step S2 is NO, and the program proceeds to step S7. In step S7, the X-axis pulse motor 26 and the Y-axis pulse motor 27 are driven according to the sewing start position data and the offset data. That is, the feed table 24 is first moved to the sewing start position by the feeding mechanism according to the sewing start position data as shown in FIG. 3B. Then, the feed table 24 is offset by the distance ΔX leftwardly in the X direction from the sewing start position according to the offset data. Next, in step S8, the feed pattern data is set by combining the straight portion data and the eyelet portion data for the after-cutting mode, and the program proceeds to step S5.
In step S5, the machine motor 8, the X-axis pulse motor 26, the Y-axis pulse motor 27 and the inverting motor 22 are driven to execute the sewing operation. As a result, the zigzag stitch 3, with the zigzag width L1, is automatically formed on the right side of the straight portion 2b of the eyelet hole 2, around the periphery of the eyelet portion, and on the left side of the straight portion 2b. During the formation of the zigzag stitch on the right side of the straight portion 2b (corresponding to the arrow A shown in FIG. 7), the feed table 4 is moved according to the straight portion data common to that for the pre-cutting mode. At this time, the sewing start position of the feed table 24 is offset by the distance ΔX leftwardly in the X direction from the sewing start position in the pre-cutting mode. Therefore, although the straight portion data common to that for the pre-cutting mode is employed in the after-cutting mode, the zigzag stitch 3 on the right side of the straight portion 2b is formed at a position spaced by the distance ΔX rightwardly from the position where the eyelet hole 2 is to be formed, as shown in FIG. 6B.
During the formation of the zigzag stitch 3 in the periphery of the eyelet portion 2a (corresponding to the arrow B in FIG. 7), the feed table 24 is moved according to the eyelet portion data for the after-cutting mode, which is different data from the eyelet portion data for the pre-cutting mode. As a result, the inside needle location points b of the zigzag stitch 3 are arranged outside the position where the eyelet portion 2a is to be formed, and the zigzag stitch 3 is so formed as to surround the outer periphery of the eyelet portion 2a to be formed later.
Further, during the formation of the zigzag stitch 3 on the left side of the straight portion 2b (corresponding to the arrow C in FIG. 7), the feed table 24 is moved from a position where the movement of the feed table 24 according to the eyelet portion data for the after-cutting mode is ended, according to the straight portion data common to that for the pre-cutting mode. At this time, the end position of the movement of the feed table 24 according to the eyelet portion data for the after-cutting mode is offset by the distance ΔX rightwardly in the X direction from the end position in the pre-cutting mode. Therefore, the zigzag stitch 3 on the left side of the straight portion 2b is formed at a position spaced by the distance ΔX leftwardly from the position where the straight portion 2b is to be formed. In this manner, the center of swing of the needle bar 16 moves relative to the work fabric 1 set on the feed table 24 along a zero bight line a' positioned outside the zero bight line a for the pre-cutting mode. As a result, there is formed a non-sewn portion having a width of 2ΔX in the X direction between the zigzag stitch 3 formed on the right side of the straight portion 2b of the eyelet hole 2 and the zigzag stitch 3 formed on the left side of the straight portion 2b. At the end of the movement of the feed table 24 according to the feed pattern data, the machine motor 8, the X-axis pulse motor 26 and the Y-axis pulse motor 27 are stopped to end the sewing operation.
After completing the sewing operation, the program proceeds to step S6. As the after-cutting mode is now selected, the decision in step S6 is YES, and the program proceeds to step S9. In step S9, the X-axis pulse motor 26 and the Y-axis pulse motor 27 are driven, and the feed table 24 is accordingly offset by the feeding mechanism by the distance ΔX rightwardly in the X direction from the end position of the sewing operation. Then, in step S10, the X-axis pulse motor 26 and the Y-axis pulse motor 27 are driven to move the sewn buttonhole on the work fabric 1, mounted on the feed table 24, to the knife operating position as shown in FIG. 3A, and the air cylinder 31 is driven to operate the hammer 30. As a result, the eyelet hole 2 is formed through the work fabric 1 by the cooperation of the hammer 30 and the lower knife 29. In this manner, the eyelet hole 2 is formed exactly at the central position of the non-sewn portion and the processing ends.
As described above, according to the preferred embodiment, when the after-cutting mode is selected, the feeding operation of the feed table 24 during sewing is carried out with the feed table 24 offset in such a direction that the zigzag stitch 3 on the right side of the straight portion 2b of the eyelet hole 2 and the zigzag stitch 3 on the left side of the straight portion 2b are spaced apart from each other. Accordingly, although the zigzag width L1 is fixed, the non-sewn portion can be formed between the zigzag stitch 3 on the right side of the straight portion 2b and the zigzag stitch 3 on the left side of the straight portion 2b. Therefore, the operator need not carry out the troublesome work needed to adjust the zigzag width as in the prior art, but the operator can very easily select either the pre-cutting mode or the after-cutting mode by operating the select switch 9.
Furthermore, according to the above preferred embodiment, in forming the zigzag stitch 3 in the periphery of the eyelet portion 2a, different feed pattern data are used in the pre-cutting mode and in the after-cutting mode. Accordingly, the above preferred embodiment has another advantage in that it is unnecessary to offset the position of the lower knife as in the prior art.
The present invention is not limited to the above preferred embodiment, but various modifications may be made without departing from the scope of the present invention.
For instance, while the above description of the preferred embodiment has been directed to the eyelet type buttonhole sewing machine for forming the zigzag stitch 3 in the periphery of the eyelet hole 2 consisting of the eyelet portion 2a and the straight portion 2b, the present invention may be applied to a straight type buttonhole sewing machine for forming a zigzag stitch in the periphery of a straight hole.
Because, in the above preferred embodiment, the offset data representing the distance ΔX and the eyelet portion data for the after-cutting mode are stored in the ROM 12, the distance ΔX cannot be changed by the operator. However, in order to variably set the distance ΔX to a desired value, an offset data inputting device may be provided In this case, when the distance ΔX, represented by the offset data, is changed, the eyelet portion data for the after-cutting mode must be also changed. Accordingly, in the case of providing such an offset data inputting device 19, the eyelet portion data for the after-cutting mode is not stored in the ROM 12, but it may be obtained by computation using eyelet portion data for the pre-cutting mode stored in the ROM 12 and the changed offset data which would be input prior to starting sewing. | In a sewing machine for creating buttonholes, a selection switch is used to designate whether the hole will be cut first or the buttonhole will be defined by stitching first. In both cases, stitch width remains constant. Where the buttonhole is outlined by stitches first, a needle bar bight line is offset by a distance ΔX from the bight line followed when the buttonhole is cut first. The result of the ΔX offset is a spacing equal to 2ΔX between the inner edges of the stitched buttonhole providing space in which to cut the buttonhole. | 3 |
CLAIM FOR PRIORITY
[0001] This application claims the benefit of priority to German Application No. 10309200.5 which was filed in the German language on Jan. 21, 2004, the contents of which are hereby incorporated by reference.
TECHNICAL FIELD OF THE INVENTION
[0002] The invention relates to a roller bearing having at least one rotatable roller, and in particular, having a rotatable roller on which an elongated body to be moved can be placed, the axis of rotation of the roller being arranged transversely with respect to the direction of movement of the body.
BACKGROUND OF THE INVENTION
[0003] Such roller bearings are used, for example, in laying energy transmission devices such as cables or gas-insulated pipelines. The route of which the device is laid often has turns, bends, depressions and hills. As a result of the twists and turns the elongated body is turned on itself along its axis of rotation. As a result of this rotation, further forces act on the roller bearing in addition to the tensile forces. Owing to the twisted, non-linear routes over which the devices are laid it is necessary that the elongated body to be moved be guided carefully in order to avoid locking of the rotatable rollers or jamming of the body in the roller bearings.
SUMMARY OF THE INVENTION
[0004] The invention specifies a roller bearing which permits locking-free movement of the elongated body. This allows the rotatable roller to be pivoted about an axis.
[0005] As a result of pivotable bearing of the rotatable roller it is possible for the supporting direction of the roller to be set according to requirements. As a result, for example when laying a pressurized-gas-insulated electrical conductor it is possible for the rollers to be pivoted over a hill or in a depression in a way that corresponds to the profile of the route. This permits the body to be transported to be deflected in a more gentle way.
[0006] In this context it is advantageously possible to provide for the axis to be located approximately parallel to the direction of movement of the body.
[0007] In particular, when the body to be transported is twisted owing to the route over which the device is laid, lateral pivoting of the rotatable roller is advantageous in order to be able to better absorb transverse sources which occur. It is thus possible, for example in the region of tight bends, for a greater degree of support to be provided for the body to be moved on the side facing the inside of the bend and for the roller to pivot into this region. In this context, the pivot axis of the roller is to be selected in such a way that it lies approximately parallel to the direction of movement of the body. In a bend region the tangent about which the roller is arranged so as to pivot around is to be adopted. Since the roller is also loaded more evenly on bend profiles or in depressions or on hills, jamming of the roller is virtually ruled out.
[0008] In a further advantageous embodiment of the invention, the at least one roller is mounted on a pivot bearing which has a fixed element and a loose element, wherein at least one of the elements has a curved sliding face which is mounted in a sliding fashion on the respective other element.
[0009] The use of a sliding face ensures virtually step-free setting of the pivoting movement of the rotatable roller. Furthermore, a slight degree of sliding is made possible when the sliding face correspondingly expands. There may be provision here for the sliding face to be, for example, curved in such a way that, in addition to the pivoting movement of the rotatable roller about an axis parallel to the direction of movement of the body, a rotational movement of the roller about a perpendicular component and/or pivoting in the direction of transport of the roller are also made possible. Such movement may be made possible, for example, by means of a ball which is mounted in a sliding fashion in a socket. The curved sliding faces can also be formed by correspondingly arranged roller bearings or the like. This reduces the friction during sliding.
[0010] Furthermore it may be advantageous to provide that the sliding face is curved concavely, or that the sliding face is curved convexly.
[0011] Concave and convex sliding faces permit reliable sliding one on the other, with the movable element being centered and mounted on the fixed element. Random sliding out is prevented owing to the shape.
[0012] In still another embodiment of the invention, the fixed element has a concave sliding face on which a convex sliding face of the loose element slides, or that the fixed element has a convex sliding face on which a concave sliding face of the loose element slides.
[0013] In addition to the concave or convex curvature in a plurality of directions so that ball and socket arrangements can be produced it is also possible to provide for the curvature to be provided in one direction so that a groove-shaped arrangement is produced. This restricts the free movability of the sliding arrangement. With such an arrangement the profile of the pivot axis is easily fixed. Furthermore, simplified fabrication methods can be applied in order to manufacture the pivot bearing.
[0000] furthering yet another advantageous embodiment of the invention, the roller is pivoted by means of forces which are caused by the body during its movement.
[0014] As already described above, transverse forces and torsional forces also occur during the laying of an elongated body which rests on the corresponding roller bearings. The pivoting movements of the roller can easily be brought about by appropriately utilizing such forces. This has the advantage that a system which controls itself and which does not require any additional supply energy from the outside is provided. If appropriate forces which occur as a result of corresponding mechanisms are to be deflected in order to permit the pivotable roller to move in the desired direction.
[0015] Furthermore it may be advantageously provided that the roller is pivoted by means of an actuating element.
[0016] Using an actuating element makes it possible to initiate the pivoting of the roller in a targeted fashion. It is possible to provide here that the actuating element can be actuated independently of the progress in the transporting of the elongating body on the roller bearing. For this purpose it is possible, for example, to use electrical or hydraulic auxiliary motors which bring about the pivoting movement.
[0017] This has the advantage that the bearing can be set in a targeted fashion. The position of the support points of the body to be transported can thus be selected and set intentionally. At the same time, steady bearing of the roller bearing itself is ensured since movements which are caused by load change reactions cannot affect the actuating elements.
[0018] The invention also specifies a method for pivoting a roller of a roller bearing as described above in order to ensure that the elongated body to be moved is laid in as gentle a way as possible.
[0019] In one embodiment of the invention, there is:
at least two support points for the body are arranged on the one roller or on at least two rollers, the roller/rollers is/are pivoted in such a way that the support forces at the support points are of approximately equal magnitude.
[0022] In particular, when the elongated body to be moved has a circular cross section, two support points are obtained, for example on two rollers which are arranged in a V shape with respect to one another, or on a roller which a concave roller body. Depending on the position of the rollers or depending on the narrowed section of the one roller and the diameter of the elongated body these support points migrate on the roller surface. When the roller or rollers is/are pivoted as a function of the support forces at the support points, symmetrical loading of the roller bearing is achieved. This symmetrical loading virtually prevents the body to be transported from tilting on the roller or rollers. As a result, the possibility of the moveable body becoming jammed on the roller bearing can be discounted.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The invention is shown schematically below with reference to exemplary embodiments in the drawings and will be described in more detail in the text which follows.
[0024] In the drawing:
[0025] FIG. 1 shows a first configuration of a roller bearing.
[0026] FIG. 2 shows a second configuration of a roller bearing.
[0027] FIG. 3 shows a third configuration of a roller bearing.
[0028] FIG. 4 shows a fourth configuration of a roller bearing.
[0029] FIG. 5 shows a fifth configuration of a roller bearing.
DETAILED DESCRIPTION OF THE INVENTION
[0030] The assemblies which have the same effect in the figures are provided with the same reference symbols. The configurations of roller bearings which are illustrated in the figures are illustrated with an elongated body fitted onto them, the body having a circular cross section.
[0031] The first embodiment of a roller bearing 1 which is shown in FIG. 1 has a first rotatable roller 2 and a second rotatable roller 3 . The first rotatable roller 2 and the second rotatable roller 3 are arranged in a V shape with respect to one another so that a gas-insulated electrical conductor 4 with an essentially circular cross section can be fitted on. The gas-insulated conductor 4 has a metallic, tubular outer casing. In the interior an electrical conductor 5 is held spaced apart from the outer casing of the gas-insulated electrical conductor by means of electrical insulators. In the operating state, the interior of the gas-insulated electrical conductor 4 is filled with an insulating gas. The gas-insulated electrical conductor 4 is composed of a plurality of pieces and forms an elongated body with a length between several hundred meters or thousands of meters. A gas-insulated electrical conductor 4 is composed of individual pieces and moved in the mounted state into its laying position on roller bearings. The rollers 2 , 3 which are illustrated in FIG. 1 are mounted in a pivot bearing 6 . The pivot bearing 6 has a fixed element 7 and a loose element 8 . The first and second rotatable rollers 2 , 3 are mounted on the loose element 8 . The loose element 8 has a curved sliding face which can slide on a planar face of the fixed element 7 . When the sliding face of the loose element 8 moves in a sliding fashion, the rollers 2 , 3 which are attached to the loose element 8 are pivoted. It is possible to provide for the loose element to be a spherical cap and pivoting movements to be made possible around all axes. The degree of freedom of movement can be restricted by guide elements, for example bolts guided in connecting links so that the roller is pivoted, for example, about one axis which slides approximately parallel to the direction of movement of the body. The direction of movement of the body is arranged perpendicularly to the plane of the drawing in FIG. 1 . In order to guide the loose element it is possible to provide corresponding mechanical devices. These may be, for example, bolts in connecting links, pins in channels or similar guide elements. It is possible to provide in this context that specific pivoted positions can be pre-selected and the loose element 8 can be secured to the fixed element 7 in this pivoted position.
[0032] FIG. 2 shows, in a modification of FIG. 1 , a second embodiment of a roller bearing 1 a with a fixed element 7 a and a loose element 8 a . The fixed element 7 a has a curved face on which a planar face of the loose element 8 a can be moved in a sliding fashion.
[0033] A modification of the roller bearing which is known from FIG. 2 is illustrated in FIG. 3 . Instead of the use of two rotatable rollers, a single rotatable roller 2 c is arranged on the loose element 8 c . Rotatable roller 2 c has a narrowed section so that a concave roller body is produced. Owing to the shaping of the roller, the elongated body 4 c which is to be transported is also supported laterally. Depending on the selection of the diameter of the body 4 c to be transported and the narrowed section of the roller 2 c , two support points A 1 , A 2 are also formed with such an arrangement. Depending on the dimensioning, these support points migrate along the rotatable roller.
[0034] FIG. 4 shows a third configuration of a roller bearing 1 d . In the roller bearing 1 d , the loose element 7 d of the sliding bearing is arranged on a spherical head, with the spherical head forming a curved sliding face. The spherical head rests in a socket 9 . The interaction of the spherical head and the socket 9 allows the rollers 2 d , 3 d to pivot. Pivoting of the rollers 2 d , 3 d parallel to an axis of the direction of movement of the body 4 d is made possible by means of an actuating element 10 . In this context it is possible to provide for the support forces at the support points 1 a and 2 a to be measured and when there is a difference beyond a permissible amount corresponding actuation of the actuating element 10 takes place. In one configuration of a roller bearing according to FIG. 4 , there is furthermore the possibility of turning the roller bearing also about the vertical axis which lies transversely with respect to the axis of movement of the elongated body and of pivoting it about further axes. For this purpose it is also possible to provide further actuating elements.
[0035] A fifth variation of a roller bearing 1 e is illustrated in FIG. 5 . The pivoting bearing which is formed from a fixed element 7 e and a loose element 8 e is configured here in the form of two concave grooves which are located one in the other. Such a configuration makes it possible to use the tilting forces or transverse forces which occur during a movement of the elongated body to generate a deflection of the rollers 2 e , 3 e . Owing to the groove design, the rollers 2 e , 3 e can be pivoted only about one axis which lies parallel to the direction of transport. When a transverse force occurs which generates an increased support force at one of the support points A 1 , A 2 , deflection is brought about in the direction of the acting transverse force owing to the sliding bearing of the loose element 8 e . As a result, the rotatable roller which has been subject to less loading is subject to greater loading until there is an approximately uniformed distribution of forces at the support points A 1 , A 2 of the rotatable rollers. When the transverse forces abate, the loose element 8 e slides back into its neutral position.
[0036] Furthermore, it is also possible to provide that a plurality of roller bearings are arranged one behind the other in the axial direction of the elongated body and the respective roller bearings are actuated, for example, by a common control device and respectively assigned actuating elements permit targeted pivoting of the rotatable rollers. As a result it is possible to counteract the generation of transverse forces as soon as they appear, as well as permitting the elongated body to be laid easily.
[0037] In addition to the configuration illustrated in the figures it is possible to interchange individual elements, for example the shape of the rollers, the shape of the sliding faces, the method of movement of the sliding faces etc., with one another so that new embodiment variants are produced. | A roller bearing having at least one rotatable roller is used to move an elongated body. The elongated body rests on the rotatable roller and can be moved transversely with respect to the axis of rotation of the roller. In order to prevent the body ( 4 ) becoming jammed on the roller, the rotatable roller can be pivoted about an axis which is oriented approximately parallel to the direction of movement of the body. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 USC §119(e)(1) to U.S. Patent Application Ser. No. 60/174,876, filed on Jan. 7, 2000, and entitled “Injection Device”, the entire contents of which are hereby incorporated by reference.
BACKGROUND
[0002] The invention relates to injection devices (e.g., injection devices including a needleless syringe), as well as components that can be used in injection devices.
[0003] Injection devices can be used for fluid injection into a body. Some injection devices can include a needleless syringe.
SUMMARY
[0004] The invention provides one or more components (e.g., a gas generant unit and/or a housing unit) that can be used in an injection device (e.g., an injection device including a needleless syringe), and injection devices containing one or more of these components.
[0005] The components can be removable, replaceable and/or adaptable to fit different sized injection devices. The injection devices can be re-usable. The injection devices can be in any of a variety of shapes and sizes.
[0006] For embodiments in which the injection device includes a gas generant unit, the gas generant unit can be removed before or after use of the injection device. Moreover, a gas generant unit that is removed from the syringe can be replaced with a different gas generant unit, which may contain the same or different gas generant compounds. Furthermore, a gas generant unit can be adaptable to fit different sized injection devices. Advantages associated with an injection device that is capable of using such a gas generant can include re-usability, relatively low cost to manufacture, relatively low cost to use, and/or enhanced flexibility in materials used as gas generant and/or injection fluid.
[0007] The injection device can include a housing that allows a fluid (e.g., a gas, such as a product of the reaction of the gas generant) to travel between the interior of the injection device and the exterior of the injection device without passing through the distal end of the injection device (e.g., the exit port of a syringe, such as a needleless syringe, contained within the injection device). In certain embodiments, this feature can be provided, for example, by including the following components in the housing: a sliding piston, a sleeve (which can have one or more venting mechanisms, such as one or more venting grooves, e.g., annular venting groove(s)), and one or more pressure relief mechanisms (e.g., one or more pressure relief holes). In these embodiments, the sliding piston can be designed to move along the sleeve so that, at one or more points along the path of motion of the sliding piston, the pressure relief mechanism(s) of the sliding piston align (e.g., partially align or fully align) with the pressure relief mechanism(s) in the sleeve. When this occurs, the fluid (e.g., reactant gas) can pass between the respective relief mechanism(s). The fluid (e.g., reactant gas) then exits the injection device via a passageway that does not include the distal end of the injection device (e.g., the exit port of a syringe, such as a needleless syringe, contained within the injection device).
[0008] In one aspect, the invention features an injection device, such as a needleless injection device, having a housing having a proximal end and a distal end, the housing defining a distal opening, and a first opening in a side of the housing and between the proximal and distal ends; a propellant disposed inside the housing and spaced from the distal end; and a movable member disposed inside the housing and between the distal end and the propellant, wherein the propellant is in fluid communication with the movable member and the first opening.
[0009] Embodiments include one or more of the following features.
[0010] The propellant is capable of forming a gas capable of moving the movable member in a distal direction and flowing through the first opening to the exterior of the housing.
[0011] The movable member comprises a piston defining a cavity, and the propellant is in fluid communication with the cavity. The movable member further defines a second opening in fluid communication with the first opening.
[0012] The device further includes a hollow sleeve configured to mate with the piston, the sleeve defining a second cavity in fluid communication with the propellant. The sleeve further defines a third opening alignable with the second opening. The sleeve further defines a groove, and the third opening is disposed in the groove.
[0013] The device further includes a button at the proximal end of the housing; a battery inside the housing and adjacent to the button; electrical leads in electrical communication with the battery; and a wire in electrical communication with the electrical leads, the wire configured to trigger the propellant.
[0014] The distal opening of the housing is configured to mate with a proximal end of a syringe. The syringe includes a plunger, and the movable member is configured to move the plunger in a distal direction.
[0015] The propellant includes a chemical pyrotechnic material.
[0016] The housing is composed of a plurality of detachable housings.
[0017] In another aspect, the invention features an injection device, such as a needleless injection device, having a housing having a proximal end and a distal end, the housing defining a distal opening, and a first opening in a side of the housing and between the proximal and distal ends; a propellant disposed inside the housing and spaced from the distal end; a sleeve disposed inside the housing and between the distal end and the propellant, the sleeve defining a second opening and a first cavity, the second opening and the first cavity in fluid communication with the propellant; and a piston mateable with the sleeve and movable in a distal direction, the piston defining a third opening alignable with the second opening, wherein the propellant is in fluid communication with the first opening when the second and third openings are aligned.
[0018] Embodiments include one or more of the following features.
[0019] The propellant is capable of forming a gas capable of flowing through the first cavity to move the piston, wherein the gas flows through the second and third openings when aligned, and through the first opening. The propellant includes a chemical pyrotechnic material.
[0020] The piston is coaxial with the sleeve and slidable over the sleeve to align the second and third openings. The piston defines a plurality of openings alignable with the second opening.
[0021] The sleeve defines a groove, such as an annular groove, the second opening disposed in the groove.
[0022] The distal opening of the housing is configured to mate with a syringe having a plunger, and the piston is configured to move the plunger.
[0023] The device further includes a button at the proximal end of the housing; a battery inside the housing and adjacent to the button; electrical leads in electrical communication with the battery; and a wire in electrical communication with the electrical leads, the wire configured to trigger the propellant.
[0024] The housing further defines an elongate passageway between the first opening and the third opening.
[0025] The device further includes a filter between the propellant and the first cavity.
[0026] The housing is composed of a plurality of detachable housings.
[0027] In another aspect, the invention features an apparatus that includes a housing, a button connected to the housing, a battery adjacent the button and connected to the housing, electrical leads in electrical communication with the battery, and a wire in electrical communication with the electrical leads.
[0028] In another aspect, the invention features an apparatus that includes a sleeve having a surface having at least one hole, a movable piston having at least one hole and a surface adjacent the surface of the sleeve, and a first housing connected to the sleeve and the movable piston.
[0029] In a further aspect, the invention features an injection device including first, second, third and fourth housings. The first housing is demountably attached to the second housing. The second housing is demountably attached to the third housing. The third housing is demountably attached to the fourth housing. The first housing includes a button and a battery adjacent the button. The second housing includes an inner housing, electrical contacts within the inner housing, a wire within the inner housing and in electrical communication with the electrical contacts, and a gas generant within the inner housing. The third housing includes a syringe adaptor housing having an outer vent sleeve, a movable piston having an end and at least one relief hole, a fixed sleeve having a groove with a hole (e.g., a pressure relief hole), the fixed sleeve being adjacent the movable piston, a drive piston having at least one groove, the drive piston being adjacent the end of the movable piston and a sealing device within the groove of the drive piston. The fourth housing includes a plunger having an end, a syringe adjacent the end of the plunger, and an elastomeric spring adjacent the syringe.
[0030] Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
[0031] [0031]FIG. 1 is a cross-sectional view of an embodiment of an injection device;
[0032] [0032]FIG. 2 is a partial cross-sectional view of an embodiment of a portion of an injection device; and
[0033] [0033]FIG. 3 is a partial cross-sectional view of an embodiment of a portion of an injection device.
DETAILED DESCRIPTION
[0034] The invention relates to injection devices (e.g., injection devices containing needleless syringes) and components that can be used in such injection devices. Advantages of the injection devices can include that they are relatively safe to use, relatively less painful to use, capable of delivering fluid in a predetermined and/or desirable manner, and/or reusable.
[0035] [0035]FIG. 1 shows a cross-sectional view of an embodiment of an injection device 5 . Device 5 includes housings 10 , 20 , 30 and 200 . Housing 10 is demountably attached to housing 20 at section 250 by, for example, screw threads or a bayonet lock. Housing 20 is demountably attached to housing 30 at section 260 by, for example, screw threads or a bayonet lock. Housing 30 is permanently attached to a bayonet interlock syringe housing adaptor 200 to provide a mechanism for fitting a syringe configuration.
[0036] Housing 10 includes a button 40 , a battery 50 , and an electrically insulative (e.g., non-metallic) cup 620 (FIG. 3).
[0037] Housing 20 encloses a housing 80 (e.g., a disposable housing) having electrical contacts 60 , a wire 70 and a propellant 90 , such as a gas generant (FIG. 2).
[0038] Housing 30 includes a syringe adaptor housing 200 having an outer vent sleeve 150 , a sliding piston 100 having pressure relief holes 130 , sleeve 110 (e.g., a fixed sleeve) having a groove 120 (e.g., an annular groove), and a drive piston 170 having grooves containing sealing devices 180 (e.g., o-rings) and a syringe interface 190 (e.g., a custom syringe interface) located at its distal end (FIG. 3).
[0039] In some embodiments, assembly 30 is assembled as follows. Sleeve 110 is permanently attached to housing 30 , followed by permanently attached outer vent sleeve 150 to the flange of sleeve 110 . Then, elastomeric spring 210 is bonded to the end of housing 30 , and syringe adaptor 200 is subsequently permanently attached to housing 30 .
[0040] Syringe adaptor 200 (e.g., an interlock adaptor) accepts a syringe housing 220 with its associated plunger 230 .
[0041] [0041]FIG. 2 shows an exploded view of an embodiment of housing 80 including electrical contacts 60 , wire 70 , propellant 90 , screen 240 , filter 250 and cap 260 with an exit hole 270 .
[0042] [0042]FIG. 3 shows an exploded view of an embodiment of sleeve 110 , annular groove 120 having hole(s) 300 , sliding piston 100 and vent holes 130 .
[0043] During operation of injection device 5 , button 40 (e.g., a molded plastic button) is pressed, compressing a wave spring 610 which causes battery 50 (e.g., a replaceable battery) to come into contact with electrical contacts 60 . This causes an electrical current to pass through wire 70 (e.g., a metal wire such as nickel/chromium wire, and/or a wire having a diameter of from about 0.005 inch to about 0.010 inch, such as about 0.010 inch), thereby heating wire 70 (e.g., causing wire 70 to become red hot in about one second). The heat generated by wire 70 is sufficient to cause the reaction of chemical components contained in propellant 90 . Such chemical components can include a fuel and an oxidant. A nonlimiting, illustrative list of examples of chemical components that can be used in propellant 90 (e.g., a gas generant) are disclosed in U.S. Pat. Nos. 4,103,684; 4,342,310; 4,447,225; 4,518,385; 4,592,742; 4,623,332; 4,680,027; 4,722,728; 4,913,699; 5,024,656; 5,049,125; 5,064,123; 5,190,523; 5,304,128; 5,312,335; 5,334,144; 5,383,851; 5,399,163; 5,499,972; 5,501,666; 5,503,628; 5,520,639; 5,569,189; 5,630,796; 5,704,911; 5,730,723; 5,840,061; 5,851,198; 5,879,327; 5,899,879; 5,899,880; 5,911,703; and 5,993,412, each of which is hereby incorporated by reference. Other chemical components are described in commonly-assigned Application No. 60/250,573, filed Nov. 30, 2000, and entitled “Injection Devices”, hereby incorporated by reference.
[0044] The gas formed by the reaction of the chemical components in propellant 90 passes through screen 240 (e.g., metal screen, such as a stainless steel screen of, for example, about 50 to 200 mesh) and filter 250 (e.g., a glass fiber filter). Screen 240 can cool the reactant gas and/or trap slag, and filter 250 can trap particulates (e.g., small particulates, such as those generated during the reaction).
[0045] After passing through filter 250 , the reactant gases cause sliding piston 100 to move along the surface of sleeve 110 . As piston 100 moves along the surface of sleeve 110 , piston 100 urges drive piston 170 to push against plunger 230 which, in turn, pushes against fluid within syringe 220 , thereby ejecting fluid from syringe 220 via outlet 310 .
[0046] The movement of piston 100 along the surface of sleeve 110 also causes holes 130 to reach ring 120 . When this occurs, the reactant gas can pass through one or more holes 300 (e.g., one, two, three or four holes) in ring 120 and one or more of holes 130 . The reactant gas that passes through holes 300 and hole(s) 130 can flow through relief channels 140 , into space 160 (e.g., an open space, or a space containing a filter material, such as glass wool) and out device 5 via gas vent 7 .
[0047] The number, size and location of holes 130 can vary to assist in controlling the pressure of fluid exiting through distal end 310 of syringe 5 . The location of holes 130 can be determined by interfacing the end of the syringe to a pressure transducer that in turn is interfaced to a real time data acquisition system. One example is a model PCI-730/6040E data acquisition board (commercially available from National Instruments of Austin, Tex.), which can be interfaced to a computer (e.g., a personal computer) for real time pressure transducer measurements. Changes in the pressure profile due to changes in the placement, shape and size of holes 130 can be monitored and optimized accordingly.
[0048] The use of annular groove 120 can obviate the need for a precise alignment of holes 130 because holes 130 are not required to be keyed to contact groove 120 .
[0049] Syringe 220 and plunger 230 can take on a variety of shapes and sizes. For example, syringe 220 and plunger 230 can be commercially available components (e.g., such as available from Bioject Medical, located in Portland, Oreg.; Injet Medical Products, Inc., located in Lake Forest, Ill.; and Avant Drug Delivery Systems, Inc., located in San Diego, Calif.).
[0050] The end of housing 30 , syringe adaptor 200 and elastomeric spring 210 form an interlock, which, in certain embodiments, can be designed to accept the attachment of commercially available syringes and/or ampules. The interlock may be one of several types including a bayonet type.
[0051] In certain embodiments, housing 80 is replaceable. In these embodiments, after an injection housing 80 can be removed and replaced with a different housing, and device 5 can be re-used.
[0052] The invention is not limited by the above description, and the invention contemplates variations and modifications to this description. For example, in some embodiments, housings 10 , 20 , 30 and/or 300 can be non-demountable.
[0053] In some embodiments, the invention provides for the delivery of a mixture of two substances.
[0054] The first substance can be a dry substance, e.g., a lyophilized protein, nucleic acid, e.g., RNA or DNA, or polysaccharide. The first substance can be a vaccine, or a drug. The first substance can be a peptide, polypeptide, or protein, e.g., an antibody, an enzyme, a hormone or growth factor. Preferred first substances include insulin. The first substance can be: a blood protein, e.g., clotting factor VIII or a IX, complement factor or component; a hormone, e.g., insulin, growth hormone, thyroid hormone, a catecholamine, a gonadotrophin, PMSG, a trophic hormone, prolactin, oxytocin, dopamine and the like; a growth factor, e.g., EGF, PDGF, NGF, IGF's and the like; a cytokine, e.g., an, interleukin, CSF, GMCSF, TNF, TGF-alpha, TGF-beta. and the 25 like; an enzyme, e.g., tissue plasminogen activator, streptokinase, cholesterol biosynthetic or degradative, glycosolases, and the like; a binding protein, e.g., a steroid binding protein, a growth hormone or growth factor binding protein and the like; an immune system protein, e.g., an antibody, SLA or MHC gene or gene product; an antigen, e.g., a bacterial, parasitic, or viral, substance or generally allergens and the like.
[0055] The second substance can be a liquid, e.g., a diluent or solute. Such liquids can include buffers, inert fillers, pharmaceutically acceptable carriers, or the like.
[0056] The subject can be a human or an animal, e.g., a laboratory animal, or pet, e.g., a dog or cat, or other animal, e.g., a bovine, a swine, a goat, or a horse. The first and second substance can be combined by the subject, or by another person.
[0057] Other embodiments are in the claims. | An injection device includes a housing having a proximal end and a distal end, the housing defining a distal opening, and a first opening in a side of the housing and between the proximal and distal ends; a propellant disposed inside the housing and spaced from the distal end; and a movable member disposed inside the housing and between the distal end and the propellant, wherein the propellant is in fluid communication with the movable member and the first opening. | 0 |
This application is a Continuation-In-Part of U.S. patent application Ser. No. 08/315,660, filed on Sep. 29, 1994, now abandoned which is a Continuation-In-Part of U.S. patent application Ser. No. 08/297,274, now abandoned filed Aug. 26, 1994, which is a Continuation-In-Part of U.S. patent application Ser. No. 08/134,209, filed Oct. 12, 1993, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to novel compounds, compounds and pharmaceutical compositions thereof, and to methods of using same in the treatment of psychiatric disorders and neurological diseases including major depression, anxiety-related disorders, post-traumatic stress disorder, supranuclear palsy, eating feeding disorders, irritable bowel syndrome, immune suppression, Alzheimer's disease, gastrointestinal diseases, anorexia nervosa, drug and alcohol withdrawal symptoms, drug addiction, inflammatory disorders, and fertility problems.
2. Description of the Related Art
Corticotropin releasing factor (herein referred to as CRF), a 41 amino acid peptide, is the primary physiological regulator of proopiomelanocortin (POMC)-derived peptide secretion from the anterior pituitary gland (J. Rivier et al., Proc. Nat. Acad. Sci. (USA) 80:4851 (1983); W. Vale et al., Science 213:1394 (1981)). In addition to its endocrine role at the pituitary gland, immunohistochemical localization of CRF has demonstrated that the hormone has a broad extrahypothalamic distribution in the central nervous system and produces a wide spectrum of autonomic, electrophysiological and behavioral effects consistent with a neurotransmitter or neuromodulator role in brain (W. Vale et al., Rec. Prog. Horm. Res. 39:245 (1983); G. F. Koob, Persp. Behav. Med. 2:39 (1985); E. B. De Souza et al., J. Neurosci. 5:3189 (1985)). There is also evidence demonstrating that CRF may also play a significant role in integrating the response of the immune system to physiological, psychological, and immunological stressors (J. E. Blalock, Physiological Reviews 69:1 (1989); J. E. Morley, Life Sci. 41:527 (1987)).
Clinical data have demonstrated that CRF may have implications in psychiatric disorders and neurological diseases including depression, anxiety-related disorders and eating disorders. A role for CRF has also been postulated in the etiology and pathophysiology of Alzheimer's disease, Parkinson's disease, Huntington's disease, progressive supranuclear palsy and amyotrophic lateral schlerosis as they relate to the dysfunction of CRF neurons in the central nervous system (for review see E. G. De Souza, Hosp. Practice 23:59 (1988)).
In affective disorder, or major depression, the concentration of CRF is significantly increased in the cerebral spinal fluid (CSF) of drug-free individuals (C. B. Nemeroff et al., Science 226:1342 (1984); C. M. Banki et al., Am. J. Psychiatry 144:873 (1987); R. D. France et al., Biol. Psychiatry 28:86 (1988); M. Arato et al., Biol. Psychiatry 25:355 (1989)). Furthermore, the density of CRF receptors is significantly decreased in the frontal cortex of suicide victims, consistent with a hypersecretion of CRF (C. B. Nemeroff et al., Arch. Gen. Psychiatry 45:577 (1988)). In addition, there is a blunted adrenocorticotropin (ACTH) response to CRF (i.v. administered) observed in depressed patients (P. W. Gold et al., Am J. Psychiatry 141:619 (1984); F. Holsboer et al., Psychoneuroendocrinolgy 9:147 (1984); P. W. Gold et al., New Eng. J. Med. 314:1129 (1986)). Preclinical studies in rats and non-human primates provide additional support for the hypothesis that hypersecretion of CRF may be involved in the symptoms seen in human depression (R. M. Sapolsky, Arch. Gen. Psychiatry 46:1047 (1989)). There is preliminary evidence that tricyclic antidepressants can alter CRF levels and thus modulate the number of CRF receptors in brain (Grigoriadis et al., Neuropsychopharmacology 2:53 (1989)).
There has also been a role postulated for CRF in the etiology of anxiety-related disorders. CRF produces anxiogenic effects in animals and interactions between benzodiazepine/non-benzodiazepine anxiolytics and CRF have been demonstrated in a variety of behavioral anxiety models (D. R. Britton et al., Life Sci. 31:363 (1982); C. W. Berridge and A. J. Dunn Regul. Peptides 16:83 (1986)). Preliminary studies using the putative CRF receptor antagonist α-helical ovine CRF (9-41) in a variety of behavioral paradigms demonstrate that the antagonist produces "anxiolytic-like" effects that are qualitatively similar to the benzodiazepines (C. W. Berridge and A. J. Dunn Horm. Behav. 21:393 (1987), Brain Research Reviews 15:71 (1990)). Neurochemical, endocrine and receptor binding studies have all demonstrated interactions between CRF and benzodiazepine anxiolytics providing further evidence for the involvement of CRF in these disorders. Chlordiazepoxide attenuates the "anxiogenic" effects of CRF in both the conflict test (K. T. Britton et al., Psychopharmacology 86:170 (1985); K. T. Britton et al., Psychopharmacology 94:306 (1988) and in the acoustic startle test (N. R. Swerdlow et al., Psychopharmacology 88:147 (1986)) in rats. The benzodiazepine receptor antagonist (Ro15-1788), which was without behavioral activity alone in the operant conflict test, reversed the effects of CRF in a dose-dependent manner while the benzodiazepine inverse agonist (FG7142) enhanced the actions of CRF (K. T. Britton et al., Psychopharmacology 94:306 (1988)).
The mechanisms and sites of action through which the standard anxiolytics and antidepressants produce their therapeutic effects remain to be elucidated. It has been hypothesized, however, that they are involved in the suppression of the CRF hypersecretion that is observed in these disorders. Of particular interest is that preliminary studies examining the effects of a CRF receptor antagonist (α-helical CRF 9-41 ) in a variety of behavioral paradigms have demonstrated that the CRF antagonist produces "anxiolytic-like" effects qualitatively similar to the benzodiazepines (for review, see G. F. Koob and K. T. Britton, In: Corticotropin-Releasing Factor: Basic and Clinical Studies of a Neuropeptide, E. B. De Souza and C. B. Nemeroff eds., CRC Press p. 221 (1990)).
In order to study these specific cell-surface receptor proteins, compounds must be identified that can interact with the CRF receptor in a specific manner dictated by the pharmacological profile of the characterized receptor. Toward that end, there is evidence that the direct CRF antagonist compounds and compositions of this invention, which can attenuate the physiological responses to stress-related disorders, will have potential therapeutic utility for the treatment of depression and anxiety-related disorders. All of the aforementioned references are hereby incorporated by reference.
U.S. Pat. Nos. 4,788,195 and 4,876,252 teach the synthesis of compounds with the general formula (A): ##STR2## The utility of these compounds is described at treatment of asthma, allergic diseases, inflammation, and diabetes in mammals.
PCT application WO 89/01938 describes the synthesis and utility of compounds with formula (B): ##STR3## These compounds can be utilized in the treatment of neurologic diseases, having an effect of regenerating and repairing nerve cells and improving and restoring learning and memory.
U.S. Pat. No. 4,783,459 describes the utility and synthesis of compounds with the following general formula (C); ##STR4## The compounds have activity as fungicides, especially against fungal diseases of plants.
U.S. Pat. No. 4,992,438 discloses the utility and synthesis of compounds with the following general formula: ##STR5## The utility of these compounds is described as fungicides with a broad spectrum activity against plant pathogenic fungi.
European Patent Application 0 013 143 A2 discloses the utility and synthesis of compounds with the following general formula: ##STR6## These compounds are described as pre- and post-emergence herbicides.
U.S. Pat. No. 5,063,245 discloses a method of producing CRF antagonism with compounds with the general formulae: ##STR7##
PCT application WO 91/18887 discloses compounds of the general formula ##STR8## wherein R 2 may be C 1 -C 4 alkyl and R 3 may be substituted phenyl, said compounds being useful for the inhibition of gastric acid secretion.
European patent application EP 0588762 A1 discloses compounds of the general formula: ##STR9## wherein R 4 may be C 1 -C 3 alkyl, said compounds being useful as protein kinase C inhibitors and antitumor agents. The application also generally discloses the use of these compounds for the treatment of AIDS, atherosclerosis, and cardiovascular and central nervous system disorders.
European patent application EP 336494 A2 discloses compounds of the general formula: ##STR10## wherein X may be N--R 4 and R 4 may be (un)substituted alkyl, said compounds being useful as herbicides.
U.S. Pat. No. 3,988,338 discloses compounds of the general formula: ##STR11## wherein R 2 may be substituted phenyl group, said compounds being useful as antiulcer agents.
Eswaran et al, Org. Prep. Proced. Int. 24(1):71-3, (1992), discloses the use of related 5,7-diazaindoles as synthetic intermediates. El-Bayouki et al, J. Heterocycl. Chem. 22(3):853-6, (1985) discloses the use of related 5,7-diazaisoindazoles as synthetic intermediates.
The compounds and methods of the present invention provide the methodology for the production of specific high-affinity compounds capable of inhibiting the action of CRF at its receptor protein in the brain. These compounds would be useful in the treatment of a variety of neurodegenerative, neuropsychiatric and stress-related disorders such as irritable bowel syndrome, immune suppression, Alzheimer's disease, gastrointestinal disease, anorexia nervosa, drug and alcohol withdrawal symptoms, drug addiction, inflammatory disorders, and fertility problems. It is further asserted that this invention may provide compounds and pharmaceutical compositions suitable for use in such a method. Further advantages of this invention will be clear to one skilled in the art from the reading of the description that follows.
SUMMARY OF THE INVENTION
The present invention relates to compositions and methods of use and preparation of N-alkyl-N-aryl-pyrimidinamines and derivatives thereof. These compounds interact with and have antagonist activity at the CRF receptor and would thus have some therapeutic effect on psychiatric disorders and neurological diseases including major depression, anxiety-related disorders, post-traumatic stress and eating disorders, supranuclear palsy, irritable bowel syndrome, immune suppression, Alzheimer's disease, gastrointestinal diseases, anorexia nervosa, drug and alcohol withdrawal symptoms, drug addiction, inflammatory disorders, and fertility problems.
Novel compounds of this invention include compounds of formula: ##STR12## or a pharmaceutically acceptable salt or prodrug thereof, wherein Y is CR 3a , N, or CR 29 ;
when Y is CR 3a or N:
R 1 is independently selected at each occurrence from the group consisting of C 1 -C 4 alkyl, C 2 -C 4 alkenyl, C 2 -C 4 alkynyl, halogen, C 1 -C 2 haloalkyl, NR 6 R 7 , OR 8 , and S(O) n R 8 ;
R 3 is C 1 -C 4 alkyl, aryl, C 3 -C 6 cycloalkyl, C 1 -C 2 haloalkyl, halogen, nitro, NR 6 R 7 , OR 8 , S(O) n R 8 , C(═O)R 9 , C(═O)NR 6 R 7 , C(═S)NR 6 R 7 , --(CHR 16 ) k NR 6 R 7 , (CH 2 ) k OR 8 , C(═O)NR 10 CH(R 11 )CO 2 R 12 , --C(OH)(R 25 )(R 25a ), --(CH 2 ) p S(O) n -alkyl, --(CHR 16 )R 25 , --C(CN)(R 25 )(R 16 ) provided that R 25 is not --NH-- containing rings, --C(═O)R 25 , --CH(CO 2 R 16 ) 2 , NR 10 C(═O)CH(R 11 )NR 10 R 12 , NR 10 CH(R 11 )CO 2 R 12 ; substituted C 1 -C 4 alkyl, substituted C 2 -C 4 alkenyl, substituted C 2 -C 4 alkynyl, substituted C 1 -C 4 alkoxy, aryl-(substituted C 1 -C 4 ) alkyl, aryl-(substituted C 1 -C 4 ) alkoxy, substituted C 3 -C 6 cycloalkyl, amino-(substituted C 1 -C 4 ) alkyl, substituted C 1 -C 4 alkylamino, where substitution by R 27 can occur on any carbon containing substituent; 2-pyridinyl, imidazolyl, 3-pyridinyl, 4-pyridinyl, 2-methyl-3-pyridinyl, 4-methyl-3-pyridinyl, furanyl, 5-methyl-2-furanyl, 2,5-dimethyl-3-furanyl, 2-thienyl, 3-thienyl, 5-methyl-2-thienyl, 2-pheno-thiazinyl, 4-pyrazinyl, azetidinyl, phenyl, 1H-indazolyl, 2-pyrrolidonyl, 2H,6H-1,5,2-dithiazinyl, 2H-pyrrolyl, 3H-indolyl, 4-piperidonyl, 4aH-carbazolyl, 4H-quinolizinyl, 6H-1,2,5-thiadiazinyl, acridinyl, azocinyl, azepinyl, benzofuranyl, benzothiophenyl, carbazolyl, chromanyl, chromenyl, cinnolinyl, decahydroquinolinyl, furazanyl, imidazolidinyl, indolinyl, indolizinyl, indolyl, isobenzofuranyl, isochromanyl, isoindolinyl, isoindolyl, isoquinolinyl benzimidazolyl, isothiazolyl, isoxazolyl, morpholinyl, naphthyridinyl, octahydroisoquinolinyl, oxazolidinyl, oxazolyl, phenanthridinyl, phenanthrolinyl, phenazinyl, phenoxathiinyl, phenoxaxinyl, phthalazinyl, piperazinyl, piperidinyl, pteridinyl, purinyl, pyranyl, pyrazolidinyl, pyrazolinyl, pyrazolyl, pyridazinyl, pyrimidinyl, pyrrolidinyl, pyrrolinyl, pyrrolyl, quinazolinyl, quinolinyl, quinoxalinyl, quinuclidinyl, β-carbolinyl, tetrahydrofuranyl, tetrahydroisoquinolinyl, tetrahydroquinolinyl, tetrazolyl, thianthrenyl, thiazolyl, thiophenyl, triazinyl, xanthenyl; or 1-tetrahydroquinolinyl or 2-tetrahydroisoquinolinyl either of which can be substituted with 0-3 groups chosen from keto and C 1 -C 4 alkyl;
J, K, and L are independently selected at each occurrence from the group of N, CH, and CX';
M is CR 5 or N;
V is CR 1a or N;
Z is CR 2 or N;
R 1a , R 2 , and R 3a are independently selected at each occurrence from the group consisting of hydrogen, halo, halomethyl, C 1 -C 3 alkyl, and cyano;
R 4 is (CH 2 ) m OR 16 , C 1 -C 4 alkyl, allyl, propargyl, (CH 2 ) m R 13 , or --(CH 2 ) m OC(O)R 16 ;
X is halogen, S(O) 2 R 8 , SR 8 , halomethyl, --(CH 2 ) p OR 8 , --OR 8 , cyano, --(CHR 16 ) p NR 4 R 15 , --C(═O)R 8 , C 1 -C 6 alkyl, C 4 -C 10 cycloalkylalkyl, C 1 -C 10 alkenyl, C 2 -C 10 alkynyl, C 1 -C 10 alkoxy, aryl-(C 2 -C 10 )-alkyl, C 3 -C 6 cycloalkyl, aryl-(C 1 -C 10 )-alkoxy, nitro, thio-(C 1 -C 10 )-alkyl, --C(═NOR 16 )-C 1 -C 4 -alkyl, --C(═NOR 16 )H, or --C(═O)NR 14 R 15 where substitution by R 18 can occur on any carbon containing substituents;
X' is independently selected at each occurrence from the group consisting of hydrogen, halogen, S(O) n R 8 , halomethyl, --(CHR 16 ) p OR 8 , cyano, --(CHR 16 ) p NR 14 R 15 , C(═O)R 8 , C 1 -C 6 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 1 -C 10 alkoxy, aryl-(C 1 -C 10 )-alkyl, C 3 -C 6 cycloalkyl, aryl-(C 1 -C 10 )-alkoxy, nitro, thio-(C 1 -C 10 )-alkyl, --C(═NOR 16 )-C 1 -C 4 -alkyl, --C(═NOR 16 )H, and --C(═O)NR 14 R 15 , where substitution by R 18 can occur on any carbon containing substituents;
R 5 is halo, --C(═NOR 16 )-C 1 -C 4 -alkyl, C 1 -C 6 alkyl, C 1 -C 3 haloalkyl, --(CHR 16 ) p OR 8 , --(CHR 16 ) p S(O) n R 8 , --(CHR 16 ) p NR 14 R 15 , C 3 -C 6 cycloalkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, aryl-(C 2 -C 10 )-alkyl, aryl-(C 1 -C 10 )-alkoxy, cyano, C 3 -C 6 cycloalkoxy, nitro, amino-(C 2 -C 10 )-alkyl, thio-(C 2 -C 10 )-alkyl, SO n (R 8 ), C(═O)R 8 , --C(═NOR 16 )H, or --C(═O)NR 14 R 15 , where substitution by R 18 can occur on any carbon containing substituents;
R 6 and R 7 are independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 6 alkyl, C 3 -C 10 cycloalkyl, C 1 -C 6 alkoxy, (C 4 -C 12 )-cycloalkylalkyl, --(CH 2 ) k R 13 , (CHR 16 ) p OR 8 , --(C 1 -C 6 alkyl)-aryl, heteroaryl, aryl, --S(O) z -aryl or --(C 1 -C 6 alkyl)-heteroaryl or aryl wherein the aryl or heteroaryl groups are optionally substituted with 1-3 groups selected from the group consisting of hydrogen, halogen, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, amino, NHC(═O)(C 1 -C 6 alkyl), NH(C 1 -C 6 alkyl), N(C 1 -C 6 alkyl) 2 , nitro, carboxy, CO 2 (C 1 -C 6 alkyl), cyano, and S(O) z --(C 1 -C 6 -alkyl); or can be taken together to form --(CH 2 ) q A(CH 2 ) r --, optionally substituted with 0-3 R 17 ; or, when considered with the commonly attached nitrogen, and be taken together to form a heterocycle, said heterocycle being substituted on carbon with 1-3 groups consisting of hydrogen, C 1 -C 6 alkyl, hydroxy, or C 1 -C 6 alkoxy;
A is CH 2 , O, NR 25 , C(═O), S(O) n , N(C(═O)R 17 ), N(R 19 ), C(H)(NR 14 R 15 ), C(H)(OR 20 ), C(H)(C(═O)R 21 ), or N(S(O) n R 21 );
R 8 is independently selected at each occurrence from the group consisting of hydrogen; C 1 -C 6 alkyl; --(C 4 -C 12 ) cycloalkylalkyl; (CH 2 ) 1 R 22 ; C 3 -C 10 cycloalkyl; --NR 6 R 7 ; aryl; --NR 16 (CH 2 ) n NR 6 R 7 ; --(CH 2 ) k R 25 ; and (CH 2 ) t heteroaryl or (CH 2 ) t aryl, either of which can optionally be substituted with 1-3 groups selected from the group consisting of hydrogen, halogen, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, amino, NHC(═O)(C 1 -C 6 alkyl), NH(C 1 -C 6 alkyl), N(C 1 -C 6 alkyl) 2 , nitro, carboxy, CO 2 (C 1 -C 6 alkyl), cyano, and S(O) z (C 1 -C 6 -alkyl);
R 9 is independently selected at each occurrence from R 10 , hydroxy, C 1 -C 4 alkoxy, C 3 -C 6 cycloalkyl, C 2 -C 4 alkenyl, aryl substituted with 0-3 R 18 , and --(C 1 -C 6 alkyl)-aryl substituted with 0-3 R 18 ;
R 10 , R 16 , R 23 , and R 24 are independently selected at each occurrence from hydrogen or C 1 -C 4 alkyl;
R 11 is C 1 -C 4 alkyl substituted with 0-3 groups chosen from the following:
keto, amino, sulfhydryl, hydroxyl, guanidinyl, p-hydroxyphenyl, amidazolyl, phenyl, indolyl, indolinyl, or, when taken together with an adjacent R 10 , are (CH 2 ) 1 ;
R 12 is hydrogen or an appropriate amine protecting group for nitrogen or an appropriate carboxylic acid protecting group for carboxyl;
R 13 is independently selected at each occurrence from the group consisting of CN, OR 19 , SR 19 , and C 3 -C 6 cycloalkyl;
R 14 and R 15 are independently selected at each occurrence from the group consisting of hydrogen, C 4 -C 10 cycloalkyl-alkyl, and R 19 ;
R 17 is independently selected at each occurrence from the group consisting of R 10 , C 1 -C 4 alkoxy, halo, OR 23 , SR 23 , NR 23 R 24 , and (C 1 -C 6 ) alkyl (C 1 -C 4 ) alkoxy;
R 18 is independently selected at each occurrence from the group consisting of R 10 , hydroxy, halogen, C 1 -C 2 haloalkyl, C 1 -C 4 alkoxy, C(═O)R 24 , and cyano;
R 19 is independently selected at each occurrence from the group consisting of C 1 -C 6 alkyl, C 3 -C 6 cycloalkyl, (CH 2 ) w R 22 , and aryl substituted with 0-3 R 18 ;
R 20 is independently selected at each occurrence from the group consisting of R 10 , C(═O)R 31 , and C 2 -C 4 alkenyl;
R 21 is independently selected at each occurrence from the group consisting of R 10 , C 1 -C 4 alkoxy, NR 23 R 24 , and hydroxyl;
R 22 is independently selected at each occurrence from the group consisting of cyano, OR 24 , SR 24 , NR 23 R 24 , C 1 -C 6 cycloalkyl, --S(O) n R 31 , and --C(═O)R 25 ;
R 25 , which can be optionally substituted with 0-3 R 17 , is independently selected at each occurrence from the group consisting of phenyl, pyrazolyl, imidazolyl, 2-methyl-3-pyridinyl, 4-methyl-3-pyridinyl, furanyl, 5-methyl-2-furanyl, 2,5-dimethyl-3-furanyl, 2-thienyl, 3-thienyl, 5-methyl-2-thienyl, 2-pheno-thiazinyl, 4-pyrazinyl, azetidinyl, 1H-indazolyl, 2-pyrrolidonyl, 2H,6H-1,5,2-diehiazinyl, 2H-pyrrolyl, 3H-indazolyl, 4-piperidonyl, 4aH-carbazolyl, 4H-quinolizinyl, 6H-1,2,5-thiadiazinyl, acridinyl, azocinyl, azepinyl, benzofuranyl, benzothiophenyl, carbazolyl, chromanyl, chromenyl, cinnolinyl, decahydroquinolinyl, furazanyl, indolinyl, indolizinyl, indolyl, isobenzofuranyl, isochromanyl, isoindolinyl, isoindolyl, isoquinolinyl benzimidazolyl, isothiazolyl, isoxazolyl, morpholinyl, naphthyridinyl, octahydroisoquinolinyl, oxazolidinyl, oxazolyl, phenanthridinyl, phenanthrolinyl, phenazinyl, phenothiazinyl, phenoxathiinyl, phenoxazinyl, phthalazinyl, piperazinyl, piperidinyl, pteridinyl, purinyl, pyranyl, pyrazolidinyl, pyradazinyl, pyridyl, pyrimidinyl, pyrrolidinyl, pyrrolinyl, pyrrolyl, quinazolinyl, quinolinyl, quinoxalinyl, quinuclidinyl, β-carbolinyl, tetrahydrofuranyl, tetrazolyl, thianthrenyl, thiazolyl, thiophenyl, triazinyl, xanthenyl; and 1-tetrahydroquinolinyl or 2-tetrahydroisoquinolinyl either of which can be substituted with 0-3 groups chosen from keto and C 1 -C 4 alkyl;
R 25a , which can be optionally substituted with 0-3 R 17 , is independently selected at each occurrence from the group consisting of H and R 25 ;
R 25 is independently selected at each occurrence from the group consisting of C 1 -C 3 alkyl, C 2 -C 4 alkenyl, C 2 -C 4 alkynyl, C 2 -C 4 alkoxy, aryl, nitro, cyano, halogen, aryloxy, and heterocycle optionally linked through O;
R 31 is independently selected at each occurrence from the group consisting of C 1 -C 4 alkyl, C 3 -C 7 cycloalkyl, C 4 -C 10 cycloalkyl-alkyl, and aryl-(C 1 -C 4 ) alkyl;
k, m, and r are independently selected at each occurrence from 1-4;
n is independently selected at each occurrence from 0-2;
p, q, and z are independently selected at each occurrence from 0-3;
t and w are independently selected at each occurrence from 1-6, provided that when J is CX' and K and L are both CH, and M is CR 5 , then
(A) when V and Y are N and Z is CH and R 1 and R 3 are methyl,
(1) and R 4 is methyl, then
(a) R 5 can not be methyl when X is OH and X' is H;
(b) R 5 can not be --NHCH 3 or --N(CH 3 ) 2 when X and X' are --OCH 3 ; and
(c) R 5 can not be --N(CH 3 ) 2 when X and X' are --OCH 2 CH 3 ;
(2) and R 4 is ethyl, then
(a) then R 5 can not be methylamine when X and X' are --OCH 3 ;
(b) R 5 can not be OH when X is Br and X' is OH; and
(c) R 5 can not be --CH 2 OH or --CH 2 N(CH 3 ) 2 when X is --SCH3 and X' is H;
(B) when V and Y are N, Z is CH, R 4 is ethyl, R 5 is iso-propyl, X is Br, X' is H, and
(1) R 1 is CH 3 , then
(a) R 3 can not be OH, piperazin-1-yl, --CH 2 -piperidin-1-yl, --CH 2 -(N-4-methylpiperazin-1-yl), --C(O)NH-phenyl, --CO 2 H, --CH 2 O-(4-pyridyl), --C(O)NH 2 , 2-indolyl, --CH 2 O-(4-carboxyphenyl), --N(CH 2 CH 3 )(2-bromo-4-isopropylphenyl);
(2) R 1 is --CH 2 CH 2 CH 3 then R 3 can not be --CH 2 CH 2 CH 3 ;
(C) when V, Y and Z are N, R 4 is ethyl, and
(1) R 5 is iso-propyl, X is bromo, and X' is H, then
(a) R 3 can not be OH or --OCH 2 CN when R 1 is CH 3 ; and
(b) R 3 can not be --N(CH 3 ) 2 when R 1 is --N(CH 3 ) 2 ;
(2) R 5 is --OCH 3 , X is --OCH 3 , and X' is H, then R 3 and R 1 can not both be chloro;
further provided that when J, K, and L are all CH and M is CR 5 , then
(D) at least one of V, Y, and Z must be N;
(E) when V is CR 1a , Z and Y can not both be N;
(F) when Y is CR 3a , Z and V can not both be N;
(G) when Z is CR 2 , V and Y must both be N;
(H) Z can be N only when both V and Y are N or when V is CR 1a and Y is CR 3a ;
(I) when V and Y are N, Z is CR 2 , and R 2 is H or C 1 -C 3 alkyl, and R 4 is C 1 -C 3 alkyl, R 3 can not be 2-pyridinyl, indolyl, indolinyl, imidazolyl, 3-pyridinyl, 4-pyridinyl, 2-methyl-3-pyridinyl, 4-methyl-3-pyridinyl, furanyl, 5-methyl-2-furanyl, 2,5-dimethyl-3-furanyl, 2-thienyl, 3-thienyl, 5-methyl-2-thienyl, 2-phenothiazinyl, or 4-pyranzinyl;
(J) when V and Y are N; Z is CR 2 ; R 2 is H or C 1 -C 3 alkyl; R 4 is C 1 -C 4 alkyl; R 5 , X, and/or X' are OH, halo, CF 3 , C 1 -C 4 alkyl, C 1 -C 4 alkoxy, C 1 -C 4 alkylthio, cyano, amino, carbamoyl, or C 1 -C 4 alkanoyl; and R 1 is C 1 -C 4 alkyl, then R 3 can not be --NH(substituted phenyl) or --N(C 1 -C 4 alkyl)(substituted phenyl);
and wherein, when Y is CR 29 :
J, K, L, M, Z, A, k, m, n, p, q, r, t, w, R 3 , R 10 , R 11 , R 12 , R 13 , R 16 , R 18 , R 19 , R 21 , R 23 , R 24 , R 25 , and R 27 are as defined above and R 25a , in addition to being as defined above, can also be C 1 -C 4 alkyl, but
V is N;
R 1 is C 1 -C 2 alkyl, C 2 -C 4 alkenyl, C 2 -C 4 alkynyl, C 2 -C 4 alkoxy, halogen, amino, methylamino, dimethylamino, aminomethyl, or N-methylaminomethyl;
R 2 is independently selected at each occurrence from the group consisting of hydrogen, halo, C 1 -C 3 alkyl, nitro, amino, and --CO 2 R 10 ;
R 4 is taken together with R 29 to form a 5-membered ring and is --C(R 28 )═ or --N═ when R 29 is --C(R 30 )═ or --N═, or --CH(R 28 )-- when R 29 is --CH(R 30 )--;
X is Cl, Br, I, S(O) n R 8 , OR 8 , halomethyl, --(CHR 16 ) p OR 8 , cyano, --(CHR 16 ) p NR 14 R 15 , C(═O)R 8 , C 1 -C 6 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 1 -C 10 alkoxy, aryl-(C 1 -C 10 )-alkyl, C 3 -C 6 cycloalkyl, aryl-(C 1 -C 10 )-alkoxy, nitro, thio-(C 1 -C 10 )-alkyl, --C(═NOR 16 )-C 1 -C 4 -alkyl, --C(═NOR 16 )H, or C(═O)NR 14 R 15 where substitution by R 18 can occur on any carbon containing substituents;
X' is hydrogen, Cl, Br, I, S(O) n R 8 , --(CHR 16 ) p OR 8 , halomethyl, cyano, --(CHR 16 ) p NR 14 R 15 , C(═O)R 8 , C 1 -C 6 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 1 -C 10 alkoxy, aryl-(C 1 -C 10 )-alkyl, C 3 -C 6 cycloalkyl, aryl-(C 2 -C 10 )-alkoxy, nitro, thio-(C 2 -C 10 )-alkyl, --C(═NOR 16 )-C 1 -C 4 -alkyl, --C(═NOR 16 )H, or C(═O)NR 8 R 15 where substitution by R 18 can occur on any carbon containing substituents;
R 5 is halo, --C(═NOR 16 )-C 1 -C 4 -alkyl, C 1 -C 6 alkyl, C1-C3 haloalkyl, C 1 -C 6 alkoxy, (CHR 16 ) p OR 8 , (CHR 16 ) p S(O) n R 8 , (CHR 16 ) p NR 14 R 15 , C 3 -C 6 cycloalkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, aryl-(C 2 -C 10 )-alkyl, aryl-(C 1 -C 10 )-alkoxy, cyano, C 3 -C 6 cycloalkoxy, nitro, amino-(C 1 -C 10 )-alkyl, thio-(C 1 -C 10 )-alkyl, SO n (R 8 ), C(═O)R 8 , --C(═NOR 16 )H, or C(═O)NR 8 R 15 where substitution by R 18 can occur on any carbon containing substituents;
R 6 and R 7 are independently selected at each occurrence from the group consisting of
hydrogen, C 1 -C 6 alkyl, C 3 -C 10 cycloalkyl, --(CH 2 ) k R 13 , (C 4 -C 12 )-cycloalkylalkyl, C 1 -C 6 alkoxy, --(C 1 -C 6 alkyl)-aryl, heteroaryl, aryl, --S(O) z -aryl or --(C 1 -C 6 alkyl)-heteroaryl or aryl wherein the aryl or heteroaryl groups are optionally substituted with 1-3 groups selected from hydrogen, halogen, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, amino, NHC(═O)(C 1 -C 6 alkyl), NH(C 1 -C 6 alkyl), N(C 1 -C 6 alkyl) 2 , nitro, carboxy, CO 2 (C 1 -C 6 akyl), and cyano; or can be taken together to form --(CH 2 ) q A(CH 2 ) r --, optionally substituted with 0-3 R 17 ; or, when considered with the commonly attached nitrogen, can be taken together to form a heterocycle, said heterocycle being substituted on carbon with 1-3 groups consisting of hydrogen, C 1 -C 6 alkyl, hydroxy, or C 1 -C 6 alkoxy;
R 8 is independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 6 alkyl, --(C 4 -C 12 ) cycloalkylalkyl, (CH 2 ) t R 22 , C 3 -C 10 cycloalkyl, --(C 1 -C 6 alkyl)-aryl, heteroaryl, --NR 16 , --N(CH 2 ) n NR 6 R 7 ; --(CH 2 ) k R 25 , --(C 1 -C 6 alkyl)-heteroaryl or aryl optionally substituted with 1-3 groups selected from hydrogen, halogen, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, amino, NHC(═O)(C 1 -C 6 alkyl), NH(C 1 -C 6 alkyl), N(C 1 -C 6 alkyl) 2 , nitro, carboxy, CO 2 (C 1 -C 6 alkyl), and cyano;
R 9 is independently selected at each occurrence from R 10 , hydroxy, C 1 -C 4 alkoxy, C 3 -C 6 cycloalkyl, C 2 -C 4 alkenyl, and aryl substituted with 0-3 R 18 ;
R 14 and R 15 are independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 6 alkyl, C 3 -C 6 cycloalkyl, (CH 2 ) 1 R 22 , and aryl substituted with 0-3 R 18 ;
R 17 is independently selected at each occurrence from the group consisting of R 10 , C 1 -C 4 alkoxy, halo, OR 23 , SR 23 , and NR 23 R 24 ;
R 20 is independently selected at each occurrence from the group consisting of R 10 and C(═O)R 31 ;
R 22 is independently selected at each occurrence from the group consisting of cyano, OR 24 , SR 24 , NR 23 R 24 , C 3 -C 6 cycloalkyl, --S(O) n R 31 , and --C(═O)R 25 ;
R 26 is hydrogen or halogen;
R 28 is C 1 -C 2 alkyl, C 2 -C 4 alkenyl, C 2 -C 4 alkynyl, hydrogen, C 1 -C 2 alkoxy, halogen, or C 2 -C 4 alkylamino;
R 29 is taken together with R 4 to form a five membered ring and is:
--CH(R 30 )-- when R 4 is --CH(R 28 )--,
--C(R 30 )═ or --N═ when R 4 is --C(R 28 )═ or --N═;
R 30 is hydrogen, cyano, C 1 -C 2 alkyl, C 1 -C 2 alkoxy, halogen, C 1 -C 2 alkenyl, nitro, amido, carboxy, or amino;
R 31 is C 1 -C 4 alkyl, C 3 -C 7 cycloalkyl, or aryl-(C 1 -C 4 ) alkyl;
provided that when J, K, and L are all CH, M is CR 5 , Z is CH, R 3 is CH 3 , R 28 is H, R 5 is iso-orpyl, X is Br, X' is H, and R 1 is CH 3 , then R 30 can not be H, --CO 2 H, or --CH 2 NH 2 ;
and further provided that when J, K and L are all CH; M is CR 5 ; Z is N; and
(A) R 29 is --C(R 30 )═; then one of R 28 or R 30 is hydrogen;
(B) R 29 is N; then R 3 is not halo, NH 2 , NO 2 , CF 3 , CO 2 H, CO 2 -alkyl, alkyl, acyl, alkoxy, OH, or --(CH 2 ) m Oalkyl;
(C) R 29 is N; then R 28 is not methyl if X or X' are bromo or methyl and R 5 is nitro; or
(D) R 29 is N, and R 1 is CH 3 and R 3 is amino; then R 5 is not halogen or methyl.
Preferred compounds of this invention are those compounds of Formula I wherein,
Y is CR 3a or N:
R 3 is C 1 -C 4 alkyl, aryl, halogen, C 1 -C 2 haloalkyl, nitro, NR 6 R 7 , OR 8 , SR 8 , C(═O)R 9 , C(═O)NR 6 R 7 , C(═S)NR 6 R 7 , (CH 2 ) k NR 6 R 7 , (CH 2 ) k OR 8 , C(═O)NR 10 CH(R 11 )CO 2 R 12 , --(CHR 16 ) p OR 8 , --C(OH)(R 25 )(R 25a ), --(CH 2 ) p S(O) n -alkyl, --C(CN)(R 25 )(R 16 ) provided that R 25 is not an --NH-- containing ring, --C(═O)R 25 , --CH(CO 2 R 26 ) 2 , NR 10 C(═O)CH(R 11 )NR 10 R 12 ; substituted C 1 -C 4 alkyl, substituted C 2 -C 4 alkenyl, substituted C 2 -C 4 alkynyl, C 3 -C 6 cycloalkyl, substituted C 1 -C 4 alkoxy, aryl-(substituted C 1 -C 4 ) alkyl, aryl-(substituted C 1 -C 4 ) alkoxy, substituted C 3 -C 6 cycloalkyl, amino-(substituted C 1 -C 4 ) alkyl, substituted C 1 -C 4 alkylamino, where substitution by R 27 can occur on any carbon containing substituent; 2-pyridinyl, indolinyl, indolyl, pyrazoyl, imidazolyl, 3-pyridinyl, 4-pyridinyl, furanyl, 2,5-dimethyl-3-furanyl, 2-thienyl, 3-thienyl, or 5-methyl-2-thienyl, azetidinyl, 2-pyrrolidonyl, 2H-pyrrolyl, 3H-indolyl, 4-piperidonyl, 4aH-carbazolyl, 4H-quinolizinyl, azocinyl, azepinyl, benzofuranyl, benzothiophenyl, carbazolyl, chromanyl, chromenyl, cinnolinyl, decahydroquinolinyl, furazanyl, imidazolidinyl, indolinyl, indolizinyl, indolyl, isobenzofuranyl, isochromanyl, isoindolinyl, isoindolyl, isoquniolinyl (benzimidazolyl), isothiazolyl, isoxazolyl, morpholinyl, naphthyridinyl, octahydroisoquinolinyl, oxazolidinyl, oxazolyl, phthalazinyl, piperazinyl, piperidinyl, pteridinyl, purinyl, pyranyl, pyrazolidinyl, pyrazolinyl, pyrazolyl, pyridazinyl, pyrimidinyl, pyrrolidinyl, pyrrolinyl, pyrrolyl, quinazolinyl, quinolinyl, quinoxalinyl, quinuclidinyl, β-carbolinyl, tetrahydrofuranyl, tetrahydroisoquinolinyl, tetrahydroquinolinyl, tetrazolyl, thiazolyl, triazinyl; or 1-tetrahydroquinolinyl or 2-tetrahydroisoquinolinyl either of which can be substituted with 0-3 groups chosen from keto and C 1 -C 4 alkyl;
J, K, and L are independently selected at each occurrence from the group consisting of CH and CX';
M is CR 5 ;
R 1a , R 2 , and R 3a are independently selected at each occurrence from the group consisting of hydrogen, halo, methyl, or cyano;
X is halogen, S(O) 2 R 8 , SR 8 halomethyl, (CH 2 ) p OR 8 , cyano, --(CHR 16 ) p NR 14 R 15 , C(═O)R 8 , - C 1 -C 6 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 1 -C 10 alkoxy, aryl-(C 1 -C 10 )-alkyl, C 3 -C 6 cycloalkyl, aryl-(C 1 -C 10 )-alkoxy, nitro, thio-(C 1 -C 10 )-alkyl, --C(═NOR 16 )-C 1 -C 4 -alkyl, --C(═NOR 16 )H, or --C(═O)NR 14 R 15 where substitution by R 18 can occur on any carbon containing substituents;
X' is hydrogen, halogen, S(O) n R 8 , halomethyl, (CH 2 ) p OR 8 , cyano, --(CHR 16 ) p NR 14 R 15 , C(═O)R 8 , C 1 -C 6 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 1 -C 10 alkoxy, aryl-(C 1 -C 10 )-alkyl, C 3 -C 6 cycloalkyl, aryl-(C 1 -C 10 )-alkoxy, nitro, thio-(C 1 -C 10 )-alkyl, --C(═NOR 16 )-C 1 -C 4 -alkyl, --C(═NOR 16 )H, or --C(═O)NR 14 R 15 where substitution by R 18 can occur on any carbon containing substituents;
R 5 is halo, --C(═NOR 16 )-C 1 -C 4 -alkyl, C 1 -C 6 alkyl, C 1 -C 3 haloalkyl, C 1 -C 6 alkoxy, (CHR 16 ) p OR 8 , (CHR 16 ) p S(O) n R 8 , (CHR 16 ) p NR 14 R 15 , C 3 -C 6 cycloalkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, aryl-(C 2 -C 10 )-akyl, aryl-(C 2 -C 10 )-alkoxy, cyano, C 3 -C 6 cycloalkoxy, nitro, amino-(C 2 -C 10 )-alkyl, thio-(C 2 -C 10 )-alkyl, SO n (R 8 ), C(═O)R 8 , --C(═NOR 16 )H, or C(═O)NR 14 R 15 where substitution by R 18 can occur on any carbon containing substituents;
R 6 and R 7 are independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 6 alkyl, C 3 -C 10 cycloalkyl, cycloalkylalkyl, --(CH 2 ) k R 13 , C 1 -C 6 alkoxy, --(CHR 16 ) p OR 8 , --(C 1 -C 6 alkyl)-aryl, aryl, heteroaryl, --(C 1 -C 6 alkyl)-heteroaryl or aryl, wherein the aryl or heteroaryl groups are optionally substituted with 1-3 groups selected from hydrogen, halogen, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, NHC(═O)(C 1 -C 6 alkyl), NH(C 1 -C 6 alkyl), N(C 1 -C 6 alkyl) 2 , carboxy, CO 2 (C 1 -C 6 alkyl), cyano, or can be taken together to form --(CH 2 ) q A(CH 2 ) r --, optionally substituted with 0-3 R 17 , or, when considered with the commonly attached nitrogen, can be taken together to form a heterocycle, said heterocycle being substituted on carbon with 1-3 groups consisting of hydrogen, C 1 -C 6 alkyl, (C 1 -C 6 ) alkyl(C 1 -C 4 )alkoxy, and C 1 -C 6 alkoxy;
R 8 is independently selected at each occurrence from the group consisting of hydrogen; C 1 -C 6 alkyl; --(C 4 -C 12 ) cycloalkylalkyl; (CH 2 ) t R 22 ; C 3 -C 10 cycloalkyl; --NR 6 R 7 ; aryl; --NR 16 (CH 2 ) n NR 6 R 7 ; --(CH 2 ) k R 25 ; and (CH 2 ) t heteroaryl or (CH 2 ) t aryl, either of which can optionally be substituted with 1-3 groups selected from the group consisting of hydrogen, halogen, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, NHC(═O)(C 1 -C 6 alkyl), NH(C 1 -C 6 alkyl), N(C 1 -C 6 alkyl) 2 , carboxy, and CO 2 (C 1 -C 6 alkyl);
R 10 is hydrogen;
R 13 is independently selected at each occurrence from the group consisting of OR 19 , SR 19 , and C 3 -C 6 cycloalkyl;
R 14 and R 15 are independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 6 alkyl, C 3 -C 6 cycloalkyl, and C 4 -C 10 cycloalkyl-alkyl;
R 17 is independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 4 alkyl, C 1 -C 4 alkoxy, and (C 1 -C 6 )alkyl(C 1 -C 4 )alkoxy;
R 19 is independently selected at each occurrence from the group consisting of C 1 -C 6 alkyl, C 3 -C 6 cycloalkyl, and aryl substituted with 0-3 R 18 ;
R 22 is independently selected at each occurrence from the group consisting of cyano, OR 24 , SR 24 , NR 23 R 24 , C 3 -C 6 cycloalkyl, --S(O) n R 31 , and --C(═O)R 25 ;
R 25 , which can be optionally substituted with 0-3 R 17 , is independently selected at each occurrence from the group consisting of phenyl, pyrazolyl, imidazolyl, 2-methyl-3-pyridinyl, 4-methyl-3-pyridinyl, furanyl, 5-methyl-2-furanyl, 2,5-dimenthyl-3-furanyl, 2-thienyl, 3-thienyl, 5-methyl-2-thienyl, 2-pheno-thiazinyl, 4-pyrazinyl, 1H-indazolyl, 2-pyrrolidonyl, 2H-pyrrolyl, 3H-indolyl, 4-piperidonyl, 4aH-carbozolyl, 4H-quinolizinyl, azocinyl, benzofuranyl, carbazolyl, chromanyl, chromenyl, cinnolinyl, decahydroquinolinyl, furazanyl, indolinyl, indolizinyl, indolyl, isobezofuranyl, isochromanyl, isoindolinyl, isoindolyl, isoquinolinyl (benzimidazolyl), isothiazolyl, isoxazolyl, morpholinyl, naphthyridinyl, octahydroisoquinolinyl, oxazolidinyl, oxazolyl, piperazinyl, piperidinyl, pteridinyl, purinyl, pyranyl, pyrazolidinyl, pyridazinyl, pyridyl, pyrimidinyl, pyrrolidinyl, pyrrolinyl, pyrroyl, quinazolinyl, quinolinyl, quinoxalinyl, quinuclidinyl, β-carbolinyl, tetrahydrofuranyl, tetrazolyl, thiazolyl, triazinyl; and 1-tetrahydroquinolinyl or 2-tetrahydroisoquinolinyl either of which can be substituted with 0-3 groups chosen from keto and C 1 -C 4 alkyl;
R 25a , which can be optionally substituted with 0-3 R 17 , is independently selected at each occurrence from the group consisting of H, phenyl, pyrazolyl, imidazolyl, 2-methyl-3-pyridinyl, 4-methyl-3-pyridinyl, furanyl, 5-methyl-2-furanyl, 2,5-dimethyl-3-furanyl, 2-thienyl, 3-thienyl, 5-methyl-2-thienyl, 4-pyrazinyl, 1H-indazolyl, 2-pyrrolidonyl, 2H-pyrrolyl, 3H-indolyl, 4-piperidonyl, 4aH-carbazolyl, 4H-quinolizinyl, azocinyl, benzofuranyl, benzothiophenyl, carbazolyl, chromanyl, chromenyl, cinnolinyl, decahydroquinolinyl, furazanyl, indolinyl, indolizinyl, indolyl, isobenzofuranyl, isochromanyol, isoindolinyl, isoindolyl, isoquinolinyl (benzimidazolyl), isothiazolyl, isoxazolyl, morpholinyl, naphthyridinyl, octahydroisoquinolinyl, oxazolidinyl, oxazolyl, piperazinyl, piperidinyl, pteridinyl, purinyl, pyranyl, pyrazolidinyl, pyridazinyl, pyridyl, pyrimidinyl, pyrrolidinyl, pyrrolinyl, pyrrolyl, quinazolinyl, quinolinyl, quinoxalinyl, quinuclidinyl, β-carbolinyl, tetrahydrofuranyl, tetrazolyl, thiazolyl, thiophenyl, triazinyl; and 1-tetrahydroquinolinyl or 2-tetrahydroisoquinolinyl either of which can be substituted with 0-3 groups chosen from keto and C 1 -C 4 alkyl;
t is independently selected at each occurrence from 1-3; and
w is 1-3.
Other preferred compounds of this invention are those compounds of Formula I wherein,
Y is CR 29 :
Z is CR 2 ;
R 1 is methyl, amino, chloro, or methylamino;
R 2 is hydrogen;
R 3 is C 1 -C 4 alkyl, aryl, halogen, nitro, NR 6 R 7 , OR 8 , SR 8 , C(═O)R 9 , C(═O)NR 6 R 7 , (CH 2 ) k NR 6 R 7 , (CH 2 ) k OR 8 , --C(OH)(R 25 )(R 25a ), --(CH 2 ) p S(O) n -alkyl, --C(═O)R 25 , --CH(CO 2 R 16 ) 2 ; substituted C 1 -C 4 alkyl, substituted C 2 -C 4 alkenyl, substituted C 2 -C 4 alkynyl, C 3 -C 6 cycloalkyl, substituted C 1 -C 4 alkoxy, aryl-(substituted C 1 -C 4 ) alkyl, aryl-(substituted C 1 -C 4 ) alkoxy, substituted C 3 -C 6 cycloalkyl, amino-(substituted C 1 -C 4 ) alkyl, substituted C 1 -C 4 alkylamino, or is N-linked piperidinyl, piperazinyl, morpholino, thiomorpholino, imidazolyl, 2-pyridinyl, 3-pyridinyl, 4-pyridinyl, where substitution by R 27 can occur on any carbon containing substituent;
J, K, and L are independently selected at each occurrence from the group consisting of CH and CX';
M is CR 5 ;
R 4 is taken together with R 29 to form a five membered ring and is --CH═;
X is Br, I, S(O) n R 8 , OR 8 , NR 14 R 15 , R 18 substituted alkyl, or amino-(C 1 -C 2 ) alkyl;
X' is hydrogen, Br, I, S(O) n R 8 , OR 8 , NR 14 R 15 , R 18 substituted alkyl, or amino-(C 1 -C 2 ) alkyl;
R 5 is independently selected at each occurrence from the group consisting of halogen, --C(═NOR 16 )-C 1 -C 4 -alkyl, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, (CHR 16 ) p OR 8 , --NR 14 R 15 , (CHR 16 ) p S(O) n R 8 , (CHR 16 ) p NR 14 R 15 , C 3 -C 6 cycloalkyl, C(═O)R 8 , and C(═O)NR 8 R 15 ;
R 6 and R 7 are independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 6 alkyl, C 3 -C 6 cycloalkyl, --(CH 2 ) k R 13 , (C 3 -C 6 )cycloalkyl-(C 1 -C 6 )alkyl, --(C 1 -C 6 alkyl)-aryl, heteroaryl, --(C 1 -C 6 alkyl)-heteroaryl or aryl, wherein the aryl or heteroaryl groups are optionally substituted with 1-3 groups selected from hydrogen, C 1 -C 2 alkyl, C 1 -C 2 alkoxy, amino, NHC(═O)(C 1 -C 2 alkyl), NH(C 1 -C 2 alkyl), and N(C 1 -C 2 alkyl) 2 , or can be taken together to form --(CH 2 ) q A(CH 2 O r --, optionally substituted with 0-2 R 17 , or, when considered with the commonly attached nitrogen, can be taken together to form a heterocycle, said heterocycle being substituted on carbon with 1-2 groups consisting of hydrogen, C 1 -C 3 alkyl, hydroxy, or C 1 -C 3 alkoxy;
A is CH 2 , O, NR 25 , C(═O), or S(O) n ;
R 8 is independently selected at each occurrence from the group consisting of hydrogen; C 1 -C 6 alkyl; --(C 4 -C 12 ) cycloalkylalkyl; (CH 2 ) t R 22 ; C 3 -C 10 cycloalkyl; --NR 6 R 7 ; aryl; --NR 16 (CH 2 ) n NR 6 R 7 ; --(CH 2 ) k R 25 ; and (CH 2 ) t heteroaryl or (CH 2 ) t aryl, either of which can optionally be substituted with 1-3 groups selected from the group consisting of hydrogen, C 1 -C 2 alkyl, C 1 -C 2 alkoxy, amino, NHC(═O)(C 1 -C 2 alkyl), NH(C 1 -C 2 alkyl), N(C 1 -C 2 alkyl) 2 , R 9 is hydroxy, C 1 -C 4 alkyl, C 1 -C 4 alkoxy, and C 3 -C 6 cycloalkyl substituted with 0-2 R 18 ;
R 14 and R 15 are independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 2 alkyl, (CH 2 ) t R 22 , and aryl substituted with 0-2 R 18 ;
R 16 is independently selected at each occurrence from the group consisting of hydrogen and C 1 -C 2 alkyl;
R 17 is independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 2 alkyl, C 1 -C 2 alkoxy, halo, and NR 23 R 24 ;
R 18 is independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 2 alkyl, C 1 -C 2 alkoxy, halo, and NR 23 R 24 ;
R 22 is independently selected at each occurrence from the group consisting of OR 24 , SR 24 , NR 23 R 24 , and --C(═O)R 25 ;
R 23 and R 24 are independently selected at each occurrence from hydrogen and C 1 -C 2 alkyl;
R 25 , which can be optionally substituted with 0-3 R 17 , is independently selected at each occurrence from the group consisting of phenyl, pyrazolyl, imidazolyl, 2-methyl-3-pyridinyl, 4-methyl-3-pyridinyl, furanyl, 5-methyl-2-furanyl, 2,5-dimethyl-3-furanyl, 2-thienyl, 3-thienyl, 5-methyl-2-thienyl, 2-pheno-thiazinyl, 4-pyrazinyl, 1H-indazolyl, 2-pyrrolidonyl, 2H-pyrrolyl, 3H-indolyl, 4-piperidonyl, 4aH-carbazolyl, 4H-quinolizinyl, azocinyl, benzofuranyl, carbazolyl, chromanyl, chromenyl, cinnolinyl, decahydroquinolinyl, furazanyl, indolinyl, indolizinyl, indolyl, isobenzofuranyl, isochromanyl, isoindolinyl, isoindolyl, isoquinolinyl, benzimidazolyl, isothiazolyl, isoxazolyl, morpholinyl, naphthyridinyl, octahydoisoquinolinyl, oxazolidinyl, oxazolyl, piperazinyl, piperidinyl, pteridinyl, purinyl, pyranyl, pyrazolidinyl, pyridazinyl, pyridyl, pyrimidinyl, pyrrolidinyl, pyrrolinyl, pyrrolyl, quinazolinyl, quinolinyl, quinoxalinyl, quinuclidinyl, β-carbolinyl, tetrahydrofuranyl, tetrazolyl, thiazolyl, triazinly; and 1-tetrahydroquinolinyl or 2-tetrahydroisoquinolinyl either of which can be substituted with 0-3 groups chosen from keto and C 1 -C 4 alkyl;
R 35a is independently selected at each occurrence from the group consisting of H and C 1 -C 4 alkyl;
R 29 is taken together with R 4 to form a five membered ring and is --C(R 30 )═;
R 30 is hydrogen, cyano, C 1 -C 2 alkyl, or halogen;
k is 1-3;
p is 0-2;
q and r are 2; and
t and w are independently selected at each occurrence from 1-2.
More preferred compounds of this invention are those compounds of Formula I wherein, when Y is CR 3a or N:
R 1 is independently selected at each occurrence from the group consisting of C 1 -C 2 alkyl, C 1 -C 2 haloalkyl, NR 6 R 7 , and OR 8 ;
R 3 is independently selected at each occurrence from the group consisting of C 1 -C 4 alkyl, C 1 -C 2 haloalkyl, NR 6 R 7 , OR 8 , C(═O)R 9 , C(═O)NR 6 R 7 , (CH 2 ) k NR 6 R 7 , (CH 2 O k OR 8 , --C(CN)(R 25 )(R 16 ) provided that R 25 is not an --NH-- containing ring, --C(OH)(R 25 )(R 25a ), --(CH 2 ) p S(O) n -alkyl, --C(═O)R 23 , --CH(CO 2 R 16 ) 2 , 2-pyridinyl, indolinyl, indolyl, pyrazoyl, imidazolyl, 3-pyridinyl, 4-pyridinyl, furanyl, 2,5-dimethyl-3-furanyl, 2-thienyl, 3-thienyl, 5-methyl-2-thienyl, 1H-indazolyl, 2H-pyrrolyl, 3H-indolyl, 4-piperidonyl, 4H-quinolizinyl, benzofuranyl, carbazolyl, chromenyl, cinnolinyl, decahydroquinolinyl, furazanyl, imidazolidinyl, indolinyl, indolizinyl, indolyl, isobenzofuranyl, isoindolinyl, isoindolyl, isoquinolinyl (benzimidazolyl), isothiazolyl, isoxazolyl, morpholinyl, naphthyridinyl, octahydroisoquinolinyl, oxazolidinyl., oxazolyl, piperazinyl, piperidinyl, pteridinyl, purinyl, pyranyl, pyrazolidinyl, pyrazolinyl, pyrazolyl, pyridazinyl, pyrimidinyl, pyrrolidinyl, pyrrolinyl, pyrrolyl, quinazolinyl, quinolinyl, quinoxalinyl, quinclidinyl, β-carbolinyl, tetrahydrofuranyl, tetrahydroisoquinolinyl, tetrahydroquinolinyl, tetrazolyl, thiazolyl, triazinyl; and 1-tetrahydroquinolinyl or 2-tetrahydroisoquinolinyl either of which can be substituted with 0-3 groups chosen from keto and C 1 -C 4 alkyl;
R 1a , R 2 , and R 3a are independently selected at each occurrence from the group consisting of hydrogen, methyl, and cyano;
X is Cl, Br, I, OR 8 , NR 14 R 15 , (CH 2 ) m OR 16 , or (CHR 16 )NR 14 R 15 ;
X' is hydrogen, Cl, Br, I, OR 8 , NR 14 R 15 , (CH 2 ) m OR 16 , or (CHR 16 )NR 14 R 15 ;
R 5 is halo, C 1 -C 6 alkyl, C 1 -C 3 haloalkyl, C 1 -C 6 alkoxy, (CHR 16 ) p OR 8 , (CHR 16 ) p NR 14 R 15 , or C 3 -C 6 cycloalkyl;
R 6 and R 7 are independently selected at each occurrence from the group consisting of
C 1 -C 6 alkyl, (CHR 16 ) p OR 8 , C 1 -C 6 alkoxy, and --(CH 2 ) k R 13 , or can be taken together to form --(CH 2 ) q A(CH 2 ) r --, optionally substituted with --CH 2 OCH 3 ;
A is CH 2 , O, S(O) n , N(C(═O)R 17 ), N(R 19 ), C(H)(OR 20 ), NR 25 , or C(═O);
R 8 is independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 6 alkyl, C 3 -C 6 cycloalkyl, (CH 2 ) t R 22 , --NR 6 R 7 , --NR 16 (CH 2 O n NR 6 R 7 , and --(CH 2 ) k R 25 ,
R 9 is C 1 -C 4 alkyl;
R 14 and R 15 are independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 2 alkyl, C 3 -C 6 cycloalkyl, and C 4 -C 6 cycloalkyl-alkyl;
R 16 is hydrogen;
R 19 is C 1 -C 3 alkyl;
R 20 is independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 2 alkyl, and C 2 -C 3 alkenyl;
R 22 is independently selected at each occurrence from the group consisting of OR 24 , --S(O) n R 19 , and --C(═O)R 25 ;
R 25 and R 24 are independently selected at each occurrence from hydrogen and C 1 -C 2 alkyl;
R 25 , which can be optionally substituted with 0-3 R 17 , is independently selected at each occurrence from the group consisting of phenyl, pyrazolyl, imidazolyl, 2-methyl-3-pyridinyl, 4-methyl-3-pyridinyl, furanyl, 5-methyl-2-furanyl, 2,5-dimethyl-3-furanyl, 2-thienyl, 3-thienyl, 5-methyl-2-thienyl, 2-pheno-thiazinyl, 4-pyrazinyl, 1H-indazolyl, 2-pyrrolidonyl, 2H-pyrrolyl, 3H-indolyl, 4-piperidonyl, 4aH-carbazolyl, 4H-quinolizinyl, azocinyl, cinnolinyl, decahydroquinolinyl, furazanyl, indolinyl, indolizinyl, indolyl, isoindolinyl, isoindolyl, isoquinolinyl (benzimidazolyl), isothiazolyl, isoxazolyl, morpholinyl, naphthyridinyl, octahydroisoquinolinyl, oxazolidinyl, oxazolyl, piperazinyl, piperidinyl, pteridinyl, purinyl, pyranyl, pyrazolidinyl, pyridazinyl, pyridyl, pyrimidinyl, pyrrolidinyl, pyrrolinyl, pyrrolyl, quinazolinyl, quinolinyl, quinoxalinyl, quinuclidinyl, tetrahydrofuranyl, tetrazolyl, thiazolyl, triazinyl; and 1-tetrahydroquinolinyl or 2-tetrahydroisoquinolinyl either of which can be substituted with 0-3 groups chosen from keto and C 1 -C 4 alkyl;
R 25a , which can be optionally substituted with 0-3 R 17 , is independently selected at each occurrence from the group consisting of H, phenyl, pyrazolyl, imidazolyl, 2-methyl-3-pyridinyl, 4-methyl-3-pyridinyl, furanyl, 5-methyl-2-furanyl, 2,5-dimethyl-3-furanyl, 2-thienyl, 3-thienyl, 5-methyl-2-thienyl, 2-pheno-thiazinyl, 4-pyrazinyl, 1H-indazolyl, 2-pyrrolidonyl, 2H-pyrrolyl, 3H-indolyl, 4H-quinolizinyl, azocinyl, cinnolinyl, decahydroquinolinyl, furazanyl, indolinyl, indolizinyl, indolyl, isobenzofuranyl, isoindolinyl, isoindolyl, isoquinolinyl, benzimidazolyl, isothiazolyl, isoxazolyl, morpholinyl, naphthyridinyl, octahydroisoquinolinyl, oxazolindinyl, oxazolyl, piperazinyl, piperidinyl, pyranyl, pyrazolidinyl, pyridazinyl, pyridyl, pyrimidinyl, pyrrolidinyl, pyrrolinyl, pyrrolyl, quinazolinyl, quinolinyl, quinoxalinyl, β-carbolinyl, tetrahydrofuranyl, tetrazolyl, thiazolyl, triazinyl; and 1-tetrahydroquinolinyl or 2-tetrahydroisoquinolinyl either of which can be substituted with 0-3 groups chosen from keto and C 1 -C 4 alkyl;
k is 1-3;
p and q are 0-2; and
r is 1-2.
Other more preferred compounds of this invention are those compounds of Formula I wherein, when Y is CR 29 :
R 1 is methyl;
R 3 is C 1 -C 2 alkyl, NR 6 R 7 , OR 8 , SR 8 , C 1 -C 2 alkyl or aryl substituted with R 27 , halogen, or is N-linked piperidinyl, piperazinyl, morpholino, thiomorpholino, imidazolyl, or is 2-pyridinyl, 3-pyridinyl, 4-pyridinyl, where substitution by R 27 can occur on any carbon containing substituent;
X is Br, I, S(O) n R 8 , OR 8 , NR 14 R 15 , or alkyl substituted with R 5 ;
X' is hydrogen, Br, I, S(O) n R 8 , OR 8 , NR 14 R 15 , or alkyl substituted with R 5 ;
R 5 is halogen, C 1 -C 2 alkyl, C 1 -C 2 alkoxy, or --NR 14 R 15 ;
R 6 and R 7 are independently selected at each occurrence from the group consisting of hydrogen and C 1 -C 2 alkyl, or, when considered with the commonly attached nitrogen, can be taken together to form piperidine, piperazine, morpholine or thiomorpholine;
R 8 is independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 2 alkyl, and aryl optionally substituted with 1-2 groups selected from hydrogen, C 1 -C 2 alkyl, C 1 -C 2 alkoxy, NHC(═O)(C 1 -C 2 alkyl), NH(C 1 -C 2 alkyl), and N(C 1 -C 2 alkyl) 2 ;
R 14 and R 15 are independently selected at each occurrence from the group consisting of hydrogen and C 1 -C 2 alkyl; and
R 30 is hydrogen or cyano.
The following compounds are specifically preferred:
N-(2,4-dimethoxyphenyl)-N-methyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromophenyl)-N-allyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-methyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-4-methylphenyl)-N-methyl-4-morpholino-6-methyl-2-pyrimidinamine;
N-(2,4-dimethoxyphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2,4-dibromophenyl)-N-methyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-4-ethylphenyl)-N-methyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-4-tert-butylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-4-tert-butylphenyl)-N-methyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-4-trifluromethylphenyl)-N-methyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-4-trifluoromethylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2,4,6-trimethoxyphenyl)-N-methyl-4,6-dimethyl-2-pyrimidinamine;
N-(2,4,6-trimethoxyphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-morpholino-6-methyl-2-pyrimidinamine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-allyl-4-morpholino-6-methyl-2-pyrimidinamine;
N-(2-bromo-4-n-butylphenyl)-N-allyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-4-n-butylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-4-n-butylphenyl)-N-propyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-4-cyclohexylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4,6-diethyl-2-pyrimidinamine;
N-(2-bromo-4-n-butylphenyl)-N-ethyl-4,6-diethyl-2-pyrimidinamine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(4-formyl-piperazino)-6-methyl-2-pyrimidinamine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-allyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-iodo-4-(1-methylethyl)phenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-methyl-6-trifluoromethyl-2-pyrimidinamine;
N-(2-bromo-4-methoxyethyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-iodo-4-(1-methylethyl)phenyl)-N-ethyl-4-morpholino-6-methyl-2-pyrimidinamine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-methyl-6-(2-thiopheno)-2-pyrimidinamine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-cyanomethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-cyclopropylmethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-propargyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-iodo-4-(1-methylethyl)phenyl)-N-ethyl-4-thiomorpholino-6-methyl-2-pyrimidinamine;
N-(2-iodo-4-methoxyethylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-iodo-4-methoxymethylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-iodo-4-methoxyethylphenyl)-N-ethyl-4-morpholino-6-methyl-2-pyrimidinamine;
N-(2-iodo-4-methoxymethylphenyl)-N-ethyl-4-morpholino-6-methyl-2-pyrimidinamine;
N-(2-methylthio-4-methoxymethylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-dimethylamino-4-methoxymethylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-methylthio-4-methoxymethylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-methylthio-4-(1-methylethyl)phenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-dimethylamino-4-(1-methylethyl)phenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2,4-dimethylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-methylthio-4-methylthiomethylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2,6-dibromo-4-(1-methylethyl)phenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2,6-dibromo-4-(1-methylethyl)phenyl)-N-ethyl-4-methyl-6-thiomorpholino-2-pyrimidinamine;
N-(2,4-diiodophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2,4-diiodophenyl)-N-ethyl-4-morpholino-6-methyl-2-pyrimidinamine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-methyl-2-pyrimidinamine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-methyl-6-(N-methyl-2-hydroxyethylamino)-2-pyrimidinamine;
N-(2,6-dimethoxy-4-methylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(4-iodophenyl)-N-methyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-iodophenyl)-N-methyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-trifluoromethylphenyl)-N-methyl-4,6-dimethyl-2-pyrimidinamine;
4,6-dimethyl-2-(N-(2-bromo-4-(1-methylethyl)phenyl)-N-methylamino)pyridine;
4,6-dimethyl-2-(N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethylamino)pyridine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-2,4-dimethoxy-6-pyrimidinamine;
2,6-dimethyl-4-(N-(2-bromo-4-(1-methylethyl)phenyl)amino)pyridine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-6-methyl-4-(4-morpholinylcarbonyl)-2-pyrimidinamine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-6-methyl-4-(morpholinylmethyl)-2-pyrimidinamine;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-6-methyl-4-(1-piperidinylcarbonyl)-2-pyrimidinamine;
Methyl 2-((2-bromo-4-(1-methylethyl)phenyl)ethylamino)-6-methyl-4-pyrimidinecarboxylate;
2-((2-bromo-4-(1-methylethyl)phenyl)ethylamino)-N-cyclohexyl-6-methyl-4-pyrimidinecarboxamide;
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-6-methyl-4-(4-methyl-1-piperazinylcarbonyl)-2-pyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4,6-dimethyl-1,3,5-triazin-2-amine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-methyl-6-(4-morpholinyl)-1,3,5-triazin-2-amine;
N-ethyl-N-{2-iodo-4-(1-methylethyl)phenyl}-4-methyl-6-(4-thiomorpholinyl)-1,3,5-triazin-2-amine;
N-ethyl-N-{2-iodo-4-(1-methylethyl)phenyl}-4-methyl-6-(4-morpholinyl)-1,3,5-triazin-2-amine;
N-ethyl-N-{2-iodo-4-(1-methylethyl)phenyl}-4-methyl-6-(1-piperidinyl)-1,3,5-triazin-2-amine;
1-(2-bromo-4-isopropylphenyl)-4,6-dimethyl-7-azaindole;
1-(2-bromo-4-isopropylphenyl)-3-cyano-4,6-dimethyl-7-azaindole;
1-(2-bromo-4-isopropylphenyl)-3-cyano-4-phenyl-6-methyl-7-azaindole;
1-(2-bromo-4-isopropylphenyl)-4-phenyl-6-methyl-7-azaindole;
1-(2-bromo-4,6-dimethoxyphenyl)-3-cyano-4,6-dimethyl-7-azaindole;
1-(2-bromo-4,6-dimethoxyphenyl)-4,6-dimethyl-7-azaindole;
N-{2-bromo-4(1-methylethyl)phenyl}-N-ethyl-4-N,N-diethylamino-6-methyl-1,3,5 triazin-2-amine;
N-{2-bromo-4(1-methylethyl)phenyl}-N-ethyl-4,6-dichloro-1,3,5 triazin-2-amine;
N-{2-bromo-4(1-methylethyl)phenyl}-N-ethyl-4,6-dimethoxy-1,3,5 triazin-2-amine;
N-{2-bromo-4(1-methylethyl)phenyl}-N-ethyl-4-imidazolino-6-methyl-1,3,5 triazin-2-amine;
N-(2-bromo-4,6-dimethoxyphenyl)-N-ethyl-4-morpholino-6-methyl-1,3,5 triazin-2-amine;
N-(2-bromo-4,6-dimethoxyphenyl)-N-ethyl-4-N,N-dimethylamino-6-methyl-1,3,5 triazin-2-amine;
N-(2,4,6-trimethoxyphenyl)-N-ethyl-4-morpholino-6-methyl-1,3,5 triazin-2-amine;
N-{2-bromo-4(1-methylethyl)phenyl}-N-ethyl-4-N,N-dimethylamino-6-methyl-1,3,5 triazin-2-amine;
N-{2-bromo-4(1-methylethyl)phenyl}-N-ethyl-4-thiozolidino-6-methyl-1,3,5 triazin-2-amine;
N-{2-bromo-4(1-methylethyl)phenyl}-N-ethyl-4-benzyloxy-6-methyl-1,3,5 triazin-2-amine;
N-{2-bromo-4(1-methylethyl)phenyl}-N-ethyl-4-phenyloxy-6-methyl-1,3,5 triazin-2-amine;
N-(2-bromo-4,6-dimethoxyphenyl)-N-ethyl-4-{4-(ethylpiperizinoate)}-6-methyl-1,3,5 triazin-2-amine;
N-2-bromo-4,6-dimethoxyphenyl)-N-ethyl-4-{4-(piperizinic acid)}-6-methyl-1,3,5 triazin-2-amine;
N-{2-bromo-4(1-methylethyl)phenyl}-N-ethyl-4-{3-(malon-2-yl diethyl ester)}-6-methyl-1,3,5-triazin-2-amine;
N-(2-bromo-4,6-dimethoxyphenyl)-N-ethyl-4-(1-cyano-1-phenylmethyl)-6-methyl-1,3,5 triazin-2-amine;
N-(2-bromo-4,6-dimethoxyphenyl)-N-1-methylethyl-4-morpholino-6-methyl-1,3,5 triazin-2-amine;
N-(2-iodo-4-dimethylhydroxymethylphenyl)-N-ethyl-4,6-dichloro-1,3,5 triazin-2-amine;
N-{2-bromo-4(1-methylethyl)phenyl}-N-ethyl-4-methyl-6-(thiomethyl)-2-pyrimidinamine;
N-{2-bromo-4(1-methylethyl)phenyl}-N-ethyl-4-methyl-6-(thiomethyl)-2-pyrimidinamine, S-dioxide;
N-{2-bromo-4(1-methylethyl)phenyl}-N-ethyl-4-methyl-6-(thiomethyl)-2-pyrimidinamine, S-oxide;
N-{2-bromo-4(1-methylethyl)phenyl}-N-ethyl-4-methyl-6-benzyloxy-1,3,5 triazin-2-amine;
N-(2-iodo-4-dimethylhydroxymethyl)-N-ethyl-4,6-dichloro-1,3,5 triazin-2-amine;
N-{2-iodo-4-(1-methylethyl)phenyl}-N-allyl-4-morpholino-6-methyl-2-pyrimidinamine;
N-{2-iodo-4-(1-methylethyl)phenyl}-N-ethyl-4-chloro-6-methyl-2-pyrimidinamine;
N-{2-methylthio-4-(1-methylethyl)phenyl}-N-ethyl-4(S)-(N-methyl-2'-pyrrolidinomethoxy)-6-methyl-2-pyrimidinamine;
N-{2,6-dibromo-4-(1-methylethyl)phenyl}-4-thiomorpholino-6-methyl-2-pyrimidinamine;
N-{2-methylthio-4-(1-methylethyl)phenyl}-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-{2-methylthio-4-(1-methylethyl)phenyl}-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-{2-methylsulfinyl-4-(1-methylethyl)phenyl}-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-{2-iodo-4-(1-methylethyl)phenyl}-N-ethyl-4-thiazolidino-6-methyl-2-pyrimidinamine;
N-(2-iodo-4-methoxymethylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(4,6-dimethyl-2-pyrimidinamino)-2,3,4,5-tetrahydro-4-(1-methylethyl)-1,5-benzothiazepine;
N-{2-methylsulfonyl-4-(1-methylethyl)phenyl}-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-{2ethylthio-4-(1-methylethyl)phenyl}-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-ethylthio-4-methoxyiminoethylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-methylthio-4-methoxyiminoethylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-methylsulfonyl-4-methoxyiminoethylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(4-bromo-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(4-ethyl-2-methylthiophenyl)-N-(1-methylethyl)-4,6-dimethyl-2-pyrimidinamine;
N-(4-ethyl-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-{2-methylthio-4-(N-acetyl-N-methylamino)phenyl}-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(4-carboethoxy-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(4-methoxy-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(4-cyano-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(4-acetyl-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(4-propionyl-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-{4-(1-methoxyethyl)-2-methylthiophenyl}-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-{4-(N-methylamino)-2-methylthiophenyl}-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-{4-(N,N-dimethylamino)-2-methylthiophenyl}-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-formyl-6-methyl-2-pyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-hydroxyethoxymethyl-6-methyl-2-pyrimidinamine;
N-(2-bromo-6-hydroxy-4-methoxyphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(3-bromo-4,6-dimethoxyphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2,3-dibromo-4,6-dimethoxyphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2,6-dibromo-4-(ethoxy)phenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
1-(2-bromo-4-isopropylphenyl)-3-cyano-4,6-dimethyl-7-azaindole;
1-(2-bromo-4-isopropylphenyl)-4,6-dimethyl-7-azaindole;
1-(2-bromo-4-isopropylphenyl)-3-cyano-6-methyl-4-phenyl-7-azaindole;
1-(2-bromo-4-isopropylphenyl)-6-methyl-4-phenyl-7-azaindole;
1-(2-bromo-4,6-dimethoxyphenyl)-3-cyano-4,6-dimethyl-7-azaindole;
1-(2-bromo-4,6-dimethoxyphenyl)-4,6-dimethyl-7-azaindole;
1-(2-bromo-4-isopropylphenyl)-6-chloro-3-cyano-4-methyl-7-azaindole;
1-(2-bromo-4-isopropylphenyl)-6-chloro-4-methyl-7-azaindole;
1-(2-bromo-4-isopropylphenyl)-4-chloro-3-cyano-6-methyl-7-azaindole;
1-(2-bromo-4-isopropylphenyl)-4-chloro-6-methyl-7-azaindole;
N-(2-bromo-6-methoxy-pyridin-3-yl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(3-bromo-5-methyl-pyridin-2-yl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(6-methoxy-pyridin-3-yl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine;
N-(2-bromo-6-methoxy-pyridin-3-yl)-N-ethyl-4-methyl-6-(4-morpholinyl)-1,3,5 triazin-2-amine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-{N-(2-furylmethyl)-N-methylamino}carbonyl-6-methylpyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-{(4,4-ethylenedioxypiperidino)carbonyl}-6-methylpyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-(4-oxopiperidino)carbonyl-6-methylpyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-(4-oxopiperidino)methyl-6-methylpyrimidinamine, hydrochloride salt;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-(imidazol-1-yl)methyl-6-methylpyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-{3-methoxyphenyl)methoxymethyl}-6-methylpyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-(2-thiazolyl)carbonyl-6-methylpyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-(2-imidazolyl)carbonyl-6-methylpyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-(5-indolylcarbonyl)-6-methylpyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-(4-fluorophenyl)carbonyl-6-methylpyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-carboxy-6-methylpyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-acetyl-6-methylpyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-(hydroxy-3-pyridylmethyl)-6-methylpyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-{4-(methoxyphenyl)-3-pyridyl-hydroxymethyl}-6-methylpyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-(3-pyrazolyl)-6-methylpyrimidinamine, hydrochloride salt;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-(1-aminoethyl)-6-methylpyrimidinamine;
N-{2-bromo-4-(1-methylethyl)phenyl}-N-ethyl-4-{2-(4-tetrazolyl)-1-methylethyl}-6-methylpyrimidinamine;
2-(N-{2-bromo-4-(2-propyl)phenyl}amino)-4-carbomethoxy-6-methylpyrimidine;
2-(N-{2-bromo-4-(2-propyl)phenyl}-N-ethylamino)-4-carbomethoxy-6-methylpyrimidine;
2-(N-{2-bromo-4-(2-propyl)phenyl}-N-ethylamino)-6-methylpyrimidine-4-morpholinocarbonyl;
9{2-bromo-4-(2-propyl)phenyl}-2-methyl-6-morpholino purine;
9{2-bromo-4-(2-propyl)phenyl}-2-methyl-6-morpholino-8-azapurine;
1{2-bromo-4-(2-propyl)phenyl}-2-methyl-6-morpholino-5,7-diazaindazole; and
2-(N-{2-bromo-4-(2-propyl)phenyl}-N-ethylamino)-4-(morpholinomethyl)-6-methylpyrimidine.
The above-described compounds and their corresponding salts possess antagonistic activity for the corticotropin releasing factor receptor and can be used for treating affective disorders, anxiety, depression, irritable bowel syndrome, immune suppression, Alzheimer's disease, gastrointestinal diseases, anorexia nervosa, drug and alcohol withdrawal symptoms, drug addition, inflammatory disorders, or fertility problems in mammals.
Further included in this invention is a method of treating affective disorders, anxiety, depression, irritable bowel syndrome, immune suppression, Alzheimer's disease, gastrointestinal diseases, anorexia nervosa, drug and alcohol withdrawal symptoms, drug addiction, inflammatory disorders, or fertility problems in mammals in need of such treatment comprising administering to the mammal a therapeutically effective amount of a compound of formula (I): ##STR13## or a pharmaceutically acceptable salt or prodrug thereof, wherein Y is CR 3a , N, or CR 29 ;
when Y is CR 3a or N:
R 1 is independently selected at each occurrence from the group consisting of C 1 -C 4 alkyl, halogen, C 1 -C 2 haloalkyl, NR 6 R 7 , OR 8 , and S(O) n R 8 ;
R 3 is C 1 -C 4 alkyl, aryl, C 3 -C 6 cycloalkyl, C 1 -C 2 haloalkyl, halogen, nitro, NR 6 R 7 , OR 8 , S(O) n R 8 , C(═O)R 9 , C(═O)NR 6 R 7 , C(═S)NR 6 R 7 , --(CHR 16 ) k NR 6 R 7 , (CH 2 ) k OR 8 , C(═O)NR 10 CH(R 11 )CO 2 R 12 , --C(OH)(R 25 )(R 25a ), --(CH 2 ) p S(O) n -alkyl, --(CHR 16 )R 25 , --C(CN)(R 25 )(R 16 ) provided that R 25 is not --NH-- containing rings, --C(═O)R 25 , --CH(CO 2 R 16 ) 2 , NR 10 C(═O)CH(R 11 )NR 10 R 12 , NR 10 CH(R 11 )CO 2 R 12 ; substituted C 1 -C 4 alkyl, substituted C 2 -C 4 alkenyl, substituted C 2 -C 4 alkynyl, substituted C 1 -C 4 alkoxy, aryl-(substituted C 1 -C 4 ) alkyl, aryl-(substituted C 1 -C 4 ) alkoxy, substituted C 3 -C 6 cycloalkyl, amino-(substituted C 1 -C 4 ) alkyl, substituted C 1 -C 4 alkylamino, where substitution by R 27 can occur on any carbon containing substituent; 2-pyridinyl, imidazolyl, 3-pyridinyl, 4-pyridinyl,2-methyl-3-pyridinyl, 4-methyl-3-pyridinyl, furanyl, 5-methyl-2-furanyl, 2,5-dimethyl-3-furanyl, 2-thienyl, 3-thienyl, 5-methyl-2-thienyl, 2-pheno-thiazinyl, 4-pyrazinyl, azetidinyl, phenyl, 1H-indazolyl, 2-pyrrolidonyl, 2H,6H-1,5,2-dithiazinyl, 2H-pyrrolyl, 3H-indolyl, 4-piperidonyl, 4aH-carbazolyl, 4H-quinolizinyl, 6H-1,2,5-thiadiazinyl, acridinyl, azocinyl, azepinyl, benzofuranyl, benzothiophenyl, carbazolyl, chromanyl, chromenyl, cinnolinyl, decahydroquinolinyl, furazanyl, imidazolidinyl, indolinyl, indolizinyl, indolyl, isobenzofuranyl, isochromanyl, isoindolinyl, isoindolyl, isoquinolinyl benzimidazolyl, isothiazolyl, isoxazolyl, morpholinyl, naphthyridinyl, octahydroisoquinolinyl, oxazolidinyl, oxazolyl, phenanthridinyl, phenanthrolinyl, phenazinyl, phenoxathiinyl, phenoxazinyl, phthalazinyl, piperazinyl, piperidinyl, pteridinyl, purinyl, pyranyl, pyrazolidinyl, pyrazolinyl, pyrazolyl, pyridazinyl, pyrimidinyl, pyrrolidinyl, pyrrolinyl, pyrrolyl, quinazolinyl, quinolinyl, quinoxalinyl, quinuclidinyl, β-carbolinyl, tetrahydrofuranyl, tetrahydroisoquinolinyl, tetrahydroquinolinyl, tetrazolyl, thianthrenyl, thiazolyl, thiophenyl, triazinyl, xanthenyl; or 1-tetrahydroquinolinyl or 2-tetrahydroisoquinolinyl either of which can be substituted with 0-3 groups chosen from keto and C 1 -C 4 alkyl;
J, K, and L are independently selected at each occurrence from the group of N, CH, and CX';
M is CR 5 or N;
V is CR 1a or N;
Z is CR 2 or N;
R 1a , R 2 , and R 3a are independently selected at each occurrence from the group consisting of hydrogen, halo, halomethyl, C 1 -C 3 alkyl, and cyano;
R 4 is (CH 2 ) m OR 16 , C 1 -C 4 alkyl, allyl, propargyl, (CH 2 ) m R 13 , or --(CH 2 ) m OC(O)R 16 ;
X is halogen, S(O) 2 R 8 , SR 8 , halomethyl, --(CH 2 ) p OR 8 , --OR 8 , cyano, --(CHR 16 ) p NR 14 R 15 , --C(═O)R 8 , C 1 -C 6 alkyl, C 4 -C 10 cycloalkylalkyl, C 1 -C 10 alkenyl, C 2 -C 10 alkynyl, C 1 -C 10 alkoxy, aryl-(C 2 -C 10 )-alkyl, C 3 -C 6 cycloalkyl, aryl-(C 1 -C 10 )-alkoxy, nitro, thio-(C 1 -C 10 )-alkyl, --C(═NOR 16 )-C 1 -C 4 -alkyl, --C(═NOR 16 )H, or --C(═O)NR 14 R 15 where substitution by R 18 can occur on any carbon containing substituents;
X' is independently selected at each occurrence from the group consisting of hydrogen, halogen, S(O) n R 8 , halomethyl, --(CHR 16 ) p OR 8 , cyano, --(CHR 16 ) p NR 14 R 15 , C(═O)R 8 , C 1 -C 6 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 1 -C 10 alkoxy, aryl-(C 1 -C 10 )-alkyl, C 3 -C 6 cycloalkyl, aryl-(C 1 -C 10 )-alkoxy, nitro, thio-(C 1 -C 10 )-alkyl, --C(═NOR 16 )-C 1 -C 4 -alkyl, --C(═NOR 16 )H, and --C(═O)NR 14 R 15 where substitution by R 18 can occur on any carbon containing substituents;
R 5 is halo, --C(═NOR 16 )-C 1 -C 4 -alkyl, C 1 -C 6 alkyl, C 1 -C 3 haloalkyl, --(CHR 16 ) p OR 8 , --(CHR 16 ) p S(O) n R 8 ,--(CHR 16 ) p NR 14 R 15 ,C 3 -C 6 cycloalkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, aryl-(C 2 -C 10 )-akyl, aryl-(C 1 -C 10 )-alkoxy, cyano, C 3 -C 6 cycloalkoxy, nitro, amino-(C 2 -C 10 )-alkyl, thio-(C 2 -C 10 )-alkyl, SO n (R 8 ), C(═O)R 8 , --C(═NOR 16 )H, or --C(═O)NR 14 R 15 , where substitution by R 18 can occur on any carbon containing substituents;
R 6 and R 7 are independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 6 alkyl, C 3 -C 10 cycloalkyl, C 1 -C 6 alkoxy, (C 4 -C 12 )-cycloalkylalkyl, --(CH 2 ) k R 13 , (CHR 16 ) p OR 8 ,--(C 1 -C 6 alkyl)-aryl, heteroaryl, aryl, --S(O) z -aryl or --(C 1 -C 6 alkyl)-heteroaryl or aryl wherein the aryl or heteroaryl groups are optionally substituted with 1-3 groups selected from the group consisting of hydrogen, halogen, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, amino, NHC(═O)(C 1 -C 6 alkyl), NH(C 1 -C 6 alkyl), N(C 1 -C 6 alkyl) 2 , nitro, carboxy, CO 2 (C 1 -C 6 alkyl), cyano, and S(O) z --(C 1 -C 6 -alkyl); or can be taken together to form --(CH 2 ) q A(CH 2 ) r --, optionally substituted with 0-3 R 17 ; or, when considered with the commonly attached nitrogen, can be taken together to form a heterocycle, said heterocycle being substituted on carbon with 1-3 groups consisting of hydrogen, C 1 -C 6 alkyl, hydroxy, or C 1 -C 6 alkoxy;
A is CH 2 , O, NR 25 , C(═O), S(O) n , N(C(═O)R 17 ), N(R 19 ), C(H)(NR 14 R 15 ), C(H)(OR 20 ), C(H)(C(═O)R 21 ), or N(S(O) n R 21 );
R 8 is independently selected at each occurrence from the group consisting of hydrogen; C 1 -C 6 alkyl; --(C 4 -C 12 ) cycloalkylalkyl; (CH 2 ) t R 22 ; C 3 -C 10 cycloalkyl; --NR 6 R 7 ; aryl; --NR 16 (CH 2 ) n NR 6 R 7 ; --(CH 2 ) k R 25 ; and (CH 2 ) t heteroaryl or (CH 2 ) t aryl, either of which can optionally be substituted with 1-3 groups selected from the group consisting of hydrogen, halogen, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, amino, NHC(═O)(C 1 -C 6 alkyl), NH(C 1 -C 6 alkyl), N(C 1 -C 6 alkyl) 2 , nitro, carboxy, CO 2 (C 1 -C 6 alkyl), cyano, and S(O) z (C 1 -C 6 -alkyl);
R 9 is independently selected at each occurrence from R 10 , hydroxy, C 1 -C 4 alkoxy, C 3 -C 6 cycloalkyl, C 2 -C 4 alkenyl, aryl substituted with 0-3 R 18 , and --(C 1 -C 6 alkyl)-aryl substituted with 0-3 R 18 ;
R 10 , R 16 , R 23 , and R 24 are independently selected at each occurrence from hydrogen or C 1 -C 4 alkyl;
R 11 is C 1 -C 4 alkyl substituted with 0-3 groups chosen from the following:
keto, amino, sulfhydryl, hydroxyl, guanidinyl, p-hydroxyphenyl, imidazolyl, phenyl, indolyl, indolinyl,
or, when taken together with an adjacent R 10 , are (CH 2 ) t ;
R 12 is hydrogen or an appropriate amine protecting group for nitrogen or an appropriate carboxylic acid protecting group for carboxyl;
R 13 is independently selected at each occurrence from the group consisting of CN, OR 19 , SR 19 , and C 3 -C 6 cycloalkyl;
R 14 and R 15 are independently selected at each occurrence from the group consisting of hydrogen, C 4 -C 10 cycloalkyl-alkyl, and R 19 ;
R 17 is independently selected at each occurrence from the group consisting of R 10 , C 1 -C 4 alkoxy, halo, OR 23 , SR 23 , NR 23 R 24 , and (C 1 -C 6 )alkyl (C 1 -C 4 ) alkoxy;
R 18 is independently selected at each occurrence from the group consisting of R 10 , hydroxy, halogen, C 1 -C 2 haloalkyl, C 1 -C 4 alkoxy, C(═O)R 24 , and cyano;
R 19 is independently selected at each occurrence from the group consisting of C 1 -C 6 alkyl, C 3 -C 6 cycloalkyl, (CH 2 ) w R 22 , and aryl substituted with 0-3 R 18 ;
R 20 is independently selected at each occurrence from the group consisting of R 10 , C(═O)R 31 , and C 2 -C 4 alkenyl;
R 21 is independently selected at each occurrence from the group consisting of R 10 , C 1 -C 4 - alkoxy, NR 23 R 24 , and hydroxyl;
R 22 is independently selected at each occurrence from the group consisting of cyano, OR 24 , SR 24 , NR 23 R 24 , C 1 -C 6 alkyl, C 3 -C 6 cycloalkyl, --S(O) n R 31 , and --C(═O)R 25 ;
R 25 , which can be optionally substituted with 0-3 R 17 , is independently selected at each occurrence from the group consisting of phenyl, pyrazolyl, imidazolyl, 2-methyl-3-pyridinyl, 4-methyl-3-pyridinyl, furanyl, 5-methyl-2-furanyl, 2,5-dimethyl-3-furanyl, 2-thienyl, 3-thienyl, 5-methyl-2-thienyl, 2-pheno-thiazinyl, 4-pyrazinyl, azetidinyl, 1H-indazolyl, 2-pyrrolidonyl, 2H,6H-1,5,2-dithiazinyl, 2H-pyrrolyl, 3H-indolyl, 4-piperidonyl, 4aH-carbazolyl, 4H-quinolizinyl, 6H-1,2,5-thiadiazinyl, acridinyl, azocinyl, azepinyl, benzofuranyl, benzothiophenyl, carbazolyl, chromanyl, chromenyl, cinnolinyl, decahydroquinolinyl, furazanyl, indolinyl, indolizinyl, indolyl, isobenzofuranyl, isochromanyl, isoindolinyl, isoindolyl, isoquinolinyl benzimidazolyl, isothiazolyl, isoxazolyl, morpholinyl, naphthyridinyl, octahydroisoquinolinyl, oxazolidinyl, oxazolyl, phenanthridinyl, phenanthrolinyl, phenazinyl, phenothiazinyl, phenoxathiinyl, phenoxazinyl, phthalazinyl, piperazinyl, piperidinyl, pteridinyl, purinyl, pyranyl, pyrazolidinyl, pyridazinyl, pyridyl, pyrimidinyl, pyrrolidinyl, pyrrolinyl, pyrrolyl, quinazolinyl, quinolinyl, quinoxalinyl, quinuclidinyl, β-carbolinyl, tetrahydrofuranyl, tetrazolyl, thianthrenyl, thiazolyl, thiophenyl, triazinyl, xanthenyl; and 1-tetrahydroquinolinyl or 2-tetrahydroisoquinolinyl either of which can be substituted with 0-3 groups chosen from keto and C 1 -C 4 alkyl;
R 25a , which can be optionally substituted with 0-3 R 17 , is independently selected at each occurrence from the group consisting of H and R 25 ;
R 27 is independently selected at each occurrence from the group consisting of C 1 -C 3 alkyl, C 2 -C 4 alkenyl, C 2 -C 4 alkynyl, C 2 -C 4 alkoxy, aryl, nitro, cyano, halogen, aryloxy, and heterocycle optionally linked through O;
R 31 is independently selected at each occurrence from the group consisting of C 1 -C 4 alkyl, C 3 -C 7 cycloalkyl, C 4 -C 10 cycloalkyl-alkyl, and aryl-(C 1 -C 4 ) alkyl;
k, m, and r are independently selected at each occurrence from 1-4;
n is independently selected at each occurrence from 0-2;
p, q, and z are independently selected at each occurrence from 0-3;
t and w are independently selected at each occurrence from 1-6,
provided that when J is CX' and K and L are both CH, and M is CR 5 , then
(A) when V and Y are N and Z is CH and R 1 and R 3 are methyl,
(1) and R 4 is methyl, then
(a) R 5 can not be methyl when X is OH and X' is H;
(b) R 5 can not be --NHCH 3 or --N(CH 3 ) 2 when X and X' are --OCH 3 ; and
(c) R 5 can not be --N(CH 3 ) 2 when X and X' are --OCH 2 CH 3 ;
(2) and R 4 is ethyl, then
(a) then R 5 can not be methylamine when X and X' are --OCH 3 ;
(b) R 5 can not be OH when X is Br and X' is OH; and
(c) R 5 can not be --CH 2 OH or --CH 2 N(CH 3 ) 2 when X is --SCH3 and X' is H;
(B) when V and Y are N, Z is CH, R 4 is ethyl, R 5 is iso-propyl, X is Br, X' is H, and
(1) R 1 is CH 3 , then
(a) R 3 can not be OH, piperazin-1-yl, --CH 2 -piperidin-1-yl, --CH 2 --(N-4-methylpiperazin-1-yl), --C(O)NH-phenyl, --CO 2 H, --CH 2 O-(4-pyridyl), --C(O)NH 2 , 2-indolyl, --CH 2 O-(4-carboxyphenyl), --N(CH 2 CH 3 )(2-bromo-4-isopropylphenyl);
(2) R 1 is --CH 2 CH 2 CH 3 then R 3 can not be --CH 2 CH 2 CH 3 ;
(C) when V, Y and Z are N, R 4 is ethyl, and
(1) R 5 is iso-propyl, X is bromo, and X' is H, then
(a) R 3 can not be OH or --OCH 2 CN when R 1 is CH 3 ; and
(b) R 3 can not be --N(CH 3 ) 2 when R 1 is --N(CH 3 ) 2 ;
(2) R 5 is --OCH 3 , X is --OCH 3 , and X' is H, then R 3 and R 1 can not both be chloro;
further provided that when J, K, and L are all CH and M is CR 5 , then
(D) at least one of V, Y, and Z must be N;
(E) when V is CR 1a , Z and Y can not both be N;
(F) when Y is CR 3a , Z and V can not both be N;
(G) when Z is CR 2 , V and Y must both be N;
(H) Z can be N only when both V and Y are N or when V is CR 1a and Y is CR 3a ;
(I) when V and Y are N, Z is CR 2 , and R 2 is H or C 1 -C 3 alkyl, and R 4 is C 1 -C 3 alkyl, R 3 can not be 2-pyridinyl, indolyl, indolinyl, imidazolyl, 3-pyridinyl, 4-pyridinyl, 2-methyl-3-pyridinyl, 4-methyl-3-pyridinyl, furanyl, 5-methyl-2-furanyl, 2,5-dimethyl-3-furanyl, 2-thienyl, 3-thienyl, 5-methyl-2-thienyl, 2-phenothiazinyl, or 4-pyrazinyl;
(J) when V and Y are N; Z is CR 2 ; R 2 is H or C 1 -C 3 alkyl; R 4 is C 1 -C 4 alkyl; R 5 , X, and/or X' are OH, halo, CF 3 , C 1 -C 4 alkyl, C 1 -C 4 alkoxy, C 1 -C 4 alkylthio, cyano, amino, carbamoyl, or
C 1 -C 4 alkanoyl; and R 1 is C 1 -C 4 alkyl, then R 3 can not be --NH(substituted phenyl) or --N(C 1 -C 4 alkyl) (substituted phenyl);
and wherein, when Y is CR 29 :
J, K, L, M, Z, A, k, m, n, p, q, r, t, w, R 3 , R 10 , R 11 , R 12 , R 13 , R 16 , R 18 , R 19 , R 21 , R 23 , R 24 , R 25 , and R 27 are as defined above and R 25a , in addition to being as defined above, can also be C 1 -C 4 alkyl, but
V is N;
R 1 is C 1 -C 2 alkyl, C 2 -C 4 alkenyl, C 2 -C 4 alkynyl, C 2 -C 4 alkoxy, halogen, amino, methylamino, dimethylamino, aminomethyl, or N-methylaminomethyl;
R 2 is independently selected at each occurrence from the group consisting of hydrogen, halo, C 1 -C 3 alkyl, nitro, amino, --CO 2 R 10 ;
R 4 is taken together with R 29 to form a 5-membered ring and is --C(R 28 )═ or --N═ when R 29 is --C(R 30 )═ or --N═, or --CH(R 28 )-- when R 29 is --CH(R 30 )--;
X is Cl, Br, I, S(O) n R 8 , OR 8 , halomethyl, --(CHR 16 ) p OR 8 , cyano, --(CHR 16 ) p NR 14 R 15 , C(═O)R 8 , C 1 -C 6 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 1 -C 10 alkoxy, aryl-(C 1 -C 10 )-alkyl, C 3 -C 6 cycloalkyl, aryl-(C 1 -C 10 )-alkoxy, nitro, thio-(C 1 -C 10 )-alkyl, --C(═NOR 16 )-C 1 -C 4 -alkyl, --C(═NOR 16 )H, or C(═O)NR 14 R 15 where substitution by R 18 can occur on any carbon containing substituents;
X' is hydrogen, Cl, Br, I, S(O) n R 8 , --(CHR 16 ) p OR 8 , halomethyl, cyano, --(CHR 16 ) p NR 14 R 15 , C(═O)R 8 , C 1 -C 6 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 1 -C 10 alkoxy, aryl-(C 1 -C 10 )-alkyl, C 3 -C 6 cycloalkyl, aryl-(C 2 -C 10 )-alkoxy, nitro, thio-(C 2 -C 10 )-alkyl, --C(═NOR 16 )-C 1 -C 4 -alkyl, --C(═NOR 16 )H, or C(═O)NR 8 R 15 where substitution by R 18 can occur on any carbon containing substituents;
R 5 is halo, --C(═NOR 16 )-C 1 -C 4 -alkyl, C 1 -C 6 alkyl, C1-C3 haloalkyl, C 1 -C 6 alkoxy, (CHR 16 ) p OR 8 , (CHR 16 ) p S(O) n R 8 , (CHR 16 ) p NR 14 R 15 , C 3 -C 6 cycloalkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, aryl-(C 2 -C 10 )-alkyl, aryl-(C 1 -C 10 )-alkoxy, cyano, C 3 -C 6 cycloalkoxy, nitro, amino-(C 1 -C 10 )-alkyl, thio-(C 1 -C 10 )-alkyl, SO n (R 8 ), C(═O)R 8 , --C(═NOR 16 )H, or C(═O)NR 8 R 15 where substitution by R 18 can occur on any carbon containing substituents;
R 6 and R 7 are independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 6 alkyl, C 3 -C 10 cycloalkyl, --(CH 2 ) k R 13 , (C 4 -C 12 )-cycloalkylalkyl, C 1 -C 6 alkoxy, --(C 1 -C 6 alkyl)-aryl, heteroaryl, aryl, --S(O) 2 -aryl, or --(C 1 -C 6 alkyl)-heteroaryl or aryl wherein the ary or heteroaryl groups are optionally substituted with 1-3 groups selected from hydrogen, halogen, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, amino, NHC(═O)(C 1 -C 6 alkyl), NH(C 1 -C 6 alkyl), N(C 1 -C 6 alkyl) 2 , nitro, carboxy, CO 2 (C 1 -C 6 alkyl), and cyano; or can be taken together to form --(CH 2 ) q A(CH 2 ) r --, optionally substituted with 0-3 R 17 ; or, when considered with the commonly attached nitrogen, can be taken together to form a heterocycle, said heterocycle being substituted on carbon with 1-3 groups consisting of hydrogen, C 1 -C 6 alkyl, hydroxy, or C 1 -C 6 alkoxy;
R 8 is independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 6 alkyl, --(C 4 -C 12 ) cycloalkylalkyl, (CH 2 ) t R 22 , C 3 -C 10 cycloalkyl, --(C 1 -C 6 alkyl)-aryl, heteroaryl, --NR 16 , --N(CH 2 ) n NR 6 R 7 ; --(CH 2 ) k R 25 , --(C 1 -C 6 alkyl)-heteroaryl or aryl optionally substituted with 1-3 groups selected from hydrogen, halogen, C 1 -C 6 alkyl, C 1 -C 6 alkoxy, amino, NHC(═O)(C 1 -C 6 alkyl), NH(C 1 -C 6 alkyl), N(C 1 -C 6 alkyl) 2 , nitro, carboxy, CO 2 (C 1 -C 6 alkyl), and cyano;
R 9 is independently selected at each occurrence from R 10 , hydroxy, C 1 -C 4 alkoxy, C 3 -C 6 cycloalkyl, C 2 -C 4 alkenyl, and aryl substituted with 0-3 R 18 ;
R 14 and R 15 are independently selected at each occurrence from the group consisting of hydrogen, C 1 -C 6 alkyl, C 3 -C 6 cycloalkyl, (CH 2 ) t R 22 , and aryl substituted with 0-3 R 18 ;
R 17 is independently selected at each occurrence from the group consisting of R 10 , C 1 -C 4 alkoxy, halo, OR 23 , SR 23 , and NR 23 R 24 ;
R 20 is independently selected at each occurrence from the group consisting of R 10 and C(═O)R 31 ;
R 22 is independently selected at each occurrence from the group consisting of cyano, OR 24 , SR 24 , NR 23 R 24 , C 3 -C 6 cycloalkyl, --S(O) n R 31 , and --C(═O)R 25 ;
R 26 is hydrogen or halogen;
R 28 is C 1 -C 2 alkyl, C 2 -C 4 alkenyl, C 2 -C 4 alkynyl, hydrogen, C 1 -C 2 alkoxy, halogen, or C 2 -C 4 alkylamino;
R 29 is taken together with R 4 to form a five membered ring and is:
--CH(R 30 )-- when R 4 is --CH(R 28 )--,
--C(R 30 )═ or --N═ when R 4 is --C(R 28 )═ or --N═;
R 30 is hydrogen, cyano, C 1 -C 2 alkyl, C 1 -C 2 alkoxy, halogen, C 1 -C 2 alkenyl, nitro, amido, carboxy, or amino;
R 31 is C 1 -C 4 alkyl, C 3 -C 7 cycloalkyl, or aryl-(C 1 -C 4 ) alkyl; provided that when J, K, and L are all CH, M is CR 5 , Z is CH, R 3 is CH 3 , R 28 is H, R 5 is iso-propyl, X is Br, X' is H, and R 1 is CH 3 , then R 30 can not be H, --CO 2 H, or --CH 2 NH 2 ;
and further provided that when J, K and L are all CH; M is CR 5 ; Z is N; and
(A) R 29 is --C(R 30 )═; then one of R 28 or R 30 is hydrogen;
(B) R 29 is N; then R 3 is not halo, NH 2 , NO 2 , CF 3 , CO 2 H, CO 2 -alkyl, alkyl, acyl, alkoxy, OH, or --(CH 2 ) m Oalkyl;
(C) R 29 is N; then R 28 is not methyl if X or X' are bromo or methyl and R 5 is nitro; or
(D) R 29 is N, and R 1 is CH 3 and R 3 is amino; then R 5 is not halogen or methyl.
Further included in this invention are pharmaceutical compositions comprising a pharmaceutically acceptable carrier and a therapeutically effective amount of any one of the above-described compounds.
The compounds provided by this invention (and especially labelled compounds of this invention) are also useful as standards and reagents in determining the ability of a potential pharmaceutical to bind to the CRF receptor. These would be provided in commercial kits comprising a compound provided by this invention
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the present invention it has been discovered that the provided compounds are useful as antagonists of Corticotropin Releasing Factor and for the treatment of affective disorders, anxiety, or depression.
The present invention also provides methods for the treatment of affective disorder, anxiety or depression by administering to a compromised host a therapeutically effective amount of a compound of formula (I) as described above. By therapeutically effective amount is meant an amount of a compound of the present invention effective to antagonize abnormal levels of CRF or treat the symptoms of affective disorder, anxiety or depression in a host.
The compounds herein described may have asymmetric centers. All chiral, diastereomeric, and racemic forms are included in the present invention. Many geometric isomers of olefins, C═N double bonds, and the like can also be present in the compounds described herein, and all such stable isomers are contemplated in the present invention. It will be appreciated that certain compounds of the present invention contain an asymmetrically substituted carbon atom, and may be isolated in optically active or racemic forms. It is well known in the art how to prepare optically active forms, such as by resolution of racemic forms or by synthesis, from optically active starting materials. Also, it is realized that cis and trans geometric isomers of the compounds of the present invention are described and may be isolated as a mixture of isomers or as separated isomeric forms. All chiral, diastereomeric, and racemic forms and all geometric isomeric forms of a structure are intended, unless the specific stereochemistry or isomer form is specifically indicated.
When any variable (for example, R 1 through R 10 , m, n, A, w, Z, etc.) occurs more than one time in any constituent or in formula (I) or any other formula herein, its definition on each occurrence is independent of its definition at every other occurrence. Thus, for example, in --NR 8 R 9 , each of the substituents may be independently selected from the list of possible R 8 and R 9 groups defined. Also, combinations of substituents and/or variables are permissible only if such combinations result in stable compounds.
As used herein, "alkyl" is intended to include both branched and straight-chain saturated aliphatic hydrocarbon groups having the specified number of carbon atoms. "Alkenyl" is intended to include hydrocarbon chains of either a straight or branched configuration and one or more unsaturated carbon-carbon bonds which may occur at any stable point along the chain, such as ethenyl, propenyl, and the like. "Alkynyl" is intended to include hydrocarbon chains of either a straight or branched configuration and one or more triple carbon-carbon bonds which may occur at any stable point along the chain, such as ethynyl, propynyl and the like. "Haloalkyl" is intended to include both branched and straight-chain saturated aliphatic hydrocarbon groups having the specified number of carbon atoms, substituted with 1 or more halogens; "alkoxy" represents an alkyl group of indicated number of carbon atoms attached through an oxygen bridge; "cycloalkyl" is intended to include saturated ring groups, including mono-, bi- or poly-cyclic ring systems, such as cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, and so forth. "Halo" or "halogen" as used herein refers to fluoro, chloro, bromo, and iodo.
As used herein, "aryl" or "aromatic residue" is intended to mean phenyl, biphenyl or naphthyl.
The term "heteroaryl" is meant to include unsubstituted, monosubstituted or disubstituted 5-, 6- or 10-membered mono- or bicyclic aromatic rings, which can optionally contain from 1 to 3 heteroatoms selected from the group consisting of O, N, and S and are expected to be active. Included in the definition of the group heteroaryl, but not limited thereto, are the following: 2-, or 3-, or 4-pyridyl; 2- or 3-furyl; 2- or 3-benzofuranyl; 2-, or 3-thiophenyl; 2- or 3-benzo [b]thiophenyl; 2-, or 3-, or 4-quinolinyl; 1-, or 3-, or 4-isoquinolinyl; 2- or 3-pyrrolyl; 1- or 2- or 3-indolyl; 2-, or 4-, or 5-oxazolyl; 2-benzoxazolyl; 2- or 4- or 5-imidazolyl; 1- or 2-benzimidazolyl; 2- or 4- or 5-thiazolyl; 2-benzothiazolyl; 3- or 4- or 5-isoxazolyl; 3- or 4- or 5-pyrazolyl; 3- or 4- or 5-isothiazolyl; 3- or 4-pyridazinyl; 2- or 4- or 5-pyrimidinyl; 2-pyrazinyl; 2- triazinyl; 3- or 4-cinnolinyl; 1-phthalazinyl; 2- or 4-quinazolinyl; or 2-quinoxalinyl ring. Particularly preferred are 2-, 3-, or 4-pyridyl; 2- or 3-furyl; 2-, or 3-thiophenyl; 2-, 3-, or 4-quinolinyl; or 1-, 3-, or 4-isoquinolinyl.
As used herein, "carbocycle" or "carbocyclic residue" is intended to mean any stable 3- to 7-membered monocyclic or bicyclic or 7- to 14-membered bicyclic or tricyclic or an up to 26-membered polycyclic carbon ring, any of which may be saturated, partially unsaturated, or aromatic. Examples of such carbocyles include, but are not limited to, cyclopropyl, cyclopentyl, cyclohexyl, phenyl, biphenyl, naphthyl, indanyl, adamantly, or tetrahydronaphthyl (tetralin),
As used herein, the term "heterocycle" is intended to mean a stable 5- to 7-membered monocyclic or bicyclic or 7- to 10-membered bicyclic heterocyclic ring which is either saturated or unsaturated, and which consists of carbon atoms and from 1 to 4 heteroatoms independently selected from the group consisting of N, O and S and wherein the nitrogen and sulfur heteroatoms may optionally be oxidized, and the nitrogen may optionally be quaternized, and including any bicyclic group in which any of the above-defined heterocyclic rings is fused to a benzene ring. The heterocyclic ring may be attached to its pendant group at any heteroatom or carbon atom which results in a stable structure. The heterocyclic rings described herein may be substituted on carbon or on a nitrogen atom if the resulting compound is stable. Examples of such heterocycles include, but are not limited to, pyridyl, pyrimidinyl, furanyl, thienyl, pyrrolyl, pyrazolyl, imidazolyl, tetrazolyl, benzofuranyl, benzothiophenyl, indolyl, indolenyl, quinolinyl, isoquinolinyl or benzimidazolyl, piperidinyl, 4-piperidonyl, pyrrolidinyl, 2-pyrrolidonyl, pyrrolinyl, tetrahydrofuranyl, tetrahydroquinolinyl, tetrahydroisoquinolinyl, decahydroquinolinyl or octahydroisoquinolinyl, azocinyl, triazinyl, 6H-1,2,5-thiadiazinyl,2H,6H-1,5,2-dithiazinyl, thiophenyl, thianthrenyl, furanyl, pyranyl, isobenzofuranyl, chromenyl, xanthenyl, phenoxathiinyl, 2H-pyrrolyl, pyrrole, imidazolyl, pyrazolyl, isothiazolyl, isoxazole, pyridinyl, pyrazinyl, pyrimidinyl, pyridazinyl, indolizinyl, isoindole, 3H-indolyl, indolyl, 1H-indazolyl, purinyl, 4H-quinolizinyl, isoquinolinyl, quinolinyl, phthalazinyl, naphthyridinyl, quinoxalinyl, quinazolinyl, cinnolinyl, pteridinyl, 4aH-carbazolyl, carbazolyl, β-carbolinyl, phenanthridinyl, acridinyl, perimidinyl, phenanthrolinyl, phenazinyl, phenothiazinyl, furazanyl, phenoxazinyl, isochromanyl, chromanyl, pyrrolidinyl, pyrrolinyl, imidazolidinyl, imidazolinyl, pyrazolidinyl, pyrazolinyl, piperidinyl, piperazinyl, indolinyl, isoindolinyl, quinuclidinyl, morpholinyl or oxazolidinyl. Also included are fused ring and spiro compounds containing, for example, the above heterocycles.
The term "substituted", as used herein, means that one or more hydrogens of the designated moiety is replaced with a selection from the indicated group, provided that no atom's normal valency is exceeded, and that the substitution results in a stable compound. When a substituent is keto (i.e., ═O), then 2 hydrogens attached to an atom of the moiety are replaced.
By "stable compound" or "stable structure" is meant herein a compound that is sufficiently robust to survive isolation to a useful degree of purity from a reaction mixture and formulation into an efficacious therapeutic agent.
As used herein, the term "appropriate amino acid protecting group" means any group known in the art of organic synthesis for the protection of amine or carboxylic acid groups. Such amine protecting groups include those listed in Greene and Wuts, "Protective Groups in Organic Synthesis" John Wiley & Sons, New York (1991) and "The Peptides: Analysis, Synthesis, Biology, Vol. 3, Academic Press, New York (1981), the disclosure of which is hereby incorporated by reference. Any amine protecting group known in the art can be used. Examples of amine protecting groups include, but are not limited to, the following: 1) acyl types such as formyl, trifluoroacetyl, phthalyl, and p-toluenesulfonyl; 2) aromatic carbamate types such as benzyloxycarbonyl (Cbz) and substituted benzyloxycarbonyls, 1-(p-biphenyl)-1-methylethoxycarbonyl, and 9-fluorenylmethyloxycarbonyl (Fmoc); 3) aliphatic carbamate types such as tert-butyloxycarbonyl (Boc), ethoxycarbonyl, diisopropylmethoxycarbonyl, and allyloxycarbonyl; 4) cyclic alkyl carbamate types such as cyclopentyloxycarbonyl and adamantyloxycarbonyl; 5) alkyl types such as triphenylmethyl and benzyl; 6) trialkylsilane such as trimethylsilane; and 7) thiol containing types such as phenylthiocarbonyl and dithiasuccinoyl.
The term "amino acid" as used herein means an organic compound containing both a basic amino group and an acidic carboxyl group. Included within this term are natural amino acids, modified and unusual amino acids, as well as amino acids that are known to occur biologically in free or combined form but usually do not occur in proteins. Included within this term are modified and unusual amino acids, such as, those disclosed in, for example, Roberts and Vellaccio (1983) The Peptides, 5: 342-429, the teaching of which is hereby incorporated by reference. Modified or unusual amino acids that can be used in the practice of the invention include, but are not limited to, D-amino acids, hydroxylysine, 4-hydroxyproline, an N-Cbz-protected amino acid, ornithine, 2,4-diaminobutyric acid, homoarginine, norleucine, N-methylaminobutyric acid, naphthylalanine, phenylglycine, β-phenylproline, tert-leucine, 4-aminocyclohexylalanine, N-methyl-norleucine, 3,4-dehydroproline, N,N-dimethylaminoglycine, N-methylaminoglycine, 4-aminopiperidine-4-carboxylic acid, 6-aminocaproic acid, trans-4-(aminomethyl)-cyclohexanecarboxylic acid, 2-, 3-, and 4-(aminomethyl)-benzoic acid, 1-aminocyclopentanecarboxylic acid, 1-aminocyclopropanecarboxylic acid, and 2-benzyl-5-aminopentanoic acid.
The term "amino acid residue" as used herein means that portion of an amino acid (as defined herein) that is present in a peptide.
The term "peptide" as used herein means a compound that consists of two or more amino acids (as defined herein) that are linked by means of a peptide bond. The term "peptide" also includes compounds containing both peptide and non-peptide components, such as pseudopeptide or peptide mimetic residues or other non-amino acid components. Such a compound containing both peptide and non-peptide components may also be referred to as a "peptide analog".
The term "peptide bond" means a covalent amide linkage formed by loss of a molecule of water between the carboxyl group of one amino acid and the amino group of a second amino acid.
As used herein, "pharmaceutically acceptable salt" refer to derivatives of the disclosed compounds wherein the parent compound of formula (I) is modified by making acid or base salts of the compound of formula (I). Examples of pharmaceutically acceptable salts include, but are not limited to, mineral or organic acid salts of basic residues such as amines; alkali or organic salts of acidic residues such as carboxylic acids; and the like.
"Prodrugs" are considered to be any covalently bonded carriers that release the active parent drug according to formula (I) in vivo when such prodrug is administered to a mammalian subject. Prodrugs of the compounds of formula (I) are prepared by modifying functional groups present in the compounds in such a way that the modifications are cleaved, either in routine manipulation or in vivo, to the parent compounds. Prodrugs include compounds of formula (I) wherein hydroxy, amine, or sulfhydryl groups are bonded to any group that, when administered to a mammalian subject, cleaves to form a free hydroxyl, amino, or sulfhydryl group, respectively. Examples of prodrugs include, but are not limited to, acetate, formate and benzoate derivatives of alcohol and amine functional groups in the compounds of formula (I); and the like.
Pharmaceutically acceptable salts of the compounds of the invention can be prepared by reacting the free acid or base forms of these compounds with a stoichiometric amount of the appropriate base or acid in water or in an organic solvent, or in a mixture of the two; generally, nonaqueous media like ether, ethyl acetate, ethanol, isopropanol, or acetonitrile are preferred. Lists of suitable salts are found in Remington's Pharmaceutical Sciences, 17th ed., Mack Publishing Company, Easton, Pa. (1985), p. 1418, the disclosure of which is hereby incorporated by reference.
SYNTHESIS
The novel substituted-2-pyridinamines, substituted triazines, substituted pyridines and substituted anilines of the present invention can be prepared by one of the general schemes outlined below (Scheme 1-23).
Compounds of the Formula (I), wherein Z is CR 2 and J is CX' and K and L are both CH, can be prepared as shown in Scheme 1. 2-Hydroxy-4,6-dialkylpyrimidine (II) was converted to the corresponding derivative (III) with an appropriate leaving group in the 2-position such as, but not limited to, Cl, Br, SO 2 CH 3 , OSO 2 CH 3 , or OSO 2 C 6 H 4 --CH 3 , or SCH 3 by treatment with phosphorous oxychloride (POCl 3 ), phosphorous oxybromide (POBr 3 ), methanesulfonyl chloride (MsCl), p-toluenesulfonyl chloride (TsCl), or sodium thiomethoxide optionally followed by oxidation with hydrogen peroxide, chlorine gas, or an organic peracid, such as, m-chloroperbenzoic ##STR14## acid, respectively. This derivative was reacted with the appropriate 2,4-substituted aniline (IV) in a high boiling solvent, such as, but not limited to, ethylene glycol, methoxyethoxyethanol etc., or in an aprotic solvent such as tetrahydrofuran, dioxane, toluene, xylene, or N,N-dimethyformamide, facilitated by the optional use of a base such as sodium hydride (NaH), lithium diisopropylamide (LDA), which are preferred. The coupled product (V) was treated with a base such as NaH or LDA in an aprotic solvent such as tetrahydrofuran (THF) or N,N-dimethylformamide (DMF) or in a combination of potassium tert-butoxide in t-butanol (tBuOK/tBuOH) followed by an alkylating agent R 4 L', such as an alkyl iodide, mesylate or tosylate to afford the corresponding alkylated product of Formula (I).
The compounds of Formula (I), wherein V and Y are N and Z, J, K, and L are all CH, can be prepared as shown in Scheme 2. The substituted aniline (VI) was converted to the corresponding guanidinium salt (VII) by treatment with the appropriate reagent such as cyanamide. ##STR15## The guanidinium salt (VII) was reacted with a β-diketone (VIII) in the presence of a base such as potassium carbonate (K 2 CO 3 ) in N,N-dimethylformamide (DMF) or in an alcoholic solvent in the presence of the corresponding alkoxide to afford the corresponding pyrimidine (IX). This was subsequently alkylated to provide (X), a compound of Formula (I) where X' is hydrogen, by conditions identical to those described in Scheme 1.
Compounds of the Formula (I), wherein V and Y are N and Z, J, K, and L are all CH and R 3 is NR 6 R 7 , can be prepared as shown in Scheme 3. Treatment of 2,4-dichloro-6-alkylpyrimidine (XI) with a primary or secondary amine in the presence of a non-nucleophilic base such as a trialkylamine afforded selectively the corresponding 4-substituted amino adduct (XII). ##STR16## This in turn, was reacted with the substituted aniline (IV) under conditions identical to those described in Scheme 1 to afford the corresponding secondary pyrimidinamine (XIII). This was alkylated under conditions described in Schemes 1 and 2. ##STR17##
Compounds of Formula (I) wherein J, K, and L are CH and Z is CR 2 and V and Y are N can also be prepared by the route outlined in Scheme 4. The guanidinium salt (XII) was reacted with a β-ketoester (XV) in the presence of a base such as an alkoxide in the corresponding alcoholic solvent to give the adduct (XVI). Treatment of the hydroxy group in (XVI) with either phosphorous oxychloride, phosphorous oxybromide, methanesulfonyl chloride, p-toluenesulfonyl chloride, or trifluoromethanesulfonic anhydride provided (XVII), wherein the L is a leaving group and is, respectively, Cl, Br, I, OMs, OTs, or OTf. The L group of (XVII) was displaced with a nucleophile such as NR 6 R 7 , OR 6 , SR 6 , CN, an organolithium, organomagnesium, organosodium, organopotassium, an alkyl cuprate, or in general an organometallic reagent to the corresponding adduct (IX), which was further alkylated under the standard conditions to produce (XVIII).
Compounds of the Formula (I) that are substituted at the 2-position of the phenyl ring could be prepared as outlined in Scheme 5. ##STR18##
Compounds of the Formula (I) wherein X is other than bromine can be prepared by the intermediates shown in Scheme 5. Reaction of the 2-halo compound (V) wherein X is bromine or hydrogen with a metalating agent such as, but not limited to, n-BuLi or t-BuLi in an aprotic solvent, preferably ether or tetrahydrofuran, provided the corresponding 2-lithio intermediate (X=Li, not isolated) which was further reacted with an electrophile such as iodine or trimethyltin chloride ((CH 3 ) 3 SnCl) to give the corresponding 2-substituted product (XIX). These intermediates can also be further reacted using palladium-catalyzed coupling reactions well known to one of skill in the art to prepare the compounds of the invention.
Compounds of the Formula (I) wherein Z, K and L are all CH, J is N or CH, and R 4 is ethyl can be prepared as illustrated in Scheme 6. Sequential addition/re-oxidation of an alkyllithium to 2-chloropyrimidine can provide intermediate (XXII) wherein the R 1 and R 3 can be independent of one another. Displacement of the chlorine by a suitable nitrogen nucleophile such as an aniline under similar conditions of Scheme 1, followed by attachment of the R 4 group by alkylation in an analogous method of Schemes 1 or 2 provide the compounds of the invention. ##STR19##
Compounds of the Formula (I) wherein Z is N can be prepared according to the method outlined in Scheme 7. Known triazine (XXIII), synthesis of which is reported in J. Amer. Chem. Soc. 77:2447 (1956), can be reacted with a substituted aniline (IV) in a analogous manner to Scheme 1. Similarly, the 2,4 dichloro 6-methyltriazine, which can be prepared via the method reported in U.S. Pat. No. 3,947,374can be coupled to the substituted aniline (IV) to provide (XXIV) where R 3 is chlorine. Nucleophilic addition in protic or aprotic solvents allows for a variety of substituents at this position (XXV). Alkylation of the secondary amine as previously described provide triazine compounds of formula (I). ##STR20##
Compounds wherein R 3 is carboxy-derived are synthesized according to Scheme 8. A pyrimidine ester of formula (XXVI), which is prepared by the literature method reported in Budesinsky and Roubinek, Collection. Czech. Chem. Comm. 26:2871-2885 (1961) is reacted with an amine of formula (IV) in the presence of an inert solvent to afford an intermediate of formula (XXVII). Inert solvents include lower alkyl alcohols of 1 to 6 carbons, dialkyl ethers of 4 to 10 carbons, cyclic ethers of 4 to 10 carbons (preferably dioxane), dialkylformamides (preferably N,N-dimethylformamide), dialkylacetamides, (preferably N,N-dimethylacetamide),cyclic amides, (preferably N-methylpyrrolidinone), dialkyl sulfoxides (preferably dimethyl sulfoxide), hydrocarbons of 5 to 10 carbons or aromatic hydrocabons of 6 to 10 carbons. Compounds of formula (XXVII) are treated with a base and a compound of Formula R 4 X, where X is halogen (preferably Cl, Br or I) in an inert solvent. Such bases include a tertiary amine, an alkali metal hydride ##STR21##
R 1 is an alkyl protecting group
(preferably sodium hydride), an aromatic amine (preferably pyridine), or an alkali metal carbonate or alkoxide. The choice of inert solvent must be compatible with the choice of base (see J. March, Advanced Organic Chemistry (New York: J. Wiley and Sons, 1985) pp. 364-366, 412; H.O. House, Modern Synthetic Reactions (New York: W.A. Benjamin Inc., 1972, pp. 510-536)). Solvents include lower alkyl alcohols of 1 to 6 carbons, lower alkanenitriles (preferably acetonitrile), dialkyl ethers of 4 to 10 carbons, cyclic ethers of 4 to 10 carbons (preferably tetrahydrofuran or dioxane), dialkylformamides (preferably N,N-dimethylformamide),cyclic amides, (preferably N-methylpyrrolidinone), dialkyl sulfoxides (preferably dimethyl sulfoxide), hydrocarbons of 5 to 10 carbons or aromatic hydrocarbons to 6 to 10 carbons. Esters of formula (XXVIII) may be converted to acids of formula (XXIX) by acidic or basic hydrolysis (cf. J. March, Advanced Organic Chemistry (New York: J. Wiley and Sons, 1985) pp. 334-338) or by treatment with an alkali metal salt (preferably Lil or NaCN) in the presence of an inert solvent at temperatures ranging from 50 to 200° C. (preferably 100 to 180° C.) (cf. McMurray, J. E. Organic Reactions, Dauben, W. G. et. al., eds., J. Wiley and Sons, New York (1976), Vol. 24, pp. 187-224). Inert solvents include dialkylformamides (preferably N,N-dimethylformamide), dialkylacetamides, (preferably N,N-dimethylacetamide), cyclic amides, (preferably N-methylpyrrolidinone), and dialkyl sulfoxides (preferably dimethyl sulfoxide), or aromatic amines (preferably pyridine). Acids of formula (XXIX) may be treated with a halogenating agent to give an acid halide, which may or may not be isolated, then reacted with an amine of formula HNR 6 R 7 , with or without an inert solvent, with or without a base, as taught by the literature (J. March, Advanced Organic Chemistry, J. Wiley and Sons, New York (1985), pp. 370-373, 389), to provide amides of formula (XXX). Halogenating agents include thionyl chloride (SOCl 2 ), oxalyl chloride ((COCl) 2 ), phosphorous trichloride (PCl 3 ), phosphorous pentachloride (PCl 5 ), or phosphorous oxychloride (POCl 3 ). Inert solvents include lower halocarbons of 1 to 6 carbons and 2 to 6 halogens (preferably dichloromethane or dichloroethane, dialkyl ethers of 4 to 10 carbons, cyclic ethers of 4 to 10 carbons (preferably dioxane) or aromatic hydrocabons to 6 to 10 carbons. Bases include trialkyl amines or aromatic amines (preferably pyridine). Alternatively, esters of formula (XXVIII) may be reacted with an amine of formula HNR 6 R 7 , with or without an inert solvent, with or without a base, as taught by the literature (cf. J. March, Advanced Organic Chemistry (New York: J. Wiley and Sons, 1985) pp. 370-373, 389) to generate amides of formula (XXX). Solvents include lower alkyl alcohols of 1 to 6 carbons, lower alkanenitriles (preferably acetonitrile), dialkyl ethers of 4 to 10 carbons, cyclic ethers of 4 to 10 carbons (preferably tetrahydrofuran or dioxane), dialkylformamides (preferably N,N-dimethylformamide), dialkylacetamides, (preferably N,N-dimethylacetamide), cyclic amides, (preferably N-methylpyrrolidinone), dialkyl sulfoxides (preferably dimethyl sulfoxide), hydrocarbons of 5 to 10 carbons or aromatic hydrocarbons to 6 to 10 carbons. Such bases include a tertiary amine, an alkali metal hydride (preferably sodium hydride), an aromatic amine (preferably pyridine), or an alkali metal carbonate or alkoxide. Amides of formula (XXX) may be treated with a reducing agent in an inert solvent to provide amines of formula (XXXI). Such reducing agents include, but are not limited to, alkali metal aluminum hydrides, preferably lithium aluminum hydride, alkali metal borohydrides (preferably lithium borohydride), alkali metal trialkoxyaluminum hydrides (such as lithium tri-t-butoxyaluminum hydride), dialkylaluminum hydrides (such as di-isobutylaluminum hydride), borane, dialkylboranes (such as di-isoamyl borane), alkali metal trialkylboron hydrides (such as lithium triethylboron hydride). Inert solvents include lower alkyl alcohols of 1 to 6 carbons, ethereal solvents (such as diethyl ether or tetrahydrofuran), aromatic or non-aromatic hydrocarbons of 6 to 10 carbons. Reaction temperatures for the reduction range from about -78° to 200° C., preferably about 50° to 120° C. The choice of reducing agent and solvent is known to those skilled in the art as taught in the above cited March reference (pp. 1093-1110).
Scheme 9 depicts the synthesis and chemical modifications to form compounds of formula (XXXIII). Esters of formula (XXVIII) or acids of formula (XXIX) may be treated with a reducing agent in an inert solvent to provide alcohols of formula (XXXII). Such reducing agents include, but are not limited to, alkali metal aluminum hydrides, preferably lithium aluminum hydride, alkali metal borohydrides (preferably lithium borohydride), alkali metal trialkoxyaluminum hydrides (such as lithium tri-t-butoxyaluminum hydride), dialkylaluminum hydrides (such as di-isobutylaluminum hydride), borane, dialkylboranes (such as di-isoamyl borane), alkali metal trialkylboron hydrides (such a lithium triethylboron hydride). Inert solvents include lower alkyl alcohols of 1 to 6 carbons, ethereal solvents (such as diethyl ether or tetrahydrofuran), aromatic or non-aromatic hydrocabons of 6 to 10 carbons. Reaction temperatures for the reduction range from about -78° to 200° C., preferably about 50° to 120° C. The choice of reducing agent and solvent is known to those skilled in the art as taught in the above cited March reference (pp. 1093-1110). Alcohols of Formula (XXXII) may be converted to ethers of formula (XXXIII) by treatment with a base and a compound of Formula R 8 X, where X is halogen. Bases which may be used for this reaction include, but are not limited to, alkali metal hydrides, preferably sodium hydride, alkali metal carbonates, preferably potassium carbonate, alkali metal dialkylamides, preferably lithium di-isopropylamide, alkali metal bis-(trialkylsilyl) amides, preferably sodium bis-(trimethylsilyl)amide, alkyl alkali metal compounds (such as butyl lithium), alkali metal alkoxides (such as sodium ethoxide), alkyl alkaline earth metal halides (such as methyl magnesium bromide), trialkylamines (such as triethylamine or di-isopropylethylamine), polycyclic di-amines (such as 1,4 diazabicyclo[2.2.2]octane or 1,8-diazabicyclo-[5.4.0]undecene) or quaternary ammonium salts (such as Triton B). The choice of inert solvent must be compatible with the choice of base (J. March, Advanced Organic Chemistry (New York: J. Wiley and Sons, 1985) pp. 255-446; H.O. House, Modern Synthetic Reactions (New York: ##STR22## W.A. Benjamin Inc., 1972, pp. 546-553)). Solvents include lower alkyl alcohols of 1 to 6 carbons, dialkyl ethers of 4 to 10 carbons, cyclic ethers of 4 to 10 carbons, preferably tetrahydrofuran or dioxane, dialkylformamides, preferably N,N-dimethylformamide, dialkylacetamides, preferably N,N-dimethylacetamide, cyclic amides, preferably N-methylpyrrolidinone, hydrocarbons of 5 to 10 carbons or aromatic hydrocarbons to 6 to 10 carbons.
Alternatively, compounds of formula (XXXII) may be converted to compounds of formula (XXXIV), where Y is halide, arylsulfonyloxy (preferably p-toluenesulfonyloxy), alkylsulfonyloxy (such as methanesulfonyloxy), haloalkylsulfonyloxy (preferably trifluoromethyl-sulfonyloxy), by reaction with a halogenating agent or a sulfonylating agent. Examples of halogenating agents include, but are not limited to, SOCl 2 , PCl 3 , PCl 5 , POCl 3 , Ph 3 P--CCl 4 , Ph 3 P--CBr 4 , Ph 3 P--Br 2 , Ph 3 P--I 2 , PBr 3 , PBr 5 . The choice of halogenating agents and reaction conditions are known to those skilled in the prior art (March reference, pp. 382-384). Sulfonylating agents include, but are not limited to, (lower alkyl)sulfonyl chlorides (preferably methanesulfonyl chloride), (lower haloalkyl) sulfonic anhydrides (preferably trifluoromethylsulfonic anhydride, phenyl or alkyl substituted-phenyl sulfonyl chlorides (preferably p-toluenesulfonyl chloride). The sulfonylation or halogenations may require a base as taught by the literature (March reference, pp. 1172, 382-384). Such bases include a tertiary amine, an alkali metal hydride (preferably sodium hydride), an aromatic amine (preferably pyridine), or an alkali metal carbonate or alkoxide. Solvents for the halogenation or sulfonylation should be inert under the reaction conditions as taught by the literature. Such solvents include lower halocarbons (preferably dichloromethane or dichloroethane), or ethereal solvents (preferably tetrahydrofuran or dioxane). Intermediates of formula (XXXIV) may then be converted to compounds of formula (XXXIII) by treatment with a compound of formula R 8 OH with or without a base, in an inert solvent (March reference, pp. 342-343). Such bases include alkali metal hydrides, preferably sodium hydride, alkali metal carbonates, preferably potassium carbonate, alkali metal dialkylamides, preferably lithium diiisopropylamide, alkali metal bis-(trialkylsilyl) amides, preferably sodium bis-(trimethylsilyl)amide, alkyl alkali metal compounds (such as n-butyllithium), alkali metal alkoxides (such as sodium ethoxide), alkyl alkaline earth metal halides (such as methyl magnesium bromide), trialkylamines (such as triethylamine or di-isopropylethlamine, polycyclic diamines (such as 1,4 diazabicylco[2.2.2]octane or 1,8-diazabicyclo[5.4.0]undecene) or quaternary ammonium salts (such as Triton B). Solvents include lower alkyl alcohols of 1 to 6 carbons, dialkyl ethers of 4 to 10 carbons, cyclic ethers of 4 to 10 carbons, preferably tetrahydrofuran or dioxane, dialkylformamides, preferably N,N-dimethylformamide, dialkylacetamides, preferably N,N-dimethylacetamide, cyclic amides, preferably N-methylpyrrolidinone, hydrocarbons of 5 to 10 carbons or aromatic hydrocarbons to 6 to 10 carbons.
Intermediates of formula (XXXIII) may be prepared from intermediates of formula (XXXII) by reaction with a triarylphosphine (preferably triphenylphosphine), a di-(lower alkyl)azodiacarboxylate) and a compound of formula R 8 OH in the presence of an inert solvent as described in the general literature (Mitsunobu, O., Synthesis 1:1-28 (1981)).
Compounds of formula (XXXI) may be prepared by treatment of a compound of formula (XXXIV) with a compound of Formula HNR 6 R 7 , with or without a base, in an inert solvent (Scheme 9). Such bases and inert solvents may be the same ones used for the transformation of compounds (XXVIII) to compounds (XXX) in Scheme 8.
Compounds of Formula (I) which are substituted at the 4-position of the pyrimidine ring can be prepared as outlined in Scheme 10. ##STR23##
Known pyrimidine (XXXV), synthesis of which is reported in Eur. J. Med. Chem. 23:60 (1988), can be reacted with a substituted aniline (IV) in an analogous manner to Scheme 1. Treatment of the hydroxy group in (XXXVI) with either phosphorous oxychloride, phosphorous oxybromide, p-toluenesulfonyl chloride, or trifluoromethanesulfonic anhydride provided (XXXVII), wherein the L is a leaving group. Alkylation under the standard conditions gives (XXXVIII). The L group of (XXXVIII) was displaced with a nucleophile such as NR 6 R 7 , OR 6 , SR 6 , CN, or an organometallic reagent to the corresponding adduct (XXXIX).
Compounds of the Formula (I), wherein X or X' is alkylmercapto, or functionalized alkylmercapto can be synthesized under the conditions described in Scheme 11. ##STR24##
Treatment of the appropriately ortho-functionalized aniline XXXIX with a substituted 2-mercaptopyrimidine XL in the presence of a base such as potassium carbonate, sodium carbonate, alkalki metal alkoxide, potassium, sodium or lithium hydride, a lithium, sodium or potassium dialkylamide, or an alkali metal in the presence of copper powder or copper salts gives the corresponding aryl sulfide XLI which is subjected to a Smiles rearrangement by treatment with an strong acid such as hydrochloric, hydrobromic, hydriodic, sulfuric, phosphoric or perchloric, to give the corresponding disulfide XLIII. This is reduced to the sulfide XLIV with a reducing agent such as sodium borohydride and alkylated on the sulfur with the appropriate alkylating agent such as an alkyl halide, tosylate or mesylate. The rearrangement of XLI may be carried out with a strong base such as lithium, sodium, or potassium hydride; lithium, sodium, or potassium dialkylamide; or lithium, sodium or potassium metal, in an appropriate solvent such as decahydronaphthalene, xylenes, high boiling alcohols, dimethylformamide, dimethylsulfoxide, dimethylacetamide, and N-methylpyrrolidinone. The rearrangement product can be selectively alkylated on the sulfur with the use of a base such as potassium, sodium or lithium carbonate, potassium, sodium or lithium alkoxide, or trialkylamine and the appropriate alkylating agent as described above. The alkylsulfide can be further alkylated on the nitrogen by using identical conditions as described above to yield compound XLV.
Compounds of formula (I), wherein R 3 is (CH 2 ) k OR 8 and R 8 is (CH 2 ) t C(═O)OR 24 , (CH 2 ) t C(═O)NR 6 R 7 , or (CH 2 ) t NR 6 R 7 can be made according to Scheme 12. ##STR25##
Compounds XLVII, XLVIII, and XLIX are made using the product of Example 24 as starting material by procedures analogous to those used to make the products of Examples 25, 16, and 17 respectively.
The novel 7-azaindoles of the present invention are prepared by Scheme 13 outlined below. The potassium salt of formylsuccinonitrile is treated with the appropriate substituted aniline L to give LI. This undergoes base catalyzed cyclization to a 1-aryl-2-amino-4-cyanopyrrole LII. Reaction with an appropriate 1,3-dicarbonyl compound gives the desired 7-azaindole LIII. ##STR26##
The nitrile substituent at position 3 of structure LIII is readily removed by refluxing the 3-cyano compound with 65% sulfuric acid. Position 3 then can be resubstituted by halogenation or nitration. Reduction of the nitro group can provide the 3-amino substituent.
Alternatively, the nitrile group can be converted to desired L groups by methods described in "Comprehensive Organic Transformations", by Richard C. Larock, VCH Publishers, Inc., New York, N.Y., 1989. For instance, the nitrile group can be reduced with diisobutylaluminum hydride to give the 3-aldehyde. The 3-aldehyde can be reduced via the hydrazone under Wolff-Kishner conditions (KOH in hot diethylene glycol) to give L=methyl. Furthermore, the aldehyde can be converted to L═CH═CH 2 by adding it to a mixture of methyltriphenylphosphonium bromide and potassium tertiary-butoxide in tetrahydrofuran (Wittig reaction). Reduction of the ethenyl group to give L═CH 2 CH 3 can be effected by hydroboration-protonolysis (J. Am. Chem. Soc. 81:4108 (1959)).
Scheme 13 generally provides a mixture isomeric in substituents R 1 and R 3 , which then can be separated. Sometimes the preferred isomer is the one obtained in lower yield. In the event Scheme 14 can be used to prepare the preferred isomer. Intermediate LII is treated with the appropriate acyl- or aroyl-acetic ester under either thermal or acid-catalyzed conditions to give the 6-hydroxy compound LV. Compound LV is converted to the 6-chloro compound LVI and de-cyanylated to compound LVII. When R 1 substituents other than chloro are desired, the chloro group can be converted to other substituents. For instance, treatment of compound LVII with an alkyl Grignard reagent can provide compound LVIII where R 1 ═alkyl. Heating with a primary or secondary amine can provide compound LVIII where R 1 ═amino. ##STR27##
Scheme 15 affords another route to compounds of this invention. Intermediate LII can be treated with the appropriate acylacetaldehyde dialkyl acetal under acid catalyzed conditions to give compounds LXa and LXb, 7-azaindoles unsubstituted at positions 4 and 7 respectively. Compound LXa can be oxidized with m-chloroperoxybenzoic acid to give the N-oxide compound LXI. Heating compound LXI with phosphorus oxychloride can give compound XIIa, which can be decyanylated to compound LXIII.
Compound LXIV where R 3 is an amino substituent can be prepared by heating LXIII with the appropriate amine; where R 3 =alkoxide, the metal alkoxide can be heated with LXIII; where R 3 =aryl, compound LXIII can treated with the arylboronic acid in the presence of tetrakis(triphenylphosphine)palladium (TTPP) and sodium carbonate; and where R 3 =alkyl, alkenyl, aralkyl, and cycloalkyl, compound LXIII can be coupled with the appropriate organotin reagent, also in the presence of TTPP.
Compound LXIV where R 3 is a nitro group can be prepared by nitration of LXI, decyanylation, and reduction of the N-oxide with a trivalent phosphorus compound such as triethyl phosphite.
Compound LXb can be substituted in the 6 position using methods described for the substitution of LXa. ##STR28##
The novel 7-azabenzimidazoles of this invention can be prepared as outlined in Scheme 16 where R 29 is nitrogen. Compounds L and LXV can react upon heating in the presence of a base, e.g. sodium hydride, to give the diarylamine LXVI. Reduction of the nitro group with stannous chloride can give LXVII, which can be closed to the 7-azabenzimidazole LXVIII. ##STR29##
The purines of this invention can be prepared as shown in Schemes 17 and 18.
Compounds L and LXIX (J. Heterocyclic Chem. 28:465 (1991)) can be heated in the presence of a base, e.g. sodium hydride, to give compound LXX. Heating LXX with the appropriate carboxylic acid in the presence of a mineral acid catalyst can give LXXI where R 28 is hydrogen, alkyl, alkenyl, or alkynyl. The chloro substituent can then be converted to R 3 to give compounds LXXII by using one of the methods described above for the introduction of R 3 to obtain compounds LXIV. ##STR30##
Scheme 18 can be used to prepare purines where R 28 is halogen or alkoxide. Compounds LXX can be heated with a dialkyl carbonate, such as diethyl carbonate, to give the carbonyl compound LXXIII; if the conversion is undesirably slow, more reactive species such as trichloromethyl chlorocarbonate or carbonyl diimidazole can be used in place of diethyl carbonate. The chloro substituent can then be converted to R 3 to give LXXIV by using one of the methods described above for the introduction of R 3 to obtain LXIV. Heating LXXIV with phosphorus oxychloride can give the 2-chloropurine, LXXV. To prepare the 2-alkoxypurines, LXXVI, LXXV can be heated with a metal salt of the alcohol R 31 OH, e.g. the sodium or potassium salt, wherein in R 31 is C 1 -C 4 alkyl. ##STR31##
The method of synthesis of the 7-azaindolines of this invention is shown in Scheme 19.
A number of compounds of the general structure LXXVIII with desired R 1 and R 2 groups have been described by W. Paudler and T.-K. Chem, J. Heterocyclic Chem. 7:767 (1970). These can be oxidized with a peracid, e.g. m-chloroperoxybenzoic acid, to the sulfone LXXIX. Sulfone LXXIX can be heated in the presence of the desired aniline and a base, e.g. sodium hydride to give the diaryl amine LXXX. Alkylation of LXXX with the desired unsubstituted or 4-substituted-3-butynyl iodide (or 3-butynol mesylate) can give LXXXI. LXXXI can undergo an intramolecular Diels-Alder reaction to give LXXXII.
In a number of cases, the desired 4-substituted 3-butynyl iodide is not readily available or is unstable. In that event unsubstituted 3-butynyl iodide is used to give compound LXXXII where R 3=H . ##STR32##
The synthesis of the 5,7-diazaindoles of this invention is outlined in Scheme 20.
The desired formamidine LXXXIII can be treated with LXXXIV in the presence of sodium ethoxide in ethanol to give the pyrimidine LXXXV. Refluxing LXXXV in phosphorus oxychloride gives the dichloropyrimidine LXXXVI. Compound LXXXVI can be converted to the carbonyl compound LXXXVII by treatment with one equivalent of ozone at -78° to give an ozonide, which on treatment with sodium iodide and acetic acid gives the desired carbonyl compound. The preparation of LXXXVII (R 1 =H, R 28 =CH 3 and R 1 =R 28 =CH 3 ) by a different route has been described by E. Basagni, et. al., Bull. Soc. Chim. Fr., 4338 (1969).
Before the coupling reaction, the carbonyl of compound LXXXVII is protected by treatment with 2,2-dimethoxypropane in the presence of a catalytic amount of acid to give compound LXXXVIII. Compound LXXXVIII is then coupled with the appropriate aniline L by heating in the presence of a base, e.g. sodium hydride, to give compound LXXXIX. Compound LXXXIX can be cyclized to give the 5,7-diazaindole XC, the target compound wherein R 3 =Cl. Compound XC is also a useful intermediate for the preparation of Compounds XCI with other R 3 groups. For example, heating the chloro compound with the appropriate amine gives the desired amino compound. Heating with a metal alkoxide gives the desired alkoxy compound. Treating compound XC(R 3 =Cl) with R 3 MgBr (R 3 =alkyl, aryl, or aralkyl) converts the chloro compound to the desired alkyl, aryl, or aralkyl compound XCI. ##STR33##
Compounds wherein R 5 is dimethylhydroxymethyl, X' is iodine and R 1 and R 3 are chlorine can be prepared according to scheme 21. Ethyl 4-aminobenzoate is iodinated in a methylene chloride/water (50:50) mixture in the presence of sodium bicarbonate to provide compound (XCII). This material is coupled to cyanuric chloride, then the secondary amine is alkylated in an analogous manner to that in Scheme 1 to yield XCIII. Compound XCIII is treated with 5 equivalents of MeMgBr to provide the desired material of formula (XCIV). ##STR34##
Scheme 22 depicts the synthesis of compounds of Formula (I), where Y=N, Z=CR 2 and R 3 is COR 25 , CH(OH)R 25 or C(OH)R 25 R 25a . An ester of Formula (XCVI) may be converted to an amide of Formula (C) by treatment with an amine of Formula HN(OR a )R b , where R a and R b are lower alkyl (preferably Me), in the presence of a trialkylaluminum reagent (preferably Me 3 Al) in an inert solvent preferably an aromatic hydrocarbon (e.g., benzone) or an ethereal solvent (e.g., tetrahydrofuran) as taught by the prior art (cf. J. I. Levin, E. Turos, S. M. Weinreb, Synthetic Communications 12:989-993 (1982)). Amides of Formula (C) may be converted to ketones of Formula (CI) by treatment with an organolithium reagent R 25 Li or an organomagnesium halide R 25 MgX, where X=Cl, Br or I, in an inert solvent, preferably an ethereal solvent (e.g., diethyl ether or tetrahydrofuran), as taught by the prior art (cf. S. Nahm and S. M. Weinreb, Tetrahedron Letters 22:3815-3818 (1981)). Alternatively, ketones of Formula (CI) can be prepared from acids of Formula (XCV) by treatment with an organolithium reagent R 25 Li in the presence of an inorganic salt (preferably a transition metal halide (e.g., CeCl 3 )) in an inert solvent (preferably an ethereal solvent (e.g., tetrahydrofuran)) as taught by the prior art (cf. Y. Ahn and T. Cohen, Tetrahedron Letters 35:203-206 (1994)). Alternatively, esters of Formula (XCVI) can be converted directly to ketones of Formula (XCVIII) by reaction with an organolithium reagent R 25 Li or an organomagnesium halide R 25 MgX, where X=Cl, Br or I, in an inert solvent (preferably an ethereal solvent e.g., diethyl ether or tetrahydrofuran) at temperatures ranging from -100 to 150° C. (preferably -78 to 80° C.) (cf. J. March, Advanced Organic Chemistry (New York: J. Wiley and Sons, 1985, pp. 433-434). Ketones of Formula (XCVIII) can be converted to alcohols of Formula (XCIX) by reaction with an organolithium reagent R 25a Li or an organomagnesium halide R 25a MgX, where X=Cl, Br or I, in an inert solvent (preferably an ethereal solvent (e.g. diethyl ether or tetrahydrofuran) at temperatures ranging from -100 to 150° C. (preferably -78 to 80° C.) (cf. The above March reference, pp. 434-435). Alternatively, esters of Formula (XCVI) can be converted to alcohols of Formula (XCIX) by reaction with an organolithium reagent R 25a Li or an organomagnesium halide R 25a MgX, where X=Cl, Br or I, in an inert solvent (preferably an ethereal solvent e.g., diethyl ether or tetrahydrofuran) at temperatures ranging from -100 to 150° C. (preferably -78 to 100° C.), preferably using an excess amount of organometallic reagent (cf. the above March reference, pp. 434-435). In this last instance, R 25 =R 25a . Ketones of Formula (XCVIII) can be converted to alcohols of Formula (C) by treatment with a reducing agent in an inert solvent. Such reducing agents include, but are not limited to, alkali metal aluminum hydrides, preferably lithium aluminum hydride, alkali metal borohydrides (preferably sodium borohydride), alkali metal trialkoxyaluminum hydrides (such as lithium tri-t-butoxyaluminum hydride), dialkylaluminum hydrides (such as di-isobutylaluminum hydride), borane, dialkylboranes (such as di-isoamyl borane), alkali metal trialkylboron hydrides (such as lithium triethylboron hydride). Inert solvents include lower alkyl alcohols of 1 to 6 carbons, ethereal solvents (such as diethyl ether or tetrahydrofuran), aromatic or non-aromatic hydrocarbons of 6 to 10 carbons. Reaction temperatures for the reduction range from about -78° to about 200° C., preferably about 0° to about 120° C. The choice of reducing agent and solvent is known to those skilled in the art as taught in the above cited March reference (Advanced Organic Chemistry, pp. 1093-1110). ##STR35##
Compounds of Formula (I) can also be prepared by the procedures outlined in Scheme 23. A compound of Formula (CI) (Formula I, where Z=CR 2 , Y=N, R 3 =(CHR 11 ) p CN) can be reacted with sodium azide and ammonium chloride in a polar solvent at high temperatures (preferably 70 to 150° C.) to give a tetrazole of Formula (CII) as taught by the prior art (cf. R. N. Butlet, Tetrazoles, in Comprehensive Heterocyclic Chemistry; A. R. Katritzky, C. W. Rees, Eds.; (New York: Pergamon Press, 1984), pp. 828-832). Such polar solvents may be dialkylformamides (preferably N,N-dimethylformamide), dialkylacetamides, (preferably N,N-dimethylacetamide), cyclic amides, (preferably N-methylpyrrolidinone), dialkyl sulfoxides (preferably dimethyl sulfoxide) or dioxane. A compound of Formula (CIII) (Formula I, where Y=N, Z=CR 2 and R 3 =COCH 3 ) may be treated with a halogenating agent in an inert solvent to give a haloketone of Formula (CIV). Such halogenating agents include bromine, chlorine, iodine, N-halosuccinimides (e.g. N-bromosuccinimide), N-halophthalimides (e.g., N-bromophthalimide) or N-tetrasubstituted ammonium perbromides (e.g., tetraethylammonium perbromide) (cf. The above March reference, Advanced Organic Chemistry, pp. 539-531; S. Kajiigaeshi, T. Kakinami, T. Okamoto, S. Fujiisaki, Bull. Chem. Soc. Japan 60:1159-1160 (1987) and references cited therein). Inert solvents include lower halocarbons of 1 to 6 carbons and 2 to 6 halogens (preferably dichloromethane or dichloroethane), dialkyl ethers of 4 to 10 carbons, cyclic ethers of 4 to 10 carbons (preferably dioxane) or aromatic hydrocarbons to 6 to 10 carbons. Haloketones of Formula (CIV) may be converted to imidazoles of Formula (CVII) by treatment with formamide with or without an inert solvent as taught by the prior art (H. Brederick and G. Theilig, Chem. Ber. 86:88-108 (1953)). Alternatively, ketones of Formula (CIII) may be converted to vinylogous amides (CV) by reaction with N,N-di(lower alkyl)formamide di(lower alkyl)acetals (e.g., N,N-dimethylformamide dimethyl acetal) or Gold's reagent ((dimethylaminomethyleneaminomethylene)-dimethylammonium chloride) in an inert solvent with or without base as taught by the prior art (cf. J. T. Gupton, S. S. Andrew, C. Colon, Synthetic Communications 12:35-41 (1982); R. F. Abdulla, K. H. Fuhr, J. Organic Chem. 43:4248-4250 (1978)). Such inert solvents include aromatic hydrocarbons of 6 to 10 carbons, lower alkyl alcohols of 1 to 6 carbons, dialkyl ethers of 4 to 10 carbons, or cyclic ethers of 4 to 10 carbons (preferably dioxane). Such bases may include a tertiary amine, an alkali metal hydride (preferably sodium hydride), an aromatic amine (preferably pyridine), or an alkali metal carbonate or alkoxide. Vinylogous amides (CV) can be condensed with hydrazine in an inert solvent to form pyrazoles of Formula (CVI) as taught by the prior art (cf. G. Sarodnick, Chemische Zeitung 115:217-218 (1991); Y. Lin, S. A. Lang, J. Heterocyclic Chem. 14:345 (1977); E. Stark et al., Chemische Zeitung 101:161 (1977); J. V. Greenhill, Chem. Soc. Reviews 6:277 (1977)). Such inert solvents include aromatic hydrocarbons of 6 to 10 carbons, lower alkyl alcohols of 1 to 6 carbons, dialkyl ethers of 4 to 10 carbons, or cyclic ethers of 4 to 10 carbons (preferably dioxane). ##STR36##
The purines and 8-aza-purines of the present invention are readily synthesized following the methods shown in Schemes 24 and 25. The purine (CXI) is derived from an appropriately substituted pyrimidine (CVIII). The trisubstituted hydroxypyrimidine is nitrated under standard conditions with fuming nitric acid. Following conversion of the hydroxy compound to the chloro derivative via treatment with phosphorus oxychloride, reduction of the nitro group with iron powder in acetic acid and methanol yielded the aminopyrimidine (CIX). Compound CIX is reacted with the appropriately substituted aniline in the presence of base catalyst to yield an anilinopyrimidine (CX), which was then converted to the desired purine (CXI) via reaction with triethylorthoformate in acetic anhydride. Starting from compound CX, the desired 8-aza-purine can be prepared via reaction with sodium nitrite in acetic acid. ##STR37##
If R 3 of the purine is a chloro group, that substituent can be further elaborated to other R 3 substituents as shown in Scheme 25. Compound (CXII), wherein R 3 is chlorine, is reacted with a nucleophile with or without an inert solvent at temperatures ranging from 20° C. to 200° C., to effect the formation of the 8-azapurine (CXIII). In a similar fashion, the R 3 of an appropriately substituted purine (CXI) may be converted to other functional groups to yield the purine (CXIV) having the desired substitution pattern. Similarly, if R 1 is a chloro group, it may be converted to another functional group via reaction with an appropriate nucleophile. Nucleophiles include amine, hydroxy, or mercapto compounds or their salts. ##STR38##
Compounds of the Formula (I) wherein J, K, and/or L are N, such as (CXXVII), (CXXVIII), (CXXIX), or (CXXX), were prepared according to Schemes 26 and 27. The preparation of the lower ring heterocycle of the compound of the Formula (I) is shown in Scheme 26. 2,4-Dihydroxy-5-nitropyrimidine (CXV) was first converted to the dichloro compound (CXVI) via treatment with phosphorus oxychloride. Compound (CXVI) was then converted to the symmetrically bis-substituted pyrimidines, (CXVII) and (CXVIII), via reaction with the appropriate R 5 or X group radicals, MR 5 and MX, respectively, where M is a metal atom. It is understood that compounds of the Formula (I) wherein R 5 and X have the same definition fall within the scope of this invention. A method of forming the unsymmetrically bis-substituted compounds (CXIX) and (CXX) is treatment of (CXVI) with equimolar amounts of MR 5 and X to form a statistical distribution of products, (CXVII), (CXVIII), (CXIX) and (CXX), which can be purified by standard techniques, such as, recrystallization or chromatography.
The desired (N-pyrimidino-N-alkyl)aminopyrimidines of the present invention were prepared according to Scheme 27. An appropriately substituted 2-hydroxypyrimidine (CXXI) was converted to the 2-chlorpyrimidine (CXXII) via treatment with phosphorus oxychloride. The intermediate (N-pyrimidino)aminopyrimidines, (CXXIII), (CXXIV), (CXXV), and (CXXVI), were prepared via treatment of (CXXII) with the appropriate 5-aminopyrimidine, (CXVII), (CXVIII), (CXIX) and (CXX) respectively, in the presence of a base, such as, NaH. Simple alkylation of the amino groups in (CXXIII), (CXXIV), (CXXV), and (CXXVI) via treatment with R 4 I and sodium hydride gave the desire (N-pyrimidino-N-alkyl)aminopyrimidines, (CXXVII), (CXXVIII), (CXXIX), and (CXXX). ##STR39##
The (N-heterocycle-N-alkyl)aminopyrimidines or N-heterocycle-N-alkyl)aminotriazines of the present invention may also be prepared according to Scheme 28. Commercially available amino substituted heterocycles (CXXXI) may be brominated using a tetrasubstituted ammonium tribromide, preferably benzyltrimethylammonium tribromide (BTMA Br 3 ) to yield the appropriately substituted o-bromo-aminoheterocycle (CXXXII). Such reactions are carried out in an inert solvent, such as, lower alcohols or halocarbons of 1 to 4 carbons and 1 to 4 halogens in the presence of a base, such as, alkali metal or alkaline earth metal carbonates. Compound (CXXXII) is then coupled to a substituted pyrimidine or triazine (CXXXIII) to form an (N-heterocycle-N-alkyl)aminopyrimidine (CXXXIVa) or (N-heterocycle)aminotriazine (CXXXIVb). (CXXXIVa or b) is then further alkylated in the presence of a base to the target (N-heterocycle-N-alkyl)aminopyrimidine (CXXXVa) or (N-heterocycle-N-alkyl)aminotriazine (CXXXVb), respectively. ##STR40##
Description of Scheme 29
Alternatively purines (CXIV) and triazolopyrimides (CXIII) of the present invention may be readily synthesized by following one of the approaches outlined in Scheme 29. Substituted anilines may be readily coupled with 2,4-dichloro-5-nitropyrimidines (CXXXVI) in the presence or absence of solvents such as DMSO or DMF or THF to provide compounds CXXXVII or CXXXVIII. CXXXVII or CXXXVIII are readily elaborated to compounds CX or CSII by following standard conditions outlined in Schemes 24, 25 and 29. In another approach nucleophiles R 3 H may be added to CXXXVI in the presence or absence of bases in solvents such as halogenated solvents, alkyl ethers and cyclic ethers to afford compound CXXXIX. Substituted anilines may be readily added to CXXXIX in the presence or absence of solvents such as dialkylsulfoxide or N,N-dialkylformamides or N,N-dialkylacetamides or cyclic amides such as N-methylpyrrolidinone to provide compounds of structure CXL. Starting from compound CXL, compounds of the present invention purines (CXIV) or triazolopyrimidines (CXIII) can be prepared under standard conditions described in Schemes 24 and 29.
An alternative synthesis of triazolopyridines is described in Scheme 30: ##STR41##
Treatment of compounds of Formula (CLIV) with an aliphatic or aromatic amine in an appropriate organic solvent but not limited to, alkyl alcohols such as methanol, ethanol, propanol, butanol, alkyl alkanoates such as ethyl acetate, alkanenitriles such as acetonitrile, dialkyl formamides such as DMF gives the corresponding ammonium salt, which upon treatment with POCl 3 at temperatures from 25 to 120° C., give compounds of Formula (CLVI). Treatment of compounds of Formula (CLVI) with appropriate primary amines in an organic solvent such as but not limited to alkyl alcohols such as methanol, ethanol, propanol, butanol, alkyl alkanoates such as ethyl acetate, alkanenitriles such as acetonitrile, dialkyl formamides such as DMF, dialkylsulfoxides at temperatures from 25 to 120° C. gives (CLVII). This is converted to (LXV) by treatment with POCl 3 at temperatures from 25 to 120° C. Compounds of Formula (LXV) can be coupled with Ar--NH 2 with or without the presence of solvent at temperatures from 25 to 200° C. to give products (LXVI). These can be converted to intermediates (LXVII) by reduction of the nitro group under a variety of reducing conditions, such as those used for the same conversion in Scheme 16 or other reducing reagents such as sodium dithionate, H2/catalyst, Fe/acid. The final cyclizaton can be carried out by treatment with NaNO2 in the presence of an acid such as acetic, hydrochloric to give triazolopyridines of Formula (LXVIII, R 3 ═NHR 6 ).
Treatment of compounds of Formula (CLIV) with POCl 3 in the presence of N,N-diethylaniline gives the dichloro compounds of Formula (CLV). These react selectively with secondary amines HNR 5 R 6 to give the 4-adduct of Formula (LXV). Compounds of Formula (LXV) can be subjected to the same reaction sequence described above to give compounds of Formula (LXVIII, R 3 ═NR 6 R 7 ).
The compounds of the invention and their syntheses are further illustrated by the following examples and preparations. All temperatures are in degrees Celsius.
EXAMPLE 1
N-(2-bromo-4-methylphenyl)-N-methyl-4,6-dimethyl-2-pyrimidinamine
Part A: To 4,6-dimethyl-2-hydroxypyrimidine (37.1 g), cooled in an ice bath was slowly added phosphorous oxychloride (60 mL) and the mixture was stirred at 0° C. for 15 minutes and heated to reflux for 23 hours. The mixture was allowed to cool to room temperature, poured slowly over ice and extracted with diethyl ether (20×100 mL). The combined ether layers were dried over magnesium sulfate and concentrated in vacuo to yield an off-white crystalline solid (19.77 g). The remaining material was subjected to lighter-than-water liquid/liquid extraction using diethyl ether for 19.5 hours to yield additional off-white crystalline solid (3.53 g) after concentration. A total of 23.32 g of 2-chloro-4,6-dimethylpyrimidine was obtained (55% yield).
Part B: To a solution of the product from Part A (2.0 g) in ethylene glycol (80 mL) was added 2-bromo-4-methylaniline (2.6 g, 1 eq) and the mixture was heated to reflux for 4.5 hours. After cooling to room temperature, the mixture was partitioned between water )200 mL) with ethyl acetate (3×100 mL). The ethyl acetate layers were combined, washed with brine, dried over magnesium sulfate, and concentrated under vacuum to yield a brown solid (4.92 g). This product was purified on a silica gel-60 column using 25% ethyl acetate in hexanes as eluent. The intermediate, N-(2-bromo-4-methylphenyl)-4,6-dimethyl-2-pyrimidinamine (3.29 g) was obtained as light tan fine crystals (80% yield).
Part C: To the product from Part B (1.0 g) in dry tetrahydrofuran (40 mL) was added potassium tert-butoxide in 2-methyl-2-propanol (1.0 M, 6.8 mL) and iodomethane (1.0 mL, 5 eq). The mixture was stirred for 72 hours at room temperature. After partitioning between water (50 ml) using ethyl acetate (2×100 ml), the ethyl acetate layers were combined, washed with brine, dried over magnesium sulfate, and concentrated in vacuo to yield a yellow liquid (1.06 g). The crude product was purified on a silica gel-60 column using 15% ethyl acetate in hexanes as eluent. The title compound, as the free base, was obtained as a thick yellow liquid (0.89 g; 85% yield). Anal. Calcd C 14 H 16 BrN 3 : % C: 54.92; % H: 5.27; % N: 13.72; % Br: 26.09. Found: % C: 54.61; % H: 5.25; % N: 13.55; % Br: 26.32.
The hydrochloride salt was made using anhydrous hydrogen chloride in diethyl ether; mp 120-121° C.
EXAMPLE 2
N-(2-bromo-4-(1-methylethyl)phenyl)-N-methyl-4,6-dimethyl-2-pyrimidianamine
Part A: A mixture of the product from Example 1, Part A (2.01 g, 14.01 mmoles), 2-bromo-4-(1-methylethyl)aniline (3 g, 14.10 mmoles) in ethylene glycol (20 mL) was heated to reflux for 1.5 hours. Following cooling to room temperature and partitioning between ethyl acetate (200 mL) and aqueous sodium hydroxide (1 M, 50 mL), the organic layer was washed with brine, dried, and concentrated in vacuo. The residue was chromatographed on silica gel using 5% ethyl acetate in hexanes to give 2-N-(2-bromo-4-(1-methylethyl)phenyl)-4,6-dimethylpyrimidinamine (3.28 g).
Part B: The product from Part A (1.64 g, 5.12 mmoles) was treated with sodium hydride (60% in oil, 0.41 g, 10.25 mmoles) in tetrahydrofuran (10 mL) at 25° C. for 15 minutes and iodomethane (0.82 mL, 13 mmoles) was added. The mixture was stirred at 25° C. for 90 hours and partitioned between ethyl acetate (100 mL) and water (30 mL). The water was extracted with additional ethyl acetate (60 mL) and the combined organic extracts were washed with brine, dried, and concentrated in vacuo. The residue was chromatographed on silica gel using 8% ethyl acetate in hexanes to give the title compound (1.4 g) as the free-base.
The free-base was dissolved in ether (10 mL) and treated with a solution of anhydrous hydrogen chloride in ether (1 M, 6 mL). The precipitated solid was collected and dried under vacuum (mp 163-164° C.).
EXAMPLE 3
N-(2-bromo-4-ethylphenyl)-N-methyl-4,6-dimethyl-2-pyrimidinamine
Part A: 2-Bromo-4-acetylacetanilide (2 g, 7.81 mmoles) was dissolved in trifluoroacetic acid (20 mL) and triethylsilane (2.8 mL, 17.5 mmoles) was added. The mixture became warm and was stirred without cooling for 4 h. Then it was basified with conc. NH 4 OH and NaHCO 3 and extracted with EtOAc (2×100 mL). The organic extracts were combined, washed with brine, dried and stripped in vacuo. The residue was >90% clean and directly used in the next step.
Part B: Using the product from Part A and the procedure outlined for Example 1, the desired compound was obtained in good yield.
EXAMPLE 4
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-morpholino-6-methyl-2-pyrimidinamine
Part A: A mixture of 2,4-dichloro-6-methylpyrimidine (4 g, 24.54 mmoles), morpholine (2.14 mL, 24.54 mmoles) and N,N-diisopropylethylamine (4.52 mL) in ethanol (60 mL) was stirred at 0° C. for 3 hours, 25° C. for 24 hours, followed by reflux for 1 hour. The solvent was removed under vacuum and the residue was partitioned between ethyl acetate (200 mL) and aq. sodium hydroxide (1 M, 50 mL). The organic layer was washed with water and brine and dried and concentrated in vacuo. The residue was recrystallized from ethyl acetate/hexanes to give 2-chloro-4-morpholino-6-methylpyrimidine (3.8 g).
Part B: The product from Part A (1 g, 4.67 mmoles) and 2-bromo-4-(1-methylethyl)aniline (1 g, 4.67 mmoles) were heated to reflux in ethylene glycol (6 mL) for 1.5 hours. After cooling, the mixture was partitioned between ethyl acetate (100 mL) and aq. sodium hydroxide (1 M, 20 mL). The organic layer was washed with water and brine, dried and concentrated on a rotary evaporator. The residue was chromatographed on silica gel using 25% ethyl acetate in hexanes to give 2-N-(2-bromo-4-(1-methylethyl)phenyl)-4-morpholino-6-methylpyrimidinamine (1.5 g).
Part C: The product from Part B (1.0 g, 2.56 mmoles) was treated with sodium hydride (60% in oil, 0.15 g, 3.75 mmoles) in tetrahydrofuran (10 mL) at 25° C. for 20 minutes, followed by addition of iodoethane (0.32 mL, 4 mmoles). The mixture was stirred at 25° C. for 24 hours and heated to reflux for 5 hours. After partitioning between ethyl acetate (100 mL) and water (20 mL), the organic extract was washed with brine, dried, and concentrated in vacuo. The residue was chromatographed on silica gel using 12% ethyl acetate in hexanes to give the title compound (0.94 g) as the free-base.
The hydrochloride salt of the above title compound was prepared by dissolving the isolate in ether (10 mL) and treating with anhydrous hydrogen chloride in ether (1 M, 4 mL). The precipitated solid was collected and dried under vacuum (mp 219-222° C.).
EXAMPLE 5
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
Part A: To a solution of 2-bromo-4-(1-methylethyl)aniline (6 g, 28.2 mmoles) and cyanamide (4.7 g, 112.08 mmoles) dissolved in ethyl acetate (100 mL) and ethanol (13 mL) was added hydrogen chloride in ether (1 M, 38 mL, 38 mmoles) and the mixture was stirred at 25° C. for 1 hours. The volume of the reaction was reduced by 75 mL by distillation. The residue was heated to reflux for 3 hours and after cooling, ether (120 mL) was added. The precipitated solid, 2-bromo-4-(1-methylethyl)phenylguanidinium hydrochloride, was collected and dried (10.4 g), and was used in the next reaction without purification.
Part B: A mixture of the product from Part A (5.0 g, 13.47 mmoles), potassium carbonate (1.86 g, 13.47 mmoles) and 2,4-pentanedione (2.8 mL, 27.28 mmoles) in N,N-dimethylformamide (35 mL) was heated to reflux for 24 hours. After cooling, the reaction was partitioned between ethyl acetate (120 mL) and aq. sodium hydroxide (0.5 M, 100 mL). The aqueous layer was extracted with additional ethyl acetate (120 mL) and the combined organic extracts were washed with water, brine, dried and concentrated in vacuo. The residue was chromatographed on silica gel eluting with 8% ethyl acetate in hexanes to give 2-N-(2-bromo-4-(1-methylethyl)phenyl)-4,6-dimethylpyrimidinamine (3.37 g).
Part C: The product isolated from Part B (3.0 g, 9.37 mmoles) was alkylated with sodium hydride and iodoethane in tetrahydrofuran in an analogous manner to that described for Example 4, Part C. The title compound was isolated as the free-base (2.88 g).
The hydrochloride salt was prepared in a manner analogous to that of Example 4 using hydrogen chloride in ether, to give a solid, mp 151-153° C.
EXAMPLE 6
N-ethyl-N-(2-bromo-4-(2-methoxyethyl)phenyl)-4-morpholino-6-methyl-2-pyrimidinamine
Part A: To 4-Hydroxyethylaniline, 16.55 g (0.12 moles) in a mixture of pyridine (23 mL, 0.29 moles) and CH 2 Cl 2 (100 mL) cooled to 0° C. was added acetyl chloride (18.8 mL, 0.26 moles) dropwise. The mixture was stirred at 0° C. for 2 h and at 25° C. for 48 h and then added to saturated NaHCO 3 solution (100 mL). The CH 2 Cl 2 was separated, washed with brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 25% and 1:1 EtOAc/hexanes to give the product (24 g, 90% yield).
Part B: 4-Acetoxyethylacetanilide was brominated according to the method described in Org. Synth. Coll. Vol I, 111, wherein the anilide (14 g, 63 mmoles) was dissolved in glacial acetic acid (70 mL) and bromine (4 mL, 77.4 mmoles) was added dropwise. The resulting solution was stirred at 25° C. for 60 hours. A solution of sodium sulfite (20 mL) was then added, followed by H 2 O (200 mL) and the precipitated bromide was isolated by filtration. The filtrate was further diluted with H 2 O (300 mL) and cooled to give an additional amount of bromide. The isolated bromide was heated to reflux in HCl solution (6M, 100 mL) for 2 h and the resulting mixture was neutralized with solid NaHCO 3 and extracted with EtOAc (2×160 mL each). The combined EtOAc extracts were washed with brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 1:1 EtOAc/hexanes to give the produce (2.8 g) in 20% yield for the two steps.
Part C: 2-Bromo-4-hydroxyethylaniline (1.6 g, 7.3 mmoles) and 2-chloro-4,6-dimethylpyrimidine (1.1 g, 7.3 mmoles) were reacted in ethylene glycol (6 mL) at reflux for 1.5 h. After cooling the mixture was partitioned between EtOAc (100 mL) and NaOH solution (0.5M, 25 mL). The aqueous layer was extracted with additional EtOAc (50 mL) and the combined organic extracts were washed with brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 1:1 EtOAc/hexanes to give the product (1.3 g) in 64% yield.
Part D: The product from Part C (1.39 g, 4.77 mmoles) was dissolved in dry CH 2 Cl 2 (30 mL) and 3,4-dihydro-2H-pyran (1.65 mL, 11.98 mmoles) was added, followed by conc. sulfuric acid (Conc. H 2 SO 4 , 0.2 mL). The mixture was stirred at 25° C. for 60 h and solid K 2 CO 3 (1 g) was added, followed by saturated NaHCO 3 (50 mL). The mixture was partitioned between EtOAc (120 mL) and NaHCO 3 solution (20 mL). The EtOAc was washed with brine, dried, and stripped in vacuo. The dried crude product, dissolved in dry THF (15 mL) was treated with sodium hydride (60% in oil, 380 mg) at 25° C. for 15 min and then iodoethane (1 mL, 9.45 mmoles) was added. The mixture was stirred at 25° C. for 12 h and heated to reflux for 4 h. Then it was partitioned between EtOAc (120 mL) and H 2 O (20 mL). The EtOAc was washed with brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 15% EtOAc/hexanes to give the product (1.6 g) in 78% yield for the two steps.
Part E: The product from Part D was dissolved in MeOH (20 mL) and conc. H 2 SO 4 (0.4 mL) was added, followed by HCl in ether (1M, 1.5 mL). The mixture was stirred at 25° C. for 2 h, quenched with solid K 2 CO 3 (1 g), and partitioned between EtOAc (100 mL) and NaHCO 3 solution (30 mL) and NaOH solution (2 mL, 2 M). The H 2 O layer was extracted with additional EtOAc (60 mL) and the combined EtOAc extracts were washed with brine, dried, and stripped in vacuo. The residue was chromatographed on silica gel using 40% EtOAc/hexanes to give the product (1.23 g) in 95% yield.
Part F: The product from Part E (720 mg, 2.06 mmoles) was treated with NaH (60% in oil, 120 mg, 3 mmoles) in THF (10 mL) at 0° C. for 5 min and at 25° C. for 15 min. Iodomethane (0.25 mL, 4 mmoles) was added and the resulting mixture was stirred at 25° C. for 20 h. The reaction was partitioned between EtOAc (100 mL) and H 2 O (25 mL). The EtOAc was washed with brine, dried, and stripped in vacuo. The residue was chromatographed on silica gel using 20% EtOAc/hexanes to give the product (680 mg) (91% yield), which was converted into the hydrochloride salt by treatment with 1 M HCl/ether, mp 117-118.5° C.
EXAMPLE 7
N-Ethyl-N-(2-iodo-4-(1-methylethyl)phenyl)-4-morpholinyl-6-methyl-2-pyrimidinamine
A solution of the free-based Example 4 (1.4 g, 3.34 mmoles) dissolved in tetrahydrofuran (15 mL) at -78° C. was treated with n-butyllithium (1.6 M in hexanes, 3.3 mL, 3.7 mmoles). After stirring 15 minutes, a solution of iodine (1.0 g, 4 mmoles) in tetrahydrofuran (5 mL) was added dropwise and the mixture was stirred at -78° C. for an additional 30 minutes before warming to 25° C. The reaction was partitioned between ethyl acetate (100 mL) and sodium bisulfite solution (satd., 20 mL). The ethyl acetate layer was washed with water, brine, dried and concentrated in vacuo. The residue was chromatographed on silica gel using 15% ethyl acetate in hexanes as eluent to give the title compound (0.9 g) as a solid, mp 96-98° C.
EXAMPLE 8
N-(2-Bromo-4-(1-methylethyl)phenyl)-N-ethyl-6-methyl-4-(2-thienyl)-2-pyrimidinamine
Part A: 2-Chloropyrimidine (2.0 g) was dissolved in diethyl ether (50 mL) and chilled to -30° C. A solution of methyllithum in ether (1.4 molar, 15 mL) was slowly added and the reaction was stirred at -30° C. for 30 minutes, then at 0° C. for an additional 30 minutes. A mixture of acetic acid (glacial, 1.2 mL), water (0.5 mL) and tetrahydrofuran (5 mL) was added to quench the reaction. 2,3-Dichloro-5,6-dicyano-1,4-benzoquinone (4.79 g) in tetrahydrofuran (20 mL) was then and the reaction was allowed to stir for 5 minutes at room temperature. The mixture was chilled to 0° C. and aqueous sodium hydroxide solution (3 M, 50 mL) was added and the reaction mixture allowed to stir for 10 minutes. The organic layer was separated and washed with water and dried with magnesium sulfate. The solvent was removed in vacuo and the resulting residue chromatographed on silica gel (solvent 30% ethyl acetate in hexanes; R f 0.4) to yield 2-chloro-4-methylpyrimidine (1.4 g), m.p. 48-50° C.
Part B: To thiophene (0.66 g) in dry ether (25 mL) at 0° C. was added n-butyl lithium in hexanes (1.6 M, 2.7 mL) and the reaction was stirred at 0° C. for 15 minutes. After cooling to -30° C., a solution of 2-chloro-4-methylpyrimidine (1.0 g) in ether (10 mL) was slowly added and the reaction was stirred at -30° C. for 30 minutes and at 0° C. an additional 30 minutes before quenching with a mixture of acetic acid (glacial, 0.45 mL), water (0.5 mL) and tetrahydrofuran (1.0 mL). 2,3-Dichloro-5,6-dicyano-1,4-benzoquinone (1.77 g) in tetrahydrofuran (5 mL) was added and the reaction mixture was stirred at room temperature for 5 minutes, then cooled to 0° C. before aq. sodium hydroxide solution (3 M, 50 mL) was added. The organic layer was separated, washed with water, and dried with magnesium sulfate. The solvent was evaporated and the resultant crude oil was chromatographed on silica gel (30% ethyl acetate in hexanes; R f 0.55) to yield 2-chloro-4-methyl-6-(2-thienyl)pyrimidine (0.21 g). Anal. Calc.: % C: 51.46: % H: 3.33: % N: 13.33. Found: % C: 51.77: % H: 3.35; % N: 12.97.
Part C: 2-Bromo-4-(1-methylethyl)aniline (0.26 g) and 2-chloro-4-methyl-6-(2-thienyl)pyrimidine (0.21 g) in ethylene glycol were heated at reflux for 24 hours. The reaction mixture was diluted with ethyl acetate, washed with aq. sodium hydroxide solution (10%, 3×100 mL) and the organic phase was dried. Solvent removal gave a crude brown oil, which was purified on silica gel using 20% ethyl acetate in hexanes (R f 0.5) as eluent to provide N-(2-bromo-4-isopropylphenyl)-4-methyl-6-(2-thienyl)-2-pyrimidinamine (0.1 g) as a solid, mp 98-101° C. Mass spec (NH 3 --CI/DDIP); 390 (M+H) + .
Part D: The product from Part C (0.1 g) was slowly added to a solution of sodium hydride (50 mg) in dry tetrahydrofuran, after which iodoethane (0.1 g) was added and the mixture was refluxed for 24 hours. The reaction mixture was cooled and water (0.5 mL) was added. The solvent was evaporated and the crude material was taken up in ethyl acetate, washed with water (3×50 mL) and dried. The solvent was evaporated and the crude product chromatographed on silica gel using 10% ethyl acetate in hexanes (F f 0.5) to give the title compound (70 mg) as the free-base.
The HCl salt of this material was prepared using the procedure reported above; mp 95-97° C.; Mass spec. (NH 3 --CI/DDIP): 417 (M+h) + . Anal. Calcd for C 20 H 22 N 3 BrS.HXl: % C: 53.10; % H: 5.09; % N: 9.51. Found: % C: 53.78; % H: 5.22; % N: 9.10.
EXAMPLE 9
N-(2-Bromo-4-(1-methylethyl)phenyl)-N-cyclopropylmethyl-4,6-dimethyl-2-pyrimidinamine)
By analogy to Example 2 the title compound was prepared by substituting 2-bromo-4-(1-methylethyl)aniline (4.0 g) and 2-chloro-4,6-dimethylpyrimidine in Part A, to give the desired pyrimidinamine intermediate, Mass spec. (NH 3 --CI/DDIP): 321 (M+H) + . By substituting (bromomethyl)cyclopropane in Part B of this same Example, the desired material was obtained, Mass spec. (NH 3 --CI/DDIP): 374 (M+H) + .
The hydrochloride salt of this free base was prepared, mp 146-148° C.
EXAMPLE 10
N-(2-Bromo-4-(1-methylethyl)phenyl)-N-propargyl-4,6-dimethyl-2-pyrimidinamine
By using 2-(2-bromo-4-(1-methylethyl)anilino)-4,6-dimethylpyrimidine and substituting propargyl chloride in Example 9, the title compound was isolated as the free-base, Mass spec. (NH 3 --CI/DDIP): 358 (m+H) + .
The hydrochloride salt of the free base was prepared.
EXAMPLE 11
N-Ethyl-N-(2-iodo-4-(2-methoxyethyl)phenyl)-4,6-dimethyl-2-pyrimidinamine, hydrochloride
Part A: 4-Hydroxyethylaniline was iodinated in a manner analogous to that described in Example 6 in conjunction with that reported in Tet. Lett. 33:373-376 (1992). The aniline (2 g, 14.58 mmoles) was dissolved in CH 3 CH (25 mL) and H 2 O (15 mL) containing NaHCO 3 (1.68 g, 20 mmoles) was added. The mixture was cooled to 12-15° C. by addition of ice and iodine (3.9 g, 15.35 mmoles) was added. The mixture was stirred at 25° C. for 16 h and then it was partitioned between EtOAc (100 mL) and NaOH solution (20 mL, 1M). The EtOAc was washed with brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 1:1 EtOAc/hexanes to give 1.8 g product, a 47% yield.
Part B: The product from Part A (6.3 g, 23.94 mmoles) was dissolved in a mixture of EtOAc (100 mL) and EtOH (10 mL) and cyanamide (4.7 g, 112.5 mmoles) was added, followed by HCl in ether (31 mL, 1 M). The flask was fitted with a distillation head and 50 mL solvent was distilled off. The residual mixture was diluted with EtOH (15 mL) and heated to reflux for 5 h. After cooling, Et 2 O (100 mL) was added and the precipitated salt was washed with EtOAc and dried to give the product (4.5 g) in 55% yield.
Part C: The guanidinium salt from Part B (8.53 g, 24.95 mmoles), potassium carbonate (3.84 g, 27.72 mmoles) and 2,4-pentanedione (9 mL, 42.65 mmoles) were heated to reflux in DMF (70 mL) for 16 h. The reaction mixture was partitioned between EtOAc (150 mL) and H 2 O (50 mL) and the organic layer was washed with H 2 O (2×80 mL), brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 1:1 EtOAc/hexanes to give the product (2.8 g) in 30% yield.
Part D: To the product from Part C (3.3 g (8.93 mmoles) in CH 2 Cl 2 (60 mL) and 3,4-dihydro-2H-pyran (3.1 mL, 22.7 mmoles) was added Conc. H 2 SO 4 (0.5 mL) and the mixture was stirred at 25° C. for 16 h. An additional portion of H 2 SO 4 (0.2 mL) was added and stirring was continued for 3 h. EtOAc (100 mL) and saturated NaHCO 3 (100 mL) was added and the layers separated. The aqueous layer was extracted with additional EtOAc (100 mL) and the combined organic extracts were washed with NaHCO 3 , brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 20% EtOAc/hexanes to give the product (1.2 g) in 31% yield.
Part E: The product from Part D was dissolved in dry THF (15 mL) and NaH (60% in oil, 220 mg, 5.5 mmoles) was added. The mixture was stirred at 25° C. for 15 min and iodoethane (0.5 mL, 5.7 mmoles) was added. The mixture was stirred at 25° C. for 16 h and then heated to reflux for 2 h. The reaction product was then partitioned between EtOAc (100 mL) and H 2 O (30 mL). The organic layer was washed with brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 10% EtOAc/hexanes to give the product (1.1 g). This material was dissolved in MeOH (20 mL). HCl in ether (3 mL, 1M) was added and the mixture was stirred at 25° C. for 2 h. Then it was partitioned between EtOAc (100 mL) and NaOH (30 mL, 1 M). The EtOAc was washed with brine, dried and stripped in vacuo. The residue was used in the next step without purification.
Part F: The product from Part E (950 mg, 2.4 mmoles) in dry THF (10 mL) was treated with NaH (60% in oil, 140 mg, 3.5 mmoles), stirred at 25° C. for 15 min and 0.25 mL iodoethane (4 mmoles) was added. The resulting mixture was stirred at 25° C. for 16 h and then partitioned between EtOAc (100 mL) and h 2 O (20 mL). The organic layer was washed with brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 20% EtOAc/hexanes to give the product (500 mg), which was converted into the hydrochloride salt in the usual manner, mp 129-131 C.
EXAMPLE 12
N-(2-Bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-methyl-2-pyrimidinamine
Part A: The product from Example 8, Part A (0.2 g) and 2-bromo-4-(1-methylethyl)aniline were coupled using the same method described in Example 8, Part C to provide N-(2-bromo-4-(1-methylethyl)phenyl)-4-methyl-2-pyrimidinamine (0.7 g) as a viscous oil; Mass spec. (NH 3 --CI/DDIP): 307 (M+H).
Part B: The product from Part A was alkylated with iodoethane using the same method described in Example 8, Part D to give the desired N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-methyl-2-pyrimidinamine (0.3 g) as the free base.
The hydrochloride salt of this material was prepared in the usual manner; mp 145-147° C. Mass spec. (NH 3 --CI/DDIP): 334 (M+H) + .
EXAMPLE 13
N-(2-Bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-methyl-6-(N-methyl-2-hydroxyethylamino)-2-pyrimidianamine
Part A: A solution of 2,4-dichloro-6-methylpyrimidine (1.0 g) and 2-(methylamino)ethanol (0.4 g) in ethanol (50 mL) was refluxed for 24 hours. The solvent was evaporated to give a crude residue, which was chromatographed on silica gel using 5% methanol in chloroform to yield 2-chloro-4-methyl-6-(N-methyl-2-hydroxyethylamino)pyrimidine (370 mg). Mass spec. (NH 3 --CI/DDIP): 202 (M+H) + .
Part B: The hydroxyl group in the product from Part A was protected the methoxymethyl ether (MOM-ether) using N,N-di(1- methylethyl)ethylamine and bromomethyl methyl ether (0.35 g) in dry tetrahydrofuran to provide the protected adduct (310 mg, Mass spec. 246 (M+H) + ), which was carried on without purification.
Part C: The protected MOM-ether was coupled with 2-bromo-4-(1-methylethyl)aniline using the procedure of Example 8, Part C. Under these conditions, the methoxymethyl protecting group was also removed providing N-(2-bromo-4-(1-methylethyl)phenyl)-4-methyl-6-(N-methyl-2-hydroxyethylamine)-2-pyrimidinamine (mass spec. NH 3 --CI/DDIP 379 (M+H) + ). This hydroxyl group was reprotected for subsequent reactions as described in Part B, (Mass spec. for MOM-ether (NH 3 --CI/DDIP): 453 (M+H) + ). Alkylation with iodoethane was carried out using the method of Example 8, Part D. The MOM-ether was deprotected by stirring at room temperature in a solution of methanol (5 mL) and hydrochloric acid (1 M, 5 mL) for 24 hours. Upon workup and isolation, the title compound was obtained as the free-base.
The hydrochloride salt was prepared using the described procedure High Res. Mass Spec; 407.144640 (M+H) + ; Expected 407.144648 (M+H) + .
EXAMPLE 14
N-Ethyl-N-(2-Iodo-4-(1-Methylethyl)Phenyl)-4-Thiomorpholino-6-Methyl-2-Pyrimidinamine, S-oxide
The desired product was obtained by sodium periodate oxidation of the product of Example 22, according to the method of J. H. Bushweller et. al. J. Org. Chem. 54:2404, (1989).
EXAMPLE 15
N-(2-Bromo-4-(Isopropoxy)Phenyl)-N-Ethyl-4,6-Dimethyl-2-Pyrimidinamine
Part A: The synthesis of 2-bromo-4-isopropoxy-aniline was accomplished using the bromination procedure for 4-isopropoxy-aniline reported by Kajigaeshi et al. in Bull. Chem. Soc. Jpn. 61:597-599 (1988). The aniline, 1 eq. benzyltrimethylammonium tribromide, and 2 eq. calcium carbonate were stirred at room temperature in a solution of MeOH:CH 2 Cl 2 (2:5) for one hour. The solids were removed by filtration and the filtrate was evaporated under vacuum. The residue was taken up in H 2 O and this mixture was then extracted three times with CH 2 Cl 2 . The combined extracted were dried over MgSO 4 , filtered, and evaporated under vacuum to give a brown oil, which was purified on silica gel using 15% EtOAc in hexanes. (R f =0.43)
Part B: Using the procedure for Example 1, parts B-C and substituting the aniline from Part A, the title compound was obtained.
EXAMPLE 16
N-(2-Bromo-4-(1-Methylethyl)Phenyl)-N-Ethyl-4-Methyl-6-(4-Morpholinylcarbonyl)-2-Pyrimidinamine
To sodium hydride (60% in oil, 0.24 g, 6.0 mmol) suspended in anhydrous THF (10 mL) was added morpholine (0.52 g, 6.0 mmol) with stirring; the reaction mixture was warmed to reflux temperature and stirred for 1 hour. The reaction mixture was then cooled to ambient temperature and 2-(N-(2-bromo-4-(2-propyl)-phenyl)-N-ethylamino)-4-carbomethoxy-6-methyl-pyrimidine (2.0 g, 5.1 mmol) was added. Stirring was continued for 26 hours. The reaction mixture was then poured onto a 1 N NaOH solution, stirred and extracted three time with EtOAc. The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo. Column chromatography (Et 2 O) afforded the title compound as a solid (900 mg, 39% yield): mp 145° C.; NMR (CDCl 3 , 300 MHz): d 7.5 (d, 1H, J=1), 7.2 (dd, 1H, J=7.1), 7.1 (d, 1H, J=7), 6.8 (br s, 1H), 4.3-4.15 (m, 1H), 3.9-3.3 (m, 11H), 3.1-3.0 (m, 1H), 2.9 (septet, 1H, J=7), 1.3 (d, 6H, J=7), 1.15 (t, 3H, J=7); Anal. (C 21 H 27 BrN 4 O 2 ) Calcd: C, 56.38, H, 6.08, N, 12.52, Br, 17.86; Found: C, 56.07, H, 6.05, N, 12.29, Br, 18.08.
EXAMPLE 17
N-(2-Bromo-4-(1-Methylethyl)Phenyl)-N-Ethyl-6-Methyl-4-(4-Morpholinylmethyl)-2-Pyrimidinamine
A solution of N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-methyl-6-(4-morpholinylcarbonyl)-2-pyrimidinamine (750 mg, 1.72 mmol) in anhydrous THF (1.4 mL) was stirred at ambient temperature under a nitrogen atmosphere. A solution of borane in THF (1 M, 3.6 mL, 3.6 mmol) was added dropwise. The reaction mixture was then warmed to reflux temperature and stirred for 20 hours. After cooling to room temperature, acetic acid (3.5 mL) was added slowly and the mixture was heated to reflux temperature and stirred for 30 min. After being cooled to ambient temperature, the reaction mixture was poured onto a 3 N NaOH solution, mixed and extracted three times with EtOAc. The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo. Column chromatography (EtOAc) of the residue afforded the title compound as an oil (300 mg, 39% yield, R f 0.3): NMR (CDCl 3 , 300 MHz): d 7.5 (s, 1H), 7.2 (d, 1H, J=7), 7.15 (d, 1H, J=7), 6.5 (s, 1H), 4.3-4.1 (m, 1H), 3.8-3.6 (m, 7H), 3.5-3.3 (m, 2H), 2.9 (septet, 1H, J=7), 2.55-2.35 (br m, 3H), 2.35-2.25 (m, 2H), 1.3 (d, 6H, J=7), 1.2 (t, 3H, J=7); CI-HRMS: calcd: 4.33.1603 (M+H), found: 433.1586.
EXAMPLE 18
Methyl 2-((2-Bromo-4-(1-Methylethyl)Phenyl)Ethylamino)-6-Methyl-4-Pyrimidinecarboxylate
To sodium hydride (60% in oil, 4.8 g, 120 mmol) in THF (150 mL) at ambient temperature under a nitrogen atmosphere was added methyl 2-((2-bromo-4-(1-methylethyl)phenyl)amino)-6-methyl-4-pyrimidinecarboxylate (42.8 g, 118 mmol) portionwise over 30 min. After the gas evolution subsided, iodoethane (31.2 g, 16 mL, 200 mmol) was added in one portion and the reaction mixture was heated to a gentle reflux for 24 h. After cooling to room temperature, the reaction mixture was quenched carefully with water and extracted three times with ethyl acetate. The combined organic extracts were washed with water twice, dried over magnesium sulfate and filtered. Solvent was removed in vacuo to afford a brown oil. Column chromatography of the oil (Et 2 O:hexanes::1:1) provided two fractions: (1) methyl 2-((2-bromo-4-(1-methylethyl)phenyl)amino)-6-methyl-4-pyrimidinecarboxylate (4.6 g, 11% yield, R f =0.8) and (2) the title product (20 g, R f =0.7) as a crude oil. The title product was recrystallized from hexanes and dried in vacuo to give a solid (18.0 g, 39% yield): mp 81-82° C.: NMR (CDCl 3 , 300 MHz):d 7.5 (br s, 1H), 7.25 (d, 1H, J=7), 7.15 (d, 1H, J=7), 7.1 (s, 1H), 4.3-4.1 (m, 1H), 4.05-3.75 (m, 4H), 2.95 (septet, 1H, J=7), 2.3 (br s, 3H), 1.3 (d, 6H, J=7), 1.25 (t, 3H, J=7); CI-HRMS: calcd: 392.0974 (M+H), found: 392.0960.
EXAMPLE 19
N-(2-Bromo-4-(1-Methylethyl)Phenyl)-N-Ethyl-4-Methyl-6-(4-Methylpiperazinylcarbonyl)-2-Pyrimidinamine
Using a method analogous to that used for Example16, but substituting 4-methylpiperazine, the desired product was obtained; mp 81-82° C.
EXAMPLE 20
N-(2-Bromo-4-(2-Hydroxyethyl)Phenyl-N-Ethyl-4,6-Dimethyl-2-Pyrimidinamine
The THP-hydroxyl protecting group was removed using HCl in ether product as described earlier to arrive at the title compound; mp 58-60° C.
EXAMPLE 21
N-Ethyl-N-(2-Methoxy-4-(1-Methylethyl)Phenyl)-4,6-Dimethyl-2-Pyrimidinamine
Part A: Using the method of Example 1 and substituting 2-amino-5-methylphenol, the intermediate secondary amine was obtained.
Part B: By double methylating the amino and the phenol groups using excess sodium hydride and iodomethane in THF, the desired product was obtained.
EXAMPLE 22
N-Ethyl-N-(2-Iodo-4-(1-Methylethyl)Phenyl)-4-Thiomorpholino-6-Methyl-2-Pyrimidinamine
Using the iodination method of Example 11 and the general synthesis described in Example 4 the desired compound was obtained; mp 51-53° C.
EXAMPLE 23
N-[2-Bromo-4-(1-Methylethyl)Phenyl]-N-Ethyl-4-Methyl-6-(4-Morpholinyl)-1,3,5-Triazin-2-Amine
Part A: Methyl magnesium bromide (300 mmol, 3 M in ether, Aldrich) was added dropwise over a 10 min period to a solution of cyanuric chloride (12.9 g, 69.9 mmole) in CH 2 Cl 2 (300 mL) under N 2 at -20° C. and stirring was continued at -20° C. for 4.5 hours. Water (36 mL) was added dropwise while keeping the reaction temperature below -15° C. The reaction mixture was allowed to reach room temperature and magnesium sulfate (40 g) was added. It was let stand for one hour. The reaction mixture was filtered and the solvent removed leaving a yellow solid (11.06 g). This material was purified using flash chromatography (CH 2 Cl 2 , silica) and gave 2,4-dichloro-6-methyl-s-triazine as a white solid (7.44 g) in 65% yield.
Part B: 2,4-dichloro-6-methyl-s-triazine (3 g, 18.29 mmol), 2-bromo-N-ethyl-4-isopropylaniline (6.07 g, 25.07 mmol) and diisopropylethylamine (3.2 g, 25.07 mmol) in dioxane (60 mL) under N 2 were heated at reflux for three hours. The solvent was removed and the residue was purified using flash chromatography (CH 2 Cl 2 , silica) to provide the product (4.58 g) as a clear oil in 68% yield.
Part C: The product from Part B (500 mg, 1.35 mmol) was dissolved in dioxane (20 mL) under N 2 at room temperature and morpholine (247 mg, 2.84 mmol) was added in one portion. Stirring was continued at room temperature for 17 hours. The reaction solvent was stripped away and the residue was triturated with ethyl acetate/hexane (1:3). The triturated material was purified using flash chromatography (EtOAc/hexane, 1:3 Silica). The product was collected as a clear oil (550 mg) in 97% yield. C 19 H 26 N 3 OBr
EXAMPLE 24
N-(2-Bromo-4-(1-Methylethyl)Phenyl)-N-Ethyl-4-Methyl-6-(Hydroxymethyl)-2-Pyrimidinamine
The product of Example 18 and lithium borohydride (1.5 eq.) were stirred in dry THF under nitrogen for fifty hours. The reaction was then poured into water and extracted three times with CHCl 3 . The combined extracts were dried over MgSO 4 , filtered, and evaporated under vacuum to give a nearly quantitative yield of the product as a light yellow oil.
EXAMPLE 25
N-(2-Bromo-4-(1-Methylethyl)Phenyl)-N-Ethyl-4-Methyl-6-(Methoxymethyl)-2-Pyrimidinamine
To the product of Example 24 and sodium hydride (1.1 eq.) in dry THF under nitrogen was added iodomethane (1.1 eq.) and after four hours the reaction was poured into H 2 O and extracted three times with CHCl 3 . The combined extracts were dried over MgSO 4 , filtered, and evaporated under vacuum. The material was purified by chromatography on silica gel using 10% EtOAc in hexanes to give a light yellow oil. (R f =0.37)
EXAMPLE 26
N-(2-Bromo-4-(1-Methylethyl)Phenyl)-N-Ethyl-4-Methyl-6-(Thiomethyl)-2-Pyrimidinamine
Part A: 2-Bromo-4-isopropylaniline (8.9 g, 42 mmol) and 6-hydroxy-4-methyl-2-thiomethylpyrimidine (5 g, 32 mmol) were combined under N 2 and heated at 190° C. for 8 hours. The reaction mixture was cooled to room temperature. The residue was purified using flash chromatography (CH 2 Cl 3 /MeOH, 25:1, silica) to provide 9.16 g (89% yield) white solid.
Part B: The product from Part A (6 g, 18.6 mmol) and phosphorus oxychloride (20 ml, 214 mmol) were refluxed under N 2 for 15 minutes. The reaction mixture was cooled to room temperature, slowly poured onto ice (200 g), stirred about 30 minutes until the ice had melted, and the aqueous mixture was extracted with ethyl acetate (3×100 ml). The combined organic extracts were treated with water (100 mL) and brine (100 mL), dried over anhydrous sodium sulfate, filtered and stripped leaving 6.1 g tan oil. This material was purified using flash chromatography (CH 2 Cl 2 /hexane, 1:1, silica) to give 4.48 g (70% yield) of clear oil.
Part C: To the product of Part B (4.3 g, 12.65 mmol) in dimethylformamide (30 mL) under N 2 was added sodium hydride (658 mg, 16.45 mmol, 60% dispersion in oil) was added in small portions. After addition was complete, stirring was continued 4 hours at room temperature. Water (100 mL) was added to the reaction mixture and it was extracted with ethyl acetate (3×100 mL). The combined organic extracts were treated with water (100 mL) and brine (100 mL). The organic layer was dried over anhydrous sodium sulfate, filtered and stripped leaving 4.8 g tan oil. This material was purified using flash chromatography (EtOAc/hexane, 1:6, silica gel) to afford 4.4 g (95% yield) of oil.
Part D: The product of Part C (2 g, 5.4 mmol) and sodium thiomethoxide (558 mg, 7.6 mmol) in dioxane (50 mL) under N 2 were heated to reflux (20 hrs.). The solvent was stripped and the residue was purified using flash chromatography (CH 2 Cl 2 /hexane, 1:1, silica) to give 1.86 g (91% yield) of clear oil. Analysis: MS (NH3-Cl/DDIP):380 (M+H) + .
EXAMPLE 27
N-(2-Bromo-4-(1-Methylethyl)Phenyl)-N-Ethyl-4-Methyl-6-(Thiomethyl)-2-Pyrimidinamine, S-dioxide
To the product of example (26 (1.8 g=4.8 mmol) in CH 2 Cl 2 (100 mL) under N 2 was added 3-chloroperbenzoic acid (3.16 g, 14.67 mmol, 80-85% purity) in small portions and after addition, stirring was continued for 30 minutes. Unreacted peroxide was consumed using 10% sodium sulfite (5 mL), and the reaction mixture was diluted with CH 2 Cl 2 (150 mL) followed by washing with 5% sodium bicarbonate (100 mL) and brine (100 mL). The organic layer was dried over anhydrous sodium sulfate, filtered and stripped leaving 2.19 g yellow oil. This material was purified using flash chromatography (CH 2 Cl 2 , silica) to provide 1.6 g of oil (79% yield). MS (NH3--CI/DDIP): 412 (M+H) + .
EXAMPLE 28
N-(2-Bromo-4-(1-Methylethyl)Phenyl)-N-Ethyl-4-Methyl-6-(Thiomethyl)-2-Pyrimidinamine, S-oxide
To Example 26 product (770 mg, 2 mmol) in methanol (200 mL) was added sodium periodate (648 mg, 3 mmol) in water (10 mL) in one portion and the reaction mixture was refluxed 28 hours. The reaction solvent was stripped away and the residue was partitioned between ethyl acetate (200 mL) and water (50 mL). The organic layer was separated and treated with brine (50 mL). The organic layer was dried over anhydrous sodium sulfate, filtered and stripped leaving 820 mg tan residue. This material was purified using flash chromatography (EtOAc/hexane, 1:1, silica) to afford 570 mg (71% yield) of oil. MS (NH3--CI/DDIP):396 (M+H) + .
EXAMPLE 29
N-[2-Bromo-4(1-Methylethyl)Phenyl]-N-Ethyl-4-Methyl-6-Benzyloxy-1,3,5 Triazin-2-Amine
Benzyl alcohol (197 mg, 1.82 mmol, 1.2 eq) was added slowly to a solution of NaH (73 mg 60% dispersion, 1.82 mmol) in dry DMF and stirred at room temperature for 15 minutes. The product from Part B (560 mg, 1.52 mmol) was then added and the resulting mixture stirred at room temperature for 2 hours. The reaction mixture was then poured into water and extracted three times with ethyl acetate. The organic layer was dried over magnesium sulfate, filtered and concentrated in vacuo. The crude oil was chromatographed on silica using 20% ethyl acetate in hexanes as solvent to afford the title compound. C 22 H 25 N 4 OBr Calcd: C, 55.46, H, 5.46, N, 11.76; Found: C, 55.30, H, 5.41, N, 12.02.
EXAMPLE 30
N-[2-Iodo-4-Dimethylhydroxymethylphenyl]-N-Ethyl-4-6-Dichloro-1,3,5 Triazin-2-Amine
Part A: Ethyl 4-aminobenzoate (5.0 gr, 30.27 mmol) and sodium bicarbonate (3.81 g, 45.40 mmol, 1.5 eq.) were added to a 50:50 mixture of methylene chloride and water. The mixture was chilled to 0 degree and I 2 (11.53 g, 45.40 mmol, 1.5 eq.) was added slowly. The reaction mixture was allowed to come to room temperature and was stirred for 72 hours. The layers were then separated and the aqueous layer washed with methylene chloride. All organics were combined and dried over magnesium sulfate, filtered and concentrated in vacuo. The resulting oil was chromatographed on silica using 30% ethyl acetate in hexanes as solvent to afford ethyl 3-iodo-4-aminobenzoate. C 9 H 10 NO 2 I MS 292 (M+H) + 309 (M+NH 4 ) + .
Part B: The product from part A (1.0 g, 3.4 mmol) was added to a stirring solution of NaH (0.21 gr, 5.2 mmol) in 25 mL of dry DMF and allowed to stir at room temperature for 10 minutes. Ethyl iodide (0.8 g, 5.2 mmol) was then added and the mixture as allow to stir for 24 hours. The reaction was then poured into water and extracted with ethyl acetate. The organic layer was dried with magnesium sulfate, filtered, and concentrated in vacuo. The crude material was chromatographed on silica using 30% ethyl acetate in hexanes as solvent to afford ethyl 3-iodo-4-(N-ethyl)aminobenzoate. C 11 H 14 NO 2 I MS 320(M+H) + .
Part C: The product from part B (0.32 g, 1.0 mmol) was dissolved in dioxane and cyanuric chloride (0.18 g, 1.0 mmol) was added slowly. The reaction was heated to reflux for 4 hours, stirred at room temperature for 24 hours, then poured into water and extracted with ethyl acetate. The organic layer was dried with magnesium sulfate, filtered, and concentrated in vacuo. The crude material was chromatographed on silica using 10% ethyl acetate in hexanes as solvent to afford N-[2-iodo-4-ethylcarboylate]-N-ethyl-4-6-dichloro-1,3,5 triazin-2-amine. C 14 H 13 N 4 O 2 Cl 2 I MS 467 (M+H) + .
Part D: The product of part C (0.26 g, 0.6 mmol) was dissolved in 20 mL methylene chloride and chilled to -20 degrees. Methyl magnesium bromide (3 molar in ether, 0.9 mL, 0.33 g, 3.0 mmol, 5 eq.) was added slowly. The reaction was allowed to come to room temperature and stirred for 4 hours, then poured into water and the layers were separated. The aqueous layer was extracted with methylene chloride and the organic layers combined, dried with magnesium sulfate, filtered, and concentrated in vacuo. The crude material was chromatographed on silica gel using 30% ethyl acetate in hexanes as solvent to afford the title compound. C 15 H 18 N 4 OICl MS 453 (M+H) + .
EXAMPLE 31
N-(2-Iodo-4-(1-Methylethyl)Phenyl)-N-Allyl-4-Morpholino-6-Methyl-2-Pyrimidinamine
mp 109-112° C. Elemental analysis for C 21 H 27 N 4 IO HCl: Theory C: 48.99, H: 5.48, N: 10.88, I: 24.65, Cl: 6.89. Found C: 48:81, H: 5.43, N: 10.59, I: 24.67, Cl: 6.86
EXAMPLE 32
N-(2-Iodo-4-(1-Methylethyl)Phenyl)-N-Ethyl-4-Chloro-6-Methyl-2-Pyrimidinamine
Guanidine 39.5 mmoles crude, obtained by treatment of the corresponding guanidinium salt with K 2 CO 3 , 15 mL (118 mmoles) ethyl acetoacetate and 2.0 g (14.47 mmoles) K 2 CO 3 were heated to reflux in 120 mL absolute ethanol for 100 hr. Then the solvent was stripped in vacuo and the residue was chromatographed on silica gel using 40% EtOAc/hexanes as eluent to give 4 g product, a 27% yield for the three steps.
The 4-hydroxypyrimidine obtained from the above reaction (2.47 g, 6.69 mmoles) was dissolved into 20 mL POCl 3 and stirred at 25° C. for 4 hr. The reaction mixture was poured into ice, stirred for 30 min, and extracted with 100 mL EtOAc. The EtOAc extract was washed with brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 20% EtOAc/hexanes to give 1.64 g of the corresponding 4-chloropyrimidine (63% yield).
1.6 g (4.13 mmoles) 4-chloropyrimidine obtained above, and 0.33 g (8.25 mmoles) of NaH (60% in oil) in 10 mL dry DMF at 25° C. were stirred together for 15 min. Then 0.7 mL (8.75 mmoles) of EtI was added and the reaction was stirred at 0° C. for 2 h and at 25° C. for 16 h. It was then partitioned between 100 mL EtOAc and 25 mL water and the EtOAc was washed with water (2×30 mL), brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 8% EtOAc/hexanes to give 1.2 g product as a viscous liquid (70% yield); elemental analysis for C 16 H 19 N 3 ClI: Theory: C: 46.23, H: 4.61, N: 10.11, Cl: 8.53, I: 30.53. Found C: 46.36, H: 4.57, N: 9.89, Cl: 8.79, I: 30.38.
EXAMPLE 33
N-(2-Methylthio-4-(1-Methylethyl)Phenyl)-N-Ethyl-4(S)-(N-Methyl-2'-Pyrrolidinomethoxy)-6-Methyl-2-Pyrimidinamine
The chloropyrimidine described above, 0.66 g (1.59 mmoles), 70 mg (1.76 mmoles) of NaH (60% in oil) and 0.19 mL (1.6 mmoles) (S)-N-methylprolinol in 10 mL of dry THF under nitrogen were stirred at 25° C. for 36 h and then refluxed for 2 h. The mixture was partitioned between 10 mL EtOAc and 20 mL water and the EtOAc was washed with water, brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 0.5% NH 4 OH/5% CH 3 OH/CH 2 Cl 2 as eluent to give 340 mg product, which was converted into the dihydrochloride salt by treatment with 1 M HCl in ether, mp 101-103° C. (dec). Elemental analysis for C 22 H 31 N 4 IO 2HCl: Theory C: 46.57, H: 5.86, N: 9.88, Cl: 12.50. Found C: 46.69, H: 6.02, N: 9.45, Cl: 12.69.
EXAMPLE 34
N-(2,6-Dibromo-4-(1-Methylethyl)Phenyl)-4-Thiomorpholino-6-Methyl-2-Pyrimidinamine
580 mg (2.46 mmoles) of 2-chloro-4-thiomorpholino-6-methylpyrimidine, 793 mg (2.7 mmoles) of 2,6-dibromo-4-isopropylaniline and 216 mg (5.4 mmoles) of NaH (60% in oil) were refluxed in toluene for 6 hr and purified by silica gel chromatography using 25% EtOAc/hexanes (79% yield); mp 194-195° C. Elemental analysis for C 18 H 22 N 4 Br 2 S: Theory C: 44.46, H: 4.56, N: 11.52, Br: 32.87, S: 6.59. Found: C: 44.67, H: 4.54, N: 11.24, Br: 32.8, S: 6.62.
EXAMPLE 35
N-(2-Methylthio-4-(1-Methylethyl)Phenyl)-N-Ethyl-4,6-Dimethyl-2-Pyrimidinamine
The product was synthesized by lithium-bromine exchange of the appropriately substituted 2-bromo-4-isopropylanilinopyrimidine with nBuLi in THF at 0° C. followed by reaction with dimethyldisulfide. It was purified by silica gel chromatography using 8% EtOAc/hexanes as eluent, (37% yield); mp 64-66° C. Elemental analysis for C 18 H 25 N 3 S: C: 68.53, H: 7.99, N: 13.32, S: 10.16. Found: C: 68.43, H: 7.94, N: 13.16, S: 10.02.
EXAMPLE 36
N-(2-Methylthio-4-(1-Methylethyl)Phenyl)-N-Ethyl-4,6-Dimethyl-2-Pyrimidinamine
The hydrochloride salt of Example 35, was formed in the usual manner; mp 141-142° C. Elemental analysis for C 18 H 25 N 3 S HCl: Theory C: 61.43, H: 7.45, N: 11.94, S: 9.11, Cl: 10.07. Found: C: 61.07, H: 7.40, N: 11.80, S: 9.37, Cl: 9.77.
EXAMPLE 37
N-(2-Methylsulfinyl-4-(1-Methylethyl)Phenyl)-N-Ethyl-4,6-Dimethyl-2-Pyrimidinamine
The sulfide of Example 35, (300 mg, 0.95 mmoles), was reacted with 300 mg (1.41 mmoles) NaIO 4 in 6 mL MeOH and 3 mL water at 25° C. for 24 h. The reaction mixture was partitioned between 100 mL EtOAc and 25 mL water and the EtOAc extract was washed with water, brine, dried and stripped in vacuo. The residue was purified by silica gel chromatography using 1:1 EtOAc/hexanes as eluent to give 220 mg product, (70% yield); mp 144-146° C. Elemental analysis for C 18 H 25 N 3 O 5 : Theory C: 65.22, H: 7.60, N: 12.68, S: 9.67. Found: C: 65.12, H: 7.63, N: 12.48, S: 9.71.
EXAMPLE 38
N-(2-Iodo-4-(1-Methylethyl)Phenyl)-N-Ethyl-4-Thiazolidino-6-Methyl-2-Pyrimidinamine
The title compound was obtained as a viscous liquid. Elemental analysis for C 19 H 25 N 4 IS: Theory C: 48.72, H: 5.38, N: 11.96, S: 6.84, I: 27.09. Found: C: 48.80, H: 5.36, N: 11.84, S: 6.95, I: 27.05.
EXAMPLE 39
N-(2-Iodo-4-Methoxymethylphenyl)-N-Ethyl-4,6-Dimethyl-2-Pyrimidinamine
The title compound was obtained as a viscous liquid. Elemental analysis for C 16 H 20 N 3 IO: Theory C: 48.37, H: 5.08, N: 10.58. Found C: 48.27, H: 5.00, N: 10.07.
EXAMPLE 40
N-(4,6-Dimethyl-2-Pyrimidinamino)-2,3,4,5-Tetrahydro-4-(1-Methylethyl)-1,5-Benzothiazepine
To 4 grams, (15.32 mmoles) of 2-iodo-4-isopropylaniline, and 2.53 g (18.4 mmoles) of 4,6-dimethyl-2-mercaptopyrimidine in 30 mL DMF, were added 4.8 g (34.4 mmoles) of K 2 CO 3 and 600 mg (9.2 mmoles) of Cu powder and the resulting mixture was heated to reflux for 2 h. After cooling, 30 mL EtOAc was added and the solids were filtered off. The filtrate was partitioned between 200 mL EtOAc and 50 mL water and the EtOAc layer was washed with water (3×60 mL), brine, dried and stripped in vacuo to provide an oily residue that was used without further purification; MS(m/e) 275 (M+2, 20%); 274 (M+1, 100%).
To 0.6 g(2.2 mmoles) of the above crude product in 8 ml dry xylenes was added 132 mg (3.3 mmoles) NaH (60% in oil) and the mixture was heated to reflux for 5 h. Then 0.22 mL (2.2 mmoles) of 1,3-dibromopropane was added and the reaction was heated for another 2 h. Another 60 mg (1.2 mmoles) NaH (60% in oil) was added and heating was continued for another 3 h. After cooling the solids were filtered off, the solvent removed in vacuo, and the filtrate chromatographed on silica gel using 8% EtOAc/hexanes to give 220 mg product (32% yield for the two steps); High res MS: calc 314.169095; measured; 314.168333. This was converted into the hydrochloride salt by treatment 1 M HCl in ether, mp 157-159° C.
EXAMPLE 41
N-(2-methylsulfonyl-4-(1-methylethyl)phenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
The sulfoxide of Example 37, (100 mg, 0.3 mmoles) was stirred at 4 mL of CH 2 Cl 2 and 8 mL water with 20 mg (0.09 mmole) of benzyltriethylammonium chloride and 94.5 mg (0.6 mmole) KMnO 4 at 25° C. for 16 h. The mixture was partitioned between 60 mL EtOAc and 40 mL water and the EtOAc was washed with water, brine, dried and stripped in vacuo. The residue was purified by silica gel chromatography using 25% EtOAc/hexanes to give 85 mg product (81% yield); mp 174-175.3° C. Elemental analysis for C 18 H 25 N 3 O 2 S: Theory C: 62.22, H: 7.25, N: 12.09, S: 9.23, Found: C: 62.13, H: 7.28 , N: 11.93, S: 9.12.
EXAMPLE 42
N-(2-ethylthio-4-(1-methylethyl)phenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
The title compound was prepared in the same manner as the product of Example 36; mp 128-130° C. Elemental analysis for C 19 H 27 N 3 S CHl: Theory C: 62.36, H: 7.71, N: 11.48, S: 8.76, Cl: 9.69, Found: C: 62.64, H: 7.75, N: 11.43, S: 8.59, Cl: 9.58.
EXAMPLE 43
N-(2-ethylthio-4-methoxyiminoethylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
The title compound was prepared in the same manner as the product of Example 44; mp 77-78° C. Elemental analysis for C 19 H 26 N 4 OS. Theory C: 63.66, H: 7.31, N: 15.63, S: 8.95. Found C: 63.70, H: 7.32, N: 15.64 , S: 8.94.
EXAMPLE 44
N-(2-methylthio-4-methoxyiminoethylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
To 4 g (29.6 mmoles) of 4'-aminoacetophenone in 20 mL, CH 2 Cl 2 and 50 mL water containing 3.6 g (42 mmoles) NaCHO 3 was added 9.0 g (35.4 mmoles) of I 2 . The mixture was stirred at 25° C. for 20 h. Then 20 mL of saturated aqueous Na 2 OS 3 was added and the mixture was stirred for 10 min and partitioned between 120 mL EtOAc and 10 mL water. The EtOAc extract was washed with brine, dried and stripped in vacuo and the residue chromatographed on silica gel using 255 EtOAc/hexanes as eluent to give 6.1 g product (79% yield).
To 3.05 g (11.69 mmoles) of 4'-amino-3'-iodoacetophenone in a mixture of 40 mL ethanol and 10 mL 3 M NaOH was added 2.10 g (25.20 mmoles) methoxyamine hydrochloride and the mixture was heated to reflux for 2 h. The ethanol was stripped off in vacuo, the residue was partitioned between 100 mL EtOAc and 30 mL water and the EtOAc was washed with water, brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 20% EtOAc/hexanes to give 2.8 g product (83% yield).
The above product 1.5 g (5.18 mmoles) was coupled with 4,6-dimethyl-2-mercaptopyrimidine as described above, to give the corresponding adduct in 70% yield, after chromatographic purification.
The above product, 1.1 g (3.64 mmoles) was treated with 190 mg (4.73 mmoles) NaH (60% in oil) in 7 mL dry xylenes at reflux for 5.5 hours. The reaction mixture was then partitioned between 100 mL EtOAc and 20 mL water and the EtOAc was washed with water, brine, dried and stripped in vacuo. The residue was purified by silica gel chromatography using 25% EtOAc/hexanes to give 900 mg product (82% yield).
The above product, 900 mg (2.98 mmoles) was treated with 470 mg (3.4 mmoles) K 2 CO 3 and 0.22 mL (3.54 mmoles) CH 3 I at 25° C. for 4 h. Then it was partitioned between 100 mL EtOAc and 20 mL water, the EtOAc was washed with brine, dried and stripped in vacuo. The residue was used for the next reaction without further purification.
The above product, 940 mg (2.97 mmoles) was treated with 160 mg (4.0 mmoles) NaH (60% in oil) in 7 mL dry DMF for 20 min at 25° C. and then 0.32 mL (4.0 mmoles) EtI was added. The mixture was stirred at 25° C. for 16 and partitioned between 100 mL EtOAc and 20 mL water, the EtOAc was washed with brine, dried, stripped in vacuo and the residue was chromatographed on silica gel using 20% EtOAc/hexanes to give 600 mg product (58% yield); mp 106-108° C. Elemental analysis for C 18 H 24 N 4 OS: Theory C: 672.76, H: 7.02, N: 16.27, S: 9.31. Found C: 62.75, H: 7.03, N: 16.12, S: 9.45.
EXAMPLE 45
N-(2-methylsulfonyl-4-methoxyiminoethylphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
The sulfide obtained from the sequence described above (0.2 g, 0.87 mmoles) was dissolved in 10 mL CH 2 Cl 2 and 0.53 g (2.61 mmoles) of m-chloroperbenzoic acid (mCPBA 85%) was added and the mixture was stirred at 25° C. for 16 min. The reaction mixture was quenched with Na 2 SO 3 and partitioned between 40 mL CH 2 Cl 2 and 30 mL 5% NaHCO 3 . The organic layer was dried, stripped in vacuo and the residue was chromatographed on silica gel using 40% EtOAc/hexanes to give 430 mg product, a 40% yield, mp 151-154° C. Elemental analysis for C 18 H 24 N 4 O 3 S: Theory C: 57.43, H: 6.43, N: 14.88, S:8.52. Found C: 57.24, H: 6.40, N: 14.18, S: 8.60.
EXAMPLE 46
N-(4-bromo-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
2-Iodo-4-bromoaniline was coupled with 4,6-dimethyl-2-mercaptopyrimidine in 93% yield. One gram of the adduct (3.22 mmoles) was dissolved in 10 mL methanol and 4mL (4 mmoles) 1 M HCl in ether was added. The mixture was stirred at 25° C. for 2 h, the solvent was stripped in vacuo and the residue was partitioned between 150 mL of an 1:1 mixture EtOAc and CH 2 Cl 2 and 80 mL satd. NaHCO 3 . The organic layer was dried and stripped in vacuo to give 900 mg of the disulfide product, which was dissolved in 10 mL absolute ethanol and cooled to 0° C. To that solution 110 mg (2.92 mmoles) of NaBH 4 was added and the mixture was allowed to warm to 25° C. and stirred for 20 min before 0.36 ml (5.76 mmoles) CH 3 I was added and the mixture was stirred at 25° C. for 2 h. The solvent was stripped in vacuo and the residue was partitioned between 100 mL EtOAc and 30 mL satd. NaCHO 3 . The EtOAc was washed with brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 20% EtOAc/hexanes to give 840 mg product, 80% yield for the two steps. MS(m/e): 326 (M+3, 100%); 324 (M+1, 93%).
This was ethylated under the conditions described above in 90% yield, mp 91-93° C. Elemental analysis for C 15 H 18 BrN 3 S: Theory C:51.15, H:5.15, N: 11.93, Br: 22.68, S: 9.10. Found C:51.15, H: 5.15, N: 11.89, Br: 22.42, S: 9.22.
EXAMPLE 47
N-(4-ethyl-2-methylthiophenyl)-N-(1-methylethyl)-4,6-dimethyl-2-pyrimidinamine
The title compound was prepared in a manner similar to the product of Example 46; mp 85-87° C. Elemental analysis for C 18 H 25 N 3 S: Theory C: 68.53; H: 7.99, N: 13.32, S: 10.16. Found C: 68.56, H: 8.08, N: 13.24, S: 10.27.
EXAMPLE 48
N-(4-ethyl-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
The title compound was prepared in a manner similar to the product of Example 46; mp 140-141° C. Elemental analysis for C 17 H 23 N 3 S. HCl: Theory C: 60.43, H: 7.16, N: 12.44, S: 9.49, Cl: 10.49. Found C: 60.42, H: 6.89, N: 12.36, S: 9.61, Cl: 10.63.
EXAMPLE 49
N-(2-methylthio-4-(N-acetyl-N-methylamino)phenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
The title compound was prepared in a manner similar to the product of Example 46; mp 158-160° C. Elemental analysis for C 18- h 24 N 4 OS: Theory C: 62.76, H: 7.02, N: 16.26, S: 9.31. Found C: 62.67, H: 7.07, N: 16.24, S: 9.56.
EXAMPLE 50
N-(4-carboethoxy-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
The title compound was prepared in a manner similar to the product of Example 46; mp 99-100° C. Elemental analysis for C 18 H 23 N 3 O 2 S: Theory C: 62.58, H: 6.71, N: 12.16, S: 9.28. Found C: 62.83, H: 6.78, N: 12.08, S: 9.44.
EXAMPLE 51
N-(4-methoxy-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
A mixture of 352 mg (1 mmole) 4-bromo-2-methylmercaptoanilinopyrinidine, 14.3 mg (0.1 mmole) CuBr and 0.5 mL (2.5 mmoles) 25% w/w MeONa in MeOH was heated to reflux in 5 mL dry DMF for 1.5 h. The reaction mixture was partitioned between 100 mL EtOAc and 30 mL water and the EtOAc layer was washed with water (2×30 mL), brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 20% EtOAc/hexanes to give 210 mg product (69% yield); mp 128-130° C. Elemental analysis for C 16 H 21 N 3 OS1/4H 2 O: Theory C: 62.41, H: 7.07, N: 13.64, S: 10.41. Found C: 62.06, H: 6.97, N: 13.26, S: 10.47.
EXAMPLE 52
N-(4-cyano-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
The title compound was prepared in a manner similar to the product of Example 51; mp 112-113° C. Elemental analysis for C 16 H 18 N 4 S: Theory C: 64.40, H: 6.08, N: 18.78, S: 10.74. Found: C: 64.28, H: 6.16, N: 18.58, S: 11.08.
EXAMPLE 53
N-(4-acetyl-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
To 0.5 g (1.68 mmoles) of the nitrile of Example 52 in 10 mL dry C 6 H 6 was added 1.1 mL (3.3 mmoles) of a 3 M solution CH 3 MgI in ether and the mixture was stirred at 25° C. for 2 h and at reflux for 1 h. The reaction was quenched with water and 10% HCl and stirred for 20 min before 1 M NaOH was added until the solution was alkaline and the mixture was extracted with 100 mL EtOAc. The organic layer was washed with water, brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 20% EtOAc/hexanes to give 370 mg product (70% yield); mp 125-126° C. Elemental analysis for C 17 H 21 N 3 OS: Theory C: 64.73, H: 6.71 , N: 13.32, S: 10.16. Found C: 64.53, H: 6.73, N: 13.08. S: 10.19.
EXAMPLE 54
N-(4-propionyl-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
The title compound was prepared in a manner similar to the product of Example 53; mp 139-141° C. Elemental analysis for C 18 H 23 N 3 OS: Theory C: 65.62, H: 7.04, N: 12.75, S: 9.73. Found C: 65.33, H: 7.19, N: 12.51, S: 9.62.
EXAMPLE 55
N-(4-(1-methoxyethyl)-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
To 1.05 g (3.33 mmoles) of the ketone of Example 53 in 20 mL absolute ethanol cooled to 0° C. was added 127 mg (3.33 mmoles) NaBH 4 , and the mixture was allowed to warm to 25° C. and stirred for 16 h. Then the solvent was stripped in vacuo and the residue was partitioned between 100 mL EtOAc and 30 mL 0.3 M NaOH. The EtOAc was washed with water, brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 2:1 EtOAc/hexanes to give 1 g product; mp 46-49° C. The above alcohol, 0.72 g (2.27 mmoles), was reacted with 108.09 mg (2.7 mmoles ) of NaH (60% in oil) in 5 mL dry DMF at 25° C. for 20 min and then 0.3 mL (4.8 mmoles) of CH 3 I was added. The mixture was stirred for 20 h and an additional 60 mg (1.5 mmoles) of NaH (60%) was added, as well as 0.1 mL CH 3 I and the mixture was stirred for an additional 16 h. It was then partitioned between 100 mL EtOAc and 20 mL water and the EtOAc was washed with water (2×30 mL), brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 20% EtOAc/hexanes to give 600 mg product as a viscous liquid. This was converted into the hydrochloride salt by treatment with 1 M HCl in ether, mp 120-122° C.
EXAMPLE 56
N-(4-N-methylamino)-2-methylthiophenyl)-N_ethyl-4,6-dimethyl-2-pyrimidinamine
A solution of 0.2 g (0.58 mmole) 4-N-acetyl-N-methyl-2-methylmercaptoanilinopyrinidine, in 10 mL ethanol and 2 mL water containing 272 mg (5 mmoles ) KOH was refluxed for 4 h. An additional 200 mg of KOH was added and the heating was continued for 3 h. The ethanol was stripped in vacuo and the residue was partitioned between 100 mL EtOAc and 30 mL water. The EtOAc extract was washed with brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 1:1 EtOAc/hexanes to give 140 mg product, an 80% yield, mp 141-142° C. Elemental analysis for C 16 H 22 N 4 S: Theory C: 63.54, H: 7.33, N: 18.52, S: 10.60. Found C: 63.63, H: 7.41, N: 18.55, S: 10.80.
EXAMPLE 57
N-(4-(N,N-dimethylamino)-2-methylthiophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
To 0.36 g (1.2 mmoles) 4-N-methyl-2-methylmercaptoanilinopyrinidine in 4 mL dry DMF was added 60 mg (1.5 mmoles) NaH (60% in oil) and the mixture was stirred for 20 min before 0.1 mL (1.67 mmoles) CH 3 I was added and the reaction was continued at 25° C. for 16 h. It was then partitioned between 100 mL EtOAc and 20 mL water. The EtOAc extract was washed with water, brine, dried and stripped in vacuo. The residue was chromatographed on silica gel using 20% EtOAc/hexanes to give 150 mg product (40% yield); mp 119-120° C. Elemental analysis for C 17 H 24 N 4 S: Theory C: 64.52, H: 7.64, N: 17.70, S: 10.13. Found C: 64.55, H: 7.65, N: 17.50, S: 10.31.
EXAMPLE 58
N-(2-Bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-formyl-6-methyl-2-pyrimidinamine
Example 23 product (453 mg, 1.2 mmol) and manganese dioxide (1.7 g, 20 mmol) were heated to reflux in 25 mL dichloromethane for three days. The reaction was filtered through a pad of Celite, and the filtrate was concentrated in vacuo to give a light yellow oil. The oil was purified by silica gel chromatography using 1-0% ethyl acetate in hexanes to yield 112 mg of a white solid. C1-HRMS: calcd: 362.0868 (M+H), found: 362.0864.
EXAMPLE 59
N-(2-Bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-hydroxyethoxymethyl-6-methyl-2-pyrimidinamine
Compound XLVII from Scheme 12 above (0.41 g, 0.92 mmol) and sodium borohydride (76 mg. 2 mmol) in 10 mL ethanol were stirred for 21 hours at room temperature. The reaction was acidified with 1.0 N hyrdochloric acid, stirred for ten minutes, basified with 1.0 N sodium hydroxide and extracted with dichloromethane. The combined extracts were dried with magnesium sulfate and stripped in vacuo to yield a clear oil which was chromatographed on silica gel using 30% ethyl acetate in hexanes to give 345 mg product (92% yield). C1-HRMS: calcd: 408.1287 (M+H), found: 408.1284.
EXAMPLE 60
N-(2-Bromo-6-hydroxy-4-methoxyphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
N-(2-Bromo-4,6-dimethoxyphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine (214 mg, 0.58 mmol) in 15 mL dichloromethane under nitrogen was cooled in a dry ice/acetone bath, and boron tribromide (1.0 M in dichloromethane, 0.58 mL) was slowly added. The reaction was allowed gradually to warm to room temperature whereupon it was stirred overnight. After quenching with water, the aqueous portion was basified with saturated sodium bicarbonate and extracted with dichloromethane. The combined extracts were dried with magnesium sulfate and concentrated in vacuo to give a tan solid. The solid was recrystallized form ethyl acetate/hexanes to yield 58 mg product; mp 157-160° C. Anal. Calcd. %C: 51.15: %H: 5.15: %N: 11.93: %Br: 22.69. Found %C: 51.02: %H: 5.10: %N: 11.83: %Br: 22.52.
EXAMPLE 61
N-(3-Bromo-4,6-dimethoxyphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
Part A (Synthesis of 3-bromo-4,6-dimethoxy aniline): To a mixture of 2,4-dimethoxy aniline (5.0 g, 33 mmol) and potassium carbonate (10.4 g, 75 mmol) in 30 mL chloroform was slowly added bromine (5.27 g, 33 mmol) in 20 mL chloroform. After stirring two hours the reaction was washed three times with water, dried with magnesium sulfate, and concentrated in vacuo to give a dark solid. The material was purified by chromatography on silica gel using 20% ethyl acetate in hexanes to yield 1.77 g product as a tan solid (23% yield).
Part B: Using the procedure for Example 1, Parts B-C and substituting the aniline from Part A above, the title compound was obtained.
EXAMPLE 62
N-(2,3-Dibromo-4,6-dimethoxyphenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
Part A (Synthesis of 2,3-dibromo-4,6-dimethoxy aniline): 2,4-dimethoxy aniline, 1 eq. benzyltrimethylammonium tribromide, and 2 eq. calcium carbonate were stirred at room temperature in a solution of methanol:dichloromethane (2.5) for one hour. The solution was filtered, the filtrate was evaporated under vacuum, and the residue taken up in water and extracted three times with dichloromethane. The combined extracts were dried over magnesium sulfate, filtered, and evaporated under vacuum to give a brown oil, which was purified on silica gel using 20% ethyl acetate in hexanes (Rf=0.2).
Part B: Using the procedure for Example 1, Parts B-C and substituting the aniline from Part A above, the title compound was obtained.
EXAMPLE 63
N-(2,6-Dibromo-4-(ethoxy)phenyl)-N-ethyl-4,6-dimethyl-2-pyrimidinamine
Part A: The synthesis of 2,6-dibromo-4-ethoxy-aniline was accomplished using the bromination procedure for 4-ethoxy-aniline reported by Kajigaeshi et. al. in Bull. Chem. Soc. Jpn. 61:597-599 (1988). The aniline, 1 eq. benzyltrimethylammonium tribromide, and 2 eq. calcium carbonate were stirred at room temperature in a solution of MeOH: CH 2 Cl 2 (2.5) for one hour. The solids were collected, the filtrate was evaporated under vacuum, and the residue taken up in H 2 O and extracted three times with CH 2 Cl 2 . The combined extracts were dried over MgSO 4 , filtered, and evaporated under vacuum to give a brown oil, which was purified on silica gel using 10% EtOAc in hexanes.
Part B: Using the procedure for Example 1, Parts B-C and substituting the aniline from Part A above, the title compound was obtained.
EXAMPLE 64
1-(2-Bromo-4-isopropylphenyl)-3-cyano-4,6-dimethyl-7-azaindole
Part A: A solution of 42.80 g (0.200 mole) of the potassium salt of formyl-succinonitrile (K. Gewald, Z. Chem., 1:349 (1961)) and 29.20 g (0.200 mole) of 2-bromo-4-isopropylaniline in a mixture of 50 mL of glacial acetic acid and 120 mL of ethanol was refluxed (nitrogen atmosphere) for two hours. The mixture was stripped of most of the acetic acid and ethanol and the residue was taken up in ethyl acetate. This solution was washed with 10% sodium bicarbonate solution, dried with anhydrous sodium sulfate, and evaporated to give a dark, oily residue, which was chromatographed on silica gel with 80:20 hexane-ethyl acetate to give 24.23 g (40%) of N-(2-bromo-4-isopropylphenyl)-aminomethylene-succinonitrile. Mass spec: (m+NH 4 ) + =321.0; caluculated, 321.0.
Part B: To a solution of 10 mL of 1 M potassium tert-butoxide in tetrahydrofuran and a 10 mL of ethanol was added 1.11 g (3.65 mmole) of N-(2-bromo-4-isopropyl-phenyl)-aminomethylene-succinonitrile (Part A). The mixture was stirred for 16 hrs under a nitrogen atmosphere. The solvents were removed by evaporation. The residue was taken up in ethyl acetate and washed successively with 1 N hyrdochloric acid, 10% sodium bicarbonate solution, and brine. The solution was dried with anhydrous sodium sulfate and evaporated to give a dark residue. The residue was dissolved in dichloromethane, 20 g of silica gel was added, and the mixture was evaporated to dryness. This mixture was placed on top of a chromatographic column of 150 g of silica gel in hexane. The column was eluted successively with 10, 15, 20, 25, and 30% ethyl acetate in hexane to give 0.65 g (59% yield) of 1-(2-bromo-4-isopropylphenyl)-2-amino-4-cyano-pyrrole. Mass spec: (m+H) + =304.0; calculated, 304.0. The R f =0.22 on silica gel thin layer chromatography by elution with 70:30 hexane-ethyl acetate. The preparation was scaled up for Part C.
Part C: A mixture of 18.51 g (0.0609 mole) of 1-(2-bromo-4-isopropylphenyl)-2-amino-4-cyano-pyrrole, 300 mL of ethanol, 0.6 mL of conc. hydrochloric acid, and 10 mL (9.75 g, 0.0974 mole) of 2,4-pentanedione was refluxed with stirring under a nitrogen atmosphere for 4 hrs. The mixture was allowed to cool and the solvent was removed under reduced pressure. The residue was dissolved in ethyl acetate. The solution was washed with 10% sodium bicarbonate solution, then with brine. The solution was dried with anhydrous sodium sulfate and evaporated to give 21.76 g of dark, tarry residue. The residue was chromatographed on silica gel by eluting in step gradients of 0, 10, 15, 20, 25, and 30% ethyl acetate in hexane. The initial fraction is 17.6 g (78%) 1-(2-bromo-4-isopropylphenyl)-3-cyano-4,6-dimethyl-7-azaindole; m.p. 105.8°. Mass spec: (m+H.sup.° =368.0749; calculated, 368.0762 ( 79 Br). R f =0.45 on silica gel thin layer chromatography with 70:30 hexane-ethyl acetate.
EXAMPLE 65
1-(2-Bromo-4-isopropylphenyl)-4,6-dimethyl-7azaindole
A mixture of 4.00 g of 1(2-bromo-4-isopropylphenyl)-3-cyano-4,6-dimethyl-7-azaindole and 40 mL of 65% sulfuric acid was refluxed for one hour. The solution was cooled and poured onto ice. Conc. ammonium hydroxide was added until the mixture was alkaline to pH paper. The mixture was extracted with ethyl acetate. The solution was dissolved in 60:40 hexane-ethyl acetate and passed through a short column of silica gel. The eluate was evaporated, and the residue was crystallized from 20 mL of hexane to give 2.45 g (66% yield) of 1-(2-bromo-4-isopropylphenyl)-4,6-dimethyl-7-azaindole. Mass spec: (m+H) + =343.0818; calculated, 343.0810. R f =0.57 on silica gel with 70:30 hexane-ethyl acetate.
EXAMPLE 66
1-(2-Bromo-4-isopropylphenyl)-3-cyano-6-methyl-4-phenyl--7-azaindole
A mixture of 737 mg (2.00 mmole) of the product from Example 64 (Part B), 324 mg (2.00 mmole) of benzolyacetone and 25 mL of xylene was heated in a flask equipped with a water separator for 2 hours. The solvent was removed by evaporation, and the residue chromatographed on silica gel, eluting in step gradients with 0, 5, 10, and 15% ethyl acetate in hexane. Both 1-(2-bromo-4-isopropylphenyl)-3-cyano-4-methyl-6-phenyl-7-azaindole and 1-(2-bromo-4-isopropylphenyl)-3-cyano-6-methyl-4-methyl-7-azaindole were obtained. The R f values were respectively 0.38 and 0.28 (silica gel with 80:20 hexane-ethyl acetate). The assignment of the structures was based on the nmr data of the de-cyanylated compounds in Example 67.
EXAMPLE 67
1-(2-Bromo-4-isopropylphenyl)-6-methyl-4-phenyl-7-azaindole
A mixture of 130 mg (0.302 mmole) of 1-(2-bromo-4-isopropylphenyl)-3-cyano-6-methyl-4-phenyl-7-azaindole (Example 66) and 10 mL of 65% sulfuric acid were refluxed for one hour. The mixture was poured onto ice. Conc. ammonium hydroxide was added until the mixture was basic to pH paper. The mixture was extracted with ethyl acetate. The extract was evaporated and chromatographed on silica gel with 70:30 hexane-ethyl acetate. There was obtained 112 mg (92% yield) of 1-(2-bromo-4-isopropylphenyl)-6-methyl-4-phenyl-7-azaindole. Mass spec: (M+H) + =4.05.10; calculated, 405.10.
In the same way, 1-(2-bromo-4-isopropylphenyl)-4-methyl-6-phenyl-7-azaindole was obtained, mp 95.8°.
EXAMPLE 68
1-(2-Bromo-4,6-dimethoxyphenyl)-3-cyano-4,6-dimethyl-7-azaindole
Part A: N-(2-bromo-4,6-dimethoxyphenyl)-aminomethylene-succinonitrile was prepared from 2-bromo-4,6-dimethoxyaniline by the method described in Example 64, Part A. Mass spec (m+H) + =322.0; calculated, 332.16. R f =0.19 (silica gel with 60:40 hexane-ethyl acetate).
Part B: The product from Part A was cyclized by the method described in Example 64, Part B to give 1-(2-bromo-4,6-dimethoxy-phenyl)-2-amino-4-cyano-pyrrole (79% yield). R f =0.19 (silica gel with 60:40 hexane-ethyl acetate).
Part C: The product from Part B was treated with 2,4-pentanedione as described in Example 64, Part C to give 1-(2-bromo-4,6-dimethoxyphenyl)-3-cyano-4,6-dimethyl-7-azaindole (92% yield). Mass spec: (m+H) + =388.0; calculated, 388.0. R f =0.44 (silica gel with 60:40 hexane-ethyl acetate).
EXAMPLE 69
1-(2-bromo-4,6-dimethoxyphenyl)-4,6-dimethyl-7-azaindole
A mixture of 200 mg of 1-(2-bromo-4,6-dimethoxyphenyl)-3-cyano-4,6-dimethyl-7-azaindole and 10 ml of 65% sulfuric acid was refluxed for one hour. The mixture was worked up as described in Example 65 to give 185 mg of crude product. A 40 mg portion was purified by preparative liquid chromatography on a nitrile column using 95:5 1-chlorobutane-acetonitrile to give 11 mg of 1-(2-bromo-4,6-dimethoxyphenyl)-4,6-dimethyl-7-azaindole. Mass spec: (M+H) + =360.9; calculated, 361.1.
EXAMPLE 70
1-(2-Bromo-4-isopropylphenyl)-6-chloro-3-cyano-4-methyl-7-azaindole
Part A: A solution of 3.04 g of the product of Example 64 (Part B), 1.9 mL (1.94 g; 14.9 mmole) of ethyl acetoacetate, and 0.1 mL of conc. hydrochloric acid in 30 mL of ethanol was refluxed for 16 hours. A precipitate formed upon cooling. The precipitate was removed by filtration to give 1.68 g of crystals; mp 202.4° C., of 1-(2-bromo-4-isopropylphenyl)-4-methyl-7-azaindole-6-one. TLC on silica gel with 70:30 hexane-ethyl acetate showed a single spot, R f =0.29. Mass spec. (m+H) + =370.5; calcd., 370.05 ( 79 Br).
Part B: A mixture of 185 mg of the 7-azaindole-6-one (Part A) and 50 ml of phosphorus oxychloride was heated in an autoclave at 180° C. for 10 hrs. The excess phosphorus oxychloride was removed by distillation at reduced pressure. The residue was distributed between ethyl acetate and water. The ethyl acetate layer was separated and washed with 10% sodium bicarbonate solution, then with brine. The solution was dried (Na 2 SO 4 ) and evaporated. TLC of the residue on silica gel with 70:30 hexane-ethyl acetate showed a major new product, R f =0.52 with minor spots at R f 0.45 and 0.29. Chromatography on silica gel with step gradients of 5, 10, 15, and 20% ethyl acetate in hexane gave 109 mg of the R f 0.52 product; mp 123.8° C. This is 1-(2-bromo-4-isopropylphenyl)-6-chloro-3-cyano-4-methyl-7-azaindole.
EXAMPLE 71
1-(2-Bromo-4-isopropylphenyl)-6-chloro-4-methyl-7-azaindole
A mixture of 52 mg of 1-(2-bromo-4-isopropylphenyl)-6-chloro-3-cyano-4-methyl-7-azaindole and 10 mL of 65% sulfuric acid was refluxed for one hour. The cooled solution was poured onto ice, and 17 mL of conc. ammonium hydroxide was added. The alkaline mixture was extracted with ethyl acetate. The extract was washed (brine), dried (Na 2 SO 4 ), and evaporated. TLC of the residue on silica gel with 70:30 hexane-ethyl acetate showed a major new spot, R f =0.58, with a trace of unchanged starting material (R f 0.52). The crude product was purified by preparative TLC to give 39 mg of non-crystalline product, which slowly crystallized on standing. Mass spec. (m+H) + =363.0247; calcd., 363.0264 ( 79 Br, 35 Cl).
EXAMPLE 72
1-(2-Bromo-4-isopropylphenyl)-3-cyano-6-methyl-7-azaindole
To a solution of 1.085 g (5.07 mmole) of the product from Example 64 (part B) and 0.80 mL (0.797 g; 6.03 mmole) of acetoacetaldehyde dimethyl acetal in 20 mL of ethanol was added 0.10 mL of conc. hydrochloric acid. The mixture was refluxed for 16 hours, then cooled and evaporated to give a dark, thick oil. TLC on silica gel with 70:30 hexane-ethyl acetate showed two major spots at Rf 0.47 and 0.41. The oil was dissolved in ethyl acetate, 20 mL silica gel powder was added, and the mixture was evaporated to dryness. The powdery residue was loaded on top of a column of 60 mL of silica gel in hexane. The column was eluted in step gradients of 0, 5, 10, 15, 20, and 25% ethyl acetate in hexane. The first fraction to elute was 0.32 g of the desired 1-(2-bromo-4-isopropyl-phenyl)-3-cyano-6-methyl-7-azaindole. Rf 0.47. The material can be crystallized from hexane to give 176 mg of crystals; mp 176.0° C. Mass spec. (m+H) + =354.0595; calcd., 354.0606.
EXAMPLE 73
1-(2-Bromo-4-isopropylphenyl)-6-methyl-7-azaindole
Material from Example 72 was treated with 65% sulfuric acid as described in Example 65 to give the desired product as a viscous oil. TLC on silica gel with 70:30 hexane-ethyl acetate showed Rf=0.57. Mass spec. (m+H) + =329.0641; calcd., 329.0653 ( 79 Br).
EXAMPLE 74
1-(2-Bromo-4-isopropylphenyl)-4-chloro-3-cyano-6-methyl-7-azaindole
Part A: A solution of 1.24 g of 1-(2-bromo-4-isopropyl-phenyl)-3-cyano-6-methyl-7-azaindole (Example 72) and 1.42 g of 85% of 3-chloroperoxybenzoic acid in 20 mL of chloroform was refluxed for 6 hrs. The mixture was cooled and washed first with 10% sodium bicarbonate solution, then with brine. The solution was dried (Na 2 SO 4 ) and evaporated to give a residue. TLC on silica gel with 95:5 dichloromethane-methanol showed a trace spot at R f 0.88 and a major spot at R f 0.34. The material was purified by chromatography on silica gel with dichloromethane, followed by 1% methanol in dichloromethane, to give a trace of unchanged 1-(2-bromo-4-isopropylphenyl)-3-cyano-6-methyl-7-azaindole R f 0.88) and 0.92 g of 1-(2-bromo-4-isopropylphenyl)-3-cyano-6-methyl-7-azaindole-7-oxide (R f 0.34); mp 179.2°, Mass spec. (m+H) + =370.0559; calcd., 370.0555 ( 79 Br).
Part B: A mixture of 370 mg of the 7-oxide (Part A) and 5 mL of phosphorus oxychloride was refluxed for two hours. The solution was cooled, poured on ice, and stirred until most of the phosphorus oxychloride was hydrolysed. The mixture was made alkaline with conc. ammonium hydroxide and extracted with ethyl acetate. The extract was dried (Na 2 SO 4 ) and evaporated to give a viscous residue. TLC on silica gel with 95:5 dichloromethane-methanol showed a major spot at R f =0.79. The material was purified by preparative TLC on silica gel with 70:30 hexane-ethyl acetate to give crystals. Recrystallization from hexane gave 158 mg of 1-(2-bromo-4-isopropylphenyl)-4-chloro-3-cyano-6-methyl-7-azaindole; mp 123.3° C. Mass spec. (m+H) + =388.0197; calcd., 388.0216 ( 79 Br, 35 Cl).
EXAMPLE 75
1-(2-Bromo-4-isopropylphenyl)-4-chloro-6-methyl-7-azaindole
A mixture of 190 mg of the 3-cyano-7-azaindole (Example 71) and 5 mL of 65% sulfuric acid was refluxed for 30 minutes. The solution was poured onto ice and extracted with ethyl acetate. The extract was washed with brine, dried (Na 2 SO 4 ), and evaporated to give a residue. TLC of the residue on silica gel with 60:40 hexane-ethyl acetate showed a major spot at R f =0.67. The residue was purified by preparative TLC to give 130 mg of a viscous oil, which is 1-(2-Bromo-4-isopropylphenyl)-4-chloro-6-methyl-7-azaindole. Mass spec. (m+H) + =363.0246; calcd., 363.0264 ( 79 Br, 35 Cl).
EXAMPLE 76
N-[2-bromo-6-methoxy-pyridin-3-yl]-N-ethyl-4-6-dimethyl-2-pyrimidinamine
Part A: To 3.18 grams (25.6 mmol) of commercially available 5-amino-2-methoxypyridine in a solution of methylene chloride (50 ml) and methanol (20 ml) was added benzyltrimethylammonium tribromide (10 g, 25.6 mmol) and the mixture was stirred at room temperature for 24 hours. The solvent was then stripped and the resulting residue was taken up in water and extracted (3×100 mL) with ethyl acetate. The organic extracts were dried with magnesium sulfate, filtered, and concentrated in vacuo. The crude material was chromatographed on silica using 30% ethyl acetate in hexanes as solvent to afford 5-amino-2-bromo-6-methoxypyridine. C 6 H 7 N 2 OBr MS 203 (M+H) + .
Part B: The product of part A above was coupled to 2-chloro-4,6-dimethylpyrimidine (Example 1, part A) using NaH (1.2 eq) in DMF to give N-[2-bromo-6-methoxy-pyridin-3-yl]-4,6-dimethyl-2-pyrimidinamine. C 12 H 13 N 4 OBr MS 309 (M+H) + .
Part C: The product of part B above was alkylated in the same manner as used in Example 4, part C to provide the title compound. C 14 H 17 N 4 OBr MS 337 (M+H) + .
EXAMPLE 77
N-[3-bromo-5-methyl-pyridin-2-yl]-N-ethyl-4-6-dimethyl-2-pyrimidinamine
Part A: A 1.0 gram (5.35 mmol) portion of commercially available 2 -amino-3-bromo-5-methylpyridine was coupled to 2-chloro-4,6-dimethylpyrimidine (Example 1, part A) using NaH (1.2 eq) in DMF to give N-[3-bromo-5-methyl-pyridin-2-yl]-4,6-dimethyl-2-pyrimidinamine. C 12 H 13 N 4 Br MS 293 (M+H) + .
Part B: The product of part A was alkylated in the same manner as used in Example 4, part C to provide the title compound. C 14 H 17 N 4 Br MS 321 (M+H) + .
EXAMPLE 78
N-[6-methoxy-pyridin-3-yl]-N-ethyl-4-6-dimethyl-2-pyrimidinamine
To 200 mg of N-[2-bromo-6-methoxy-pyridin-3-yl]-N-ethyl-4-6-dimethyl-2-pyrimidinamine in 25 ml dry DMF was added 500 mg K 2 CO 3 , 100 mg of CuI, and 0.4 mL of morpholine and the reaction was heated to reflux for 6 hour. The reaction mixture was then filtered and poured into water and then extracted with ethyl acetate (3×50 mL). The extracts were dried and the solvent removed and the resulting residue was chromatographed on silica gel with 20% ethyl acetate in hexane as the solvent (rf 0.4) to provide the title compound. C 14 H 18 N 4 O MS 259 (M+H) + .
EXAMPLE 79
N-[2-bromo-6-methoxy-pyridin-3-yl]-N-ethyl-4-methyl-6-(4-morpholinyl)-1,3,5 triazin-2-amine
Part A: To 2,4-dichloro-6-methyl-s-triazine (Part A, Example 23, 2.0 grams, 12.3 mmol) in 50 mL of CH 2 Cl 2 chilled to 0 degrees was added morpholine (1.1 mL, 12.3 mmol) and the reaction was allowed to come to room temperature and stirred for 2 hours. The reaction was then poured into water and the layers separated. The aqueous layer was washed with CH 2 Cl 2 (3×50 mL) and the organic layers were combined and dried. The solvent was stripped and the crude material was chromatographed on silica with 30% ethyl acetate in hexane as the solvent to give 2-chloro-4-(N-morpholino)-6-methyl-s-triazine. C 8 H 11 N 4 OCl (M+H) + .
Part B: The product of Example 76, Part A (0.6 gram, 3.0 mmol) and the product of Example 79, Part A (0.63 gram, 3.0 mmol) indioxane were stirred at room temperature for 24 hours. The reaction mixture poured into water then extracted with ethyl acetate (3×50 mL). The extracts were dried with magnesium sulfate, filtered, and concentrated in vacuo. The crude material was chromatographed on silica using 30% ethyl acetate in hexanes as solvent to afford the coupled material C 14 H 17 N 6 O 2 Br MS 381 (M+H) + .
Part C: The product of part B above was alkylated in the same manner as used in Example 5, part C to provide the title compound. C 16 H 21 N 6 O 2 Br MS 409 (M+H) + .
EXAMPLE 80
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(N-2-furylmethyl)-N-methaylamino)carbonyl-6-methylpyrimidinamine
Sodium hydride (60% in oil, 0.1 g, 2.4 mmol), washed with hexanes and decanted twice, was suspended in anhydrous N,N-dimethylformamide (DMF) (5 mL) and a solution of N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-((2-furylmethyl)-amino)carbonyl-6-methylpyrimidinamine (1.0 g, 2.2 mmol) in anhydrous DMF (5 mL) was added dropwise with stirring. After 30 min. iodomethane (0.37 g, 2.6 mmol) was added and the reaction mixture was stirred for 18 h. Water (50 mL) was added carefully and the aqueous mix was extracted three times with chloroform. The combined layers were dried over MgSO 4 , filtered and concentrated in vacuo to give a brown oil. Column chromatography (ethyl acetate:hexanes::1:2) afforded the title product as a brown oil (850 mg, 82% yield, R f 0.35).
NMR (CDCl 3 , 300 MHz); 7.5 (d, 1H, J=9), 7.3 (d, 1H, J=12), 7.25-7.2 (m, 1H), 7.12 (dd, 1H, J=8, 1), 6.8 (s, 1H), 6.3 (d, 1H, J=12), 6.0 (br s, 0.5H), 5.9 (br s, 0.5H), 4.65 (br s 2H), 4.2 (br s, 1H), 3.75-3.6 (m, 1H), 3.0-2.8 (m, 4H), 2.4 (br s, 3H), 1.40 (d, 6H, J=7), 1.2 (t, 3H, J=8);
Cl-HRMS:Calcd (C 23 H 27 BrN 4 O 2 ): 471.1396 (M+H); Found 471.1387.
EXAMPLE 81
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-((4,4-ethylenedioxypiperidino))carbonyl-6-methylpyrimidinamine
Sodium hydride (60% in oil, 0.12 g, 3 mmol), washed with hexanes and decanted twice, was suspended in anhydrous THF (5 mL) and a solution of 4-piperidone ethylene glycol ketal (0.43 g, 3 mmol) in anhydrous THF (5 mL) was added dropwise with stirring. The reaction mixture was heated to reflux temperature, stirred for 30 min and then cooled to ambient temperature. A solution of methyl 2-((2-bromo-4-(1-methylethyl)-phenyl)-ethylamino)-6-methyl-4-pyrimidinaminecarboxylate (Example 18) (1.0 g, 2.54 mmol) in anhydrous THF (10 mL) was added and the reaction mixture was stirred at room temperature for 98 h. The reaction mixture was poured onto a 1N NaOH solution (100 mL), mixed and extracted three times with ethyl acetate and the combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo to give a brown oil. Column chromatography (chloroform:methanol::9:1) afforded N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(4,4-ethylenedioxy-piperidino)carbonyl-6-methylpyrimidinamine as an orange-yellow oil (260 mg, 52% yield, R f 0.75):Cl-HRMS: Calcd (C 24 H 31 BrN 4 O 3 ): 503.16578 (M+H); Found: 503.16571.
EXAMPLE 82
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(4-oxopiperidino))carbonyl-6-methylpyrimidinamine
A solution of N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(4,4-ethylenedioxypiperidino))carbonyl)-6-methylpyrimidinamine (260 mg) in a mixture of a 1N HCl solution (2.5 mL) and THF (2.5 mL) was stirred at reflux temperature for 20 h. The reaction mixture was poured into a 1N NaOH solution, and extracted three times with ethyl acetate. The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo to give the title product as a yellow oil (240 mg, 100% yield, R f 0.75); NMR (CDCl 3 , 300 MHz); 7.5 (s, 1H), 7.2 (d, 1H, J=8), 7.1 (d, 1H, J=8), 6.8 (br s, 1H), 4.3-4.1 (m, 1H), 3.95-3.85 (m, 1H), 3.75-3.6 (m, 1H), 3.55-3.4 (m, 1H), 2.95-2.85 (m, 1H), 2.6-2.3 (m, 4H), 2.01-1.6 (m, 2H), 1.4-1.15 (m, 12H), CI-HRMS: Calcd (C 22 H 27 BrN 4 O 2 ): 459.1396 (M+H); Found: 459.1386.
EXAMPLE 83
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(4-oxopiperidino)methyl-6-methylpyrimidinamine, hydrochloride salt
A solution of borane in tetrahydrofuran (1M, 29 mL, 29 mmol) was added dropwise to a solution of N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(4,4-ethylenedioxy-piperidino)carbonyl-6-methylpyrimidinamine (1.67 g, 3.3 mmol) in anhydrous THF (7 mL) with stirring under a nitrogen atmosphere. The reaction mixture was heated to reflux temperature and stirred for 20 h, then cooled to ambient temperature. A solution of glacial acetic acid was added dropwise; then the reaction mixture was heated to reflux temperature and stirred for 4 h, then cooled to ambient temperature. The reaction mixture was concentrated in vacuo; the residue was treated with excess 1N NaOH solution, and extracted three times with ethyl acetate. The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo to give an oil. Column chromatography (ethyl acetate) afforded N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(4,4-ethylenedioxy-piperidino)methyl-6-methylpyrimidinamine as a pale brown oil (860 mg); CI-MS; 489, 491 (M+H).
The ketal was dissolved in a mixture of a 33% HCl solution (10 mL) and THF (5 mL). The resulting solution was stirred at reflux for 65 h, then cooled to ambient temperature and basified with a 1N NaOH solution. The aqueous mix was extracted three times with ethyl acetate. The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo to give an oil. Column chromatography (ethyl acetate:hexanes::4:1) afforded the title product as its free base and as an oil (600 mg, 41% overall yield); CI-HRMS; Calcd (C 22 H 29 BrN 4 O): 444.1603 (M+H); Found: 444.1594.
The above oil (0.55 g, 1.24 mmol) was dissolved in ether (5 mL) and treated with a 1N HCl solution in ether. The resulting precipitate was collected and washed with copious amounts of ether. Drying in vacuo afforded a white powder (500 mg, 85% yield): mp 186-188° C.: Anal. (C 22 H 29 BrN 4 O-HCl): C, 54.92, H, 6.24, N, 11.65, Br, 16.64, Cl, 7.39; Found: C, 54.62, H, 6.37, N, 11.41, Br, 16.57, Cl, 7.35.
EXAMPLE 84
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(imidazol-1-yl)methyl-6-methylpyrimidinamine
To a mixture of N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-hydroxymethyl-6-methylpyrimidinamine (1.57 g, 4.3 mmol), triethylamine (2.5 mL, 17 mmol) and dichloromethane (15 mL) at 0° C. under a nitrogen atmosphere was added methanesulfonyl chloride (0.54 g, 4.7 mmol) dropwise and the reaction mixture was stirred at 0° C. for 1.5 h. It was then washed successively with an ice-cold 1N HCl solution, a saturated NaHCO 3 solution and a saturated NaCl solution. Drying the methylene chloride solution over MgSO 4 , filtration and removal of solvent in vacuo gave N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-methanesulfonyloxymethyl-6-methylpyrimidinamine as a clear colorless oil (1.6 g): NMR (CDCl 3 , 300 MHz); 7.5 (d, 1H, J=1), 7.25-7.1 (m, 2H), 6.5 (s, 1H), 5.05-4.9 (br s, 2H), 4.3-4.1 (m, 1H), 3.8-3.6 (m, 1H), 3.0-2.85 (m, 1H), 2.8-2.6 (br s, 3H), 2.5-2.25 (br m, 3H), 1.3 (d, 6H, J=8), 1.2 (t, 3H, J=8); CI-MS: 442, 444 (M+H).
To sodium hydride (60% in oil, 0.1 g, 2.4 mmol), washed with hexanes and decanted twice, suspended in anhydrous THF (10 mL) was added imidazole (146 mg, 2.14 mmol) in one portion and the reaction mixture was warmed to reflux temperature and stirred for 2 h. A solution of the crude mesylate in anhydrous THF (10 mL) was added dropwise to the reaction mixture, which had been cooled to ambient temperature. The reaction mixture was stirred for 68 h, then it was poured onto water and extracted three times with ethyl acetate. The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo to give an oil. Column chromatography (ethyl acetate) afforded (1) N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-hydoxymethyl-6-methylpyrimidinamine (130 mg, 8% overall yield, R f 0.7) and (2) the title product (600 mg, 59% overall yield, R f 0.07): NMR (CDCl 3 , 300 MHz); 7.6-7.4 (m, 2H), 7.2 (dd, 1H, J=7, 1) 7.15 (d, 1H, J=8), 7.05 (s, 1H), 7.0-6.8 (m, 1H), 6.05 (s, 1H), 4.95-4.8 (m, 2H), 4.25-4.1 (m, 1H), 3.8-3.6 (m, 1H), 3.0-2.85 (m, 1H), 2.4-2.1 (br m, 3H), 1.3 (d, 6H, J=8), 1.2 (t, 3H, J=8); CI-HRMS: Calcd (C 20 H 24 BrN 5 ): 413.1293 (M+H), Found: 413.1275.
EXAMPLE 85
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(3-(methoxyphenyl)methoxymethyl)-6-methylpyrimidinamine
To a mixture of N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-hydroxymethyl-6-methylpyrimidinamine (1.0 g, 2.7 mmol), triethylamine (1.4 mL, 10 mmol) and dichloromethane (20 mL) at 0° C. under a nitrogen atmosphere was added methanesulfonyl chloride (0.34 g, 3.0 mmol) dropwise. The reaction was performed as for Example 84, except the reaction time was 15 min.
Sodium hydride (0.12 g, 3 mmol) and 3-methoxybenzyl alcohol (0.41 g, 3 mmol) were reacted in anhydrous THF (10 mL) as for Example 84. A solution of the crude mesylate in anhydrous THF (10 mL) was added dropwise. The reaction mixture was stirred at reflux temperature for 18 h, cooled to room temperature, poured into a 1N NaOH solution and extracted three times with ethyl acetate. The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo to give an oil. Column chromatography (ethyl acetate:hexanes::1:1) afforded the title product as a viscous yellow liquid (800 mg, 60% overall yield, R f 0.7): NMR (CDCl 3 , 300 MHz): 7.5 (s, 1H), 7.3-7.1 (m, 4H), 6.95-6.9 (m, 2H), 6.85 (br d, 1H, J=8), 6.75 (s, 1H), 5.6 (br s, 2H), 4.45-4.3 (m, 2H), 4.25-4.05 (m, 1H), 3.8 (s, 3H), 3.8-3.6 (m, 1H), 2.9 (septet, 1H, J=7), 2.3 (br s, 3H), 1.3 (d, 6H, J=7), 1.2 (t, 3H, J=7); CI-HRMS: Calcd (C 25 H 30 BrN 3 O 2 ): 484, 1599, Found: 484.1592.
EXAMPLE 86
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(2-thiazolyl)carbonyl-6-methylpyrimidinamine
To a solution of n-butyl lithium in hexanes (2.4 M, 1.34 mL, 3.24 mmol) in anhydrous THF (5 mL) at -78° C. under a nitrogen atmosphere was added 2-bromothiazole (0.49 g, 0.27 mL, 3.0 mmol) dropwise. After the addition was complete, the reaction mixture was stirred at -78° C. for 30 min. A solution of methyl 2-(N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethylamino)-6-methyl-4-pyrimidinaminecarboxylate (Example 18), (1.0 g, 2.5 mmol) in anhydrous THF (10 mL) was added dropwise. The reaction mixture was then warmed to -60° C. and stirred for 4 h. A saturated aqueous solution of NaHCO 3 was added and the reaction mixture was warmed to ambient temperature. Three extractions with ethyl acetate, followed by two washings of the combined organic layers with water, drying over MgSO 4 , filtration and concentration in vacuo gave a dark brown oil. Column chromatography(ethyl acetate:hexanes::1:1) afforded the title product, a brown solid (950 mg, 85% yield, R f 0.43 ); mp 97-98.5° C.; NMR (CDCl 3 , 300 MHz); 8.0 (s, 1H), 7.60 (s, 1H), 7.4-7.2 (m, 4H, J=6), 3.05-2.9 (m, 1H), 2.8-2.7 (m, 1H), 2.6 (br s, 3H), 1.4-1.2 (m, 9H); CI-HRMS Calcd: 445.0698 (M+H), Found: 445.0699; Anal. (C 20 H 21 BrN 4 S); C, 54.05, H, 4.73, N, 12.61, Br, 18.02, S, 7.21; Found: C, 53.86, H, 4.66, N, 12.53, Br, 18.20, S, 7.46.
EXAMPLE 87
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(2-imidazolyl)carbonyl-6-methylpyrimidinamine
To a solution of 1-(dimethylaminomethyl)imidazole (0.63 g, 5 mmol) in anhydrous diethyl ether (50 mL) at -78° C. under a nitrogen atmosphere was added a solution of n-butyl lithium in hexanes (2.4 M, 2.1 mL, 5 mmol) dropwise and the pale yellow suspension was stirred at -78° C. for 1 h. Methyl 2-(N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethylamino)-6-methyl-4-pyrimidinaminecarboxylate (Example 18) (1.47 g, 5 mmol) was added in one portion and the reaction mixture was warmed to room temperature over 23 h. A 1N HCl solution was added until pH=1 (test paper) and the reaction mixture was stirred for 4 h. A 3N NaOH solution was added until the solution became basic (pH=10, test paper). Three extractions with ethyl acetate, drying the combined organic layers over MgSO 4 , filtration and concentration in vacuo gave a brown oily solid. Column chromatography (chloroform:methanol::9:1) afforded the title product, a yellow glass (900 mg, 42% yield, R f 0.43); mp 75-76° C., NMR (CDCl 3 , 300 MHz); 12.2-12.1 (m, 1H), 7.7 (d, 1H, J=1), 7.45-7.35 (m, 2H), 7.3-7.2 (m, 2H), 6.55 (br s, 1H), 4.3 sextet, 1H, J=7), 3.8 (sextet, 1H, J=7), 3.05 (septet, 1H, J=7), 2.65 (br s, 3H), 1.4 (d, 6H, J=7), 1.3 (t, 3H, J=7); CI-HRMS; Calcd: 428.1086 (M+H), Found: 428.1089; Anal (C 20 H 24 BrN 5 O) C, 56.08, H, 5.18, N, 16.35, Br, 18.66; Found: C, 56.20, H, 5.10, N, 15.88, Br, 18.73.
EXAMPLE 88
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(5-indolylcarbonyl-6-methylpyrimidinamine
To a suspension of potassium hydride (35% in oil, 0.16 g, 1.4 mmol), washed with hexanes and decanted twice, in anhydrous ether (5 mL), cooled to 0° C. under a nitrogen atmosphere was added a solution of 5-bromoindole (0.27 g, 1.4 mmol) in anhydrous ether. After being stirred for 30 min., the reaction mixture was cooled to -78° C. and transferred via cannula to a precooled (-78° C.) mixture of t-butyl lithium (1.7 M in pentane, 1.6 mL, 2.7 mmol) in dry ether (5 mL). The resulting white suspension was stirred at -78° C. for 30 min and a solution of methyl 2-(N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethylamino)-6-methyl-4-pyrimidinaminecarboxylate (Example 18) (0.5 g, 1.25 mmol) in anhydrous ether (5 mL) was added dropwise. After quenching the reaction mixture as in Example 87, it was extracted three times with ethyl acetate, followed by two washings of the combined organic layers with a saturated NaHCO 3 solution, drying over MgSO 4 , filtration and concentration in vacuo to give a dark brown oil. Column chromatography (ethyl acetate: hexanes::1:4) afforded the title product, a light brown solid (140 mg, 24% yield, R f 0.2); mp 77-79° C.; NMR (DMSO-d 6 , 400 MHz, 90° C.); 11.6-11.35 (br s, 1H), 8.30 (s, 1H), 7.75 (dd, 1H, J=8, 1), 7.55 (d, 1H, J=1), 7.4-7.35 (m, 2H), 7.35-7.25 (m, 2H), 6.9 (s, 1H), 6.60-6.55 (m, 1H), 4.1-3.7 (m, 2H), 2.95-2.8 (m, 1H), 2.4 (br s, 3H), 1.25-1.1 (m, 9H); Anal (C 25 H 25 BrN 4 O): C, 62.90, H, 5.28, N, 11.74, Br, 16.74; Found: C, 63.13, H, 5.60, N, 11.37, Br, 16.80.
EXAMPLE 89
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(4-fluorophenyl)carbonyl-6-methylpyrimidinamine
To a suspension of N,O-dimethylhydroxylamine hydrochloride (1.46 g, 15 mmol) in benzene (20 mL) at 5-10° C. under a nitrogen atmosphere was added a solution of trimethyl aluminum in toluene (2 M, 7.5 mL, 15 mmol) dropwise and the reaction mixture was then warmed to ambient temperature over 1 h. The reaction mixture was transferred to an addition funnel and added dropwise to a solution of methyl 2-(N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethylamino)-6-methyl-4-pyrimidinaminecarboxylate (Example 18) (2.25 g, 5.73 mmol) in benzene (40 mL). The reaction mixture was heated at reflux and stirred for 16 h. After being cooled to room temperature, the mixture was poured into a 5% HCl solution (100 mL), mixed and extracted three times with ethyl acetate. The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo to give a brown oil. Column chromatography (ethyl acetate: hexanes::1:4) afforded N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl)phenyl)-N-ethyl-4-(N-methyl-N-methoxycarboxamido)-6-methylpyrimidinamine (1.0 g, 41% yield, R f 0.4); CI-MS: 421, 423 (M+H).
The crude amide was dissolved in anhydrous THF (10 mL). A solution of 4-fluorophenylmagnesium bromide in ether (2 M, 1.25 mL, 2.5 mmol) was added dropwise and the reaction mixture was stirred for 22 h. The reaction was quenched by pouring onto a 1 N NaOH solution (50 mL). The aqueous solution was extracted three times with ethyl acetate. The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo to give an orange yellow oil. Column chromatography (ethyl acetate: hexanes::1:9) afforded the title product as a yellow solid (700 mg, 65% yield, R f 0.5): mp 70° C.; NMR (CDCl 3 , 300 MHz, 8.3-8.05 (m, 1H), 7.55 (dd, 1H, J=1), 7.2-6.75 (m, 5H), 4.85-4.7 (m, 1H), 4.3-4.15 (m, 2H), 2.95 (septet, 1H, J=7), 2.5(br s, 3H), 1.4-1.15 (m, 9H), CI-HRMS: Calcd (C 23 H 23 BrFN 3 O): 456.1087 (M+H), Found: 456.1084.
EXAMPLE 90
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-carboxy-6-methylpyrimidinamine
A mixture of methyl 2-(N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethylamino)-6-methyl-4-pyrimidinaminecarboxylate (Example 18) (10 g, 25 mmol), ethanol (100 mL) and a 1N NaOH solution (250 mL) was stirred at reflux temperature for 18 h. After being cooled to ambient temperature, the reaction mixture was concentrated twofold in vacuo and acidified with a concentrated HCl solution. Three extractions with chloroform, drying the combined organic layers over MgSO 4 , filtration and removal of solvent in vacuo gave a pale brown solid (9.0 g, 95% yield): mp 102-104° C.; NMR CDCl 3 , 300 MHz); 7.55 (d, 1H, J=1), 7.25-7.20 (m, 2H), 7.15 (d, 1H, J=7), 4.30-4.10 (m, 1H), 3.88-3.7 (m, 1H), 3.00-2.85 (m, 1H), 2.55 (br s, 3H), 2.30 (br s, 1H), 1.30 (d, 6H, J=7), 1.20 (t, 3H, J=7); CI-HRMS: Calcd(C 17 H 20 BrN 3 O): 378.0817(M+H); Found: 378.0813.
EXAMPLE 91
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-acetyl-6-methylpyrimidinamine
Cerium trichloride (4.9 g, 19.6 mmol) was dried, with magnetic stirring at 180° C. in vacuo for 4 h. After being cooled to room temperature and placed under a nitrogen atmosphere, the solid was stirred for 16 h in anhydrous THF (50 mL).
A solution of N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-carboxy-6-methylpyrimidinamine (3.7 g, 9.8 mmol) in anhydrous THF (25 mL) was cooled with stirring to 31 78° C. under a nitrogen atmosphere. A solution of methyl lithium in ether (1.4M, 7 mL, 9.8 mmol) was added dropwise and the reaction mixture was stirred at -78° C. for 1 h. The CeCl 3 suspension was transferred via cannula into the reaction mixture and stirring at -78° C. was continued for 5 h. A solution of methyl lithium in ether (1.4M, 7 mL, 9.8 mmol) was added dropwise and the reaction mixture was then warmed gradually to room temperature over 16 h. After cooling the reaction mixture to -78° C., the reaction was quenched with a 1N HCl solution and warmed to room temperature. The resulting mixture was extracted three times with ethyl acetate. The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo to give an orange yellow oil. Column chromatography (ethyl acetate:hexanes::1:4) afforded the title product as an oil (2.5 g, 68% yield, R f 0.5): NMR (CDCl 3 , 300 MHz): 7.55 (d, 1H, J=1), 7.25-7.15 (m, 2H), 6.95 (s, 1H), 4.30-4.10 (m, 1H), 3.90-3.70 (m, 1H), 3.00-2.85 (m, 1H), 2.80-2.05 (m, 6H), 1.35-1.20 (m, 9H); CI-HRMS: Calcd (C 18 H 22 BrN 3 O): 376.1024 (M+H), Found: 376.1042.
EXAMPLE 92
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(hydroxy-3-pyridyl-methyl)-6-methylpyrimidinamine (XU472)
Sodium borohydride (0.11 g, 2.8 mmol) was added to a solution of N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(3-pyridylcarbonyl)-6-methylpyrimidinamine (0.6 g, 1.4 mmol) in ethanol (5 mL). After being stirred for 71 h, the reaction mixture was concentrated in vacuo, treated with a 1N NaOH solution and extracted three times with ethyl acetate. The combined organic layers were washed with brine, dried over MgSO 4 , filtered and concentrated in vacuo to give a colorless oil. Column chromatography (chloroform:methanol::9:1) afforded the title product as an oil (600 mg, 96% yield, R f 0.4): NMR (CDCl 3 , 300 MHz): 8.65-8.45 (m, 2H), 7.55 (br s, 2H), 7.3-7.1 (m, 2H), 6.25-6.15 (m, 1H), 5.7-5.5 (m, 0.5H), 5.45-5.3 (m, 0.5H), 5.15-4.95 (m, 1H), 4.3-4.1 (m, 1H), 3.9-3.7 (m, 1H), 3.0-2.85 (m, 1H), 2.45-2.2 (m, 3H), 2.3-2.2 (m, 1H), 1.35-1.2 (m, 9H); CI-HRMS: Calcd (C 22 H 25 BrN 4 O): 441.1290 (M+H), Found: 441.1274.
EXAMPLE 93
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(4-(methoxyphenyl)-3-pyridyl-hydroxymethyl)-6-methylpyrimidinamine
A solution of 4-bromoanisole (0.2 g, 1.1 mmol) in anhydrous THF (10 mL) was cooled with stirring to -78° C. under a nitrogen atmosphere. A solution of t-butyl lithium in pentane (1.7M, 1.4 mL, 2.4 mmol) was added dropwise and the reaction mixture was stirred for 0.5 h. A solution of N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(3-pyridyl-carbonyl)-6-methylpyrimidinamine (0.45 g, 1 mmol) in anhydrous THF (10 mL) was added dropwise and the reaction mixture was warmed gradually to ambient temperature over 18 h. The reaction mixture was poured onto a saturated NH 4 Cl solution and extracted three times with ethyl acetate. The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo to give an oil. Column chromatography (ethyl acetate:hexanes::4:1) afforded the title product as a pale brown glass (170 mg, 31% yield, R f 0.2): mp 68-70° C.; NMR (CDCl 3 , 300 MHz): 8.6-8.4 (m, 2H), 7.7-7.5 (m, 1H), 7.5 (s, 1H), 7.25-7.05 (m, 6H), 6.95-6.75 (m, 2H), 6.25-6.2 (m, 1H), 5.85-5.7 (m, 1H), 4.25-4.05 (m, 1H), 3.8 (br s, 3H), 3.95-3.75 (m, 1H), 3.00-2.8 (m, 1H), 2.45-2.1 (br s, 3H), 1.35-1.15 (m, 9H); CI-HRMS: Calcd(C 29 H 31 BrN 4 O 2 ): 547.1709 (M+H), Found: 547.1709.
EXAMPLE 94
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(3-pyrazolyl)-6-methylpyrimidinamine, hydrochloride salt
Sodium (0.08 g, 3.5 mmol) was added to methanol (20 mL) with stirring. After the sodium reacted, a solution of N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-acetyl-6-methyl-pyrimidinamine (1.0 g, 2.67 mmol) in methanol (5 mL) was added and the reaction mixture was stirred for 5 min. Gold's reagent ((dimethylaminomethyleneaminomethylene))dimethyl-ammonium chloride (0.66 g, 4 mmol) was added and stirring was continued for 19 h. The reaction mixture was concentrated in vacuo; the residue was dissolved in chloroform and the solution was washed with a saturated NaHCO 3 solution, dried over MgSO 4 and filtered solvent removal in vacuo gave a brown solid, which upon trituration with hexanes afforded N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(3-dimethylaminopropenoyl)-6-methylpyrimidinamine as a yellow solid (700 mg): NMR (CDCl 3 , 300 MHz): 7.9-7.65 (br s, 1H), 7.5 (s, 1H), 7.25-7.2 (m, 2H), 7.15 (s, 1H), 6.1-5.8 (br s, 1H), 4.3-4.15 (m, 1H), 3.9-3.75 (m, 1H), 3.2-3.0 (br s, 3H), 3.0-2.85 (m, 1H), 2.8-2.6 (br s, 3H), 2.5-2.3 (br s, 3H), 1.35-1.2 (m, 9H); CI-MS: 431, 433 (M+H).
A solution of the above vinylogous amide and anhydrous hydrazine (0.15 g, 4.7 mmol) in toluene (15 mL) was stirred at reflux temperature under a nitrogen atmosphere for 16 h. The reaction mixture was poured onto water and extracted three times with ethyl acetate. The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo to give an oil. Column chromatography (ether) afforded the free base of the title product as a pale yellow glass (600 mg, 59% overally yield, R f 0.4): NMR (CDCl 3 , 300 MHz): 7.6 (s, 1H), 7.55 (s, 1H), 7.3-7.2 (m, 2H), 6.8 (s, 1H), 6.75-6.6 (br s, 1H), 4.3-4.15 (m, 1H), 3.9-3.7 (m, 1H), 3.00-2.85 (m, 1H), 2.5-2.2 (br s, 3H), 1.3 (d, 6H, J=8), 1.25 (t, 3H, J=8); CI-HRMS: Calcd (C 19 H 22 BrN 5 ): 399.1137 (M+H), Found: 399.1140.
The free base was dissolved in ether and treated with an excess amount of a 1N HCl solution in ether. The resulting precipitate was collected and washed with copious amounts of ether. Drying in vacuo at 60° C. afforded the title product as a powder (500 mg, 72% yield) mp 235-237° C.; NMR (DMSO-d 6 , 300 MHz): 7.9-7.7 (m, 1H), 7.6 (s, 1H), 7.4-7.3 (m, 2H), 7.2 (m, 1H), 7.05-6.85 (m, 1H), 4.3-4.1 (m, 1H), 3.85-3.65 (m, 1H), 3.05-2.9 (m, 1H), 2.45-2.1 (br m, 3H), 1.25 (d, 6H, J=8), 1.2 (t, 3H, J=8); Anal. (C 19 H 22 BrN 5 -HCl): C, 52.75, H, 5.31, N, 16.03, Br, 18.29, Cl, 8.12; Found: C, 52.53, H, 5.28, N, 15.93, Br, 18.44, Cl, 8.17.
EXAMPLE 95
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(1-aminoethyl)-6-methylpyrimidinamine
A mixture of N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-acetyl-6-methyl-pyrimidinamine (0.5 g, 1.33 mmol), ammonium acetate (1.1 g, 14 mmol), sodium cyanoborohydride (59 mg, 0.9 mmol) and methanol (5 mL) was stirred at ambient temperature for 90 h. A concentrated HCl solution was added until the solution became acidic (pH=2), then the reaction mixture was concentrated in vacuo. The residue was taken up in water, basified with a concentrated NaOH solution and extracted three times with ether. The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo to give an oil. Column chromatography (ethyl acetate:hexanes::1:1), then chloroform:methanol:NH 4 OH::95:0.5) gave (1) N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(1-aminothyl)-6-methyl-pyrimidinamine (80 mg, 16% yield, R f 0.34 (ethyl acetate:hexanes::1:1) and (2) the title product as a brown oil (180 mg, 36% yield, R f 0.34 (chloroform:methanol:NH 4 OH:: 95:5:0.5)): NMR (CDCl 3 , 300 MHz): 7.5 (d, 1H, J=1), 7.2-7.1 (m, 2H), 6.4 (s, 1H), 4.25-4.05 (m, 1H), 3.9-3.65 (m, 2H), 3.0-2.85 (m, 1H), 2.4-2.2 (br m, 3H), 1.9-1.6 (br m, 3H), 1.3 (d, 6H, J=8), 1.2 (t, 3H, J=8); CI-HRMS (C 18 H 25 BrN 4 ): 377.1341 (M+H), Found: 377.1330.
EXAMPLE 96
N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(2-(4-tetrazolyl)-1-methylethyl)-6-methylpyrimidinamine
A mixture of N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(1-hydroxyethyl)-6-methylpyrimidinamine (1.1 g, 2.7 mmol), triethylamine (1.5 mL, 11 mmol) and dichloromethane (15 mL) was stirred at 0° C. under a nitrogen atmosphere. Methanesulfonylchloride (364 mg, 3.2 mmol) was added dropwise and the reaction mixture was then stirred for 1.5 h. The resulting turbid solution was washed successively with an ice-cold 1N HCl solution, a saturated NaHCO 3 solution and a saturated NaCl solution. Drying over MgSO 4 , filtration and removal of solvent in vacuo gave N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(1-methanesulfonyloxyethyl)-6-methylpyrimidinamine as a clear colorless oil (1.0 g); NMR (CDCl 3 , 300 MHz): 7.5 (d, 1H, J=1), 7.25-7.1 (m, 2H), 6.55 (s, 1H), 4.3-4.05 (m, 1H), 3.85-3.6 (m, 1H), 3.0-2.5 (m, 4H), 2.5-2.05 (br m, 3H), 1.3 (d, 6H, J=8), 1.2 (t, 3H, J=8); CI-MS: 456, 458 (M+H).
The crude mesylate was mixed with sodium cyanide (0.54 g, 11 mmol) in N,N-dimethylformamide (DMF) (20 mL) and stirred at reflux temperature for 67 h. After being cooled to room temperature, the reaction mix was poured onto water (200 mL), mixed and extracted with ethyl acetate three times. The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo to give an oil. Column chromatography (ethyl acetate:hexanes::1:9) afforded N-(2-bromo-4-(1-methylethyl)phenyl)-N-ethyl-4-(1-cyanoethyl)-6-methylpyrimidinamine as an oil (440 mg, R f 0.24): NMR (CDCl 3 , 300 MHz): 7.5 (d, 1H, J=1), 7.25-7.1 (m, 2H), 6.65-6.55 (m, 1H), 4.3-4.05 (m, 1H), 3.9-3.5 (m, 2H), 3.0-2.85 (m, 1H), 2.55-2.0 (br m, 3H), 1.8-1.4 (br m, 3H), 1.4-1.1 (m, 9H); CI-MS: 387,389 (M+H).
A mixture of the crude cyanide, sodium azide (600 mg, 9 mmol), ammonium chloride (492 mg, 9 mmol) and DMF (20 mL) was stirred at 100-105° C. for 112 h. After being cooled to room temperature, the reaction mixture was poured onto water (200 mL), basified with a 1N NaOH solution (pH>10) and extracted three times with chloroform. The combined organic layers were dried over MgSO 4 , filtered and concentrated in vacuo to give an oil. Column chromatography (chloroform:methanol::9:1) afforded a brown solid (R f 0.22). Recrystallization from ether gave the title product as a white solid (35 mg, 3% overall yield): mp 127-129° C.; NMR (CDCl 3 , 400 MHz): 7.75 (s, 0.4H), 7.7 (s, 0.6H), 7.45 (d, 0.6H, J=8), 7.4 (d, 0.4H, J=8), 7.3-7.2 (m, 2H), 6.5 (s, 0.4H), 6.48 (s, 0.6H), 4.28-4.0 (m, 1.4H), 4.28-4.18 (m, 0.6H), 3.94-3.82 (m, 0.6H), 3.8-3.7 (m, 0.4H), 3.1-3.0 (m, 1H), 2.45 (s, 3H), 1.5 (d, 3H, J=8), 1.4-1.3 (m, 5H), 1.3-1.2 (m, 4H); CI-HRMS: 430.1355 (M+H); 430.1347.
EXAMPLE 97
2-(N-(2-bromo-4-(2-propyl)phenyl)amino)-4-carbomethoxy-6-methylpyrimidine
A mixture of 2-chloro-4-carbomethoxy-6-methylpyrimidine (47 g, 252 mmol) and 2-bromo-4-(2-propyl)aniline (54.0 g, 252 mmol) in dioxane (400 mL) was stirred at reflux temperature for 20 h under a nitrogen atmosphere. The reaction mixture was cooled to ambient temperature and concentrated on a rotary evaporator. The residue was treated with a saturated sodium bicarbonate solution and extracted three times with ethyl acetate. The combined organic layers were dried over magnesium sulfate and filtered. Solvent was removed in vacuo to provide a red oil. Column chromatography (ethyl acetate:hexanes::1:1) gave the title product as a crude oil. Recrystallization from ether-hexanes, collection by filtration and drying in vacuo afforded the title compound as a solid (42.8 g, 47% yield): mp 75-76° C.; NMR (CDCl 3 , 300 MHz): 8.4 (d, 1H, J=8); 7.65 (br s, 1H), 7.4 (d, 1H, J=1), 7.3 (s, 1H), 7.2 (dd, 1H, J=8,1), 4.0 (s, 3H), 2.85 (septet, 1H, J=7), 2.5 (br s, 3H), 1.25 (d, 6H, J=7); Anal.(C 16 H 18 BrN 3 O 2 ): C, 52.76, H, 4.98, N, 11.54, Br, 21.94; Found: C, 52.71, H, 4.99, N, 11.38, Br, 21.83.
EXAMPLE 98
2-(N-(2-bromo-4-(2-propyl)phenyl)-N-ethylamino)-4-carbomethoxy-6-methylpyrimidine
To sodium hydride (60% in oil, 4.8 g, 120 mmol), washed with hexanes (50 mL) twice and decanted in anhydrous tetrahydrofuran (150 mL) at ambient temperature under a nitrogen atmosphere was stirred 2-(N-(2-bromo-4-(2-propyl)phenylamino)-4-carbomethoxy-6-methylpyrimidine (42.8 g, 118 mmol) portionwise over 30 min. After gas evolution subsided, iodoethane (31.2 g, 16 mL, 200 mmol) was added in one portion and the reaction mixture was heated to a gentle reflux and stirred for 24 h. After being cooled to room temperature, the reaction mixture was quenched carefully with water and extracted three times with ethyl acetate. The combined organic layers were washed with water twice, dried over magnesium sulfate and filtered. Solvent was removed in vacuo to afford a brown oil. Column chromatography (ether:hexanes::1:1) provided two fractions: (1) 2-(N-(2-bromo-4-(2-propyl)phenylamino)-4-carbomethoxy-6-methylpyrimidine (4.6 g, 11% yield, R f =0.8) and (2) the title product (20 g, R f =0.7) as a crude oil.
The title product was recrystallized from hexanes and dried in vacuo to give a solid (18.0 g, 39% yield): mp 81-82° C.: NMR (CDCl 3 , 300 MHz): 7.5 (br s, 1H), 7.25 (d, 1H, J=7), 7.15 (d, 1H, J=7), 7.1 (s, 1H), 4.3-4.1 (m, 1H), 4.05-3.75 (m, 4H), 2.95 (septet, 1H, J=7), 2.3 (br s, 3H), 1.3 (d, 6H, J=7), 1.25 (t, 3H, J=7); CI-HRMS: calcd: 392.0974 (M+H), found: 392.0960.
EXAMPLE 99
2-(N-(2-bromo-4-(2-propyl)phenyl)-N-ethylamino)-6-methylpyrimidine-4-carboxylic acid, morpholine amide
To sodium hydride (60% in oil, 0.24 g, 6.0 mmol), washed with hexanes twice and decanted, and suspended in anhydrous tetrahydrofuran (10 mL) was added morpholine (0.52 g, 6.0 mmol) and the reaction mixture was warmed to reflux temperature and stirred for 1 h. The reaction mixture was then cooled to ambient temperature and 2-(N-(2-bromo-4-(2-propyl)phenyl)-N-ethylamino)-4-carbomethoxy-6-methyl-pyrimidine (2.0 g, 5.1 mmol) was added and stirring was continued for 26 h. The reaction mixture was then poured onto a 1N NaOH solution, stirred and extracted three times with ethyl acetate. The combined organic layers were dried over magnesium sulfate, filtered and concentrated in vacuo. Column chromatography (ether) afforded the title compound as a solid (900 mg, 39% yield): mp 145° C.; NMR (CDCl 3 , 300 MHz): 7.5 (d, 1H, J=1), 7.2 (dd, 1H, J=7,1), 7.1 (d, 1H, J=7), 6.8 (br s, 1H), 4.3-4.15 (m, 1H), 3.9-3.3 (m, 11H), 3.1-3.0 (m, 1H), 2.9 (septet, 1H, J=7), 1.3 (d, 6H, J=7), 1.15 (t, 3H, J=7); Anal. (C 21 H 27 BrN 4 O 2 ) Calcd: C, 56.38, H, 6.08, N, 12.52, Br, 17.86; Found: C, 56.07, H, 6.05, N, 12.29, Br, 18.08.
EXAMPLE 100
2-(N-(2-bromo-4-(2-propyl)phenyl)-N-ethylamino)-4-(morpholinomethyl)-6-methylpyrimidine
To a solution of 2-(N-(2-bromo-4-(2-propyl)phenyl)-N-ethylamino)-6-methylpyrimidine-4-carboxylic acid, morpholine amide (750 mg, 1.72 mmol) in anhydrous tetrahydrofuran (1.4 mL) at ambient temperature under a nitrogen atmosphere was added a solution of borane in tetrahydrofuran (1M, 3.6 mL, 3.6 mmol) dropwise and the reaction mixture was heated at reflux temperature for 20 h. After cooling to room, acetic acid (3.5 mL) was slowly added and the mixture was heated at reflux for 30 min. After being cooled to ambient temperature, the reaction mixture was poured into a 3N NaOH solution and extracted three times with ethyl acetate. The combined organic layers were dried over magnesium sulfate, filtered and concentrated in vacuo. Column chromatography (ethyl acetate) afforded the title compound as an oil (300 mg, 39% yield, R f 0.3): NMR (CDCl 3 , 300 MHz) 7.5 (s, 1H), 7.2 (d, 1H, J=7), 7.15 (d, 1H, J=7), 6.5 (s, 1H), 4.3-4.1 (m, 1H), 3.8-3.6 (m, 7H), 3.5-3.3 (m, 2H), 2.9 (septet, 1H, J=7), 1.2 (t, 3H, J=7); CI-HRMS: calcd: 433.1603 (M+H), found: 433.1586.
EXAMPLE 101
9[2-bromo-4(2-propyl)phenyl]-2-methyl-6-chloropurine
Part A: Fuming nitric acid (40 mL) was added in portions to 4,6-dihydroxy-2-methylpyrimidine while cooling the reaction flask on ice. After completion of addition, the reaction was stirred an additional 60 min over ice followed by another 60 min at room temperature. The reaction mixture was then poured over ice (60 g) and the ice allowed to melt. A light pink solid was isolated by filtration and washed with cold water (50 mL). The solid was dried in a vacuum oven overnight to yield 22.6 g of product.
Part B: The product of Part A was added portionwise to phosphorus oxychloride (125 mL) under a nitrogen atmosphere. N,N-diethylaniline (25 mL) was added portionwise and the reaction mixture was refluxed for 150 min, then cooled to room temperature. The reaction mixture was poured over ice (750 g) and stirred for 1 h. The aqueous layer was extracted with diethyl ether (4×400 mL) and the extracts combined. The extracts were washed with brine (300 mL) and the organic layer dried over Na 2 SO 4 . The dried organic layer was filtered and stripped down to a tan solid (21.51 g).
Part C: The product of Part B (3.0 g) was added to acetic acid (5.5 mL) and methanol (25 mL). The solution was added to iron powder (3.0 g) and the reaction was stirred for two hrs at 60-65° C. The reaction was cooled to room temperature and the product was filtered. The filtrate was stripped to a brown solid, which was extracted with ethyl acetate (3×100 mL). The combined organic extracts were washed with NaOH (1N, 2×100 mL), water (100 mL), and brine (100 mL). The organic layer was dried over Na 2 SO 4 , filtered, and stripped to yield (2.13 g) an amber liquid that solidified upon cooling. MS M+H) + 178.
Part D: The product of Part C (2.0 g), 2-bromo-4-isopropylaniline (2.4 g), and diisopropylethylamine (1.52 g) were mixed and the reaction mass was heated to 160° C. for 25 min. Purification of the reaction mass by flash chromatography (CH 2 Cl 2 :MeOH, 50.1, silica) followed by stripping of the product-containing fractions yielded (1.45 g) an off white solid. MS (M+H) + 356.
Part E: The product of Part D (1.32 g), triethylorthoformate (10 mL), and acetic anhydride (10 mL) were mixed under nitrogen and refluxed for 4.5 hrs. The reaction mixture was reduced to an oil and water (50 mL) was added. The aqueous mixture was basified (pH 8) with solid Na 2 CO 3 and extracted with CHCl 3 (3×80 mL). The combined organic extracts were dried over Na 2 SO 4 , filtered and stripped to yield an amber oil (1.63 g). Purification by flash chromatography (CH 2 Cl 2 :MeOH, 50.1, silica) yielded a light amber glass 9[2-bromo-4(2-propyl)phenyl]-2-methyl-6-chloropurine (0.94 g). Mp49-52° C. MS (M+H) + 367.
EXAMPLE 102
9[2-bromo-4(2-propyl)phenyl]-2-methyl-6-morpholinopurine
9[2-bromo-4(2-propyl)phenyl]-2-methyl-6-chloropurine (1.3 g) and morpholine (10 mL) were combined under nitrogen and refluxed for 6 hrs. The reaction mixture was concentrated by rotovap and the residue was purified by flash chromatography (CH 2 Cl 2 :MeOH, 50:1, silica) to yield a yellow solid (0.54 g). MS (M+H) + 416, 418.
EXAMPLE 103
9[2-bromo-4(2-propyl)phenyl]-8-aza-2-methyl-6-chloropurine
Part A: Fuming nitric acid (40 mL) was added in portions to 4,6-dihydroxy-2-methylpyrimidine while cooling the reaction flask on ice. After completion of addition, the reaction was stirred an additional 60 min over ice followed by another 60 min at room temperature. The reaction mass was then poured over ice (60 g) and the ice allowed to melt. A light pink solid was isolated by filtration and washed with cold water (50 mL). The solid was dried in a vacuum oven overnight to yield 22.6 g of product.
Part B: The product of Part A was added portionwise to phosphorus oxychloride (125 mL) under a nitrogen atmosphere and N,N-diethylaniline (25 mL) was added portionwise. The reaction mixture was refluxed for 150 min, cooled to room temperature, poured over ice (750 g) and stirred for 1 h. The aqueous layer was extracted with diethyl ether (4×400 mL) and the extracts combined. The extracts were washed with brine (300 mL), dried over Na 2 SO 4 , filtered, and stripped down to a tan solid (21.51 g).
Part C: The product of Part B (6.5 g) was added to acetic acid (11 mL) and methanol (50 mL). This solution was added to iron powder (6.0 g), stirred for two hrs at 60-65° C., cooled to room temperature, and filtered. The filtrate was stripped to a brown solid, which was extracted with ethyl acetate (3×100 mL). The combined organic extracts were washed with NaOH (1N, 2×100 mL), water (100 mL), and brine (100 mL). The organic layer was dried over Na 2 SO 4 , filtered, and stripped to yield (4.75 g) an amber liquid that solidified upon cooling. MS (M+H) + 178.
Part D: The product of Part C (4.75 g) and 2-bromo-4-isopropylaniline (5.71 g) were mixed and the reaction mass heated to 140° C. for 60 min. The reaction mass was suspended in CH 2 Cl s (300 mL) and the organic solution was washed with NaOH (1N, 3×250 mL) and brine (250 mL). The organic phase was dried over Na 2 SO 4 , and stripped to a dark liquid (9.28 g). The liquid was purified by flash chromatography (CH 2 Cl 2 :MeOH, 50:1, silica) to yield (6.27 g) a light red solid. MS (M+H) + 356.
Part E: The product of Part D (2.0 g) was added to acetic acid (50%, 20 mL) and sodium nitrite (0.407 g) in water (2.0 mL) was added dropwise at room temperature. After 4.25 hrs, the reaction mixture was filtered and the collected solid was purified by flash chromatography (CH 2 Cl 2 :MeOH, 50:1; silica) to yield an orange oil 9[2-bromo-4(2-propyl)phenyl]-8-aza-2-methyl-6-chloropurine (0.75 g). MS (M+H) + 368.
EXAMPLE 104
9[2-bromo-4(2-propyl)phenyl]-8-aza-2-methyl-6-morpholinopurine
9[2-bromo-4(2-propyl)phenyl]-8-aza-2-methyl-6-chloropurine (1.34 g) and morpholine (10 mL) were combined under nitrogen and refluxed for 2.5 hrs. CH 2 Cl 2 (200 mL) was added to the reaction mixture and the resulting solution washed with water (2×100 mL) and brine (100 mL). The organic phase was dried over Na 2 SO 4 , concentrated by rotovap and the residue purified by flash chromatography (CH 2 Cl 2 , silica) to yield a yellow solid (0.62 g). MP 145-148° C. MS (M+H) + 417, 419.
EXAMPLE 105
2-(N-(2,4-dimethyoxypyrimidin-5-yl)-N-ethylamino)-4,6-dimethylpyrimidine
Part A: 5-Nitrouracil (25 g) was added to phosphorus oxychloride (130 mL) and N,N-diethylamine (32 mL) and the reaction was heated to reflux for 70 min. under nitrogen. After cooling to room temperature, the reaction mixture was poured over ice (600 g) and the mixture stirred until it reached room temperature (60 min). The aqueous layer was extracted with diethyl ether (4×300 mL). The extracts were combined, washed with brine (200 mL), and dried over Na 2 SO 4 . The organic layer was then stripped to yield an orange red liquid (17.69 g).
Part B: The product of Part A (17.69 g) in 60 mL methanol was added dropwise to a solution of sodium methoxide (30% wt, 38 mL) while cooling the flask in an ice bath. After addition was complete, the reaction mixture was stirred overnight at room temperature and then refluxed for 4 hrs. After cooling to room temperature, the reaction mixture was poured over ice (500 g) and the white precipitate that formed (10.38 g) was collected by filtration.
Part C: The product of Part B (4.1 g) and Pd/C (10% wt, 0.15 g) were added to ethanol (70 mL), methanol (10 mL) and water (1 mL) in a Parr reactor. The reaction mass was treated with hydrogen until TLC analysis showed no starting material. The reaction mass was filtered through celite and the filtrate stripped yielding a tan solid (3.32 g).
Part D: The product of Part C (1.086 g) and 2-chloro-4,6-dimethyl-pyrimidine (1.0 g) were dissolved in THF (50 mL) under nitrogen. Sodium hydride (0.336 g, 60% wt dispersion in oil) was added portionwise. After addition, the reaction was refluxed for 5.5 hrs, cooled to room temperature and the solid removed by filtration. The filtrate was concentrated and purified by flash chromatography (CH 2 Cl 2 :MeOH, 90:10, silica) to give a solid (0.52 g). MS (M+H) + 262.
Part E: The product of Part D (2.0 g) and iodoethane (1.49 g) were dissolved in dimethylformamide (20 mL) under nitrogen. Sodium hydride (0.383 g, 60% wt dispersion in oil) was added portionwise. After addition, stirring was continued at room temperature for 22 hrs. Water (200 mL) was added and the mixture was extracted with ethyl acetate (3×200 mL). The combined extracts were washed with water (100 mL) and brine (100 mL), dried over Na 2 SO 4 , filtered, and stripped to give an amber liquid 2-(N-(2,4-dimethyoxypyrimidin-5-yl)-N-ethylamino)-4,6-dimethylpyrimidine (2.68 g). MS (M+H) + 290.
Many of the compounds described above may be converted to their salts by addition of the corresponding acid in a solution of the compound in an organic solvent. The choice of addition salt described above is not intended to limit the invention, and is intended to be illustrative of the generally of the described syntheses. Physical properties of representative compounds that can be synthesized utilizing the methods described above are provided in the tables below (Table 1 through Table 17). The column in the tables headed "Synth. Ex." refers to the synthesis example 1-105, supra. The designations "MS" and "HRMS" refer to low and high resolution mass spectral data, respectively.
EXAMPLE 106
9-[2-Bromo-4-(1-methylethyl)phenyl]-6-(N-ethylbutyl)-2-methyl-9H-imidazo[4,5-d]pyrimidin-6-amine
Part A: N-[3-{2-Bromo-4-(1-methylethyl)phenyl}]-6-chloro-2-methyl pyrimidin-4,5-diamine
5-Amino-4,6-dichloro-2-methylpyrimidine (28.5 g, 0.16 mol) and 2-bromo-4-isopropylaniline (34.24 g, 0.16 mol) in 2-ethoxyethanol (100 mL) were refluxed at 135° C. for 30 h. After cooling the reaction mixture, the solvent was removed in vacuo and the residue taken up into dichloromethane and the organic phase washed with water, dried over anhydrous magnesium sulfate and filtered. Solvent removal gave an oil that was purified by flash chromatography (silica gel) using methanol/CH 2 Cl 2 (1:100) to yield the desired product as a cream colored solid (32.1 g, 56%); mp 144.5-146° C.
Part B: 9-[2-Bromo-4-(1-methylethyl)phenyl]-6-chloro-2-methyl-9H-imidazo[4,5-d]pyrimidine
The product of Part A of example 106 ((12.2 g, 0.034 mol) dissolved in triethylorthoformate (90 mL) and acetic anhydride (90 mL) was heated at 120° C. for 5 h. The solvent was stripped off in vacuo and the residue was partitioned between chloroform and water, and the pH of the aqueous phase adjusted to 8. After extracting with additional chloroform, the extracts were washed with brine, dried with anhydrous magnesium sulfate, and stripped down to a brown oil. The crude oil was purified by flash chromatography (silica gel) using CH 2 Cl 2 , followed by recrystallization from petroleum ether to give desired product as an off-white crystalline solid (4.9 g, 40%): mp 90-91° C.; 1 H NMR (CDCl 3 ) δ 1.25 (d, 6H, CH(CH 3 ) 2 ), 2.8 (s, 3H, C-2 CH 3 ), 3.0 {m, 1H, CH(CH 3 ) 2 }, 7.2 (m, 2H, Ar), 7.45 (s, 1H, Ar), 8.18 (s, 1H, C-8 CH).
Part C: N,N-Bis(2-methoxyethyl))-9-[2-bromo-4-(1-methylethyl)phenyl]-2-methyl-9H-imidazo[4,5-d]pyrimidin-6-amine
The product of Part B of above (1.1 g, 3 mmol) dissolved in N-ethylbutylamine (5.0 g) was heated at reflux for 1 h. The excess amine was removed under vacuum and the residue was partitioned between ethyl acetate and water. The organic layer was washed with brine, dried with anhydrous magnesium sulfate, and stripped down to a pale yellow liquid. The crude residue was purified by a flash chromatography (silica gel) using CH 2 Cl 2 to give title product as a light brown oil (0.73 g, 56%): 1 H NMR (CDCl 3 ) δ 1.0-1.2 (2t, 6H, 2*CH 3 ), 1.25 (d, 6H, CH(CH 3 ) 2 ), 1.4-1.6 (2m, 4H, 2*CH 2 ) 2.58 (s, 3H, C-2 CH 3 ), 3.0 (m, 1H, CH(CH 3 ) 2 ), 3.5 (q, 2H, --N--CH 2 CH 3 ), 4.0 (br, 2H, --N--CH 2 ), 7.25-7.4 (m, 2H, Ar), 7.6 (s, 1H, Ar), 7.8 (s, 1H, C-8 CH); MS: M + =430.1; M+2=432.1
EXAMPLE 107
N,N-Bis{2-methoxyethyl)-9-[2-bromo-4,6-dimethoxyphenyl]-2-methyl-9H-imidazo[4,5-d]pyrimidin-6-amine
Part A
N,N-Bis{2-methoxyethyl}])-6-chloro-2-methyl-5-nitropyrimidin-4-amine:
To 4,6-dichloro-5-nitropyrimidine (4.16 g, 20 mmol) in ethanol (50 mL) was added triethylamine (2.02 g, 20.0 mmol) followed by dropwise addition of bis(2-methoxyethyl)amine (2.7 g, 20.0 mmol) in ethanol (10.0 mL) over 30 mins at room temperature. After stirring the reaction mixture at room temperature for an additional 1 h, solvent removal in vacuo gave a residue that was partitioned between ethyl acetate and water. The organic layer was washed with brine, dried with anhydrous magnesium sulfate, and stripped down to a residue that was purified by a flash chromatography (silica gel, CH 2 Cl 2 ) to afford 5.9 g (97%) of an orange yellow liquid. 1 H NMR (CDCl 3 ) δ 2.45 (s, 3H, C-2 CH 3 ), 3.35 (s, 6H, 2 --OCH 3 's), 3.55 (t, 4H, 2 --N--CH 2 's), 3.75 (t, 4H, 2 --O--CH 2 's).
Part B
4-[N,N-Bis{2-methoxyethyl}]-6-[N-{2-bromo-4,6-dimethoxyphenyl}]-2-methyl-5-nitropyrimidin-4,6-diamine:
The product of Part A of above (3.85 g, 12.6 mmol) dissolved in anhydrous DMF (30.0 mL) was added 2-bromo-4,6-dimethoxyaniline (3.07 g; 13.3 mmol) and heated at 60° C. for 6 days. Solvent removal in vacuo gave a residue that was partitioned between ethyl acetate and water. The organic layer was then washed with brine, dried with anhydrous magnesium sulfate, and stripped down to a residue that was purified by a flash chromatography (silica gel, 1:50 MeOH+CH 2 Cl 2 ) to afford anticipated product (4.03 g, 64%) as a yellow crystalline solid: mp 95-96° C.; 1 H NMR (CDCl 3 ) δ 2.15 (s, 3H, CH 3 ), 3.4 (s, 6H, 2*O--CH 3 ), 3.6-3.75 (m, 8H, 4*CH 2 ), 3.8-3.83 (2 s, 6H, 2*Ar--OCH 3 ), 6.45 (S, 1H, Ar--H), 6.8 (s, 1H, Ar--H), 9.15 (s, 1H, NH). HRMS: calcd. for M+H (C 19 H 27 N 5 O 6 Br 1 ) 500.114470; found 500.114616.
Part C
4-[N,N-Bis{2-methoxyethyl})-6-[N-{2-bromo-4,6-dimethoxyphenyl}]-2-methyl-pyrimidin-4,5,6-triamine:
The product of Part B of above was reduced according to the method described in the preparation of Part C of example 103 to afford the desired product as a viscous oil (72%): 1 H NMR (CDCl 3 ) δ 2.35 (s, 3H, CH 3 ), 3.4 (s, 6H, 2*O--CH 3 ), 3.5-3.6 (2 t, 8H, 4*CH 2 ), 3.75-3.80 (2 s, 6H, 2*Ar--OCH 3 ), 6.25 (bs, 1H, NH), 6.45 (s, 1H, Ar--H), 6.75 (s, 1H, Ar--H).
Part D
6-{N,N-Bis(2-methoxyethyl)}-9-[2-bromo-4,6-dimethoxyphenyl]-2-methyl-9H-imidazo[4,5-d]pyrimidin-6-amine:
The product of Part C of above was cyclized using the method described in Part B of example 106 to afford the title compound as a off-white crystalline solid (mp: 137-138° C.). 1 H NMR (CDCl 3 ) δ 2.5 (s, 3H, CH 3 ), 3.4 (s, 6H, 2*O--CH 3 ), 3.6-3.8 (2 t, 8H, 4*CH 2 ), 3.75-3.85 (2 s, 6H, 2*Ar--OCH 3 ), 6.45 (s, 1H, Ar--H), 6.85 (s, 1H, Ar--H), 7.6 (s, 1H, 8-CH).
EXAMPLE 108
6-{N,N-Bis(2-methoxyethyl)}-2-methyl-9-(2,4,6-trimethyl)phenyl-9H-imidazo[4,5-d]pyrimidin-6-amine
Part A
4,6-Dichloro-2-methyl-5-nitropyrimidine (12.58 g, 60.48 mmol) was dissolved in DMSO (200 ml) followed by addition of 2,4,6-trimethylaniline (7.43 ml, 52.8 mmol) dropwise via syringe over 1 hour. The reaction was stirred at room temperature for 18 hours, then poured onto water (1.6 L) and allowed to stir overnight. The resultant precipitated pyrimidone was filtered and dried to constant weight affording 8.02 g (51%) as a light yellow solid, mp >225° C. 1 H NMR (CDCl 3 , 300 MHz) δ 12.23 (bs, 1H), 10.60 (s, 1H), 6.95 (s, 2H), 2.34 (s, 3H), 2.33 (s, 3H), 2.16 (s, 6H);
Anal. Calcd. for (C 14 H 16 N 4 O 3 ): C, 58.32; H, 5.59; N, 19.43. Found: C, 58.00; H, 5.45; N, 19.30.
Part B
The product from Part A (3.1 g, 11 mmol) was suspended in phosphorous oxychloride (25 ml) and heated to just under reflux for 1 hour, to give a dark homogeneous reaction. The reaction was pipetted slowly and cautiously onto 700 ml ice/water, stirred 30 minutes at room temperature, diluted with methylene chloride (200 ml) and transferred to a separatory funnel. The aqueous layer was extracted and reextracted with methylene chloride (3×50 ml). The combined organic extracts were dried over anhydrous magnesium sulfate, filtered and concentrated in-vacuo to constant weight to afford 3.18 g (97%) of the product as a bright yellow solid, mp 128-130° C. 1 H NMR (CDCl 3 , 300 MHz) δ 8.79 (bs, 1H), 6.96 (s, 2H), 2.42 (s, 3H), 2.33 (s, 3H), 2.15 (s, 6H).
Part C
The product from Part B (2.73 g, 8.9 mmol) was suspended in 60 ml methanol, followed by addition of acetic acid (3.4 ml), cooling to 0° C. in an ice/acetone bath, and addition of iron (1.84 g). The heterogeneous reaction was stirred 5 minutes at 0° C., then refluxed 3 hours, cooled, and filtered through celite. The celite pad was washed with 500 ml ethyl acetate. The dark filtrate was concentrated in-vacuo to near dryness, redissolved in ethyl acetate/water and extracted. The aqueous layer was reextracted several times with ethyl acetate. The combined organic extracts were dried over anhydrous magnesium sulfate, filtered and concentrated in-vacuo. Chromatography on silica gel (300 g, 1/1 ethyl acetate/hexanes) gave the desired reduction product, 2.18 g (88%) as an off-white solid. 1 H NMR (CDCl 3 , 300 MHz) δ 6.93 (s, 2H), 6.25 (bs, 1H), 3.13 (bs, 2H), 2.36 (s, 3H), 2.31 (s, 3H), 2.17 (s, 6H);
HRMS calcd. for M+(C 14 H 17 N 4 Cl 1 ): 276.1142. Found: 276.1138.
Part D
The product from Part C (1.75 g, 6.33 mmol) was suspended in triethylorthoformate (40 ml) and conc, hydrochloric acid (1.75 ml). The reaction was stirred 3.5 hours at room temperature, neutralized with aqueous sodium bicarbonate, diluted with water (200 ml) and extracted with methylene chloride (3×50 ml). The combined organic extracts were dried over anhydrous magnesium sulfate, concentrated in-vacuo and purified by column chromatography on silica gel (200 g) to afford the imidazopyridine, 1.27 g (70%), as a crystalline solid. 1 H NMR (CDCl 3 , 300 MHz) δ 7.98 (s, 1H), 7.15 (s, 2H), 2.77 (s, 3H), 2.39 (s, 3H), 1.95 (s, 6H).
Part E
The product from Part D (255 mg, 0.89 mmol) was suspended in ethanol (10 ml), treated with bis(methoxyethyl)amine (656 ml, 4.45 mmol) and brought to reflux for 24 hours. The reaction was concentrated to dryness in-vacuo and purified by column chromatography on silica gel (50 g) eluting with hexanes/ethyl acetate (2/1) to afford title compound, 294 mg (86%), as a crystalline solid, mp 117-120° C. 1 H NMR (CDCl 3 , 300 MHz) δ 7.57 (s, 1H), 7.00 (s, 2H), 4.5-4.1 (very broad singlet, 4H), 3.75 (m, 4H), 3.41 (s, 6H), 2.48 (s, 3H), 2.34 (s, 3H), 1.96 (s, 6H).
Anal. Calcd. for C 21 H 29 N 5 O 2 : C, 65.77; H, 7.62; N, 18.26. Found: 65.99; H, 7.57; N, 18.22.
Examples 109 to 145 were prepared in a similar manner by following the methods outlined in examples 106-108.
EXAMPLE 146
9-[2-Bromo-4-(1-methylethyl)phenyl]-6-(N-ethylbutyl)-2-methyl-8-trifluromethyl-9H-imidazo[4,5-d]pyrimidin-6-amine
Part A
4-[2-Bromo-4-(1-methylethyl)phenylamino]-6-chloro-2-methyl-5-trifluoroacetylaminopyrimidine:
The product of Part A of example 106 (2.5 g, 7 mmol) dissolved in 15 mL of trifluoroacetic anhydride was refluxed under nitrogen overnight. Solvent removal in vacuo gave a homogeneous oil [TLC-silica: 1:50 MeOH/methylene chloride: Rf (SM) 0.41; Rf (prod) 0.65] that was used without further purification for the cyclization process.
Part B
9-[2-Bromo-4-(1-methylethyl)phenyl]-6-hydroxy-2-methyl-9H-imidazo[4,5-d]pyrimidine:
The above residue was taken up into 15 mL of p-xylene and reluxed overnight. Solvent removal gave, after crytallization from EtOH, 2.4 g of white solid that turned out to be the pyrimidone analog of part A: mp >265° C.; MS: M+433. To 1.65 g (0.0038 mol) of this pyrimidone-amide in 35 mL of EtOH was added 1.5 mL of triethylamine and the solution was refluxed overnight. The solvent was removed in vacuo and the residue taken up into methylene chloride, washed with water and dried. Solvent removal gave 1.55 g (99%) of which was converted to the chloride without further purification.
Part C
Conversion of OH to Cl:
To 1.85 g (4.5 mmol) of the above Part B material in 20 ml of POCl 3 was added 0.8 g of N,N-diethylaniline dropwise over a 10 min period and the reaction mixture was refluxed for 3 h. After solvent removal in vacuo, the brown residue was treated with ice-water and the mixture was stirred for 1 h. then extracted with ether. The combined extracts were washed with water and dried with MgSO4. Solvent removal gave a viscous residue that was chromatographed (methylene chloride) to afford 1.1 g of oil that crystallized upon trituration with pentanes to give 1.05 g (54%) of white crystalline mp 132-133° C.
Part D
9-[2-bromo-4-(1-methylethyl)phenyl]-6-(N-ethylbutyl)-2-methyl-8-trifluromethyl-9H-imidazo[4,5-d]pyrimidin-6-amine:
The product of Part C of above (0.2 g, 0.46 mmol) dissolved in 10 ml of dichloromethane was added N-ethylbutylamine (1.0 g) and stirred at room temperature for 16 h. The excess amine and the solvent were removed under vacuum and the residue was partitioned between ethyl acetate and water. The organic layer was washed with brine, dried with anhydrous magnesium sulfate, and stripped down to a pale yellow liquid. The crude residue was purified by a flash chromatography (silica gel) using methylene chloride to give title product as a colorless oil.
Example 147 was prepared in a similar manner described in Example 146, Part D using Part C material of example 146.
EXAMPLE 148
6-(N-Ethylbutyl)-8-methoxy-2-methyl-9-[2-bromo-4-(1-methylethyl) phenyl]-9H-imidazo[4,5-d]pyrimidin-6-amine
Part A
The product from Example 101, Part D (2.3 g, 6.47 mmol) was dissolved in anhydrous toluene (200 ml) and treated with phosgene (33.5 ml, 64.70 mmol, 1.93 M/toluene solution) for 2 hours at 80° C. The reaction was diluted with water (250 ml) and extracted with ethyl acetate (4×100 ml). The combined organic extracts were dried over anhydrous magnesium sulfate, concentrated in-vacuo and purified by column chromatography on silica gel (200 g) eluting with hexanes/ethyl acetate 1/1) to provide the urea, 2.34 g (95%), as a crystalline solid, mp 229-230° C.
Anal. Calcd. for C 15 H 14 N 4 O 1 Br 1 Cl 1 : C, 47.20; H, 3.71; N, 14.68. Found: C, 47.19; H, 3.65; N, 14.49.
Part B
The product from Part A (800 mg, 2.10 mmol) was treated with butylethylamine (10 ml), refluxed 24 hours, and concentrated to dryness in-vacuo. Purification on silica gel (100 g) eluting with hexanes/ethyl acetate (4/1) afforded the addition product, 793 mg (85%), as a crystalline solid, mp 165-167° C.
Anal. Calcd. for C 21 H 28 N 5 O 1 Br 1 : C, 56.50; H, 6.32; N, 15.69. Found: C, 56.34; H, 6.23; N, 15.50.
Part C
The product from Part B (75 mg, 0.17 mmol) was dissolved in anhydrous methylene chloride (3 ml) and treated with trimethyloxonium tetrafluoroborate (50 mg, 0.34 mmol). The reaction was stirred 18 hours at room temperature, treated with two additional equivalents of trimethyloxonium tetrafluoroborate (50 mg) and stirred an additional 24 hours at room temperature. The reaction was diluted with water (15 ml) and extracted with ethyl acetate (3×10 ml). The combined organic extracts were dried over anhydrous magnesium sulfate, concentrated in-vacuo and purified by column chromatography on silica gel (30 g) eluting with hexanes/ethyl acetate (4/1) to afford the title compound, 30.2 mg (39%), as a clear oil. 1 H NMR (CDCl 3 ,300 MHz) δ 7.57 (s, 1H), 7.30 (s, 2H), 4.06 (s, 3H), 3.96 (m, 2H), 3.85 (m, 2H), 2.95 (m, 1H), 2.45 (s, 3H), 1.70 (m, 2H), 1.42 (m, 2H), 1.28 (d, 6H, J=7.0 Hz), 1.26 (t, 3H, J=7.0 Hz), 0.99 (t, 3H, J=7.3 Hz).
HRMS calcd. for M+H (C 22 H 31 N 5 O 1 Br 1 ): 460.1712. Found: 460.1733.
EXAMPLE 149
8-Chloro-6-(N-ethylbutyl)-2-methyl-9-[2-bromo-4-(1-methylethyl) phenyl]-9H-imidazo[4,5-d]pyrimidin-6-amine
The product from Example 148, Part B (275 mg, 0.62 mmol) was suspended in phosphorous oxychloride (5 ml) and heated to reflux for 3 days. The reaction was poured onto ice (100 ml) and extracted with ethyl acetate (4×25 ml). The combined organic extracts were dried over anhydrous magnesium sulfate, concentrated in-vacuo and purified by column chromatography on silica gel (50 g) eluting with hexanes/ethyl acetate (1/1) to provide the title compound, 87 mg (30%) as a clear oil. 1 H NMR (CDCl 3 , 300 MHz) δ 7.61 (d, 1H, J=1.5 Hz), 7.34 (dd, 1H, J=1.5, 8.0 Hz), 7.29 (d, 1H, J=8.2 Hz), 4.0-3.8 (broad signal, 4H), 2.99 (m, 1H), 2.46 (s, 3H), 1.69 (m, 2H), 1.43 (m, 2H), 1.31 (d, 6H, J=7.0 Hz), 1.29 (t, 3H, J=6.6 Hz), 0.99 (t, 3H, J=7.7 Hz).
HRMS calcd. for M+H (C 21 H 28 N 5 Cl 1 Br 1 ): 466.1196. Found: 466.1183.
Examples 150-153 were made by following one of the methods described in examples 106 to 108 and 146 to 149
EXAMPLE 154
N,N-Bis(2-methoxyethyl)-3-[2-bromo-4-(1-methylethyl)phenyl]-5-methyl-3H-1,2,3-triazolo[4,5-d]pyrimidin-7-amine
Part A
3-[2-bromo-4-(1-methylethyl)phenyl]-7-chloro-5-methyl-3H-1,2,3-triazolo[4,5-d]pyrimidine:
To the product of Part A of example 106 (12.5 g, 0.035 mol) dissolved in dichloromethane (125 mL) and 50% aqueous acetic acid (125 mL) was added sodium nitrite (2.55 g, 0.037 mol) in water (10 mL) dropwise at room temperature. After addition, the reaction was stirred for an additional 15 mins. The organic layer was then separated, washed with water and dried with anhydrous magnesium sulfate. Solvent removal gave a residue that was purified by flash chromatography (silica gel) using CH 2 Cl 2 to afford a light brown oil. Crystallization from 1:1 hexane+pentane (15 mL) yielded desired product as a white solid (12.1 g, 94%); mp 72-74° C.
Part B
N,N-Bis(2-methoxyethyl)-3-[2-bromo-4-(1-methylethyl)phenyl]-5-methyl-3H-1,2,3-triazolo[4,5-d]pyrimidin-7-amine:
To the product of Part A of above (3.1 g, 8.45 mmol) was dissolved in ethanol (50 mL) and added bis(2-methoxyethyl)amine (1.35 g, 10.1 mmol) followed by triethylamine (1.02 g, 10.1 mmol) and the reaction mixture was refluxed for 3 h. Solvent removal in vacuo gave a residue that was partitioned between ethyl acetate and water. The organic layer was then washed with brine, dried with anhydrous magnesium sulfate, and stripped down to a pale yellow liquid that was purified by a flash chromatography (silica gel) using CH 2 Cl 2 ). Recrystallization of the isolated product from hexane gave the title product as a white crystalline solid (3.62 g, 92%): mp 93-94° C.; 1 H NMR (CDCl 3 ) δ 1.25 (d, 6H, CH(CH 3 ) 2 ), 2.58 (s, 3H, C-5 CH 3 ), 3.0 (m, 1H, CH(CH 3 ) 2 ), 3.39-3.4 (2s, 6H, 2*OCH 3 ), 3.7-3.85 (2t, 4H, 2*N--CH 2 ), 4.1-4.6 (2t, 4H, 2* --CH 2 --O--CH 3 ), 7.4-7.6 (2m, 3H, Ar); MS (CI) M - =463.2; M+2=465.2
Examples 155 to 190 were prepared in a similar manner described in example 154.
EXAMPLE 191
3-[2-bromo-4-(1-methylethyl)phenyl]-7-(1-methoxymethylpropoxy)-5-methyl-3H-1,2,3-triazolo[4,5-d]pyrimidine
To 1-methoxy-2butanol (0.26 g, 2.4 mmol) in toluene (20 mL) was added 60% NaH-mineral oil (0.12 g; 2.4 mmol) and the mixture was stirred at room temperature for 10 mins. The product of Part A of example 154 (0.74 g; 2.0 mmol) was then added and the reaction mixture was refluxed for 1 h, cooled to room temperature and quenched with water (10 mL). The organic layer was separated, washed with brine, dried with anhydrous magnesium sulfate, and stripped down to a pale yellow liquid that was purified by a flash chromatography (silica gel) using CH 2 Cl 2 as a eluent to afford as a colorless oil (0.54 g, 62%): 1 H NMR (CDCl 3 ) δ 1.05 (t, 3H; CH 3 ), 1.35 (d, 6H, CH(CH 3 ) 2 ), 1.95 (q, 2H, CH 2 ), 2.78 (s, 3H, C-5 CH 3 ), 3.0 (m, 1H, CH(CH 3 ) 2 ), 3.4 (s, 3H, OCH 3 ), 3.6-3.8 (m, 2H, O--CH 2 ), 5.85 (m, H, O--CH), 7.4 (m, 2H, Ar), 7.6 (s, 1H, Ar); MS: M + =434.2; M+2=436.2
Examples 192 to 200 were prepared by following one of the methods outlined in examples 154 and 191.
EXAMPLE 201
N,N-Bis(2-methoxyethyl)-3-[2-bromo-4,6-dimethoxyphenyl]-5-methyl-3H-1,2,3-triazolo[4,5-d]pyrimidin-7-amine
The product of Part C of example 107 was cyclized according to the method outlined in Part A of example 154 to afford the title product as a white crystalline solid (46%): mp 124-126° C.; 1 H NMR (CDCl 3 ) δ 2.55 (s, 3H, CH 3 ), 3.4 (s, 6H, 2 O--CH 3 's), 3.65 s, 3H, Ar--OCH 3 ), 3.75-3.85 (2 t, 4H, 2 CH 2 's), 3.9 (s, 3H, Ar--OCH 3 ), 4.1 (t, 2H, CH 2 ), 4.55 (t, 2H, CH 2 ), 6.55 (s, 1H, Ar--H), 6.85 (s, 1H, Ar--H). Mass M + =481.1 and M+2=483.1.
EXAMPLE 202
7-chloro-5-methyl-3-(2,4,6-trimethyl)phenyl-3H-1,2,3-triazolo[4,5-d]pyrimidine
The product from example 108, Part C (1.28 g, 4.63 mmol) was dissolved in methylene chloride (20 ml) and treated with 50% aqueous acetic acid (14 ml) and sodium nitrite (338 mg, 4.90 mmol, as a solution in 1 ml chilled water). The reaction was stirred at room temperature for 3 hours, diluted with water (100 ml) and extracted with methylene chloride (75 ml). The aqueous layer was reextracted with methylene chloride (3×75 ml) and the combined organic extracts dried over anhydrous magnesium sulfate and concentrated in-vacuo. Purification on silica gel (200 g) eluting with hexanes/ethyl acetate (4/1) afforded product as a crystalline solid, mp 186-188° C. 1 H NMR (CDCl 3 , 300 MHz) δ 7.08 (s, 2H), 2.82 (s, 3H), 2.40 (s, 3H), 1.92 (s, 6H).
HRMS calcd. for M+H (C 14 H 15 N 5 Cl 1 ): 288.1016. Found: 288.1008.
EXAMPLE 203
N,N-Bis(2-methoxyethyl)}-5-methyl-3-(2,4,6-trimethyl)phenyl-3H-1,2,3-triazolo[4,5-d]pyrimidin-7-amine
The product from example 202 (450 mg, 1.56 mmol) was suspended in ethanol (10 ml) and treated with triethylamine (0.261 ml, 1.87 mmol) and bis(2-methoxyethyl)amine (0.277 ml, 1.87 mmol). The reaction was refluxed 1 hour and concentrated directly to dryness in-vacuo. Purification by column chromatography on silica gel (150 g) eluting with hexanes/ethyl acetate (3/2) afforded the title compound, 589 mg (98%), as a crystalline solid, mp 84-85° C. 1 H NMR (CDCl 3 , 300 MHz) δ 7.02 (s, 2H), 4.57 (t, 2H, J=5.5 Hz), 4.14 (t, 2H, J=5.7 Hz), 3.84 (t, 2H, J=5.1 Hz), 3.74 (t, 2H, J=5.9 Hz), 3.41 (s, 3H), 3.39 (s, 3H, 2.41 (s, 3H), 2.36 (s, 3H), 1.93 (s, 6H).
Anal. Calcd. for (C 20 H 28 N 6 O 2 ): C, 62.48, H, 7.34; N, 21.86. Found: C, 62.26; H, 7.14; N, 22.00.
Examples 204 to 268 were made by following one of the procedures outlined for examples 154, 191 and 201 to 203.
EXAMPLE 269
7-chloro-5-methyl-3-(2,4,6-trimethyl)phenyl-3H-1,2,3-triazolo[4,5-d]pyrimidine
Part A
3-Amino-2,4,6-trimethylpyridine.
3-Nitro-2,4,6-trimethylpyridine (14.89 g, 89.70 mmol) in methanol (250 ml) containing 10% palladium/carbon (1.5 g) was hydrogenated at 55 psi for 2 hours. The reaction mixture was filtered through wet celite, and the celite filter rinsed with methanol (5×30 ml). The filtrate was concentrated in vacuo to dryness and the residue purified by chromatography (silica gel; methylene chloride/methanol, 95/5) to 3-amino-2,4,6-trimethylpyridine (12.42 g, 100%) as a viscous oil.
Part B
N-[4-{2,4,6-trimethylpyridyl}]-6-chloro-2-methyl-5-nitropyrimidin-4-amine:
To 4,6-dichloro-2-methyl-5-nitropyrimidine 13 (10.10 g, 48.60 mmol) in anhydrous tetrahydrofuran (200 ml) was added triethylamine (6.8 ml, 48.60 mmol) and 3-amino-2,4,6-trimethylpyridine (3.30 g, 24.3 mmol) and the reaction was stirred 72 hours at room temperature. The solution was diluted with water (1 L) and extracted with ethyl acetate (4×200 ml). The combined organic extracts were dried over anhydrous magnesium sulfate, filtered and concentrated to dryness in vacuo. Chromatography of the crude product (silica gel; ethyl acetate/hexanes, 1/1) gave desired product (4.8 g, 64%) as a faint yellow solid: mp 134-136° C.; 1 H NMR (CDCl 3 ) δ 8.78 (bs, 1H), 6.97 (s, 1H), 2.43 (s, 3H), 2.39 (s, 3H), 2.16 (s, 3H), 2.05 (s, 3H).
Part C
N-[4-{2,4,6-trimethylpyridyl}]-6-chloro-2-methylpyrimidin-4,5-diamine:
To the product of Part B of above (4.8 g, 15.6 mmol) was dissolved in acetic acid (6 ml) and added powdered iron (4.36 g, 78.0 mmol) and the heterogeneous reaction was stirred 5 minutes at 0° C., then refluxed 3 hours, cooled, and filtered through celite. The celite pad was washed with ethyl acetate (500 ml) and the dark filtrate was concentrated in-vacuo to near dryness. The residue was redissolved in ethyl acetate/water and the layers separated. The aqueous layer was extracted several times with ethyl acetate and the combined extracts were dried over anhydrous magnesium sulfate, filtered and concentrated in-vacuo. Chromatography of the crude product on (silica gel; methylene chloride/methanol, 95/5) gave desired product (3.1 g, 72%): 1H NMR (CDCl 3 ) δ 6.94 (s, 1H), 6.26 (bs, 1H), 3.36 (bs, 2H), 2.52 (s, 3H), 2.40 (s, 3H), 2.34 (s, 3H), 2.16 (s, 3H).
Part D
7-chloro-5-methyl-3-(2,4,6-trimethyl)phenyl-3H-1,2,3-triazolo[4,5-d]pyrimidine:
The product of part C of above was cyclized in a similar manner as described in example 202 to afford the desired product (mp 204-206° C.).
Examples 270-274 were prepared using the product of example 269, part D and following the one of the methods described in 154, 191 and 201 to 203.
EXAMPLE 275 (Ex. 1100)
Part A
2,4-Dichloro-6-methyl-3-nitropyridine
4-hydroxy-6-methyl-3-nitropyridone, (18.67 g, 0.11 mol) was heated at reflux with diethylaniline (19 mL, 0.12 mol) in POCl 3 (85 mL) for 3 h. After cooling it was poured into ice/water (800 mL), allowed to react for 2.5 h and extracted with EtOAc (3×400 mL). The combined organic extracts were washed with NaHCO 3 (200 mL), brine (200 mL), dried (MgSO 4 ) and stripped in vacuo. The residue was dissolved in EtOAc (100 mL) and passed through a glass funnel packed with 1 in silica gel and 1 in celite. The filtrate was stripped in vacuo to give the product. NMR (CDCl 3 ) 7.30 (s, 1H), 2.61 (s, 3H).
Part B
2-Chloro-4-(N-butyl-N-ethylamino)-6-methyl-3-nitropyridine
2,4-Dichloro-6-methyl-3-nitropyridine (1 g, 4.83 mmol), N-ethylbutylamine (0.75 mL, 5.55 mmol), and N,N-diisopropylethylamine (1 mL, 6 mmol) were stirred at 25° C. for 24 h and at reflux for 5 h. Then the mixture was stripped in vacuo and the residue was partitioned between EtOAc (75 mL), and water (50 mL). The organic layer was washed with water (30 mL), brine (30 mL), dried (MgSO 4 ) and stripped in vacuo. The residue was chromatographed on silica gel (10%) EtOAc/hexanes eluent) to give the two regiomers 270 mg and 840 mg. The major regioisomer was characterized as the 4-adduct by nOe NMR experiments. minor: NMR (CDCl 3 ) 6.56 (s, 1H), 3.30-3.42 (m, 4H), 2.38 (s, 3H), 1.49-1.59 (m, 2H), 1.23-1.35 (m, 2H), 1.15 (t, 3H, J=7.3 Hz), 0.92 (t, 3H, J=7.0 Hz); major: NMR (CDCl 3 ) 6.52 (s, 1H), 3.28 (q, 2H, J=7.0), 3.18 (dd, 2H, J 1 =7.3 Hz, J 2 =8.1 Hz), 2.44 (s, 3H), 1.49-1.60 (m, 2H), 1.24-1.37 (m, 2H), 1.17 (t, 3H, J=7.3 Hz), 0.94 (t 3H, J=7.3 Hz).
Part C
2-N-(2-Bromo-4-(1-methylethyl)phenyl)-4-(N-butyl-N-ethyl amino)-6-methyl-3-nitropyridine
2-chloro-4-(N-butyl-N-ethyl amino)-6-methyl-3-nitropyridine, (1.088 g, 4 mmol) and 2-bromo-4-isopropylaniline (1.712 g, 8 mmol) were heated at 140° C. for 4.5 h. Then it was partitioned between EtOAc (11 mL) and 0.5 N NaOH (30 mL). The EtOAc was washed with brine (30 mL) dried (MgSO 4 ) and stripped in vacuo. The residue was chromatographed on silica gel (5% EtOAc/hexanes eluent) to give the product (920 mg, 51%). NMR (CDCl 3 ) 9.54 (s, 1H), 8.33 (d, 1H, J=8.8 Hz), 7.41 (d, 1H, J=1.8 Hz), 7.14 (dd, 1H, J1=8.8 Hz, J2=1.8 Hz), 6.24 (s, 1H), 3.18-3.32 (m, 4H), 2.80-2.90 (m, 1H), 2.36 (s, 3H), 1.54-1.65 (m, 2H), 1.18-1.40 (m, 11H), 0.93 (t, 3H, J=7.0 Hz).
Part D
3-Amino-2-N-(2-Bromo-4-(1-methylethyl)phenyl)-4-(N-butyl-N-ethyl amino)-6-methylpyridine:
2-N-(2-Bromo-4-(1-methylethyl))-4-(N-butyl-N-ethyl amino)-6-methyl-3-nitropyridine (1.17 g, 2.6 mmol), was dissolved in dioxane (60 mL) and water (60 mL) containing concNH 4 OH (2 mL). Then Na 2 S 2 O 4 was added (3.63 g, 20.8 mmol) and the mixture was stirred at 25° C. for 2 h. The reaction was extracted with EtOAc (160 mL) and the organic extract was washed with water (3×50 mL), brine (50 mL), dried (MgSO 4 ) and stripped in vacuo. The residue was chromatographed on silica gel (5% EtOAc/hexanes eluent) to give the product (960 mg, 88%). NMR (CDCl 3 ) 7.59 (d, 1H, J=8.4 Hz), 7.36 (d, 1H, J=2.2 Hz),
Part E (Ex. 1100)
Sodium nitrite (87.5 mg, 1.27 mmol), was added into a two phase mixture containing 3-amino-2-N-(2-Bromo-4-(1-methylethyl)-4-(N-butyl-N-ethyl amino)-6-methylpyridine 0.5 g, 1.19 mmol) dissolved in CH2Cl2 and 50% AcOH (4 mL) in small portions. The mixture was stirred at 25° C. for 2 h and partitioned between EtOAc (80 mL) and water (30 mL). The organic extract was washed with brine (30 mL), dried (MgSO 4 ) and stripped in vacuo. The residue was chromatographed on silica gel (10% EtOAc/hexanes eluent) to give the product (360 mg, 70%). NMR (CDCl 3 ) 7.63 (d, 1H J=1.5 Hz), 7.44 (d, 1H J=8.1 Hz), 7.33 (dd, 1H J1=8.1 Hz, J2=1.5 Hz), 6.10 (s, 1H), 3.8-4.0 (br m, 4H), 2.90-3.05 (m, 1H), 2.49 (s, 3H, 1.70-1.82 (m, 2H), 1.40-1.55 (m, 2H), 1.35 (t, 3H J=6.9 Hz), 1.30 (d, 6H 7.0 Hz), 1.01 (t, 3H, J=7.0 Hz).
This was converted to the hydrochloride salt with HCl in ether.
Elemental analysis (C 21 H 28 BrN 5 .HCl): Calc. C 54.03, H 6.26, N 15.00, Br 17.12; Found C 54.35, H 6.25, N 14.89, Br 16.81.
EXAMPLE 276 (Ex. 1000 )
To a solution of 3-amino-2-N-(2-bromo-4-(1-methylethyl))-4-(N-butyl-N-ethyl amino)-6-methylpyridine (460 mg, 1.1 mmol), in triethylorthoacetate (5 mL), 0.5 mL concHCl was added. The reaction was stirred at 25° C. for 2 h and partitioned between EtOAc (75 mL) and NaHCO 3 (50 mL). The organic extract was washed with brine (30 mL), dried (MgSO 4 ) and stripped in vacuo. The residue was chromatographed on silica gel (20% EtOAc/hexanes eluent) to give the product (330 mg, 68%). NMR (CDCl 3 ) 7.59 (s, 1H), 7.32 dd, 1H J1=8.4 Hz, J2=1.8 Hz), 7.28 (d, 1H J=8.4 Hz), 6.13 (s, 1H), 3.6-4.0 (m, 4H), 2.9-3.03 (m, 1H), 2.41 (s, 3H), 2.29 (s, 3H), 1.61-1.75 (m, 2H), 1.35-1.5 (m, 2H),
This was converted to the hydrochloride salt with HCl in ether.
Elemental analysis C 23 H 31 BrN 4 .HCl.H 2 O: Calc. C 55.48, H 6.88, N 11.25; Found C 55.31, H 7.14, N 10.63.
EXAMPLE 277 (Ex. 1101)
Part A
2-Chloro-4-(N,N-dimethoxyethylamino)-6-methyl-3-nitropyridine:
Synthesized by the same procedure described earlier for 2-chloro-4-(N-butyl-N-ethyl amino)-6-methyl-3-nitropyridine. 2,4-Dichloro-6-methyl-3-nitropyridine (4 g, 19.32 mmol) was reacted with dimethoxyethylamine (3.5 mL, 23.66 mmol) in the presence of N,N-diisopropylethylamine in ethanol (30 mL) at 25° C. for 60 h and at reflux for 7 h. The product was purified by silica gel chromatography (20% EtOAc/hexanes, followed by 40% EtOAc/hexanes, 4 g, 68% yield.
Part B
2-N-(2-Bromo-4-(1-methylethyl)phenyl)-4-(N,N-dimethoxyethylamino)-6-methyl-3-nitropyridine
Synthesized by coupling 2-chloro-4-(N,N-dimethoxyethylamino)-6-methyl-3-nitropyridine (1.87 g, 6.15 mmol), with 2-bromo-4-isopropylaniline (2.63 g, 12.3 mmol) at 140° C. for 6 h. The product was purified by silica gel chromatography (25% EtOAc/hexanes eluent, 1.3 g, 44%)
Part C
3-Amino-2-N-(2-Bromo-4-(1-methylethyl)phenyl)-4-(N,N-dimethoxyethylamino)-6-methylpyridine:
Synthesized by reducing the corresponding 3-nitro analog as described earlier. The product was purified by silica gel chromatography (20% EtOAc/hexanes eluent, 96% yield).
Part D: (Ex 1101)
Synthesized by cyclization of the above 3-aminopyridine with NaNO 2 under AcOH catalysis. The product was purified by silica gel chromatography (2% MeOH/CH 2 Cl 2 eluent), followed by HCl salt formation and crystallization fron EtOAc/ether/hexanes in 45% yield. NMR (CDCl 3 ) 7.68 (s, 1H), 7.55 (d, 1H J=8.0 Hz), 7.45 (d, 1H J=8 Hz), 6.42 (s, 1H), 4.6-4.7 (m, 1H).
Elemental analysis (C 21 H 28 BrN 5 O 2 .HCl.H 2 O): Calc. C 48.80, H 6.06, N 13.55, Br 15.46, Cl 6.86; Found C 48.96, H 6.11, N 13.40, Br 15.55, Cl 7.01 (average of two measurements).
EXAMPLE 278 (Ex 1001)
Synthesized by cyclization of 3-Amino-2-N-(2-Bromo-4-(1-methylethyl))-4-(N,N-dimethoxyethylamino)-6-methylpyridine with triethylorthoacetate under HCl catalysis as described earlier. The product was purified by silica gel chromatography (25% EtOAc/hexanes eluent, 90% yield).
Elemental analysis (C 23 H 31 BrN 4 O 2 .HCl.H 2 O): Calc. C 52.13, H 6.47, N 10.57; Found C 51.94, H 6.50, N 10.22.
EXAMPLE 279 (1102)
Part A
4-Isopropyl-2-thiomethylaniline:
2-Iodo-4-isopropylaniline (60 g, 23.0 mmol), sodium thiomethoxide (1.9 g, 26.4 mmol), copper powder (0.70 g, 11.0 mmol) and anhydrous DMF (50 mL) were refluxed for 1 h. Filtered the mixture through celite and washed the solids with EtOAc (2×50 mL). Partitioned the filtrates between EtOAc and H 2 O (30 mL). Washed the organic layer with H 2 O (2×20 mL), brine (20 mL), dried (MgSO 4 ), filtered and stripped in vacuo. The residue was chromatographed on silica gel (5% EtOAc/hexanes eluent) to give the product, brown liquid (2.10 g, 50%).
Part B
2-N-(2-Thiomethyl-4-(1-methylethyl))-4-(N-butyl-N-ethyl amino)-6-methyl-3-nitropyridine:
Synthesized by coupling 2-chloro-4-(N-butyl-N-ethyl amino)-6-methyl-3-nitropyridine, (1.0 g, 3.7 mmol) and 4-isopropyl-2-thiomethylaniline (1.3 g, 7.4 mmol) at 140° C. for 2 h. The product was purified by silica gel chromatography (95% hexanes/3% EtOAc/2% CHCl 2 eluent) to give an oil (1.0 g, 65%).
Part C
3-Amino-2-N-(2-Thiomethyl-4-(1-methylethyl))-4-(N-butyl-N-ethylamino)-6-methylpyridine:
Synthesized by reducing the corresponding 3-nitro analog as described earlier. The product was purified by silica gel (10% EtOAc/CH 2 Cl 2 eluent) to give the product (0.41 g, 62% yield).
Part D: (Ex 1102)
Synthesized by cyclization of the above 3-aminopyridine with NaNO 2 under AcOH catalysis. The product was purified by silica gel chromatography (20% EtOAc/hexanes eluent) to give an oil (0.30 g, 81% yield).
Elemental analysis (C 22 H 31 N 5 S): Calc. C 66.46, H 7.869, N 17.61, S 8.075; Found C 66.69, H 7.52, N 17.41, S 8.48.
EXAMPLE 280 (Ex 1103)
Synthesized by following the synthetic route described synthetic example 275. The final product was purified by silica gel chromatography (20-30% EtOAc-hexanes eluent) to give 0.24 g, 74% yield.
Elemental analysis (C 22 H 31 N 5 O 2 S): Calc. C 61.51, H 7.27, N 16.3, S 7.46; Found C 61.33, H 7.12, N 16.05, S 7.76.
EXAMPLE 281 (Ex. 1104)
Part A
Oxidized the methyl sulfide (Ex 1102) (250 mg, 0.63 mmol), in a mixture of MeOH (5 mL) and H 2 O (2.5 mL) while adding NaIO 4 (200 mg, 0.95 mmol) at RT. Stirred at RT. overnight. Partitioned between H 2 O (20 mL) and EtOAc (50 mL). Extracted the H 2 O layer with EtOAc (2×20 mL). Combined the organics and washed with brine, dried (MgSO 4 ), filtered and stripped in vacuo to give the crude product (0.24 g, 92% yield).
Part B (Ex. 1104)
Oxidized the corresponding sulfoxide (0.24 g, 0.58 mmol) to the sulfone by stirring in a mixture of CH 2 Cl 2 (5 mL) and H 2 O (5 mL) while adding benzyltriethylammonium chloride (132 mg, 0.58 mmol) followed by KMnO 4 (275 mg, 1.74 mmol). Stirred at RT. overnight. Partitioned between H 2 O (20 mL) and EtOAc (50 mL). Extracted the H 2 O with EtOAc (2×20 mL). Combined the organics and washed with H 2 O, brine, dried (MgSO 4 ), filtered and concentrated in vacuo to give the crude product. The residue was chromatographed on silica gel (20-30% EtOAc/hexanes eluent) to give the product (0.17 g, 68% yield).
Anal. Calcd. for C 22 H 31 N 5 O 2 S: C, 61.51; H, 7.27; N, 16.30; S, 746. Found: C, 61.35; H, 7.21; N, 16.21; S, 7.45.
EXAMPLE 282 (Ex1107)
Synthesized by following the route described in synthetic scheme 275. The product was purified by silica gel chromatography (20% EtOAc-hexanes eluent) to give a crystalline solid (0.40 g, 42%), mp 106-108° C.
Anal. Calcd. for C 20 H 26 BrN 5 O.1/2H 2 O: C, 54.43; H, 6.17; N, 15.87; Br, 18.10. Found C, 54.69; H, 5.84; N, 15.88; Br, 18.47 (an average of two measurements).
EXAMPLE 283 (Ex1111)
Part A
2-N-(2-Bromo-4-iodophenyl)-4-(N-diisopropylmethyl)-6-methyl-3-nitropyridine
Synthesized by coupling the diisopropylamino-2-chloro-3-nitropyridine (1.26 g, 4.4 mmol) and 2-bromo-4-iodoaniline (2.6 g, 8.8 mmol) at 140° C. for 3 h. The product was purified by silica gel chromatography (5% EtOAc/hexanes) to give a foam, 1.91 g, 79% yield.
Part B
2-N-(4-Acetyl-2-Bromophenyl)-4-(N-diisopropylmethyl)-6-methyl-3-nitropyridine:
To the corresponding 3-nitropyridine (1.91 g, 3.5 mmol) was added bis (triphenyl-phosphine)palladium dichloride (58 mg, 0.08 mmol) and anhydrous toluene (15 mL). To this mixture was added via syringe 1-ethoxyvinyltributyltin (1.5 mL, 4.3 mmol). Refluxed for 2.5 h. Filtered the rxn mixture through celite, and washed the solids with EtOAc (3×30 mL). Concentrated the filtrates to near dryness. Stirred the residue with 1M HCl (100 mL) for 1.5 h. Added EtOAc and separated the layers. Extracted the H2O with EtOAc (20 mL). Concentrated the organics to near dryness and added sat. KF solution (50 mL). Stirred for 1 h. Separated the layers. Extracted the H2O with EtOAc (20 mL). Dried (MgSO4), filtered, and concentrated in vacuo to give the crude brown product. Purified by silica gel chromatography (10% EtOAc/hexanes eluent) to give an orange solid, 1.03 g, 64% yield.
Part C
3-Amino-2-N-(2-Thiomethyl-4-Acetylphenyl)-4-(N-diisopropylmethyl)-6-methylpyridine:
Synthesized by reducing the corresponding 3-nitro analog as described earlier. There was no further purification. Obtained a crude pale yellow solid, 0.75 g, 79% yield.
Part D: (Ex. 1111)
Synthesized by cyclization of the above 3-aminopyridine with NaNO 2 under AcOH catalysis. The product was purified by silica gel chromatography (15-30% EtOAc-hexanes eluent) to give a white amorphous solid, 0.42 g, 56% yield.
Anal. Calcd. for C 21 H 26 BrN 5 O: C, 56.76; H, 5.907; N, 15.76. Found; C, 56.77; H, 5.76; N, 15.52.
EXAMPLE 284 (Ex. 1113)
Part A
4-Chloro-6-methyl-3-nitropyridone:
4-Hydroxy-6-methyl-3-nitropyridone (4.0 g, 23.52 mmol) was treated with cyclohexylamine (2.8 mL, 24.46 mmol) in MeOH (50 mL) until all dissolved. The MeOH was stripped in vacuo and the resulting salt was dried and treated with POCl 3 (30 mL) at 25° C. for 30 h. The reaction was then poured into ice/water (400 mL) and extracted with EtOAc (2×200 mL). The combined EtOAc extracts were washed with water (100 mL), 1 N NaOH (20 mL), water (100 mL) and brine, dried (MgSO 4 ) and stripped in vacuo. The residue was washed with 20% EtOAc/hexanes (2×30 mL) to give the product (2.9 g).
Part B
6-Methyl-3-nitro-4-(1-propylbutylamino) pyridone:
4-Chloro-6-methyl-3-nitropyridone (2.9 g, 15.40 mmol) was treated with 1-propylbutylamine (4 mL, 26.8 mmol) in CH 3 CN (30 mL) at 25° C. for 64 h and at reflux for 2 h. The reaction mixture was partitioned between EtOAc (200 mL) and water (50 mL). The EtOAc was washed with water (2×50 mL), brine, dried (MgSO 4 ) and stripped in vacuo. The residue was washed with 20% EtOAc/hexanes (22×20 mL) to give the product (3.7 g).
Part C: 2-Chloro-6-methyl-3-nitro-N-(1-propylbutyl)pyridin-4-amine:
6-Methyl-3-nitro-4-(1-propylbutylamino) pyridone (3.7 g, 13.84 mmol), was treated with POCl 3 (14 mL) at 25° C. for 20 h. Then it was poured into ice/water (200 mL) and extracted with EtOAc (300 mL). The EtOAc was washed with water, brine, dried (MgSO 4 ) and stripped in vacuo. The residue was chromatographed on silica gel (20% EtOAc/hexanes eluting solvent) to give the product (3.3 g).
Part D: N-[2-Bromo-4-(1-methylethyl)phenyl]-6-methyl-3-nitro-N-(1-propylbutyl)pyridin-2,4-diamine:
2-Chloro-6-methyl-3-nitro-N-(1-pyridin-4-amine (0.5 g, 1.75 mmol) and 2-bromo-4-isopropylaniline (0.74 g, 3.5 mmol) were heated at 140° C. for 4.5 h. After cooling it was dissolved in CH 2 Cl 2 and filtered through a short column of silica gel. The filtrate was concentrated and chromatographed on silica gel (5% EtOAc/hexanes eluting solvent) to give the product (0.7 g).
Part E: N-[2-Bromo-4-(1-methylethyl)phenyl]-6-methyl-N-(1-propylbuty) pyridine-2,3,4-triamine:
N-[2-Bromo-4-(1-methylethyl)phenyl]-6-methyl-3-nitro-N-(1-propyl-butyl)pyridin-2,4-diamine (0.7 g, 1.51 mmol), was suspended between dioxane (30 mL) and water (30 mL) containing conc. NH 4 OH (1.2 mL). To that Na 2 S 2 O 4 was added (2.1 g, 12.06 mmol) and the mixture was stirred at 25° C. for 2 h. Then an additional 1 g Na 2 S 2 O 4 was added followd by 10 mL dioxane and 10 mL water. After stirring for 1 h at 25° C. the mixture was patritioned between EtOAc (120 mL) and water (20 mL). The EtOAc was washed with water (100 mL), brine, dried (MgSO 4 ) and stripped in vacuo. The residue was chromatographed on silica gel (20% EtOAc/hexanes eluting solvent) to give the product (0.5 g).
Part F: (Ex. 1113):
N-[2-Bromo-4-(1-methylethyl)phenyl]-6-methyl-N-(1-propylbutyl)pyridine-2,3,4-triamine (0.5 g, 1.15 mmol), dissolved in CH 2 Cl 2 (6 mL) and 50% AcOH (4 mL) was treated with NaNO 2 (0.0846 g, 1.22 mmol) at 25° C. for 16 h. The mixture was patritioned between EtOAc (100 mL) and water (20 mL) The EtOAc was washed with water (20 mL), brine, dried and stripped in vacuo. The residue was chromatographed on silica gel (20% EtOAc/hexanes eluting solvent) to give the product (0.1.9 g). Anal. Calcd. for C 22 H 30 BrN 5 : C, 59.46; H, 6.80; N, 15.76; Br, 17.98. Found: C 59.66, H 6.80, N 15.77, Br 18.01.
EXAMPLE 285
(Ex. 1114)
N-[4-(1-methylethyl)phenyl-2-methylthio]-6-methyl-N-(1-propylbutyl) pyridine-2,3,4-triamine (0.72 g, 1.80 mmol), obtained by following the synthetic route described in synthetic example 275, dissolved in CH 2 Cl 2 (10 mL) and 50% AcOH (7 mL) was treated with NaNO 2 (0.132 g, 1.91 mmol) at 25° C. for 2 h. The final product was purified by column chromatrography (silica gel (20% EtOAc/hexanes eluting solvent, 0.29 g). Anal. Calcd. for C 22 H 30 BrN 5 : C 67.11, H 8.08, N 17.01. Found: C 66.96, H 8.16, N 16.90.
EXAMPLE 286
(Ex 1117)
Part A: 2-N-(2-Bromo-4-iodophenyl)-4-(N-1-propylbutyl)-6-methyl-3-nitropyridine
Synthesized by the procedure for the coupling of the nitropyridine (0.8 g, 2.9 mmoles) and 2-Bromo-4-iodoaniline (1.7 g, 5.7 mmoles). Preabsorbed the crude material on 12 g. of silica gel before chromatographing on silica gel (5% EtOAc/hexane eluen) to give an orange solid, 1.47 g. of the desired product.
Part B: 2-N-(4-Acetyl-2-Bromo)-4-(N-1-propylbutyl)-6-methyl-3-nitropyridine
To the coupled 2-Bromo-4-iodoanilinonitropyridine (0.60 g, 1.1 mmoles) in a dried flask, under nitrogen, was added Bis(triphenylposphine)palladium (II) chloride (18 mg, 0.026 mmoles) and anhydrous toluene (5 mL). Added 1-Ethoxyvinyltributyltin (0.46 ml, 1.36 mmoles) and stirred at reflux temperature for 11/2 hours. Dissolved into ethyl acetate then filtered off the insolubles through celite. Washed the solids 2× with ethyl acetate. Concentrated in-vacuo the filtrates to near dryness. Stirred the residue with 70 ml 1M hydrochloric acid for 1/2 hour. Added some ethyl acetate and separated the layers, extracted the water layer with 2×20 ml ethyl acetate. Concentrated the combined organics to near dryness. Stirred the residue in a saturated potassium fluoride (20 ml) for 1/2 hour. Separated the layers. Extracted the water layer with 2×20 ml ethyl acetate. Washed the combined extracts with 10 ml water and 20 ml brine. Chromatographed the crude material on silica gel to give a solid, 0.37 g (73%) of the desired product.
Part c: 3-Amino-2-N-(4-acetyl-2-bromo)-4-(N-1-propylbutyl)-6-methylpyridine:
Using the product obtained from Part B (0.70 g, 1.5 mmoles), 10 ml tetrahydrofuran, 10 ml water, 0.70 ml ammonium hydroxide solution (38-40%) and sodium dithionite (2.1 g, 12 mmoles) followed the standard procedure to reduce the nitroanilinopyridine. Obtained the crude solid, 0.65 g, which was of sufficient purity for further reaction.
Part D (Ex 1117):
Followed the standard procedure to cyclize the product obtained in Part C (0.63 g, 1.45 mmoles), using 10 ml methylene chloride, 10 ml acetic acid/water (50%), and sodium nitrite (0.18 g, 2.59 mmoles) in 1 ml water. Chromatographed on silica gel (10% ethyl acetate/hexane) to give a white solid, 0.31 g, (48%) of desired product, mp 165-166° C. Anal. Calcd. for C 21 H 26 BrN 5 O: C, 56.76; H, 5.91; N, 15.76; Br, 17.98. Found: C, 56.75; H, 5.76; N, 15.71; Br, 17.22.
EXAMPLE 287
(Ex 1110)
Synthesized by coupling the 4-diisopropylmethylamino-6-methyl-3-nitropyridine with the 2-bromo-4-thiomethylaniline using the route described in synthetic example 283 to obtaine the final product after purification by silica gel chromatography (5-30% EtOAc/hexanes) to give a solid (crystallized from hexane) mp 149-152° C. Anal. Calcd. for C 20 H 26 BrN 5 S: C 53.57, H 5.84, N 15.62. Found: C53.84, H 5.88, N 15.37.
EXAMPLE 287
(Ex 1112)
Oxidized to the sulfone using the method as described in synthetic example 281. Purified by silica gel chromatography to give a white crystalline solid, 0.12 g, 68% yield. mp 204-206° C. Anal. Calcd. for C 20 H 26 BrN 5 SO 2 : C, 50.00; H, 5.465; N, 14.58. Found: C, 50.09; H, 5.34; N, 14.49.
TABLE 1__________________________________________________________________________ ##STR42## Synth.Ex. Ex. R.sup.1 R.sup.3 R.sup.4 X, X' R.sup.5 mp, ° C.__________________________________________________________________________ 1* 1 CH.sub.3 CH.sub.3 CH.sub.3 Br, H CH.sub.3 120-121 2 CH.sub.3 CH.sub.3 CH.sub.3 CH.sub.3 O, H CH.sub.3 O 112-113 3* CH.sub.3 CH.sub.3 allyl Br, H H 127-129 4* 2 CH.sub.3 CH.sub.3 CH.sub.3 Br, H iC.sub.3 H.sub.7 163-164 5 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 Br, H H 94-95 6 CH.sub.3 morpholino CH.sub.3 Br, H CH.sub.3 40-42 7 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 CH.sub.3 O, H CH.sub.3 O 120-121 8 CH.sub.3 CH.sub.3 CH.sub.3 Br, H Br 101-103 9* 3 CH.sub.3 CH.sub.3 CH.sub.3 Br, H C.sub.2 H.sub.5 126-127 10* CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 Br, H tC.sub.4 H.sub.9 191-193 11* CH.sub.3 CH.sub.3 CH.sub.3 Br, H tC.sub.4 H.sub.9 193-195 12 CH.sub.3 CH.sub.3 CH.sub.3 Br, H CF.sub.3 106-107 13* CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 Br, H CF.sub.3 125-130 14 CH.sub.3 CH.sub.3 CH.sub.3 CH.sub.3 O, CH.sub.3 O 145-146 CH.sub.3 O 15 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 CH.sub.3 O, CH.sub.3 O 115-116 CH.sub.3 O 16* 4 CH.sub.3 morpholino C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 219-222 17* CH.sub.3 morpholino allyl Br, H iC.sub.3 H.sub.7 208-211 18* CH.sub.3 CH.sub.3 allyl Br, H nC.sub.4 H.sub.9 116-118 19* CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 Br, H nC.sub.4 H.sub.9 124-126 20 CH.sub.3 CH.sub.3 nC.sub.3 H.sub.7 Br, H nC.sub.4 H.sub.9 49-50 21* 5 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 151-153 22* CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 Br, H cC.sub.6 H.sub.11 170-172 23* C.sub.2 H.sub.5 C.sub.2 H.sub.5 C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 120-121 24* C.sub.2 H.sub.5 C.sub.2 H.sub.5 C.sub.2 H.sub.5 Br, H nC.sub.4 H.sub.9 116-118 25 CH.sub.3 4-CHO- C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 61-63 piperazino 26* CH.sub.3 CH.sub.3 allyl Br, H iC.sub.3 H.sub.7 141-142 27* CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 I, H iC.sub.3 H.sub.7 149-150 28 CH.sub.3 CF.sub.3 C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 liquid 29* 6 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 Br, H C.sub.2 H.sub.4 -- 117-119 OCH.sub.3 30 7 CH.sub.3 4-morpholino C.sub.2 H.sub.5 I, H iC.sub.3 H.sub.7 96-98 31* 8 CH.sub.3 2-thiopheno C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 95-97 32 CH.sub.3 CH.sub.3 CH.sub.2 CN Br, H iC.sub.3 H.sub.7 33* 9 CH.sub.3 CH.sub.3 CH.sub.2 cyclo- Br, H iC.sub.3 H.sub.7 146-148 propyl 34 10 CH.sub.3 CH.sub.3 propargyl Br, H iC.sub.3 H.sub.7 MS 35 11 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 I, H C.sub.2 H.sub.4 -- OCH.sub.3 36 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 I, H CH.sub.2 --OCH.sub.3 37* CH.sub.3 4-allyloxy- C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 piperidin-l-yl 38 CH.sub.3 morpholino C.sub.2 H.sub.5 I, H CH.sub.2 --OCH.sub.3 39 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 CH.sub.3 S, H CH.sub.2 --OCH.sub.3 40 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 (CH.sub.3).sub.2 N, CH.sub.2 --OCH.sub.3 H 41 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 CH.sub.3 S, H iC.sub.3 H.sub.7 42 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 (CH.sub.3).sub.2 N, iC.sub.3 H.sub.7 H 43 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 CH.sub.3 S, H CH.sub.3 S 44 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 CH.sub.3 S, H CH.sub.2 --SCH.sub.3 45 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 Br, Br iC.sub.3 H.sub.7 46 CH.sub.3 thio-morpholino C.sub.2 H.sub.5 Br, Br iC.sub.3 H.sub.7 47 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 I, H I 48 CH.sub.3 morpholino C.sub.2 H.sub.5 I, H I 49* 12 H CH.sub.3 C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 145-147 50 13 CH.sub.3 N(CH.sub.3)CH.sub.2 -- C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 HRMS CH.sub.2 OH 51* CH.sub.3 CH.sub.3 CH.sub.2 CH.sub.3 CH.sub.3 O, CH.sub.3 CH.sub.3 O 52* CH.sub.3 CH.sub.3 CH.sub.3 H, H I 175-177 53* CH.sub.3 CH.sub.3 CH.sub.3 I, H H 164-166 54* CH.sub.3 CH.sub.3 CH.sub.3 CF.sub.3, H H 55* CH.sub.3 CH.sub.3 CH.sub.2 CH.sub.3 Br, H C.sub.2 H.sub.4 -- 127-129 OCH.sub.2 CH.sub.3 56 14 CH.sub.3 thiomorpho-lino- C.sub.2 H.sub.5 I, H iC.sub.3 H.sub.7 52-55 S-oxide 57* 15 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 Br, H O-iC.sub.3 H.sub.7 MS 58 16 CH.sub.3 C(═O)-4- C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 145 morpholino 59 17 CH.sub.3 CH.sub.2 -4- C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 liquid morpholino 60 CH.sub.3 C(═O)-1- C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 107-108 piperidinyl 61 18 CH.sub.3 C(═O)OCH.sub.3 C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 81-82 62 CH.sub.3 C(═O)NH- C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 115 cyclohexyl 63 19 CH.sub.3 C(═O)-(4- C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 81-82 methyl)-1- piperazinyl 64* 20 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 Br, H CH.sub.2 -- 58-60 CH.sub.2 OH 65* 21 CH.sub.3 CH.sub.3 CH.sub.3 OCH.sub.3, H CH.sub.3 66* CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 H, H iC.sub.3 H.sub.7 67 CF.sub.3 CH.sub.3 C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 68* CH.sub.3 CH.sub.3 CH.sub.3 H, H I 175-177 69* CH.sub.3 CH.sub.3 CH.sub.3 CF.sub.3, H H 70* CH.sub.3 CH.sub.3 CH.sub.2 CN Br, H iC.sub.3 H.sub.7 71* CH.sub.3 CH.sub.3 CH.sub.3 Br, H H 72* CH.sub.3 (2-methoxy CH.sub.3 Br, H H methyl)-1- pyrrolyl 73 22 CH.sub.3 4-thio- C.sub.2 H.sub.5 I, H iC.sub.3 H.sub.7 51-53 morpholino 73* 22 CH.sub.3 4-thio- C.sub.2 H.sub.5 I, H iC.sub.3 H.sub.7 234-236 morpholino 74 CH.sub.3 4-hydroxy-1- C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 61-63 piperidinyl138 24 CH.sub.3 CH.sub.2 OH CH.sub.3 Br, H iC.sub.3 H.sub.7 oil, MS139 25 CH.sub.3 CH.sub.2 OCH.sub.3 CH.sub.3 Br, H iC.sub.3 H.sub.7 oil, MS140 26 CH.sub.3 SCH.sub.3 C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 oil, MS141 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 CH.sub.3 O, Cl CH.sub.3 O 99-102142 CH.sub.3 ##STR43## C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 78-81143* CH.sub.3 ##STR44## C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 131-135144* CH.sub.3 ##STR45## C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 98-102145 CH.sub.3 CH.sub.3 H CH.sub.3 O, Cl CH.sub.3 O 170-173146* CH.sub.3 NHNH.sub.2 C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 117-121147 CH.sub.3 ##STR46## C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 oil, MS148 CH.sub.3 ##STR47## C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 oil, MS149 CH.sub.3 OCH.sub.2 Ph C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 oil, MS150 CH.sub.3 O(CH.sub.2).sub.3 SCH.sub.3 C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 oil, MS152 CH.sub.3 ##STR48## C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 oil, MS153 CH.sub.3 ##STR49## C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 oil, MS154 CH.sub.3 Cl C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 oil, MS155 CH.sub.3 NH.sub.2 C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 oil, MS156 CH.sub.3 O(CH.sub.2).sub.3 SO.sub.2 CH.sub.3 C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 oil, MS157 CH.sub.3 ##STR50## C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 oil, MS158 CH.sub.3 ##STR51## C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 oil, MS159 27 CH.sub.3 SO.sub.2 CH.sub.3 C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 oil, MS160 28 CH.sub.3 SOCH.sub.3 C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 oil, MS161* CH.sub.3 O(CH.sub.2).sub.2 N C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 143-146 (CH.sub.3).sub.2162 CH.sub.3 O(CH.sub.2).sub.3 SOCH.sub.3 C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 oil, MS163 CH.sub.3 NH(CH.sub.2).sub.2 C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 oil, MS N(CH.sub.3).sub.2164 CH.sub.3 NH(CH.sub.2).sub.4 NH.sub.2 C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 oil, MS165 31 CH.sub.3 morpholino allyl I, H iC.sub.3 H.sub.7 109-112166 34 CH.sub.3 thiomorpholino H Br, Br iC.sub.3 H.sub.7 194-195167 32 CH.sub.3 Cl C.sub.2 H.sub.5 I, H iC.sub.3 H.sub.7 liquid168 35 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 SCH.sub.3, H iC.sub.3 H.sub.7 64-66169 37 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 S(O)CH.sub.3, iC.sub.3 H.sub.7 144-146 H170* 36 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 SCH.sub.3, H iC.sub.3 H.sub.7 141-142171 38 CH.sub.3 thiazolidino C.sub.2 H.sub.5 I, H iC.sub.3 H.sub.7 liquid172 39 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 I, H CH.sub.3 OCH.sub.2 liquid173* 40 CH.sub.3 CH.sub.3 C.sub.3 H.sub.6 S--, H iC.sub.3 H.sub.7 157-159174 41 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 S(O).sub.2 CH.sub.3, iC.sub.3 H.sub.7 174-176 H175* 42 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 SC.sub.2 H.sub.5, H iC.sub.3 H.sub.7 128-130176 43 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 SC.sub.2 H.sub.5, H CH.sub.3 CNO-- 77-78 CH.sub.3177 33 CH.sub.3 N-methyl C.sub.2 H.sub.5 SCH.sub.3, H iC.sub.3 H.sub.7 101-103 prolinol178 44 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 SCH.sub.3, H CH.sub.3 CNO-- 106-108 CH.sub.3179 45 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 S(O).sub.2 CH.sub.3, CH.sub.3 CNO-- 151-154 H CH.sub.3180 46 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 SCH.sub.3, H Br 91-93181 47 CH.sub.3 CH.sub.3 iC.sub.3 H.sub.7 SCH.sub.3, H C.sub.2 H.sub.5 85-87182* 48 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 SCH.sub.3, H C.sub.2 H.sub.5 140-141183 49 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 SCH.sub.3, H CH.sub.3 NCO-- 158-160 CH.sub.3184 50 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 SCH.sub.3, H CO.sub.2 C.sub.2 H.sub.5 99-100185 51 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 SCH.sub.3, H OCH.sub.3 128-130186 52 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 SCH.sub.3, H CN 99-100187 53 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 SCH.sub.3, H COCH.sub.3 125-126188 54 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 SCH.sub.3, H COC.sub.2 H.sub.5 139-141189 55 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 SCH.sub.3, H CH(OCH.sub.3) liquid CH.sub.3190 56 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 SCH.sub.3, H NHCH.sub.3 141-142191 57 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 SCH.sub.3, H N(CH.sub.3).sub.2 119-120192 CH.sub.3 pyrrolidino C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 106-107193 CH.sub.3 pyrrolidino CH.sub.3 Br, H iC.sub.3 H.sub.7 119-120194 CH.sub.3 piperidino C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 211-212195 CH.sub.3 piperidino CH.sub.3 Br, H iC.sub.3 H.sub.7 186-187196 CH.sub.3 CH.sub.3 C.sub.3 H.sub.7 Br, H iC.sub.3 H.sub.7 150-151197 CH.sub.3 CH.sub.3 C.sub.4 H.sub.9 Br, H iC.sub.3 H.sub.7 159-160198 CH.sub.3 CH.sub.3 N,N- Br, H iC.sub.3 H.sub.7 101-102 diethylac- etamidino199 CH.sub.3 CH.sub.3 N,N- Br, H iC.sub.3 H.sub.7 65-66 diethyla- minoethyl200 CH.sub.3 CH.sub.3 N,N- Br, H iC.sub.3 H.sub.7 118-120 dimethyl- amino- ethyl201 CH.sub.3 CH.sub.3 Et Br, H OEt HRMS202 CH.sub.3 CH.sub.3 Et Br, OMe OMe 113-115203 CH.sub.3 CH.sub.3 H Br, OMe OMe 177-179204 CH.sub.3 CH.sub.3 H Br, H OMe 118-119205 CH.sub.3 CH.sub.3 Allyl Br, OMe OMe 88-90206 CH.sub.3 CH.sub.3 Et Br, H OMe HRMS207 CH.sub.3 CH.sub.2 OCH.sub.3 Et I, H iC.sub.3 H.sub.7 HRMS208 CH.sub.3 CH.sub.2 O(4- Et Br, H iC.sub.3 H.sub.7 HRMS methoxyphenyl)209 CH.sub.3 CH.sub.2 OPh Et Br, H iC.sub.3 H.sub.7 HRMS210 CH.sub.3 CH.sub.2 O(2-pyridyl) Et Br, H iC.sub.3 H.sub.7 HRMS211 CH.sub.3 CH.sub.2 OCH.sub.2 (4- Et Br, H iC.sub.3 H.sub.7 HRMS methyl benzoate)212 CH.sub.3 CH.sub.2 OCH.sub.2 (3,4,5- Et Br, H iC.sub.3 H.sub.7 HRMS trimethoxy- phenyl)213 CH.sub.3 CH.sub.2 O(2- Et Br, H iC.sub.3 H.sub.7 HRMS pyrimidinyl)214 CH.sub.3 CH.sub.2 O(3,4,5- Et Br, H iC.sub.3 H.sub.7 HRMS trimethoxy- phenyl)215 CH.sub.3 CH.sub.2 O(3-(N,N- Et Br, H iC.sub.3 H.sub.7 HRMS dimethyl)-anilino)216 CH.sub.3 CH.sub.2 OCH.sub.2 (3- Et Br, H iC.sub.3 H.sub.7 HRMS pyridyl)217 CH.sub.3 CH.sub.2 O(4-methyl Et Br, H iC.sub.3 H.sub.7 136-139 benzoate)218 CH.sub.3 CH.sub.2 O(4-(1- Et Br, H iC.sub.3 H.sub.7 HRMS imidazole)- phenyl)219 CH.sub.3 CH.sub.2 OCH.sub.2 (4- Et Br, H iC.sub.3 H.sub.7 HRMS pyridyl)220 CH.sub.3 CH.sub.2 OCH.sub.3 Et Br, H iC.sub.3 H.sub.7221 CH.sub.3 CH.sub.2 OCH.sub.2 (2- Et Br, H iC.sub.3 H.sub.7 HRMS furyl)222 58 CH.sub.3 CHO Et Br, H iC.sub.3 H.sub.7 HRMS223 CH.sub.3 CH.sub.3 H Br, Br OMe 175-177224 63 CH.sub.3 CH.sub.3 Et Br, Br OEt 107-108225 59 CH.sub.3 CH.sub.2 OCH.sub.2 CH.sub.2 OH Et Br, H iC.sub.3 H.sub.7 HRMS226 CH.sub.3 CH.sub.3 Et Br, Br OMe 101-103227 CH.sub.3 CH.sub.2 OCH.sub.2 CH.sub.2 OC Et Br, H iC.sub.3 H.sub.7 HRMS H.sub.3228 CH.sub.3 CH.sub.3 H Br, Br OEt 165-167229 CH.sub.3 CH.sub.2 OCH.sub.2 CO (4- Et Br, H iC.sub.3 H.sub.7 HRMS morpholino)230 60 CH.sub.3 CH.sub.3 Et Br, OH OMe 157-160231 CH.sub.3 CH.sub.2 OCH.sub.2 CH.sub.2 Et Br, H iC.sub.3 H.sub.7 HRMS (4-morpholino)268 CH.sub.3 (4-(2-methoxy- Et Br, H iC.sub.3 H.sub.7 57-60 phenyl)- piperazinyl)- carbonyl269 CH.sub.3 (1,2,3,4- Et Br, H iC.sub.3 H.sub.7 143-145 tetrahydro- quinolinyl)- carbonyl270 CH.sub.3 (2-furyl- Et Br, H iC.sub.3 H.sub.7 87-88 methyl)amino- carbonyl271 CH.sub.3 MeNHCO Et Br, H iC.sub.3 H.sub.7 oil, MS272 CH.sub.3 (4-pyrazinyl) Et Br, H iC.sub.3 H.sub.7 51-53 piperazino) carbonyl273 CH.sub.3 (4-(2-pyrimi- Et Br, H iC.sub.3 H.sub.7 114-116 dyl)pipera- zino)carbonyl274 CH.sub.3 (4-(2- Et Br, H iC.sub.3 H.sub.7 oil, MS pyridyl)piper azino)-carbonyl275 CH.sub.3 (4-(2-methoxy- Et Br, H iC.sub.3 H.sub.7 102-104 phenyl)- piperazinyl)- methyl.HCl salt276 CH.sub.3 N-(2-furyl- Et Br, H iC.sub.3 H.sub.7 oil, MS methyl)-N- methylamino- methyl277 CH.sub.3 (1,2,3,4- Et Br, H iC.sub.3 H.sub.7 88-90 tetrahydro- quinolinyl)- methyl.HCl salt278 CH.sub.3 (4-pyrazinyl- Et Br, H iC.sub.3 H.sub.7 oil, MS piperazino)- methyl279 CH.sub.3 dimethyl-amino- Et Br, H iC.sub.3 H.sub.7 oil, MS methyl280 CH.sub.3 (4-(2- Et Br, H iC.sub.3 H.sub.7 117-119 pyridyl)piper- azino)methyl, HCl salt281 CH.sub.3 (4-(2-pyrimi- Et Br, H iC.sub.3 H.sub.7 125-127 dyl)pipera- zino)methyl, HCl salt282 CH.sub.3 Me.sub.2 NCO Et Br, H iC.sub.3 H.sub.7 80-82283 CH.sub.3 3-indolyl- Et Br, H iC.sub.3 H.sub.7 105-107 carbonyl, HCL salt284 CH.sub.3 3-pyridyl- Et Br, H iC.sub.3 H.sub.7 165-167 carbonyl285 CH.sub.3 3-phenyl- Et Br, H iC.sub.3 H.sub.7 oil, MS carbonyl286 CH.sub.3 3-pyrazolyl- Et Br, H iC.sub.3 H.sub.7 171-173 carbonyl287 CH.sub.3 4-methoxy- Et Br, H iC.sub.3 H.sub.7 104-106 phenyl-carbonyl288 CH.sub.3 2-furylcarbonyl Et Br, H iC.sub.3 H.sub.7 136-138289 CH.sub.3 bis(4-methoxy- Et Br, H iC.sub.3 H.sub.7 63-65 phenyl)hydroxy methyl290 CH.sub.3 bis(2-furyl)- Et Br, H iC.sub.3 H.sub.7 97-99 hydroxymethyl291 CH.sub.3 (2-furyl)- Et Br, H iC.sub.3 H.sub.7 oil, MS hydroxymethyl292 CH.sub.3 (4-methoxy- Et Br, H iC.sub.3 H.sub.7 oil, MS phenyl)hydroxy methyl293 CH.sub.3 diphenyl- Et Br, H iC.sub.3 H.sub.7 56-58 hydroxymethyl294 CH.sub.3 bis(4-pyridyl) Et Br, H iC.sub.3 H.sub.7 68-70 hydroxymethyl295 CH.sub.3 (1-hydroxy-1- Et Br, H iC.sub.3 H.sub.7 oil, MS methyl)ethyl296 CH.sub.3 1-hydroxy-ethyl Et Br, H iC.sub.3 H.sub.7 oil, MS__________________________________________________________________________ *Hydrochloride salt
TABLE 2__________________________________________________________________________ ##STR52##Ex. R.sup.1 R.sup.3 R.sup.4 X, X' R.sup.5 mp, ° C.__________________________________________________________________________ 75 CH.sub.3 CH.sub.3 CH.sub.3 Br, H CH.sub.3 76 CH.sub.3 CH.sub.3 CH.sub.3 CH.sub.3 O, H CH.sub.3 O 77 CH.sub.3 CH.sub.3 allyl Br, H H 78* CH.sub.3 CH.sub.3 CH.sub.3 Br, H iC.sub.3 H.sub.7 178-179 79 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 Br, H H 80 CH.sub.3 morpholino CH.sub.3 Br, H CH.sub.3 81 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 CH.sub.3 O, H CH.sub.3 O 82 CH.sub.3 CH.sub.3 CH.sub.3 Br, H Br 83 CH.sub.3 CH.sub.3 CH.sub.3 Br, H C.sub.2 H.sub.5 84 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 Br, H tC.sub.4 H.sub.9 85 CH.sub.3 CH.sub.3 CH.sub.3 Br, H tC.sub.4 H.sub.9 86 CH.sub.3 CH.sub.3 CH.sub.3 Br, H CF.sub.3 87 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 Br, H CF.sub.3 88 CH.sub.3 CH.sub.3 CH.sub.3 CH.sub.3 O, CH.sub.3 O CH.sub.3 O 89 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 CH.sub.3 O, CH.sub.3 O CH.sub.3 O 90 CH.sub.3 morpholino C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 91 CH.sub.3 morpholino allyl Br, H iC.sub.3 H.sub.7 92 CH.sub.3 CH.sub.3 allyl Br, H nC.sub.4 H.sub.9 93 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 Br, H nC.sub.4 H.sub.9 94 CH.sub.3 CH.sub.3 nC.sub.3 H.sub.7 Br, H nC.sub.4 H.sub.9 95* CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 194-196 96 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 Br, H cC.sub.6 H.sub.11 97 C.sub.2 H.sub.5 C.sub.2 H.sub.5 C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 98 C.sub.2 H.sub.5 C.sub.2 H.sub.5 C.sub.2 H.sub.5 Br, H nC.sub.4 H.sub.9 99 CH.sub.3 4-CHO- C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 piperazino100 CH.sub.3 CH.sub.3 allyl Br, H iC.sub.3 H.sub.7101 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 I, H iC.sub.3 H.sub.7102 CH.sub.3 CF.sub.3 C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7103 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 Br, H C.sub.2 H.sub.4 --OCH.sub.3104 CH.sub.3 morpholino C.sub.2 H.sub.5 I, H iC.sub.3 H.sub.7105 CH.sub.3 2-thiopheno C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7106 CH.sub.3 CH.sub.3 CH.sub.2 CN Br, H iC.sub.3 H.sub.7107 CH.sub.3 CH.sub.3 CH.sub.2 cyclo- Br, H iC.sub.3 H.sub.7 propyl108 CH.sub.3 CH.sub.3 propargyl Br, H iC.sub.3 H.sub.7109 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 I, H C.sub.2 H.sub.4 --OCH.sub.3110 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 I, H CH.sub.2 --OCH.sub.3111 CH.sub.3 morpholino C.sub.2 H.sub.5 I, H C.sub.2 H.sub.4 --OCH.sub.3112 CH.sub.3 morpholino C.sub.2 H.sub.5 I, H CH.sub.2 --OCH.sub.3113 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 CH.sub.3 S, H CH.sub.2 --OCH.sub.3114 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 (CH.sub.3).sub.2 N, CH.sub.2 --OCH.sub.3 H115 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 CH.sub.3 S, H iC.sub.3 H.sub.7116 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 (CH.sub.3).sub.2 N, iC.sub.3 H.sub.7 H117 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 CH.sub.3 S, H CH.sub.3 S118 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 CH.sub.3 S, H CH.sub.2 --SCH.sub.3119 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 Br, Br iC.sub.3 H.sub.7120 CH.sub.3 thio- C.sub.2 H.sub.5 Br, Br iC.sub.3 H.sub.7 morpholino121 CH.sub.3 CH.sub.3 C.sub.2 H.sub.5 I, H I122 CH.sub.3 morpholino C.sub.2 H.sub.5 I, H I123 H CH.sub.3 C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7124 CH.sub.3 N(CH.sub.3)CH.sub.2 -- C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 CH.sub.2 OH125 CH.sub.3 CH.sub.3 CH.sub.2 CH.sub.3 CH.sub.3 O, CH.sub.3 CH.sub.3 O126 CH.sub.3 CH.sub.3 CH.sub.3 H, H I127 CH.sub.3 CH.sub.3 CH.sub.3 I, H H128 CH.sub.3 CH.sub.3 CH.sub.3 CF.sub.3, H H129* H H CH.sub.2 CH.sub.3 Br, H iC.sub.3 H.sub.7__________________________________________________________________________ *Hydrochloride salt
TABLE 3______________________________________ ##STR53##Ex. R.sup.1 R.sup.3 R.sup.4 X, X' R.sup.5 mp, ° C.______________________________________130* CH.sub.3 O CH.sub.3 O CH.sub.2 CH.sub.3 Br, H iC.sub.3 H.sub.7 104-106______________________________________ *Hydrochloride salt
TABLE 4______________________________________ ##STR54##Ex. R.sup.1 R.sup.3 R.sup.4 X, X' R.sup.5 mp, ° C.______________________________________131* CH.sub.3 CH.sub.3 H Br, H iC.sub.3 H.sub.7 124-125______________________________________ *Hydrochloride salt
TABLE 5______________________________________ ##STR55##Ex. R.sup.1 R.sup.3 R.sup.4 X, X' R.sup.5 mp, ° C.______________________________________132* CH.sub.3 CH.sub.3 CH.sub.2 CH.sub.3 Br, H iC.sub.3 H.sub.7 144-145______________________________________ *Hydrochloride salt
TABLE 6__________________________________________________________________________ ##STR56## Synth.Ex. Ex. R.sup.1 R.sup.3 R.sup.4 X, X' R.sup.5 mp, ° C.__________________________________________________________________________133 CH.sub.3 CH.sub.3 Et Br, H iC.sub.3 H.sub.7 oil, MS134 23 CH.sub.3 morpholino Et Br, H iC.sub.3 H.sub.7 oil, MS134* CH.sub.3 morpholino Et Br, H iC.sub.3 H.sub.7 59-63135 CH.sub.3 thio- Et I, H iC.sub.3 H.sub.7 oil, MS morpholino136 CH.sub.3 morpholino Et I, H iC.sub.3 H.sub.7 oil, MS137 CH.sub.3 piperidinyl Et I, H iC.sub.3 H.sub.7 oil, MS232 CH.sub.3 N'N-diethyl Et Br, H iC.sub.3 H.sub.7 oil, MS233 Cl Cl Et Br, H iC.sub.3 H.sub.7 oil, MS234 OCH.sub.3 OCH.sub.3 Et Br, H iC.sub.3 H.sub.7 oil, MS235 Cl Cl Et I, H iC.sub.3 H.sub.7 oil, MS236 CH.sub.3 imidazolino Et Br, H iC.sub.3 H.sub.7 >200237 CH.sub.3 morpholino Et Br, CH.sub.3 O CH.sub.3 O 90-95238 CH.sub.3 N(CH.sub.3).sub.2 Et Br, CH.sub.3 O CH.sub.3 O 65-58239 CH.sub.3 morpholino Et CH.sub.3 O, CH.sub.3 O oil, MS CH.sub.3 O240 CH.sub.3 N(CH.sub.3).sub.2 Et Br, H iC.sub.3 H.sub.7 72-75241 CH.sub.3 thiazolidino Et Br, H iC.sub.3 H.sub.7 70-72242* 29 CH.sub.3 benzyloxy Et Br, H iC.sub.3 H.sub.7 89-90243 CH.sub.3 phenyloxy Et Br, H iC.sub.3 H.sub.7 140-142244 CH.sub.3 4-ethyl- Et Br, CH.sub.3 O CH.sub.3 O 65-70 carboxy piperizine245 CH.sub.3 4-carboxy Et Br, CH.sub.3 O CH.sub.3 O 95-100 piperizine246 CH.sub.3 HC(CO.sub.2 Et).sub.2 Et Br, H iC.sub.3 H.sub.7 oil, MS247 CH.sub.3 PhCHCN Et Br, CH.sub.3 O CH.sub.3 O 50-52248 CH.sub.3 morpholino iC.sub.3 H.sub.7 O Br, CH.sub.3 O CH.sub.3 O oil, MS249* 30 Cl Cl Et I, H CH(CH.sub.3).sub.2 OH oil, MS250 CH.sub.3 Cl C.sub.2 H.sub.5 Br, H iC.sub.3 H.sub.7 oil, MS__________________________________________________________________________ *Hydrochloride salt
TABLE 7______________________________________ ##STR57##Synth.Ex. Ex. R.sup.1 R.sup.2 R.sup.4 X', X R.sup.5 R.sup.6 mp, ° C.______________________________________251 62 CH.sub.3 CH.sub.3 Et Br, OMe OMe Br 133-138252 CH.sub.3 CH.sub.3 H H, OMe OMe Br 179-181253 61 CH.sub.3 CH.sub.3 Et H, OMe OMe Br 143-145______________________________________
TABLE 8__________________________________________________________________________ ##STR58## Synth.Ex. Ex. R.sup.1 R.sup.3 R.sup.30 X X' R.sup.5 mp, ° C.__________________________________________________________________________254 64 CH.sub.3 CH.sub.3 CN Br H i-Pr 105.8313 CH.sub.3 CH.sub.3 CN I H i-Pr314 CH.sub.3 CH.sub.3 CN Br 6-CH.sub.3 i-Pr315 CH.sub.3morpholino CN I 6-CH.sub.3 i-Pr316 CH.sub.3 Cl CN I H 1-methoxy ethyl317 CH.sub.3 Ph CN I H 1-methoxy ethyl318 CH.sub.3 CH.sub.3 CN Cl H 1-methoxy ethyl319 CH.sub.3 CH.sub.3 CN I H 1-methoxy ethyl320 CH.sub.3 CH.sub.3 CN Br H 1-methoxy ethyl321 CH.sub.3morpholino CN I CH.sub.3 OCH.sub.3255 74 CH.sub.3 Cl CN Br H i-Pr 179.2256 66 CH.sub.3 Ph CN Br H i-Pr oil322 CH.sub.3 Ph CN --SCH.sub.3 H i-Pr323 CH.sub.3 CH.sub.3 H Cl OCH.sub.3 i-Pr257 65 CH.sub.3 CH.sub.3 H Br H i-Pr MS 343.08324 CH.sub.3 CH.sub.3 H --SCH.sub.3 H i-Pr258 68 CH.sub.3 CH.sub.3 CN Br OCH.sub.3 OCH.sub.3 MS 388.0325 CH.sub.3morpholino H I 6-OCH.sub.3 i-Pr259 75 CH.sub.3 Cl H Br H i-Pr MS 363.0326 CH.sub.3 Ph H I H 1-methoxy ethyl260 69 CH.sub.3 CH.sub.3 H Br OCH.sub.3 OCH.sub.3 MS 360.9327 CH.sub.3 CH.sub.3 H I H 1-methoxy ethyl328 CH.sub.3 CH.sub.3 H Br H 1-methoxy ethyl329 CH.sub.3morpholino H I 6-CH.sub.3 OCH.sub.3330 CH.sub.3 Cl H I 6-CH.sub.3 i-Pr261 67 CH.sub.3 Ph H Br H i-Pr MS 405.1331 CH.sub.3 --NHEt H Br H i-Pr332 CH.sub.3 --NHC(═O) H Br H i-Pr CH.sub.3333 CH.sub.3 OCH.sub.3 H Br H i-Pr334 CH.sub.3 --OCH.sub.2 Ph H Br H i-Pr335 CH.sub.3 CH.sub.2 OPh H Br H i-Pr336 CH.sub.3 2-thiophenyl- H Br H i-Pr methoxy337 CH.sub.3 --OCH(OH)Ph H Br H i-Pr338 CH.sub.3n-propoxy H Br H i-Pr339 CH.sub.3 --C(═O)N H Br H i-Pr (Me).sub.2340 CH.sub.3 --NHCH.sub.2 Ph H Br H i-Pr262 70 Cl CH.sub.3 CN Br H i-Pr 123.8341 N- CH.sub.3 H Br H i-Pr Me.sub.2342 CH.sub.3 --CH.sub.2 OCH.sub.3 H Br H i-Pr263 71 Cl CH.sub.3 H Br H i-Pr MS 363.0343 CH.sub.3 CH.sub.3 Et Br H i-Pr344 CH.sub.3 CH.sub.3 --CCH Br H i-Pr__________________________________________________________________________
TABLE 9______________________________________ ##STR59##Ex. R.sup.1 R.sup.3 X X' R.sup.5______________________________________345 CH.sub.3 CH.sub.3 Br H i-Pr346 CH.sub.3 CH.sub.3 I H i-Pr347 CH.sub.3 CH.sub.3 Br 6-OCH.sub.3 OCH.sub.3348 CH.sub.3morpholino I 6-CH.sub.3 i-Pr349 CH.sub.3 Ph Br H i-Pr350 CH.sub.3 CH.sub.3 SMe H i-Pr______________________________________
TABLE 9a__________________________________________________________________________ ##STR60## Synth. MpEx. Ex R.sup.3 X X' R.sup.5 M (° C.)__________________________________________________________________________1000* 276 --N(n-Bu)Et Br H i-Pr CH.sub.3 a1001* 278 --N(C.sub.2 H.sub.4 OCH.sub.3).sub.2 Br H i-Pr CH.sub.3 a1002 --N(n-Bu)Et Br H i-Pr H1003 --N(C.sub.2 H.sub.4 OCH.sub.3).sub.2 Br H i-Pr H1004 --N(n-Bu)Et Br H i-Pr OCH.sub.31005 --N(C.sub.2 H.sub.4 OCH.sub.3).sub.2 Br H i-Pr OCH.sub.31006 --NHCHEt.sub.2 Cl H OCH.sub.3 CH.sub.31007 --NHCHEt.sub.2 CH.sub.3 H OCH.sub.3 CH.sub.31008 --NHCHEt.sub.2 Br H OCH.sub.3 CH.sub.31009 --NHCHEt.sub.2 CH.sub.3 6-CH.sub.3 OCH.sub.3 CH.sub.31010 --NHCHEt.sub.2 Cl H CN CH.sub.31011 --NHCHEt.sub.2 Cl H SO.sub.2 CH.sub.3 CH.sub.31012 --NHCH(i-Pr).sub.2 CH.sub.3 H OCH.sub.3 CH.sub.31013 --NHCH(i-Pr).sub.2 Cl 6-CH.sub.3 OCH.sub.3 CH.sub.3__________________________________________________________________________ a: amorphous
TABLE 10______________________________________ ##STR61##Ex. R.sup.1 R.sup.3 R.sup.30 X X' R.sup.5______________________________________351 CH.sub.3 CH.sub.3 H Br H i-Pr352 CH.sub.3 CH.sub.3 H I H i-Pr353 CH.sub.3morpholino CN Br H i-Pr354 CH.sub.3 Ph CN Br H i-Pr355 CH.sub.3 CH.sub.3 H SMe H i-Pr______________________________________
TABLE 11__________________________________________________________________________ ##STR62## Synth. msEx. Ex. R.sup.5 R.sup.4 R.sup.3 X Z K L (m + H)__________________________________________________________________________264* CH.sub.3 ethyl CH.sub.3 Br CH CH CH 321265* OCH.sub.3 ethyl CH.sub.3 Br CH CH N 337266* OCH.sub.3 ethyl CH.sub.3 H CH CH N 259267* OCH.sub.3 ethyl CH.sub.3 Br N CH N 409356 i-Pr ethyl CH.sub.3 Br N N N357 i-Pr allyl CH.sub.3 Br N N N358 i-Pr allyl CH.sub.3 Br CH N N359 i-Pr ethyl CH.sub.3 Br CH N N360 i-Pr ethyl morpholino Br N N N361 i-Pr allyl morpholino Br N N N362 i-Pr allyl morpholino Br CH N N363 i-Pr ethyl morpholino Br CH N N364 OCH.sub.3 ethyl CH.sub.3 Br N N N365 OCH.sub.3 allyl CH.sub.3 Br N N N366 OCH.sub.3 allyl CH.sub.3 Br CH N N367 OCH.sub.3 ethyl CH.sub.3 Br CH N N368 OCH.sub.3 ethyl morpholino Br N N N369 OCH.sub.3 allyl morpholino Br N N N370 OCH.sub.3 allyl morpholino Br CH N N371 OCH.sub.3 ethyl morpholino Br CH N N372 OCH.sub.3 ethyl CH.sub.3 OCH.sub.3 N N N373 OCH.sub.3 allyl CH.sub.3 OCH.sub.3 N N N374 105 OCH.sub.3 allyl CH.sub.3 OCH.sub.3 CH N N 290375 OCH.sub.3 ethyl CH.sub.3 OCH.sub.3 CH N N376 OCH.sub.3 ethyl morpholino OCH.sub.3 N N N377 OCH.sub.3 allyl morpholino OCH.sub.3 N N N378 OCH.sub.3 allyl morpholino OCH.sub.3 CH N N379 OCH.sub.3 ethyl morpholino OCH.sub.3 CH N N380 OCH.sub.3 ethyl OCH.sub.3 OCH.sub.3 N N N381 OCH.sub.3 allyl OCH.sub.3 OCH.sub.3 N N N382 OCH.sub.3 allyl OCH.sub.3 OCH.sub.3 CH N N383 OCH.sub.3 ethyl OCH.sub.3 OCH.sub.3 CH N N384 OCH.sub.3 ethyl OCH.sub.2 CH.sub.3 OCH.sub.3 N N N385 OCH.sub.3 allyl OCH.sub.2 CH.sub.3 OCH.sub.3 N N N386 OCH.sub.3 allyl OCH.sub.2 CH.sub.3 OCH.sub.3 CH N N387 OCH.sub.3 ethyl OCH.sub.2 CH.sub.3 OCH.sub.3 CH N N__________________________________________________________________________ *Hydrochloride salt
TABLE 12__________________________________________________________________________ ##STR63##Ex. R.sup.1 R.sup.3 R.sup.30 X X' R.sup.5__________________________________________________________________________388 CH.sub.3 CH.sub.3 CN Br H i-Pr389 CH.sub.3 CH.sub.3 CN I H i-Pr390 CH.sub.3 CH.sub.3 CN Br 6-CH.sub.3 i-Pr391 CH.sub.3morpholino CN I 6-CH.sub.3 i-Pr392 CH.sub.3 Cl CN I H 1-methoxy ethyl393 CH.sub.3 Ph CN I H 1-methoxy ethyl394 CH.sub.3 CH.sub.3 CN Cl H 1-methoxy ethyl395 CH.sub.3 CH.sub.3 CN I H 1-methoxy ethyl396 CH.sub.3 CH.sub.3 CN Br H 1-methoxy ethyl397 CH.sub.3morpholino CN I CH.sub.3 OCH.sub.3398 CH.sub.3 Cl CN Br H i-Pr399 CH.sub.3 Ph CN Br H i-Pr400 CH.sub.3 Ph CN --SCH.sub.3 H i-Pr401 CH.sub.3 CH.sub.3 H Cl OCH.sub.3 i-Pr402 CH.sub.3 CH.sub.3 H Br H i-Pr403 CH.sub.3 CH.sub.3 H --SCH.sub.3 H i-Pr404 CH.sub.3 CH.sub.3 CN Br OCH.sub.3 OCH.sub.3405 CH.sub.3morpholino H I 6-OCH.sub.3 i-Pr406 CH.sub.3 Cl H Br H i-Pr407 CH.sub.3 Ph H I H 1-methoxy ethyl408 CH.sub.3 CH.sub.3 H Br OCH.sub.3 OCH.sub.3409 CH.sub.3 CH.sub.3 H I H 1-methoxy ethyl410 CH.sub.3 CH.sub.3 H Br H 1-methoxy ethyl411 CH.sub.3morpholino H I 6-CH.sub.3 OCH.sub.3412 CH.sub.3 Cl H I 6-CH.sub.3 i-Pr413 CH.sub.3 Ph H Br H i-Pr414 CH.sub.3 --NHEt H Br H i-Pr415 CH.sub.3 --NHC(═O)CH.sub.3 H Br H i-Pr416 CH.sub.3 OCH.sub.3 H Br H i-Pr417 CH.sub.3 --OCH.sub.2 Ph H Br H i-Pr418 CH.sub.3 CH.sub.2 OPh H Br H i-Pr419 CH.sub.3 2-thiophenyl H Br H i-Pr methoxy420 CH.sub.3 OCH(OH)Ph H Br H i-Pr421 CH.sub.3n-propoxy H Br H i-Pr422 CH.sub.3 --C(═O)N(Me).sub.2 H Br H i-Pr423 CH.sub.3 --NHCH.sub.2 Ph H Br H i-Pr424 Cl CH.sub.3 CN Br H i-Pr425 N--Me.sub.2 CH.sub.3 H Br H i-Pr426 CH.sub.3 --CH.sub.2 OCH.sub.3 H Br H i-Pr427 Cl CH.sub.3 H Br H i-Pr428 CH.sub.3 CH.sub.3 Et Br H i-Pr429 CH.sub.3 CH.sub.3 --CCH Br H i-Pr__________________________________________________________________________
TABLE 13__________________________________________________________________________ ##STR64##Ex. R.sup.1 R.sup.3 R.sup.30 X X' R.sup.5__________________________________________________________________________430 CH.sub.3 CH.sub.3 CN Br H i-Pr431 CH.sub.3 CH.sub.3 CN I H i-Pr432 CH.sub.3 CH.sub.3 CN Br 6-CH.sub.3 i-Pr433 CH.sub.3morpholino CN I 6-CH.sub.3 i-Pr434 CH.sub.3 Cl CN I H 1-methoxy ethyl435 CH.sub.3 Ph CN I H 1-methoxy ethyl436 CH.sub.3 CH.sub.3 CN Cl H 1-methoxy ethyl437 CH.sub.3 CH.sub.3 CN I H 1-methoxy ethyl438 CH.sub.3 CH.sub.3 CN Br H 1-methoxy ethyl439 CH.sub.3morpholino CN I CH.sub.3 OCH.sub.3440 CH.sub.3 Cl CN Br H i-Pr441 CH.sub.3 Ph CN Br H i-Pr442 CH.sub.3 Ph CN --SCH.sub.3 H i-Pr443 CH.sub.3 CH.sub.3 H Cl OCH.sub.3 i-Pr444 CH.sub.3 CH.sub.3 H Br H i-Pr445 CH.sub.3 CH.sub.3 H --SCH.sub.3 H i-Pr446 CH.sub.3 CH.sub.3 CN Br OCH.sub.3 OCH.sub.3447 CH.sub.3morpholino H I 6-OCH.sub.3 i-Pr448 CH.sub.3 Cl H Br H i-Pr449 CH.sub.3 Ph H I H 1-methoxy ethyl450 CH.sub.3 CH.sub.3 H Br OCH.sub.3 OCH.sub.3451 CH.sub.3 CH.sub.3 H I H 1-methoxy ethyl452 CH.sub.3 CH.sub.3 H Br H 1-methoxy ethyl453 CH.sub.3morpholino H I 6-CH.sub.3 OCH.sub.3454 CH.sub.3 Cl H I 6-CH.sub.3 i-Pr455 CH.sub.3 Ph H Br H i-Pr456 CH.sub.3 --NHEt H Br H i-Pr457 CH.sub.3 --NHC(═O)CH.sub.3 H Br H i-Pr458 CH.sub.3 OCH.sub.3 H Br H i-Pr459 CH.sub.3 --OCH.sub.2 Ph H Br H i-Pr460 CH.sub.3 CH.sub.2 OPh H Br H i-Pr461 CH.sub.3 2-thiophenyl H Br H i-Pr methoxy462 CH.sub.3 OCH(OH)Ph H Br H i-Pr463 CH.sub.3n-propoxy H Br H i-Pr464 CH.sub.3 --C(═O)N(Me).sub.2 H Br H i-Pr465 CH.sub.3 --NHCH.sub.2 Ph H Br H i-Pr466 Cl CH.sub.3 CN Br H i-Pr467 N--Me.sub.2 CH.sub.3 H Br H i-Pr468 CH.sub.3 --CH.sub.2 OCH.sub.3 H Br H i-Pr469 Cl CH.sub.3 H Br H i-Pr470 CH.sub.3 CH.sub.3 Et Br H i-Pr471 CH.sub.3 CH.sub.3 --CCH Br H i-Pr__________________________________________________________________________
TABLE 14______________________________________ ##STR65##Ex. R.sup.1 R.sup.3 R.sup.30 X X' R.sup.5______________________________________472 CH.sub.3 CH.sub.3 CN Br H i-Pr473 CH.sub.3 CH.sub.3 CN I H i-Pr474 CH.sub.3 CH.sub.3 CN Br 6-CH.sub.3 i-Pr475 CH.sub.3morpholinoCN I 6-CH.sub.3 i-Pr476 CH.sub.3 Cl CN I H 1-meth- oxy ethyl477 CH.sub.3 Ph CN I H 1-meth- oxy ethyl478 CH.sub.3 CH.sub.3 CN Cl H 1-meth- oxy ethyl479 CH.sub.3 CH.sub.3 CN I H 1-meth- oxy ethyl480 CH.sub.3 CH.sub.3 CN Br H 1-meth- oxy ethyl481 CH.sub.3morpholinoCN I CH.sub.3 OCH.sub.3482 CH.sub.3 Cl CN Br H i-Pr483 CH.sub.3 Ph CN Br H i-Pr484 CH.sub.3 Ph CN --SCH.sub.3 H i-Pr485 CH.sub.3 CH.sub.3 H Cl OCH.sub.3 i-Pr486 CH.sub.3 CH.sub.3 H Br H i-Pr487 CH.sub.3 CH.sub.3 H --SCH.sub.3 H i-Pr488 CH.sub.3 CH.sub.3 CN Br OCH.sub.3 OCH.sub.3489 CH.sub.3morpholinoH I 6-OCH.sub.3 i-Pr490 CH.sub.3 Cl H Br H i-Pr491 CH.sub.3 Ph H I H 1-meth- oxy ethyl492 CH.sub.3 CH.sub.3 H Br OCH.sub.3 OCH.sub.3493 CH.sub.3 CH.sub.3 H I H 1-meth- oxy ethyl494 CH.sub.3 CH.sub.3 H Br H 1-meth- oxy ethyl495 CH.sub.3morpholinoH I 6-CH.sub.3 OCH.sub.3496 CH.sub.3 Cl H I 6-CH.sub.3 i-Pr497 CH.sub.3 Ph H Br H i-Pr498 CH.sub.3 --NHEt H Br H i-Pr499 CH.sub.3 --NHC(═O)CH.sub.3 H Br H i-Pr500 CH.sub.3 OCH.sub.3 H Br H i-Pr501 CH.sub.3 --OCH.sub.2 Ph H Br H i-Pr502 CH.sub.3 CH.sub.2 OPh H Br H i-Pr503 CH.sub.3 2-thiophenyl H Br H i-Pr methoxy504 CH.sub.3 OCH(OH)Ph H Br H i-Pr505 CH.sub.3n-propoxyH Br H i-Pr506 CH.sub.3 C(═O)N(Me).sub.2 H Br H i-Pr507 CH.sub.3 --NHCH.sub.2 Ph H Br H i-Pr508 Cl CH.sub.3 CN Br H i-Pr509 N-Me.sub.2 CH.sub.3 H Br H i-Pr510 CH.sub.3 --CH.sub.2 OCH.sub.3 H Br H i-Pr511 Cl CH.sub.3 H Br H i-Pr512 CH.sub.3 CH.sub.3 Et Br H i-Pr513 CH.sub.3 CH.sub.3 --CCH Br H i-Pr______________________________________
TABLE 15__________________________________________________________________________ ##STR66## Synth.Ex. Ex. R.sup.1 R.sup.3 X X' R.sup.5 Mp (° C.)__________________________________________________________________________514 CH.sub.3 CH.sub.3 Br H i-Pr515 CH.sub.3 CH.sub.3 I H i-Pr516 CH.sub.3 CH.sub.3 Br 6-OCH.sub.3 OCH.sub.3517 CH.sub.3morpholino I 6-CH.sub.3 i-Pr518 CH.sub.3 Ph Br H i-Pr519 CH.sub.3 CH.sub.3 SMe H i-Pr520 101 CH.sub.3 Cl Br H i-Pr 49-52521 CH.sub.3 CH.sub.3 Br H i-Pr522 CH.sub.3 CH.sub.3 I H i-Pr523 CH.sub.3 CH.sub.3 Br 6-OCH.sub.3 OCH.sub.3524 CH.sub.3morpholino I 6-CH.sub.3 i-Pr525 CH.sub.3 Ph Br H i-Pr526 CH.sub.3 CH.sub.3 SMe H i-Pr527 102 CH.sub.3morpholino Br H i-Pr 132-135528 CH.sub.2 CH.sub.3 CH.sub.3 Br H i-Pr529 CH.sub.2 CH.sub.3 CH.sub.3 I H i-Pr530 CH.sub.2 CH.sub.3 CH.sub.3 Br 6-OCH.sub.3 OCH.sub.3531 CH.sub.2 CH.sub.3morpholino I 6-CH.sub.3 i-Pr532 CH.sub.2 CH.sub.3 Ph Br H i-Pr533 CH.sub.2 CH.sub.3 CH.sub.3 SMe H i-Pr534 CH.sub.2 CH.sub.3 Cl Br H i-Pr535 CH.sub.2 CH.sub.3 CH.sub.3 Br H i-Pr536 CH.sub.2 CH.sub.3 CH.sub.3 I H i-Pr537 CH.sub.2 CH.sub.3 CH.sub.3 Br 6-OCH.sub.3 OCH.sub.3538 CH.sub.2 CH.sub.3morpholino I 6-CH.sub.3 i-Pr539 CH.sub.2 CH.sub.3 Ph Br H i-Pr540 CH.sub.2 CH.sub.3 CH.sub.3 SMe H i-Pr541 CH.sub.2 CH.sub.3morpholino Br H i-Pr__________________________________________________________________________
TABLE 16__________________________________________________________________________ ##STR67## Synth.Ex. Ex. R.sup.1 R.sup.3 X X' R.sup.5 Mp (° C.)__________________________________________________________________________542 CH.sub.3 CH.sub.3 Br H i-Pr543 CH.sub.3 CH.sub.3 I H i-Pr544 CH.sub.3 CH.sub.3 Br 6-OCH.sub.3 OCH.sub.3545 CH.sub.3morpholino I 6-CH.sub.3 i-Pr546 CH.sub.3 Ph Br H i-Pr547 CH.sub.3 CH.sub.3 SMe H i-Pr548 103 CH.sub.3 Cl Br H i-Pr MS 368549 CH.sub.3 CH.sub.3 Br H i-Pr550 CH.sub.3 CH.sub.3 I H i-Pr551 CH.sub.3 CH.sub.3 Br 6-OCH.sub.3 OCH.sub.3552 CH.sub.3morpholino I 6-CH.sub.3 i-Pr553 CH.sub.3 Ph Br H i-Pr554 CH.sub.3 CH.sub.3 SMe H i-Pr555 104 CH.sub.3morpholino Br H i-Pr 145-148556 CH.sub.2 CH.sub.3 CH.sub.3 Br H i-Pr557 CH.sub.2 CH.sub.3 CH.sub.3 I H i-Pr558 CH.sub.2 CH.sub.3 CH.sub.3 Br 6-OCH.sub.3 OCH.sub.3559 CH.sub.2 CH.sub.3morpholino I 6-CH.sub.3 i-Pr560 CH.sub.2 CH.sub.3 Ph Br H i-Pr561 CH.sub.2 CH.sub.3 CH.sub.3 SMe H i-Pr562 CH.sub.2 CH.sub.3 Cl Br H i-Pr563 CH.sub.2 CH.sub.3 CH.sub.3 Br H i-Pr564 CH.sub.2 CH.sub.3 CH.sub.3 I H i-Pr565 CH.sub.2 CH.sub.3 CH.sub.3 Br 6-OCH.sub.3 OCH.sub.3566 CH.sub.2 CH.sub.3morpholino I 6-CH.sub.3 i-Pr567 CH.sub.2 CH.sub.3 Ph Br H i-Pr568 CH.sub.2 CH.sub.3 CH.sub.3 SMe H i-Pr569 CH.sub.2 CH.sub.3morpholino Br H i-Pr__________________________________________________________________________
TABLE 17__________________________________________________________________________ ##STR68## Synth.Ex. Ex. R.sup.1 R.sup.3 X X' R.sup.5 mp (° C.)__________________________________________________________________________850 106 Me N(Et)n-Bu Br H i-Pr oil851 107 Me N[(CH.sub.2).sub.2 OCH.sub.3 ].sub.2 Br 6-OMe OMe oil852 108 Me N(CH.sub.2 CH.sub.2 --OMe).sub.2 CH.sub.3 6-CH.sub.3 CH.sub.3 117-120853 109 Me CN Br H i-Pr oil854 110 Me N(Et).sub.2 Br H i-Pr oil855 111 Me N(Et)CH.sub.2 CH.sub.2 OH Br H i-Pr oil856 112 Me N(Et)(CH.sub.2).sub.2 OCH.sub.3 Br H i-Pr oil857 113 Me N(Et)(CH.sub.2).sub.2 N(CH.sub.3).sub.2 Br H i-Pr oil858 114 Me N(Me)(CH.sub.2).sub.2 CN Br H i-Pr 125-126859 115 Me N(n-Pr).sub.2 Br H i-Pr 81-83860 116 Me N(n-Pr)(c-PrCH.sub.2) Br H i-Pr oil861 117 Me N(allyl).sub.2 Br H i-Pr oil862 118 Me N(n-Bu).sub.2 Br H i-Pr oil863 119 Me N(n-Pr)(CH.sub.2).sub.2 OCH.sub.3 Br H i-Pr oil864 120 Me N[(CH.sub.2).sub.2 OCH.sub.3 ].sub.2 Br H i-Pr oil865 121 Me N[(CH.sub.2).sub.2 OC.sub.2 H.sub.5 ].sub.2 Br H i-Pr oil866 122 Me NH[(CH.sub.2).sub.2 OCH.sub.3 ] Br H i-Pr 125-126867 123 Me NH[CH(Et)(CH.sub.2).sub.2 CH.sub.3 ] Br H i-Pr amorphous868 124 Me NH[CH(Et)(CH.sub.2).sub.3 CH.sub.3 ] Br H i-Pr oil869 125 Me NHCH.sub.2 [CH(Et)(CH.sub.2).sub.3 CH.sub.3 ] Br H i-Pr oil870 126 Me NH[CH{(CH.sub.2).sub.2 CH.sub.3 }.sub.2 ] Br H i-Pr 87-88871 127 Me NH[CH{(CH.sub.2).sub.3 CH.sub.3 ].sub.2 }] Br H i-Pr 109-110872 128 Me NH[CH(Me)(CH.sub.2)OCH.sub.3 ] Br H i-Pr 52-54873 129 Me NH[CH(Et)(CH.sub.2 OH] Br H i-Pr 85-87874 130 Me NH[CH(n-Pr)(CH.sub.2 OH] Br H i-Pr 129-130875 131 Me NH[CH(Et)(CH.sub.2)OCH.sub.3 ] Br H i-Pr 105-106876 132 Me O[CH(Et)CH.sub.2 OMe] Br H i-Pr 75-76877 133 Me OCH(Et).sub.2 Br H i-Pr oil878 134 Me OCH(Et)(CH.sub.2).sub.3 Me Br H i-Pr oil879 135 Me N(CH.sub.2 CH.sub.3).sub.2 CH.sub.3 6-CH.sub.3 CH.sub.3 106-108880 136 Me N(CH.sub.2 CH.sub.2 --CH.sub.3).sub.2 CH.sub.3 6-CH.sub.3 CH.sub.3 103-104881 137 Me N(CH.sub.2 CH.sub.2 --CH.sub.3)(CH.sub.2 -cPr) CH.sub.3 6-CH.sub.3 CH.sub.3 74-76882 138 Me N(Et)n-Bu CH.sub.3 6-CH.sub.3 CH.sub.3 86-88883 139 Me N[(CH.sub.2).sub.2 OCH.sub.3 ].sub.2 Cl 6-OMe OMe 141.5 142884 140 Me N(Et)n-Bu Cl 6-OMe OMe 126-127885 141 Me N(Et)n-Bu Br 6-OMe OMe 125-126__________________________________________________________________________
TABLE 18__________________________________________________________________________ ##STR69## Synth.Ex. Ex. R.sup.1 R.sup.3 X X' R.sup.5 R.sup.28 mp (° C.)__________________________________________________________________________900 142 Me Cl Br H i-Pr Me 115-116901 143 Me N(Et)n-Bu Br H i-Pr Me oil902 144 Me N[(CH.sub.2).sub.2 OCH.sub.3 ].sub.2 Br H i-Pr Me oil903 145 Me NH[CH(Et)(CH.sub.2)OCH.sub.3 ] Br H i-Pr Me 50-51904 146 Me N(Et)n-Bu Br H i-Pr CF.sub.3 oil905 147 Me NH[CH(Et)(CH.sub.2)OCH.sub.3 Br H i-Pr CF.sub.3 112-113906 148 Me N(Et)n-Bu Br H i-Pr OMe MS461907 149 Me N(Et)n-Bu Br H i-Pr Cl MS465908 150 Me N(Et)n-Bu Cl 6-OMe OMe Me 107-109909 151 Me N[(CH.sub.2).sub.2 OCH.sub.3 ].sub.2 Cl 6-OMe OMe Me 125-126910 152 Me Cl Br H i-Pr CF.sub.3 132-133911 153 Me N(Et)n-Bu Cl 6-OMe OMe n-Bu oil__________________________________________________________________________
TABLE 19__________________________________________________________________________ ##STR70## Synth.Ex. Ex. R.sup.1 R.sup.3 X X' R.sup.5 mp (° C.)__________________________________________________________________________570 154 Me N[(CH.sub.2).sub.2 OCH.sub.3 ].sub.2 Br H i-Pr 93-94571 155 Me N(Et)n-Bu Br H i-Pr 85-86572 156 Me N(Et)(CH.sub.2).sub.2 OCH.sub.3 Br H i-Pr oil573 157 Me N(n-Pr).sub.2 Br H i-Pr oil574 158 Me N(n-Pr)(c-Pr-CH.sub.2) Br H i-Pr oil575 159 Me N(n-Bu).sub.2 Br H i-Pr oil576 160 Me N(n-Pr)(CH.sub.2).sub.2 OCH.sub.3 Br H i-Pr oil577 161 Me N[(CH.sub.2).sub.2 OH].sub.2 Br H i-Pr amorphous578 162 Me N[(CH.sub.2).sub.2 OCH.sub.3 ](CH.sub.2).sub.2 OH Br H i-Pr 120-22579 163 Me N(Et).sub.2 Br H i-Pr 92-93580 164 Me N[(CH.sub.2).sub.2 OCH.sub.3 ](CH.sub.2).sub.3 OCH.sub.3 Br H i-Pr oil582 166 Me N[(CH.sub.2).sub.2 OCH.sub.3 ]-3-picolyl Br H i-Pr 94-95583 167 Me N[(CH.sub.2).sub.2 CN]-3-picolyl Br H i-Pr 70-73584 168 Me N[(CH.sub.2).sub.2 OCH.sub.3 ](c-Pr-CH.sub.2) Br H i-Pr oil585 169 Me N[(CH.sub.2).sub.2 OCH.sub.3 ]benzyl Br H i-Pr 117-118586 170 Me N[(CH.sub.2).sub.2 OCH.sub.3 ]--(CH.sub.2).sub.2 OCH.sub.2 Br H i-Pr oil587 171 Me N[(CH.sub.2).sub.2 OC.sub.2 H.sub.5 ].sub.2 Br H i-Pr oil588 172 Me N[(CH.sub.2).sub.2 O-benzyl].sub.2 Br H i-Pr oil589 173 Me NH[(CH.sub.2).sub.2 OCH.sub.3 ] Br H i-Pr 134-36590 174 Me NH[(CH.sub.2).sub.3 OCH.sub.3 ] Br H i-Pr 109-110591 175 Me NH(n-Pr) Br H i-Pr 156-157592 176 Me NH(c-Pr-CH.sub.2) Br H i-Pr 166-167593 177 Me NH(n-Bu) Br H i-Pr 149-151594 178 Me NH[CH(Et).sub.2 ] Br H i-Pr 171-72595 179 Me NH[CH(Et)(CH.sub.2).sub.2 CH.sub.3 ] Br H i-Pr 154-55596 180 Me NH[CH(Et)(CH.sub.2).sub.3 CH.sub.3 ] Br H i-Pr 137-138597 181 Me NH[CH[(CH.sub.2).sub.2 CH.sub.3 ].sub.2 ] Br H i-Pr 162-63598 182 Me NH[CH[(CH.sub.2).sub.3 CH.sub.3 ].sub.2 ] Br H i-Pr 132-33599 183 Me NH[CH(Et)(CH.sub.2)OH] Br H i-Pr 157-159600 184 Me NH[CH(n-Pr)(CH.sub.2)OH] Br H i-Pr 154-155601 185 Me NH[CH(Et)(CH.sub.2)OCH.sub.3 ] Br H i-Pr 132-134602 186 Me (+)-NH[CH(Et)(CH.sub.2)OCH.sub.3 ] Br H i-Pr 114-115603 187 Me (-)-NH[CH(Et)(CH.sub.2)OCH.sub.3 ] Br H i-Pr 114-115604 188 Me (+)-N(Me)[CH(Et)(CH.sub.2)OCH.sub.3 ] Br H i-Pr oil605 189 Me NH[CH(Bz)(CH.sub.2)OCH.sub.3 ] Br H i-Pr 67-69606 190 Me NH[CH(Et)COOCH.sub.3 ] Br H i-Pr 67-69607 191 Me OCH(Et)CH.sub.2 OMe Br H i-Pr 69-70608 192 Me OEt Br H i-Pr oil609 193 Me OCH(Et).sub.2 Br H i-Pr oil610 194 Me OCH(Et)(CH.sub.2).sub.3 Me Br H i-Pr oil611 195 H Cl Br H i-Pr 207-209612 196 H N(Et)n-Bu Br H i-Pr oil613 197 H N[(CH.sub.2).sub.2 OCH.sub.3 ].sub.2 Br H i-Pr oil614 198 H NH[CH(Et)(CH.sub.2)OCH.sub.3 ] Br H i-Pr 117-118615 199 Me N[(CH.sub.2).sub.2 OCH.sub.3 ].sub.2 H H i-Pr 80-81616 200 Me N[(CH.sub.2).sub.2 OCH.sub.3 ].sub.2 I H i-Pr 87-88617 201 Me N[(CH.sub.2).sub.2 OCH.sub.3 ].sub.2 Br 6-OMe OMe oil618 202 Me Cl CH.sub.3 6-CH.sub.3 CH.sub.3 186-188619 203 Me N(CH.sub.2 CH.sub.2 --OCH.sub.3).sub.2 CH.sub.3 6-CH.sub.3 CH.sub.3 83-85620 204 Me N(Et)n-Bu CH.sub.3 6-CH.sub.3 CH.sub.3 MS 353621 205 Me N(n-propyl) (CH.sub.2 cPr) CH.sub.3 6-CH.sub.3 CH.sub.3 83-85622 206 Me N(CH.sub.2 CH.sub.3).sub.2 CH.sub.3 6-CH.sub.3 CH.sub.3 127-129623 207 Me N(n-propyl).sub.2 CH.sub.3 6-CH.sub.3 CH.sub.3 66-68624 208 Me N(H)(CH.sub.2 --CH.sub.2 OCH.sub.3) CH.sub.3 6-CH.sub.3 CH.sub.3 142-144625 209 Me N(CH.sub.2 CH.sub.3)(CH.sub.2 CH.sub.2 O--CH.sub.3) CH.sub.3 6-CH.sub.3 CH.sub.3 MS 355626 210 Me N(cPr)(CH.sub.2 --CH.sub.2 OCH.sub.3) CH.sub.3 6-CH.sub.3 CH.sub.3 77-79627 211 Me N(benzyl)(CH.sub.2 --CH.sub.2 OCH.sub.3) CH.sub.3 6-CH.sub.3 CH.sub.3 MS 417628 212 Me N(H)[CH(Et)(CH.sub.2 OCH.sub.3)] CH.sub.3 6-CH.sub.3 CH.sub.3 156-158629 213 Me N(H)[CH(Et)(n-butyl)] CH.sub.3 6-CH.sub.3 CH.sub.3 141-143630 214 Me N(H)[CH(CH.sub.2 --CH.sub.2 CH.sub.3).sub.2 ] CH.sub.3 6-CH.sub.3 CH.sub.3 145-147631 215 Me N(H)[CH--(CH.sub.2 CH.sub.3).sub.2 ] CH.sub.3 6-CH.sub.3 CH.sub.3 185-187632 216 Me N(H)[CH--(CH.sub.2 CH.sub.3)(CH.sub.2 --CH.sub.2 CH.sub.3)] CH.sub.3 6-CH.sub.3 CH.sub.3 170-172633 217 Me N(H)[CH(CH.sub.3)(CH.sub.2 CH--(CH.sub.3).sub.2)] CH.sub.3 6-CH.sub.3 CH.sub.3 176-178634 218 Me N(H)[CH(CH.sub.3)(CH.sub.2 CH.sub.3)] CH.sub.3 6-CH.sub.3 CH.sub.3 163-165635 219 Me N(H)[CH(CH.sub.3)(CH.sub.2 CH.sub.2 CH.sub.3)] CH.sub.3 6-CH.sub.3 CH.sub.3 151-152636 220 Me N(H)[CH(CH.sub.3)(CH(CH.sub.3).sub.2)] CH.sub.3 6-CH.sub.3 CH.sub.3 175-176637 221 Me N(H)cyclopentane CH.sub.3 6-CH.sub.3 CH.sub.3 190-191638 222 Me N(H)cyclohexane CH.sub.3 6-CH.sub.3 CH.sub.3 164-166639 223 Me N(H)4-methylcyclohexane CH.sub.3 6-CH.sub.3 CH.sub.3 177-179640 224 Me N(H)3-tetrahydrofuran CH.sub.3 6-CH.sub.3 CH.sub.3 168-170641 225 Me (R)-(+)-N(H) [CH(CH.sub.2 CH.sub.3)--(CH.sub.2 OCH.sub.3)] CH.sub.3 6-CH.sub.3 CH.sub.3 158-160642 226 Me N(H)(2-methoxy-6-methylphenyl) CH.sub.3 6-CH.sub.3 CH.sub.3 217-219643 227 Me (S)-N(H)[CH (benzyl)(CH.sub.2 OCH.sub.3)] CH.sub.3 6-CH.sub.3 CH.sub.3 MS 417644 228 Me N(H)[CH (CH.sub.2 CH.sub.3) (CH.sub.2 OH)] CH.sub.3 6-CH.sub.3 CH.sub.3 177-178645 229 Me N(H)[CH (CH.sub.2 CH.sub.2 CH.sub.3)--(CH.sub.2 N(CH.sub.3).sub.2 ] CH.sub.3 6-CH.sub.3 CH.sub.3 158-159646 230 Me CH(Et)(CH.sub.2 OCH.sub.3) Br 6-OCH.sub.3 OCH.sub.3 120-121647 231 Me CH(CO.sub.2 CH.sub.3).sub.2 Br 6-CH.sub.3 CH.sub.3 MS 384648 232 Me N(COCH.sub.3) (n-butyl) CH.sub.3 6-CH.sub.3 CH.sub.3 MS 367649 233 Me N(CH.sub.2 CH.sub.3) (n-butyl) CF.sub.3 H NMe.sub.2 142-143650 234 Me N(n-propyl) (CH.sub.2 cPr) CF.sub.3 H NMe.sub.2 118-120651 235 Me N(n-propyl).sub.2 CF.sub.3 H NMe.sub.2 133-135652 236 Me N(CH.sub.2 CH.sub.2 --OCH.sub.3).sub.2 CF.sub.3 H NMe.sub.2 105-109653 237 Me N(Et)n-Bu Br H SMe oil654 238 Me N(Et)n-Bu Br H SO.sub.2 Me 141655 239 Me N(Et)n-Bu Br H COMe oil656 240 Me N[(CH.sub.2).sub.2 OCH.sub.3 ].sub.2 Br H Br oil657 241 Me N(Et)n-Bu Br H Br oil658 242 Me N(Et)n-Bu Br H I oil659 243 Me N[(CH.sub.2).sub.2 OCH.sub.3 ].sub.2 Br H I oil660 244 Me N[(CH.sub.2).sub.2 OCH.sub.3 ].sub.2 Cl 6-OMe OMe 116-117661 245 Me N(Et)n-Bu Cl 6-OMe OMe oil662 246 Me N[(CH.sub.2).sub.2 CH.sub.3 ].sub.2 Cl 6-OMe OMe 110-113663 247 Me N(n-propyl) (CH.sub.2 cPr) Cl 6-OMe OMe 112-114664 248 Me N(H)[CH(Et)(CH.sub.2 OCH.sub.3)] Cl 6-OMe OMe 121-122665 249 Me N(Et)n-Bu Br 6-OMe OMe 118-119666 250 Me N[(CH.sub.2).sub.2 OCH.sub.3 ].sub.2 Br H OCF.sub.3 oil667 251 Me N(Et)n-Bu Br H OCF.sub.3 oil668 252 Me N(n-propyl) (CH.sub.2 cPr) Br H OCF.sub.3 oil669 253 Me N[CH.sub.2 CH.sub.3 ].sub.2 Br H OCF.sub.3 oil670 254 Me N(H)[CH(Et)(CH.sub.2 OCH.sub.3)] Br H OCF.sub.3 oil671 255 Me N[(CH.sub.2).sub.2 OCH.sub.3 ].sub.2 Br 6-OMe NMe.sub.2 oil672 256 Me N(Et)n-Bu Br 6-OMe NMe.sub.2 oil673 257 Me N(H)[CH(Et)(CH.sub.2 OCH.sub.3)] Br 6-OMe NMe.sub.2 oil674 258 Me N(n-propyl).sub.2 Br 6-OMe NMe.sub.2 oil675 259 Me N((CH.sub.2 Ph)[CH.sub.2 CH.sub.2 OCH.sub.3 ] Br 6-OMe NMe.sub.2 oil676 260 Me N((CH.sub.2 c-Pr)[CH.sub.2 CH.sub.2 OCH.sub.3 ] Br 6-OMe NMe.sub.2 oil677 261 Me N(H)[CH(Et)(n-butyl)] Br 6-OMe NMe.sub.2 oil678 262 Me N(H)[CH(CH.sub.2 NMe.sub.2)(n-propyl)] Br H i-Pr 179-180679 263 Me N(H)[CH(CH.sub.2 NMe.sub.2)(n-propyl)] Br H i-Pr 158-159680 264 Me N(Me)[CH(Et)(CH.sub.2 OCH.sub.3)] Br H OCF.sub.3 oil681 265 Me N[CH.sub.2 CH.sub.3 ].sub.2 Br H NMe.sub.2 139-140682 266 Me N(Et)n-Bu Br H NMe.sub.2 113-114683 267 Me N[(CH.sub.2).sub.2 OCH.sub.3 ].sub.2 Br H NMe.sub.2 108-109684 268 Me N(n-propyl).sub.2 Br H Br 118-119685 Me N(Et).sub.2 Me H OMe686 Me N(Et)n-Bu Me H OMe687 Me N(Et)(CH.sub.2).sub.2 OCH.sub.3 Me H OMe688 Me N(n-Pr).sub.2 Me H OMe689 Me N(n-Pr)(c-Pr-CH.sub.2) Me H OMe690 Me N(n-Bu).sub.2 Me H OMe691 Me N(n-Pr)(CH.sub.2).sub.2 OCH.sub.3 Me H OMe692 Me N[(CH.sub.2).sub.2 OCH.sub.3 ].sub.2 Me H OMe693 Me N[(CH.sub.2).sub.2 OCH.sub.3 ](CH.sub.2).sub.3 OCH.sub.3 Me H OMe694 Me N[(CH.sub.2).sub.2 OCH.sub.3 ](CH.sub.2).sub.2 OC.sub.2 H.sub.5 Me H OMe695 Me N[(CH.sub.2).sub.2 OCH.sub.3 ]-3-picolyl Me H OMe696 Me N[(CH.sub.2).sub.2 CN]-3-picolyl Me H OMe697 Me N[(CH.sub.2).sub.2 OCH.sub.3 ](c-Pr-CH.sub.2) Me H OMe698 Me N[(CH.sub.2).sub.2 OCH.sub.3 ]benzyl Me H OMe699 Me N[(CH.sub.2).sub.2 OCH.sub.3 ]--(CH.sub.2).sub.2 OCH.sub.2 Me H OMe700 Me N[(CH.sub.2).sub.2 OC.sub.2 H.sub.5 ].sub.2 Me H OMe701 Me N[(CH.sub.2).sub.2 O-benzyl].sub.2 Me H OMe702 Me NH[CH(Et).sub.2 ] Me H OMe703 Me NH[CH(Et)(CH.sub.2).sub.2 CH.sub.3 ] Me H OMe704 Me NH[CH(Et)(CH.sub.2).sub.3 CH.sub.3 ] Me H OMe705 Me NH[CH[(CH.sub.2).sub.2 CH.sub.3 ].sub.2 ] Me H OMe706 Me NH[CH[(CH.sub.2).sub.3 CH.sub.3 ].sub.2 ] Me H OMe707 Me NH[CH(Et)(CH.sub.2)OH] Me H OMe708 Me NH[CH(Et)(CH.sub.2)OCH.sub.3 ] Me H OMe709 Me N(Et).sub.2 Cl 6-Me Me710 Me N(Et)n-Bu Cl 6-Me Me711 Me N(Et)(CH.sub.2).sub.2 OCH.sub.3 Cl 6-Me Me712 Me N(n-Pr).sub.2 Cl 6-Me Me713 Me N(n-Pr)(c-Pr-CH.sub.2) Cl 6-Me Me714 Me N(n-Bu).sub.2 Cl 6-Me Me715 Me N(n-Pr)(CH.sub.2).sub.2 OCH.sub.3 Cl 6-Me Me716 Me N[(CH.sub.2).sub.2 OCH.sub.3 ].sub.2 Cl 6-Me Me717 Me N[(CH.sub.2).sub.2 OCH.sub.3 ](CH.sub.2).sub.3 OCH.sub.3 Cl 6-Me Me718 Me N[(CH.sub.2).sub.2 OCH.sub.3 ](CH.sub.2).sub.2 OC.sub.2 H.sub.5 Cl 6-Me Me719 Me N[(CH.sub.2).sub.2 OCH.sub.3 ]-3-picolyl Cl 6-Me Me720 Me N[(CH.sub.2).sub.2 CN]-3-picolyl Cl 6-Me Me721 Me N[(CH.sub.2).sub.2 OCH.sub.3 ](c-Pr-CH.sub.2) Cl 6-Me Me722 Me N[(CH.sub.2).sub.2 OCH.sub.3 ]benzyl Cl 6-Me Me723 Me N[(CH.sub.2).sub.2 OCH.sub.3 ]- (CH.sub.2).sub.2 OCH.sub.2 Cl 6-Me Me724 Me N[(CH.sub.2).sub.2 OC.sub.2 H.sub.5 ].sub.2 Cl 6-Me Me725 Me N[(CH.sub.2).sub.2 O-benzyl].sub.2 Cl 6-Me Me726 Me NH[CH(Et).sub.2 ] Cl 6-Me Me727 Me NH[CH(Et)(CH.sub.2).sub.2 CH.sub.3 ] Cl 6-Me Me728 Me NH[CH(Et)(CH.sub.2).sub.3 CH.sub.3 ] Cl 6-Me Me729 Me NH[CH[(CH.sub.2).sub.2 CH.sub.3 ].sub.2 ] Cl 6-Me Me730 Me NH[CH[(CH.sub.2).sub.3 CH.sub.3 ].sub.2 ] Cl 6-Me Me731 Me NH[CH(Et)(CH.sub.2)OCH.sub.3 ] Cl 6-Me Me732 Me N[(CH.sub.2).sub.2 OCH.sub.3 ].sub.2 Me 5-Me OMe733 Me N[(CH.sub.2).sub.2 OCH.sub.3 ].sub.2 Me 5-OMe OMe734 Me N[(CH.sub.2).sub.2 OCH.sub.3 ].sub.2 Me 5-F OMe__________________________________________________________________________
TABLE 20______________________________________ ##STR71##Synth.Ex. Ex. L R.sup.3 X X' R.sup.5 mp (° C.)______________________________________800 269 N Cl Me 6-Me Me 204-206801 270 N N[(CH.sub.2).sub.2 OCH.sub.3 ].sub.2 Me 6-Me Me MS386802 271 N N(n-Bu)Et Me 6-Me Me MS354803 272 N N(n-propyl).sub.2 Me 6-Me Me MS354804 273 N N(n-propyl)(CH.sub.2 cPr) Me 6-Me Me MS366805 274 N N(H)[CH(Et)(n-Bu)] Me 6-Me Me 122-130______________________________________
TABLE 21__________________________________________________________________________ ##STR72## Synth.Ex. Ex. R.sup.1 R.sup.3 X X' R.sup.5 Mp (° C.)__________________________________________________________________________1100* 275 CH.sub.3 --N(n-Bu)Et Br H i-Pr 168-1711101* 277 CH.sub.3 --N(C.sub.2 H.sub.4 OCH.sub.3).sub.2 Br H i-Pr 87.5-89.51102 279 CH.sub.3 --N(n-Bu)Et SCH.sub.3 H i-Pr 11103 280 CH.sub.3 --N(C.sub.2 H.sub.4 OCH.sub.3).sub.2 SCH.sub.3 H i-Pr a1104 281 CH.sub.3 --N(n-Bu)Et SO.sub.2 CH.sub.3 H i-Pr 151-1531105 CH.sub.3 --N(C.sub.2 H.sub.4 OCH.sub.3).sub.2 SO.sub.2 CH.sub.3 H i-Pr 143-1451106 CH.sub.3 --NHCH(CH.sub.2 OCH.sub.3)Et SCH.sub.3 H i-Pr 124-1271107 282 CH.sub.3 --NHCH(CH.sub.2 OCH.sub.3)Et Br H i-Pr 106-1081108 CH.sub.3 --NHCH(i-Pr).sub.2 Br H i-Pr 180-1821109 CH.sub.3 --NHCH(i-Pr).sub.2 SCH.sub.3 H i-Pr1110 287 CH.sub.3 --NHCH(i-Pr).sub.2 Br H SCH.sub.3 149-1521111 283 CH.sub.3 --NHCH(i-Pr).sub.2 Br H COCH.sub.3 a1112 288 CH.sub.3 --NHCH(i-Pr).sub.2 Br H SO.sub.2 CH.sub.3 203-2061113 284 CH.sub.3 --NHCH(n-Pr).sub.2 Br H i-Pr 131-1331114 285 CH.sub.3 --NHCH(n-Pr).sub.2 SCH.sub.3 H i-Pr 101-1041115 CH.sub.3 --NHCH(n-Pr).sub.2 Br H I 151-1521116 CH.sub.3 --NHCH(n-Pr).sub.2 Br H Br 140-1421117 286 CH.sub.3 --NHCH(n-Pr).sub.2 Br H COCH.sub.3 165-1661118 CH.sub.3 --NHEt.sub.2 Br H Br 112-1141119 CH.sub.3 --NHCH(CH.sub.2 OCH.sub.3)Et CH.sub.3 6-CH.sub.3 CH.sub.3 143-1461120 CH.sub.3 --NH(c-Pr) Br H Br 201-2031121 CH.sub.3 --NHCH(CH.sub.2 OCH.sub.3).sub.2 CH.sub.3 6-CH.sub.3 CH.sub.3 118-1201122 CH.sub.3 --NHCH(CH.sub.2 OCH.sub.3).sub.2 CH.sub.3 6-SCH.sub.3 CH.sub.3 128-1311123 CH.sub.3 --NHCH(CH.sub.2 OCH.sub.3).sub.2 Cl H Cl 114-1161124 CH.sub.3 --NHEt.sub.2 Cl H OCH.sub.31125 CH.sub.3 --NHEt.sub.2 CH.sub.3 H OCH.sub.31126 CH.sub.3 --NHEt.sub.2 CH.sub.3 6-CH.sub.3 OCH.sub.31127 CH.sub.3 --NHEt.sub.2 Cl H COCH.sub.31128 CH.sub.3 --NHEt.sub.2 CH.sub.3 H COCH.sub.31129 CH.sub.3 --NHEt.sub.2 CH.sub.3 6-CH.sub.3 COCH.sub.31130 CH.sub.3 --NHEt.sub.2 Cl H SO.sub.2 CH.sub.31131 CH.sub.3 --NHEt.sub.2 CH.sub.3 H SO.sub.2 CH.sub.31132 CH.sub.3 --NHEt.sub.2 CH.sub.3 6-CH.sub.3 SO.sub.2 CH.sub.31133 CH.sub.3 --NH(c-Pr).sub.2 Cl H OCH.sub.31134 CH.sub.3 --NH(c-Pr).sub.2 CH.sub.3 H OCH.sub.31135 CH.sub.3 --NH(c-Pr).sub.2 CH.sub.3 6-CH.sub.3 OCH.sub.31136 CH.sub.3 --NH(c-Pr).sub.2 Cl H COCH.sub.31137 CH.sub.3 --NH(c-Pr).sub.2 CH.sub.3 H COCH.sub.31138 CH.sub.3 --NH(c-Pr).sub.2 CH.sub.3 6-CH.sub.3 COCH.sub.31139 CH.sub.3 --NH(c-Pr).sub.2 Cl H SO.sub.2 CH.sub.31140 CH.sub.3 --NH(c-Pr).sub.2 CH.sub.3 H SO.sub.2 CH.sub.31141 CH.sub.3 --NH(c-Pr).sub.2 CH.sub.3 6-CH.sub.3 SO.sub.2 CH.sub.31142 CH.sub.3 --N(C.sub.2 H.sub.4 OCH.sub.3).sub.2 Cl H OCH.sub.31143 CH.sub.3 --N(C.sub.2 H.sub.4 OCH.sub.3).sub.2 CH.sub.3 H OCH.sub.31144 CH.sub.3 --N(C.sub.2 H.sub.4 OCH.sub.3).sub.2 CH.sub.3 6-CH.sub.3 OCH.sub.3__________________________________________________________________________ *Hydrochloride salt. .sup.+ Racemic. l: liquid, a: amorphous
Utility
In vitro Receptor Binding Assay:
Tissue Preparation:
Male Sprague Dawley rats (180-200 g) were sacrificed by decapitation and the cortex was dissected on ice, frozen whole in liquid nitrogen and stored at -70° C. until use. On the day of assay, frozen tissue was weighed and homogenized in 20 volumes of ice cold buffer containing 50 mM Tris, 10 mM MgCl 2 , 2 mM EGTA, pH 7.0 at 22° C. using a Polytron (Brinkmann Instruments, Westbury, N.Y.; setting 6) for 20 s. The homogenate was centrifuged at 48,000×g for 10 min at 4° C. The supernatant was discarded, and the pellet was re-homogenized in the same volume of buffer and centrifuged at 48,000×g for 10 min at 4° C. The resulting pellet was resuspended in the above buffer to a final concentration of 20-40 mg original wet weight/mL and used in the assays described below. Protein determinations were performed according to the method of Lowry (Lowry et al., J. Biol. Chem. 193:265 (1951)) using bovine serum albumin as a standard.
CRF Receptor Binding:
Receptor binding assays were carried out essentially as described by E. B. De Souza, J. Neurosci. 7:88 (1987).
Saturation Curve Analysis
In saturation studies, 100 μl 125 I-ovine CRF (50 pM-10 nM final concentration), 100 μl of assay buffer (with or without 1 mM r/hCRF final concentration, to define the non-specific binding) and 100 μl of membrane suspension (as described above) were added in sequence to 1.5 mL polypropylene microfuge tubes for a final volume of 300 μl. All assays were carried out at equilibrium for 2 h at 22° C. as described by E. B. De Souza, J. Neurosci. 7:88 (1987). The reaction was terminated by centrifugation of the tubes in a Beckman microfuge for 5 min at 12,000×g. Aliquots of the supernatant were collected to determine the "free" radioligand concentation. The remaining supernatant was aspirated and the pellets washed gently with ice-cold PBS plus 0.01% Triton X-100, centrifuged again and monitored for bound radioactivity as described above. Data from saturation curves were analyzed using the non-linear least-squares curve-fitting program LIGAND (P. J. Munson and D. Rodbard, Anal. Biochem. 107:220 (1980)). This program has the distinct advantage of fitting the raw experimental data on an untransformed coordinate system where errors are most likely to be normally distributed and uncorrelated with the independent variable. LIGAND does not expect the non-specific binding to be defined arbitrarily by the investigator, rather it estimates the value as an independent variable from the entire data set. The parameters for the affinity constants (K D ) and receptor densities (B max ) are also provided along with statistics on the general "fit" of the estimated parameters to the raw data. This program also offers the versatility of analyzing multiple curves simultaneously, thus improving the reliability of the data analysis and hence the validity of the final estimated parameters for any saturation experiment.
Competition Curve Analysis
In competition studies, 100 μl [ 125 I] ovine CRF ([ 125 I] oCRF; final concentration 200-300 pM) was incubated along with 100 μl buffer (in the presence of varying concentrations of competing ligands, typically 1 pM to 10 mM) and 100 μl of membrane suspensions as prepared above to give a total reaction volume of 300 μl. The reaction was initiated by the addition of membrane homogenates, allowed to proceed to equilibrium for 2 h at 22° C. and was terminated by centrifugation (12,000×g) in a Beckman microfuge to separate the bound radioligand from free radioligand. The resulting pellets were surface washed twice by centrifugation with 1 mL of ice-cold phosphate buffered saline and 0.01% Triton X-100, the supernatants discarded and the pellets monitored for radioactivity at approximately 80% efficiency. The level of non-specific binding was defined in the presence of 1 mM unlabeled rat/humanCRF(r/hCRF). Data from competition curves were analyzed by the program LIGAND. For each competition curve, estimates of the affinity of the radiolabeled ligand for the CRF receptor ([ 125 I]CRF) were obtained in independent saturation experiments and these estimates were constrained during the analysis of the apparent inhibitory constants (K i ) for the peptides tested. Routinely, the data were analyzed using a one- and two-site model comparing the "goodness of fit" between the models in order to accurately determine the K i . Satistical analyses provided by LIGAND allowed the determination of whether a single-site or multiple-site model should be used. For both peptides (α-helical CRF 9-41 and d-PheCRF 12-41 ), as well as for all compounds of this invention, data were fit significantly to a single site model; a two-site model was either not possible or did not significantly improve the fit of the estimated parameters to the data.
The results of the in vitro testing of the compounds of the invention are shown in Table 17. It was found, for a representative number of compounds of the invention, that either form of the compound, be it the free-base or the hydrochloride salt, produced essentially the same inhibition value in the binding assay.
A compound is considered to be active if it has an K i value of less than about 10000 nM for the inhibition of CRF. In Table 17, the K 1 values were determined using the assay conditions described above. The K i values are indicated as follows: +++=<500 nM; ++=501-2000 nM; +=2001-10000 nM.
TABLE 17______________________________________Example Synth. InhibitionNo. Ex. K.sub.i (nM)______________________________________ 1 1 ++ 2 ++ 3 ++ 4 2 +++ 5 ++ 6 ++ 7 +++ 8 +++ 9 3 +++ 10 +++ 11 +++ 12 ++ 13 +++ 14 ++ 15 +++ 16 4 +++ 17 +++ 18 +++ 19 +++ 20 +++ 21 5 +++ 22 ++ 23 +++ 24 ++ 25 +++ 26 +++ 27 +++ 28 +++ 29 6 +++ 30 7 +++ 31 8 +++ 32 +++ 33 9 +++ 34 10 +++ 37 +++ 49 12 + 50 13 +++ 51 ++ 52 + 53 + 54 + 55 +++ 56 14 +++ 57 15 +++ 58 36 +++ 59 17 +++ 60 ++ 61 18 +++ 62 ++ 63 19 + 64 20 + 65 21 + 66 + 68 + 69 + 70 + 71 + 72 + 73 22 +++ 74 +++ 78 + 95 ++130 ++131 +132 +133 ++134 23 +++i35 +++136 +++137 +++138 24 +++139 25 +++140 26 +++141 +++142 +++143 +++145 +146 +147 +++148 +++149 +++150 +++151 +++152 +++153 +++154 +++155 +++156 +++157 +++158 +++159 27 +++160 28 +++161 +++162 +++163 ++165 31 +++166 34 +++167 32 +++168 35 +++170 36 +++171 38 +++172 39 +++173 40 ++174 41 +++175 42 ++176 43 +++177 33 ++178 44 +++179 45 +180 46 +++181 47 +++182 48 +++183 49 +184 ++185 51 +++186 52 +++187 +++188 54 +++189 55 +++190 56 +++191 57 +++192 +++193 +++194 +++195 +++196 +++197 ++201 +++203 ++204 +205 +++206 +++207 +++208 +++209 +++210 ++211 +++212 +++213 +++214 ++215 ++216 +++217 +++218 +++219 +++221 +++222 58 ++223 ++224 63 +++225 59 +++226 +++227 +++228 ++229 +230 60 +++231 +232 +++236 +++237 +++238 +++239 +++240 +++241 +++242 29 ++243 +244 +245 +246 +++247 +++248 +++249 30 +250 ++251 62 ++252 +253 61 ++254 64 +++255 74 ++256 66 +++257 65 +++258 68 +++259 75 +++260 69 +++261 67 +++262 70 +++263 71 +++264 77 +265 76 +++266 78 ++267 79 +++268 +++269 +++270 +271 +++272 +273 ++274 +275 +++276 +++277 +++278 +++279 +++280 +++281 +++282 +++283 +284 +++285 +++286 +++287 ++288 +++289 +++290 +++291 +++292 +++293 +++294 +++295 +++296 +++297 80 +++298 82 +++299 83 +++300 84 +++301 85 +++302 86 +++303 87 +++304 88 +++305 89 +++307 91 +++308 92 +++309 93 +++310 94 ++311 95 +++312 96 +++______________________________________
Inhibition of CRF-Stimulated Adenylate Cyclase Activity
Inhibition of CRF-stimulated adenylate cyclase activity was performed as described by G. Battaglia et al., Synapse 1:572 (1987). Briefly, assays were carried out at 37° C. for 10 min in 200 mL of buffer containing 100 mM Tris-HCl (pH 7.4 at 37° C.), 10 mM MgCl 2 , 0.4 mM EGTA, 0.1% BSA, 1 mM isobutylmethylxanthine (IBMX), 250 units/mL phosphocreatine kinase, 5 mM creatine phosphate, 100 mM guanosine 5'-triphosphate, 100 nM oCRF, antagonist peptides (concentration range 10 -9 to 10 -6m ) and 0.8 mg original wet weight tissue (approximately 40-60 mg protein). Reactions were initiated by the addition of 1 mM ATP/ 32 P]ATP (approximately 2-4 mCi/tube) and terminated by the addition of 100 mL of 50 mM Tris-HCl, 45 mM ATP and 2% sodium dodecyl sulfate. In order to monitor the recovery of cAMP, 1 μl of [ 3 H]cAMP (approximately 40,000 dpm) was added to each tube prior to separation. The separation of [ 32 P]cAMP from [ 32 P]ATP was performed by sequential elution over Dowex and alumina columns. Recovery was consistently greater than 80%.
Representative compounds of this invention were found to be active in this assay. IC 50 ≦10,000 nanomolar.
In Vivo Biological Assay
The in vivo activity of the compounds of the present invention can be assessed using any one of the biological assays available and accepted within the art. Illustrative of these tests include the Acoustic Startle Assay, the Stair Climbing Test, and the Chronic Adminisitration Assay. These and other models useful for the testing of compounds of the present invention have been outlined in C. W. Berridge and A. J. Dunn Brain Research Reviews 15:71 (1990).
Compounds may be tested in any species of rodent or small mammal. Disclosure of the assays herein is not intended to limit the enablement of the invention.
The foregoing tests results demonstrate that compounds of this invention have utility in the treatment of imbalances associated with abnormal levels of corticotropin releasing factor in patients suffering from depression, affective disorders, and/or anxiety. The foregoing tests also demonstrate that compounds of this invention have utility in the treatment of uterine contraction disorders.
Compounds of this invention can be administered to treat said abnormalities by means that produce contact of the active agent with the agent's site of action in the body of a mammal. The compounds can be administered by any conventional means available for use in conjunction with pharmaceuticals either as individual therapeutic agents or in a combination of therapeutic agents. They can be administered alone, but are generally administered with a pharmaceutical carrier selected on the basis of the chosen route of administration and standard pharmaceutical practice.
The dosage administered will vary depending on the use and known factors such as the pharmacodynamic character of the particular agent, and its mode and route of administration; the recipient's age, weight, and health; nature and extent of symptoms; kind of concurrent treatment; frequency of treatment; and desired effect. For use in the treatment of said diseases or conditions, the compounds of this invention can be orally administered daily at a dosage of the active ingredient of 0.002 to 200 mg/kg of body weight. Ordinarily, a dose of 0.01 to 10 mg/kg in divided doses one to four times a day, or in sustained release formulation is effective in obtaining the desired pharmacological effect.
Dosage forms (compositions) suitable for administration contain from about 1 mg to about 100 mg of active ingredient per unit. In these pharmaceutical compositions, the active ingredient will ordinarily be present in an amount of about 0.5 to 95% by weight based on the total weight of the composition.
The active ingredient can be administered orally in solid dosage forms, such as capsules, tablets and powders; or in liquid forms such as elixirs, syrups, and/or suspensions. The compounds of this invention can also be administered parenterally in sterile liquid dose formulations.
Gelatin capsules can be used to contain the active ingredient and a suitable carrier, such as, but not limited to, lactose, starch, magnesium stearate, steric acid, or cellulose derivatives. Similar diluents can be used to make compressed tablets. Both tablets and capsules can be manufactured as sustained release products to provide for continuous release of medication over a period of time. Compressed tablets can be sugar-coated or film-coated to mask any unpleasant taste, or used to protect the active ingredients from the atmosphere, or to allow selective disintegration of the tablet in the gastrointestinal tract.
Liquid dose forms for oral administration can contain coloring or flavoring agents to increase patient acceptance.
In general, water, pharmaceutically acceptable oils, saline, aqueous dextrose (glucose), and related sugar solutions and glycols, such as propylene glycol or polyethylene glycol, are suitable carriers for parenteral solutions. Solutions for parenteral administration preferably contain a water soluble salt of the active ingredient, suitable stabilizing agents, and if necessary, buffer substances. Antioxidizing agents, such as sodium bisulfate, sodium sulfite, or ascorbic acid, either alone or in combination, are suitable stabilizing agents. Also used are citric acid and its salts, and EDTA. In addition, parenteral solutions can contain preservatives such as benzalkonium chloride, methyl- or propyl-paraben, and chlorobutanol.
Suitable pharmaceutical carriers are described in "Remington's Pharmaceutical Sciences", A. Osol, a standard reference in the field.
Useful pharmaceutical dosage-forms for administration of the compounds of this invention can be illustrated as follows:
Capsules
A large number of units in the form of capsules are prepared by filling standard two-piece hard gelatin capsules each with 100 mg of powdered active ingredient, 150 mg lactose, 50 mg cellulose, and 6 mg magnesium stearate.
Soft Gelatin Capsules
A mixture of active ingredient in a digestible oil such as soybean, cottonseed oil, or olive oil is prepared and injected by means of a positive displacement into gelatin to form soft gelatin capsules containing 100 mg of the active ingredient. The capsules are washed and dried.
Tablets
A large number of tablets are prepared by conventional procedures so that the dosage unit is 100 mg active ingredient, 0.2 mg of colloidal silicon dioxide, 5 mg of magnesium stearate, 275 mg of microcrystalline cellulose, 11 mg of starch, and 98.8 mg lactose. Appropriate coatings may be applied to increase palatability or delayed adsorption.
The compounds of this invention may also be used as reagents or standards in the biochemical study of neurological function, dysfunction, and disease. | The present invention provides novel compounds, compounds and pharmaceutical compositions thereof, and methods of using same in the treatment of affective disorders, anxiety, depression, post-traumatic stress disorders, eating disorders, supranuclear palsy, irritable bowel syndrome, immune suppression, Alzheimer's disease, gastrointestinal diseases, anorexia nervosa, drug and alcohol withdrawal symptoms, drug addiction, inflammatory disorders, or fertility problems. The novel compounds provided by this invention are those of formula: ##STR1## wherein R 1 , R 3 , R 4 , R 5 , Z, Y, V, X, X', J, K, L, and M are as defined herein. | 2 |
[0001] The present invention relates to ionophore antibiotic compositions and particularly, but not solely, to ionophore antibiotic compositions capable of dilution with water, suitable for inclusion directly or via a holding tank in the drinking water of an animal to have administered and/or self administered an ionophore antibiotic or ionophore antibiotics.
BACKGROUND
[0002] Administration of ionophore antibiotics such as monensin to animals (preferably ruminants) is known to achieve in appropriate dosages advantages for a number of different purposes. These include the treatment or prevention of ketosis and/or bloat, the enhancement of milk production, enhancement of milk protein content in milk, enhancement of mineral uptake, enhancement of weight gain, and/or enhancement of feed conversion efficiency (in ruminants), desirable reproduction advantages and as a milk replacement. See U.S. Pat. No. 3,829,557.
[0003] In this respect we refer to European Patent Specification 0,139,595 A2 of KOFFOLK (1949) LTD which relates to a liquid ionophore antibiotic composition for ruminants and poultry where the antibiotic is dissolved in a non-toxic water-soluble organic solvent rather than a water soluble organic solvent, and in use the resulting solution is admixed with a liquid feed, a liquid vitamin concentrate or drinking water. There are claims for stability on standing.
[0004] The composition of EP 0,139,595 indicates that because monensin and its sodium salt is only slightly soluble in water that it is generally administered in a dry form in an animal feed and/or in dry liquid milk replacer compositions. The same is also indicated as being true for another ionophore antibiotic lasalocid which in U.S. Pat. No. 3,715,372 is reported to be completely insoluble in water.
[0005] The composition of EP 0,139,595 uses as an organic solvent for the ionophore antibiotic a solvent selected from the group comprising propylene glycol, glycerol, ethanol and isopropanol and mixtures thereof.
[0006] Example 1 of EP 0,139,595 indicates that 250 g of a mycelium containing 10% monensin was mixed at room temperature with 1250 cc propylene glycol for 2 hours by exposing the mixture to ultrasound. There is an indication that 50% of the monensin was found in solution in the propylene glycol.
[0007] Monensin is usually available commercially as the sodium salt of the acid. Monensin sodium is available in two forms, namely, a crystalline form or a mycelial form. The mycelial form has only about a 20% activity while the crystalline form has greater than 90% active monensin sodium.
[0008] Reference herein to “monensin” where the context allows encompasses all forms thereof including monensin, alkali metal salts of monensin and monensin esters and includes mixtures. Likewise for the other ionophore antibiotics.
[0009] In our New Zealand Patent Specification 272574/272940 (equivalent to PCT/NZ96/00068 WO 97/03650) we disclose an aqueous base suspension concentrate of an ionophore antibiotic or ionophore antibiotics such as monensin.
[0010] In one aspect in NZ 272574/272940 that invention is defined as an aqueous base suspension concentrate of an ionophore antibiotic or ionophore antibiotics capable of aqueous dilution (if desired) and capable (with or without such aqueous dilution) of being orally administered to an animal by an active dosing regime (eg; by drenching), said concentrate comprising or including
[0011] (I) at least one ionophore antibiotic in
[0012] (II) an aqueous system containing
[0013] (i) a wetting and/or surfactant agent, (preferably alkyl polyglycoside)
[0014] (ii) an antifreeze agent or agents in which the ionophore antibiotic or antibiotics is or are no more than sparingly soluble,
[0015] (iii) a suspension agent (eg gum(s)),
[0016] (iv) optionally, an antifoam agent or system,
[0017] (v) optionally, a preservative,
[0018] (vi) optionally, a de-bittering agent,
[0019] (vii) optionally, a pH buffering system, and
[0020] (viii) water.
[0021] The preferred ionophore antibiotic of NZ 272574/272940 is sodium monensin. Preferably an antifreeze agent or agents in which the ionophore antibiotic(s) is no more than sparingly soluble (such as a glycol or polyglycol) is present. Additional, preferably an antifoam agent is present (e.g. simethicone and a particulate carrier such as silicon dioxide therefor).
[0022] NZ 272574/272940 also discloses a method of drenching an animal with such an ionophore antibiotic which involves administering orally to such an animal a diluted form of the compositions, such dilution being with water.
[0023] We have found monopropylene glycol to be a poor solvent of monensin. While we have in NZ 272574/272940 referred to monopropylene glycol as being an antifreeze agent in which the ionophore antibiotic is sparingly soluble, we do appreciate that solubility to the extent referred to in Example 1 of EP 0,139,595 may be achieved when induced with ultrasound or heating.
[0024] The form of crystalline monensin used for the examples in NZ272574/272940 has a mean particle size of the order of about 40 microns and in order to hold such large particles in suspension an aggressive supporting system for that purpose has been required.
[0025] Thus despite the advances represented by the invention disclosed in NZ272574/272940 (providing compositions useful for an active system of administering ionophore antibiotics to ruminants), and despite assertions of EP139595, there continues to be a substantial need for compositions containing ionophore antibiotics which are inherently poorly soluble or insoluble in aqueous based systems, suitable for passive system administrations to ruminants. Such compositions must, to avoid under-dosing or toxic dosing, remain substantially homogeneous for extended periods of time.
[0026] The present invention investigates alternatives to such aggressive systems and targets a dosable composition capable of dispersion stability as a suspension in highly dilute drinking water for animals.
[0027] The present invention relies upon both a preferred smaller mean particle size of the ionophore antibiotic and an associated regime including related methods of manufacture, uses etc.
[0028] The present invention also recognises inter alia the therapeutic, energy and productivity benefits were monensin or any other suitable ionophore antibiotic (see the listing in our aforementioned patent specification, and below) to be used as a trough treatment.
[0029] Trough Treatment Systems
[0030] Currently three types of trough treatment system for animal drinking water and not hitherto used with an ionophore antibiotic are known.
[0031] Three types are in use:
[0032] 1. Proportional feed systems e.g. that branded DOSATRON™
[0033] delivers a %mix in proportion to demand (from 0.2-2% for dosatron). Aim is to spread delivery of the complete batch over 24 hours
[0034] 2. Dump systems
[0035] Continually delivers drench into lines regardless of demand. Tends to be all used up within 5 hours.
[0036] 3. Individual trough systems e.g. PETA™ dispenser
[0037] Delivers concentrated drench in relation to demand but pay out is skewed early on.
[0038] The present invention includes an ionophore antibiotic base composition capable of aqueous dilution which may be useful in such a trough treatment system. The object of the present invention is to provide such a composition and/or to provide drinking water for an animal to allow administration of an ionophore antibiotic to the animal.
[0039] We have determined that a microfine form of an ionophore antibiotic with its smaller mass to surface area ratio is a significant advantage over less fine (eg; 40 micron mean particle size) ionophore antibiotic inclusions in an aqueous composition and more so when it is to be used in such a way where it is subjected to unsupervised dilution, eg; to provide an infeed (directly or indirectly) into a dilution quantity of trough make up water. Such advantages to uniform suspendability we believe to be equally applicable to the more preferred crystalline forms as well as the less preferred mycellial forms of the ionophore(s).
[0040] We have also determined that a suitable glycol such as monopropylene glycol can be used in such a way to pre-prepare an ionophore antibiotic for subsequent suspension as a aqueous concentrate and thereafter to carry at least an antifreeze advantage over to its subsequent use (eg; as an infeed aqueous concentrate for a dose-certain water system) without leading to crashing out of the ionophore antibiotic. Glycols (such as monopropylene glycol) unless agressively treated provide no significant uptake of the stably suspended ionophore antibiotic (such as monensin) from an aqueous system. This we consider desirable since an organic uptake can lead to crashing out on dilution. For example, an organic solvent, such as methanol, allows monensin to crash out of solution if any water is added.
[0041] In the preferred forms of the present invention the ionophore antibiotic of choice is monensin in any of its appropriate forms (eg; sodium monensin). Other ionophore antibiotics however fall within the scope of the present invention and these include Lonomycin, Ionomycin, Laidlomycin, Nigericin, Grisorixin, Dianemycin, Lenoremycin, Salinomycin, Narasin, Antibiotic X206, Alborixin, Septamycin, Antibiotic A204, Maduramicin and Semduramicin, Compound 47224, Lasalocid (also including factors A, B, C, D and E), Mutalomycin, Isolasalocid A, Lysocellin, Tetronasin, Echeromycin, Antibiotic X-14766a, Antibiotic A23187, Antibiotic A32887, Compound 51532 and K41.
STATEMENTS OF THE INVENTION
[0042] In a first aspect the present invention consists in a method of forming an aqueous suspension capable of subsequent dilution, said method including prior to any substantial presence of water and/or a suspension agent (such as a suitable gum), milling the ionophore antibiotic or ionophore antibiotics (preferably in a crystalline form) with at least a suitable glycol.
[0043] Preferably said milling is to a mean particle size very much less than 40 microns.
[0044] Preferably the mean particle size is less than 20 microns, more preferably less than 5 microns and most preferably into a mean particle size of from 0.1 to 1.0 microns.
[0045] Preferably said milling includes the presence of a suitable lignosulfonate and/or a suitable polyglycoside.
[0046] Preferably said milling includes the presence of an antifoam agent.
[0047] Preferably said milling includes at least some water.
[0048] Preferably no suspension agent (eg; a gum typified by xanthan gum or guar gum) is present at said milling.
[0049] Preferably said method is performed substantially as hereinafter described with reference to the accompanying drawing.
[0050] Preferably the product includes as its suitable glycol monopropylene glycol.
[0051] Preferably the aqueous suspension is of a kind hereinafter described which includes monopropylene glycol, an additional wetting agent (eg; a lignosulfonate or polyglycoside or both) and a suspension agent.
[0052] Preferably the ionophore antibiotic is monensin and preferably that monensin is in a crystalline form.
[0053] In a further aspect the present invention consists in a method of forming an aqueous suspension of at least one ionophore antibiotic capable of subsequent dilution, said method including milling the ionophore antibiotic or ionophore antibiotics (preferably in a crystalline form) with at least a suitable polyglycoside or a suitable lignosulfonate.
[0054] Preferably said method performs part of a method as previously defined.
[0055] In yet a further aspect the present invention consists in a method of forming an aqueous suspension of at least one ionophore antibiotic capable of subsequent dilution, said method comprising or including
[0056] milling an ionophore antibiotic or ionophore antibiotics (preferably in a crystalline form) with at least (i) a suitable glycol and (ii) at least one of a suitable lignosulfonate and a suitable polyglycoside, and
[0057] subsequently formulating the suspension with at least water or, optionally, additional water.
[0058] Preferably said subsequent formulation involves the addition of a suitable dispersion agent.
[0059] Preferably said suitable dispersion agent is a suitable gum typified by xanthan gum and guar gum.
[0060] Other suitable dispersion agents include hydroxy-ethyl cellulose, bentonite clay, montrnorillinite clay and fumed silica.
[0061] Preferably said ionophore antibiotic is of sufficient purity as to minimise any requirement for an anti foaming agent but if an anti foaming agent is necessary, preferably said anti foaming agent is a GENSIL™ system, i.e. of simethicone/silicon dioxide support for the simethicone.
[0062] Preferably said suspension includes a buffer system.
[0063] Preferably said suspension includes a preservative.
[0064] Where reference is made to a suitable glycol preferably said glycol is a liquid and preferably said glycol assumes an anti freezing role in the resultant aqueous suspension.
[0065] Example of a suitable glycol is monopropylene glycol but other examples include ethylene glycol, diethylene glycol and dipropylene glycol.
[0066] Preferably the ionophore antibiotic or ionophore antibiotics is at least primarily of a crystalline form but in other forms it can in part be of the mycelial form. For example, if as is preferred, the ionophore antibiotic is monensin (e.g. present for example as sodium monensin), preferably the ionophore antibiotic is substantially free of the mycelial form. Were the mycelial formed to be utilised however, preferably there are commensurate changes in the inclusions to reflect the lesser activity of that form or an additional input to any dilution system to achieve appropriate activities.
[0067] Preferably said milling is in liquid supported conditions (preferably as a result of a liquid glycol inclusion), preferably with a minimum of water necessary for the purpose (if any), and preferably is such as to reduce the antibiotic to a microfine form.
[0068] In a preferred form of the present invention, irrespective of whether or not the milling is dry or in a liquid environment, preferably the ionophore antibiotic is reduced to a mean particle size less than 50 microns.
[0069] Preferably said mean particle size is reduced to less than 20 microns.
[0070] Most preferably the microfine condition of the ionophore antibiotic is to a mean particle size less than 5 microns.
[0071] Most preferably the mean particle size resulting from the milling procedure or procedures (can be a single or multiple milling procedures) is such as to provide a mean particle size of the preferably crystalline ionophore antibiotic (e.g. monensin) in a range of from 0.1 to 1.0 microns.
[0072] Preferably the milling stage or stages involves milling with a suitable polyglycoside or lignosulfonate, or both. One such polyglycoside is alkyl polyglycoside. One possible lignosulfonate compound is ULTRAZINE NA™ or BORRESPERSE NA™ [of Borregaard Industries Ltd of Norway] (most preferably ULTRAZINE NA™). Optionally GENSIL™ or another suitable antifoam agent is also milled with the crystalline monensin or other antibiotic.
[0073] Preferably the milling of all coating agents is simultaneous although it can be in part or totally serially.
[0074] In a preferred mix the ionophore antibiotic is milled simultaneously with liquid monopropylene glycol and a suitable polyglycoside and/or lignosulfonate compound (more preferably a lignosulfonate) having a “wetting” function and (optionally) an antifoam agent and/or some water.
[0075] In a further aspect the present invention consists in an aqueous suspension formed by one or more of the methods of the present invention.
[0076] In still a further aspect the present invention consists in an aqueous ionophore antibiotic suspension capable of further dilution without any substantial crashing out of the ionophore inclusion, said aqueous concentrate comprising or including
[0077] an ionophore antibiotic,
[0078] monoproplyene glycol (or other suitable glycol),
[0079] optionally a further material having a wetting characteristic,
[0080] a suspension agent,
[0081] optionally an antifoam agent, and water,
[0082] wherein at least the monopropylene glycol and the ionophore antibiotic have been milled together prior to mixing with the water or at least any substantial amount of the water.
[0083] Preferably the further material having a wetting characteristic is a suitable polyglycoside or lignosulfonate.
[0084] Preferably said suitable polyglycoside is alkyl polyglycoside although more preferably the additional wetting agent is a lignosulfonate typified by ULLTRAZINE NA™ or BORRESPERSE NA™ (more preferably ULIRAZINE NA™).
[0085] Preferably the ionophore antibiotic is a crystalline form rather than a mycellial form.
[0086] Preferably the ionophore antibiotic is monensin or a monensin.
[0087] Preferably the ionophore antibiotic at least post milling has a particle size less than 5 microns and more preferably below 2 microns.
[0088] Preferably the particle size range of the antibiotic is from 0.1 microns to 1.0 microns.
[0089] Preferably the aqueous ionophore antibiotic suspension remains substantially homogeneous for a period longer than 7 days; more preferably for a period longer than 24 days.
[0090] It does not matter whether or not the milling reduces the ionophore antibiotic to the requisite mean particle size or whether or not it is already milled almost to that size. What is important is to have resultant particles of that size appropriately coated with the “wetting” agents which includes preferably a multifunctional glycol (eg; monopropylene glycol) and preferably an additional wetting agent.
[0091] In a further aspect the present invention consists in an aqueous ionophore antibiotic suspension comprising or including
[0092] 0 to 20% w/v of a microfine (i.e. less than 40 micron mean particle size) crystalline ionophore antibiotic,
[0093] 2 to 20% w/v of monopropylene glycol,
[0094] 0 to 10% w/v of a wetting agent,
[0095] 0.1 to 5% w/v suspension agent, and
[0096] water.
[0097] Preferably the aqueous ionophore antibiotic suspension remains substantially homogeneous for a period longer than 7 days; more preferably for a period longer than 24 days.
[0098] Preferably the formulation is substantially as described in any one of Examples 1 to 5.
[0099] In another aspect the present invention is directed to a composition suitable for providing a direct in feed and/or indirect in feed (e.g. via a make up tank) into a water system from which target animal can drink,
[0100] said composition being an aqueous composition of (at least)
[0101] (a) microfine ionophore antibiotic or microfine ionophore antibiotics,
[0102] (b) a glycol in which the ionophore antibiotic(s) is or are no more than sparingly soluble,
[0103] (c) a wetting agent,
[0104] (d) a suspension agent, and
[0105] (e) water, and
[0106] optionally any one or more of
[0107] an antifoam agent or system,
[0108] a preservative,
[0109] a debittering agent, and
[0110] a pH buffering system.
[0111] Preferably the aqueous ionophore antibiotic suspension remains substantially homogeneous for a period longer than 7 days; more preferably for a period longer than 24 days.
[0112] Preferably said suspension agent is xanthan gum.
[0113] Preferably said wetting and/or surfactant agent (c) is a lignosulphonate (e.g. ULTRAZINE NA™N) or a polyglycoside (preferably alkyl polyglycoside).
[0114] Preferably said ionophore antibiotic is in either a crystalline or mycellial form or both.
[0115] Preferably a crystalline form is utilised.
[0116] Preferably said ionophore antibiotic is monensin (e.g. sodium monensin).
[0117] Preferably said microfine ionophore antibiotic is of a particle size less than 5 microns (preferably less than 2 microns) and preferably has a mean particle size in the range of from 0.1 to 1.0 microns.
[0118] Preferably xanthan gum is present and in a quantity greater than 0.16 w/v % and preferably about 0.4 w/v % (ie, the amount required being more for the more concentrated aqueous concentrate, eg; will unlimited dilute none may be required).
[0119] Preferably the mode of mixing and formulation is substantially as disclosed herein with a preferred composition being substantially as follows (wherein preferably the mean sodium monensin particle size is substantially 5 microns)—
Ingredient (common/chemical name) Quantity (% w/w) Function Sodium Monensin 6.33% (about 6% monensin) w/v Ionophore antibiotic Monopropylene glycol 10% w/v Antifreeze/ Alkyl Polyglycoside or 0.5% w/v Surfactant/Wetting agent ULTRAZINE NA ™ 4-5% w/v Disodium Phosphate Anhydrous 0.355% w/v Buffer MonoPotassium phosphate Dihydrate 0.04% w/v Buffer Dialkyl dimethyl ammonium bromide .0064% w/v Preservative Xanthan Gum 0.4% w/v Suspension agent Simethicone 0.333% w/v) (e.g. GENSIL ™ Silicon Dioxide 0.167% w/v) Antifoam system) Water to 100%
[0120] An alternative preferred formulation is (wherein preferably the mean sodium monensin particle size is substantially 5 microns):
Ingredient name (common or chemical) Quantity (% w/w) Function Sodium Monensin QA 166H 6.747% Active Monopropylene glycol 10% Antifreeze Didecyl dimethyl Ammonium 0.1% Preservative Bromide Xanthan Gum 0.5% Suspension agent Sodium lignosulphonate 4.1% Wetting agent Alkyl Polyglycoside 3.8% Wetting agent Simethicone 0.333% Antifoam Silicon Dioxide 0.167% Antifoam Water balance q.v 74.47% diluent
[0121] In other aspect the present invention is a pre mill mix or post mill mix of the present invention as hereinafter described.
[0122] In yet a further aspect the present invention consists in a composition for inclusion in a water trough fed in system being a composition as previously defined which without dilution is adapted to be in feed into the water supply.
[0123] In still a further aspect the present invention consists in a drinking water supply for an animal (preferably a ruminant animal) which has an in feed therein of a composition as previously defined.
[0124] In yet a further aspect the present invention consists in a method of providing an ionophore antibiotic to a target mammal which comprises providing to the animal drinking water with a dispersed ionophore antibiotic, said ionophore antibiotic having been included in the water supply by an intake from a composition as previously defined.
[0125] According to a further aspect of the invention there is provided an ionophore antibiotic composition capable of dilution with water to a substantially stable dispersed form in all water then present, said composition comprising or including:
[0126] at least one ionophore antibiotic of a mean particle size of less than 20 microns,
[0127] and at least one dispersing agent.
[0128] Preferably the mean particle size of at least one ionophore antibiotic is substantially 5 microns.
[0129] Preferably the dispensed form in water remains substantially homogeneous for at least 24 days.
[0130] Preferably the at least one dispersing agent is selected from one or more of the following:
[0131] i) a compatible polyglycoside capable of acting as a dispersing agent,
[0132] ii) a compatible lignosulfonate capable of acting as a dispersing agent, and
[0133] iii) a compatible and suitable glycol in a form capable of acting as a dispersing agent.
[0134] Preferably a liquid vehicle is or is also present which preferably is or includes water.
[0135] Preferably or alternatively said liquid vehicle is or includes one compatible liquid organic compound, preferably selected from mineral and vegetable oils.
[0136] Preferably the ionophore antibiotic(s) has been milled in the presence of at least one of:
[0137] i) a compatible polyglycoside capable of acting as a dispersing agent,
[0138] ii) a compatible lignosulfonate capable of acting as a dispersing agent, and
[0139] iii) a compatible and suitable glycol in a form capable of acting as a dispersing agent.
[0140] Preferably the milling is in the absence of any suspension agent, or alternatively a suspension agent selected from the gums as previously described is present; preferably the suspension agent is one or more of xanthan gum, guar gum, acacia gum and a cellulose gum.
[0141] Preferably a liquid vehicle(s) was present at the time of milling of the ionophore antibiotic sufficient to reduce the consistency of the mill mix to a millable consistency.
[0142] According to a further aspect of the invention there is provided animal drinking water having at least one particulate ionophore antibiotic substantially uniformly suspended therein, wherein the ionophore antibiotic is stably suspended.
[0143] Preferably the ionophore antibiotic remains stably suspended for at least 24 days.
[0144] Preferably particles of the ionophore antibiotic(s) are of a mean particle size of less than 10 microns; more preferably they are of a mean particle size of substantially 5 microns.
[0145] Preferably the drinking water is made by a proportioned mix dispensing there into of a more concentrated aqueous suspension of the ionophore antibiotic and dispersing agents present in that more concentrated aqueous suspension provides the substantially uniform dispersion of the ionophore antibiotic(s) in the drinking water.
[0146] Preferably the more concentrated aqueous suspension contains ore or more suspension agents.
[0147] According to a further aspect of the invention there is provided animal drinking water having at least one particulate ionophore antibiotic substantially uniformly suspended therein, wherein the particles of the ionophore antibiotics are of a mean particle size less than 10 microns; more preferably the particle size of the ionophore antibiotics are of a mean particle size of substantially 5 microns.
[0148] Preferably the ionophore antibiotic remains stably suspended for at least 24 days.
[0149] According to a further aspect of the invention there is provided trough water accessible to an animal to drink, the water having a particulate ionophore antibiotic substantially uniformly suspended therein, wherein the ionophore antibiotic is stably suspended. Preferably the ionophore antibiotic remains stably suspended for at least 24 days. Preferably the particles of the ionophore antibiotic(s) is of a mean particle size of less than 10 microns; more preferably the particles of the ionophore antibiotic(s) is of a mean particle size of substantially 5 microns.
[0150] Preferably the trough water is made by a proportioned mix dispensing there into of a more concentrated aqueous suspension of the ionophore antibiotic and dispersing agents present in that more concentrated form provides the substantially uniform dispersion of the ionophore antibiotic(s) in the drinking water.
[0151] Preferably the more concentrated aqueous suspension contains ore or more suspension agents.
[0152] According to a further aspect of the invention there is provided trough water accessible to an animal to drink the water having a particulate ionophore antibiotic substantially uniformly suspended therein, wherein the ionophore antibiotic remains stably suspended for at least 24 days.
[0153] Preferably the particle size of the ionophore antibiotics are substantially 5 microns. Preferably the ionophore antibiotic remains stably suspended for at least 24 days.
[0154] According to a further aspect of the invention there is provided a method of dispensing a particulate ionophore antibiotic into a body of drinking water which comprises or includes the steps of:
[0155] taking a composition comprising or including at least one ionophore antibiotic of mean particle size of less than 20 microns and at least one dispersing agent:
[0156] forming an aqueous suspension of the composition that has the ionophore antibiotic(s) substantially uniformly dispersed therein and which aqueous suspension is available for dispensing into animal drinking water, and
[0157] dispensing at a rate (continuously or continually), that aqueous suspension into the drinking water or a makeup supply of water thereto so as to provide the body of drinking water with a uniform dispersion of the ionophore antibiotic(s) therein which is within an acceptable imbibing concentration range for the animal or animals having access thereto.
[0158] Preferably the mean particle size of the at least one ionophore antibiotic is substantially 5 microns.
[0159] Preferably said composition is in the form of a stable aqueous suspension prior to the forming of an aqueous suspension and the subsequent dispensing thereof into the drinking water or a make up supply of water.
[0160] Preferably said composition includes one or more dispersing agent selected from one or more of the following:
[0161] i) a compatible polyglycoside capable of acting as a dispersing agent,
[0162] ii) a compatible lignosulfonate capable of acting as a dispersing agent, and
[0163] iii) a compatible and suitable glycol in a form capable of acting as a dispersing agent.
[0164] Preferably a suspension agent selected from gums (as previously described) is present.
[0165] Preferably the ionophore antibiotic(s) remains stably suspended for at least 24 days.
[0166] According to a further aspect of the invention there is provided a body of drinking water having a particulate ionophore suspended therein prepared by the method as previously described.
[0167] According to a further aspect of the invention there is provided a method of forming a suspendable composition of at least one ionophore antibiotic and which suspendable composition is capable of subsequent dilution, said method including, prior to any optional presence of water and optional presence of a suspension agent, milling the ionophore antibiotic(s) with a suitable glycol.
[0168] Preferably said milling takes place in the presence of at least some liquid, which preferably includes water.
[0169] Preferably no gum is present.
[0170] Preferably said milling is to a mean particle size very much less than 20 microns; more preferably the mean particle size is of about 5 microns.
[0171] Preferably the milling takes place in the presence of a suitable lignosulfonate.
[0172] Preferably said milling takes place in the presence of a suitable Polyglycoside.
[0173] Preferably said milling takes place in the presence of a suitable antifoam agent.
[0174] According to a further aspect of the invention there is provided a suspendable composition of at least one ionophore antibiotic prepared according to the method as previously described.
[0175] According to a further aspect of the invention there is provided a method of forming a suspendable composition of at least one ionophore antibiotic and which suspendable composition is capable of subsequent dilution, said method including, prior to any optional presence of water and optional presence of a suspension agent, milling the ionophore antibiotic(s) with a suitable dispersion agent.
[0176] Preferably the milling takes place in the presence of a suitable lignosulfonate. Preferably or alternatively said milling takes place in the presence of a suitable polyglycoside.
[0177] Preferably said suitable dispersion agent is selected from the group consisting of a suitable lignosulfonate and a suitable polyglycoside.
[0178] Preferably the mean particle size is less than 20 microns; more preferably less than 10 microns; even more preferably the mean particle size is substantially 5 microns.
[0179] Preferably said milling takes place in the presence of a suitable antifoam agent.
[0180] Preferably said milling takes place in the presence of at least some liquid.
[0181] Preferably a suitable glycol is present.
[0182] Preferably no gum is present.
[0183] According to a further aspect of the invention there is provided a dose dispensable ionophore antibiotic composition comprising or including:
[0184] at least one ionophore antibiotic,
[0185] at least one dispersing agent,
[0186] at least one suspension agent, and
[0187] water,
[0188] wherein the ionophore antibiotic(s) and at least one dispersing agent have been milled together in the presence of a liquid (which may be water or may include water but not necessarily so) and where the dispersing agent has been added post-milling in the presence of water.
[0189] Preferably the ionophore antibiotic is of a mean particle size of less than 50 microns; more preferably a mean particle size of less than 20 microns.
[0190] Preferably at least one suspension agent is or includes a gum and no such gum was present at the milling procedure.
[0191] Preferably some water was present at the milling procedure.
[0192] Preferably a polyglycoside was present as a dispersing agent at the milling stage.
[0193] Preferably a lignosulfonate was present as a dispersing agent at the milling stage.
[0194] Preferably a glycol was present as a dispersing agent at the milling stage.
[0195] Preferably an alkyl polyglycoside, a lignosulfonate and a propylene glycol are present at the milling stage.
[0196] Preferably any one or more of an antifoam agent or system, a preservative, a debittering agent and a pH buffering system is present.
[0197] According to a further aspect of the invention there is provided a milled product useful in providing an aqueous suspension of at least one ionophore antibiotic, said product being the milled outcome of a mill mix of at least
[0198] at least one ionophore antibiotic, and
[0199] at least one dispersing agent,
[0200] wherein the mill mix has been substantially free of suspension agents selected from the gums previously described and the mill mix has included at least one liquid component (which optionally can be the or one of the dispersing agent(s) or an additional material),
[0201] and wherein, in the product, the process of milling has resulted in some physical association of the or at least one dispersing agent on the ionophore antibiotic particles,
[0202] and wherein, in the product, the mean particle size of the ionophore antibiotic(s) is less than 20 microns.
[0203] Preferably the mean particle size is substantially 5 microns.
[0204] According to a further aspect of the invention there is provide a suspendable composition for substantial dilution by water, said method comprising or including:
[0205] (I) milling at least one ionophore antibiotic and at least one dispersing agent so as to provide some physical association of the or at least one dispersing agent on ionophore antibiotic particles of a mean particle size of less than 20 microns, and
[0206] (II) blending the post mill ionophore antibiotic(s)/dispersing agent(s) milled outcome with at least a suspension agent.
[0207] This invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more of said parts, elements or features, and where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.
[0208] The invention consists in the foregoing and also envisages constructions of which the following gives examples.
[0209] Definitions
[0210] Wherein the specification the following terms are used there are a number of possible alternatives, examples of which follow:
[0211] Surfactants/Dispersants:
[0212] sorbitan esters
[0213] ethoxylated sorbitan esters
[0214] castor oil ethoxylates
[0215] ethoxylated fatty acids
[0216] ethoxylated alcohols
[0217] polyethylene glycol fatty acids
[0218] condensed napthalene sulphonic acid
[0219] glycerol esters
[0220] phosphate esters
[0221] sodium lauryl sulphate
[0222] sodium polyacrylate
[0223] ammonium polyacrylate
[0224] octyl phenyl ethoxylates
[0225] nonyl phenyl ethoxylates
[0226] quaternary ammonium compounds
[0227] sulphosuccinates
[0228] soya lecithin
[0229] Suspending aids, including gums:
[0230] aluminium stearate
[0231] silicon dioxide
[0232] modified clay including Smectite, Monmorillonite, Hectorite, Bentonite
[0233] dehydrogenated castor oil
[0234] titanium chelates
[0235] alkali soluble acrylic polymers
[0236] nonionic diurethanes
[0237] polyvinyl pyrollidone
[0238] polyvinyl alcohol
[0239] guar gum
[0240] gum arabic
[0241] hydroxy propyl methyl cellulose
[0242] hydroxy ethyl cellulose
[0243] sodium carboxy methyl cellulose
[0244] hydrophobically modified hydroxy ethyl cellulose
[0245] Defoamers/Antifoams
[0246] polymethyl siloxane
[0247] unsaturated hydrocarbon oil
[0248] mineral oil
[0249] silica in oil type
[0250] Preservatives:
[0251] oxazolidines
[0252] benzothiazoles
[0253] benzalkonium chloride
[0254] substituted triazines
[0255] isothiazolones
[0256] hemiacetals
[0257] substituted benzoates
[0258] zinc pyridinethiol oxide
[0259] sodium pyridinethiol oxide
[0260] Buffering agents:
[0261] potassium tetroxalate
[0262] potassium hydrogen tartrate
[0263] potassium hydrogen phthalate
[0264] borax
DETAILED DESCRIPTION OF THE INVENTION
[0265] Preferred forms of the present invention will now be described with reference to the accompanying drawings in which
[0266] [0266]FIG. 1: shows one mixing procedure utilised in accordance with the invention,
[0267] [0267]FIG. 2: shows a second mixing procedure utilised in accordance with the invention, and
[0268] FIGS. 3 A- 3 C: illustrate a DOSTATRON™ trough treatment system in three different modes of operation.
[0269] Shown in FIGS. 3A to 3 C are three installations of a DOSATRON™ type installation used for dosing materials into drinking water. The DOSATRON™ apparatus is recommended as being usable in line (FIG. 3A), on a bypass line (FIG. 3B) and in parallel (FIG. 3C). In this respect see the publicity materials available from the New Zealand distributor Mark Bell-Booth Ltd.
[0270] The DOSATRON™ apparatus itself employees a dosing piston driven by a volumetric hydraulic piston motor. The spread rhythm of the motor is proportional to the flow of water passing through the system and thus the rate of injection will likewise remain proportional in its reciprocating motion.
[0271] The apparatus has the capability of a wide range of daily dose settings and the parallel arrangement shown in FIG. 3 allows these to be doubled owing to the use of two DOSATRON™ dispensing units.
[0272] Preferred forms will now be described with reference to the following examples of which the mixing procedures utilised is preferably as depicted and sequenced in one of FIG. 1 or 2 .
[0273] The present invention recognises that having evolved a suitable stable aqueous suspension of microfine monensin a predictable in feed thereof to animals is possible simply by providing to the animal drinking water which includes the microfine ionophore antibiotic dispersed therein, said ionophore antibiotic having been included in the water supply by an intake directly or indirectly from a composition as previously defined. The less dilute the concentrate the more suspension agent we have found to be desirable.
[0274] Preferably the composition is for use in one or more of the trough treatment systems available.
EXAMPLE 1
[0275] [0275] Sodium Monensin 6.33% (about 6% monensin) w/v Monopropylene glycol 10% w/v ULTRAZINE NA ™ 4-5% w/v Disodium Phosphate Anhydrous 0.355% w/v MonoPotassium phosphate Dihydrate 0.04% w/v Dialkyl dimethyl ammonium bromide .0064% w/v Xanthan Gum 0.4% w/v Simethicone ] GENSIL ™ 0.333% w/v Silicon Dioxide] Antifoam 0.167% w/v Water to 100%
[0276] Milling has resulted in a mean particle size for sodium monensin of 5 microns.
EXAMPLE 2
[0277] [0277] Sodium Monensin 6.33% (about 6% monensin) w/v Monopropylene glycol 10% w/v Alkyl Polyglycoside 0.5% w/v Disodium Phosphate Anhydrous 0.355% w/v MonoPotassium phosphate Dihydrate 0.04% w/v Dialkyl dimethyl ammonium bromide .0064% w/v Xanthan Gum 0.4% w/v Simethicone] GENSIL ™ 0.333% w/v Silicon Dioxide] Antifoam 0.167% w/v Water to 100%
[0278] Milling has resulted in a mean particle size for sodium monensin of 5 microns.
EXAMPLE 3
[0279] [0279] Sodium Monensin 6.33% (about 6% monensin) w/v Monopropylene glycol 10% w/v ULTRAZINE NA ™ 4-5% w/v Disodium Phosphate Anhydrous 0.355% w/v MonoPotassium phosphate Dihydrate 0.04% w/v Dialkyl dimethyl ammonium bromide .0064% w/v Xanthan Gum 0.4% w/v Simethicone] GENSIL ™ 0.333% w/v Silicon Dioxide] Antifoam 0.167% w/v Sorbitol as a Debittering agent 3.5% w/v Water to 100%
[0280] Milling has resulted in a mean particle size for sodium monensin of 5 microns.
EXAMPLE 4
[0281] [0281] Sodium Monensin 6.33% (about 6% monensin) w/v Monopropylene glycol 10% w/v Alkyl Polyglycoside 0.5% w/v Disodium Phosphate Anhydrous 0.355% w/v MonoPotassium phosphate Dihydrate 0.04% w/v Dialkyl dimethyl ammonium bromide .0064% w/v Xanthan Gum 0.4% w/v Simethicone] GENSIL ™ 0.333% w/v Silicon Dioxide] Antifoam 0.167% w/v Sorbitol as a Debittering agent 3.5% w/v Water to 100%
[0282] Milling has resulted in a mean particle size for sodium monensin of 5 microns.
EXAMPLE 5
[0283] [0283] Ingredient name (common or chemical) CAS number Quantity (% w/w) Function Sodium Monensin 17090-79-8 6.747% Active QA 166H Monopropylene 57-55-6 10% Antifreeze glycol Didecyl dimethyl 2390-68-3 0.1% Preservative Ammonium Bromide Xanthan Gum 11138-66-2 0.5% Suspension agent Sodium ligno- 8061-51-6 4.1% Wetting agent sulphonate Alkyl Polyglycoside 68515-73-1 3.8% Wetting agent Simethicone 8050-81-5 0.333% Antifoam Silicon Dioxide 7631-86-9 0.167% Antifoam Water balance q.v 7732-18-5 74.47% diluent
[0284] Milling has resulted in a mean particle size for sodium monensin of 5 microns.
[0285] Simethicone and Silicon dioxide together make up the proprietary brand “Gensil”.
[0286] 1. Preparation Procedure
[0287] The formulations of each of Examples 1 to 4 can be prepared by the procedure shown in FIG. 1. The formulation of Example 5 is prepared by the procedure shown in FIG. 2. The preferred method of preparing a formulation such as Example 1 is as follows.
[0288] As can been seen from FIGS. 1 and 2 a blending vessel (A) which can, if desired, be the horizontal bead mill (B) but is preferably not, and a blending vessel (C) are utilised as the apparatus.
[0289] Most preferably however there is a three stage equipment base for the process viz. blending vessel (A), horizontal bead mill (B) for microfining the ionophore antibiotic and a blending vessel (C).
[0290] As can be seen from FIG. 1 ingredients 1 through 6 are blended in the reference number sequence in the blending vessel (A) prior to passage into the horizontal bead mill (B). These pre-blended materials include:
[0291] monopropylene glycol,
[0292] dialkyl dimethyl ammonium bromide,
[0293] GENSIL™ antifoam,
[0294] some water,
[0295] ULTRAZINE NA™ wetting agent, and
[0296] monensin.
[0297] After the milling that premill mix, the product can be taken away either as an intermediate product (eg; post mill product) for subsequent use elsewhere for blending. Preferably however the output milled mix passes to blending vessel (C) where it is blended with the rest of the water (7), the remainder of the ULTRAZINE NA™ wetting agent (8) and the xanthan gum or other dispersion agent (9).
[0298] With a formulation whether to the formula of Example 1 or Example 3 or another (FIGS. 1 and 2 do not refer to the buffering system nor to a debittering agent) very good suspensibility is obtained both of the concentrate and of a subsequent diluted form (eg; in a trough usage where the dilution is, for example, to about 3 to 6 ppm monensin).
[0299] The numerals 1-9 (FIG. 1) or 1-11 (FIG. 2) indicate the preferred sequence of ingredient addition. With reference to FIG. 1, a pre-mill non sequenced mix of components 1 through 6 in the blending vessel (A) will still lead to a good mill mix yet is detrimental to the best suspensibility of the diluted form.
[0300] A preferred formulation as in Example 1 made by a procedure as in FIG. 1 has a capability of being added as an aqueous concentrate into a large volume of water such as might be experienced in providing an infeed into a water system.
[0301] It is important to note the following processing issues:
[0302] the order of addition of the components to the grind base premix is not critical
[0303] the appropriate particle size induced by the grinding operation is critical
[0304] the order of addition of the components in the makeup tank is critical.
[0305] 2. The Mill Mix
[0306] The mill mix is an important factor in the invention. It is the pre-mix of components which are added into the bead mill. The composition (identity and amount) is important in determining the ultimate particle size and the coatings on the particles which result. The relative quantities (eg of MPG: monensin) are important in this respect.
[0307] 3. Stability Data
[0308] a) Shelf Life Stability
[0309] The following shelf file stability data indicates the 6% concentrate exhibits stability, at differing temperatures for at least 3 months (the length of time of the trials).
[0310] Trough Treatment 6% Concentrate Shelf Life Study
Batch number: I183 Time 0 1 months 2 months 3 months Appearance Normal Normal Normal Normal 25° C. Sample Coliforms <1 <1 <1 <1 Monensin Biopotency 5.7 5.5 5.4 5.6 PH 8.11 8.00 7.77 7.51 Yeasts and Moulds <1 <1 <1 <1 APC <10 <10 <10 <10 42° C. Sample: Coliforms <1 <1 <1 <1 Monensin Biopotency 5.7 5.6 5.4 5.4 PH 8.11 7.60 7.39 7.28 Yeasts and Moulds <1 <1 <1 <1 APC <10 <10 <10 <10
[0311] b) Positional Stability
[0312] The following experiments detail the positional stability of the trough treatment of the invention (TT).
[0313] Positional stability studies were conducted with a DOSATRON™ trough treatment system. This is a proportional feed system which delivers a % mix in proportion to demand. Such an administration system is able to spread delivery of a complete batch over 24 hours.
[0314] [0314]FIG. 3 illustrates a dosation system used in obtaining the positional stability data
EXAMPLE 1
[0315] Trough Treatment (TT) (600 ppm) in a 200L plastic solution tank with a functioning Dosatron 8000.
[0316] Method:
[0317] 100 litres water were added to the solution tank connected to a Dosatron 8000.
[0318] [0318] 2 litres TT were mixed well with 2 litres water.
[0319] This mix was added to the half-full solution tank, filled to the 200 litre level, mixed thoroughly.
[0320] The Dosatron was set at 2% and the water flow at 400 litres/hour to ensure the solution tank is completely used within 24 hours.
[0321] The draw off tube from the Dosatron was set at a height 10 cm from the bottom of the tank.
[0322] Sampling
[0323] Samples for assay were taken from the draw-off taps. Before sampling, a 50 ml sample was drawn off and discarded. 1×100 ml samples are taken from each of the 4 taps set at either the top, middle or bottom of the tank. Samples will be taken at the specified time intervals.
[0324] Each sample taken was individually identified and 50 ml from each sample taken and to a pooled sample (total Vol 200 ml).
[0325] This sample was that assayed and the other samples retained.
[0326] Samples were also taken from the four-tap set, here positioned in the plastic tank at a level 10 cm from the bottom of the tank.
[0327] Samples were taken 0, 12, 24 hours after mixing.
[0328] After 24 hours a further 4×100 ml samples were taken from the bottom of the tank. Each sample taken was individually identified and 50 ml from each sample taken and pooled (total Vol 200 ml). This sample was assayed and the other samples retained. In this case the drench gun tube attached to the rod was used.
EXAMPLE 2
[0329] Measurement of the positional stability of the TT (3000 ppm) in a static 200 L plastic solution tank over a 4 day period
[0330] Method
[0331] Before filling the tank, the bottom tap hoses were bent so the end was 5 cm from the bottom of the tank.
[0332] 100 litres of water was added to the solution tank.
[0333] 10 litres of TT was mixed well with 10 litres water.
[0334] This mix was added to the half-full solution tank, filled to the 200 litre level and mixed.
[0335] Sampling
[0336] Samples for assay were taken from the draw-off taps. Before sampling, a 50 ml sample was drawn off and discarded. Each sample taken was individually identified and 50 ml from each sample taken and pooled (total Vol 200 ml). This sample was that assayed and the other samples retained.
[0337] Samples were taken from the top, middle and bottom of the tank at the intervals of 0, 12 hrs, 24 hrs, 2 days and 4 days after mixing.
EXAMPLE 3
[0338] Measurement of the positional stability of TT (6 ppm) in a concrete trough over a 24 day period.
[0339] Method
[0340] 50 litres of water was added to the solution tank connected to the Dosatron 8000. 1 litre of TF was mixed well with 1 litre water.
[0341] This mix was added to the half-full solution tank, filled to the 100 litre level and mixed.
[0342] Set the Dosatron at 1% to ensure a trough concentration of 6 ppm.
[0343] The trough was connected to the solution tank containing the Dosatron and TT.
[0344] The new concrete trough was scrubbed clean and the water in the trough pH tested before use.
[0345] A neutral pH (7-8) is acceptable.
[0346] The water was discarded before filling from the Dosatron 8000
[0347] Activation of the ball-cock filled the trough with TT (6 ppm).
[0348] After filling the trough herd drinking was simulated by siphoning water from the top of the trough to activate the ball-cock. 5000 litres was siphoned from the trough over a 24 hour period
[0349] Sampling
[0350] The draw-off tube from the drench gun was attached to a rigid pole. The end of the draw off tube was set to sample the trough from 3 levels—top, middle and bottom. 4×100 ml samples was taken from each position.
[0351] Each sample taken was individually identified and 50 ml from each sample taken and pooled (total Vol 200 ml).
[0352] This sample was that assayed and the other samples retained.
[0353] Sampling of the trough at the intervals of 0, 6 hrs, 12 hrs, 24 hrs, 5 days, 10 days and 24 days after mixing.
EXAMPLE 4
[0354] Measurement of the amount of monensin settling in the drum after mixing TT at 3000 ppm and leaving for 4 days undisturbed.
[0355] Methods
[0356] 100 litres water was added to the solution tank connected to the Dosatron 8000. 10 litres of TT was mixed with 10 litres of water.
[0357] This mix was added to the half-full solution tank, filled to the 200 litre level and mixed.
[0358] Sampling
[0359] Samples for assay were taken from the bottom of the tank.
[0360] Before sampling, opened all middle taps and bottom taps to provide a slow release of tank mix. The rate of removal of the fluid was slow enough so the bottom of the tank was not disturbed.
[0361] After the level of water fell below the bottom taps, mixed the bottom of the tank thoroughly and drew off 4×100 ml samples taken at different locations.
[0362] Each sample taken was individually identified and 50 ml from each of the samples taken and pooled (total Vol 200 ml).
[0363] The sample was that assayed and the other samples retained.
[0364] N. B Please calculate the volume of water left in the drum before taking the samples. This will be to calculate the total amount of monensin settling in the bottom of the tank after 4 days
[0365] Positional Stability Results and Discussion
[0366] The test had the following accuracy parameters:
[0367] Repeatability. The difference between results of duplicate portions of the same sample tested in the same run should not exceed 10% of the mean result. Recent results indicate that duplicate results are not exceeding 5.4% of the mean result.
[0368] Reproducibility: The difference between results of portions of the same sample tested at different times by different analysts should not exceed 15% of the mean result.
[0369] The repeatability and reproducibility data affords us quantifiable parameters for substantial homogeneity, indicating a substantially uniform suspension over time.
TABLE 1 Example 1 Results (600 ppm) Time Bottom Sample Result 0 hours 556 ppm 12 hours 504 ppm 24 hours 439 ppm
[0370] [0370] TABLE 2 Example 1 Repeated Trial Results (600 ppm) Time Bottom Sample Result 0 hours 580 ppm 12 hours 470 ppm 24 hours 420 ppm
[0371] [0371] TABLE 3 Example 2 Results (3000 ppm) Top Sample Middle Sample Bottom Sample Time (ppm) (ppm) (ppm) 0 hours 2970 2900 3030 12 hours 2680 2720 2760 24 hours 2930 2970 3060 2 days 2960 2950 3030 4 days 2190 2930 3050
[0372] [0372] TABLE 4 Example 3 Results (6 ppm) Top Sample Middle Sample Bottom Sample Time (ppm) (ppm) (ppm) 0 hours 5.0 5.5 5.1 6 hours 4.9 4.6 5.2 12 hours 4.7 4.9 5.0 24 hours 5.6 5.2 5.0 4 days 5.1 5.3 4.3 10 days 5.5 5.1 5.8 24 days 5.0 5.0 5.3 | The invention relates to an ionophore antibiotic composition capable of dilution with water to a substantially stable dispersed form in all water then present, said composition comprising or including:—at least one ionophore antibiotic (preferably monensin) of a mean particle size of less than 20 microns,—and at least one dispersing agent. A method of preparing the ionophore antibiotic composition is also disclosed. | 0 |
BACKGROUND
[0001] Downhole wellbores are utilized to extract methane gas from coal beds below ground. The amount of methane extracted can be increased by reducing the pressure on the coal bed. Typically, this is accomplished by removing water from above the beds. This reduces the pressure and thereby increases the rate at which methane is emitted from the coal. Water may be removed in a number of ways. De-watering pumps may be inserted into the wellbore and the water may be pumped out directly; however, traditional methods reach mechanical limits as the pressures decline. Alternatively, gas such as methane gas may be pumped into the wellbore, where it mixes with the water, to produce a mist or vapor that is then extracted from the wellbore.
Gas Lift Assembly and Methods
[0002] The systems and methods described herein may be utilized in wells that typically have been inaccessible to traditional gas lift methods. Such gas lift methods typically require excessive back pressures (and therefore casing packer completion) on the reservoir to operate properly. Indeed, even low water levels in a well bore can exert sufficient hydrostatic head to prevent gas flow. The systems and methods described herein can extract product gas from well with very low pressures at the well reservoir face.
[0003] Additionally, the systems and methods described herein can also be utilized in existing rod well pump applications with minimal modifications to the well. For example, the rods and pump can be removed from the well. Thereafter, the inner string, seal assembly, tool, and other components, can be inserted into the outer string and set in the seating nipple previously occupied by the rod pump. This seals the two strings and the reservoir to properly control gas flow. The configuration allows for a reduction in hydrostatic head and still enables lifting of water, in a mist form, to the surface. Use of the choke helps prevent excessive head in the inner string, and thus, prevents water from entering the tool.
[0004] In one aspect, the technology relates to an apparatus having an elongate body defining an interior chamber and a gas passage in communication with the interior chamber, the elongate body further includes a base defining a liquid opening and a cap defining an outlet opening, wherein the liquid opening is adapted to receive a liquid disposed in a wellbore, and wherein the gas passage is adapted to receive a gas, wherein an outlet of the gas passage is disposed a first distance from the base; and an inner conduit disposed in the interior chamber, and wherein the inner conduit includes: a first open end in communication with the liquid opening; and a second open end in communication with the interior chamber, wherein the second open end is disposed a second distance from the base.
[0005] In another aspect, the technology relates to an apparatus which includes an elongate body defining an interior chamber, a liquid inlet, a gas inlet in communication with the interior chamber, and a liquid-gas outlet in communication with the interior chamber; and an inner conduit disposed within the elongate body and in communication with liquid inlet, wherein the inner conduit defines a liquid outlet in communication with the interior chamber, and wherein the gas inlet is disposed a first distance from the liquid inlet and wherein the liquid outlet is disposed a second distance from the liquid inlet, wherein the second distance is less than the first distance.
[0006] In yet another aspect, the technology relates to a method which includes pressurizing, with a working gas, an outer string of a downhole wellbore so as to expel water from the outer string; pressurizing, with the working gas, an inner string of a downhole wellbore so as to expel water from the inner string and a tool disposed therein; reducing pressure in the inner string, wherein reducing pressure in the inner string allows water to enter the tool from an inlet; causing the working gas to flow from the outer string through the tool, wherein the flow of working gas and water, in combination, produce an upward flow of mist in the inner string; and collecting the mist from the inner string.
[0007] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The same number represents the same element or same type of element in all drawings.
[0009] FIG. 1A and 1B depict a schematic side sectional view of a wellbore.
[0010] FIG. 2 depicts a schematic side sectional view of one embodiment of a gas lift assembly.
[0011] FIG. 3 depicts a schematic side sectional view of the gas lift assembly of FIG. 2 disposed in a wellbore.
[0012] FIG. 4 depicts a schematic side sectional view of another embodiment of a gas lift assembly disposed in a wellbore.
[0013] FIG. 5 depicts a schematic side sectional view of another embodiment of a gas lift assembly disposed in a wellbore.
[0014] FIGS. 6A-6C depict a method of removing water from a downhole wellbore.
DETAILED DESCRIPTION
[0015] The present disclosure is directed generally to systems and methods that are utilized to extract methane gas product from a downhole wellbore. In general, an extraction tool is inserted into a wellbore and pressurized with a compressed working gas, to remove water present in the wellbore. The water is then entrained within the compressed working gas being injected around the tool. This entrainment produces a vapor, mist, or other generally lighter mixture of water and working gas that allows the water to be extracted from the wellbore. The tool allows the water table to drawn down to and maintained at the lowest reservoir level, thereby reducing the pressure on the coal bed and increasing the rate at which the coal bed generates gas.
[0016] Certain terminology used herein describes the relative relationships between pressures, flow rates, etc., as well as the states of the various fluids that are moved through the wellbore and tool. For example, use of the term “high pressure” in one portion of the wellbore does not necessarily mean that the pressure in that portion is at a certain measured threshold in excess of ambient. Instead, use of the term is meant to describe a condition where the pressure in one portion of the wellbore is higher than a pressure in another portion of the wellbore. In another example, the term “mist” or “vapor” is used to describe a mixture of water and working gas that is extracted from the wellbore utilizing the tools described herein. These terms are used for convenience to describe a condition where water is entrained within a working gas being injected upwards into the extraction tool and implies a state where a plurality of discrete, small volumes of water are separated from each other by a volume of working gas, such that the water can be lifted or otherwise extracted out of the wellbore by the pressure of the working gas. It is not necessarily utilized to mean a change in state of the water due to temperatures, pressure, or molecular changes, although such definitions are not excluded from the terms “mist” or “vapor” or similar terms used herein.
[0017] FIG. 1A and 1B depict a schematic side sectional view of a wellbore 100 . FIG. 1A depicts an upper portion of the wellbore 100 , while FIG. 1B depicts a lower portion thereof. The upper and lower portions are joined at line X-X, and can be any desired or required length. These two figures are described simultaneously. The wellbore 100 is drilled and lined with a casing 102 . A lower portion 104 of the casing 102 is perforated or screened so as to allow introduction of water W and natural gas into an interior of the casing 102 . An outer pipe or conduit, often referred to as an outer string 106 is inserted into the casing 102 . A number of components are fixed to a bottom portion of the outer string 106 such that they extend into the water W below the casing perforations. These include a perforated or otherwise open tailpipe 108 to allow passage of the water W, as does a seating nipple 114 that is disposed in the outer string 106 . In certain embodiments, the seating nipple 104 can be disposed in the outer string 106 approximately 30 feet above the end thereof. A screen 110 used to filter the water W during extraction operations and seal assembly 112 are secured to an inner pipe or conduit, referred to as an inner string 118 , is inserted into the outer string 106 . A no-go 116 is disposed about the inner string 118 and rests on the seating nipple 114 so as to prevent the inner string 118 from dropping further into the outer string 106 . A gas injection tool 200 (embodiments of which are described below) can be integral with, or inserted into, the inner string 118 .
[0018] A number of valved conduits are connected to the various internal volumes of the wellbore 100 . For example, a product valve 120 controls removal of a product P, such as methane gas, from an interior of the casing 102 . A working gas valve 122 controls the injection of a working gas G into the outer string 106 . An isolation valve 124 controls extraction of a mist M (formed of the working gas G and the water W) from the inner string 118 . Of course, other components may be installed on the various lines proximate the various valves 120 , 122 , 124 so as to control and monitor the various flows therein. Such components can include, for example, pressure regulators, temperature, pressure, and flow sensors, automatic emergency shut-off valves, and so on, as known in the art. Methods of utilizing the working gas G so as to remove the mist M (containing the water W) are described herein.
[0019] FIG. 2 depicts a schematic side sectional view of one embodiment of a gas lift assembly or tool 200 . The tool 200 is a generally elongate device that includes an elongate body 202 defining an interior chamber 204 . The body 202 includes a base 206 that defines a liquid inlet 208 for allowing entry of water W when the tool 200 is inserted into a wellbore. A choke 210 having a diameter less than that of the liquid inlet 208 may be disposed proximate thereto so as to limit the flow of water W into the tool 200 . An inner conduit 212 is disposed within the elongate body 202 and defines a liquid inlet 214 and a liquid outlet 216 . The liquid inlet 214 of the inner conduit 212 is in fluidic communication with the liquid inlet 208 defined by the base 206 . The elongate body 202 may include an outer wall 218 that defines a gas passage or gas inlet 220 therethrough. Each of the liquid outlet 216 and the gas passage 220 are spaced from the liquid inlet 208 in the base 206 . In the depicted embodiment, the liquid outlet 216 is disposed a distance D 1 from the base 206 , while the gas passage 220 is disposed a distance D 2 from the base 206 . In the depicted embodiment, the distance D 2 is less than the distance D 1 . This helps ensure proper mixing of gas G and water W so as to form a mist M for extraction from the inner string 118 . A no-go 222 connects the elongate body 202 to a cap 224 . The cap 224 includes an enlarged head 226 that functions as a retrieval neck, such as a configuration often referred to as a fishing neck, which allows the tool 200 to be lowered into the inner string 118 with a wireline unit during operation, and later removed as required or desired. The cap 224 defines a mist outlet 228 through which the mist M of gas G and water W exits during extraction operations. The depicted tool 200 also includes one or more seal assemblies 230 that substantially surround the elongate body 202 . The seal assemblies 230 allow for connection to one or more elements, not shown, that can aid in insertion of the tool 200 into the inner string 118 .
[0020] FIG. 3 depicts a schematic side sectional view of the gas lift assembly 200 of FIG. 2 disposed in a wellbore 100 . A casing 102 , such as that described above in FIGS. 1A and 1B is not depicted in whole for clarity. Additional elements of the wellbore 100 are described above with regard to FIGS. 1A and 1B and are therefore not necessarily described further. A number of components of the tool 200 are described above with regard to FIG. 2 and are therefore not necessarily described further. The tool 200 is disposed within an inner string 118 that is, in turn, disposed within an outer string 106 . The depicted tool 200 also includes two bore supports 232 , which help maintain alignment of the elongate body 202 within the inner string 118 along an axis A. In certain embodiments, the surfaces of the bore supports 232 may be polished or otherwise smooth to provide pressure containment between the seal assemblies 230 . The two bore supports 232 also create the chamber where gas can enter through the outer string to the tool 200 gaining access to the gas inlet 220 . The tool 200 is lowered into the inner string 118 until a desired depth is achieved. The inner string 118 defines one or more string gas passages 118 a , which allows passage of the working gas G from the outer string 106 into the inner string 118 . Notably, the string gas passages 118 a are disposed a distance D 3 from the no-go 116 . With this known distance D 3 , the tool 200 may be inserted such that the distance D 3 is less than both of distances D 2 and D 1 , as described above. Thus, when working gas G is injected downward into the outer string 106 , the direction of the gas G turns upwards as it enters the inner string 118 via the gas passages 118 a . Once within the inner string 118 , the working gas G travels upwards as it enters the elongate body 202 of the tool 200 through gas inlet 220 . The gas G is still travelling upward as it makes contact with and mists the water W that is flowing out from the liquid outlet 216 of the inner conduit 212 . By controlling the flow rate of gas, this upward flow of working gas G and water W efficiently mixes the gas G and water W such that a fine mist M is produced. This mist M is easily removed from the tool 200 via the mist outlet 228 , thereby dewatering the well. Long term operation of the dewatering tool, then, allows the water table near the well to be lowered and maintained substantially at the depth of the tool.
[0021] FIG. 4 depicts a schematic side sectional view of another embodiment of a gas lift assembly 300 disposed in a wellbore 100 . A number of the components of the wellbore 100 are described above and are therefore not necessarily described further. Certain components of the gas lift tool 300 are already described above with regard to the tool 200 depicted in FIG. 2 . These components are numbered similarly to the components of FIG. 2 (e.g., choke 210 , 310 ; interior chamber 204 , 304 ; etc.) and are not necessarily described further. The tool 300 in this embodiment is integrated into the inner string 118 and may comprise a bottom-most portion of the inner string 118 that is inserted into the outer string 106 . The tool 300 includes a manifold 350 that defines a plurality of passages, as described in more detail below. The manifold 350 may be secured in the inner string 118 above a choke 310 . At least one gas passage or inlet 320 penetrates the manifold 350 and the inner string 118 . Multiple gas passages 320 are joined within the manifold 350 so as to allow passage of a working gas G out of a single gas outlet 352 that is axially disposed within the manifold 350 and inner string 118 . Water W enters one or more conduits 312 formed in the manifold 350 at a liquid inlet 308 and exits the conduits 312 at a liquid outlet 316 . Here, a plurality of conduits 312 are formed about a circumference of the manifold 350 , but other locations within the tool 300 are contemplated. In the depicted embodiment, the gas outlet 352 may be a distance D 4 above the liquid outlets 316 . The water W and working gas G produce a mist M in the interior chamber 304 and may pass through a throat 354 having a reduced diameter, relative to the interior chamber 304 . This mist M then is discharged from, drawn out of, or otherwise expelled from the inner string 118 . Again, as with the embodiment of FIG. 3 , changing the direction of the working gas G to an upward flow prior to mixing with the water W helps efficiently produce the mist M.
[0022] FIG. 5 depicts a schematic side sectional view of another embodiment of a gas lift assembly 400 disposed in a wellbore 100 . A number of the components of the wellbore 100 are described and are therefore not necessarily described further. Certain components of the gas lift tool 400 are already described above with regard to the tools depicted in FIGS. 2 and 3 . These components are numbered similarly to the components of FIGS. 2 and 3 (e.g., choke 210 , 310 , 410 ; interior chamber 204 , 304 , 404 ; etc.) and are not necessarily described further. The tool 400 in this embodiment is integrated into the inner string 118 and may comprise a bottom-most portion of the inner string 118 that is inserted into the outer string 106 . A support 460 holds the inner conduit 412 in place and may align the conduit 412 within the inner string 118 along axis A. A liquid inlet 408 of the inner conduit 412 allows water W to enter the conduit 412 . One or more gas passages 420 penetrate the inner string 118 and are disposed a distance D 5 from the liquid inlet 408 . As with other embodiments described herein, gas passages 420 change the downward flow of the working gas G into an upward flow as it enters the inner string 118 . A choke 410 is disposed at an outlet 416 of the inner conduit 412 at a distance D 6 from the liquid inlet 408 . The water W and gas G mix in an interior chamber 404 and form a mist M that is discharged from the inner string 118 at the top of the well.
[0023] FIGS. 6A-6C depict a method 500 of removing water from a downhole wellbore 100 . Although the method 500 is depicted in parallel with a wellbore 100 configuration utilizing the tool 200 described above, a person of skill in the art would recognize the modifications required to utilize tool 300 , tool 400 , or other tool configurations, so as to perform the method 500 . The method 500 begins with insertion of a tool 200 into the wellbore 100 , defined by the casing 102 , operation 502 . In the depicted embodiment, the tool 200 is lowered L into the inner string 118 , so as to be disposed below a level of water W in the wellbore 100 . In other embodiments, the tool may be integral with the inner string 118 , such that when the inner string 118 is inserted into the outer string 106 , the tool is also inserted. As can be seen in the figure corresponding to operation 502 , water W is disposed in the wellbore 100 and enters the casing 102 at least through open portions 104 a of the casing 102 . Once disposed at the desired depth, operation 504 , the tool 200 is also filled with water W from the wellbore 100 , as depicted in the corresponding figure.
[0024] In operation 506 , a working gas G is used to pressurize the outer string 106 of the wellbore 100 , so as to expel water W from the outer string 106 . In operation 508 , working gas G is also used to pressurize the inner string 118 in operation 506 , so as to expel water W from both the inner string 118 and the tool 200 disposed therein. In general, operations 506 and 508 are performed substantially simultaneously, while water W continues to fill the space between the casing 102 and outer string 106 .
[0025] The purpose of operations 506 and 508 is to drive the water from the tool before the gas lift is initiated. Generally, it may be desirable that water W is expelled to a level below that of the string gas passages 118 a in the wall of the inner string 118 . As can be seen in the same figure, water W is substantially expelled from the tool 200 , so as to only be present at the liquid inlet 208 thereof.
[0026] The method 500 continues at operation 510 , where working gas G pressure on the inner string 118 is reduced. This allows water W, under pressure from the surrounding water table, to enter the tool 200 and flow up the inner conduit 212 thereof. Additionally, the working gas G flows from the outer string 106 , through the string gas passages 118 a and into the inner string 118 . The working gas G continues to flow upwards within the inner string 118 and then into the tool 200 via the tool gas passages 220 . In an alternative embodiment, the working gas G pressure within the inner string 118 may be maintained and the working gas G pressure in the outer string 106 may be increased to as to have the same effect. The interaction of the upwardly-flowing working gas G and water W in the interior chamber 204 produces a mist M that is expelled from the tool 200 and collected at the surface. Here, the water may be separated from the mist M.
[0027] This circulation of working gas G continues. In operation 512 , a flow rate of the water W entering the tool 200 or leaving the well may be monitored during the injection of the working gas G. This flow rate may be used as a basis to adjust the working gas circulation flow rate or adjust a differential pressure between the outer string 106 pressure and the inner string 118 pressure, as in operation 514 . As this injection of working gas G continues, mist M continues to be produced, which removes water W from the wellbore 100 , such that the level of water W outside the casing 102 drops below the level of the open portion 104 a thereof, as depicted in the figure accompanying operations 512 and 514 . In certain embodiments, the working gas G flow may be balanced against the water W flow so as to remove substantially all or all of the water W from the tool 200 as a mist M. Once the pressure on a nearby coal bed is reduced due to the removal of water W from the wellbore 100 as a mist M, methane gas product P is extracted, passively or actively, via the space between the casing 102 and the outer string 106 , as depicted in operation 516 and the accompanying figure.
[0028] Injection rates for the working gas G may be determined by the Coleman method “Critical Flow for Water Removal”. Based on wellhead pressures ranges from 5 to 50 psig, the required injection rates would range from 50 to 100 MCFD (thousand standard cubic feet/day, sometimes also shown as MSCFD) in order to lift water from the inner tubing string. The Coleman method “Critical Flow for Water Removal” is:
[0000]
v
c
(
water
)
=
4.43
(
67
-
0.0031
p
)
0.25
(
0.0031
p
)
0.5
Additionally,
[0029]
q
c
(
Mscf
/
D
)
=
3060
pv
c
A
Tz
[0000] In the above equations:
[0030] T tf =Flowing tubing temperature, ° R
[0031] q c =Critical flow rate, MCFD
[0032] p=Wellhead pressure, psi
[0033] v c =Critical velocity of water, ft/sec
[0034] A=Cross sectional area, ft 2
[0035] Z=Compressibility factor
[0036] A pressure/head differential from the wellbore/casing into the inner string is utilized so that the water W flows into the tool. The injected working gas G can carry the mist M to the surface. If the combined back pressure/head in the inner string is greater than the head pressure at the equivalent depth in the casing, no fluid will enter the tool, as depicted in the equation below:
[0000] ( P w )>( P t )
[0000] Where the inner string combined pressure at the tool (P t )=Surface Pressure+Working Gas Head+Water Head+Friction. The wellbore combined pressure (P w )=Surface Pressure+Working Gas Head+Water Head+Friction. For ease of application, certain assumptions may be made. For example, the Surface Pressure is assumed to be the same for both P t and P w . Additionally, the Working Gas Head is considered to be negligible (e.g., less than 5 psig). Friction in the casing is also assumed to be negligible, given the large diameter of the casing.
[0037] Thus, for P w to be greater than P t , Water Head in the wellbore must be greater than the Water Head in the inner string plus Friction in the inner string. In an embodiment, a ⅛″ choke is placed below the tool to regulate water flow into the inner string and keep the water head to a manageable level in the inner string (e.g., 0.25 to 3 GPM calculated). With typical tubing/inner string depth of 3000 ft., it takes less than about 2 minutes to clear the inner string of water. Additionally, the greater the working gas injection rate, the faster the inner string is cleared of water and the greater the reduction in water volume/head. An increase in working gas injection rate, however, increases friction. Conversely, when the working gas injection rate is lowered, the friction falls. This reduction in working gas injection rate, however, increases water head and allows more water to enter the inner string.
[0038] In one embodiment, a starting point for working gas injection is about 100 MCFD and it normally takes up to 30 minutes or more before mist M is seen at the surface. Water rates in the mist M range from 1 to 8 barrel of water per day (which indicates that the differential pressure of the wellbore to inner string is less than 1 psi). Wellbores utilizing the tools described herein may require 20 to 60 psig injection pressure at 100 MCFD injection rate with approximately 5 psig at the surface. In certain embodiments, inner string depths of about 1000 ft. are injected at about 20 psig, while inner string depths greater than 3500 ft. may require about 60 psig injection pressure. In other embodiments, wellbores may require more pressure, e.g., approximately 100 psig to inject 100 MCFD, depending on the configuration of the tool utilized. Because most of the pressure drop happens across the nozzle, the depth of inner string does not affect the injection pressure as much as the tool.
[0039] This disclosure described some embodiments of the present technology with reference to the accompanying drawings, in which only some of the possible embodiments were shown. Other aspects may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments were provided so that this disclosure was thorough and complete and fully conveyed the scope of the possible embodiments to those skilled in the art.
[0040] Although specific embodiments were described herein, the scope of the technology is not limited to those specific embodiments. One skilled in the art will recognize other embodiments or improvements that are within the scope and spirit of the present technology. Therefore, the specific structure, acts, or media are disclosed only as illustrative embodiments. The scope of the technology is defined by the following claims and any equivalents therein. | An apparatus has an elongate body defining an interior chamber and a gas passage in communication with the interior chamber. The elongate body further includes a base defining a liquid opening and a cap defining an outlet opening. The liquid opening is adapted to receive a liquid disposed in a wellbore. The gas passage is adapted to receive a gas. An outlet of the gas passage is disposed a first distance from the base and an inner conduit is disposed in the interior chamber. The inner conduit includes a first open end in communication with the liquid opening and a second open end in communication with the interior chamber. The second open end is disposed a second distance from the base. | 4 |
BACKGROUND OF THE INVENTION
1. FIELD OF THE INVENTION
The present invention relates to an electrical dust collector, and more particularly to an electrical dust collector for electrically collecting and removing particle impurities, such as dust particles, in air.
2. Description of the Prior Art
Known domestic or office air conditioners have been generally used for conditioning room air optimally and provided with an air filter for purifying the room air by filtering off particle impurities, such as dust particles. However, the known air filter has a problem in that it can not filter off micro impurities, such as cigarette smoke.
In order to overcome such a problem of the known air filter, there has been proposed several types of electrical dust collectors. FIG. 1 shows a construction of a general type of known electrical dust collector. As shown in this drawing, the electrical dust collector generally includes a main body 1 provided with an inlet 1a and an outlet 1b at opposite ends thereof, respectively. In the main body 1 between the inlet 1a and the outlet 1b, a plurality of dust collect electrodes 3 and a plurality of discharge electrodes 4 are longitudinally alternately arranged such that they face and parallel to each other. These electrodes 3 and 4 are applied with high voltages of opposite polarities supplied by a high voltage generator 2. The known electric dust collector further includes a blower 5 disposed at a position near the outlet 1b for causing the air to be introduced into the body 1 through the inlet 1a and exhausted therefrom through the outlet 1b after purification.
In operation of this type of known electric dust collector, the electrodes 3 and 4 are applied with negative (-) voltage and positive (+) voltage, both supplied by the high voltage generator 2, respectively. Hence, an ionization field is formed between the electrodes 3 and 4. In this condition, when the room air reaches the ionization field as result of blower operation, the dust particles in the room air are ionized by the discharge electrodes 4, which are applied with the positive (+) voltage as aforementioned, and positively charged. This positively charged dust particles are then collected by the dust collect electrodes 3 which are applied with the negative (-) voltage. The dust particles in the room air are, therefore, removed from the room air and the purified air is exhausted from the main body 1 through the outlet 1b.
However, it has been noted that the dust collect efficiently of the known electric dust collector is remarkably affected by construction and arrangement of the dust collect electrodes 3 and the discharge electrodes 4.
With reference to FIG. 2, which is a perspective view of an embodiment of a dust collect part of the know electric dust collector, this dust collect part includes a charged plate 6 provided with a plurality of openings 6a. This dust collect part further includes a plurality of discharge electrode plates 7 each of which is integrally formed with a plurality of wedge-shaped electrodes 7a horizontally extending from a longitudinal side of the plate 7. Here, all of the discharge electrode plates 7 are arranged with respect to the charged plate 6 such that their wedge-shaped electrodes 7aface predetermined positions of individual openings 6aof the charged plate 6. In addition, a plurality of dust collect plates 8 are arranged between the discharge electrode plates 7 such that the plates 7 and 8 are alternately disposed. The discharge plates 7 and the dust collect plates 8 are applied with positive (+) voltage and negative (-) voltage from a high voltage generator (not shown), respectively. In the same manner as described in the electrical dust collector of FIG. 1, the dust particles in the room air passing through the collector are ionized with cations by the wedge-shaped electrodes 7a of the discharge plates 7 applied with the positive (+) voltage, and positively charged. These positively charged dust particles are then collected by the dust collect plates 8 applied with the negative (-) voltage. Thus, the dust particles are removed from the room air and the purification of the room air is achieved.
However, it is very difficult to position the discharge electrode plates 7 with respect to the charged plate 6 such that the wedge-shaped electrodes 7a of the plates 7 accurately face the predetermined positions of the individual openings 6a of the charged plates 6. This reduces productivity and increases manufacturing cost. Furthermore, the dust particles are collected and coated by the additionally mounted dust collect plates 8 and this causes another problem of the dust collector to be resided in that the dust collect efficiency is inevitably deteriorated.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide an electrical dust collector in which the above problems of the prior are can be overcome, and of which a charged plate for collecting ionized dust particles has a plurality of vertically erected dust collect electrodes spaced from and facing individual erected discharge electrodes of a discharge plate thereby causing the assembling of the charged plate with the discharge plate to be easily achieved.
It is another object of the present invention to provide an electrical dust collector which reduces manufacturing cost.
It is still another object of the present invention to provide an electrical dust collector which improves dust collect efficiency by introducing uniform discharge between dust collect electrodes and discharge electrodes.
In accordance with a preferred embodiment of the present invention, the above objects can be accomplished by providing an electrical dust collector for collecting and removing dust particles in a room air by ionizing said dust particles comprising a charged plate being adapted for collecting the ionized dust particles and being provided with a plurality of through holes each of which has an erected dust collect electrode provided at a side thereof; and a discharge plate being adapted for ionizing the dust particles and being arranged to face and to be spaced apart from the charged plate with a distance provided between them, and being provided with a plurality of discharge electrodes which are erected in an opposite direction to the dust collect electrodes of the
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and aspects of the invention will become apparent from the following description of embodiments with reference to the accompanying drawings in which:
FIG. 1 is a schematic view showing a construction of a general type of known electric dust collector;
FIG. 2 is a partially exploded perspective view of an embodiment of a dust collect part of a known electric dust collector;
FIGS. 3A and 3B show an embodiment of a charged plate of an electrical dust collector according to the present invention, respectively, in which:
FIG. 3A is an elevational view; and
FIG. 3B is a side view;
FIGS. 4A and 4B show an embodiment of a discharge plate of an electrical dust collector according to the present invention, respectively, in which:
FIG. 4A is an elevational view; and
FIG. 4B is a side view;
FIG. 5 is an elevational view of a dust collect part provided by assembling the charged plate with the discharge plate of the present invention;
FIG. 6 is an enlarged sectional view of the circled section A of FIG. 5; and
FIGS. 7A and 7B are graphs showing relation of dust collect efficiency of the electrical dust collector of the present invention as a functioning of a distance between a dust collect electrode of the charged plate and a discharge electrode of the discharged plate.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The electrical dust collector of the present invention includes a charged plate 10 shown in FIGS. 3A and 3B. As depicted in these drawings, the charged plate 10, which is used for collecting ionized and positively charged dust particles when it includes a base portion 9 applied with negative (-) voltage, is provided with a plurality of generally rectangular through holes 10a. The holes are square, i.e., the width x 1 and length x 2 of each hole 10a are equal to each other. In addition, this charged plate 10 is integrally provided with a plurality of dust collect electrodes 11 at individual through holes 10a. In order to provide the dust collect electrodes 11 for the charged plate 10, each of the holes 10a is cut at three sides, and thereafter, the remaining cut part is erected at the other side of the hole 10a such that this remaining cut part is perpendicular to the plane of the charged plate 10. This erected cut part functions as the dust collect electrode 11.
Turning to FIGS. 4A and 4B, there is shown a discharge plate 20 which is made of a stainless steel and used for ionizing the dust particles when it is applied with positive (+) voltage. As depicted in FIG. 4A, this discharge plate 20 includes a base portion 19 provided with a plurality of through-holes in the shape of longitudinal openings 20a each of which is integrally provided with a plurality of wedge-shaped discharge electrodes 21 at a side thereof. As best seen in FIG. 4B, these wedge-shaped discharge electrodes 21 have individual sharpened tips and are erected such that they are perpendicular to the discharge plate 20.
Here, it is preferred to form the discharge electrodes 21 such that the distances y 1 , y 2 and y 3 between them are equal to each other.
Referring next to FIG. 5, the charged plate 10 and the discharge plate 20 are assembled into a dust collect part. In assembling the plates 10 and 20 into the dust collect part, the charged plate 10 is arranged in an insulating main body 30. The discharge plate 20 is, thereafter, arranged in the main body 30 such that the discharge plate 20 is parallel to and spaced apart from the charged plate 10 with a predetermined interval therebetween. As a result of such an assembling of the plates 10 and 20, the discharge electrodes 21 of the discharge plate 20 face individual dust collect electrodes 11 of the charged plate 10 in parallel and are spaced apart from the dust collect electrodes 11 by a predetermined distance.
Otherwise stated, as best seen in FIG. 6, each of the discharge electrodes 21 is arranged between two dust collect electrodes 11 of the charged plate 10 so as to be parallel to the dust collect electrodes 11.
Here, when let the distance between the dust collect electrode 11 and the discharge electrode 21 be x, let the width and the length of the through hole 10a of the charged plate 10 be x 1 and x 2 , respectively, let a thickness of the discharge electrode 21 be t, let the distances between the discharge electrodes 21 of the discharge plate 20 be y 1 , y 2 and y 3 , respectively, and let a gap between the charged plate 10 and the discharge electrode 21 be t 1 , the distance x between the electrodes 11 and 21 should be determined to satisfy following relation (1)
x.sub.1 /2-t≦x≦x.sub.1 /2+t/2 (1)
wherein x 1 =x 2 , y 1 =y 2 =y 3 and t=t 1 .
Referring to FIGS. 7A and 7B, there are shown graphs representing relation of dust collect efficiency of the electrical dust collector of this invention as a function of the distance x between the dust collect electrode 11 and the discharge electrode 21. As represented in FIG. 7A, the distance x of 6.0-6.5 mm produces the optimum dust collect efficiency of the dust collector when the average diameter of the dust particles in the room air is 0.3 μmm, and as indicated in FIG. 7B, the distance x of 6.0-6.9 mm produces the optimum dust collect efficiency of the dust collector when the average diameter of the dust particles is 0.5 μmm.
Hereinafter, the operational effect of the present electrical dust collector will be described.
Upon applying the positive (+) voltage to the discharge plate 20 at the same time of applying the negative (-) voltage to the charged plate 10, uniform electric potential and uniform electric field are provided between the plates 10 and 20. Such a uniform electric potential as well as the uniform electric field is provided because the dust collect electrodes 11 of the charged plate 10 and the discharge electrodes 21 of the discharge plate 20 are characteristically arranged, as aforementioned, such as that no wedge-shaped electrode is disposed in the through holes 10a of the charged plate 10.
The uniform electric potential and the uniform electric field prevent generation of corona discharge and this causes uniform discharge between the charged plate 10 and the discharge plate 20. Hence, the room air containing dust particles passing by the discharge electrodes 21 and passing through the through holes 10a of the charged plate 10 are applied with the high frequency of 800 Hz-1500 KHz. This causes the dust particles to be divided into micro particles which are in turn charged with cations. These positively charged micro dust particles are easily collected by the negatively charged plate 10.
As described above, the present invention provides an electrical dust collector which includes a discharge plate provided with a plurality of longitudinal openings, each having a plurality of vertically erected discharge electrodes having individual sharpened tips. The present dust collector further includes a charged plate having a plurality of through holes provided with individual dust collect electrodes. The discharge plate and the charged plate are assembled into a dust collect part such that the discharge electrodes of the discharge plate face individual dust collect electrodes of the charged plate in parallel and are spaced apart therefrom by a predetermined distance. Hence, the present invention causes a uniform discharge between the dust collect electrodes and the discharge electrodes and, as a result, provides an advantage in that the dust collect efficiency of the dust collector is remarkably improved. Furthermore, the charged plate and the discharge plate can be easily assembled. Thus, another advantage of this invention is resided in that the manufacturing cost of the electrical dust collector is reduced.
Having described specific preferred embodiments of the invention with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit of the invention as defined in the appended claims. | An electrical dust collector includes a discharge plate of one polarity and a dust collect plate of an opposite polarity arranged one in front of the other with respect to an air flow. The discharge plate includes a base portion formed with partial cut-outs that are bent outwardly to form discharge electrodes. The dust collect plate includes a base portion formed with partial cut-outs that are bent outwardly to form dust collect electrodes. The discharge electrodes project in opposite directions relative to the dust collect electrodes and are arranged to face respective dust collect electrodes. | 1 |
CROSS REFERENCES TO RELATED APPLICATIONS
This application is a U.S. national stage application of International Application No. PCT/F101/00319, filed Apr. 3, 2001, and claims priority on Finnish Application No. 20000788 filed Apr. 4, 2000, the disclosures of both of which applications are incorporated by reference herein.
STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
The present invention relates to paper and board machines. More specifically, the present invention relates to a method and an arrangement for controlling evaporation and moisture in a multinip calender when a continuous fibrous web is calendered in calendering nips placed one after the other before the fibrous web is wound on a reel-up/winder.
Calendering is a method by means of which the properties, such as smoothness, of a web-like material, such as a paper or board web, are sought to be generally improved. In calendering the web is passed into a nip which is formed between rolls pressed against each other and in which the web is deformed by the action of temperature, moisture and nip load, in which connection the physical properties of the web can be affected by controlling the above-mentioned parameters and the time of action, and the obtained smoothness is a function of the work done to the web.
In the papermaking art, grades of ever higher quality are required today. As the running speeds required of paper machines are continuously increasing, the direction in calendering technology is more and more towards on-line solutions, which include soft calendering and multinip on-line calendering. When the aim is to make higher quality printing paper grades having a PPS surface smoothness <2 μm, such as, for example, SC-A and LWC-roto grades and glossy coated paper grades, a substantial problem is that these kinds of grades can be produced in practice only by using, after drying a fibrous web, intermediate winding and off-line supercalenders, several of said supercalenders, usually three, being used side by side to meet production capacity.
Supercalendering is calendering in a calender unit in which nips are formed between a smooth-surface press roll, such as a metal roll, and a roll covered with a resilient cover, such as a polymer roll. The resilient-surface roll adapts itself to the contours of the surface of paper and presses the opposite side of paper evenly against the smooth-surface press roll. Today, the supercalender typically comprises 10-12 nips and for the purpose of treating the sides of the web, the supercalender comprises a so-called reversing nip in which there are two resilient-surface rolls against each other. Supercalendering is an off-line calendering method, and at the moment it provides the best paper qualities having a PPS surface smoothness <1.5 μm, such as, for example, WFC, LWC-roto and. SC-A. Multinip on-line calendering is calendering in a calender unit in which nips are formed between a smooth-surface press roll, such as a metal roll, and a roll covered with a resilient cover, such as a polymer roll, which rolls are placed alternately one after the other. The resilient-surface roll conforms to the contours of the surface of paper and presses the opposite side of paper evenly against the smooth-surface press roll. A multinip on-line calender unit typically comprises 8 rolls and 7 nips. Linear load increases in the multinip on-line calender, in the same manner as in the supercalender, from the top nip to the bottom nip because of the force of gravity. Multinip on-line calendering is a calendering method by means of which it is possible to produce grades having a PPS surface smoothness >1.0 μm, such as, for example, film coated LWC and SC-C as well as lower-quality offset LWC and SC-B. Soft calendering is calendering in a calender unit in which nips are formed between a smooth-surface press roll, such as a metal roll, and a roll covered with a resilient cover, such as a polymer roll. In a soft calender, the nips are formed between separate roll pairs. In order to treat both sides of the web in the soft calender, the order of the roll pairs forming the successive nips is inverted with respect to the web so that the resilient-surface roll may be caused to work on both surfaces of the web. Soft calendering is an on-line calendering method by means of which it is possible to produce grades having a PPS surface smoothness >1.5 μm, such as, for example, MFC and lower-quality film coated LWC as well as SC-C.
Linear load increases in multinip calenders from the top nip to the bottom nip because of the force of gravity. In order to eliminate this downwardly increasing linear load, to control the deflection line of the roll, and also to quickly open the set of rolls, today's multiroll calenders employ roll relieving which is accomplished by means of a cylinder and lever arm mechanism and which compensates for the force of gravity. One such relieving system for rolls is provided in OptiLoad™ calenders.
Smoothness/work done on OptiLoad™ calenders roughly complies with the pattern shown in the graph of FIG. 2 .
By means of the initial moisture content of the web before the calender and by means of the calendering temperature and steam treatments of the web the smoothness/impulse curve can be displaced, in particular in the temperature range of 100 EC-150 EC, typically by 0.2 μm in the smoothness scale in its direction.
Today, calendering problems are mainly caused by the following matters.
a. Initial moisture content, the number of steam treatments and calendering temperature are mainly determined on the basis of the final moisture content after calendering such that
i. when the final moisture content is too low, the web absorbs moisture, which results in deterioration of the achieved gloss in the form of after-roughening, and ii. when the final moisture content is too high, the drying of the web effectively destroys the obtained quality values.
b. On the other hand, determination of the initial moisture content in calendering is affected by the desired optical properties and the level of blackening. When the final moisture content becomes too high, the opacity, or translucence, of the web deteriorates, which appears in finished paper product as an increase in print-through values, and the level of blackening rises, which diminishes the selling value of paper in the form of reduced brightness and poor visual impression.
Because of these matters, the real control variables of a modern calender are relatively limited and the operating window of a single calender has become relatively narrow with increasing drying capacity of the calender. Today, quality can be successfully improved in practice only by increasing the number of nips of the calender. In connection with this, the controllability problem is aggravated by the fact that with increasing number of nips, difficulties also increase in setting the initial moisture content and initial temperature of the web such that curl of the web is avoided and that the web is still sufficiently moist in the lowermost nips of the calender and thus mouldable, which is of high significance for achieving smoothness in particular and also density.
In known multinip calenders, the web is usually passed from one nip to another by means of take-out or turning rolls, which are each situated at the take-out of the nip. It is also known that in connection with the take-out of the nip there are provided different steam boxes, spray devices and equivalent, by which attempts are made to control the change of the moisture content of the web.
Today, the final and initial moisture contents are largely dependent on the properties of fibre material and on the functional properties required of the end product, and since the best result is achieved by simultaneously controlling the calendering and final moisture content, which should be close to the equilibrium moisture content in a situation of final use in order to avoid large roughening and dimensional change effects, the primary object of the invention is not only to reduce the above-noted drawbacks and problems associated with calendering but also to generally improve control of evaporation and moisture in the calender in order to increase the quality potential at a given impulse level. Evaporation and drying of the web occurring in different running situations are strongly dependent on running speed, linear load and temperature, wherefore moisturizing and, thus, final quality and final moisture content are very difficult to control in different situations when there is a change in the calender. For this reason, an object of the invention is also to improve controllability in order that the moisture content of the web might be controlled in different situations of operation of the calender, for example, when there are changes in speed, roll temperatures and linear load.
SUMMARY OF THE INVENTION
The invention is thus based on the new and inventive idea that by replacing one or more take-out rolls with an air-float chamber of the turning airborne type, the net evaporation from and the final moisture content of the web can be made constant in different running situations. Thus, in accordance with the invention, it is advantageous that the calender comprises an air-float chamber of the turning airborne type in connection with the outlet of at least one nip. In a multiroll calender, the best result is achieved when there are several air-float chambers and preferably in connection with the outlet of each nip, in which connection moisture and evaporation can be made constant in the area of the entire calender, with the result that the web is not subject to large drying/moisturizing cycles, which is advantageous from the point of view of strength, dimensional stability, curling and after-roughening.
As an essential advantage associated with the invention it shall be further mentioned that by means of the invention retaining of the core moisture in the web is improved and, owing to this, higher temperatures can generally be used in calendering. The most effective way to mould, for example, paper is to mould fibre polymers at temperatures which are higher than the glass transition temperature, wherefore a substantial increase in temperature becomes possible in particular in multinip calenders with 6 and 8 rolls. With respect to advantages, it may be further mentioned that air-conditioning in the machine hall can be reduced and, in connection with SC paper, steam boxes can be dispensed with.
When the moisture level in a paper web is 5-10%, so-called glass transition temperatures are in the range of 120-90 EC, said glass transition temperature being the middle of the glass transition region characteristic of each fibre polymer pulp, such as mechanical and chemical fibre pulp, and the mouldability of pulp and thereby its capability of being calendered being at their best at said glass transition temperature. In a multinip calender with 6 or 8 rolls, in which the surface temperatures of the rolls are today typically 140-150 EC, because of high running speeds, the temperature of the web can rise only to the level of 80-70 EC, which is substantially below optimal calendering temperature, but the moisture control according to the invention makes it possible to preserve the core moisture of the web and thus to use higher calendering temperatures, with the result that the temperature of the web can be raised to an optimal level of 120-90 EC corresponding to the glass transition temperature. In calenders with 10 and 12 rolls, the temperature of the web rises because of the longer dwell time to a clearly higher level than in calenders with 6 and 8 rolls. In today's calenders with 10 or 12 rolls, typical drying of the web in the last nips, however, limits the use of temperatures and, in practice, the surface temperatures of rolls remain at about 120 EC and the temperature of the web remains at a level of about 90 EC, which is only just within the optimal calendering temperature range. Controlling moisture in accordance with the invention enables the core moisture of the web to be preserved and thus calendering temperatures to be used which are considerably higher than today's temperatures, i.e. 150 EC max, in which connection the temperature of the web can be raised to a clearly optimal level of 120-90 EC corresponding to the glass transition temperature. A further advantage of the invention is that the arrangement according to the invention for control of the moisture content of the web can be used instead of and/or in addition to steam boxes placed before the calender.
BRIEF DESCRIPTION OF THE DRAWINGS
With a view to explaining the advantages and details of the invention, the invention will be described below by means of one embodiment thereof, regarded as advantageous, by way of example with reference to the accompanying patent drawing of
FIG. 1 which schematically shows a multinip calender in accordance with the invention.
FIG. 2 is a graph showing the smoothness/work done on OptiLoad™ calenders.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1 , a multinip calender 10 is a calender of the supercalender type which comprises six rolls 11 , 12 , 13 , 14 , 15 and 16 and five nips 1 , 2 , 3 , 4 and 5 . In order to treat the sides of a web W, one nip 3 of the supercalender 10 is a so-called reversing nip, in which there are two resilient-surface rolls 13 and 14 against each other. This reversing nip 3 is in the running direction of the web W after the two topmost nips 1 and 2 before the two lowermost nips 4 and 5 , in which connection substantially identical nip impulses can be applied to the web W before and after the reversing nip 3 .
Polymer is a general name of macromolecular compounds. In partially crystalline polymers, such as in mechanical pulps, the composition of pulps corresponds to the original composition of wood, in which connection molecules are in the crystalline and amorphous regions. Typically, wood contains three different types of biopolymer: partially crystalline cellulose (crystallinity degree 45-90%), amorphous hemicelluloses and amorphous lignin. The proportion of these to one another varies from tree species to tree species. Norway spruce ( Picea abies ), which is most commonly used as raw material for mechanical pulp in the Nordic countries, contains about 42% of cellulose, about 28% of hemicelluloses and about 27% of lignin. The lignin content in chemical pulp is lower than in mechanical pulp. Pine sulphate pulp contains about 75% of cellulose, about 19% of hemicelluloses and about 6% of lignin. Deformations occurring in the fibre polymers of such mechanical and chemical pulps are dependent on time and partly irreversible, i.e. viscoelastic. Viscoelastic behaviour substantially depends on the shear rate, the structure of polymers, and temperature. Since the increase of temperature speeds up the movement of molecules and their segments, the increase of temperature causes the amorphous phase to react more quickly to an external force. In that connection, permanent deformations are brought about in the material by an external force of shorter duration. Below a certain temperature specific to each polymer, the amorphous phase is in the glass state, in which amorphous polymers and the amorphous parts of partially crystalline polymers have solidified so as to be hard and brittle. By the action of an external force, in the glass-state amorphous phase there may occur, in addition to reversible deformation (elastic component), permanent deformation (viscous component), which is called plastic deformation. An increase in the temperature of the amorphous phase occurring in the glass-state region does not affect its viscoelastic behaviour to any significant extent. When the temperature of polymer rises to the glass transition region, all the physical and mechanical properties of the amorphous phase of the polymer change drastically and a considerable increase in the proportion of the viscous component is observed in the viscoelastic behaviour of the amorphous phase. The middle of the glass transition region is known as the so-called glass transition temperature. Below the glass transition temperature, large-scale fast segmental movements of amorphous polymers are totally inhibited, but by raising the temperature in the glass transition region a situation is reached in which polymer segments are capable of sliding past one another because of their thermal energy. As an example of glass transition temperatures it may be mentioned that in bone dry conditions, depending on the crystallinity degree, the glass transition temperatures vary as follows:
for cellulose, in the range of 200. EC-250 EC, for hemicellulose, in the range of 150 EC-220 EC, and for lignin, in the range of 130 EC-205 EC.
Moisture has a lowering effect on these temperatures. It shall be noted that lignin is capable of absorbing moisture only to a limited degree, and its glass transition temperature remains constant when the moisture content exceeds 2.5%, and that when the moisture level rises over 5%, it can be found that mechanical pulp has two different glass transition temperatures, a lower one for the cellulose fraction and an upper one for the lignin fraction.
As shown in FIG. 1 , the web W runs around a guide roll 6
either, as shown in FIG. 1 , via an initial moisturizing device 17 , or directly from the guide roll 6 , which is enabled by the present invention, into the first, topmost nip 1 of the calender 10 , which nip is between the topmost rolls 11 and 12 of the calender. The lower roll of the roll pair 11 , 12 is in the example illustrated in FIG. 1 advantageously a smooth-surface press roll 12 , such as a metal roll, and the upper roll of the roll pair 11 , 12 is advantageously a roll 11 covered with a resilient cover, such as a polymer roll.
From the topmost nip 1 , the web W passes further into a secondary moisturizing device 21 , 22 which is disposed in connection with the outlet of the first nip 1 and between the outlet of the roll pair 11 , 12 forming the topmost nip 1 and a take-out or turning roll 7 placed after the roll pair and referred to hereafter with the term “turning roll”. After the secondary moisturizing device 21 , 22 , the web W runs over the turning roll 7 into the second calendering nip 2 , which is formed, like the first nip 1 , advantageously between a smooth-surface press roll 12 , such as a metal roll, and a roll 13 covered with a resilient cover, such as a polymer roll. A difference between the first and second nips 1 and 2 is that the roll 11 covered with a resilient cover is the upper roll in the first nip 1 , while the roll 13 covered with a resilient cover is the lower roll in the second nip 2 .
The web W passes from the second nip 2 into an air-float chamber 20 of the turning airborne type of the invention disposed in connection with the outlet of the second nip 2 , which chamber also functions as a means for turning the running direction of the web W and for guiding it into the third nip, which is the reversing nip 3 of the calender, said nip being between two rolls 13 and 14 covered with a resilient cover, such as polymer rolls, in which connection work is done to both sides of the web W by means of a resilient-surface roll. In that connection, no turning roll is needed in the portion between the second nip 2 and the third nip 3 .
The web W runs from the third nip 3 over a turning roll 7 into the fourth calendering nip 4 , which is formed, like the first nip 1 , advantageously between a smooth-surface press roll 15 , such as a metal roll, which is the lower roll of the fourth nip 4 , and a roll 14 covered with a resilient cover, such as a polymer roll, which is the upper roll of the fourth nip 4 .
FIG. 1 does not illustrate the possibility that an air-float chamber 20 of the web W according to the invention can also be disposed in connection with the outlet of the first nip 1 , the third nip 3 and/or the fourth nip 4 .
From the fourth nip 4 the web W runs again over a turning roll 7 into the fifth calendering nip 5 , which is formed, like the second calendering nip 2 , advantageously between a smooth-surface press roll 15 , such as a metal roll, which is the upper roll of the fifth nip 5 , and a roll 16 covered with a resilient cover, such as a polymer roll, which is the lower roll of the fifth nip 5 .
In the exemplifying case shown in FIG. 1 , after the fifth nip 5 , the web W is arranged to run via a closed draw instead of a free draw in order that the temperature and moisture content of the web might be regulated by means of a temperature and moisture regulation unit 8 , which is, for example, an infrared airborne web-dryer, even still after the fifth nip 5 before the last turning roll 7 , from which the web W runs to a reel-up/winder 9 .
Thus, in accordance with the invention, there is an air-float chamber of the turning airborne type or an equivalent in connection with the take-out of at least one nip 1 , 2 , 3 , 4 , 5 of the calender 10 for the purpose of controlling the moisture content of the web W, which chamber is closed and extends across the entire width of the web W. Advantageously, an air-float chamber 20 is placed in connection with the take-out of each nip 1 , 2 , 3 , 4 and 5 of the calender 10 , in which connection the compensation of evaporation and moisture is distributed and equalized uniformly over the entire area of the calender 10 . This means that the web will not be liable to large drying/moisturizing cycles, which is advantageous from the point of view of strength, dimensional stability, curling and after-roughening.
In the embodiment shown in FIG. 1 , the secondary web moisturizing means 21 , 22 is disposed in connection with the lake-out of the first nip 1 . The secondary moisturizing means 21 , 22 according to this embodiment, situated between the outlet of the nip 1 and the turning roll 7 situated after the roll pair 11 , 12 forming the nip 1 , is a closed steam or air blow box, spray device, atomizing device or device which operates according to a given control to control evaporation and comprising an upper hood part 21 defining inside it an upper pocket that affects the web W from above and a lower hood part 22 defining inside it a lower pocket affecting the web W from below, said box/device/means extending across the entire width of the web W. In this kind of secondary moisturizing device formed of the hood parts 21 and 22 , the web W runs between the hood parts 21 and 22 and it uses steam, water or moist air for moisturizing the web W. It is advantageous that the feed of a moisturizing medium, in particular its feed pressure and feed temperature as well as feed amount, into the upper or the lower hood part 21 or 22 is independent of the feed of a moisturizing medium into the other hood part 22 or 21 , respectively, in which connection regulation of the temperature of and evaporation from one side of the web W is independent of the temperature of and evaporation from the other side of the web W. In order that the moisturizing of the web W might also be regulated in the CD direction transverse to the machine direction of the paper machine, it is advantageous that the hood parts 21 and 22 are divided into compartments by means of partition walls in this cross machine direction, in which connection, for example, the edge parts of the web W can be moisturized differently from the middle parts of the web.
In the embodiment shown in FIG. 1 , the air-float chamber 20 of the turning airborne type for the web is disposed in connection with the take-out of the second nip 2 . The air-float chamber 20 in accordance with this embodiment is closed and extends across the entire width of the web W. In the air-float chamber 20 , the run of the web W passes in the air-conditioned passage of the air-float chamber, in which the web W is not in contact with the walls defining the passage and which is defined by an outer blow box 23 and an inner blow box 24 , which both blow air or steam to the web, the temperatures, moisture contents and flow quantities of said air or steam being adjustable independently of one another in order to moisturize the web W. It is advantageous that the feed of a medium, in particular its feed pressure, feed temperature and feed quantity, into the outer blow box 23 is independent of the feed of a medium fed into the inner blow box 24 and vice versa, in which connection regulation of the temperature of and evaporation from one side of the web W is independent of regulation of the temperature of and evaporation from the other side of the web W. In order that the moisture content of and evaporation from the web W might also be regulated in the cross direction with respect to the machine direction of the paper machine, it is advantageous that the blow boxes 23 and 24 are compartmentalized or divided in this cross direction, in which connection, for example, the edge parts of the web W can be treated differently from the middle parts of the web.
In accordance with an application of another embodiment of the invention regarded as advantageous, the air-float chamber 20 includes, enclosed in a common housing:
a turning device whose surface facing the web W is curved outwards and which is not in contact with the web, the turning device serving as an inner blow box 24 and its curved surface facing the web W being perforated, and an outer blow box 23 whose surface facing the web W is curved inwards and which is not in contact with the web and whose curved surface facing the web W is perforated.
The curved surface of the outer blow box 23 substantially corresponds in shape to the curved surface of the inner blow box 24 , but its radius of curvature is larger than the radius of curvature of the inner blow box 24 for forming for the web W a passage that extends through the air-float chamber 20 and which is not in contact with the web W.
Since in the secondary moisturizing device in accordance with the invention, the hood parts 21 and 22 as well as the blow boxes 23 and 24 blow a feed pressure, feed temperature and feed quantity, into the outer blow box 23 is independent of the feed of a medium fed into the inner blow box 24 and vice versa, in which connection regulation of the temperature of and evaporation from one side of the web W is independent of regulation of the temperature of and evaporation from the other side of the web W. In order that the moisture content of and evaporation from the web W might also be regulated in the cross direction with respect to the machine direction of the paper machine, it is advantageous that the blow boxes 23 and 24 are compartmentalized or divided in this cross direction, in which connection, for example, the edge parts of the web W can be treated differently from the middle parts of the web.
In accordance with an application of another embodiment of the invention regarded as advantageous, the air-float chamber 20 includes, enclosed in a common housing:
a turning device whose surface facing the web W is curved outwards and which is not in contact with the web, the turning device serving as an inner blow box 24 and its curved surface facing the web W being perforated, and an outer blow box 23 whose surface facing the web W is curved inwards and which is not in contact with the web and whose curved surface facing the web W is perforated.
The curved surface of the outer blow box 23 substantially corresponds in shape to the curved surface of the inner blow box 24 , but its radius of curvature is larger than the radius of curvature of the inner blow box 24 for forming for the web W a passage that extends through the air-float chamber 20 and which is not in contact with the web W.
Since in the secondary moisturizing device in accordance with the invention, the hood parts 21 and 22 as well as the blow boxes 23 and 24 blow a medium to the opposite surfaces of the web W, the blow flows act as blow flows that reduce the medium flow through the web W, which, on the one hand, assures contactless running of the web W through the secondary moisturizing device 21 , 22 and through the air-float chamber 20 and, on the other hand, facilitates the forming of a medium bed, causing the web W to float, between the web W and the lower hood part 22 or the inner blow box 24 . An advantage of the medium flows supplied to both sides of the web W is also that the different sides of the web can be treated independently of each other in different ways.
In this connection, it must be noted that, from the point of view of operativeness of the invention, it is not necessary to apply medium flows to both sides of the web W in the secondary moisturizing device 21 ,_ 22 or in the air-float chamber 20 , since it is sufficient for adequate control of evaporation and moisture that the medium flow is applied only to one surface of the web W, in which connection it is advantageous that the medium flow is directed at the web such that it is possible to achieve the effect of floating the web W.
Above, the invention has been described only by way of example with the help of some of its embodiments regarded as advantageous. This is, of course, not intended to limit the invention and, as is clear to a person skilled in the art, many different alternative arrangements and modifications are feasible within the inventive idea and in its scope of protection defined in the accompanying claims. It shall be particularly noted that the invention can be used widely in different multinip calender applications and that also other gaseous mediums can be used instead of air and steam | A method and an arrangement for controlling evaporation and moisture in a multinip calender ( 10 ) when a continuous fibrous web (W) is calendered in calendering nips ( 1, _ 2, — 3, — 4, — 5 ) placed one after the other before the fibrous web is wound on a reel-up/winder ( 9 ). With a view to making the net evaporation from and the final moisture content of the web (W) constant when the running situations in the calender ( 10 ) change, the web is passed in the calender from the outlet of at least one nip into an air-float chamber ( 20 ) of the turning airborne type. | 3 |
[0001] This patent application claims priority from a Provisional Patent Application filed on Oct. 20, 2000, having Ser. No. 60/241,951.
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] This invention pertains to the art of internal combustion engines, and more particularly to the art of methods and apparatuses for easily starting such internal combustion engines, and most specifically, in the preferred embodiment, a method and apparatus for easily starting an internal combustion engine mounted on a lawn and garden apparatus, such as a lawn mower, a snow thrower, a chipper/shredder, a tiller, or other types of lawn and garden devices powered by internal combustion engines.
[0004] 2. Description of the Related Art
[0005] It is well known to affix an internal combustion engine to a lawn and garden apparatus. It is also known to affix a handle to such apparatuses so that an operator can direct an apparatus over the desired portion of the lawn or garden. It is known to affix throttle mechanisms to the handle of such apparatuses. It is also known to affix a bail to such handles to provide an “operator present” safety feature.
[0006] However, it has not heretofore been known to provide an apparatus and method for starting an internal combustion engine by means of a bail and, an optional throttle control, and a starting assembly mounted on a handle.
[0007] Turning to FIG. 1, a typical walk-behind lawn mower 100 is shown. However, it is important to understand that the invention has equal applicability to a wide variety of products powered by internal combustion engines having power outputs ranging from 1 horsepower to 15 horsepower. The invention is most applicable and generally designed for lawn mowers with horsepower ranges small enough to be typically started by hand, i.e., without the benefit of an electric starter. In the typical application, the operator must pull on a string or cable, which is wrapped around the flywheel of the engine. As the operator pulls on the cable, the cable unwinds, perhaps a length of five feet. As it unwinds, the rope turns the engine, causing the spark plug to fire and, hopefully, creating enough compression, spark, fuel, etc. to start the engine. Sometimes, the operator must pull on the cable more than once, even several times, in order to start the engine.
[0008] Because of the physical effort involved in starting an engine by way of a pull cable, some operators have difficulty starting the engine. Others are simply physically unable to generate the force necessary to pull hard enough on the pull cable to start the engine. Because of this problem, persons that are generally less strong, for example smaller people, females, elderly, or those suffering from shoulder and arm injuries, may not be able to operate the lawn and garden apparatus without assistance. For operators who generally have the strength and endurance to continually pull the pull cable, the present invention is convenient.
[0009] The Briggs & Stratton Corporation made an important development in this area when they developed an engine, which was introduced in the year 2000 . This engine utilized a spring within a canister to store energy generated by the engine flywheel. In essence, the engine needed to be started the first time by the pull cable. However, when the engine was stopped, for example by turning the engine off, the flywheel driven by the engine possessed a certain amount of momentum. The Briggs & Stratton invention utilized this energy possessed by the flywheel to start the engine the next time. The brake was applied to the flywheel so that energy was transferred from the flywheel to a relaxed spring. The spring was mounted within a canister. As the braking mechanism slowed revolutions of the flywheel, the spring was coiled within the canister. By this mechanism, kinetic energy from the flywheel was stored as potential energy within the coiled spring. The next time the operator wanted to start the engine, the energy stored in the coiled spring was sufficient to cause the engine to turn and for the combustion process to begin.
[0010] The applicant believed that improvements were desirable in the system designed by Briggs & Stratton. The applicant then invented what is believed to be an improved method and apparatus for starting the Briggs & Stratton engine. That improved method and apparatus would be discussed as follows.
SUMMARY OF THE INVENTION
[0011] An apparatus and method for starting an engine is provided. An apparatus comprises a frame and an internal combustion engine operatively mounted to the frame. A control member is operatively connected to the frame, wherein the control member has an activated position and a deactivated position. The control member is adapted to complete an engine circuit when in the activated position. An energy storage medium is operatively associated with the engine such that release of energy stored in the energy storage medium turns the engine and facilitates its starting. A starting assembly is utilized to release the stored energy in the energy storage medium. Accordingly, it is an object of the present invention to provide an apparatus and method for starting an internal combustion engine, which requires an operator to utilize two separate and distinct actions, activating the control member and activating the starting assembly, to restart the internal combustion engine.
[0012] It is yet another object of the present invention to provide an apparatus, wherein the control member is a bail.
[0013] Another object of the present invention is to provide an apparatus, wherein the energy storage medium is a canister assembly comprising a spring within a canister, the spring being adapted to absorb kinetic energy from a flywheel of the engine when the engine is disabled.
[0014] Further, another object of the present invention is to provide an apparatus, wherein the starting assembly further comprises a cable operatively associated with the frame, the cable having a first end and a second end, the second end of the cable being connected to the energy storage medium, wherein stored energy is adapted to be released when a predetermined amount of force places tension on the cable.
[0015] Yet, another object of the present invention is to provide an apparatus, wherein the apparatus further comprises a handle operatively mounted to the frame, and the starting assembly further comprises a hook attached to the handle, the cable adapted to pass through the hook, and a cap attached to the first end of the cable, the cap adapted to maintain the cable within the hook.
[0016] Still another object of the present invention is to provide an apparatus, wherein the control member is a bail, the apparatus further comprising a handle operatively mounted to the frame, the starting assembly further comprising:
[0017] a U-shaped rod having a first end and a second end, the second end attaching the bail to the handle;
[0018] a button having a stem extending therefrom, the stem attaching to the rod; and, a bracket attached to the first end of the rod, the bracket extending upwardly and outwardly from the first end, the bracket having a receiving means, the cable connected to the bracket, the receiving means adapted to engage the stem.
[0019] Another object of the present invention is to provide an apparatus, wherein the control member is a bail, the apparatus further comprising a handle operatively mounted to the frame, the starting assembly further comprising:
[0020] a U-shaped bracket having the cable attached thereto, the U-shaped bracket having legs extending therefrom, each of the legs having at least one hole defined therein for receiving the bail;
[0021] first biasing means for biasing the U-shaped bracket in a substantially upright position;
[0022] a second bracket fixedly attached to the bail, the bracket having a top and a bottom, the top and the bottom having an aperture defined therein;
[0023] a button operatively connected to the second bracket, the button having a stem attached thereto, the apertures receiving the stem, the stem adapted to be positioned in an interfering relationship with the U-shaped bracket when the button is depressed; and,
[0024] second biasing means disposed between the top and bottom of the second bracket, the biasing means biasing the button and the stem in a substantially upright position.
[0025] Yet another object of the present invention is to provide an apparatus, wherein the first biasing means is a spring, the second biasing means is a spring, and the second spring adapted to receive the stem of the button.
[0026] Still other benefits and advantages of the invention will become apparent to those skilled in the art to which it pertains upon a reading and understanding of the following detailed specification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The invention may take physical form in certain parts and arrangement of parts, a preferred embodiment of which will be described in detail in this specification and illustrated in the accompanying drawings which form a part hereof and herein:
[0028] [0028]FIG. 1 is a side elevational view of a lawn care vehicle with a schematic representation of the canister assembly.
[0029] [0029]FIG. 2 is a perspective view of a first embodiment of the starting assembly showing a bail lock out feature, a hook and a cap.
[0030] [0030]FIG. 3 is an enlarged view of the starting assembly shown in FIG. 2 wherein the bail is in the activated position.
[0031] [0031]FIG. 4 is an enlarged view of the starting assembly shown in FIG. 2 wherein the bail is in the deactivated position.
[0032] [0032]FIG. 5 is a perspective view of a second embodiment of the starting assembly illustrating a lock out trigger and a trigger lever in a first position such that fuel cannot flow to the engine.
[0033] [0033]FIG. 6 is another perspective view of the starting assembly showing the lock out trigger and the trigger lever in the second position to enable fuel flow.
[0034] [0034]FIG. 7 is a perspective view of a third embodiment of the starting assembly in a deactivated position.
[0035] [0035]FIG. 8 is a perspective view of the third embodiment of the starting assembly showing the button being slightly depressed.
[0036] [0036]FIG. 9 is another perspective of the third embodiment of the starting assembly showing the receiving means engaging the first member of the button.
[0037] [0037]FIG. 10 is yet another perspective view of the third embodiment of the starting assembly showing the bail rotating the first receiving member of the starting assembly to release stored energy from the energy storage medium.
[0038] [0038]FIG. 11 is a top perspective view of the fourth embodiment of the starting assembly mounted to the frame of a lawn care vehicle.
[0039] [0039]FIG. 12 is a perspective view of a fourth embodiment of the starting assembly showing the stem of the button in a non-interference position with the U-shaped bracket.
[0040] [0040]FIG. 13 is another perspective view of the fourth embodiment of the starting assembly showing the stem of the button in an interference position with the U-shaped bracket.
[0041] [0041]FIG. 14 is enlarged perspective view of the fourth embodiment of the starting assembly shown in FIG. 12.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0042] Referring now to the drawings wherein the showings are for purposes of illustrating a preferred embodiment of the invention only and not for purposes of limiting the same, the present invention is illustrated in FIGS. 1 - 14 .
[0043] With reference to FIGS. 1 - 15 , the inventive method and apparatus will be disclosed in the context of a walk-behind lawn mower. However, as already stated earlier in this specification, the invention is not limited to lawn mowers or the specific embodiments shown in the FIGURES. The lawn mower 100 features an internal combustion engine 110 , a deck 120 , a handle 130 , and wheels 132 . Beneath the deck 120 , as shown in the cut away FIG. 1, is one or more blades 140 which are rotated by the engine 110 . Mounted onto the handle 130 is a bail 128 , which may be spring biased.
[0044] In operation to start the engine 110 , the bail 128 performs two functions. First, the bail 128 completes the associated engine circuit and allows power to be transferred to the engine 128 and, secondly, the bail 128 unlocks the throttle to facilitate the transfer of fuel to the engine 110 . However, for the engine 110 to start, energy must be transferred to the spark plug to cause the spark plug to fire. This invention utilizes a spring within a canister system 150 designed by Briggs & Stratton Corporation of Milwaukee, Wis. This canister system 150 provides the energy needed to turn a flywheel 112 of the engine 110 , and thus, start the engine 110 . The canister system 150 is operatively connected to both the engine 110 and a starting assembly 160 .
[0045] In operation to start the engine 110 , both the starting assembly 160 and the bail 128 must be activated to start the engine 110 . Activation of the starting assembly 160 causes the energy stored in the canister system 150 to be released so that the spark plugs can be fired. While, activation of the bail 128 completes the associated engine circuit and opens the throttle so that fuel can flow to the engine 110 . Therefore, a user must use a first hand to activate the starting assembly 160 and a second hand to activate the bail 128 . Since both of the user's hands must be on the handle 130 to start the mower 100 , this increases the safety of the mower 100 .
[0046] With reference to FIGS. 2 - 4 , the first embodiment of the starting assembly 160 features a bail 128 mounted onto a handle 130 with a lock out feature 102 . The method of operation is that the operator would first move the lock out feature 102 to a second position as shown in FIG. 3. This enables the bail 128 to be depressed. The bail 128 was then depressed and, by that mechanism, the energy in the spring was released and the engine would start.
[0047] Still viewing FIGS. 2 - 4 , the starting assembly 160 includes cable 162 , such as a nylon cord, having first and second ends 166 , 168 , a cap 170 attached to the first end 166 of the cable 162 , and a hook 172 attached to the handle 130 . The second end 168 of the cable 162 is connected to the canister system 150 and extends upwardly therefrom and through the hook 172 . The cap 170 prevents the cable 162 from slipping through the hook 172 . When the starting assembly 160 is in its inactivated state, there is no tension on the cable 162 and, thus, the canister system 150 is not activated. However, the starting assembly 160 can be activated by pulling on the cap 170 in an upward direction to place tension on the cable 162 , which causes the energy stored within the canister assembly 152 to be released.
[0048] With reference to FIGS. 5 and 6, a second embodiment of the starting assembly 160 is shown. In this embodiment, a starting assembly 160 is mounted to the handle 130 . The starting assembly 160 includes lock out trigger 114 . In normal operation, the bail 128 moves from a first position as shown in FIG. 5 to a second position as shown in FIG. 6. When the bail 128 is in the second position, it contacts the handle 130 ; however, the engine 110 does not start. The bail 128 moves the lock out trigger 114 from a first position, as shown in FIG. 5, to a second position as shown in FIG. 6. The lock out trigger 114 functions to enable the throttle to be opened. When the lock out trigger 114 is in the first position, as shown in FIG. 5, a mechanical lock (not shown) prevents a throttle lever 118 from being moved from a first position, as shown in FIG. 5, to a second position as in FIG. 6. The throttle lever 118 may be spring-loaded. When the throttle lever 118 is in the first position, no fuel flows to the engine 110 . However, when the throttle lever 118 is moved away from the handle 130 and into the second position, or positions between the first position and the second position, various amounts of fuel flow to the engine 110 . As illustrated in FIG. 6, when the throttle lever 118 is in the second position, the engine 110 is being provided the maximum prescribed amount of fuel. When the bail is released, the throttle lever 118 and the lock out trigger 114 return to their first positions as shown in FIG. 5, which stops the engine 110 .
[0049] In operation to start the engine 110 , the bail 128 is rotated towards the handle 130 as shown in FIG. 6. The bail 128 contacts and pushes the lock out trigger 114 downward. The mechanical lock releases the throttle lever 118 such that the throttle lever 118 can be selectively rotated. Next, the throttle lever 118 is moved forward, meaning away from the handle 130 , which enables various amounts of fuel to flow to the engine 110 . Once the throttle lever 118 achieves a position to permit fuel to flow to the engine 110 , energy is released from the energy storage medium 150 to restart the engine 110 . Releasing the bail 128 causes the throttle lever 118 to return to its original position shown in FIG. 5.
[0050] With reference to FIGS. 7 - 10 , a third embodiment of the starting assembly 160 is shown. In this embodiment, only the starting assembly 160 and the bail 128 are mounted onto the handle 130 . However, the starting assembly 160 and the bail 128 perform the same functions that they performed in the first embodiment, namely, the starting assembly 160 releases the energy stored in the canister system 150 and the bail 128 completes the associated engine circuit and unlocks the throttle to allow fuel to flow to the engine 110 .
[0051] The primary difference between the first, second and third embodiments is the design of the starting assembly 160 . The starting assembly 160 is comprised of a U-shaped rod 180 having a first end 182 , a middle 184 , and a second end 186 that attaches the bail 128 to the handle 130 . The middle 184 of the rod 180 is attached to a first member 188 having a button 190 . The button 190 causes the first member 188 to extend in an outward direction toward the handle 130 when the button 190 is depressed. A bracket 192 having a first receiving means 194 is attached to the second end 186 of the rod 180 and extends upwardly and outwardly therefrom. The cable 162 , which attaches the canister system 150 to the starting assembly 160 , is connected to the bracket 192 .
[0052] In operation to start the engine 110 , the bail 128 is depressed towards the handle 130 to complete the associated engine circuit and unlock the throttle. However, the engine cannot be started by just depressing the bail 128 . When the bail 128 is depressed, the starting assembly 160 is also rotated in the direction of the handle 130 . However, the housing 161 surrounding the starting assembly 160 is sufficiently large enough so that rotation of the bail 128 will not cause the bracket 192 to rotate. It is the rotation of the bracket 192 , which is attached to the cable 162 that applies tension to the cable 162 and thereby causes the canister system 150 to release its stored energy. The bracket 192 is only rotated when the button 190 is depressed. When the button 190 is depressed, the first member 188 extends outwardly which engages the first receiving member 194 of the bracket 192 . Once the first member 188 engages the first receiving member 194 of the bracket 192 , rotation of the bail 128 will also cause rotation of the bracket 192 . This rotation causes tension to be applied to the cable 162 , which also causes the canister system 150 to release its energy.
[0053] In operation to start the engine 110 , the button 190 must be depressed before the bail 128 is activated. If the bail 128 is activated first, the first member 188 will have been rotated away from the first receiving member 194 and, thus, the first member 188 cannot engage the first receiving member 194 to activate the canister system 150 .
[0054] Accordingly, in this embodiment, a user must also have both hands positioned on the handle 130 to start the mower 100 . The user must use a first hand to depress the button 190 of the starting assembly 160 . In addition, the user must use a second hand to depress the bail 128 .
[0055] With reference to FIGS. 11 - 14 , a fourth embodiment of the starting assembly 160 is shown. Except for the design of the starting assembly 160 , this embodiment is very similar to the third embodiment since it also requires a two-step process of pressing the button 190 and then pulling a bail 128 back, in order to start the engine 110 . The starting assembly 160 also includes a housing (not shown), which is very similar to the housing shown in FIG. 8.
[0056] Still viewing FIGS. 11 - 14 , the starting assembly 160 is comprised of a first U-shaped bracket 200 having a first end 202 , a middle 204 , and a second end 206 . The cable 162 is attached to the U-shaped bracket 200 . The cable 162 is operatively associated with the handle 130 . As shown in the FIGURES, the cable 162 runs down the length of the handle 130 and connects to the engine 110 . At the lower end of the first and second ends 202 , 206 of the U-shaped bracket 200 , holes are defined therein and receive the bail 128 . A first biasing means 208 fits around the bail 128 between the first and second ends 202 , 206 of the bracket 200 . As shown in FIGS. 11 - 14 , the first biasing means 208 may be a spring 209 , which biases the bail 128 , including the button 190 to the bracket 200 . The cable 162 exerts attention on this bracket 200 biasing it toward a substantially upright position.
[0057] Above the U-shaped bracket 200 , the button 190 with a stem 191 is positioned onto the bail 128 . This button 190 and stem 191 are received within a second bracket 210 that is fixedly attached to the bail 128 . This second bracket 210 has a top 212 and a bottom 214 , each with an opening 216 that receives the button stem 191 . Between the top 212 and the bottom 214 of the second bracket 210 , a second biasing means 216 , which could also be a spring 218 , receives the button stem 191 . This spring 218 biases the button 190 and stem 191 toward a substantially upright position. When the button 190 is pressed, the lower end of the stem 191 extends into an interference position with the U-shaped bracket 200 .
[0058] In operation to start the engine 110 , both the bail 128 and the starting assembly 160 must be activated to start the mower 100 . The bail 128 can be depressed without depressing the button 190 , but this will not supply tension to the cable 162 and, thus, the energy in the canister system 152 will not be released. The engine 110 can only be started by first activating the starting assembly 160 and then depressing the bail 128 . To start the engine 110 , the operator first presses the button 190 . This causes the button stem 191 to extend in front of the U-shaped bracket 200 . While holding the button 191 down, and, therefore, holding the interference between the button 190 and the U-shaped bracket 200 , the operator pulls the bail 128 backwards towards the handle 130 . This increases the tension in the cable 162 , permitting the mower engine 1 10 to start. It should be noted that, once the bail 128 is pulled back to the running condition, the biasing of the first spring 209 maintains the button stem 191 into its extended position. It should be noted that, if the operator does not press the button 190 , the bail 128 can still be moved backwards towards the handle 130 . However, the U-shaped bracket 200 , in this condition, does not move back and, therefore, the engine 1 10 is not started. If the engine 110 has been started and is running, with the bail 128 in the forward back position, and the operator lets go of the bail 128 , both the bail 128 and the U-shaped bracket 200 are pulled forward and the engine 110 is stopped. Accordingly, a user must use both hands to start the engine 110 , which allows for safe starting of the engine 110 .
[0059] The invention has been described with reference to preferred embodiment. Obviously, modifications and alterations will occur to others upon a reading and understanding of this specification. It is intended to include all such modifications and alternations in so far as they come within the scope of the appended claims or the equivalence thereof.
[0060] Having thus described the invention, it is now claimed: | The present invention is an apparatus and method for starting an engine. An apparatus comprises a frame and an internal combustion engine operatively mounted to the frame. A control member is operatively connected to the frame, wherein the control member has an activated position and a deactivated position. The control member adapted to complete an engine circuit when in the activated position. An energy storage medium is operatively associated with the engine such that release of energy stored in the energy storage medium turns the engine and facilitates its starting. A starting assembly is utilized to release the stored energy in the energy storage medium. As such, an operator must utilize two separate and distinct actions, activating the control member and activating the starting assembly, to restart the internal combustion engine. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is continuation application of U.S. application Ser. No. 12/801,952, filed Jul. 2, 2010, which was a continuation of U.S. application Ser. No. 12/659,980, filed Mar. 26, 2010, which issued as U.S. Pat. No. 7,797,970, which was a divisional of U.S. application Ser. No. 11/806,245, filed May 30, 2007, which issued as U.S. Pat. No. 7,743,633, which in turn claims the benefit of Korean Patent Application Nos. 2006-49501 and 2006-49482, both filed on Jun. 1, 2006, in the Korean Intellectual Property Office, the disclosures of which are incorporated herein by reference.
BACKGROUND
[0002] 1. Field
[0003] The present invention relates generally to a washing machine having at least one balancer, and more particularly to a washing machine having at least one balancer that increases durability by reinforcing strength and that is installed on a rotating tub in a convenient way.
[0004] 2. Description of the Related Art
[0005] In general, washing machines do the laundry by spinning a spin tub containing the laundry by driving the spin tub with a driving motor. In a washing process, the spin tub is spun forward and backward at a low speed. In a dehydrating process, the spin tub is spun in one direction at a high speed.
[0006] When the spin tub is spun at a high speed in the dehydrating process, if the laundry leans to one side without uniform distribution in the spin tub or if the laundry leans to one side by an abrupt acceleration of the spin tub in the early stage of the dehydrating process, the spin tub undergoes a misalignment between the center of gravity and the center of rotation, which thus causes noise and vibration. The repetition of this phenomenon causes parts, such as a spin tub and its rotating shaft, a driving motor, etc., to break or to undergo a reduced life span.
[0007] Particularly, a drum type washing machine has a structure in which the spin tub containing laundry is horizontally disposed, and when the spin tub is spun at a high speed when the laundry is collected on the bottom of the spin tub by gravity in the dehydrating process, the spin tub undergoes a misalignment between the center of gravity and the center of rotation, thus resulting in a high possibility of causing excess noise and vibration.
[0008] Thus, the drum type washing machine is typically provided with at least one balancer for maintaining a dynamic balance of the spin tub. A balancer may also be applied to an upright type washing machine in which the spin tub is vertically installed.
[0009] An example of a washing machine having ball balancers is disclosed in Korean Patent Publication No. 1999-0038279. The ball balancers of a conventional washing machine include racers installed on the top and the bottom of a spin tub in order to maintain a dynamic balance when the spin tub is spun at a high speed, and steel balls and viscous oil are disposed within the racers to freely move in the racers.
[0010] Thus, when the spin tub is spun without maintaining a dynamic balance due to an unbalanced eccentric structure of the spin tub itself and lopsided distribution of the laundry in the spin tub, the steel balls compensate for this imbalance, and thus the spin tub can maintain the dynamic balance.
[0011] However, the ball balancers of the conventional washing machine have a structure in which upper and lower plates formed of plastic by injection molding are fused to each other, and a plurality of steel balls are disposed between the fused plates to make a circular motion, so that the ball balancers are continuously supplied with centrifugal force that is generated when the steel balls make a circular motion, and thus are deformed at walls thereof, which reduces the life span of the balancer.
[0012] Further, the ball balancers of the conventional washing machine do not have a means for guiding the ball balancers to be installed on the spin tub in place, so that it takes time to assemble the balancers to the spin tub.
[0013] In addition, the ball balancers of the conventional washing machine have a structure in which a racer includes upper and lower plates fused to each other, so that fusion scraps generated during fusion fall down both inwardly and outwardly of the racer. The fusion scraps that fall down inwardly of the racer prevent motion of the balls in the racer, and simultaneously result in generating vibration and noise.
SUMMARY
[0014] Accordingly, the present invention has been made to solve the above-mentioned problems occurring in the prior art, and an object of the present invention is to provide a washing machine having at least one balancer that increases durability by reinforcing the strength of the balancer, which is installed on a rotating tub in a rapid and convenient way.
[0015] Another object of the present invention is to provide a washing machine having at least one balancer, in which fusion scraps generated by fusion of the balancer are prevented from falling down inward and outward of the balancer.
[0016] Additional aspects and/or advantages of the invention will be set forth in part in the description which follows and, in part, will be apparent from the description, or may be learned by practice of the invention.
[0017] In order to accomplish these objects, according to an aspect of the present invention, there is provided a washing machine having a spin tub to hold laundry to be washed and at least one balancer. The balancer includes first and second housings, the first housing having at least one support for reinforcing a strength of the balancer. The first and second housings have an annular shape and are fused together to form a closed internal space.
[0018] Here, the first housing may have the cross section of an approximately “C” shape, and the support protrudes outwardly from at least one of opposite walls of the first housing.
[0019] Further, the spin tub may include at least one annular recess corresponding to the balancer such that the balancer is able to be coupled to the spin tub by being fitted within the recess.
[0020] Further, the support may protrude from the first housing and comes into contact with a wall of the recess, and guides the balancer to be maintained in the recess in place.
[0021] Also, the supports may be continuously formed along and perpendicular to the opposite walls of the first housing.
[0022] Further, the supports may be disposed parallel to the opposite walls of the first housing at regular intervals.
[0023] Meanwhile, the washing machine may be a drum type washing machine. A front member may be attached to a front end of the spin tub and a rear member may be attached to a rear end of the spin tub. The recesses may be provided at the front and rear members of the spin tub, and the balancers may be coupled to opposite ends of the spin tub at the recesses of the front and rear members.
[0024] The foregoing and/or other aspects of the present invention can be achieved by providing a washing machine having at least one balancer. The balancer includes a first housing and a second housing fused to the first housing, and the first and second housings are fused together to form at least one pocket between the first housing and the second housing, the pocket capable of collecting fusion scraps generated during fusion.
[0025] Here, the first housing may include protruding fusion ridges protruding from ends of the first housing, and the second housing may include fusion grooves receiving the fusion ridges of the first housing when the first housing and the second housing are fused together.
[0026] Further, the first housing may further include inner pocket ridges protruding from the first housing and spaced inwardly apart with respect to the fusion ridges of the first housing.
[0027] Further, the second housing may further include outer pocket flanges protruding from the second housing and being situated on outer sides of the fusion grooves when the first housing is fused together with the second housing so the outer pocket flanges are spaced apart from the fusion ridges of the first housing by a predetermined distance, causing an outer pocket to be formed between the fusion ridges and the outer pocket flanges.
[0028] Further, the second housing may include guide ridges protruding from the second housing and protruding toward the first housing to closely contact the inner pocket ridges of the first housing when the first and second housings are fused together.
[0029] Also, the balancer may further include a plurality of balls disposed within an internal space formed by fusing the first and second housings together, the balls performing a balancing function.
[0030] In addition, the washing machine may further include a spin tub disposed horizontally, and the balancers may be installed at front and rear ends of the spin tub.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The above and other aspects, features and advantages of the present invention will be more apparent from the following detailed description of the embodiments, taken in conjunction with the accompanying drawings, in which
[0032] FIG. 1 is a sectional view illustrating a schematic structure of a washing machine according to the present invention;
[0033] FIG. 2 is a perspective view illustrating balancers according to the present invention, in which the balancers are disassembled from a spin tub;
[0034] FIG. 3 is a perspective view illustrating a balancer according to a first embodiment of the present invention;
[0035] FIG. 4 is an enlarged view illustrating section A of FIG. 1 in order to show the sectional structure of a balancer according to a first embodiment of the present invention;
[0036] FIG. 5 is a perspective view illustrating a balancer according to a second embodiment of the present invention;
[0037] FIG. 6 is an enlarged view illustrating the sectional structure of a balancer according to the second embodiment of the present invention;
[0038] FIG. 7 is a perspective view illustrating a disassembled balancer according to a third embodiment of the present invention;
[0039] FIG. 8 is a perspective view illustrating an assembled balancer according to the third embodiment of the present invention;
[0040] FIG. 9 is a partially enlarged view of FIG. 7 ; and
[0041] FIG. 10 is a sectional view taken line A-A of FIG. 8 .
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0042] Reference will now be made in detail to the embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiments are described below to explain the present invention by referring to the figures.
[0043] Hereinafter, exemplary embodiments of the present invention will be described with reference to the attached drawings.
[0044] FIG. 1 is a sectional view illustrating the schematic structure of a washing machine according to the present invention.
[0045] As illustrated in FIG. 1 , a washing machine according to the present invention includes a housing 1 forming an external structure of the washing machine, a water reservoir 2 installed in the housing 1 and containing washing water, a spin tub 10 disposed rotatably in the water reservoir 2 which allows laundry to be placed in and washed therein, and a door 4 hinged to an open front of the housing 1 .
[0046] The water reservoir 2 has a feed pipe 5 and a detergent feeder 6 both disposed above the water reservoir 2 in order to supply washing water and detergent to the water reservoir 2 , and a drain pipe 7 installed therebelow in order to drain the washing water contained in the water reservoir 2 to the outside of the housing 1 when the laundry is completely done.
[0047] The spin tub 10 has a rotating shaft 8 disposed at the rear thereof so as to extend through the rear of the water reservoir 2 , and a driving motor 9 , with which the rotating shaft 8 is coupled, installed on a rear outer side thereof. Therefore, when the driving motor 9 is driven, the rotating shaft 8 is rotated together with the spin tub 10 .
[0048] The spin tub 10 is provided with a plurality of dehydrating holes 10 a at a periphery thereof so as to allow the water contained in the water reservoir 2 to flow into the spin tub 10 together with the detergent to wash the laundry in a washing cycle, and to allow the water to be drained to the outside of the housing 1 through a drain pipe 7 in a dehydrating cycle.
[0049] The spin tub 10 has a plurality of lifters 10 b disposed longitudinally therein. Thereby, as the spin tub 10 rotates at a low speed in the washing cycle, the laundry submerged in the water is raised up from the bottom of the spin tub 10 and then is lowered to the bottom of the spin tub 10 , so that the laundry can be effectively washed.
[0050] Thus, in the washing cycle, the rotating shaft 8 alternately rotates forward and backward by of the driving of the driving motor 9 to spin the spin tub 10 at a low speed, so that the laundry is washed. In the dehydrating cycle, the rotating shaft 8 rotates in one direction to spin the spin tub 10 at a high speed, so that the laundry is dehydrated.
[0051] When spun at a high speed in the dehydrating process, the spin tub 10 itself may undergo misalignment between the center of gravity and the center of rotation, or the laundry may lean to one side without uniform distribution in the spin tub 10 . In this case, the spin tub 10 does not maintain a dynamic balance.
[0052] In order to prevent this dynamic imbalance to allow the spin tub 10 to be spun at a high speed with the center of gravity and the center of rotation thereof matched with each other, the spin tub 10 is provided with balancers 20 or 30 according to a first or a second embodiment of the present invention (wherein only the balancer 20 according to a first embodiment is shown in FIGS. 1-4 ) at front and rear ends thereof. The structure of the balancers 20 and 30 according to the first and second embodiments of the present invention will be described with reference to FIGS. 2 through 6 .
[0053] FIG. 2 is a perspective view illustrating balancers according to the present invention, in which the balancers are disassembled from a spin tub.
[0054] As illustrated in FIG. 2 , the spin tub 10 includes a cylindrical body 11 that has open front and rear parts and is provided with the dehydrating holes 10 a and lifters 10 b, a front member 12 that is coupled to the open front part of the body 11 and is provided with an opening 14 permitting the laundry to be placed within or removed from the body 11 , and a rear member 13 that is coupled to the open rear part of the body 11 and with the rotating shaft 8 (see FIG. 1 ) for spinning the spin tub 10 .
[0055] The front member 12 is provided, at an edge thereof, with an annular recess 15 that has the cross section of an approximately “C” shape and is open to the front of the front member 12 in order to hold any one of the balancers 20 . Similarly, the rear member 13 is provided, at an edge thereof, with an annular recess 15 (not shown) that is open to the rear of the front member 12 in order to hold the other of the balancers 20 .
[0056] The front and rear members 12 and 13 are fitted into and coupled to the front or rear edges of the body 11 in a screwed fashion or in any other fashion that allows the front and rear members 12 and 13 to be maintained to the body 11 of the spin tub 10 .
[0057] The balancers 20 , which are installed in the recesses 15 of the front and rear members 12 and 13 , have an annular shape and are filled therein with a plurality of metal balls 21 performing a balancing function and a viscous fluid (not shown) capable of adjusting a speed of motion of the balls 21 .
[0058] Now, the structure of the balancers 20 and 30 according to the first and second embodiments of the present invention will be described with reference to FIGS. 3 through 6 .
[0059] FIG. 3 is a perspective view illustrating a balancer according to a first embodiment of the present invention, and FIG. 4 is an enlarged view illustrating part A of FIG. 1 in order to show the sectional structure of a balancer according to a first embodiment of the present invention.
[0060] As illustrated in FIGS. 3 and 4 , a balancer 20 according to a first embodiment of the present invention has an annular shape and includes first and second housings 22 and 23 that are fused to define a closed internal space 20 a.
[0061] The first housing 22 has first and second walls 22 a and 22 b facing each other, and a third wall 22 c connecting ends of the first and second walls 22 a and 22 b, and thus has a cross section of an approximately “C” shape. The second housing 23 has opposite edges that protrude toward the first housing 22 and that are coupled to corresponding opposite ends 22 d of the first housing 22 by heat fusion.
[0062] The opposite ends 22 d of the first housing 22 protrude outward from the first and second walls 22 a and 22 b of the first housing 22 , and the edges of the second housing 23 are sized to cover the ends 22 d of the first housing 22 .
[0063] Thus, when the balancer 20 is fitted into the recess 15 of the front member 12 of the spin tub 10 , the first and second walls 22 a and 22 b are spaced apart from a wall of the recess 15 because of the ends and edges of the first and second housings 22 and 23 which protrude outward from the first and second walls 22 a and 22 b. Further, because the first and second walls 22 a and 22 b are relatively thin, the first and second walls 22 a and 22 b are raised outward when centrifugal force is applied thereto by the plurality of balls 21 that move in the internal space 20 a of the balancer 20 in order to perform the balancing function.
[0064] In this manner, the plurality of balls 21 make a circular motion in the balancer 20 , so that the first and second walls 22 a and 22 b are deformed by the centrifugal force applied to the first and second walls 22 a and 22 b of the first housing 22 . In order to prevent this deformation, the second housing 22 is provided with supports 24 according to a first embodiment of the present invention.
[0065] The supports 24 protrude from and perpendicular to the first and second walls 22 a and 22 b of the first housing 22 which are opposite each other, and may be continued along an outer surface of the first housing 22 , thereby having an overall annular shape.
[0066] The supports 24 have a length such that they extend from the first housing 22 to contact the wall of the recess 15 . Hence, the first and second walls 22 a and 22 b are further increased in strength, and additionally function to guide the balancer 20 so as to be maintained in the recess 15 in place.
[0067] Here, when the plurality of balls 21 make a circular motion in the first housing 22 , the centrifugal force acts in the direction moving away from the center of rotation of the spin tub 10 . Hence, the centrifugal force acts on the first wall 22 a to a stronger level when viewed in FIG. 4 . Thus, the supports 24 may be formed only on the first wall 22 a.
[0068] In the balancer 20 according to the first embodiment of the present invention, when the first and second housings 22 and 23 are fused together and fitted into the recess 15 of the spin tub 10 , the supports 24 are maintained in place while positioned along the wall of the recess 15 . Finally, the balancer 20 is coupled and fixed to the front member 12 of the spin tub 10 by screws (not shown) or in any other fashion that allows the balancer 20 to be coupled to the front member 12 .
[0069] Although not illustrated in detail, the balancer 20 is similarly installed on the rear member 13 of the spin tub 10 .
[0070] The ends 22 d of the first housing 22 include fusion ridges 42 a that protrude toward the second housing 23 . The fusion ridges 42 a are inserted within fusion grooves 43 a of the second housing 23 .
[0071] FIGS. 5 and 6 correspond to FIGS. 3 and 4 , and illustrate a balancer 30 according to a second embodiment of the present invention.
[0072] The balancer 30 according to the second embodiment of the present invention has an annular shape and includes first and second housings 32 and 33 that are fused together forming an internal space 30 a therebetween in which a plurality of balls 31 are disposed. The balancer 30 according to the second embodiment of the present invention is similar to that of balancer 20 according to the first embodiment of the present invention, except the structure of supports 34 of balancer 30 is different from that of the structure of the supports 24 of balancer 20 .
[0073] As illustrated in FIGS. 5 and 6 , the supports 34 according to the second embodiment of the present invention protrude parallel to first and second walls 32 a and 32 b of a first housing 32 which are opposite each other, and the supports 34 are disposed at regular intervals along the first and second walls 32 a and 32 b. The first housing 32 further includes a third wall 32 c . Ends 22 d of the first housing 32 extend from an end of the first and second walls 32 a and 32 b .
[0074] Similar to the supports 24 according to the first embodiment, the supports 34 of the second embodiment have a length such that the supports 34 extend from the first housing 32 to contact the wall of the recess 15 . The surfaces of the supports 34 thereby abut portions of the front member 12 . Hence, the first and second walls 32 a and 32 b are further increased in strength, and additionally function to guide the balancer 30 so as to be maintained in the recess 15 in place.
[0075] Next, the construction of a balancer 40 according to a third embodiment of the present invention will be described with reference to FIGS. 7 through 10 .
[0076] FIGS. 7 and 8 are perspective views illustrating disassembled and assembled balancers according to the third embodiment of the present invention, FIG. 9 is a partially enlarged view of FIG. 7 , and FIG. 10 is a sectional view taken along line A-A of FIG. 8 .
[0077] As illustrated in FIGS. 7 and 8 , a balancer 40 includes a first housing 42 having an annular shape and a second housing 43 having an annular shape that is fused to the first housing 42 , thereby forming an annular housing corresponding to the recess 15 (see FIG. 2 ) of the spin tub 10 . The first and second housings 42 and 43 may be, for example, formed of synthetic resin, such as plastic by injection molding.
[0078] As illustrated in FIG. 9 , the first housing 42 has a cross section of an approximately “C” shape, includes fusion ridges 42 a protruding to the second housing 43 at opposite ends thereof which are coupled with the second housing 43 , and inner pocket ridges 42 b protruding to the second housing 43 spaced inwardly apart from the fusion ridges 42 a.
[0079] The second housing 43 , which is coupled to opposite ends of the first housing 42 in order to form a closed internal space 40 a for holding a plurality of balls 41 and a viscous fluid, includes fusion grooves 43 a recessed along edges thereof so as to correspond to the fusion ridges 42 a, outer pocket flanges 43 b and guide ridges 43 c. The outer pocket flanges protrude to the first housing 42 on outer sides of the fusion grooves 43 a so as to be spaced apart from the fusion ridges 42 a of the first housing 42 by a predetermined distance. The guide ridges 43 c protrude to the first housing 42 on inner sides of the fusion grooves 43 a and closely contact the inner pocket ridges 42 b of the first housing 42 .
[0080] The guide ridges 43 c of the second housing 43 move in contact with the inner pocket ridges 42 b of the first housing 42 when the second housing 43 is fitted into the first housing 42 , to thereby guide the fusion ridges 42 a of the first housing 42 to be fitted into the fusion grooves 43 a of the second housing 43 rapidly and precisely.
[0081] Thus, when the fusion ridges 42 a of the first housing 42 are fitted into the fusion grooves 43 a of the second housing 43 in order to fuse the first housing 42 with the second housing 43 , as shown in FIG. 10 , an inner pocket 40 b having a predetermined spacing is formed between the fusion ridges 42 a and inner pocket ridges 42 b, and an outer pocket 40 c having a predetermined spacing is formed between the fusion ridges 42 a and the outer pocket flanges 43 b.
[0082] In this state, when heat is generated between the fusion ridges 42 a of the first housing 42 and the fusion grooves 43 a of the second housing 43 , the fusion ridges 42 a and the fusion grooves 43 a are firmly fused with each other. At fusion, fusion scraps that are generated by heat and fall down inward of the first housing 42 are collected in the inner pocket 40 b, so that the scraps are not introduced into the internal space 40 a of the balancer 40 in which the balls 41 move. Fusion scraps falling down outward of the first housing 42 are collected in the outer pocket 40 c, and thus are prevented from falling down outward of the balancer 40 .
[0083] In the embodiments, the balancers 20 , 30 and 40 have been described to be installed on a drum type washing machine by way of example, but it is apparent that the balancers can be applied to an upright type washing machine having a structure in which a spin tub is vertically installed.
[0084] As described above in detail, the washing machine according to the embodiments of the present invention has a high-strength structure in which at least one balancer is provided with at least one support protruding outward from the wall thereof, so that, although the strong centrifugal force acts on the wall of the balancer due to a plurality of balls making a circular motion in the balancer, the wall of the balancer is not deformed. Thus, the plurality of balls can make a smooth circular motion without causing excess vibration and noise, and thus increasing the durability and life span of the balancer.
[0085] Further, the washing machine according to the embodiments of the present invention has a structure in which the balancer can be rapidly and exactly positioned in the recess of the spin tub by the supports, so that an assembly time of the balance can be reduced.
[0086] In addition, the washing machine according to the present invention has a structure in which fusion scraps generated when the balancer is fused are collected in a plurality of pockets, and thus are prevented from falling down inward and outward of the balancer, so that the internal space of the balancer, in which a plurality of balls are filled and move in a circular motion, has a smooth surface without the addition of fusion scraps. As a result, the balls are able to move more smoothly, and excess noise and vibration are minimized. The balancer may have a clear outer surface to provide a fine appearance without the fusion scraps, so that it can be exactly coupled to the spin tub without obstruction caused by the fusion scraps.
[0087] Although a few embodiments of the present invention have been described for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims and their equivalents. | A front loading washing machine including a housing; a water reservoir installed in the housing for containing washing water; a spin tub provided in the water reservoir to hold laundry to be washed, the spin tub having an annular recess and rotating with respect to a horizontal axis of the washing machine; and at least one balancer installed in the annular recess of the spin tub, the balancer comprising an annular shaped race formed of a plastic material. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a National Phase filing under 35 U.S.C. §371 of International Application No. PCT/JP2006/324802 filed on Dec. 13, 2006, and which claims priority to Japanese Patent Application No. 2005-375852 filed on Dec. 27, 2005.
TECHNICAL FIELD
An aspect of the present invention relates to a variable resistance element comprising a first electrode and a second electrode and a variable resistor in which the variable resistor is sandwiched between the first electrode and the second electrode and its electric resistance is changed when a voltage pulse is applied between both electrodes, and its manufacturing method. Another aspect of the present invention relates to a semiconductor memory device comprising the above variable resistance element.
BACKGROUND ART
Recently, as a next generation high-speed nonvolatile random access memory (NVRAM) to replace a flash memory, various kinds of device structures such as a FeRAM (Ferroelectric RAM), a MRAM (Magnetic RAM), a PRAM (Phase Change RAM) are proposed and there are severe development races among them, seeking for high performance, high reliability, low cost and process consistency. However, the above memory devices at the present have both merits and demerits and an ideal “universal memory” having all merits of a SRAM, a DRAM, and a flash memory is far from practical use.
A nonvolatile RRAM (Resistive Random Access Memory) using a variable resistance element whose electric resistance is reversibly changed by applying a voltage pulse has been proposed based on the existing technique. This constitution is shown in FIG. 1 .
As shown in FIG. 1 , a conventional variable resistance element comprises a lower electrode 3 , a variable resistor 2 and an upper electrode 1 laminated sequentially in which its resistance value can be reversibly changed when a voltage pulse is applied between the upper electrode 1 and the lower electrode 3 . A new nonvolatile semiconductor memory device can be implemented by reading the resistance value changed by the reversible resistance changing operation (referred to as “switching operation” hereinafter).
The nonvolatile semiconductor memory device comprises a memory cell array having a plurality of memory cells each having a variable resistance element and disposed in a row direction and column direction like a matrix, and peripheral circuits for controlling programming, erasing and reading actions of data for each memory cell of the memory cell array. Thus, this memory cell includes memory cells having different components, such as a memory cell having one selection transistor T and one variable resistance element R (called “1T/1R type”) and a memory cell having only one variable resistance element R (called “1R type”).
Meanwhile, regarding a material constituting the variable resistor 2 , a method for changing an electric resistance reversibly by applying a voltage pulse to a perovskite material known for having a colossal magnetoresistance effect is disclosed by Shangquing Liu, Alex Ignatiev et al., in University of Houston, U.S.A. in the following patent document 1 and a non-patent document 1. This is an extremely epoch-making method because even when the perovskite material known for having the colossal magnetoresistance effect is used, a resistance change ranging over several digits can be seen at room temperature without applying a magnetic field. In addition, according to an element structure shown in the patent document 1, the variable resistor is formed of a perovskite-type oxide such as a crystalline praseodymium calcium manganese oxide Pr 1-X Ca X MnO 3 (PCMO) film.
In addition, it is known from a non-patent document 2 and a patent document 2 that regarding the material of the variable resistor 2 , a titanium oxide (TiO 2 ) film, a nickel oxide (NiO) film, a zinc oxide (ZnO) film, and a niobium oxide (Nb 2 O 5 ) film formed of a transition metal oxide also show reversible resistance change. Especially, titanium oxide and nickel oxide is considered to be a material in which the resistance is changed when a region in which resistivity is locally lowered in the oxide (referred to as “filament path” occasionally hereinafter) is formed and the filament path is broken due to heat increase caused by a current flowing in the variable resistance element.
Furthermore, it is known from the non-patent document 2 and the patent document 2 that regarding the material of the variable resistor 2 , the titanium oxide (TiO 2 ) film, the nickel oxide (NiO) film, the zinc oxide (ZnO) film, and the niobium oxide (Nb 2 O 5 ) film formed of the transition metal oxide also show reversible resistance change. Among the above materials, the phenomena of switching operations with titanium oxide and nickel oxide are reported in detail in non-patent documents 3 to 6 and a non-patent document 7, respectively.
Patent document 1: U.S. Pat. No. 6,204,139 Non-patent document 1: Liu, S. Q. et al., “Electric-pulse-induced reversible Resistance change effect in magnetoresistive films”, Applied Physics Letter, Vol. 76, pp. 2749-2751, in 2000 Non-patent document 2: H. Pagnia et al., “Bistable Switching in Electroformed Metal-Insulator-Metal Devices”, Phys. Stat. Sol. (a), vol. 108, pp. 11-65, in 1988 Patent document 2: Japanese Unexamined Publication of PCT Application No. 2002-537627 Non-patent document 3: G. Taylor et al., “RF Relaxation Oscillations in Polycrystalline TiO2 Thin Films”, Solid-State Electronics, 1976, vol. 19, pp. 669-674 Non-patent document 4: F. Argall et al., “Switching Phenomena in Titanium Oxide Thin Films”, Solid-State Electronics, Pergamon Press 1968, vol. 11, pp. 535-541 Non-patent document 5: Beam et al., Proc. IEEE, 52, 300-1, 1964 Non-patent document 6: F. Argall, Solid State Electronicis Pergamon Press 1968, vol. 11, pp. 535 Non-patent document 7: S. Seo et al., Applied Physics Letters 86, 093509, 2005
When the perovskite-type oxide is used as the material of the variable resistor 2 whose resistance is changed in response to the voltage pulse, since its crystallization temperature is as high as 500° C. to 700° C., it cannot be formed after the wiring of an LSI is formed. In addition, most constituent elements of perovskite are not used in a LSI process and since these constituent elements could affect device characteristics, it is necessary to examine and take measures against contamination of these elements.
Meanwhile, when the variable resistor 2 is formed of titanium oxide or nickel oxide, since titanium and nickel is largely used in the LSI process, they do not affect the device characteristics. However, the resistance change of the variable resistance element formed of titanium oxide and nickel oxide conventionally considered is based on a phenomenon in which low resistance and high resistance are provided when a filament path is formed and broken depending on a voltage pulse applying condition. Thus, in order to provide the switching operation, it is necessary to form the filament path by applying a specific voltage first (referred to as “forming process” hereinafter).
In addition, according to the above element, the problems are that the diameter of the filament path is increased as the number of switching operations is increased, that the resistance value fluctuates due to the change of filament density, and that it is difficult to control the resistance value because there is no area dependency in the element in a low resistance state since the resistance value is determined by a filament, so that it is not practically used as a device at the present.
The present invention was made in view of the above problems and it is an object of the present invention to provide a variable resistance element superior in LSI process consistency, capable of performing a resistance switching operation without a filament path, and showing a stable resistance value retention characteristics.
SUMMARY OF THE INVENTION
A variable resistance element according to an embodiment of the present invention to attain the above object comprises a first electrode, a second electrode and a variable resistor sandwiched between the first electrode and the second electrode, in which an electric resistance between the first electrode and the second electrode is changed by applying a voltage pulse between the first electrode and the second electrode, and it is characterized as a first characteristics in that the variable resistor is formed of titanium oxide or titanium oxynitride having a crystal grain diameter of 30 nm or less.
In addition, the variable resistance element according to the present invention embodiment is characterized as second characteristics in addition to the first characteristics in that the crystal structure of the variable resistor is anatase type.
In addition, the variable resistance element according to the present invention embodiment is characterized as third characteristics in addition to the first or second characteristics in that the 101 face of the crystal of the variable resistor is changed by applying a voltage pulse between the first electrode and the second electrode.
In addition, the variable resistance element according to the present invention embodiment is characterized as fourth characteristics in addition to the third characteristics in that the resistance value of the variable resistor is increased when the 101 face increases, and the resistance value is decreased when the 101 face decreases or disappears.
In addition, the variable resistance element according to the present invention embodiment is characterized as fifth characteristics in addition to any one of the first to fourth characteristics in that at least one of the first electrode and the second electrode contains an element selected from Pt, Ir, Os, Ru, Rh, Pd, Ti, Co, W, and an alloy of Ti and W, or contains titanium nitride.
A manufacturing example method of the variable resistance element having the first characteristics according to the present invention is characterized as first characteristics by comprising a first step for forming the second electrode, a second step for forming the variable resistor by depositing a titanium oxide film or a titanium oxynitride film having a crystal grain diameter of 30 nm or less on the upper surface of the second electrode, and a third step for forming the first electrode on the upper surface of the variable resistor.
In addition, the example manufacturing method of the variable resistance element according to the present invention is characterized as second characteristics in addition to the first characteristics in that the second step comprises a step of forming the titanium oxide film under a substrate temperature of 150° C. to 500° C.
In addition, the example manufacturing method of the variable resistance element according to the present invention is characterized as third characteristics in addition to the first characteristics in that the second step comprises a step of performing a heat treatment on the titanium oxide film at 250° C. to 500° C. under an oxygen atmosphere or an atmosphere containing oxygen after the titanium oxide film is deposited.
In addition, the example manufacturing method of the variable resistance element according to the present invention is characterized as fourth characteristics in addition to the first characteristics in that the first step comprises a step of forming a titanium nitride as the second electrode, and the second step comprises a step of forming the titanium oxide film or the titanium oxynitride film on the surface of the second electrode by performing a heat treatment on the surface of the second electrode at 250° C. to 500° C. under an oxygen atmosphere or an atmosphere containing oxygen.
A semiconductor memory device embodiment according to the present invention comprises a memory cell array in which a plurality of memory cells each having the variable resistance element having any one of the above first to firth characteristics are arranged, a selecting means for selecting a specific target memory cell from the plurality of memory cells constituting the memory cell array, and a pulse voltage generating means for generating a pulse voltage, and it is characterized in that information is written by the change of the resistance value of the variable resistance element when the pulse voltage generated from the pulse voltage generating means is applied to the variable resistance element of the target memory cell selected by the selecting means.
When the variable resistor is formed of titanium oxide or titanium oxynitride having the crystal grain diameter of 30 nm or less, the variable resistance element can implement the stable switching operation and favorable data retention characteristics.
Especially, according to the above constitution, since the crystal state of the variable resistor is changed and as a result, the resistance value is changed in response to the application of the voltage pulse, the forming process is not needed and the stable resistance switching operation can be provided. In addition, since the resistance switching operation is not performed by the filament path, the resistance fluctuation is small even after the switching is repeated, and the resistance fluctuation is small even after held over a long period at high temperature. Therefore, the element of the present invention is advantageously applied to a nonvolatile memory.
In addition, according to the constitution of the present invention, since the resistance switching operation is not performed by the filament path as described above, area dependency is provided by miniaturizing the resistance element.
Furthermore, since the variable resistance element embodiment of the present invention is formed of titanium oxide or titanium oxynitride as the variable resistor, when the lower electrode is formed of titanium or titanium nitride, the titanium oxide film or the titanium oxynitride film can be formed by oxidizing the surface of the lower electrode. That is, according to this example manufacturing method, since the variable resistor film can be formed by the general step in the semiconductor process, that is, the heat treatment, a special device for forming the film is not needed. Furthermore, since the heat treatment is performed at a low temperature of 500° C. or less, the treatment can be performed after the wiring process.
In addition, according to the semiconductor memory device embodiment comprising the variable resistance element of the present invention, the stable switching operation having a large resistance ratio and favorable data retention characteristics are implemented, it can be applied to a memory card and a recording medium of an electronic device such as a mobile phone, a mobile game, a digital camera, and a printer and the like.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view showing the structure of a variable resistance element;
FIG. 2 is a schematic sectional view showing a structure in one step of an example manufacturing process of a variable resistance element according to the present invention;
FIG. 3 is a schematic sectional view showing a structure in one step of the example manufacturing process of the variable resistance element according to the present invention;
FIG. 4 is a schematic sectional view showing a structure in one step of the example manufacturing process of the variable resistance element according to the present invention;
FIG. 5 is a schematic sectional view showing a structure in one step of the example manufacturing process of the variable resistance element according to the present invention;
FIG. 6 is a schematic sectional view showing a structure in one step of the example manufacturing process of the variable resistance element according to the present invention;
FIG. 7 is a schematic sectional view showing a structure in one step of the example manufacturing process of the variable resistance element according to the present invention;
FIG. 8 is a schematic sectional view showing a structure in one step of the example manufacturing process of the variable resistance element according to the present invention;
FIG. 9 is a schematic sectional view showing a structure in one step of the example manufacturing process of the variable resistance element according to the present invention;
FIG. 10 is a flowchart showing the example manufacturing process of the variable resistance element according to the present invention;
FIG. 11 is a block diagram showing the constitution of a measurement device to examine the resistance variable state of the variable resistance element embodiment according to the present invention;
FIG. 12 is a graph showing a change of the resistance value of the variable resistance element embodiment according to the present invention in response to voltage pulse application;
FIG. 13 is a photograph showing the variable resistance element embodiment according to the present invention taken by a super-high-resolution transmission electron microscope;
FIG. 14 is a schematic view showing the structure of the variable resistance element embodiment according to the present invention;
FIG. 15 is a graph showing switching characteristics when the crystal state of a variable resistor constituting the variable resistance element embodiment according to the present invention is changed;
FIG. 16 is a graph showing switching characteristics when the crystal state of a variable resistor constituting the variable resistance element embodiment according to the present invention is changed;
FIG. 17 is a graph showing retention characteristics of a low resistance state of the variable resistance element embodiment according to the present invention;
FIG. 18 is a graph showing retention characteristics of a high resistance state of the variable resistance element embodiment according to the present invention;
FIG. 19 is a selected area electron beam diffraction image of a fine crystal region of titanium oxide serving as one example of the variable resistor constituting the variable resistance element embodiment according to the present invention;
FIG. 20 is a schematic block diagram showing the constitution of a semiconductor memory device embodiment comprising the variable resistance element according to the present invention;
FIG. 21 is a circuit diagram showing one constitution example of a memory cell array in the semiconductor memory device embodiment according to the present invention; and
FIG. 22 is a schematic sectional view showing one example of a memory cell forming the memory cell array in the semiconductor memory device according to the present invention.
EXPLANATION OF REFERENCES
1 : Upper Electrode
2 : Variable Resistor
3 : Lower Electrode
4 : Interlayer Insulation Film
5 : Conductive Film
10 : Variable Resistance Element
11 : Contact Hole
12 : Contact Hole
20 : Measurement Device
21 : Pulse Generator
22 : Digital Oscilloscope
23 : Parameter Analyzer
24 : Switch
21 a , 21 b : Terminal
22 a , 22 b , 22 g : Terminal
23 a : Terminal
24 a , 24 b , 24 c : Terminal
30 : Semiconductor Memory Device
31 : Memory Cell Array
32 : Control Circuit
33 : Read Circuit
34 : Bit Line Decoder
35 : Word Line Decoder
36 : Voltage Pulse Generation Circuit
40 : Semiconductor Substrate
41 : Element Isolation Area
42 : Gate Insulation Film
43 : Gate Electrode
44 : Drain Diffusion Layer Area
45 : Source Diffusion Layer Area
46 : Interlayer Insulation Film
47 : Contact Hole
48 : Ohmic Contact Layer
49 : Lower Electrode
50 : Variable Resistor
51 : Upper Electrode
52 : Interlayer Insulation Film
53 : Contact Hole
54 : Contact Hole
55 : Wiring
56 : Wiring
57 : Interlayer Insulation Film
58 : Wiring
59 : Surface Protection Film
R: Variable Resistance Element
T: Selection Transistor
W 1 , W 2 , . . . , Wn: Word Line
B 1 , B 2 , . . . , Bm: Bit Line
S: Source Line
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of a variable resistance element and its manufacturing method according to the present invention (occasionally hereinafter referred to as “element of the present invention” and “method of the present invention”, respectively) will be described with reference to the drawings hereinafter. Then, a semiconductor memory device comprising the element of the present invention (referred to as “device of the present invention” occasionally hereinafter) will be described.
The element of the present invention has a constitution in which an upper electrode and an lower electrode are connected through a variable resistor, and especially when the variable resistor is formed of titanium oxide or titanium oxynitride whose crystal has a grain diameter of a predetermined value (30 nm as will be described below) or less, it is found that a switching operation in which resistance is changed in response to the application of a voltage pulse can be performed stably. Hereinafter, the manufacturing process of the element of the present invention will be described and then, the effect of the element of the present invention will be described based on verification data.
In addition, the term “grain diameter” in this specification is an average value of a long side and a short side of a circumscribed rectangular solid of a crystal observed by a super-high-resolution transmission electron microscope (referred to as “TEM” hereinafter).
FIRST EMBODIMENT
A first embodiment (referred to as “this embodiment” occasionally hereinafter) of the element of the present invention and its manufacturing method will be described with reference to FIGS. 1 to 19 . In addition, the element of the present invention is characterized by a material used for a variable resistor serving as one component and its overall constitution is the same of the variable resistance element having the conventional constitution described in the section of the background art as shown in FIG. 1 .
According to the element of the present invention in this embodiment, a variable resistor 2 contained in the variable resistance element shown in FIG. 1 is formed of titanium oxide having a grain diameter of 30 nm or less as will be described below.
FIG. 2 is a schematic section view showing the element of the present invention in this embodiment. An element 10 of the present invention comprises a lower electrode 3 , the variable resistor 2 , an upper electrode 1 laminated on a substrate in this order in the vertical direction. Thus, interlayer insulation films 4 are formed thereon, and contact holes 11 and 12 for applying a pulse voltage between the lower electrode 3 and the upper electrode 1 are provided, and a conductive film 5 is laminated so as to be connected to the lower electrode 3 or the upper electrode 1 through the contact hole. The manufacturing process of the element 10 of the present invention will be described with reference to FIGS. 2 to 10 hereinafter. In addition, each of FIGS. 2 to 9 is a schematic sectional view in one step when the element 10 of the present invention is manufactured. In addition, FIG. 10 is a flowchart showing the manufacturing process of the element 10 of the present invention and each step in the following description corresponds to one step in the flowchart shown in FIG. 10 .
In addition, since the schematic sectional views shown in FIGS. 2 to 9 are schematically shown only, it is to be noted that the contraction scale of the dimension of the actual structure does not always correspond to the contraction scale of the drawing.
First, as shown in FIG. 3 , the lower electrode 3 is deposited on a base substrate (not shown) by the sputtering method (step S 1 ). The lower electrode 3 is formed by depositing a titanium nitride (TiN) film (the lower electrode 3 is referred to as “TiN film 3 ” occasionally in this embodiment hereinafter) serving as a conductive material and having a thickness of 200 nm, for example.
Then, as shown in FIG. 4 , the variable resistor material film 2 formed of titanium oxide is formed on the surface of the TiN film 3 by the DC magnetron sputtering method (step S 2 ). A metal Ti target is used as a sputtering target and Ar having a flow rate of 5 sccm and O 2 having a flow rate of 15 sccm are introduced as process gas, and a DC voltage of 1.5 kW/cm 2 is applied to the target under a pressure of 3 to 15 mTorr. A substrate temperature at this time is set at 150° C. to 500° C. The inside is a plasma state by the voltage application and an accelerated Ar + ion in the plasma collides against the target and a Ti atom that is a target material is sputtered by collision energy and attached on the substrate. At this time, it reacts with the introduced O 2 gas and a titanium oxide film (the variable resistor 2 is referred to as “titanium oxide film 2 ” occasionally in this embodiment hereinafter) is formed on the substrate. The titanium oxide film 2 has a thickness of 5 to 50 nm.
The titanium oxide film 2 formed as described above comprises anatase-type titanium oxide having a crystal grain diameter of 30 nm or less as will be described below. Meanwhile, in the case where the substrate temperature is as low as 150° C. or less, an amorphous-type titanium oxide film is formed on the TiN film 3 . In this case, after it is formed, it is heat-treated at 250° C. to 500° C. under an oxygen-nitrogen mixed gas atmosphere having an oxygen concentration of 5% to 100% or under an oxygen-argon mixed gas atmosphere having an oxygen concentration of 5% to 100% with an electric furnace or a lamp heating device. Thus, the anatase-type titanium oxide film can be formed.
In addition, the method for forming the titanium oxide film 2 is not limited to the DC magnetron sputtering method and it may be formed by a CVD method. In the case where it is formed by the CVD method, the substrate is heated to 250° C. to 500° C. and as a raw material, TiCl 4 or organic metal such as Ti(OCH 3 ) 4 , Ti(OC 2 H 6 ) 4 , Ti(O-i-C 3 H 7 ) 4 , Ti(O-n-C 4 H 7 ) 4 , Ti(O-n-C 4 H 9 ) 4 , or Ti(O-sec-C 4 H 9 ) 4 is introduced into a reaction chamber by a carburetor to react with oxygen. In the case where the film is formed by the CVD method also, since the titanium oxide film formed at the low substrate temperature (250° C. or less) shows the amorphous type, similar to the DC magnetron sputtering method described above, the anatase-type titanium oxide film is to be formed by the heat treatment at 250° C. to 500° C. under an oxygen atmosphere after the titanium oxide has been formed.
Next, as shown in FIG. 5 , the upper electrode 1 is deposited on the titanium oxide film 2 by the sputtering method (step S 3 ). The upper electrode 1 is formed by depositing a Pt film (the upper electrode 1 is referred to as “Pt film 1 ” occasionally in this embodiment hereinafter) formed of a metal material and having a thickness of 100 nm, for example.
Then, as shown in FIG. 6 , the Pt film 1 and the titanium oxide film 2 are sequentially processed by dry etching using a resist patterned by the well-known photolithography method as a mask (step S 4 ). Similarly, the TiN film 3 is processed using a resist patterned by the photolithography method as a mask (a processing pattern is not shown).
Then, as shown in FIG. 7 , the interlayer insulation film 4 is deposited on the Pt film 1 and the TiN film 3 (step S 5 ). For example, the interlayer insulation film 4 is formed by depositing a silicon oxide film having a thickness of 500 nm such that TEOS (tetraethoxysilane) as a raw material is mixed with ozone and oxygen to be chemically vapor-deposited by an atmospheric pressure thermal CVD method. Thus, as shown in FIG. 8 , the interlayer insulation film 4 is processed by etching using a resist patterned by the photolithography method as a mask, whereby the contact hole 11 reaching the upper electrode 1 and the contact hole 12 reaching the lower electrode 3 are formed (step S 6 ).
Then, as shown in FIG. 9 , the conductive film 5 is deposited on the upper surface including the upper electrode 1 , the lower electrode 3 and the interlayer insulation film 4 to apply a voltage pulse between the upper electrode 1 and the lower electrode 3 (step S 7 ). The conductive film 5 is formed by sequentially depositing a TiN film having a thickness of 50 nm, a Al—Si—Cu film having a thickness of 400 nm, and a TiN film having a thickness of 50 nm by the sputtering method (laminated structure of TiN/Al—Si—Cu/TiN), for example. Then, the conductive film 5 is processed by etching using a resist patterned by the photolithography method as a mask, whereby a wiring connected to the upper electrode 1 through the contact hole 11 and a wiring connected to the lower electrode 3 through the contact hole 12 are formed as shown in FIG. 2 (step S 8 ).
In addition, in the above description, general steps such as a step for applying, exposing and developing the photoresist and a step for removing the photoresist after etching, and a cleaning step after etching and resist removing steps are omitted.
Next, a measurement device and a measuring process to evaluate the variable resistance element manufactured as described above will be described hereinafter.
FIG. 11 shows a measurement device to examine the resistance variable state of the variable resistance element. A measurement device 20 shown in FIG. 11 comprises a pulse generator 21 generating a pulse voltage, a digital oscilloscope 22 monitoring and storing a voltage waveform and the like, and a parameter analyzer 23 measuring current-voltage characteristics. In addition, a switch 24 selecting a connection destination is provided. As the parameter analyzer 23 , a model number 4156B produced by Agilent Technologies is used, for example.
This measurement device has a constitution in which a voltage pulse can be applied to the variable resistance element, and the resistance value of the variable resistance element after the voltage pulse is applied can be derived from the current-voltage characteristics (referred to as “I-V characteristics” occasionally hereinafter) of the variable resistance element.
This device examines whether the variable resistance element produced by the above method can change the resistance value in response to the application of the pulse voltage or not.
One end of the variable resistance element 10 is connected to a grand terminal 22 g of the digital oscilloscope 22 , and the other end thereof is connected to a fixed terminal 24 a of the switch 24 . Furthermore, one terminal 22 a of the digital oscilloscope 22 is connected to one terminal 21 a of the pulse generator 21 . In addition, one terminal 24 b of movable terminals of the switch 24 is connected to the other terminal 22 b of the digital oscilloscope 22 and to the other terminal 21 b of the pulse generator 22 , whereby one circuit is formed. Furthermore, the other terminal 24 c of the movable terminals of the switch is connected to a terminal 23 a of the parameter analyzer 22 , whereby another circuit is formed. Thus, both circuits can be switched by the switching operation of the movable terminals of the switch 24 .
When the voltage pulse is applied to the variable resistance element 10 , the fixed terminal 24 a is connected to the movable terminal 24 b by the operation of the switch 24 to electrically connect the pulse generator 21 to the variable resistance element 10 , whereby the voltage pulse generated from the pulse generator 21 is applied to the variable resistance element 10 . Thus, the voltage pulse generated at this time is observed by the digital oscilloscope 22 . Then, when the connection destination of the fixed terminal 24 a is switched from the movable terminal 24 b to the terminal 24 c of the switch 24 to be connected to the parameter analyzer 24 (cut from the pulse generator 22 ), and the current-voltage characteristics of the variable resistance element 10 is measured.
First, a voltage pulse is generated from the pulse generator 21 such that a voltage of −3V (negative pulse having a voltage amplitude of 3V) having a pulse width (pulse applying time) of 100 nsec is applied to the upper electrode 1 of the variable resistance element 10 produced by the above method, and the resistance value after the voltage is applied is derived from the I-V characteristics measured by the parameter analyzer 23 . After the measurement, a voltage pulse is generated from the pulse generator 21 such that a voltage of +3V (positive pulse having a voltage amplitude of 3V) having a pulse width of 200 nsec is applied to the upper electrode 1 of the variable resistance element 10 , and the resistance value after the voltage is applied is derived from the I-V characteristics measured by the parameter analyzer 23 .
Here, the measurement of the I-V characteristics by the parameter analyzer 23 is performed every time the voltage pulse is applied and at this time, a voltage of +0.7V is applied from the parameter analyzer 23 to the variable resistance element 1 and the I-V characteristics of the variable resistance element 11 is derived by measuring a current amount generated while the voltage is applied. While the variable resistance element 11 changes its resistance value when a voltage pulse of about ±3V is applied, it does not change its resistance value when a voltage pulse of about ±0.7V is applied. Thus, when the voltage applied from the parameter analyzer 23 for measurement is low, the resistance value can be measured without affecting the resistance value of the variable resistance element to be measured.
FIG. 12 is a graph showing a change of the resistance value when a positive voltage (3V) having a pulse width 200 nsec and a negative voltage (−3V) having a pulse width of 100 nsec are alternately applied to the upper electrode of the variable resistance element in which the electrode area of the upper electrode 1 is 0.04 μm 2 . The lateral axis shows the applied pulse voltage and the vertical axis shows the resistance value read by the parameter analyzer 23 in logarithmic scale. In addition, as the variable resistance element 10 to be measured, an element formed of titanium oxide showing the anatase type in which a crystal structure of the variable resistor has a grain diameter of 2 to 3 nm was used. The crystal structure will be described later.
According to the graph shown in FIG. 12 , when the positive voltage pulse (3V) having the pulse width of 200 nsec is applied, the resistance value shows a high resistance value (about 8×10 4 Ω) and then when the negative voltage pulse (−3V) having the pulse width of 100 nsec is applied, the resistance value shows a low resistance value (about 2×10 2 Ω). Thus, it has been confirmed that when the negative pulse and the positive pulse are alternately applied, the variable resistance element 10 shows the high resistance state and the low resistance state alternately.
That is, according to FIG. 12 , it is confirmed that the variable resistance element having the variable resistor comprising the titanium oxide film performs the switching operation at a resistance ratio (ratio of the resistance value at the high resistance state to the resistance value at the low resistance state) of about 400 times. In addition, the resistance state is maintained until the next voltage pulse is applied although it is not shown. Thus, it shows that the variable resistance element can be reversibly switched between binary data (high resistance state and low resistance state) as a nonvolatile memory element.
Next, the fact that the crystal state of the variable resistor is changed in response to the application of the voltage pulse will be described with reference to the drawing. FIG. 13 shows a sectional TEM photograph of the variable resistance element whose switching operation is performed at the ratio of 400 times taken by a TEM having a acceleration voltage of 800 keV. FIG. 13A is an actual photograph and FIG. 13B is a photograph in which crystal grains are highlighted to be easily distinguished. In addition, FIG. 14 is a conceptual view showing the structure of the variable resistance element in which the structure in FIG. 13B is schematically shown.
From the TEM photograph, it is confirmed that the titanium oxide layer sandwiched between the lower electrode and the upper electrode has many lattice images and comprises the crystal grains having a diameter of 2 to 4 nm.
Next, the fact that the crystal grain diameter of titanium oxide constituting the titanium oxide layer affects the resistance value will be described with reference to the drawing.
FIGS. 15 and 16 show the switching characteristics of the variable resistance element when the crystal state of titanium oxide used as the variable resistor is changed. As measurement objects, anatase-type titanium oxide having crystal grain diameters of 1 to 3 nm, 3 to 10 nm, 10 to 30 nm, 30 to 50 nm, and 50 nm or more, and amorphous-type titanium oxide were used. Among the above objects, measurement results of the anatase-type titanium oxide having the crystal grain diameters of 1 to 3 nm, 3 to 10 nm and 10 to 30 nm and the amorphous-type titanium oxide are shown in FIG. 15 , and measurement results of the anatase-type titanium oxide having crystal grain diameters of 30 to 50 nm and 50 nm or more are shown in FIG. 16 . In addition, the element to be measured is provided by changing the crystal state of titanium oxide by changing a gas pressure and a substrate temperature at the time of film formation in the above step S 2 .
As shown in FIG. 15 , it has been confirmed that the variable resistance element having the variable resistor formed of anatase-type titanium oxide having the crystal grain diameters 1 to 2 nm, 2 to 3 nm and 10 to 30 nm stably perform the switching operation. Especially, as the crystal grain diameter becomes small, the resistance ratio provided by the positive and negative pulse voltages is increased (in the case of the crystal grain diameter of 1 to 2 nm, the ratio is about 1000 times and in the case of the crystal grain diameter of 10 to 30 nm is about 400 times). Meanwhile, in the case of the amorphous-state titanium oxide, the resistance value at its initial state is high and there is no change in resistance value even when the positive pulse voltage and the negative pulse voltage are further applied.
Meanwhile, as shown in FIG. 16 , it has been confirmed that the switching operation of the variable resistance element comprising the variable resistor formed of the anatase-type titanium oxide having the crystal grain diameter of 30 to 50 nm is instable. In addition, according to the variable resistance element comprising the variable resistor formed of the anatase-type titanium oxide having the crystal grain diameter 50 nm or more, even when the positive pulse voltage and the negative pulse voltage are alternately applied, it is confirmed that there is no change in the resistance value.
From the measurement results in FIGS. 15 and 16 , according to the variable resistance element comprising the variable resistor 2 formed of the anatase-type titanium oxide having the crystal grain diameter of 30 nm or less, the switching operation can be performed stably by the positive and negative pulse voltages.
According to the present invention, since it is one of the objects to use the resistance value of the variable resistance element comprising the variable resistor whose resistance value is changed in response to the pulse voltage for storing information, it is important whether the resistance value of the variable resistance element determined by the application of the pulse voltage is stably maintained until the next pulse voltage application or not. Thus, this point will be examined with reference to the drawings hereinafter.
FIGS. 17 and 18 are graphs showing the resistance values of the variable resistance element at room temperature after the variable resistance element have been kept at a high temperature (150° C.) for 10 hours, 100 hours, and 1000 hours. FIG. 17 shows the case where the variable resistance element is kept in the low resistance state, and FIG. 18 shows the case where the variable resistance element is kept in the high resistance state. In addition, in either case, the measurement is performed by the same method as the measurement shown in FIG. 12 and the element formed of the anatase-type titanium oxide having the crystal grain diameter of 2 to 3 nm was used as the object to be measured similar to FIG. 12 .
As shown in FIG. 17 , according to the element of the present invention comprising the anatase-type titanium oxide having the crystal grain diameter of 2 to 3 nm, it has been confirmed that even after 1000 hours under the high-temperature state, the low resistance state can be maintained. In addition, as shown in FIG. 18 , according to the element of the present invention comprising the anatase-type titanium oxide having the crystal grain diameter of 2 to 3 nm, it has been confirmed that even after 1000 hours under the high-temperature state, the high resistance state can be maintained.
Thus, according to the measurement results in FIGS. 17 and 18 , it is confirmed that the element of the present invention can maintain the resistance value preferably under the high-temperature state. In other words, it is confirmed that the element of the present invention can write data repeatedly by the application of the voltage pulse and can be used as a nonvolatile memory device having favorable data retain characteristics under the high-temperature circumstance.
Next, the crystal structure of titanium oxide constituting the element of the present invention will be described with reference to the drawings.
FIG. 19 shows selected-area electron beam diffraction images of a fine crystal region of titanium oxide observed by a super-high-resolution transmission electron microscope. Similar to X-ray, since an electron beam satisfies the reflection condition of Bragg, a formula 1 is established where “λ” is a wavelength of an electron wave, “V” is an acceleration voltage, “−e” is the charge of an electron, and “θ” is diffraction direction.
2d sin θ=λn (n is an integer) Formula 1
Here, λ is calculated by a formula 2 where “h” is a Planck constant, and “m>” is the mass of an electron.
λ
=
h
2
m
eV
Formula
2
According to the diffraction image formed when the electron beam and the like collides against a crystal, since the electron beam emitted in a diffraction direction at angle of 2θ with respect to an incident direction forms the profile of a circular cone having a semi-apex angle of 2θ with the incident direction as an axis, an interference spot is provided on a photographic dry plate as a concentric video image. The crystal structure at the observed region can be identified from the angle and the ring interval of the interference spot.
FIG. 19A shows the diffraction image in the high resistance state, and FIG. 19B shows the diffraction image in the low resistance state. While a diffraction ring of 3.54 Å can be identified in the diffraction image shown in FIG. 19A , the diffraction ring of 3.54 Å cannot be identified in the diffraction image shown in FIG. 19B . Furthermore, after analyzing the lattice image of the fine crystal of titanium oxide by the TEM provided by the observation and two-dimensional Fourier transformation corresponding to the lattice image, it is confirmed that the diffraction ring of 3.54 Å is derived from the anatase-type (101) face based on a face interval of the diffraction spot and an appearance pattern of the diffraction spot.
More specifically, while many (101) faces exist in the crystal of the anatase-type titanium oxide programmed in the high resistance state, the number of the (101) faces is reduced in the crystal of the anatase-type titanium oxide in the low resistance state. Since the (101) face is low in atomic packing factor and has a structure in which oxygen is out on the surface. In addition, it is reported that the (101) face is low in surface energy and in a very stable state. (refer to “Static simulation of bulk and selected surfaces of anatase TiO 2 ”, Surface Science, 490 (2001), pp. 116-124 by A. Beltran et al.).
Thus, it is considered that oxygen on the (101) surface is easily absorbed and desorbed and a crystal can be easily formed. Since the formation of the crystal surface largely contributes to the switching phenomenon of the present invention, the lattice defect of oxygen and the like on the (101) face is generated due to the negative voltage pulse, and as a result, carrier conduction is generated. The positive voltage pulse complements the lattice defect of oxygen on the (101) face and the conduction is reduced.
After keen examination by the inventor of the present invention, it is found that while this phenomenon is generated in the anatase-type crystal having the crystal grain diameter of 30 nm or less, the resistance and the crystal structure are not changed in a rutile-type titanium oxide. Since the anatase type (density: 3.90 g/cm 3 ) is lower in density than the rutile type (density: 4.27 g/cm 3 ) and has a metastable crystal structure, it is easily affected by the application of the voltage pulse, and it is considered that as the crystal grain diameter becomes small, the (101) surface is changed more apparently.
In addition, although the lower electrode 3 is formed of TiN film and the upper electrode 1 is formed of Pt film in the above description, the present invention is not limited to the above materials, and they may be formed of Ir, Os, Ru, Rh, Pd, Ti, Co, W or an alloy of Ti and W. The same goes for the following embodiments. In addition, although the resistance value shows the high resistance in response to the application of the positive voltage pulse and the resistance value shows the low resistance in response to the application of the negative voltage pulse in the above description, the polarity can be changed by the combination of the upper and lower electrode materials. In addition, the applying time of the pulse is also changed by the combination of the electrode materials. This is considered because oxygen moved by the application of the voltage reaches the electrode material and the polarity, applying time and voltage is changed due to a difference in oxygen affinity of the electrode material.
In addition, in the case where the variable resistor 2 is formed of titanium oxynitride having the crystal grain diameter of 30 nm or less also, when the positive voltage (3V) having a pulse width of 200 nsec and the negative voltage (−3V) having a pulse width of 100 nsec are alternately applied, the same resistance ratio (rate of the resistance value of the high resistance state to the resistance value of the low resistance state) as the above has been confirmed. That is, the variable resistor 2 may be formed of titanium oxynitride other than titanium oxide.
SECOND EMBODIMENT
A description will be made of an element of the present invention and its manufacturing method according to a second embodiment (referred to as “this embodiment” occasionally hereinafter). According to this embodiment, a variable resistor 2 is formed of titanium oxynitride in which one part of oxygen of anatase-type titanium oxide is replaced with nitride, so that only step S 2 for depositing a variable resistor film is different from the manufacturing method of the first embodiment shown in FIG. 10 .
That is, similar to the first embodiment, a titanium nitride (TiN) film serving as a conductive material and having a thickness of 200 nm is deposited on a base substrate by the sputtering method to form a lower electrode 3 (step S 1 ). Then, oxidation treatment is performed on the surface of the TiN film 3 under an atmosphere containing oxygen. The heat treatment is performed at 250° C. to 500° C. with an electric furnace or a lamp heating device. Thus, anatase-type titanium oxynitride having a crystal grain diameter of 30 nm or less is formed on the surface of the TiN film 3 .
Then, steps S 3 to S 8 are performed by the same method as the above-described method in the first embodiment, whereby a variable resistance element is produced. According to the variable resistance element produced by the above method, since an variable resistor film is formed only by performing the oxidation treatment on the surface of the lower electrode 3 under the above condition in the step S 2 for depositing the variable resistor film, the process is simplified.
THIRD EMBODIMENT
A third embodiment (referred to as “this embodiment” occasionally hereinafter) will be described with reference to FIGS. 20 to 22 . This embodiment relates to the constitution of a semiconductor memory device comprising the element of the present invention described in the first or second embodiment.
FIG. 20 is a schematic block diagram showing the constitution of a semiconductor memory device comprising the element of the present invention (referred to as “device of the present invention” occasionally hereinafter). A device 30 of the present invention shown in FIG. 20 comprises a memory cell array 31 comprising a plurality of arranged memory cells each having the element of the present invention and, as peripheral circuits of the memory cell array 31 , a control circuit 32 , a read circuit 33 , a bit line decoder 34 , a word line decoder 35 , and voltage pulse generation circuit 36 .
The word line decoder 35 is connected to each word line of the memory cell array 31 and selects the word line of the memory cell array 31 based on an address signal, and the bit line decoder 34 is connected to each bit line of the memory cell array 31 and selects the bit line of the memory cell array 31 based on the address signal.
The voltage pulse generation circuit 36 generates voltages to be applied to the bit line and the word line used in the reading action, the programming action and the erasing action of the memory cell array 31 . At the time of programming action, the voltages of the bit line and the word line are set such that a voltage pulse having a voltage higher than the threshold voltage is applied only to between the upper electrode and the lower electrode of the variable resistance element of the memory cell selected by the address signal and the voltages are applied from the voltage pulse generation circuit 36 to the selected and unselected bit lines and the selected and unselected word lines through the bit line decoder 34 and the word line decoder 35 .
The control circuit 32 controls the programming, erasing and reading actions of information to the memory cell constituting the memory cell array 31 . When a programming command signal to program information at a specific address is applied to the control circuit 32 , the control circuit 32 gives a command of voltage pulse generation to the voltage pulse generation circuit 36 and gives a command signal for selecting the memory cell corresponding to the address signal to the bit line decoder 34 and the word line decoder 35 .
The bit line decoder 34 and the word line decoder 35 set the voltages to be applied to the bit lines and the word lines in such a manner that the pulse voltage outputted from the voltage pulse generation circuit 36 having a voltage higher than the threshold voltage is applied to only between the upper electrode and the lower electrode of the variable resistance element of the object memory cell. Thus, the voltage higher than the threshold voltage is applied to the selected memory cell, and the resistance value of the variable resistance element is changed and the information is programmed in the selected memory cell.
In addition, it is to be noted that in the programmed state, the resistance state of the variable resistance element is in the low resistance state hereinafter. At this time, when an erase command signal to erase information at the specific address is applied to the control circuit 32 , similar to the method as that of the programming, the specific memory cell to be erased is selected and the pulse voltage having the predetermined voltage value is applied to the memory cell, and the resistance state of the variable resistance element of the memory cell is changed to the high resistance state, whereby the information is erased.
In addition, according to the reading action, a voltage is applied to the selected memory cell, and a current value of the memory cell is converted to a voltage value by the bit line decoder 34 , and this voltage value is read by the read circuit 33 , whereby information is read.
In addition, the control circuit 32 is provided with functions as a general address buffer circuit, data input/output buffer circuit, and a control input buffer circuit although they are not shown.
FIG. 21 is a circuit diagram showing one constitution example of the memory cell array 31 . The memory cell array 31 shown in FIG. 21 has a so-called 1T1R constitution in which one memory cell has one selection transistor and one variable resistance element R. Referring to FIG. 21 , the gate of the selection transistor of each memory cell is connected to the word line (W 1 to Wn) and each word line is connected to the word line decoder 35 . In addition, the source of the selection transistor of each memory cell is connected to the source line S. In addition, one end (upper electrode side) of the variable resistance element R of each memory cell is connected to the bit line (B 1 to Bm), and each bit line is connected to the bit line decoder 34 . In addition, “n” and “m” are natural numbers.
The operation of the semiconductor memory device will be described with reference to FIGS. 20 and 21 .
First, the programming action of the memory cell will be described. Here, as described above, the programmed state is defined such that the variable resistance element R is in the low resistance state. The word line Wx (x is a natural number) connected to the selected cell is set at +2V according to the address signal of the word line decoder 35 , and the word line Wy (y is a natural number) connected to the unselected cell is set at 0V according to the address signal of the word line decoder 35 . Thus, the source line is set at 0V and the bit line Bx connected to the selected cell is set at +2V according to the address signal of the bit line decoder 34 , and the bit line By connected to the unselected cell is set at 0V according to the address signal of the bit line decoder 34 . Thus, since the positive voltage is applied to the upper electrode of the variable resistance element R of the selected cell, data is programmed to the low resistance state. Meanwhile, since the voltage is not applied to the variable resistor of the variable resistance element R of the unselected cell, data is not programmed (data is not changed).
Here, although the voltage applied to the word line Wx is set at +2V in the above description, this value may only have to be not less than a voltage that turns on the selection transistor (the threshold voltage of the transistor). Similarly, although the voltage applied to the bit line Bx is set at +2V in the above description, the present invention is not limited to this value and when the source line is at the ground voltage, it only has to be not less than the voltage that switches the variable resistance element (threshold voltage of the switching operation).
Next, the reading action of the memory cell will be described. The word line Wx connected to the selected cell is set at +2V according to the address signal of the word line decoder 35 , and the word line Wy connected to the unselected cell is set at 0V according to the address signal of the word line decoder 35 . Thus, the source line is set at 0V, and the bit line By connected to the unselected cell is set at 0V according to the address signal, and the bit line Bx connected to the selected cell is set at read voltage +1V according to the address signal of the bit line decoder 34 . This read voltage is not limited to +1V and it may be less than the voltage that switches the variable resistance element R (threshold voltage of the switching operation), to prevent the variable resistance element R of the unselected sell from being switched and prevent the data from being changed. For example, the read voltage may be set at +0.7V that is a voltage value applied to the variable resistance element to be measured by the parameter analyzer 23 when the I-v characteristics of the variable resistance element is measured on the condition that the resistance value is not changed in the first embodiment.
When the read voltage is applied, the memory cell current flowing in the selected memory cell is converted to a voltage value by the bit line decoder 34 , and this voltage value is outputted to the read circuit 33 and determined in the read circuit 33 , and its result is transferred to the control circuit 32 and outputted from the control circuit 32 to the outside, whereby the reading action is performed. When the resistance state of the variable resistance element of the selected memory cell is high, the memory cell current is small and when the resistance state is low, the memory cell current is large, so that data can be read by converting this current difference to the voltage value.
Next, the erasing action of the memory cell will be described. Here, as described above, the erased state is defined that the variable resistance element R is in the high resistance state. The word line Wx connected to the selected cell is set at +2V according to the address signal of the word line decoder 35 , and the word line Wy connected to the unselected cell is set at 0V according to the address signal of the word line decoder 35 . Thus, the source line is set at +2V and the bit line Bx connected to the selected cell is set at 0V according to the address signal of the bit line decoder 34 , and the bit line By connected to the unselected cell is set at +2V according to the address signal of the bit line decoder 34 . Thus, since the negative voltage is applied to the upper electrode of the variable resistance element R of the selected cell, data is erased to the high resistance state (data is written to the high resistance state). Meanwhile, since the voltage is not applied to the variable resistor of the variable resistance element R of the unselected cell, data is not erased (data is not changed).
Here, similar to the programming action, although the voltage applied to the word line Wx is set at +2V in the above description, this value is not limited to the above value as long as it is not less than the threshold voltage of the transistor, and similarly, although the voltage applied to the bit line Bx is set at +2V in the above description, when the source line is at the ground voltage, this value is not limited to the above value as long as it is not less than the threshold voltage of the switching operation.
As one example of the memory cell constituting the above-described device of the present invention, a memory cell having the 1T1R constitution as shown in a schematic sectional view in FIG. 22 can be used. The device of the present invention having the above memory cell is manufactured by the following manufacturing process.
First, a selection transistor T is formed on a semiconductor substrate 40 . That is, the selection transistor T having a gate insulation film 42 , a gate electrode 43 , a drain diffusion layer area 44 and a source diffusion layer area 45 is formed on the semiconductor substrate 40 having an element isolation area 41 . At this time, peripheral circuits (the control circuit 32 the read circuit 33 , the bit line decoder 34 , the word line decoder 35 , and the voltage pulse generation circuit 36 and the like) other than the memory cell are also formed although they are not shown.
Then, an interlayer insulation film 46 is formed of BPSG (Boron Phosphorous Silicate Glass), and a contact hole 47 reaching the drain area 44 of the selection transistor T is formed by the well-known photolithography method and dry etching method. Thus, a contact plug is formed by embedding conductive polysilicon only in the contact hole 47 .
Then, an ohmic contact layer 48 is formed by depositing a Nm film having a thickness of 100 nm/50 nm by the sputtering method, to stably ensure the electric connection between the conductive contact plug embedded in the contact hole 47 and a lower electrode 49 constituting the variable resistance element R. Then, the lower electrode 49 is formed by depositing a TiN film having a thickness of 200 nm on the ohmic contact layer 48 .
Then, a variable resistor film 50 is formed by depositing a titanium oxide film having a thickness of 5 to 50 nm on the lower electrode (TiN film) 49 by the DC magnetron sputtering method. Then, an upper electrode 51 is formed by depositing a Pt film having a thickness of 10 nm. Then, the upper electrode 51 , the variable resistor film 50 , and the lower electrode 49 are sequentially processed by the well-known photolithography and dry etching, whereby the variable resistance element R is completed. Since the detailed manufacturing method of the variable resistance element R has been described in the first embodiment, it will be omitted here.
After the variable resistance element R has been formed as described above, an interlayer insulation film 52 having a thickness of 50 to 60 nm is formed on the variable resistance element R, and a contact hole 54 connected to the variable resistance element R and a contact hole 53 connected to the source diffusion layer area 45 of the selection transistor T are formed.
Next, a wiring 55 and a wiring 56 are formed by depositing a film of TiN/Al—Si/TiN/Ti as wiring materials and processing the film by the well-known photolithography and dry etching.
Then, an interlayer insulation film 57 is formed, a contact hole (not shown) reaching the wiring 55 or the wiring 56 is formed, and a wiring 58 is formed by depositing a TiN/Al—Si/TiN/Ti film and processing the film by the well-known photolithography method and dry etching (processing pattern is not shown). Finally, an SiN film is formed as a surface protection film 59 by the plasma CVD method, whereby the semiconductor memory device comprising the variable resistance element R and the selection transistor T in the memory cell is completed.
In addition, although contact hole formation and wiring processing of the peripheral circuit are omitted in the above manufacturing process, they are to be formed at the same time of the formation of the components in the memory cell.
In addition, although the variable resistor 50 is formed by the DC magnetron sputtering method in this embodiment, it may be formed by the CVD method as described in the first embodiment.
Although the above description has been made of the driving method of the variable resistance element and the memory device having the variable resistance element as the memory cell, showing specific numeric values, since it has been confirmed that the specific numeric value varies depending on the material, the composition and the structure of the variable resistance element, so that the manufacturing method according to the present invention and the device according to the present invention are not limited to the exemplified numeric value in the above embodiments. In addition, although the functional constitution and the sectional structure of the device according to the present invention have been specifically described, the constitution and the structure are only one example, so that they can be optionally changed based on the scope of the present invention.
For example, although the memory cell has the 1T1R constitution comprising the variable resistance element R and the selection transistor in the third embodiment, the present invention is not limited to this. The memory cell may have a constitution in which the bit line and the word line are directly connected to the upper electrode or the lower electrode, respectively, and data of a variable resistor disposed at an intersection point (cross point) between both electrodes is directly read, that is, a cross-point constitution. In this case, the constitution shown in FIG. 20 showing the case where the data is read through the bit line decoder 34 may be changed to the constitution in which the data is read through the word line decoder 35 .
In addition, in order to reduce a parasitic current in the cross-point constitution, a memory cell may have a 1D1R constitution in which the variable resistance element R and a diode are connected in series. Although the diode is connected to the variable resistor in series outside the upper electrode or the lower electrode in general, the diode may be disposed between the variable resistor and the upper electrode or between the variable resistor and the lower electrode. The diode may be formed of a material showing PN diode characteristics or Schottky diode characteristics or varistor such as ZnO and Bi 2 O 3 .
In addition, although the voltage pulse for the programming, erasing and reading actions are generated from one circuit block in the voltage pulse generation circuit shown in FIG. 20 , a voltage pulse generation circuit may be provided to generate a voltage pulse with respect to each operation. Furthermore, the voltage pulse generation circuit to generate the voltage pulse for the reading action may be provided in the bit line decoder 34 and the word line decoder 35 .
In addition, according to the element of the present invention, although the variable resistor is sandwiched between the upper electrode and the lower electrode, the variable resistor is not necessarily in contact with both electrodes as long as it can be electrically connected to them. In this case, an area of the region in which either one of the electrodes and the variable resistor are opposed may be regarded as an electrode area.
Furthermore, although titanium nitride is designated by TiN in the description of each embodiment, this is only an abbreviation and its relative proportion is not limited.
In addition, although the description has been made of the anatase-type titanium oxide in the third embodiment, the material is not limited to titanium oxide but may be anatase-type titanium oxynitride in which a part of oxygen is replaced with nitrogen.
The present invention can be applied to the semiconductor memory device comprising the variable resistance element whose electric resistance is changed when a voltage pulse is applied to both ends thereof. | Provided is a variable resistance element capable of performing a stable resistance switching operation and having a favorable resistance value retention characteristics, comprising a variable resistor 2 sandwiched between a upper electrode 1 and lower electrode 3 and formed of titanium oxide or titanium oxynitride having a crystal grain diameter of 30 nm or less. When the variable resistance 2 is formed under the substrate temperature of 150° C. to 500° C., an anatase-type crystal having a crystal grain diameter of 30 nm or less is formed. Since the crystalline state of the variable resistor changes by applying a voltage pulse and the resistance value changes, no forming process is required. Moreover, it is possible to perform a stable resistance switching operation and obtain an excellent effect that the resistance fluctuation is small even if the switching is repeated, or the variable resistance element is stored for a long time under a high temperature. | 7 |
FIELD OF THE INVENTION
The present invention relates to beverage dispensing. More specifically, but not exclusively, the present invention relates to a beverage dispensing system having machine vision for use in adjusting or controlling beverage dispensing parameters.
BACKGROUND OF THE INVENTION
Consumers that desire a certain beverage are required to purchase, store, retrieve, or prepare the beverage to meet their taste. For example, pre-packaged beverages (such as beverages packaged in cans or bottles) may create storage space issues and issues with transportation. Where beverages are prepared by the consumer, there is the attendant inconvenience of preparing the beverage. In recent years, consumers are turning to single serve pods/cartridges to deliver their hot or even cold beverages through countertop or water cooler based systems. These pods typically may contain a powder, concentrate, or grounds that mix with a fluid to create the beverage. There are examples of current countertop systems that detect the type of pod and configure the system accordingly. However, the use of such systems may limit the ability of a consumer to prepare beverages which match their taste. Even where such systems allow a consumer to adjust parameters affecting taste, doing so may be inconvenient and where multiple users are using the same beverage dispensing system may require each user to modify settings before each use. What is needed is a beverage dispensing system which assists users in preparing beverages according to their individual tastes in a way that is convenient to the users.
BRIEF SUMMARY OF THE INVENTION
Therefore, it is a primary object, feature, or advantage of the present invention to improve over the state of the art.
It is another object, feature, or advantage of the present invention to provide a beverage dispensing system which is convenient to use.
Another object, feature, or advantage of the present invention is to provide a beverage dispensing system which provides customized settings to match specific consumer needs.
Yet another object, feature, or advantage of the present invention is to provide for tracking beverage usage.
A still further object, feature, or advantage of the present invention is to provide for associating users with their user preferences.
Another object, feature, or advantage of the present invention is to provide for recognizing users.
Yet another object, feature, or advantage of the present invention is to provide for recognizing containers.
A still further object, feature, or advantage of the present invention is to provide for predicting beverage settings based on user, container, time, or other information.
Another object, feature, or advantage of the present invention is to provide for associating restrictions on beverage dispensement based on the user or other parameters.
One or more of these and/or other objects, features, or advantages of the present invention will become apparent from the specification and claims that follow. No single embodiment need exhibit all of these objects, features, or advantages. The present invention is not to be limited to or by these objects, features, or advantages.
According to one aspect of the present invention, a refrigerator is provided. The refrigerator includes a refrigerator cabinet, a fresh food compartment disposed within the refrigerator cabinet, a freezer compartment disposed within the refrigerator cabinet, and a beverage dispensing system operatively connected to the refrigerator cabinet and configured to dispense beverages. The refrigerator also includes an imaging device associated with the beverage dispensing system and an intelligent control associated with the beverage dispensing system and operatively connected to the imaging device. The intelligent control may be configured to determine an identity of a user of the beverage dispensing system based upon image information acquired with the imaging device. The beverage dispensing system may be configured to adjust beverage parameters based on the identity of the user.
According to another aspect of the present invention a method of dispensing a beverage is provided. The method includes providing a refrigerator having a refrigerator cabinet, a fresh food compartment disposed within the refrigerator cabinet, a freezer compartment disposed within the refrigerator cabinet, a beverage dispensing system operatively connected to the refrigerator cabinet and configured to dispense beverages, an imaging device associated with the beverage dispensing system, and an intelligent control associated with the beverage dispensing system and operatively connected to the imaging device. The method further includes acquiring image information using the imaging device and determining a beverage dispensing system setting using the image information. The image information may include image information associated with a person and/or image information associated with a container.
According to another aspect of the present invention, a method of dispensing a beverage is provided. The method includes providing a refrigerator having a refrigerator cabinet, a fresh food compartment disposed within the refrigerator cabinet, a freezer compartment disposed within the refrigerator cabinet, a beverage dispensing system operatively connected to the refrigerator cabinet and configured to dispense beverages, a sensing device associated with the beverage dispensing system, and an intelligent control associated with the beverage dispensing system and operatively connected to the sensing device. The method further includes acquiring container information using the sensing device and determining a beverage dispensing system setting using the container information. The sensing device may be an imaging device or may be an RFID reader or other type of device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates one embodiment of a beverage dispensing system and image sensor, in this instance the beverage dispensing system and image sensor are integrated within a refrigerator.
FIG. 2 illustrates a block diagram representation of a user recognition system for a beverage dispensing system.
FIG. 3 illustrates a flow diagram representation of the various input parameters for a beverage dispensing system settings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a refrigerator 10 having a fresh food compartment 14 and a freezer compartment 12 . The fresh food compartment 14 has a door 18 and the freezer compartment 12 has a door 16 . The refrigerator 10 includes a beverage dispensing system 22 which is shown in the door 16 . The refrigerator 10 also includes an image sensor 24 which is shown in the door 16 and above the beverage dispensing system 22 , although the image sensor may be otherwise positioned. The image sensor 24 is used to assist in acquiring images for use in user recognition, image recognition or other functions. As shown in FIG. 1 , the refrigerator 10 is shown in a side-by-side configuration. Of course, the refrigerator 10 may take on other configurations as well, such as a bottom mount freezer configuration.
FIG. 2 illustrates a block diagram representation of a beverage dispensing system 22 . The beverage dispensing system 22 may include beverage dispenser components 23 . The beverage dispenser components 23 may include actuators, valves, pumps and nozzles to allow the chosen beverage (colas, sparkling water, iced tea, lemonade, fruit punch, hot chocolate, hot tea, coffee, milk, water, hot water, etc) to dispense into a consumer's chosen container (cup, glass, mug, etc). The beverage dispensing system 22 may also dispense ice cubes and or crushed ices.
Another component of the beverage dispensing system 22 is an image sensor 24 which is shown in the door 16 and above the beverage dispensing system 22 (refer to FIG. 1 ). The image sensor may be a device that converts an optical image to an electric signal. The image sensor 24 may be a charge-coupled device (CCD) or a complementary metal-oxide semiconductor (CMOS) active-pixel sensor, or other type of image sensor or camera.
Another component of the beverage dispensing system 22 is a display 26 . The display 26 may display images or symbols which represent the state of the refrigerator, such as fresh food temperature, freezer temperature, beverage dispenser functions and recognition of the present user. The display 26 may be a liquid crystal display (LCD), an organic electro luminescent device (OLED), a quantum-dot-based LED (QDLED), a interferometric modulator display (iMoD), surface-conduction electron-emitter display (SED), or a field emission display (FED). Of course, the image display 26 may use other display technology as well. The display 26 may also be a touch screen.
Another component of the beverage dispensing system 22 are user controls 28 . The user controls 28 may include controls such as buttons, touch screen display inputs, sliders or switches, which enable a user to select a preferred dispensing operation or selected other settings.
Another component of the beverage dispensing system 22 is a memory/storage device 34 . The memory/storage 34 device may be used to store individual user information and beverage usage patterns. The beverage usage patterns may be daily, weekly, monthly, yearly or for any other period of time. The memory/storage 34 device may be a magnetic memory or a form of semiconductor storage. Of course, the memory/storage device 34 may use other technology as well.
Another component of the beverage dispensing system 22 is reader/detector 25 . The reader/detector 25 may be a radio-frequency identification (RFID) system. Radio-frequency identification (RFID) tag may be affixed to the user's beverage container or a microchip may be embedded within the user's beverage container for the purpose of identifying a particular beverage container. As will be discussed later herein the beverage container may be associated with a particular user or type of beverage.
Another component of the beverage dispensing system 22 is an image processing component 32 . The image processing component 32 resides within the intelligent controller 30 and processes the electrical signal from the image sensor 24 . The image processing component 32 may be implemented in hardware or software or a combination thereof. Where the image processing component 32 is implemented in hardware a dedicated chipset may be used.
Another component of the beverage dispensing system 22 is an intelligent control 30 . The intelligent control 30 may function as a main controller. The intelligent control 30 sets the states and controls various refrigerator 10 functions based on those states, including states associated with the fresh food compartment 14 , freezer compartment 12 , and beverage dispenser components 23 . The intelligent control 30 may be a microcontroller, microprocessor, or other type of intelligent control. The intelligent control 30 is electrically connected to the beverage dispenser components 23 , and the image sensor 24 , the display 26 , the user controls 28 , the reader/detector 25 and the memory/storage device 34 .
FIG. 3 illustrates a flow diagram of the various input parameters for the beverage dispensing settings 34 to provide a safe and optimized user experience of the beverage dispenser system 22 . The image database 38 which is read and written to the memory/storage 34 contains a container image file and user image file. Each of the image files are obtained via the image sensor 24 and processed within the intelligent control 30 via the image processing component 32 . The preference database 40 which may be read and written to the memory/storage 34 contains user preferences, user usage patterns (hourly, daily, monthly, etc.), nutritional information for each beverage and user restrictions. The user interface 36 contains user controls such as buttons and/or a touch screen.
A user may setup a configuration to associate their image, a plurality of container images and a plurality of preferences via the user controls 28 . The intelligent control 30 may display user preference queries via the display 26 for the user to respond to. The intelligent control 30 may request the user to enter their name, any restrictions and any beverage preferences which are time dependent, such as coffee in the morning. The intelligent control 30 may request the user to stand still for their image and/or any preferred containers image to be acquired by the image sensor 24 . Alternatively, to add in the setup, the beverage dispensing may monitor and record use over a period of time. The data from that monitoring process may be used to assist in setting up preferences. The preferences may be parental overrides and child restrictions. Also, the preferences may be patterns of usage such as, coffee or orange juice in the morning. The beverage dispensing system 22 may identify patterns of usage such as, coffee or orange juice in the morning.
Example 1
The beverage dispensing system 22 may de-activate the hot water from dispensing when children are using the beverage dispenser components 23 . Thus in this example, the beverage dispensing system 22 provides a safe and optimized usage experience of the beverage dispenser components 23 which may prevent a child from being burned or scalded by the hot water. To do so, the image sensor 24 may acquire an image of the user and determine that the user is a child. One way of doing so is to compare an image of the user with images within a database to determine a match and to then access data associated within the image indicating that the user is a child.
Example 2
The beverage dispensing system 22 may programmed to prevent children from drinking too much of a specific type of beverage. Thus in this example, the beverage dispensing system 22 may limit a child to four caffeinated drinks per day, or no more than one caffeinated drink per hour. Additionally the beverage dispensing system may not allow the child to have caffeinated beverages after a certain hour. The beverage dispensing system 22 may then prevent a child from over indulging in a beverage which may cause them to become over caffeinated and they are therefore provided a safe and optimized beverage dispensing usage experience. To do so, the image sensor 24 may acquire an image of the user and determine that the user is a child. One way of doing so is to compare an image of the user with images within a database to determine a match and to then access data associated within the image indicating that the user is a child.
Example 3
The beverage dispensing system 22 may prepare a given drink that the consumer uses on a regular basis. Thus in this example, the beverage dispensing system 22 may provide coffee or juice in the morning, cola throughout the day. The user places their beverage container into the beverage dispenser components 23 and receives their preferred beverage without the need to make any decisions and they are therefore provided a safe and optimized beverage dispensing usage experience. To do so, the image sensor 24 may acquire an image of the user and determine the identity of that the user. One way of doing so is to compare an image of the user with images within a database to determine a match and to then access data associated within the image indicating that specific user.
Example 4
The beverage dispensing system 22 may recognize a type of container, such as a mug or a specific glass. Thus in this example, the beverage dispensing system 22 may recommend via the user interface a beverage that matches the container type or automatically dispense a beverage that matched the container type. To do so, the image sensor 24 may acquire an image of the container and determine the type of container. One way of doing so is to compare an image of the container with images within a database to determine a match and to then access data associated within the image indicating that specific container type. The user may then place their beverage container into the beverage dispenser components 23 and receive their preferred beverage and they are therefore provided a safe and optimized beverage dispensing usage experience.
Example 5
The beverage dispensing system 22 may display branded logos. Thus in this example, the beverage dispensing system 22 may utilize brandable logos for the user to make their beverage dispensing decisions. To do so, the image sensor 24 may acquire an image of the user and determine the users preferred beverages and then display a plurality of branded logos. One way of doing so is to compare an image of the user with images within a database to determine a match and to then access data associated within the image indicating that user. The user may then place their beverage container into the beverage dispenser components 23 and receive their chosen beverage and they are therefore provided a safe and optimized beverage dispensing usage experience.
Example 6
The beverage dispensing system 22 may display the status of the beverage dispensing system 22 . Thus in this example, the beverage dispensing system 22 gives the user important information graphically, iconically and/or textually to the real-time operation of the system via the display 26 . The information may include the plurality of beverage dispenser components 23 , the image sensor 24 , the reader/detector 25 , etc. Also, the beverage dispensing system 22 may presently be brewing a beverage, or carbonating a beverage, etc. As these processes occur internally they are not visible to the user, the beverage dispensing system 22 may inform to its state via the display 26 . The beverage dispensing system 22 may also notify the user of the need to replace a beverage which is now empty or its expiration date has expired. To do so, the intelligent control 30 may query and acquire the status of the various beverage dispenser components 23 , the image sensor, the display 26 , the user controls 28 the memory/storage 34 , the reader/detector 25 and the image processing component 32 . One way of doing so is to compare the existing status of the various beverage dispenser components 23 , the image sensor, the display 26 , the user controls 28 the memory/storage 34 , the reader/detector 25 or the image processing component 32 with the present status of the various beverage dispenser components 23 , the image sensor, the user controls 28 the memory/storage 34 , the reader/detector 25 and the image processing component 32 within a database to determine a change and to then to indicate that to the user via the display 26 .
Example 7
The beverage dispensing system 22 may also display drink information for each user for a given period of time. Thus in this example, the beverage dispensing system 22 gives the user important information such as nutritional or the total volume consumed for each beverage which they may use to adjust their consumption rates. The information may also be used to evaluate costs associated with each beverage over time.
Example 8
The beverage dispensing system 22 may detect a user's container utilizing RFID tags. Thus in this example, the beverage dispensing system 22 recognizes the user based upon the container. To do so, the RFID reader/detector 25 may acquire the identifying information of the container from the RFID tag affixed to the container. One way of doing so is to compare the identifying information located in the RFID tag of the container with identifying information within a database to determine a match and to then access data associated within the identifying information indicating that the user. The system may associate a specific beverage based on the container. The system may also associate the container to a specific user and their beverage preferences. The user then places their beverage container into the beverage dispenser components 23 and is then provided a safe and optimized beverage dispensing usage experience.
Example 9
The beverage dispensing system 22 may detect a user's container utilizing direct contact data communication via a microchip within the container, or other means. Thus in this example, the beverage dispensing system 22 recognizes the user based upon the container. To do so, the RFID reader/detector 25 may acquire the identifying information of the container from the microchip embedded within the container. One way of doing so is to compare the identifying information located in the microchip of the container with identifying information within a database to determine a match and to then access data associated within the identifying information indicating that the user. The system may associate a specific beverage based on the container. The system may also associate the container to a specific user and their beverage preferences. The user then places their beverage container into the beverage dispenser components 23 and is then provided a safe and optimized beverage dispensing usage experience.
Example 10
The beverage dispensing system 22 recognizes the container and not the user. Thus in this example, the beverage dispensing system 22 recognizes the container visually as opposed to utilizing a RFID tag affixed to the container or a microchip embedded into the container. The system may associate a specific beverage based on the container. The system may also associate the container to a specific user and their beverage preferences. Thus in this example, the beverage dispensing system 22 may recommend via the user interface a beverage that matches the container type. To do so, the image sensor 24 may acquire an image of the container and determine the type of container. One way of doing so is to compare an image of the container with images within a database to determine a match and to then access data associated within the image indicating that specific container type. The user may then place their beverage container into the beverage dispenser components 23 and receive their preferred beverage and they are therefore provided a safe and optimized beverage dispensing usage experience. The user then places their beverage container into the beverage dispenser components 23 and is then provided a safe and optimized beverage dispensing usage experience.
Example 11
The beverage dispensing system 22 may limit caloric intake of the user for a given period of time. Thus in this example, the beverage dispensing system 22 prevents the user from dispensing any beverage once a caloric limit has been reached for the given period of time. To do so, the image sensor 24 may acquire an image of the container and/or the user and determine the type of container and/or the user. One way of doing so is to compare an image of the container and/or the user with images within a database to determine a match and to then access data associated within the image indicating that specific container type and/or the user. The beverage dispensing system 22 may query the user regarding limiting caloric intake or the user may initiate limiting caloric intake via the user interface 36 . The user may limit their caloric intake to 1000 calories a day or any other caloric value or time period. The user may then place their beverage container into the beverage dispenser components 23 and receive their preferred beverage and they are therefore provided a safe and optimized beverage dispensing usage experience.
Example 12
The beverage dispensing system 22 may limit drink selections of the user. Thus in this example, the beverage dispensing system 22 prevents the user from dispensing certain beverages, such as sugary or caffeinated beverages, etc. To do so, the image sensor 24 may acquire an image of the container and/or the user and determine the type of container and/or the user. One way of doing so is to compare an image of the container and/or the user with images within a database to determine a match and to then access data associated within the image indicating that specific container type and/or the user. The beverage dispensing system 22 may query the user regarding limiting caloric intake or the user may initiate limiting caloric intake via the user interface 36 . The user may limit their caloric intake to 1000 calories a day or any other caloric value or time period. The user may then place their beverage container into the beverage dispenser components 23 and receive their preferred beverage and they are therefore provided a safe and optimized beverage dispensing usage experience.
Example 13
The beverage dispensing system 22 may inform the user of their beverage usage. Thus in this example, the beverage dispensing system 22 informs the user of their beverage usage via the display 26 for monitoring dietary intake. The information may include total beverages, total volume and total calories for a day, a week, a month or any length of time. The beverage dispensing system 22 may query the user regarding displaying the information or the information may be displayed as a normal operating function of the beverage dispensing system 22 . To do so, the image sensor 24 may acquire an image of the user and determine the user. One way of doing so is to compare an image of the user with images within a database to determine a match and to then access data associated within the image indicating the user and then displaying the beverage usage.
Example 14
The beverage dispensing system 22 may inform the user of their beverage usage. Thus in this example, the beverage dispensing system 22 informs the user of their beverage usage via the display 26 to assist with inventory management. The information may include total beverage usage for a day, a week, a month or any length of time. The beverage dispensing system 22 may query the user regarding displaying the information or the information may be displayed as a normal operating function of the beverage dispensing system 22 . To do so, the image sensor 24 may acquire an image of the user and determine the user. One way of doing so is to compare an image of the user with images within a database to determine a match and to then access data associated within the image indicating the user and then displaying the beverage inventory levels.
Example 15
The beverage dispensing system 22 recognizes indicia on the container. Thus in this example, the beverage dispensing system 22 may recommend via the user interface a beverage that matches the container indicia or automatically dispense a beverage that matched the container indicia. To do so, the image sensor 24 may acquire an image of the container indicia and determine the indicia on the container. One way of doing so is to compare an image of the container indicia with images within a database to determine a match and to then access data associated within the image indicating that specific container indicia. The user may then place their beverage container into the beverage dispenser components 23 and receive their preferred beverage and they are therefore provided a safe and optimized beverage dispensing usage experience.
The invention has been shown and described above with the preferred embodiments, and it is understood that many modifications, substitutions, and additions may be made which are within the intended spirit and scope of the invention. The present invention is not to be limited to any specific embodiment described herein. | A refrigerator is provided which includes a cabinet. A first compartment and second compartment are disposed within the cabinet. A first door provides access to the first compartment and a second door provides access to the second compartment. A beverage dispensing system is operatively connected to the cabinet. A machine vision system associated with the beverage dispensing system. The machine vision system has an imaging device. | 5 |
PRIORITY CLAIM
The present application is a Continuation of U.S. patent application Ser. No. 13/266,886, which is the US National Stage of International Application Serial No. PCT/CN2010/072318, filed 29 Apr. 2010, designating the United States, and claiming priorities to Chinese Patent Application Serial Nos. 200910083408.9 filed 30 Apr. 2009 and 201010158488.2 filed 28 Apr. 2010.
FIELD OF THE INVENTION
The present invention relates to the field of communications and particularly to a method and device for allocating a dedicated scheduling request resource.
BACKGROUND OF THE INVENTION
The Long Term Evolution (LTE)/Long Term Evolution-Advanced (LTE-A) system is a scheduling-based communication system, that is, if there is data to be transmitted in the transmission buffer of a User Equipment (UE), the UE firstly transmits a Buffer Status Report (BSR) to a base station to notify the base station of information of the data to be transmitted in the transmission buffer of the UE. Upon reception of the BSR transmitted from the UE, the base station will allocate the related Uplink-Shared Channel (UL-SCH) resource to the UE according to the amount of the data to be transmitted of the UE and the service type and instruct the UE to transmit the data on the allocated UL-SCH resource.
The UE transmits the BSR to the base station also on the Uplink-Shared Channel (UL-SCH) resource, and if there is a BSR to be transmitted but no uplink-shared channel resource is available, a Scheduling Request will be triggered to request the base station to allocate an uplink-shared channel resource for the BSR to be transmitted.
After the SR is triggered, the SR may be transmitted in either of two ways, i.e., the SR is transmitted on a Dedicated Scheduling Request (D-SR) resource or in a Random Access procedure (RA-SR). When the UE and the base station are synchronized, there may be no available D-SR resource, and when they are unsynchronized, there must be no D-SR resource. D-SR resource is allocated by RRC signaling and transmits on Physical Uplink Control Channel (PUCCH).
Generally, an SR is transmitted under such a fundamental principle that no RA-SR will be used so long as the D-SR resource is available. And the SR can be transmitted repeatedly on the D-SR resource until the UE gets the uplink-shared channel resource allocated by the base station.
In the LTE system, an uplink dedicated scheduling request is transmitted on PUCCH according to PUCCH format1/1a/1b for which a symbol is spread in the frequency domain by being multiplied with a 12-bit cyclic shift sequence to form a 12-bit sequence of symbols, which is in turn spread in the time domain by being multiplied with a 4-bit orthogonal sequence and mapped onto 12×4 time and frequency locations of a Physical Resource Block (PRB) on a timeslot, where three symbols are used for transmission of a Reference Signal (RS), and different users borne on the same PRB are distinguished with different cyclic shift values for a fundamental sequence.
In the system, a part of the PUCCH resource is typically reserved for each subframe as a cell-specific SR resource so that the PUCCH resource is shared amongst UEs in the cell and the base station allocates the cell-specific SR resource to the UEs in the cell according to a specific resource allocation strategy and notifies the D-SR PUCCH resource index, period and subframe offset to the UE by RRC signaling. The meanings of parameters in the RRC signaling are depicted in Table 1, where the RRC signaling includes sr-PUCCH-ResourceIndex, sr-ConfigurationIndex and dsr-TransMax, with their meanings as depicted in the table.
TABLE 1
Parameter
The Meaning of Parameter
sr-PUCCH-
This parameter designates a resource index of a
ResourceIndex
PUCCH resource in a subframe, which is allocated
to the UE for transmission of a D-SR.
sr-
This parameter represents the period and subframe
ConfigurationIndex
offset by which a D-SR is transmitted, UE can
determine its D-SR resource according to this
parameter and the starting subframe of the D-SR
resource.
dsr-TransMax
This parameter represents the maximum number of
transmissions that a D-SR can be transmitted,
and the purpose of introducing this parameter
is to improve the reliability of the D-SR.
The peak rates of the LTE-A are significantly increased compared with the LTE system, and 1 Gbps in the downlink and 500 Mbps in the uplink are required. Also the LTE-A system is required to be well compatible with the LTE system. Carrier Aggregation (CA) has been introduced to the LTE-A system in order to reach the increased peak rates, compatible with the LTE system and full use of the spectrum resource.
Carrier aggregation means that UE can aggregate more than one cell simultaneously, which is different from the legacy radio systems who can only aggregate one cell at a time. In a system supporting carrier aggregation, component carriers may or may not be continuous, and for compatibility with the LTE system, the maximum bandwidth of each component carriers is 20 MHz, and the bandwidths of different component carriers may be same or not.
As for the definition of a primary carrier, a plurality of component carriers may be supported in the uplink in the LTE-A system, and there is no definite concept of a primary carrier so far, which may be cell-specific or UE-specific. If the primary carrier is cell-specific, the primary carrier has to be supported by all of the R10 UEs; and if the primary carrier is UE-specific, the UE has to support its own primary carrier.
With the introduction of CA, a plurality of component carriers have to be supported concurrently in the uplink, so how to configure a UE-specific D-SR resource shall be taken into account in the case of a plurality of component carriers, but a relevant description is absent in the existing standards.
SUMMARY OF THE INVENTION
The invention provides a method and device for allocating a dedicated scheduling request source to configure a UE-specific D-SR resource.
A method for allocating a dedicated scheduling request source according to an embodiment of the invention includes:
configuring a carrier resource in a system supporting carrier aggregation for a user equipment according to a preset scheduling criterion, and allocating corresponding time and frequency resources on the configured carrier resource, wherein the carrier resource together with the time and frequency resources are regarded as a dedicated scheduling request resource; and notifying the user equipment of the carrier resource and/or the time and frequency resources.
A device for allocating a dedicated scheduling request source according to an embodiment of the invention includes:
a resource allocation unit configured to configure a carrier resource for a user equipment according to a preset scheduling criterion, and allocate corresponding time and frequency resources on the configured carrier resource, wherein the carrier resource together with the time and frequency resources are regarded as a dedicated scheduling request resource; and a notification unit configured to notify the user equipment of the carrier resource and/or the time and frequency resources.
A method for transmitting a dedicated scheduling request according to an embodiment of the invention includes:
receiving, by a user equipment in a system supporting carrier aggregation, carrier information and corresponding time and frequency resources information of a dedicated scheduling request resource transmitted from a base station; and transmitting a dedicated scheduling request on the corresponding time and frequency resources on the carrier designated by the base station.
A user equipment according to an embodiment of the invention includes:
a reception unit configured to receive carrier information and corresponding time and frequency resources information of a dedicated scheduling request resource transmitted from a base station; and a dedicated scheduling request transmission unit configured to transmit a dedicated scheduling request on the corresponding time and frequencies on the carrier designated by the base station.
In the embodiments of the invention, in a system supporting carrier aggregation, a carrier resource is chosen for a user equipment as a dedicated scheduling request resource of the user equipment according to a preset scheduling criterion, and time and frequency resources on the chosen uplink component carrier are also allocated for the dedicated scheduling request; and the user equipment is notified of the carrier resource and/or the time and frequency resources, thereby configuring in the system supporting carrier aggregation the time and frequency resources for a dedicated scheduling request of the user equipment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic flow chart of a method for allocating a dedicated scheduling request resource according to an embodiment of the invention;
FIG. 2 is a schematic flow chart of a first embodiment of allocating a dedicated scheduling request resource according to the invention;
FIG. 3 is a schematic flow chart of a second embodiment of allocating a dedicated scheduling request resource according to the invention;
FIG. 4 is a schematic flow chart of a third embodiment of allocating a dedicated scheduling request resource according to the invention;
FIG. 5 is a schematic flow chart of a fourth embodiment of allocating a dedicated scheduling request resource according to the invention;
FIG. 6 is a schematic diagram of switching a dedicated scheduling request resource on different uplink component carriers at different moments of time in the embodiment illustrated in FIG. 5 ;
FIG. 7 is a schematic flow chart of a method for transmitting a dedicated scheduling request according to an embodiment of the invention;
FIG. 8 is a schematic structural diagram of a device for allocating a dedicated scheduling request resource according to an embodiment of the invention; and
FIG. 9 is a schematic structural diagram of a user equipment according to an embodiment of the invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
In embodiments of the invention, in a system supporting carrier aggregation, a carrier resource is configured for a user equipment according to a preset scheduling criterion, and time and frequency resources are allocated on the configured carrier resource, where the carrier resource and the time and frequency resources are regarded as a dedicated scheduling request resource; and
the user equipment is notified of the carrier resource and/or the time and frequency resources.
Referring to FIG. 1 , a method according to an embodiment of the invention includes the following steps.
In a step 101 , in a system supporting carrier aggregation, a carrier resource is configured for a user equipment according to a preset scheduling criterion, and time and frequency resources are allocated on the configured carrier resource, where the carrier resource and/or the time and frequency resources are regarded as a dedicated scheduling request resource.
Here a carrier resource may be chosen for the user equipment according to a preset scheduling criterion as follows: a carrier resource may be chosen randomly according to UE capability information of the user equipment, a carrier resource may be chosen according to a load balance criterion, or a primary carrier may be chosen as a dedicated scheduling request resource of the user equipment. The chosen carrier resource may include one or more uplink component carriers.
The dedicated scheduling request resource may include information on time and frequency resources of one uplink component carrier allocated to the user equipment at any moment of time or information on time and frequency resources of a plurality of uplink component carriers allocated for the user equipment at any preset moment of time.
When a plurality of uplink component carriers are chosen, the user equipment may be configured to transmit a dedicated scheduling request on each of the uplink component carriers, or the user equipment may be configured to transmit a dedicated scheduling request on only one uplink component carrier in one subframe and the chosen uplink component carriers can be used in turn at different subframes.
In a step 102 , the user equipment is notified of the carrier resource and/or the time and frequency resources.
Implementation solutions of the invention are detailed below in connection with embodiments thereof.
Reference is made to FIG. 2 illustrating such an implementation solution that a base station chooses an uplink component carrier according to the capability of the user equipment in the present embodiment as follows.
In a step 201 , a base station determines uplink component carriers supported by the user equipment according to capability information reported from the user equipment. The capability information reported from the user equipment includes information of the uplink component carriers supported by the user equipment.
In a step 202 , one uplink component carrier is chosen randomly from the uplink component carriers supported by the user equipment as a carrier resource of a dedicated scheduling request of the user equipment.
In a step 203 , a resource index of a PUCCH resource on which the dedicated scheduling request is borne is allocated on the chosen uplink component carrier to the user equipment.
In a step 204 , a period and an offset at which the user equipment transmits the dedicated scheduling request are determined for the user equipment. The resource index of the PUCCH resource allocated in the step 203 and the period and offset determined in the step 204 are used as information on time and frequency resources configured for the user equipment.
In a step 205 , the user equipment is notified in an extended RRC signaling of the chosen uplink component carrier and/or the information on the configured time and frequency resources.
A component carrier indication field may be added to an existing RRC signaling so that the extended RRC signaling includes a frequency resource indication field and a time-frequency resource indication filed, and the frequency resource indication field is used to store the carrier information for the dedicated scheduling request, and the time-frequency resource indication filed is used to store the time and frequency resources for the dedicated scheduling request. The time and frequency resources include the resource index of the PUCCH resource, the period and offset for the dedicated scheduling request. The carrier information includes the index of the carrier on which the dedicated scheduling request is transmitted or the frequency of the uplink component carrier. Furthermore, the RRC signaling may include the maximum number of transmissions that the dedicated scheduling request can be transmitted.
For example, the extended RRC signaling is depicted in Table 2. Referring to Table 2, in an embodiment of the invention, a parameter, i.e., an index of a UE-specific D-SR resource (sr-Componentcarrier), can be added optionally compared with the SR configuration information elements in the protocol of LTE Release 8 (R8), so that the extended RRC signaling includes at least the UE-specific D-SR resource index (sr-Componentcarrier), and the period and offset (sr-ConfigurationIndex). Where sr-Componentcarrier represents the component carrier index assigned for the D-SR, sr-ConfigurationIndex represents the period and the subframe offset for transmission of a D-SR. The specific subframe in which a UE transmits a D-SR can be determined according to the parameter of sr-ConfigurationIndex and the starting subframe of a configured D-SR resource.
The RRC signaling may further include dsr-TransMax, which represents the maximum number of transmissions that a D-SR can be transmitted, and the purpose of this parameter is to improve the reliability of the D-SR.
It shall be noted that if the chosen carrier resource is the primary carrier, information indicating the carrier may not be carried in RRC signaling.
TABLE 2
Parameter
The Meaning of Parameter
sr-PUCCH-
The parameter designates a resource index of a
ResourceIndex
PUCCH resource in a subframe, which is allocated
to the UE for transmission of a D-SR.
sr-
The parameter represents a period and a subframe
ConfigurationIndex
offset at which a D-SR is transmitted, and a specific
subframe in which the UE transmits a D-SR may be
determined according to the parameter and a starting
subframe of a configured D-SR resource.
dsr-TransMax
The parameter represents the maximum number of
times that a D-SR is transmitted, and the purpose of
the parameter is to improve the reliability of the
D-SR.
sr-
The parameter designates an index of a component
Componentcarrier
carrier for an SR.
. . .
. . .
Reference is made to FIG. 3 illustrating an example in which a primary carrier is configured as a dedicated scheduling request resource of a user equipment in the present embodiment particularly as follows.
In a step 301 , a base station configures a primary carrier as a carrier resource of a dedicated scheduling request of a user equipment.
If the uplink primary carrier is UE-specific, the base station may determine it per UE and use it as the D-SR sending carrier for this UE. If the uplink primary carrier is cell-specific, the eNB can assign the cell-specific primary carrier as the UE-specific dedicated scheduling resource.
In a step 302 , a resource index of a PUCCH resource used for carrying dedicated scheduling request will be allocated to the user equipment on the primary carrier.
In a step 303 , the period and offset used to carry the dedicated scheduling request will be determined for the user equipment.
The allocated resource index of the PUCCH resource together with the determined period and offset can be used to deduce the time and frequency resources for transmitting the dedicated scheduling request for this user equipment.
In a step 304 , the user equipment is notified by an RRC signaling to inform the configured primary cell and/or the time and frequency resources for transmitting the dedicated scheduling request.
If UE already knows which uplink component carrier is the primary carrier, the RRC signaling can only carry the UE-specific D-SR resource index, period and subframe offset. The current RRC signaling is enough, not need to be extended.
Reference is made to FIG. 4 illustrating such a solution of the invention that a carrier resource is chosen according to a load balance criterion in the present embodiment will be described by way of an example particularly as follows.
In a step 401 , a base station determines uplink component carriers supported by the user equipment according to capability information reported from the user equipment.
In a step 402 , one uplink component carrier is chosen from the uplink component carriers supported by the user equipment as a dedicated scheduling request resource of the user equipment according to a load balance criterion dependent upon information on loads of the uplink component carriers supported by the user equipment.
In a step 403 , a resource index of a PUCCH resource on which a dedicated scheduling request is borne is allocated on the chosen uplink component carrier to the user equipment.
In a step 404 , a period and an offset at which the user equipment transmits the dedicated scheduling request are determined for the user equipment, that is, a specific subframe is configured in which the user equipment transmits the dedicated scheduling request on the chosen uplink component carrier.
In a step 405 , the user equipment is notified in an RRC signaling of the chosen uplink component carrier and/or information on configured time and frequency resources.
A component carrier indication field may be added into an existing RRC signaling as in the embodiment illustrated in FIG. 2 , and reference may be made to Table 2 for details thereof.
Reference is made to FIG. 5 illustrating such a solution of the invention that a dedicated scheduling request resource is allocated in a frequency-hopping mode in the present embodiment will be described by way of an example. In the present embodiment, a dedicated scheduling request may be hopped in frequency in a group of a part or all of uplink component carriers in a temporal order of subframes, but a dedicated scheduling request resource can be allocated on only one uplink component carrier in a subframe.
In a step 501 , a base station determines uplink component carriers supported by a user equipment according to capability information reported from the user equipment.
In a step 502 , more than one uplink component carriers are chosen from the uplink component carriers supported by the user equipment.
In a step 503 , a resource index of a PUCCH resource on which a dedicated scheduling request is borne is allocated on the chosen uplink component carriers to the user equipment.
In a step 504 , a period and an offset at which the user equipment transmits the dedicated scheduling request are determined for the user equipment.
The resource index of the PUCCH resource allocated in the step 503 and the period and offset determined in the step 504 are used as information on time and frequency resources configured for the user equipment.
For example, the base station chooses a number N of ones from the uplink component carriers supported by the UE, where N is larger than one and smaller than or equal to the number of uplink component carriers supported by the UE, and determines a carrier allocating in a subframe an SR resource according to such a criterion that only one component carrier is used in a subframe and switching is performed between the component carriers in the different subframes.
Referring to FIG. 6 , the base station chooses four uplink component carriers, e.g., CC1, CC2, CC3 and CC4, as a dedicated scheduling request resource, and configures CC1 with subframes of an uplink subframe 1, an uplink subframe 5 and an uplink subframe 9, configures CC2 with subframes of an uplink subframe 2 and an uplink subframe 6, configures CC3 with subframes of an uplink subframe 3 and an uplink subframe 7 and configures CC4 with subframes of an uplink subframe 4 and an uplink subframe 8.
That is, the user equipment may transmit a dedicated scheduling request on CC1 in the uplink subframes 1, 5 and 9, on CC2 in the uplink subframes 2 and 6 and on CC3 in the uplink subframes 3 and 7 according to the foregoing configuration.
In a step 505 , the user equipment is notified in an RRC signaling of the chosen carriers and/or information on the configured time and frequency resources. Stated otherwise, the base station notifies in an RRC signaling the location, period and offset of the UE-specific D-SR resource.
Referring to Table 3, an existing RRC signaling may be extended in the present embodiment so that the extended RRC signaling includes a frequency-hopping mode indication (hopping-mode) field and a group of hop component carriers indication (cc-group) field, where the group of hop component carriers indication field is used to store a group of hop component carriers of the user equipment, and the frequency-hopping mode indication field is used to store time and frequency information corresponding to each of the carriers in the group of hop component carriers. The carrier information includes the indexes of the carriers of the dedicated scheduling request resource or information on frequency points of the uplink component carriers as the dedicated scheduling request resource of the user equipment. Of course, the frequency-hopping mode indication field may be omitted if there is only one predefined hopping mode.
TABLE 3
Parameter
The Meaning of Parameter
cc-group
The parameter represents a group of CCs participating
in transmitting SR information of the UE
hopping-
The parameter indicates an SR hopping mode, i.e.,
mode
offsets and periods on each of the CCs
Referring to FIG. 7 , a method for transmitting a dedicated scheduling request according to another embodiment of the invention includes the following steps.
In a step 701 , in a system supporting carrier aggregation, a user equipment receives carrier information and information on time and frequency resources on each carrier of a dedicated scheduling request resource transmitted from a base station.
In a step 702 , a dedicated scheduling request is transmitted on the corresponding time and frequency resources on the carrier designated by the base station.
If the user equipment receives an RRC signaling transmitted from the base station in the step 701 , which includes a frequency resource indication field and/or a time and frequency resource indication field, where the time and frequency resource indication field indicates information on the time and frequency resources on which the dedicated scheduling request is transmitted, and the information on the time and frequency resources includes a resource index of a PUCCH resource, period and offset for the dedicated scheduling request.
Furthermore, the RRC signaling may include the maximum number of times that the dedicated scheduling request is transmitted.
Then in the step 702 , the time and frequency resources used for transmitting dedicated scheduling request can be deduced from the D-SR starting subframe and the period and subframe offset in the time and frequency resource indication field. And then can use the carrier resource indicated in the frequency resource indication field to send the dedicated scheduling request.
If the user equipment receives an RRC signaling transmitted from the base station in the step 701 , which includes a frequency-hopping mode indication field and a group of hop component carries indication field, where the group of hop component carriers indication field is used to store a group of hop component carriers of the user equipment, and the frequency-hopping mode indication field is used to store an offset and a period of a subframe on each carrier in the group of hop component carriers.
Then in the step 702 , the dedicated scheduling request may be transmitted on the corresponding time and frequency resources on an uplink component carrier in the group of hop component carriers in the RRC signaling, and frequency-hopping may be performed in the time and frequency resources indicated in the frequency-hopping mode indication field.
Referring to FIG. 8 , a device for allocating a dedicated scheduling request resource according to an embodiment of the invention includes:
a resource allocation unit 81 configured to configure a carrier resource for a user equipment according to a preset scheduling criterion, and allocate time and frequency resources on the configured carrier resource, where the carrier resource and the time and frequency resources are regarded as a dedicated scheduling request resource; and a notification unit 82 configured to notify the user equipment of the carrier resource and/or the time and frequency resources.
The dedicated scheduling request resource includes information on time and frequency resources of one uplink component carrier allocated to the user equipment at any moment of time.
The resource allocation unit 81 may include:
an uplink carrier choosing unit configured to choose one uplink component carrier for the user equipment as a carrier for a dedicated scheduling request of the user equipment according to the preset scheduling criterion; a time and frequency configuration unit configured to set a subframe for the chosen uplink component carrier; and a PUCCH resource index determination unit configured to allocate on the chosen uplink component carrier to the user equipment a resource index of a PUCCH resource for the dedicated scheduling request.
The uplink carrier choosing unit is configured to determine uplink component carriers supported by the user equipment according to capability information reported from the user equipment, and choose randomly one of the uplink component carriers supported by the user equipment as a carrier for the dedicated scheduling request of the user equipment.
The uplink carrier choosing unit is configured to choose a primary carrier as a carrier for the dedicated scheduling request of the user equipment.
The uplink carrier choosing unit is configured to determine uplink component carriers supported by the user equipment according to capability information reported from the user equipment, and to choose one of the uplink component carriers supported by the user equipment as a carrier for the dedicated scheduling request of the user equipment according to a load balance criterion dependent upon information on loads of the uplink component carriers supported by the user equipment.
The resource allocation unit 81 may be configured to determine uplink component carriers supported by the user equipment according to capability information reported from the user equipment, choose more than one of the uplink component carriers supported by the user equipment, configure on each of the chosen uplink component carriers corresponding time and frequency resources on which the user equipment transmits the dedicated scheduling request and each of which corresponds to one of the uplink component carriers, and allocate a resource index of a PUCCH resource on each of the chosen uplink component carriers to the user equipment.
Referring to FIG. 9 , a user equipment according to an embodiment of the invention includes:
a reception unit 91 configured to receive the carrier and time and frequency resources information used for transmitting the dedicated scheduling request resource; and a dedicated scheduling request transmission unit 92 configured to transmit a dedicated scheduling request on the time and frequency resources on the carrier designated by the base station.
The reception unit 91 is configured to receive an RRC signaling transmitted from the base station, which includes a frequency resource indication filed and a time and frequency resource indication filed. The frequency resource indication filed is used to store the D-SR resource index and the uplink carrier information for transmitting the dedicated scheduling request, and the time and frequency resource indication filed includes the period and subframe offset. And then the dedicated scheduling request transmission unit 92 is configured to determine the time and frequency resource as follows: the DSR resource starting subframe together with the period and offset can be used to deduce the time and frequency resource for dedicated scheduling request. Transmitting the dedicated resource index on the determined time and frequency resource of the carrier indicated in the frequency resource indication filed.
The reception unit 91 is configured to receive an RRC signaling transmitted from the base station, which includes a frequency-hopping mode indication field and a group of hop component carries indication field, where the group of hop component carriers indication field is used to store a group of hop component carriers of the user equipment, and the frequency-hopping mode indication field is used to store a relationship between a carrier and time for user of carriers in a frequency-hopping mode, and then the dedicated scheduling request transmission unit 92 is configured to transmit the dedicated scheduling request on the corresponding time and frequency resources on an uplink component carrier in the group of hop component carriers in the RRC signaling, and perform frequency-hopping in the time and frequency resources indicated in the frequency-hopping mode indication field.
In the embodiments of the invention, in a system supporting carrier aggregation, a carrier resource is chosen for a user equipment as a dedicated scheduling request resource of the user equipment according to a preset scheduling criterion, and time and frequency resources on the chosen uplink component carrier are designated for a dedicated scheduling request; and the user equipment is notified of the carrier resource and the time and frequency resources, thereby configuring a carrier and corresponding time and frequency resources on the carrier for a dedicated scheduling request of the user equipment in the system supporting carrier aggregation. Furthermore, a carrier resource may be chosen for the user equipment according to a variety of criteria, and only some general criteria have been listed in the foregoing embodiments. Of course, alternative criteria will not be precluded, e.g., the locations in frequency domain of uplink component carriers, or the bandwidths of uplink component carriers, which will not be enumerated here.
It will be appreciated that one skilled in the art may make various modifications and alterations to the present invention without departing from the scope of the present invention. Accordingly, if these modifications and alterations to the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention intends to include all these modifications and alterations. | A method and device for distributing the specific scheduling request resources. The method includes: in the multi-carrier aggregation system, according to the set scheduling principle determine the terminal sending carrier resources which may be used by the specific scheduling, the carrier resources comprises the number of carrier and serial number, the carrier resources of the specific scheduling request resources are distributed and sent to the terminal on the determined carrier according to the set scheduling principle; the distributed carrier and time frequency resources which may be used on every carrier are informed to the terminal. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is entitled to the benefit of and incorporates by reference subject matter disclosed in Provisional Patent Application No. 62/183,980 tiled on Jun. 24,2015.
FIELD OF THE INVENTION
[0002] This invention relates to a vertical axis wind turbine. More particularly, the invention relates to a vertical axis wind turbine with a dual cam cyclic pitch control.
BACKGROUND OF THE INVENTION
[0003] Wind turbines have been in use tor many centuries to perform various tasks. But there has been an increased interest in them for power generation in the last decade because of factors like global warming and the need to shift to greener power generation methods. Many different wind turbine designs exist today. The major classification of wind turbines is based on the position of the axis of rotation of the blades with respect to the wind flow direction. Wind turbines with their axes parallel to the flow are called horizontal axis wind turbines (HAWT) and they occupy a majority of the present share of commercial wind turbines. Their blades' cross sections resemble an airfoil and produce lift and drag forces while wind blows over them. The lift forces generate torque and rotate the blades when wind velocity is sufficient.
[0004] Unlike HAWTs, vertical axis wind turbines (VAWT) have blades with the axis of rotation perpendicular to the wind direction. Hence, they are also called cross flow turbines. Popular VAWTs include the Darrius Turbine and the Savonius Turbine. Different Damns Turbine configurations exist and in most cases they are not self-starting. They use the lift forces on their airfoil blades to generate the required torque.
[0005] Savonius Turbines on the other hand are drag based turbines. Most of them have two buckets with an “S” shaped cross section and rotate about a symmetrical vertical axis. The shape of the turbine causes it to experience more drag in the down wind direction than that in the upwind direction and tits net drag forces the turbine to rotate. They are simple to construct, have cheaper maintenance and work independent of wind direction. The efficiency of these turbines drops very quickly with increase in rotational speed as it adversely alters the relative velocity between the wind and the buckets. Modifications to the Savonius turbine were made to minimize the upstream drag and increase efficiency which resulted in adverse inertial effects of moving parts at high speeds, in order to increase such a turbine's efficiency, it is necessary to maximize live aiding downstream drag and minimize the adverse upstream drag simultaneously.
[0006] A similar mechanism is found in a helicopter which uses a device called swash plate. It has two circular discs which can be tilted about any planar axis passing through their center. The lower disc only tilts while the upper disc also rotates along with the blades of the helicopter. The upper disc has levers connected to the blades through a crank. When these discs are tilted, one half on their surface is elevated while the other half is lowered. The levers on the elevated side of the discs move up rotating the crank which results in having an increased pitch on those blades while the blades on the lower side experience decreased pitch by the same amount. So each blade experiences a reversal of the pitch about a mean position when it moves from the elevated side to the lowered side i.e. for every 180 degrees of rotation in a cyclic manner. The blades with increased pitch produce more thrust than the blades with reduced pitch and this difference in thrust is the reason a helicopter can pitch forward or backwards and roll to the left or right according to the input from the pilot. And the maximum pitch angle attained by each of the blades m each cycle is proportional to the angle by which the discs are tilted. The swash plate can also be moved up or down without tilting which would change the collective pitch resulting in increasing or decreasing the altitude of the helicopter.
[0007] A swash plate converts linear input into rotary output which is the gradual continuous pitch variations spread uniformly over 360 degrees of rotation of a blade. But since, the turbine of the present invention benefits from quicker rotations which must happen when the blade is changing from upstream to downstream location and vice versa, an improved system is desired.
SUMMARY OF THE INVENTION
[0008] In at least one embodiment, the present disclosure describes a dual cam pitch turbine assembly in which the turbine blades are rotated or pitched cyclically by means of a dual cam to obtain maximum differential drag between the drive stroke and the recovery stroke of the turbine cycle to maximize the efficiency and/or power output from a VAWT. This is analogous to the motion of an oar blade in the sport of shell rowing. The water is pushed backwards by an oar blade held perpendicular to the water surface during the drive stroke, and then the blade is rotated parallel to the water surface and pulled back to the initial position during the recovery. The drive stroke force and hence the work done is much larger during the recovery stroke, and net positive work is done on the system.
[0009] The system regains its initial state after completing one cycle. During this cycle, a small portion of work generated during the drive stroke is used to complete the recovery. Thus, the system can work independently and generate net positive work while capturing energy from the fluid flow.
[0010] In at least one embodiment, the present disclosure provides turbine blades that each rotate by 90 degrees twice in one cycle i.e. once each at the end of the drive stroke and then recovery stroke by means of a dual mechanical cam. The rotation can either be in the same direction or m the opposite as it would not have any effect on the resulting state. This is because rotating a blade by 90 degrees twice and rotating by 90 degrees in a certain direction and then rotating it back by 90 degrees results in a similar configuration.
[0011] In at least one embodiment, the present disclosure provides a dual cam combining two concentric end cams with a sharp rise and a sharp fall of the outer end cam aligned with a sharp fall and sharp rise respectively of the inner end cam. Followers which move over the end cams slide on the cams and rotate by 90 degrees whenever they move over the rise/fall of the end cams. The 90 degree rotation of the followers result in pitching motions of blades attached thereto. Where most mechanical cams convert input rotary motion of a shaft into a controlled linear or radial motion which can either be sudden or gradual based on requirements, linear cams convert linear motion into a modified still linear motion but in a direction perpendicular to the direction of initial motion. The dual cam of the present disclosure modifies the cam mechanism to output rotary motion from an input rotary motion.
[0012] In at least one embodiment, the present disclosure provides a dual cam cyclic pitch system with three turbine blades. Three blades are found to keep at least one blade in the drive stroke at all times, provides a compromise between simplicity and uniformity in power output However, it is understood that more or fewer blades may be utilized based on other design preferences.
[0013] In at least one embodiment the present disclosure provides for blade shapes as thin, rectangular plates. Though a rectangle may not be the optimal shape for the blades, rectangular plates are being used for simplicity and ease of analysis and comparison with other drag based VAWTs. However, the present disclosure recommends the use of a variety of known blade shapes including airfoils, variable pitch blades, oar shaped blades and the like.
[0014] The dual cam pitch turbine assembly disclosed herein is not limited to VAWT applications, or to tidal energy systems, but may be utilized in turbines of various applications such as wind turbines, propellers, and industrial turbines.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The accompanying drawings, which are incorporated herein and constitute part of this specification, illustrate the presently preferred embodiments of the invention, and, together with the general description given above and the detailed description given below, serve to explain the features of the invention. In the drawings:
[0016] FIG. 1 is a perspective view of a dual cam cyclical pitch turbine assembly in accordance with an embodiment of the present disclosure.
[0017] FIG. 2 is a perspective simplified partial view illustrating the dual cam and two of the follower mechanisms of FIG. 1 .
[0018] FIG. 3 is a perspective view of a dual cam in accordance with an embodiment of the present disclosure.
[0019] FIG. 4 is a top plan view of a dual cam in accordance with an embodiment of the present disclosure.
[0020] FIG. 5 is a right side elevational view of a dual cam in accordance with an embodiment of the present disclosure, a left side elevational view being a mirror image thereof.
[0021] FIG. 6 is a from elevational view of a dual cam in accordance with an embodiment of the present disclosure.
[0022] FIG. 7 is a bottom plan, view of a dual cam in accordance with an embodiment of the present disclosure.
[0023] FIG. 8 is a perspective view of a dual cam cyclic pitch turbine assembly in accordance with a second embodiment of the present disclosure.
[0024] FIG. 9 is a cross sectional view of the dual cam cyclical pitch turbine assembly of FIG. 8 taken through line B-B.
[0025] FIG. 10 is an enlarged exploded view of turbine blade follower bearing assembly of FIG. 7 .
[0026] FIG. 11 is an enlarged assembled view of the turbine blade follower bearing assembly of FIG. 7 .
[0027] FIG. 12 is an enlarged exploded perfective view of a hub of FIG. 7 .
[0028] FIG. 13 is an enlarged perspective view of a double connector of FIG. 7 .
[0029] FIG. 13A is an enlarged cross sectional view of the double connector along the line A-A of FIG. 13 .
[0030] FIG. 14 is an enlarged perspective view of a first follower part of FIG. 7 .
[0031] FIG. 15 is an enlarged perspective view of a second follower part of FIG. 7 .
DETAILED DESCRIPTION OF THE INVENTION
[0032] In the drawings, like numerals indicate like elements throughout. Certain terminology is used herein for convenience only and is not to be taken as a limitation on the present invention. The following describes preferred embodiments of the present invention. However, it should be understood, based on this disclosure, that the invention is not limited by the preferred embodiments described herein, or to the particular systems, devices and methods described, as these can vary.
[0033] Referring to FIGS. 1-7 , the present disclosure relates to a dual cam turbine blade assembly 100 in which a disk shaped dual cam 20 is configured with an inner cylindrical end cam 21 concentric to a cylindrical outer end cam 23 on an upper surface, and a bottom surface 18 that has an annular neck 19 for affixation to a drive shaft 98 , The dual cam 20 is designed to interact with a moving follower shaft 103 so that under a fluid force the rotational interaction between the dual cam 20 and follower shaft 103 cause a turbine blade 10 affixed at one end of the follower shaft 103 to undergo a cyclical pitch motion by means of an inner lobe 101 and an outer lobe 102 which are located on the follower shaft 103 at locations that will interact with the inner cam 21 and outer cam 23 of the dual cam 20 .
[0034] The inner cam 21 and the outer 23 cam of the dual cam 20 are uniformly molded, each having a lower surface area 26 , 27 respectively, a raised surface area 28 , 29 respectively, and a pair of sloping rises 22 , 24 each respectively, rite inner and outer cams 21 , 23 used in conjunction with the inner and outer lobes 101 , 102 of a follower shaft 103 act as mechanical switches which are activated when a fluid flow moves the turbine blades 10 , causing the inner and outer lobes 101 , 102 to rotatingly interact with sloping rises 22 , 24 of the inner and outer cams 21 , 23 , thereby changing the pitch of the turbine blades 10 with respect to the fluid by 90 degrees with each interaction. With continued movement of the follower shaft 103 , the inner and outer lobes 101 , 102 continue to interact with the sloping rises 22 , 24 , so that the turbine blades 10 undergo another rotation of 90 degrees back to their initial pitched profile positions. These changes in pitch occur in continuous cycles.
[0035] Referring to FIGS. 3-7 . the position of the sloping rises 24 of the outer cam 23 with respect to the sloping rises 22 of the inner cam 21 of the dual cam 20 determines whether the inner and outer lobes 101 , 102 of the follower shaft 103 rotate continuously in one direction or rotate back and forth in each successive pitching motion. The inner cam 21 is typically out of phase with respect to the outer cam 23 by 90 degrees, The sloping rises 22 of the inner cam 21 typically also coincide with the opposite sloping rises 24 of the outer cam 23 , and vice versa which allows the inner and outer lobes 101 , 102 to rotating roll without interference.
[0036] The dual cam 20 design allows for the inner and outer lobes 101 , 102 of a follower shaft 103 to rotate twice in the same direction whenever the lobes move over one of the sloping rises 22 , 24 of one of the inner or outer lobes 101 , 102 , which coincides the sloping rises 22 , 24 of the opposing toner or outer cam 21 , 23 . The sloping rises 22 , 24 are positioned such that they are typically 180 degrees apart but can be as little as 60 degrees apart. A turbine blade 10 connected to a follower shaft 103 rotates when the inner or outer lobe 101 , 102 interacts with the sloping rise 22 , 24 of the inner or outer cam 21 , 23 respectively. The turbine blade 10 remains in the rotated position for the next 60 to 180 degrees of follower shaft 103 rotation and then again rotates by 90 degrees when the inner or outer lobe 101 , 102 interacts with the opposite sloping rise 22 , 24 of the inner or outer cam 21 , 23 respectively, and then remains in that position for the next 60 to 180 degrees. The rotation of the turbine blades 10 is not abrupt, and is not preferred, as rotating the turbine blade 10 sharply might result in vibrations and might require more energy because the fluid around the turbine blade 10 would be displaced at a rate proportional to the speed of rotation of the follower shaft 103 .
[0037] Still referring again to FIGS. 1-7 , the inner and outer lobes 101 , 102 are typically positioned out of phase with respect to each other by 180 degrees. The inner lobe 101 interacts with the inner cam 21 . and the outer lobe 102 interacts with the outer cam 23 of the dual cam 20 . While the inner lobe is active and is undergoing rotation over either of the sloping rises 22 or 24 of the inner cam 21 , the outer lobe is passive and vice versa. And this happens alternatively for the pitching motion to be occur continuously. The inner and outer cams 21 , 23 can be modified to obtain any number rotations of the follower shaft 103 by having the corresponding number of rises 22 , 24 on the inner and outer cams 21 , 23 .
[0038] The turbine blade 10 is connected to the follower shaft 103 and rotates along with the follower shaft 103 . The follower shaft 103 is connected to the dual cam turbine blade assembly 100 through a roller bearing to the hub 90 of the assembly 100 to which all the power is transferred. A drive shaft 98 is connected to the hub 90 and is concentric to the dual cam 20 and rotates through a roller bearing about a vertical axis whenever the turbine blades 10 rotate about the same axis.
[0039] Referring now to FIGS. 8-16 , a second embodiment of a dual cam turbine blade assembly 150 is disclosed. Each of a plurality of turbine blades 10 and followers 50 work in conjunction with the dual cam 20 to provide cyclical pitch to the turbine blades 10 upon interaction with fluid forces with reduced friction by incorporation of rotatable bearings, 60 of suitable material.
[0040] As shown in FIGS. 8-16 , each follower 50 is comprised of a plurality of interlocking parts to form cam lobes which are fastened together by means of a bolt 30 whose bolt shaft 34 passes through the open centers of the plurality of parts starting at erne distal end and threadingly attaches with a threaded section 36 to a securing nut 38 . The bolt head 32 is secured within a central hub 90 along with a washer 40 and a hub bearing 42 , through which the bolt shaft 34 passes when the hub cover 94 cut outs 97 are snapped over and affixed to the hub apertures 92 . The hub 90 is affixed at a lower distal end to a drive shaft 98 . Extending outwardly from the hub 90 , the bolt shaft 34 passes through the central openings of a first bearing lobe 50 , a crisscross uniformly molded lobe connector 70 , a second bearing lobe 80 and the nut 38 . The adjacent affixation of the first bearing lobe 50 , the crisscross lobe connector 70 , and the second bearing lobe 80 form orthogonal parts that interact with the dual cam 20 to create the cyclic pitch motion of the turbine blade 10 .
[0041] Lobe bearings 60 for the reduction of friction are secured within the follower 50 in compression by the bolt 30 and securing out 38 in between the first bearing lobe 50 find an upper surface 72 of the crisscross lobe connector 70 , as well as in between the lower surface 74 of the crisscross lobe connector 70 and the second bearing lobe 80 .
[0042] Still referring to FIGS. 8-16 , the first bearing lobe 50 includes a flange 56 , a neck extending outwardly front the flange 56 in a first direction, and a pair of first lobe pins 54 , extending outwardly from the flange 56 in an opposite direction. The first lobe pins 54 are cylindrical and formed to pass through the cam bearing 60 then to rotatingly engage with annular holes 78 in an upper flange 72 of the crisscross lobe connector 70 .
[0043] The second bearing lobe 80 has second lobe pins 82 at one end and turbine blade prongs 84 at an opposite end. The second lobe pins 82 are cylindrical and pass through bearing cams 60 then rotatingly engage with annular holes 78 in a lower flange 74 of the crisscross lobe connector 70 which is uniformly molded with a cylindrically shaped middle 76 connecting the upper flange 72 to the lower flange 74 . The turbine blade prongs 84 each include a hole 86 for attaching a turbine blade 10 using a pair of standard nuts and bolts 11 .
[0044] When comparing the invention herein with other drag based VAWTs, it is apparent that since the adverse drag force, which reduces the power output by a large amount, is considerably reduced it results in better efficiency.
[0045] These and other advantages of the present invention will be apparent to those skilled in the art from the foregoing specification. Accordingly, it will be recognized by those skilled in the art that changes or modifications may be made to the above-described embodiments without departing from the broad inventive concepts of the invention. It should therefore be understood that this invention is not limited to the particular embodiments described herein, but is intended to include ail changes and modifications that are within the scope and spirit of the invention as defined in the claims. | This invention relates to a novel turbine design that increases turbine efficiency whereby turbine blades experience cyclic pitch variations while rotating about the blade axis which is accomplished by means of a concentric end cam double follower mechanism. This mechanism rotates the blades by 90 degrees about a horizontal axis which allows the blades rotating upstream and downstream to be oriented horizontally and vertically so minimum drag and maximum drag are obtained respectively. Since the aiding downstream drag is at a maximum, and the adverse upstream drag is at a minimum, this configuration allows for higher power output compared to conventional vertical axis wind turbines. | 8 |
CROSSREFERENCE TO RELATED APLICATION
This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No.2002-113323, filed on Apr. 16, 2002; the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an inspection method for a direct liquid fuel cell generator that generates electricity by supplying a liquid fuel and an oxidant, an inspection apparatus for a direct liquid fuel cell generator using the inspection method, and a direct liquid fuel cell generator comprising the inspection apparatus of the fuel cell generator.
2. Description of the Related Art
Fuel cells are generators that directly convert a chemical energy (free energy of combustion reactions) into a direct electrical energy, and are expected to have a higher conversion efficiency than thermal power generation. While power generation efficiency decreases when the scale of thermal power generation is small, power generation by the fuel cell is not decreased in small scale operation. Accordingly, the fuel cell is suitable for small scale power generation.
Among the fuel cells, developments of solid polymer electrolyte fuel cells have been accelerated in recent years as automobile power sources and domestic power sources. A gas containing hydrogen is introduced into an anode side, and oxygen gas or air is introduced into a cathode side in this solid polymer electrolyte fuel cell. An electromotive force is generated by the following reactions represented by the chemical formulae 1 and 2 at the anode and cathode sides, respectively.
Anode: 2H 2 →4H + +4 e − chemical formula 1
Cathode: O 2 +4H + +4 e − →2H 2 O chemical formula 2
The equations mean that electrons and protons are formed from hydrogen by means of a catalyst within the anode. The electrons are taken out of the cell through external circuits, and are used for power generation. The protons move in the solid electrolyte membrane and arrive at the cathode, and water is generated by a reaction between the electrons, oxygen, and the protons by a catalyst within the cathode. Electric power is generated by such cell reaction.
On the other hand, a direct methanol fuel cell has been noticed in recent years. FIG. 1 shows the structure of the direct methanol fuel cell. In the direct methanol fuel cell, a proton conductive electrolyte membrane (a perfluorocarbon sulfonic acid ion exchange membrane; Nafion made by DuPont Co. is preferably used) is sandwiched between an anode electrode and a cathode electrode. Each electrode comprises a substrate and a catalyst layer which comprises a catalyst and a proton conductive electrolyte. The catalyst is usually a precious metal or an alloy of the precious metal, which is used by being supported on carbon black. The catalyst is not supported on carbon black in some cases. A Pt—Ru alloy is preferably used as catalyst at the anode side, while Pt is preferably used as catalyst at the cathode side. Methanol and water are introduced into the anode side, and oxygen gas or air is introduced into the cathode side for operation. The reactions represented by the following chemical formulae 3 and 4 occur at the anode and cathode sides, respectively.
Anode: CH 3 OH+H 2 O→CO 2 +6H + +6 e − chemical formula 3
Cathode: (3/2) O 2 +6H + +6 e − →3 H 2 O chemical formula 4
These equations mean that electrons, protons and carbon dioxide are formed by the catalyst in the anode catalyst layer. Carbon dioxide generated is exhausted in the atmosphere. The electrons are taken out of the fuel cell through an external circuit, and are used for power generation. The protons move in a proton conductive electrolyte membrane, and arrive at the cathode. Water is formed in the cathode catalyst layer by a reaction of the electrons and oxygen and protons. The operating temperature of this direct methanol fuel cell is usually 50 to 120° C.
It was a drawback that a reformer should be provided in the fuel cell system and the entire system is forced to be large size, when a gas containing hydrogen is used as a fuel as in the solid polymer electrolyte fuel cell as described above, since the hydrogen gas is generally obtained by reforming methanol, natural gas or gasoline. The reforming process is generally performed at a high temperature of 250 to 300° C. In contrast, the system itself may be compact in the direct methanol fuel cell since no reformer is needed, and the power generation process can proceed at a relatively low temperature. Accordingly, the direct methanol fuel cell has been developed in recent years for applying it to a portable power source and an electric car power source by taking notice of this advantage of the direct methanol fuel cell.
An aqueous methanol solution or a vaporized mixture of methanol and water is supplied for feeding methanol and water to the fuel cell in the direct methanol fuel cell generator. Since a vaporizer should be provided as an auxiliary equipment of the fuel cell when methanol and water are supplied as an evaporated mixed gas, the total fuel cell system inevitably becomes large size. On the contrary, the system may be small size when the aqueous methanol solution is supplied, since no vaporizer is needed.
However, there are many difficult problems in the direct methanol fuel cell as described above as compared with solid polymer electrolyte fuel cells.
As an problem, the fuel supplied to the electrode moves within the electrode, enters a proton conductive electrolyte, moves within the electrolyte to arrive at the catalyst, and is used for generating electric power. The proton conductive electrolyte exhibits proton conductivity by being impregnated with water. It has been elucidated in the foregoing studies that introduction of methanol reduces proton conductivity (for example T. J. Chou and A. Tanioka, J. Phys. Chem., B102 (1998), 129). Methanol, water and oxygen as fuel components move by being dissolved into impregnated water in the proton conductive electrolyte in the catalyst layer. Reduced proton conductivity also reduces diffusion of water that moves by being pulled with the protons. Consequently, mobility of water and diffusion of methanol that is completely mixed with water are also decreased at the anode electrode. Methanol also exists at the cathode electrode since methanol supplied to the anode electrode arrives at the cathode electrode through the proton conductive electrolyte membrane. Accordingly, diffusion of water also decreases in the proton conductive electrolyte within the cathode catalyst layer. As a result, diffusion of oxygen is reduced since oxygen diffuses within the electrode by being dissolved in water in the proton conductive electrolyte. In summary, the fuel cell is confronted with a severe problem that diffusion abilities of all the fuel components of methanol, water and oxygen as fuels are reduced. Accordingly, it is inevitable for practical applications to elucidate characteristic values that can be readily measured in close relation with the degree of diffusion of the fuel.
As another problem, diffusion of the fuel is so poor immediately after resumption of operation that equipment is operated under a condition where response to variation of load is very poor, since water impregnated in the proton conductive electrolyte is dried up during pause period of the operation of the direct methanol fuel cell generator. In case of generators, particularly generators for potable appliances and automobiles in which the fuel cell is intermittently operated in daily work and variation of load occurs frequently, the response to variation of load becomes very poor, thereby causing troubles in driving the appliances. Consequently, the trouble may induce severe accidents that may threaten human life. Therefore, it should be confirmed how is the response to variations of load, and how much is the performance of the fuel cell before and during power generation.
As a different problem, the perfluorocarbon sulfonic acid membrane is swelled by being impregnated with water, and swelling is much larger when the membrane is impregnated with methanol. Therefore, the proton conductive electrolyte membrane and catalyst layer are damaged by excessive swelling when a high concentration of aqueous methanol solution is supplied by some reasons, and the performance of the fuel cell is largely decreased.
Consequently, it has been recognized that development of a simple method for deciding the performance of the fuel cell during power generation is also important.
The fuel cell may be severely damaged by the condition of the proton conductive electrolyte membrane, or by the condition of fuel diffusion, in the direct methanol fuel cell generator as described above. Therefore, an inspection method for always verifying the condition of the fuel cell is important.
The characteristics of the fuel cell have been mostly evaluated by measuring an I-V curve. However, the measurements of the I-V curve also involves the results including other lines of information such as catalyst activity and internal resistance other than the degree of diffusion of the fuel. Furthermore, voltages should be measured in a wide range of current density for measuring the I-V curve. In particular, a stationary state operation should be naturally interrupted for measuring the I-V curve of the fuel cell that is under a long-run stationary operation. Since this inspection procedure costs much labor, it cannot be readily applied for evaluation and inspection.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a method for inspecting a direct methanol fuel cell generator that is able to readily obtain a line of information closely related to the degree of diffusion of the fuel during power generation of the fuel cell, and to exactly decide the performance of the fuel cell.
It is another object of the invention to provide a simple and highly accurate inspection apparatus for realizing the inspection method, and a direct methanol fuel cell generator comprising the inspection apparatus.
According to a first aspect of the present invention, there is provided An inspection method for a direct liquid fuel cell generator having a plurality of cells, each comprising an anode electrode including an anode catalyst layer, a cathode electrode including a cathode catalyst layer, and an electrolyte disposed between the anode electrode and the cathode electrode, for power generation by supplying a liquid fuel to the anode electrode and an oxidant gas to the cathode electrode, wherein validity of the fuel cell is decided based on an observation result of time dependent changes of the voltage V of one electromotive unit which is caused by generating a current density change ΔI or −ΔI (ΔI in mA/cm 2 unit represents a positive value) satisfying the condition of 0.2≦ΔI≦10 in a current density I (mA/cm 2 ), which is taken out from an arbitrary number of cells connected in series constituting the direct liquid fuel cell generator under power generation, during a time interval Δt (sec) satisfying the condition of 10 −5 ≦Δt≦0.5.
According to a second aspect of the present invention, there is provided An inspection apparatus for a direct liquid fuel cell generator having a plurality of cells, each comprising an anode electrode including an anode catalysis layer, a cathode electrode including a cathode catalyst layer, and an electrolyte disposed between the anode electrode and the cathode electrode, for power generation by supplying a liquid fuel to the anode electrode and an oxidant gas to the cathode electrode, the apparatus comprising: a load connected to an output from the direct liquid fuel cell generator to consume output power thereof; means connected to the output from the direct liquid fuel cell generator, for changing an output current density by controlling the load; means for measuring an output voltage from the direct liquid fuel cell generator; and a decision device connected to the current density control means and voltage detection means, for discriminating the condition of the fuel cell generator from the initiation time of the current density change, and from the measured results of the change of the output voltage.
According to a third aspect of the present invention, there is provided a direct liquid fuel cell generator having a plurality of cells, each comprising an anode electrode including an anode catalysis layer, a cathode electrode including a cathode catalyst layer, and an electrolyte disposed between the anode electrode and the cathode electrode, for power generation by supplying a liquid fuel to the anode electrode and an oxidant gas to the cathode electrode, the liquid fuel cell generator comprising: a load connected to an output from the direct liquid fuel cell generator to consume output power thereof; means connected to the output from the direct liquid fuel cell generator, for changing an output current density by controlling the load; means for measuring an output voltage from the direct liquid fuel cell generator; and a decision device connected to the current density control means and voltage detection means, for discriminating the condition of the fuel cell generator from the initiation time of the current density change, and from the measured results of the change of the output voltage.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic cross section showing the structure of a cell as a power generation element of a direct methanol fuel cell;
FIGS. 2A and 2B are graphs for describing the principle of the inspection method of the invention, where FIG. 2A is a graph showing a time dependent change of the voltage observed by increasing the loaded electric current at a time of T=0; and FIG. 2B is a graph showing a time dependent change of the voltage observed by decreasing the loaded electric current at a time of T=0;
FIG. 3 is a graph showing a time dependent change of the voltage corresponding to the change of the current density in an example of the invention when the load current is increased from 0 mA/cm 2 to 5 mA/cm 2 , from 5 mA/cm 2 to 10 mA/cm 2 , and from 10 mA/cm 2 to 15 mA/cm 2 ;
FIG. 4 is a graph showing the voltage response by changing the time when the current density is changed, wherein the graph shows a time dependent changes of the voltage by changing the load current when the lapse of time ΔT is changed to 10 −5 , 0.5, and 3 seconds, respectively.
FIG. 5 is a graph showing the ΔT dependency of T 1 in an example of the invention;
FIG. 6 is a graph showing a time dependent change of the voltage observed by changing the magnitude of ΔI in an example of the invention;
FIG. 7 is a graph showing the ΔI dependability of T 1 in an example of invention.
FIG. 8 is a schematic diagram showing an example of the inspection apparatus for the direct methanol fuel cell generator of the invention;
FIG. 9 is a flow chart showing the inspection procedure using the inspection apparatus for the direct methanol fuel cell generator of the invention;
FIG. 10 is a graph showing a time dependent change of the voltage of a fuel cell 1 before and after changing the load current;
FIG. 11 is a graph showing a time dependent change of the voltage of a fuel cell 2 before and after changing the load current;
FIG. 12 is a graph showing a time dependent change of the voltage of a fuel cell 3 before and after changing the load current;
FIG. 13 is a graph showing I-V curves of the fuel cells 1 , 2 and 3 , respectively;
FIG. 14 is a graph showing current density dependency of output densities of the fuel cells 1 , 2 and 3 , respectively;
FIG. 15 is a schematic diagram showing another example of the inspection apparatus for the direct methanol fuel cell generator of the invention;
FIG. 16 is a flow chart showing the inspection procedure using the inspection apparatus for the direct methanol fuel cell generator of the invention;
FIG. 17 is a graph showing the time dependent changes of the voltages of fuel cells 6 and 8 , respectively, before and after changing the load current;
FIG. 18 is a graph showing the I-V curves in another example of the invention; and
FIG. 19 is a graph showing the current density dependencies of the output current density in another example of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention will be described in detail with reference to the embodiments.
[Fuel Cell]
An example of a fuel cell suitable for applying the invention is shown in FIG. 1 . The cell comprises an anode substrate 1 , an anode electrode 3 including an anode catalyst layer 2 , a cathode catalyst layer 4 , a cathode electrode 6 including a cathode substrate 5 , and a proton conductive electrolyte membrane 7 disposed between the anode electrode 3 and the cathode electrode 6 . A direct methanol fuel cell comprises a plurality of cells, which is shown in FIG. 1 . Terminals (not shown) are connected to the respective electrodes, and devices for supplying a liquid fuel and an oxidant gas to the anode electrode and cathode electrode, respectively, are provided in the fuel cell. An inspection apparatus and external load to be described below are connected to respective terminals.
While the fuel cell suitable for applying the invention comprises the plural cells, a fuel feed portion including a fuel tank for supplying a liquid fuel to the cells, an oxidant feed portion, and power terminals of the fuel cell generator, a cell having another structure and material except those shown in FIG. 1 may be employed in the fuel cell.
Examples of the liquid fuel used for the fuel cell of the invention include aqueous solutions of organic compounds such as methanol, ethanol, formic acid, formaldehyde and dimethyl ether. Among these compounds, methanol, formic acid, formaldehyde and dimethyl ether are preferable due to their high reactivity, and methanol is most preferable since it is efficiently allowed to react by a platinum-ruthenium catalyst.
[Inspection Method]
FIGS. 2A and 2B are graphs for describing the principle of the inspection method of the invention.
FIG. 2A is a graph showing changes of the voltage V dependent on the time T caused by a change ΔI of in the current density flowing through a load connected to the fuel cell. The voltage rapidly decreases immediately after the change ΔI of the current density flowing in the load. This current change becomes gentle in accordance with the lapse of time, and the voltage becomes minimum at T=T 1 . The voltage monotonously increases at T>T 1 , and settles at a constant level in accordance with the further lapse of time.
This phenomenon is conjectured to arise by the following reasons. Since the current density has increased at T=O, the surface of the catalyst and the neighboring area thereof becomes locally deficient in the fuel. Consequently, the voltage decreases with the lapse of time due to diffusion polarization. On the other hand, the fuel that has been deficient is supplied to the catalyst and the neighboring area thereof to ameliorate deficiency of the fuel. Accordingly, the voltage turns to increase with the lapse of time at T=T 1 and thereafter, and settles at a constant level.
FIG. 2B is a graph showing a change −ΔI of the current density flowing through the load connected to the fuel cell, or the time dependent change of the voltage V caused by the decreased current density. The voltage rapidly increases immediately after a current density change −ΔI. Then, the voltage change becomes gentles with the lapse of time, and the voltage becomes maximum at T=T 1 . The voltage monotonously decreases at T>T 1 , and settles to a constant level with the further lapse of time.
This phenomenon is conjectured to arise by the following reasons. Since the current density has decreased at T=O, the fuel becomes excess on the surface of the catalyst in the electrode and at the neighboring area thereof as compared before. Consequently, diffusion polarization reduces to increase the voltage with the lapse of time. On the other hand, the excess fuel moves to the catalyst and the neighboring area thereof to ameliorate local excess of the fuel. Accordingly, the voltage decreases with the lapse of tine at T=T 1 and thereafter, and settles to a constant level.
Since the change of the electromotive force accompanied by the change of the current density shown in FIGS. 2A and 2B represents the degree of diffusion of the fuel as will be apparent from the descriptions above, the fuel cell may be readily inspected based on the principle above. Diffusion of the fuel is shown to be quite poor when the time T 1 that shows the time when the voltage generated by the current change shows a minimum or maximum is larger than a prescribed time. This phenomenon indicates that the electromotive force of the fuel cell cannot follow the change of load during the operation of the cell. The fact that the time showing the maximum or minimum voltage is out of a prescribed range when the voltage change caused by the current density is measured clearly indicate that the performance of the fuel cell is poor. Therefore, the fuel cell can be simply and objectively inspected based on a criterion that T 1 is within a prescribed time.
When Δt that is a time for allowing the current density to change is too long, the behaviors shown in FIGS. 2A and 2B become so dull that a precise inspection becomes unable in the invention. On the other hand, making Δt too short is not practically preferable, since the structure of the inspection apparatus becomes complex and the apparatus becomes expansive. A range of the time Δt for allowing the current density to change of 10 −5 ≦Δt≦0.5 is preferable, because the changes as shown in FIGS. 2A and 2B becomes evident to an extent enough for achieving sufficient inspection provided by the invention, and because the inspection apparatus is cheaply manufactured. A range of 10 −5 ≦Δt≦2×10 −3 is more preferable, since the change is more evidently observed.
The inspection becomes difficult due to a too small voltage change generated when ΔI that is the current density change is too small. On the other hand, too large ΔI is also not practically preferable, since the fuel is wasted for unnecessary power generation of the fuel cell generator, or the power generation state is excessively disturbed. Therefore, the practically available range is 0.2≦ΔI≦10, more preferably 0.2≦ΔI≦5. A range of 0.2≦ΔI≦2 is particularly preferable, because disturbance of the fuel cell generator under power generation is very small.
While the current density change is linear in FIGS. 2A and 2B , the current density change may be different patterns. For example, the change may be a curve or a gradation such as two steps or more of changes. Alternatively, the change may be not necessarily a monotonous increase or decrease.
The inspection method of the invention should be performed in the process when the current density I generated by the fuel cell generator is a non-zero finite value. As an example, FIG. 3 is a graph showing time dependent changes of the voltage corresponding to the change of the current density when the current densities flowing in the load connected to the fuel cell are increased from 0 mA/cm 2 to 5 mA/cm 2 , from 5 mA/cm 2 to 10 mA/cm 2 , and from 10 mA/cm 2 to 15 mA/cm 2 , respectively. The time T 1 that shows the minimum level of the output voltage of the fuel cell caused by the current density change is in the range of 4 to 5 seconds, when the current density is increased from 5 mA/cm 2 to 10 mA/cm 2 , and from 10 mA/cm 2 to 15 mA/cm 2 . T 1 is prolonged to a far longer time of 78 seconds when the current density is increased from 0 mA/cm 2 to 5 mA/cm 2 .
It was revealed from repeated experiments by the inventors that a far more longer voltage maximum or minimum time T 1 is observed when a condition that gives a current density of 0 mA/cm 2 has appeared at least once or more in the process of change of the current density, as compared with the case where no such condition that gives a current density of zero has not been experienced in the process. The inspection method provided by the invention cannot be used when the minimum or maximum time of the voltage change is long, since the inspection efficiency is decreased to compromise reliability to the inspection results.
In the method that has been conventionally used for inspection and evaluation of the fuel cell generator, the current density generated by connecting the fuel cell to the load is changed to zero for a quite short period of time (usually several microseconds), and a current having the same magnitude as that immediately before reducing the current to zero is again loaded thereafter. The fuel cell is inspected and evaluated by the voltage change observed between before and after reducing the current density to. zero (a current shut-down method). This method is naturally quite different from the method provided by the invention, because the process of change of the current density once experiences zero current in the conventional method, and a highly reliable inspection is impossible due to disturbance of the inspection results as described above.
Since the length of the time T 1 when the voltage as a criterion of validity of the fuel cell is minimum or maximum changes depending on the characteristics required for the fuel cell inspected, the structure of the electrolyte catalyst layer and electrolyte membrane, the compositions of the catalyst and electrolyte membrane, the electrode area, the flow rate of the fuel, the structure of the flow passageway plate of the fuel, the operation temperature, and I and ΔI, it may be appropriately determined by taking these conditions into consideration. However, it is quite preferable that the setting time of T1 is shorter than 15 seconds according to the experiments by the inventors. Since the performance of the fuel cell is markedly decreased when T 1 exceeds 15 seconds, it is difficult to practically use such fuel cell.
[Inspection Apparatus: First Inspection Apparatus]
The inspection apparatus 17 shown in FIG. 8 comprises an external load 18 connected to the output from the fuel cell 11 , a voltage detector 14 that measures the output voltage of the fuel cell 11 , a decision device 15 for deciding by importing the voltage change measured by the voltage detector 14 , and an indicator 16 for indicating the decision results of the decision device 15 .
The external load 18 is provided for consuming the output power of the fuel cell in the inspection apparatus 17 while controlling the amount of load based on the control signal from the decision device 15 . A commercially available electronic load apparatus (for example a combination of EML-150L load module and EML-30B frame made by Fujitsu Access Ltd.) may be actually used as the load.
The voltage detector 14 is provided for converting the voltage of the power exported from the fuel cell 11 into a form capable of signal processing, and an apparatus for exporting the applied voltage into digital signals by an analogue-digital converter.
The decision device 15 is provided for changing the current density of the output power from the fuel cell 11 with a given time period and given magnitude, thereby changing the output voltage of the fuel cell 11 while permitting real time input of the output voltage level from the voltage detector 14 . Validity of the performance of the fuel cell as an object of the inspection is decided based on the change above. This device may be realized using a one-chip computer, general use microcomputer or logic circuitry.
The indicator 16 is provided for indicating the results from the decision device 15 or informing them by means of light, sound or vibration, and examples of the device include a display such as CRT and liquid crystal, a lamp such as LED, and a speaker.
While the fuel cell as shown in FIG. 18 exports the electric power through four terminals, the output terminals may be composed of two terminals comprising a terminal at the positive electrode and a terminal at the negative electrode. When the external load connected to the fuel cell has a large capacity for the electric current, voltage drop of the electric power applied to the voltage detector becomes so large when the fuel cell comprises two terminals that the sensed results are affected by the voltage drop. Accordingly, four terminals are preferably used in this case.
The inspection procedure using the inspection apparatus as described above is described below with reference to FIG. 9 as a flow chart of the procedure.
In FIG. 9 , the minimum time T 1 min indicating the minimum or maximum voltage as a criterion of validity of the fuel cell as the object of inspection, the maximum time T 1 max indicating the minimum or maximum of the voltage, and the current density I and the change of the current density ±ΔI are set (S 102 ) after the start of the inspection (S 101 ). T 1 min and T 1 max determine the minimum allowable time and maximum allowable time.
The fuel cell is started to operate (S 103 ), and a load current is allowed to flow after connecting the load 8 to the fuel cell, and time dependent changes of the voltage applied on the load are recorded (S 104 ). The load current is changed in this state (S 105 ) while applying the voltage to the load, and T 1 as the time when the voltage indicates the minimum or maximum level is determined (S 106 ). T 1 is decided whether it is within a prescribed time interval or not (S 107 ), and the indicator issues a warning that the fuel cell is defective when T 1 is out of the prescribed time interval (S 108 ) to allow the inspection to come to its end (S 109 ). The indicator indicates that the fuel cell is successful (S 110 ) when no defects are found, and the inspection is completed (S 111 ). Two or more setting ranges of T 1 may be provided in order to classify the inspected fuel cell generator in more detail to more precisely discriminate the condition of the fuel cell.
[Inspection Apparatus: Second Inspection Apparatus]
Another example of the inspection apparatus of the invention is shown in FIG. 15 . The same reference numerals are given to the same members in FIG. 15 as those in FIG. 8 . Different from the apparatus in FIG. 8 , the power output from the fuel cell 11 is dispensed into the external load 12 consuming the output and the inspection load 13 for inspection of the invention. The decision device 15 measures the load generated by the external load 12 and inspection load 13 while changing the load on the fuel cell by controlling the inspection load 13 in order to observe the change of the output voltage. The inspection apparatus in this embodiment is possible to discriminate the load of the fuel cell and the load for inspection, thereby making it possible to construct a fuel cell generator that can be most commonly used.
As is evident from FIG. 15 , an aqueous methanol solution and an oxidant fuel are supplied to the fuel cell 11 , and the fuel cell is operated such that the load current flows through the load 12 connected to the output power of the fuel cell 11 . The inspection device 17 in the embodiment comprises the inspection load 13 , voltage detector 14 , decision device 15 and indicator 16 . The inspection load 13 is used in order to change the load level that changes the load current flowing from the fuel cell.
While the output pour is also taken out through four terminals in the fuel cell in FIG. 15 , two terminals may be used for this purpose as same in FIG. 8 described above.
The inspection procedure using the inspection apparatus will be described below with reference to FIG. 16 as a flow chart thereof. After the start ( 201 ) of inspection, the load current density I is read out (S 202 ) as shown in FIG. 16 . Then, T 1 min, T 1 max and ±ΔI are set based on the current density I (S 203 ). However, these values may be set without reading out the current density I. Subsequently, the voltage is detected using the voltage detector 14 to record the time dependent changes (S 204 ). Then, changes of ±ΔI are given to the load current density using the inspection load (S 205 ), T 1 is determined (S 206 ), and T 1 is determined whether it is within a prescribed range or not (S 207 ). A warning is issued using an indicator when T 1 is out of the prescribed range (S 208 ), the load is controlled for security or the like (S 209 ), and the inspection comes to its end by deciding that the fuel cell is defective (S 210 ). Control of the load may be omitted, if it is desirable. Alternatively, when T 1 is within the prescribed range (S 211 ), the inspection comes to its end (S 212 ) based on the decision that the fuel cell is successful without any problems. Two or more setting ranges of T 1 may be provided in order to classify the inspected fuel cell generator in more detail for controlling the load.
[Fuel Cell Generator]
The inspection apparatus is connected to the direct methanol fuel cell in the fuel cell generator of the invention, and the fuel cell is further connected to an external load.
The fuel cell generator of the invention may be housed in a housing as one power generator, or the fuel cell generator may be divided into a plurality of members that are electrically or mechanically connected with each other as a power generator system. It is preferable to integrate the housing as a power generator in order to use it as a power source of portable electronic appliances. The power source for driving the generator may be supplied from the fuel cell itself. However, since various control devices should be operated for indicating the condition of the fuel cell even when the fuel cell is at rest, another cell is preferably mounted.
The inspection method and procedure of the fuel cell generator are preferably executed according to a program written in a nonvolatile memory integrated into the decision device constituting the inspection apparatus.
EXAMPLE
While the invention is described in more detail based on the examples, the invention is not restricted to these examples.
Example 1
Assembling of the Direct Methanol Fuel Cell
The following is the method for manufacturing the cell of the fuel cell generator used in the example of the invention. Carbon black for supporting the anode catalyst (Pt:Ru=1:1) and carbon black for supporting the cathode catalyst (Pt) were produced by a method known in the art (R. Ramakumar et. al., J. Power Sources 69 (1997), 75). The amounts of the supported catalysts were 30 and 15 parts by weight on the anode and cathode, respectively, relative to 100 parts by weight of carbon.
For preparing the anode electrode, a perfluorocarbon sulfonic acid solution (Nafion solution SE-20092 made by DuPont Co.) and ion exchange water were added to carbon black for supporting the anode catalyst prepared in the foregoing process, and a paste was prepared by dispersing carbon black for supporting the anode catalyst. This paste was applied on a sheet of carbon paper TGPG-120 (made by E-TEK Co.) after water repelling treatment followed by drying.
For preparing the cathode electrode, a perfluorocarbon sulfonic acid solution (Nafion solution SE-20092 made by DuPont Co.) and ion exchange water were added to carbon black for supporting the cathode catalyst prepared in the foregoing process, and a paste was prepared by dispersing carbon black for supporing the cathode catalyst. This paste was applied on a sheet of carbon paper TGPG-090 (made by E-TEK Co.) after water repelling treatment followed by drying.
The cell shown in FIG. 1 was prepared by bonding the anode electrode and cathode electrode prepared in the foregoing process on both faces, respectively, of a commercially available perfluorocarbon sulfonic acid membrane by hot-press (125° C., 5 minutes).
Example 2
Determination of Inspection Condition
The fuel cell was assembled by connecting five cells prepared as described above in series, followed by connecting an aqueous methanol feed device and a oxidant feed device.
The fuel cell was operated while changing the current density by changing the time ΔT as a time required for changing the current density. In this experiment, the current density I was set at 145 mA/cm 2 and the current density difference ΔI was set at 5 mA/cm 2 to change the current density from 145 mA/cm 2 to 150 mA/cm 2 . An aqueous methanol solution with a concentration of 2M was sent to the anode electrode using a commercially available feed pump. Air was sent to the cathode side using a commercially available air pump. The flow rate of air was controlled using a commercially available mass flow controller. The commercially available electronic load apparatus described above was used as the load for exporting the power of the fuel cell. A commercially available digital multimeter was used for sensing the voltage. The direct methanol fuel cell with an electrode area of 10 cm 2 was operated by controlling the operation temperature of the fuel cell at 70° C.
The results of power generation test under the operation condition above are shown in FIG. 4 . In FIG. 4 , time dependence of the voltage due to the current change is shown.
In FIG. 4 , the solid line, broken line and dotted line denote the changes of the current density at ΔT of 10 −5 , 0.5 and 3 seconds, respectively. The result at ΔT of 3 seconds is evidently different from the results at ΔT of 10 −5 and 0.5 seconds, and voltage drop and voltage raise thereafter are quite gentle. T 1 was 5.3 seconds at ΔT of 10 −5 second, 5.5 seconds at ΔT of 0.5 second, and 17 seconds at ΔT of 3 seconds.
FIG. 5 shows ΔT dependency of T 1 . While T 1 is almost constant in the range of ΔT of 0.5 second or less, T 1 is monotonously increased with the increase of ΔT when it is larger than 0.5 second. These results show that the voltage change provided in the invention becomes dull when ΔT is larger than 0.5 second, and the method of the invention cannot be used for inspection. Accordingly, it was found that the preferable upper limit of ΔT is 0.5 second.
Example 3
Determination of Inspection Condition
The magnitude of the change of the current density ΔI was changed using the same fuel cell as in Example 2, and the time T 1 before attaining the minimum or maximum voltage change was investigated.
The current density I was set at 170 mA/cm 2 , and a change of −ΔI was given to the current density. An aqueous methanol solution with a concentration of 2M was sent to the anode electrode using a commercially available feed pump. Air was sent to the cathode side using a commercially available air pump. The flow rate of air was controlled using a commercially available mass flow controller. The commercially available electronic load apparatus described above was used as the load for exporting the power of the fuel cell. A commercially available digital multimeter was used for sensing the voltage. The direct methanol fuel cell with an electrode area of 25 cm 2 was operated by controlling the operation temperature of the fuel cell at 80° C.
The results are shown in FIG. 6 . In figure, solid line indicates a case where ΔI is set to 2, and broken line indicates a case where ΔI is set to 0.1. When ΔI is 2, the maximum value of voltage is clear, so that T 1 was determined to be 6.5 seconds. On the other hand, when ΔI is 0.1, change in voltage is extremely small, so that the maximum value was not discriminated, and it was not possible to clearly determine T 1 unlike when change ΔI in current density is 2.
FIG. 7 shows ΔI dependency of T 1 . It was found that precise decision of T 1 is difficult when ΔI is less than 0.2 due to large error bars. Accordingly, the preferable lower limit of ΔI was found to be 0.2.
Example 4
Inspection Apparatus 1
The example of inspection using the fuel cell generator shown in FIG. 8 will be described below.
A program operating as a decision device and indication device was created using a commercially available programming language operated on a PC, and was used as the decision device and indication device.
The following three kinds of cells were prepared by different preparation conditions, and the cells were inspected using the inspection apparatus of the invention.
Cell 1 : the fuel cell described in Example 2 was assembled using the cell prepared in example 1.
Cell 2 : the cell prepared in Example 1 was immersed in a 4M aqueous methanol solution for 30 hours, and the fuel cell described in Example 2 was assembled.
Cell 3 : the cell prepared in Example 1 was immersed in a 7M aqueous methanol solution for 30 hours, and the fuel cell described in Example 2 was assembled.
A 2M aqueous methanol solution was sent to the anode side at a flow rate of 0.6 ml/minutes with a commercially available feed pump using the cells 1 to 3 . Air was sent at a flow rate of 60 ml/minute to the cathode side using a commercially available air pump. The flow rate of air was controlled using a commercially available mass flow controller. A commercially available electronic load apparatus was used as the load. A commercially available multimeter was used for the voltage detector. GPIB interface was attached to PC, and the load and inspection load, and voltage detector were connected to the interface using commercially available GPIB cable.
I and ΔI were set at 30 mA/cm 2 and 5 mA/cm 2 , respectively, using the inspection apparatus, and the current density was changed from 30 mA/cm 2 to 35 mA/cm 2 . Δt was set at 10 −4 . It was confirmed that the load was changed within 10 −4 second as confirmed with a commercially available ammeter. T 1 min was set at 1 second, and T 1 max was set at 5 seconds.
A commercially available buzzer as an indicator was adjusted so that it sounds when T 1 is out of the prescribed range. Other indicators available include a buzzer or ring, a LED or lamp, a vibrator, or a smelling device, or a combination thereof. The indicator is not always required.
FIG. 10 shows the time dependent change of the voltage of the cell 1 before and after the change of load current. This cell had the smallest T 1 of 2.3 seconds among the three cells. The cell 1 was decided to be good from this result.
FIG. 11 shows the time dependent change of the voltage of the cell 2 before and after the change of load current. T 1 of this cell was 2.3 seconds. The cell 2 was decided to be defective from this result.
FIG. 12 shows the time dependent change of the voltage of the cell 3 before and after the change of load current. T 1 of this cell was 149.5 seconds. The cell 3 was decided to be defective from this result.
FIG. 13 shows the results of measurements of the I-V curves of the cells 1 , 2 and 3 , respectively, and the corresponding current density dependencies of the output current density are shown in FIG. 14 . As is evident from the inspection results of the invention, the cell 1 had the highest performance. The cell 3 showed the worst performance, and the cell 2 showed an intermediate performance. Such differences were caused by the difference of damages suffered by the proton conductive electrolyte used for each cell. The cell 3 had suffered the largest damage among the three cells since it was immersed in the most concentrated aqueous methanol solution. The cell 2 had suffered small damage since it was immersed in a relatively small concentration of the aqueous methanol solution, and showed better performance than the cell 3 . The cell 1 showed best performance without suffering from any damages. It is conjectured that the difference of the degree of damages is reflected on the mobility of the fuel within the proton conductive electrolyte that is related to the difference of performance.
Example 5
Inspection Apparatus 2
The cells of the fuel cells 1 to 3 were used in this example, in which a direct methanol fuel cell comprising 10 cells with an electrode area of 50 cm 2 were used by connecting in series. An aqueous methanol solution with a concentration of 2M was introduced at the anode side of each cell at a flow rate of 0.6 ml/minute. Air was introduced into the cathode side of each cell at a flow rate of 2000 ml/minutes. The flow rate of air was adjusted using a commercially available mass flow controller. I was adjusted to 50 mA/cm 2 , ΔI was adjusted to 5 mA/cm 2 , T 1 min was adjusted to 0.5, and T 1 max was adjusted to 3. All the current flowing in 10 cells was changed from 50 mA/cm 2 to 55 mA/cm 2 . Voltage changes of the sixth cell (abbreviated as cell 6 hereinafter) and eighth cell (abbreviated as cell 8 hereinafter) were sensed. A commercially available light bulb was used for the indicator, and the light bulb was adjusted so that it blinks when T 1 is out of the prescribed range. Other indicators available include a buzzer or ring, a LED or lamp, a vibrator, or a smelling device, or a combination thereof. The indicator is not always required.
FIG. 17 shows the time dependent change of the voltage. The cell 6 was decided to be defective, while the cell was decided to be good from these results. Referring to the I-V curve, it was shown that the performance of cell 6 was poor as compared with cell 8 as was indicated by the inspection results. The result is shown in FIG. 18 . While FIG. 19 shows the current density dependency of the output current density, the maximum output current density is largely different between cell 8 and cell 6 .
While the catalyst was used by being supported on the carbon black supports, the catalyst may be supported on other supports such as titanium oxide, may be used without being supported on any supports. While Nafion 20092 made by DuPont Co. was used as the proton conductive electrolyte, examples of the electrolytes available in the invention include other perfluorocarbon sulfonic acids (a membrane made by Dow Chemical Co., Aciplex made by Asahi Chemical Co., and Flemion made by Asahi Glass Co.), sulfonated trifluorostyrene polymer, graft polymerization electrolytes prepared by introducing sukfonated polystyrene graft side chains into a ETFE, FEP base material, sulfonated styrene-butadiene random block copolymer, acid dope polybenzimidazole, sulfonated heat resistant polymers (sulfonated polyetherether ketone, polyether sulfone, polyphenyl quinoxalene, polybenzimidazole, and fluorinated polyimide), and ion conductive resin ion containing conductive vinyl monomers (sodium vinylsulfonate, sodium alsulfonate, 2-acrylamide-2-methylpropane sulfonic acid). The present invention is also effective in the fuel cell generator in which other fuels such as ethanol, diethylether, dimethoxymethane, formaldehyde, formic acid, methyl formate, methyl orthoformate, trioxane, 1-propanol, 2-propanol, 3-propanol, ethyleneglycol, glyoxal, glycerin and aqueous solutions thereof are introduced to the anode side. The inspection method and inspection apparatus of the invention, and the cell comprising the inspection method of the invention are effective not only in the fuel cell generator, but also in secondary batteries such as a nickel hydrogen secondary battery comprising a hydrogen occlusion electrode mainly comprising a hydrogen occlusion alloy for electrochemically occluding and discharging hydrogen and a nickel electrode mainly comprising nickel; and a lithium ion secondary battery comprising positive and negative electrodes that irreversibly occlude and discharge lithium ions, and an organic electrolyte solution in which an electrolyte containing lithium ions are dissolved, while the positive electrode and negative electrode are disposed with interposition of a separator.
As described above, the inspection method and inspection apparatus of the invention enable simple and objective inspections of the performance and transient response of the fuel cell. The direct fuel cell generator of the invention permits a generator comprising an inspection apparatus for deciding the performance of the cell and being controlled with high accuracy to be provided. | The invention provides a method for inspecting a fuel cell that can simply inspect fuel cell characteristics.
The method is an inspecting method for a direct methanol fuel cell generator comprising an anode electrode including an node catalyst layer, a cathode electrode including a cathode catalyst layer, and N pieces of cells having an electrolyte disposed between the anode electrode and the cathode electrode, for power generation by feeding an aqueous methanol solution to the anode electrode and an oxidant gas to the cathode electrode. The fuel cell generator is inspected by measuring voltage changes of the voltage V of one electromotive unit caused by generating a current density change ΔI or −ΔI (mA/cm 2 ) satisfying the condition of 0.2≦ΔI≦5 in a finite current density I (mA/cm 2 ) loaded on the plural electromotive units arbitrarily connected in series in the fuel cell generator under power generation during a time interval Δt (sec) satisfying the condition of 10 −5 ≦Δt≦0.5. | 7 |
BENEFIT CLAIM
[0001] This application claims the benefit of Italy application 102015000059248, filed Oct. 7, 2015, the entire contents of which are hereby incorporated by reference for all purposes as if fully set forth herein, under 35 U.S.C. §119.
BACKGROUND
[0002] Field of the Invention
[0003] The present invention refers to a faucet assembly with an aerator cartridge, in particular of the type which can be hidden, i.e. which is completely insertable into the mouth of the same faucet. The present invention also refers to a method for mounting the aerator cartridge in its seat.
[0004] Above said devices are advantageously used in the field of faucets and faucet accessories.
[0005] Known Art
[0006] Aerator devices are already largely used, in disparate home water installations, which, after being mounted on fluid outlets from the grid, in particular on faucet mouths, allow avoiding liquid seepage and homogenization of outpouring water, by mixing it with air, so that a full and regular jet is obtained. Such devices, since they achieve the jet required by users with less water flow, provide important reductions both of water usage and energy consumption due to water heating.
[0007] Increasingly, such devices are no more inserted into an additional ring nut, but are instead directly inserted into the terminal tract of the faucet, which is suitably threaded in order to allow a threaded connection inside the same. This mounting method allows the aerator cartridge to be almost invisible, and is therefore particularly preferred, since it does not negatively influence the faucet's appearance.
[0008] In such embodiments, it is known to be necessary to avoid any seepage of fluid at the threaded coupling between cartridge and inner conduit of faucet. Such occurrences, although not impairing the operation of faucet, cause, during use, a persistent lateral non homogeneous dripping with respect to delivered jet; this is esthetically displeasing and commercially unacceptable.
[0009] In order to avoid such seeping, products in the known art always provide at least a sealing gasket at or near the threaded connection.
[0010] Depending on the embodiment, the cartridge, which is screwed into the terminal male threading of the faucet tube may or may not abut against an abutting or end stop. In the first case a flat compressed gasket is introduced between cartridge and end stop; in the second case, a toroidal gasket is positioned near the threaded connection, clamped between the inner surface of faucet and an external groove of cartridge.
[0011] WO 2011/154063 discloses both the above said sealing systems: FIGS. 3-6 show the use of a flat gasket, which is clamped between the cartridge and the shoulder of faucet; FIGS. 7-11 show the use of a peripheral toroidal gasket, which is introduced into a peripheral groove of same cartridge.
[0012] In both cases, in any case, mounting and in particular dismounting operations are very complicated due to the presence of the elastic gasket.
[0013] In particular, if the gasket is compressed against the upper abutment, it is necessary to strongly tighten the cartridge, in order to ensure a good water resistance of the connection; if, on the other hand, a toroidal gasket is applied between the cartridge and the inner wall, this causes a high friction and, with time, adhesion phenomena, which hinder the removal of the same cartridge. The extraction of the cartridge by the user, which is necessary in case of service and replacement, require the application of a high torque, and cannot be done with bare hands.
[0014] In order to eliminate this drawback, the aerator cartridge is also provided with a specific wrench, which has to engage from the underside the object which is inserted into the faucet tube. On the other hand, it is clear that such a mounting wrench has a non-irrelevant price tag, and also represents an element which is often lost by the user, because of its infrequent use.
[0015] The difficulty in inserting the elastic sealing element into the mounting seat, the necessity of a periodic service as well as, and foremost, the need to provide an expansion inner counter-groove in the thin wall of faucet tube represent further important drawbacks, which are still unsolved in the embodiments of the known art.
[0016] In the past, alternative sealing systems have been proposed for faucet aerators without elastic gaskets.
[0017] U.S. Pat. No. 3,298,614 proposes, for example, various technical solutions in this direction. The majority of them provide a septum or a flange of plastic material, which, abutting against a mouth's abutment surface, defines a relatively water resistant sealing, due to strong tightening of the entire cartridge. Other solutions provide the use of a metallic element, which radially forces in an outward direction the thin wall of plastic material on which the cartridge's threading is provided, to achieve the sealing due to radial interference between screwed threads. In both cases, the solution provides the only advantage of a cost reduction of gasket, without solving, or even increasing, the difficult removal of the cartridge due to high tightening torque.
[0018] Prior documents U.S. Pat. No. 3,104,827 and GB 1 282 957 refer to other embodiments of a faucet assembly, in which the sealing of cartridge is ensured by a head gasket and/or by rigid abutments, which is strongly tightened against a shoulder of the mouth.
[0019] The technical problem to be solved by the present invention is therefore to provide a hidden aerator cartridge, which does not have the drawbacks of the known art, and in particular, which allows the prevention of a lateral dripping without requiring tightening torques, which are so high as to hinder a manual extraction of the cartridge.
SUMMARY OF THE INVENTION
[0020] The above said technical problem is solved by a faucet assembly comprising: a mouth with an internally threaded portion; and an aerator cartridge, which is inserted into said mouth, wherein said cartridge defines an internal flow path from an upstream inlet and a downstream outlet; wherein said cartridge comprises: a casing, at least one jet breaking means, which is positioned in such a way as to intercept said internal flow path, wherein said casing has an external lateral surface, which is provided with an attachment thread, which is screwed into said internally threaded portion of said mouth, for defining a threaded coupling and with at least one aeration window, opening on the internal flow path, wherein said aeration window is positioned at or underneath the attachment thread, directly contacting the same or being joined with the same by means of a continuous profile of external lateral surface.
[0021] The above said jet breaking means may be positioned inside said casing. It may comprise one or more sieves, which are disposed inside the casing, or which may even be completely integrated in said casing, for example as a lower grating.
[0022] Advantageously, in the faucet assembly according to the invention, no sealing gasket is provided for avoiding water seeping through said threaded coupling between the mouth and the cartridge, so that the torque required for unscrewing may be minimal, since it has only to overcome the friction between the threads of the threaded coupling.
[0023] In particular, in order to allow a manual unscrewing of cartridge, the required torque for unscrewing of said threaded coupling is kept under 1 Nm, preferably under 0.5 Nm, and more preferably under 0.3 Nm. Ideally, such a torque may be kept at a negligible level, i.e. it may be limited only to the torque required for overcoming sliding friction between the thread's surfaces, which are mutually engaged with a certain play.
[0024] The required unscrewing torque, as defined in the present application, is measured on a new item, at a time directly following the screwing, i.e. before adhesion phenomena, which are due to limestone depositing during the faucet's use, may influence its value.
[0025] With reference to terms used above, the aeration window may be considered to be at the thread, if it opens at least partially above he lower edge of the same thread, locally interrupting the same; underneath the thread in all other cases.
[0026] With reference to terms used above, the aeration window may be considered to be directly contacting the attachment thread if the lower edge of thread is at least partially adjoining a portion of the edge of the aeration window. The aeration window is joined, by means of a continuous profile, to the external lateral surface if, between at least a portion of the lower edge of thread and at least a portion of the edge of the aeration window, the profile does not feature ridges or troughs, that may cause the separation of the water drop which flows, through gravity, from the lower edge of thread to the inlet into the window opening.
[0027] In other words, it is necessary that the shape of the lateral external surface and the arrangement of the aeration windows with respect to the attachment thread be such as to not hinder the flow of water, which has seeped through the attachment thread towards the at least one aeration window.
[0028] In above said faucet assemblies, the applicant has observed that the expected drippings due to seepage of water through the threaded coupling without the peripheral gasket are considerably reduced and almost vanish.
[0029] The cause of this effect, totally surprising and unexpected even for the skilled in the art, is interpreted in the following, which is only a hypothesis without pretending to be neither exhaustive nor scientifically correct.
[0030] As shown in FIG. 6 , the flow of water through the cartridge defines, according to known Bernoulli equation, a local depression which sucks ambient air through the aeration windows, which are laterally positioned with respect to the same flow. It is argued, that such a sucking effect is sufficient to drag the water droplets, who have seeped towards the aeration windows, therefore reintroducing the same into the path of primary flow of aerator.
[0031] Tests conducted by the applicant have in particular shown that, in case of small sized aerators (with a diameter equal or less than 24 mm), the aeration windows, which are positioned against of thread provide the total suppression of the dripping phenomenon, even without the traditional sealing gaskets.
[0032] Similar results have been obtained also with aeration windows positioned away from the thread (not illustrated), in particular in case of a continuous joining surface.
[0033] On the other hand, FIG. 7 shows an example of a discontinuity between the aeration opening and the threaded surface. In this case, the flow seeping through the thread cannot slide along the casing until it reenters the cartridge, but is instead broken at the discontinuity, causing the dripping effect, which is avoided by the present invention.
[0034] One can therefore understand that the presence of the aeration windows in the cartridge casing is, per se, not sufficient to determine the described phenomenon of dripping recovery, since it is also required to have a contiguity between these and the thread or the superficial continuity of the interposed coupling.
[0035] It is in particular to be noted, that the absence of sealing gaskets implies the absence of grooves and similar enclosing formations, which are traditionally provided on the lateral surface of cartridge at or near the attachment thread.
[0036] The device according to the invention therefore defines an alternative sealing system, which is also considerably simplified with respect to providing the toroidal gaskets of the art.
[0037] The advantages deriving from the absence of sealing gaskets are considerable and readily comprehended by the skilled in the art: material reduction, ease of mounting and in particular dismounting of the device, simplification of the cartridge's structure and of the machining of the mouth portion of faucet, which, in this particular case, does not require a counter-groove for radial expansion of elastic gasket.
[0038] In the same way, the cartridge is not required to abut against a shoulder inside the mouth, nor is a flange required to abut against the perimeter of the same mouth, as in the known art, for avoiding dripping through axial tightening with or without interposed gaskets. The cartridge is preferably freely screwed in a male thread of tube, without abutting against any end stop.
[0039] It is therefore possible to screw the aeration cartridge in its seat without high friction caused by interposed gaskets and/or the need for an axial sealing tightening, observing above said limit for the unscrewing torque. Therefore, it is possible to manually mount and dismount the cartridge, i.e. without using any mechanical tool for inferiorly engaging the element.
[0040] The cartridge may advantageously comprise suitable elements, like for example protrusions, which are accessible from outside the faucet in the mounted position, in order to facilitate manual unscrewing by the user.
[0041] In the faucet assembly according to the present invention the aeration cartridge is in fact preferably of the hidden type, i.e. the axial extension of said casing is completely or predominantly (for the most part) inserted into said mouth.
[0042] The threaded coupling, since lacking the gasket, allows a water seepage when said faucet assembly is connected to a water grid with an operating pressure of at least 0.5 bar, preferably 1 bar.
[0043] However, water seeped through the threaded coupling is at least partially sucked into the casing of the cartridge through said aeration windows, as previously described. Preferably, seeped water is completely sucked when operating pressure is kept between 0.5 and 6 bar.
[0044] Some of the detailed characteristics of the cartridge, relating to preferred and particularly advantageous solutions, are provided in the following.
[0045] As already stated, the aeration windows may open either at the lower edge of the attachment thread; or at least partially above the lower edge of attachment thread, locally interrupting the same; or still separated from that edge. In this last case, the external lateral surface has to be provided with a continuous profile, i.e. without interposed drop-breaking formations, between the lower edge of attachment thread and the one or more aeration windows.
[0046] The shape of the external lateral surface and the arrangement of aeration windows, in particular with reference to the position of the attachment thread, are, as already noted, structured in a way that, during use, the flow of water along the internal flow path facilitates the sucking of air through the aeration windows, which is sufficiently strong to drag, at least partially, the water seeped from the attachment thread within the casing through said aeration windows.
[0047] In particular, experiments conducted by the applicant have shown a complete remission of the dripping phenomenon at pressures compatible with those of a normal water distribution grid, i.e. between 0.5 and 6 bar.
[0048] It is to be noted that said casing may comprise a plurality of parts, since the attachment thread and the aeration windows may be provided on separate parts of said casing. The casing may, for example, comprise a cup-shaped body, which is surmounted by a lid or plate, in which jet breaking openings are defined. The attachment thread and the aeration windows may in this case be completely provided on the external surface of the cup-shaped body, or they may be completely or partially provided on the upper part defining the lid.
[0049] It is to be noted that the jet breaking means of cartridge are preferably a plurality, and normally comprise at least one plate provided with a jet breaking opening, on whose downstream side one or more sieves are positioned. The jet breaking openings divide the water flow into a plurality of concentrated high speed jets. Speed then decreases when the same jets impact against the underlying sieves. The aeration windows preferably open between the plate with the breaking openings, and the sieves, wherein the flow speed is higher and therefore the sucking effect of ambient air is also higher.
[0050] Preferably, the aeration windows are more than one, for example four, and are angularly equally spaced along the periphery of the external lateral surface.
[0051] They preferably have a rectangular or trapezoidal shape.
[0052] The opening of the aeration windows occupies a considerable portion of the entire circumference of the casing at their location, preferably larger than 25%.
[0053] Best results regarding the reduction of dripping have been obtained with aeration cartridges having relatively small dimensions, i.e. a diameter of the attachment thread indicatively equal or less than 24 mm, more preferably less than 20 mm.
[0054] The casing preferably comprises at least one cup-shaped lower body, wherein said flow breaking means comprise a plurality of sieves, which are introduced into said cup-shaped body. The cup is inferiorly closed by a lower grating or by one of same sieves. Alternatively, as said, the breaking means may be provided in another way, for example it may be only comprised of the lower grating of cup.
[0055] The cup-shaped body preferably has an upper portion comprising the attachment thread, although the latter may be provided on a separate portion as, for example, a lid, which is integrated with the flow breaking plate. The cup-shaped body also comprises a lower containment portion for sieves, and a tapered joining portion between the previous two, wherein the aeration windows partially or completely open on said tapered portion.
[0056] The jet breaking means may also comprise a plate, which is provided with jet breaking openings, which plate closes the cup-shaped body on its upper side, wherein said plate is surmounted by a jet breaking screen.
[0057] Preferably, the plate engages above the cup-shaped body with a snap fit and the jet breaking screen also engages with a snap fit an upper niche of the same plate.
[0058] The above said technical problem is also solved by a method for mounting an aerator cartridge of above said type, comprising the steps of:
[0059] Providing an aerator cartridge comprised of a casing and at least one jet breaking means, which is positioned in a way to intercept an internal flow path, said casing being provided with an external lateral surface, which is provided with an attachment thread and, at or under said attachment thread, at least one aeration window, which opens on the internal flow path;
[0060] Providing an internally threaded portion on a mouth of the faucet;
[0061] Screwing, without interposing any sealing gasket between cartridge and mouth, the attachment thread into said internally threaded portion, with a tightening force lower than 1 Nm, preferably lower than 0.5 Nm, and more preferably lower than 0.3 Nm.
[0062] Advantageously, such a method may be put into practice without the help of mechanical tools for temporarily engaging the aerator cartridge.
[0063] Further characteristics and advantages can be better understood from the following detailed description of some preferred non-exclusive embodiments, of the present invention, with reference to attached figures, which are provided as non-limiting examples.
BRIEF DESCRIPTION OF THE DRAWINGS
[0064] FIG. 1 is a front view of a first embodiment of the aerator cartridge, which is part of a faucet assembly according to the present invention;
[0065] FIG. 2 is a side view of aerator cartridge according to FIG. 1 ; FIG. 3 is a side view of aerator cartridge, in a section along plane A-A of FIG. 2 ;
[0066] FIG. 4 is a perspective view from above of aerator cartridge of FIG. 1 ;
[0067] FIG. 5 is a perspective view from below of aerator cartridge of FIG. 1 ;
[0068] FIG. 6 is a sectional view of a second embodiment of the aerator cartridge being part of a faucet assembly according to the present invention and of the tract of the faucet in which it is housed;
[0069] FIG. 7 is a sectional view of an example of an aerator cartridge, which is not part of a faucet assembly according to the present invention, and of the tract of the faucet in which it is housed;
[0070] FIG. 8 and FIG. 9 are two views of a lateral jet breaking cartridge, which is part of a faucet assembly according to the present invention, which is provided with specific protruding projections for manual unscrewing of the same.
DETAILED DESCRIPTION
[0071] With reference to appended FIGS. 1-5, 1 generally indicates a first embodiment of the aerator cartridge.
[0072] On the other hand, 1 ′ indicates the second embodiment of an aerator cartridge of FIGS. 6 and 1 ″ indicates the example of an aerator cartridge, not belonging to the invention, which is shown in FIG. 7 . In these last two figures, the cartridge shown is housed in an operative position inside a terminal tract of a faucet, which in the following is indicated as mouth 100 .
[0073] FIG. 8 and FIG. 9 finally show two variants of cartridge 1 according to the first embodiment, which are provided with special protruding projections for manually unscrewing the same cartridge.
[0074] The invention refers to a faucet assembly comprising one of cartridges 1 , 1 ′; said faucet comprises a primary portion, which is not shown in appended figures, since it is known per se, which ends with a mouth 100 provided with an internally threaded portion 101 , as shown in FIG. 6 , in which the cartridge 1 , 1 ′ is screwed.
[0075] Cartridges 1 , 1 ′ and 1 ″ are shown in FIGS. 1-3 , FIGS. 6-9 according to a specific vertical operative configuration; in the following description, positions and orientations, relative and absolute, of various elements comprising the unit, defined by terms such as upper and lower, up and down, horizontal and vertical or other equivalent terms, have always to be interpreted with reference to such a configuration. Therefore, they should not be provided with any limiting value; on the contrary, the cartridges are installed, in the majority of cases, according to an inclined configuration with respect to the vertical direction.
[0076] In the first embodiment, shown in FIGS. 1-5 , cartridge 1 of the aerator is composed of a plurality of elements, which are removably associated to each other.
[0077] In particular, a casing 10 , which is inferiorly defined by a cup-shaped body 20 , internally containing a plurality of sieves 5 —in this particular case four—, which lie on a bottom grating 50 , an upper lid 40 , which snappingly engages, above the cup-shaped body 20 , defining a plate 4 , which is crossed by a plurality of frustoconical jet breaking openings, and lastly a jet breaking screen 3 , which snappingly engages above the plate 4 .
[0078] Above said elements define an internal flow path 2 for water, which is emitted by a faucet, which is provided with the device. The internal flow path extends from an upstream inlet 21 , coinciding with the jet breaking screen 3 , and a downstream outlet 22 , coinciding with the bottom grating 50 .
[0079] The cup-shaped body 20 is provided, on an upper portion of its external lateral s internal surface 11 with an attachment thread 12 , which, in the present embodiment, has a diameter of 16 mm and a pitch of 1 mm. The thread, which extends for four rotations along an overall height of 4 mm, is operable for screwing inside the internal threaded portion 101 of mouth 100 of faucet assembly.
[0080] The attachment thread 12 extends to the upper end of cup-shaped body 20 , and is surmounted only by a small attachment flange of upper lid 40 . In particular, the absence of a receiving groove for a sealing gasket may be noted.
[0081] Underneath the upper portion, which is necessarily cylindrical, the casing is provided with a tapered portion 14 , which joins the attachment thread 12 with an underlying lower portion 15 , which is also cylindrical, in which the piled sieves 5 are enclosed.
[0082] The cup-shaped body 20 of casing 10 is provided with four aeration windows 13 , which are equally angularly spaced, and have an essentially rectangular shape, whose height covers the entire extension of tapered portion 14 . The aeration windows 13 are therefore positioned immediately against the attachment thread 12 , i.e. their opening is directly underneath the lower edge of attachment thread 12 .
[0083] In the alternative embodiment of FIG. 6 , the aerator cartridge 1 ′ essentially has the same components and principal characteristics of the first embodiment, which was previously described. Such components and characteristics are therefore indicated by reference numerals previously used.
[0084] The only substantial difference between the two embodiments refers to the upper extension of aeration windows 13 , which, in this case, surmounts the lower edge of attachment thread 12 , so that interrupts the latter.
[0085] FIG. 6 also shows the operating principle on which the present invention is based. When the emitted water flow passes through the flow path 2 , it generates a local depression, which sucks an air flow A from the aeration windows. Also water W seeped through the threaded coupling is dragged, together with it, into the aerator cartridge 1 , reconnecting with the water flow, which is emitted by the bottom grating 50 .
[0086] FIG. 7 , on the other hand, shows that the simple provision of aeration window 130 does not suffice to cause the required effect, if an abrupt transition between the threaded coupling 120 and the same aeration windows is provided. In fact, in this case, the air flow A, which is sucked into the device, is not able to drag the seeped water W along the thread.
[0087] FIG. 8 and FIG. 9 finally refer, as previously indicated, to variants of the previously described aerator cartridge 1 . In these variants, protruding flaps 17 ; 17 ′ are provided, which are outwardly and downwardly directed, respectively, with respect to the lower portion of cup-shaped body 20 , and which remain accessible to the user even if the cartridge 1 is in the mounted position, defining an application surface, which facilitates the manual unscrewing of the device.
[0088] The mounting of presently described cartridges 1 , 1 ′ into the mouth 100 , in order to complete the faucet assembly, comprises the screwing of the attachment thread 12 into the internally threaded portion 101 of the same mouth. Since no sealing tightening or toroidal gaskets are provided, that generate additional friction, screwing may be accomplished using a minimal tightening torque, lower than 0.5 Nm, for example. In particular, the same can be accomplished manually without using tightening tools, the user directly gripping the lower end of casing 10 with her fingers.
[0089] Obviously, the skilled in the art, in order to meet contingent and specific needs, may introduce various modifications and variants to the invention, which, by the way, are all contained within the protection scope of the invention, as defined in the following claims. | Faucet assembly with aerator cartridge ( 1′ ), which is screwed by means of an attachment thread ( 12 ) into the mouth ( 100 ), which has no sealing gasket, wherein water (W) seeping through the attachment thread ( 12 ) is at least partially reintroduced into a casing ( 10 ) of cartridge ( 1′ ) through suitably positioned aeration windows ( 13 ), being dragged by the air flow (A), which is sucked into said aeration windows ( 13 ) by the water flow within an internal flow path ( 2 ) of said cartridge ( 1 ). | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
This is a United States Nationalization of International Patent Application PCT/EP2012/050926 filed Jan. 23, 2012 which claims priority from German Patent Application 10 2011 003 125.1 filed Jan. 25, 2011.
BACKGROUND OF THE INVENTION
The present invention relates to a simple and cost-effective method for producing iron(III) orthophosphate-carbon composites (FOP/C) with a high electrical conductivity, iron(III) orthophosphate-carbon composites produced according to the method, as well as their use for the production of LiFePO 4 cathode materials for Li-ion batteries.
Rechargeable Li-ion batteries are widely used energy storage means, in particular in the mobile electronics sector, since the Li-ion battery is characterised by a high energy density and can supply a high rated voltage, so that the Li-ion battery with a comparable performance is significantly smaller and lighter than conventional batteries. Spinels such as LiCoO 2 , LiNiO 2 , LiNi 1-x Co x O 2 and LiMn n O 4 have proved to be suitable as cathode materials. In order to increase the safety of the Li-ion batteries, especially with regard to a thermal overloading during operation, LiFePO 4 was developed as a cathode material. This material is characterised by a good performance, high specific capacity and also high thermal stability in operation. Iron orthophosphate is a starting material for the production of LiFePO 4 cathode material for Li-ion batteries.
High demands in terms of purity are placed on the cathode material of Li-ion batteries, since any contamination that may involve undesirable redox reactions during operation (charging and discharging) has a deleterious effect on the performance of the battery. The nature and concentration of the possible contaminations basically depends on the quality of the raw materials used for the production of the cathode material and their production processes per se. In the production process of the cathode material measures can be adopted for the subsequent reduction of impurities, which however is generally associated with an increase in production costs. It is therefore desirable to use starting materials and raw materials that are as pure as possible for the production of the cathode material. Apart from the purity of the starting materials, their structure and morphology also have a significant influence on the quality of the cathode material produced therefrom.
DE 10 2009 001 204 A1 describes the production of crystalline iron(III) orthophosphate (FOP) in the form of phosphosiderite crystallites (metastrengite II crystallites) with a particular morphology and purity. On account of the particular purity and the novel material properties this iron(III) orthophosphate (FOP) is particularly suitable as a starting material for the production of lithium-iron phosphate (LiFePO 4 ; LFP) for lithium ion batteries, for example according to the methods described in US 2010/0065787 A1.
Pure lithium-iron phosphate (LFP) has a poor electrical conductivity, which is why it can only be used to a limited extent in its pure form as a cathode material. Various approaches have therefore been developed in order to improve the electrical conductivity of lithium-iron phosphate.
U.S. Pat. No. 6,855,273 B2 and US 2010/0065787 A1 describe the production of a carbon coating on the LFP particles, in which a synthesised LFP or a mixture of precursor compounds, inter alia FOP, is mixed with organic materials, generally oligopolymers or polymers, and is then heated for several hours at temperatures around 700° to 800° C. in order to effect a carbonisation of the organic component on the surface of the LFP particles. If no graphitisation is thereby achieved, this can have a negative effect on the electrical conductivity of the cathode material, since only graphitic structures ensure a high electrical conductivity. The process parameters of this thermal process have to be strictly controlled, which is complicated. Also, the carbon precursor compounds required for the formation of the coating have to be chosen so as to match the process exactly. A further disadvantage is that the carbon precursor compounds have to be added in excess in relation to the carbon fraction remaining in the end product, since a part of the precursor compounds is lost in the form of thermal decomposition products. The exact adjustment and reproduction of the carbon and graphite content is complicated on account of the process.
Another disadvantage of this method is that in the thermal process a temperature of at least 650° C. must be achieved in order to carbonise and graphitise an organic carbon precursor compound. At such high temperatures it is virtually impossible to prevent a pronounced particle growth and a caking of the calcination material. However, this in particular should be avoided in the production of LFP, in order to keep the diffusion paths for the Li ions short.
US 2009/0311597 A1 describes the doping of LFP with different transition metals or transition metal compounds in order to produce cathode materials with acceptable electrical conductivities. The doping additives can in this connection be distributed homogeneously in the sense of a mixed crystal in the material or can be present as a separate crystalline phase in addition to the LFP. The doping with transmission metals or also with lanthanoid metals involves high costs for these doping additives per se and in addition requires very complicated and costly methods in order to achieve a distribution and doping that raises the conductivity. Thus, for example, US 2009/0311597 A1 discloses very high calcination temperatures of 800° C. and long calcination times of up to 96 hours, which economically is a serious disadvantage.
US 2009/0152512 A1 describes a material similar to that of US 2009/0311597 A1, though in this case exclusively nanocrystals of metal oxides are discussed, which should be present as separate phases in a cathode material matrix in order thereby to raise the electrical conductivity of the resulting material.
US 2003/0064287 A1 discloses that iron phosphates were intimately mixed with acetylene black in a ratio of 5:1 by means of a dry ball mill for 15 to 120 min (generally 90 min) in order to test the iron phosphates for activity in electrochemical cells. This ratio corresponds to a carbon content of about 17%. In this connection the particle sizes of amorphous, nano-scale iron phosphates should not alter. A crystalline iron phosphate was however comminuted from a mean particle size of about 5 μm to 500 nm. In addition the document assumes that an improved effectiveness of a carbon coating of the iron phosphate particles is achieved by increasing the mixing time. However, it was not demonstrated that a carbon coating of the iron phosphate particles was actually achieved, but was simply assumed.
The addition of extremely fine carbon particles, such as acetylene black, superP (Timcal) or Ketjen Black (Akzo Nobel), or also carbon nanotubes with their extremely special properties, appears relatively simple compared to many other described methods. These special carbons must however in turn be produced by special methods, which restricts their market availability and also makes these materials significantly more expensive compared to say conventional graphites.
A high carbon addition to the active material (cathode material) of a battery in order to achieve the necessary electrical conductivity is not economical, since a battery produced in this way would have to lose potential storage capacity at the expense of the carbon component. It is therefore desirable to achieve a sufficient electrical conductivity with at the same time as low a carbon content as possible. Apart from this the processing of slurries of the cathode material becomes more difficult with increasing carbon content, as is described for example in EP 1 094 532 A1.
BRIEF SUMMARY OF THE INVENTION
The object of the present invention was therefore to provide a method that is simple and cost-effective compared to the prior art for producing iron(III) orthophosphate-carbon composites (FOP/C) with high electrical conductivity combined with as low a carbon content as possible, and also iron(III) orthophosphate-carbon composites produced according to the method.
The object of the invention is achieved by a method for producing an iron(III) orthophosphate-carbon composite that contains iron(III) orthophosphate of the general formular FePO 4 ·nH 2 O (n≦2.5), which is characterised in that a carbon source is dispersed in a phosphoric acid aqueous Fe 2+ ion-containing solution and under addition of an oxidising agent to the dispersion iron(III) orthophosphate-carbon composite is precipitated from the aqueous solution and separated.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 a shows a scanning electron microscope image of an iron(III) orthophosphate with a metastrengite I crystal structure produced according to the prior art from Fe(II)SO4 with phosphoric acid.
FIG. 1 b shows an X-ray diffraction spectrum of the iron(III) orthophosphate of FIG. 1 a.
FIG. 2 a : Scanning electron microscope image of iron(III) orthophosphate produced from Fe3O4 according to DE 10 2009 001 204 A1, which exists predominantly in the metrastrengite II crystal structure.
FIG. 2 b shows an X-ray diffraction spectrum of the iron(III) orthophosphate of FIG. 2 a.
FIG. 3 a shows a scanning electron microscope image of iron(III) orthophosphate-carbon composite at a magnification of 5.35K×. Particles of FOP and graphite cannot be differentiated. The sample was prepared from a washed filter cake of FOP/C by dispersion in H2O.
FIG. 3 b shows a scanning electron microscope image of iron(III) orthophosphate-carbon composite at a magnification of 690×. Particles of FOP and graphite cannot be differentiated. The sample was prepared from a washed filter cake of FOP/C by dispersion in H2O.
FIG. 3 c shows a scanning electron microscope image of iron(III) orthophosphate-carbon composite at a magnification of 19.62K×. Particles of FOP and graphite cannot be differentiated. The sample was prepared from a washed filter cake of FOP/C by dispersion in H2O.
FIG. 3 d shows a scanning electron microscope image of iron(III) orthophosphate-carbon composite at a magnification of 9.00K×. Particles of FOP and graphite cannot be differentiated. The sample was prepared from a washed filter cake of FOP/C by dispersion in H2O.
FIG. 3 e shows a scanning electron microscope image of iron(III) orthophosphate-carbon composite at a magnification of 5.35K×. Particles of FOP and graphite cannot be differentiated. The sample was prepared from a washed filter cake of FOP/C by dispersion in H2O.
FIG. 4 shows a powder diffraction diagram (CuKα radiation) of a typical iron(III) orthophosphate-carbon composite (black: measured diffraction pattern; red: ICSD reference data for phosphosiderite (ICSD#076-0451); blue: ICSD reference data for graphite (ICSD#075-2078)).
FIG. 5 shows EDX analysis of a FOP/C according to the invention. The spectrum shows a pronounced peak for the C—Kα line and also for all otherwise expected elements. The Si—K-α line is due to the sample carrier, since the FOP/C was applied to a silicon wafer. An element mapping (not shown) shows that carbon is homogeneously distributed over the whole sample. An elementary analysis (CHN) showed a C content of the sample of 3.98 wt. %.
FIG. 6 shows EDX analysis of a further FOP/C according to the invention. The spectrum shows a pronounced peak for the C—Kα line and also for all otherwise expected elements. The Si—Kα line is due to the sample carrier, since the FOP/C was applied to a silicon wafer. The Au-lines are due to gold particles with which the sample was sputtered before the measurement, in order to avoid charge effects. An element mapping (not shown) shows a homogeneous distribution of P and Fe. C has a higher concentration roughly in the middle of the sample, which indicates the presence of an individual particle. An elementary analysis (CHN) gave a C content of the sample of 3.91 wt. %.
DETAILED DESCRIPTION OF THE INVENTION
In principle any phosphoric acid aqueous Fe 2+ ion-containing solution can be used for the implementation of the method according to the invention, as long as it contains Fe 2+ ions in a sufficient concentration so that the precipitation reaction according to the invention takes place. It is however particularly preferred according to the invention to use a phosphoric acid Fe 2+ solution produced according to DE 10 2009 001 204 A1.
Accordingly, in a particularly preferred embodiment of the process according to the invention the aqueous Fe 2+ ion-containing solution is prepared by introducing oxidic iron(II), iron(III) or mixed iron(II,III) compounds, selected from hydroxides, oxides, oxide-hydroxides, hydrated oxides, carbonates and hydroxide-carbonates, together with elementary iron into a phosphoric acid-containing aqueous medium and bringing Fe 2+ ions into solution and reacting Fe 3+ with elementary Fe (in a comproportionation reaction) and then separating solids from the phosphoric acid aqueous Fe 2+ solution.
In this preferred embodiment of the method according to the invention the oxidic iron compound and the elementary iron can be used in pulverulent form, preferably with grain sizes D50 in the range from 0.01 μm to 300 μm, and mixed and reacted directly with the phosphoric acid-containing aqueous medium, preferably with dilute phosphoric acid. Alternatively the starting substances or a proportion of the starting substances can first of all be freshly prepared by a precipitation and if necessary subsequent annealing and then processed further as a filter cake. A coloured and/or turbid slurry (black to brown to red) is formed owing to the solids content of the raw material.
When an aqueous solvent is mentioned hereinafter, this not only covers embodiments that contain exclusively water as liquid medium, but also those embodiments in which the liquid medium consists preferably predominently of water, although it can also contain amounts of organic and/or ionic solvents or liquids miscible with water. It is known that such solvent additives can have an influence on the crystal growth and therefore on the resultant morphology of the product.
In the phosporic acid-containing aqueous medium for the preparation of the Fe 2+ solution a redox reaction takes place between Fe 3+ from the oxidic iron raw material and the elementary iron, soluble Fe 2+ being formed in a comproportionation according to the following reaction equation (I).
2 Fe 3+ +Fe→3 Fe 2+ (I)
The temperature of the reaction batch rises by about 2° to 25° C. depending on the raw material if the resultant heat of reaction is not conducted away, which in principle is not necessary. After the end of the reaction the batch is heated to higher temperatures, preferably below 65° C., while stirring, the introduced solids reacting more or less completely, depending on the composition and purity, with the formation of a typically green-coloured Fe 2+ solution. This process step is completed after about 50 to 120 min. The duration depends inter alia on the employed raw materials and concentrations.
Depending on the purity of the employed solids the solution remains more or less cloudy, which is due to compounds that are insoluble under the reaction conditions. This remaining solids content can be removed by simple filtration, sedimentation, centrifugation or by other suitable means. The weighed-out amounts of these solids vary depending on the choice of the starting substances, acid concentration and reaction temperature employed in the process.
In order to remove further impurities and undesirable substances and compounds from the solution, specific precipitation reagents can advantageously be added to the solution. Thus, for example, the calcium content in the solution can be reduced by the addition of small amounts of sulphuric acid, with the precipitation of calcium sulphate. Furthermore an additional electrolytic precipitation or deposition of undesirable metal ions from the solution can advantageously also be carried out before the carbon source is dispersed in the iron(II) solution, and under the addition of an oxidising agent to the dispersion iron(III) orthophosphate-carbon composite is precipitated from the aqueous solution.
An advantage of preparing the iron(II) solution according to the method described in DE 10 2009 001 204 A1 is that a homogeneous phosphoric acid aqueous iron(II) solution is obtained, from which all impurities present as solids or that can be converted or electrolytically deposited into solids by precipitation additives can be separated by simple means, before the solution is used for the further reaction. Compared to other methods, the method according to the invention allows the production of a product of high purity without subsequently having to carry out particularly complicated purification processes.
In one embodiment of the method according to the invention the reaction of the oxidic iron compounds together with elementary iron in the phosphoric acid-containing aqueous medium is carried out at a temperature in the range from 15° C. to 90° C., preferably in the range from 20° C. to 75° C., particularly preferably in the range from 25° C. to 65° C. If the temperature is too low the reaction rate is slow and possibly uneconomical. With too high a temperature this can lead in some cases to a premature precipitation of iron(III) orthophosphate, inter alia on account of a possible surface reaction on the solid starting substances contained in the suspension. In addition secondary reactions are promoted if the temperature is too high.
In another embodiment of the method according to the invention the carbon source contains elementary carbon. When the description mentions that the carbon source contains elementary carbon and does not consist exclusively of elementary carbon, then the carbon source can contain apart from elementary carbon also carbon compounds, for example in the form of organic compounds, as is also specified hereinafter.
In a particularly preferred embodiment of the method according to the invention the carbon source consists exclusively of elementary carbon, i.e. no additional carbon compounds are added as carbon sources.
Carbon sources according to the invention for elementary carbon are preferably selected from graphite, expanded graphite, soots such as carbon black or smoke black, single-wall or multiwall carbon nanotubes (CNT), fullerenes, graphene, glass carbon (glass-like carbon), carbon fibres, activated charcoal or mixtures thereof.
Due to the addition of suitable carbon sources directly to the Fe 2+ solution with the formation of a dispersion, the iron(III) orthophosphate together with the material of the carbon source can be precipitated as iron(III) orthophosphate-carbon composite from the solution due to oxidation. The carbon content is freely adjustable through the added amount of carbon source. The iron(III) orthophosphate-carbon composite is suitable as a precursor material for the production of cathode materials. On account of the production according to the invention a cathode material produced from the iron(III) orthophosphate-carbon composite according to the invention has a particularly good conductivity, which in comparable materials according to the prior art can be achieved only with significantly higher carbon contents.
In the preparation of the dispersion of the carbon source in the iron(II) solution, it may be advantageous in order to increase the dispersion stability to finely distribute the carbon source in the solution by the action of mechanical forces. Apart from known methods for the application of high shear forces, the use of wet stirrer ball mills is suitable for this purpose. By using a stirrer ball mill, in addition to the fine distribution of the carbon source its mean particle size or agglomerate size can also be modified. Thus, for example, the mean particle size of a commercially available graphite can be reduced to below 300 nm. The resultant dispersions are for the most part very stable and even after several days scarcely exhibit any tendency to sedimentation of the solid material graphite, even though this generally starts with hydrophobic material properties. The surface of the graphite is possibly modified by the nature of the treatment and/or the content of phosphoric acid and the solid in the dispersion is thereby stabilised. Very stable dispersions of graphite in the iron(II) solution can also be produced if the graphite is first of all hydrophilised and only then introduced into the solution. Methods described in the literature, such as for example by Hummers et al. (J. Am. Chem. Soc.; 1958, 80, 1339), are suitable for this purpose. The graphite is in this connection partially oxidised on the surface. The polarisation resulting therefrom allows significantly stronger interactions with polar solvents, in the present case water.
In a further embodiment of the method according to the invention the carbon source contains apart from elementary carbon also organic compounds. According to the invention organic compounds suitable as carbon sources include hydrocarbons, alcohols, aldehydes, carboxylic acids, surfactants, oligomers, polymers, carbohydrates or mixtures thereof.
In a carbon source comprising a mixture of elementary carbon and an organic compound the organic compound can advantageously promote the fine distribution of the carbon source in the dispersion.
Soluble carbon sources have advantages under the acidic conditions prevailing in the iron(II) solution. Soluble organic carbon sources can adhere partially or completely to the surface of graphite and/or of precipitated FOP and remain to a certain extent in the finished product depending on the intensity of the wash process.
If the carbon source is insoluble or only partially soluble, then its dispersion in the iron(II) solution can be improved, as already described above for sources of elementary carbon, by the action of shear forces.
The addition of surfactant substances to the iron(II) solution can likewise improve the stability of the dispersion. However, when choosing dispersing auxiliaries it should be borne in mind that these can cause a contamination of the product depending on the nature of the additive, which can have a negative effect on the performance of a cathode material subsequently produced from the product of the process, such as for example a reduction of the service life of the battery due to substances that produce undesired secondary reactions during operation of the battery. Conventional ionic compounds (surfactants) are therefore not suitable in this context.
If the carbon source additionally contains organic compounds, then these can be graphitised if the product is subjected to a calcination stage, for example at temperatures of 650°-800° C. Such a calcination stage is however not absolutely essential according to the invention. If organic compounds are added, then according to the invention this takes place in a mixture with elementary, electrically conducting carbon, which then also ensures the electrical conductivity if no calcination stage is carried out. The addition of organic compounds can in addition promote the dispersion of the elementary carbon in the Fe 2+ solution.
In a preferred embodiment of the method according to the invention the dispersion of the carbon source in the phosphoric acid aqueous Fe 2+ ion-containing solution contains the carbon source in an amount of 1 to 10 wt. % carbon, preferably 1.5 to 5 wt. % carbon, particularly preferably 1.8 to 4 wt. % carbon, referred to the weight of precipitated FOP.
If the amount of the carbon source in the dispersion is too low, an insufficient electrical conductivity is obtained in the FOP/C. If the amount of the carbon source in the dispersion is too high, potential storage density in the resulting cathode material is lost. This can also lead to problems in the processing of the resultant cathode material when laminating collector foils.
In a further preferred embodiment of the method according to the invention the phosphoric acid aqueous Fe 2+ ion-containing solution used for the preparation of the dispersion contains the Fe 2+ ions in a concentration of 0.8 to 2.0 mol/l, preferably 1.0 to 1.7 mol/l, particularly preferably 1.1 to 1.3 mol/l.
If the concentration of the Fe 2+ ions in the solution is too low, the FOP is not necessarily obtained in the form of phosphosiderite, which is undesirable. If the concentration of the Fe 2+ ions in the solution is too high, this can have an adverse effect on the stability of the solution and the precipitation of iron(III) orthophosphate.
In a further preferred embodiment of the method according to the invention the phosphoric acid aqueous Fe 2+ ion-containing solution used for the preparation of the dispersion has a pH in the range from 1.5 to 2.5, preferably 1.8 to 2.3, particularly preferably 2.0 to 2.1.
If the pH of the iron(II) solution is too low, losses of yield in the precipitation of FOP occur due to stabilisation of complex ions. In order to improve the yield, the solution would have to be heated for a longer time after the oxidation. Apart from this, too low a pH value can have a deleterious effect on the modification of the precipitated FOP. If the pH of the iron(II) solution is too high, no pure phosphosiderite can be precipitated.
In a further preferred embodiment of the method according to the invention the oxidising agent that is added to the dispersion is an aqueous solution of hydrogen peroxide (H 2 O 2 ), preferably in a concentration of 15 to 50 wt. %, particularly preferably 30 to 40 wt. %.
If the concentration of the oxidising agent is too low this leads locally to a dilution and an increase of the pH during oxidation, which results in the formation of strengite and consequently no pure phophosiderite can be precipitated.
In an alternative embodiment of the method according to the invention the oxidising agent that is added to the dispersion is a gaseous medium selected from air, pure oxygen or ozone, which is blown into the dispersion.
In a further preferred embodiment of the method according to the invention the iron(III) orthophosphate-carbon composite is washed once or several times with water, an aqueous and/or organic solvent after the precipitation and separation from the aqueous solution, and is then dried at elevated temperature and/or under reduced pressure or is available as an aqueous dispersion with a solids content of 1 to 90 wt. %.
The invention also includes an iron(III) orthophosphate-carbon composite, produced by the method according to the invention described herein.
The iron(III) orthophosphate-carbon composite (FOP/C) according to the invention differs in its structure and morphology from other iron(III) orthophosphate-carbon compositions according to the prior art. It exists in the form of small flake-shaped primary crystals. The thickness of the flakes is on average normally about 30 to 40 nm, and in the other two dimensions is conveniently less than 1 μm. Agglomerates of the flakes may be a few micrometres large. The morphology (preferred crystal growth) is confirmed by X-ray diffraction analyses. These analyses reveal for the FOP/C according to the invention significant differences in the measured peak heights (scattering intensity) compared to the theoretically expected peak heights for spherical particles or reference material with a significantly larger flake thickness.
FIG. 5 shows an EDX analysis (energy dispersive X-ray analysis) of a FOP/C according to the invention. The spectrum shows a pronounced peak for the C—Kα line as well as for all otherwise expected elements. The Si—Kα line is due to the sample carrier, since the FOP/C was applied to a silicon wafer. An element mapping (not shown) shows that carbon is homogeneously distributed over the whole sample. An elementary analysis (CHN) gave a C content of the sample of 3.98 wt. %.
FIG. 6 shows an EDX analysis of a further FOP/C according to the invention. The spectrum shows a pronounced peak for the C—Kα line as well as for all otherwise expected elements. the Si—Kα line is due to the sample carrier, since the FOP/C was supported on a silicon wafer. The Au-lines are due to gold particles with which the sample was sputtered before the measurement, in order to avoid charge effects. An element mapping (not shown) shows a homogenous distribution of P and Fe. C has a higher concentration roughly in the middle of the sample, which indicates the presence of an individual particle. An elementary analysis (CHN) gave a C content of the sample of 3.91 wt. %.
The results of the EDX analyses of the FOP/C according to the invention correlate with the desired and the adjusted carbon contents in the synthesis. The specific surfaces (measured according to the BET method) of the FOP/C according to the invention are normally >10 m 2 /g, preferably >15 m 2 /g, more preferably >18 m 2 /g and particularly preferably >22 m 2 /g.
In a preferred embodiment of the invention >80 wt. %, preferably >90 wt. %, and particularly preferably >95 wt. % of the iron(III) orthophosphate-carbon composite is present in the metastrengite II (phosphosiderite) crystal structure.
In a further preferred embodiment of the invention the iron(III) orthophosphate-carbon composite has at least in one dimension a mean primary particle size <1 μm, preferably <500 nm, particularly preferable <300 nm and most particularly preferably <100 nm.
In a further preferred embodiment of the invention the iron(III) orthophosphate-carbon composite has a bulk density >400 g/l, preferably >700 g/l, particularly preferably >1000 g/l and/or a compacted bulk density >600 g/l, preferably >750 g/l, particularly preferably >1100 g/l.
The invention also includes the use of iron(III) orthophosphate-carbon composite according to the invention for the production of LiFePO 4 cathode material for Li-ion batteries.
The invention furthermore includes LiFePO 4 cathode material for Li-ion batteries, produced using iron(III) orthophosphate-carbon composite according to the invention.
The invention in addition includes a Li-ion battery comprising a LiFePO 4 cathode material according to the invention.
EXAMPLES
Preparation of the Employed Iron(II) Solution
The preparation of the employed phosphoric acid Fe 2+ solution was carried out according to DE 10 2009 001 204 A1. For this, 1875 g of 75% H 3 PO 4 were diluted with double the amount of water. 105 g of elementary iron and 300 g of magnetite (Fe 3 O 4 ) were added to the solution, causing the temperature of the solution to rise. After the exothermic effect had ceased the solution was stirred at 60° C. for 2 hrs and then separated from possible suspended substances. The solution contained 0.956 mol Fe 2+ per kg solution and 2.380 mol PO 4 3− per kg solution.
Determination of the Electrical Conductivity
To determine the electrical conductivity of products according to the invention and comparison products, compacted bodies, so-called mouldings, such as are also used for spectroscopic investigations, were produced with a commercially available compression mould. The method is one known to the person skilled in the art. The diameter of the mouldings was 12 mm, predetermined by the compression mould. The thickness of the mouldings was about 2 to 4 mm, depending on the pressed amount of sample, and was determined with a micrometer screw gauge.
Using a commercially available multifunction measuring device (Voltcraft® Digitalmultimeter M-4660) with integrated current and voltage source, the electrical resistance through the test body was measured by carefully pressing the measuring electrodes on (i) opposite positions of a surface of the mouldings and (ii) on the two opposite surfaces.
Example 1
Production of an Iron(III) Orthophosphate-Carbon Composite (FOP/C) with 7.3% Graphite
2540 g (ca. 2 L) of Fe 2+ solution were added to a mixing vessel and pumped in a circular motion with an agitator ball mill (LabStar, Fa. Netzsch), equipped with 0.4-0.6 mm size milling balls. 33.1 g of graphite (UF2 from Fa. Graphitwerk Kropfmühl KG) were then added in 4 portions within 5 min. The particle size distribution and quality of the dispersion was checked every 30 min by means of a DLS measurement (dynamic light scattering, Malvern Zetasizer). After 3 hrs there was no change compared to the two previous measurements. The experiment was terminated and the dispersion was collected in a test beaker.
1100 g of the dispersion were heated to 75° C. and 110 ml of H 2 O 2 (35% in water) were then added while stirring, in order to initiate the precipitation of FOP. After the end of the resultant evolution of gas the mixture was stirred for a further 15 min at 85° C. The solids fraction of the mixture was separated with a suction filter and then resuspended twice, each time in 1 L of deionised water and filtered. After drying in a circulating air drying cabinet at 100° C. 182 g of a grey solid were obtained. The X-ray diffraction analysis of the product showed the characteristic reflections for phosphosiderite and graphite.
Example 2
Preparation of an Iron(III) Orthophosphate-Carbon Composite (FOP/C) with 7.3% Expanded Graphite
3367 g (ca. 2.6 L) of Fe 2+ solution were added to a mixing vessel and pumped in a circular motion with an agitator ball mill (LabStar, Fa. Netzsch), equipped with 0.4-0.6 mm size milling balls. 43.9 g of expanded graphite (Fa. SGL Carbon) were then added in 4 portions within 5 min. After 2 hrs the dispersion was collected in a test beaker.
1500 g of the dispersion were heated to 75° C. and 160 ml of H 2 O 2 (35% in water) were then added while stirring, in order to initiate the precipitation of FOP. After the end of the resultant evolution of gas the mixture was stirred for a further 15 min at 85° C. The solids fraction of the mixture was separated with a suction filter and then resuspended twice, each time in 1.5 L of deionised water and filtered. After drying in a circulating air drying cabinet at 100° C. 273 g of a grey solid were obtained. The X-ray diffraction analysis of the product showed the characteristic reflections for phosphosiderite and graphite.
Example 3
Preparation of an Iron(III) Orthophosphate-Carbon Composite (FOP/C) with 4% Pretreated Graphite
Before the suspension in the ball mill, about 30 g of graphite (Fa. SGL Carbon) in 500 ml conc. HNO 3 were boiled under reflux for 1.5 hr. The solid material was then separated using a suction filter, resuspended twice in each case in 1 L of deionised water, filtered and dried overnight in a circulating air drying cabinet at 100° C. 13.2 g of the graphite treated in this way were added in 4 portions within 5 min to 1850 g (ca. 2 L) of Fe 2+ solution, while pumping the solution in a circular motion with an agitator ball mill (Labstar. Fa. Netzsch) equipped with 0.4-0.6 mm size milling balls. After 2 hrs the dispersion was collected in a test beaker.
800 g of the dispersion were heated to 75° C. and 110 ml of H 2 O 2 (35% in water) were then added while stirring, in order to initiate the precipitation of FOP. After the end of the resultant evolution of gas the mixture was stirred for a further 15 min at 85° C. The solids fraction of the mixture was separated with a suction filter and then resuspended twice, each time in 1 L of deionised water and filtered. After drying in a circulating air drying cabinet at 100° C. 133 g of a grey solid were obtained. The X-ray diffraction analysis of the product showed the characteristic reflections for phosphosiderite and graphite.
Example 4
Preparation of an Iron(III) Orthophosphate-Carbon Composite (FOP/C) with 2.3% Ketjen Black
23 g of Ketjen Black® EC-300J (Fa. Akzo Nobel) were added in portions within 15 min to 5600 g (ca. 4.5 L) of a Fe 2+ solution. Following this the solution was then pumped in a circular motion with an agitator ball mill (LabStar. Fa. Netzsch), equipped with 0.8-1.0 mm size milling ball. After 3 hr the dispersion was collected in a test beaker.
3.8 kg of the dispersion were heated to 75° C. and 390 ml of H 2 O 2 (35% in water) were then added while stirring, in order to initiate the precipitation of FOP. After the end of the resultant evolution of gas the mixture was stirred for a further 15 min at 85° C. The solids fraction of the mixture was separated with a suction filter and then resuspended twice, each time in 1 L of deionised water and filtered. After drying in a circulating air drying cabinet at 100° C. 850 g of a light grey solid were obtained. The X-ray diffraction analysis of the product showed the characteristic reflections for phosphosiderite and graphite.
Comparison Examples
1000 g of iron(III) orthosphate (FOP) were prepared according to DE 10 2009 001 204 A1 using the Fe 2+ solution described above and also used for the Examples according to the invention. As above, H 2 O 2 (35% in water) was used for the oxidation reaction. In each case 100 g of the obtained iron(III) orthophosphate were ground with the following carbons A) to H) in a pestle mill (Retsch RM100) for 90 min in each case.
A) 2.3% Ketjen Black® EC-300J (Fa. Azko Nobel)
B) 3% Ketjen Black® EC-300J (Fa. Azko Nobel)
C) 5% Ketjen Black® EC-300J (Fa. Azko Nobel)
D) 9% Ketjen Black® EC-300J (Fa. Azko Nobel)
E) 5% Expanded Graphite (Fa. SGL)
F) 9% Expanded Graphite (Fa. SGL)
G) 5% Graphite (UF2 from Fa. Graphitwerk Kropfmühl KG)
H) 9% Graphite (UF2 from Fa. Graphitwerk Kropfmühl KG)
Resistance and Conductivity Measurements
Mouldings were produced from the products of the examples according to the invention and from the comparison examples, and resistance and conductivity measurements were carried out on these. The results are shown in the following Table 1.
TABLE 1
Results of the resistance and conductivity measurements on mouldings of
products of Examples 1 to 4 according to the invention and of comparison
examples A to H
Carbon
content
referred
Moulding
Surface
Sheet
Specific
to
thickness
resistance
resistance
conductivity
Sample
Carbon source
FOP
[cm]
[Ω]
[ρ F /Ω]
[σ/S m −1 ]
1
Graphite
7.3%
0.167
1850
1850
3.24E−01
2
Expanded Graphite
7.3%
0.451
12
1.15E+01
1.93E+01
3
Graphite
4.0%
0.144
4340
4.34E+03
1.60E−01
hydrophilised
4
Ketjen Black
2.3%
0.148
5200
5.20E+03
1.30E−01
A
Ketjen Black
2.3%
0.082
18000
1.80E+04
6.78E−02
B
Ketjen Black
3%
0.198
180
1.80E+02
2.81E+00
C
Ketjen Black
5%
0.189
60
6.00E+01
8.82E+00
D
Ketjen Black
9%
0.214
23
2.30E+01
2.03E+01
E
Expanded Graphite
5%
0.164
4000000
4.00E+06
1.52E−04
F
Expanded Graphite
9%
0.144
3200000
3.20E+06
2.17E−04
G
Graphite
5%
0.072
19000000
1.90E+07
7.31E−05
H
Graphite
9%
not det..
not det.
not det.
not det.
No moulding could be produced from comparison Example H, because the graphite content was so high that in all attempts to produce a moulding, this disintegrated when removed from the mold.
The results show that when using various graphites the conductivities of iron(III) orthophosphate-carbon composites according to the invention compared to the comparison examples that had been produced by conventional methods of the prior art, were higher by orders of magnitude of at least 1000-10000. When using the carbon Ketjen Black specially developed for such a use the measured conductivity compared to the comparison example was half that of the example according to the invention.
The present invention thus enables electrically conducting iron(III) orthophosphate-carbon composites to be produced in a very simple way and far more economically and ecologically friendly compared to carbons such as Ketjen Black specially developed for such a use, as starting materials for the production of cathode material. The use of natural graphites is considerably more cost-effective compared to synthetic nanoparticles obtained from thermal processes.
If the carbon content of the iron(III) orthophosphate-carbon composites is to be reduced as far as possible and at the same time a high conductivity is to be obtained, then special carbons such as Ketjen Black are particularly advantageous. Compared to purely physical mixing according to literature methods, here an iron(III) orthophosphate-carbon composite was obtained with significantly less carbon black, and has a comparable or better conductivity.
The hydrophilisation of the carbon component before the addition to the Fe 2+ solution has a particularly advantageous effect. The results show that, despite a reduction of the carbon content by nearly half, comparable conductivities can be obtained as in the case of non-hydrophilised carbon.
The iron(III) orthophosphate-carbon composites according to the invention open up the possibility of reducing the calcination temperature to below 650° C. in the production of LiFePO 4 cathode material, since no carbonisation of a carbon precursor compounds is necessary in order to achieve corresponding conductivities. This can in turn be utilised to monitor the particle size distribution and the morphology of a cathode material in a far more flexible manner than known hitherto, which has a direct effect on the electrochemical performance of the cathode material. | A method for producing an iron(III)orthophosphate-carbon composite which contains iron(III)orthophosphate of the general formula FePO 4 ×nH 2 O (n≦2.5), a carbon source being dispersed in a phosphoric aqueous Fe 2+ ion-containing solution and orthophosphate-carbon composite being precipitated and removed from the aqueous solution when an oxidant is added to the dispersion. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
This patent application claims priority under Title 35, United States Code Section 119(e) to U.S. Provisional Patent Application No. 60/299,281 entitled “Bathroom Toilet Air Vacuum Filtering Deodorizing Venting Apparatus” filed on Jun. 19, 2001, which is incorporated in its entirety by reference and made a part hereof.
BACKGROUND OF THE INVENTION
1. Technical Field
The invention relates generally to the field of odor ventilation and, more particularly, to venting and scenting malodorous air to render it inoffensive to the human sense of smell.
2. Background Art
The need for removal of offensive odors has long been recognized. Consequently, many forced air ventilation devices that filter noxious odors have been developed. However, these devices have been subject to various disadvantages. Such devices are typically inefficient in operation, unsightly in appearance, and/or costly to manufacture. In addition, such devices require expensive installation and/or cannot be placed at the source of the odor generation. Further, such devices have generally not been effective in treatment of malodorous air from the area in which the device is operated. As a result, many of these devices have not achieved as widespread commercial success as could be possible.
Attempted elimination of noxious odors has been addressed in many ways including room exhaust fans, aerosol dispensed freshening deodorants, and forced air charcoal filtering. Many of these devices are intended for use in positions relatively far from the source of malodorous air and are thus rendered less effective for this reason. A further disadvantage of many such prior art devices is the large number of working parts that makes the device relatively complex to assemble and expensive to manufacture. A related problem is that such complex devices wear out or break relatively soon due to their numerous parts and part couplings that are critical to the device's operation. In general, the larger the number of parts and part couplings a device has, the sooner the device will wear out or break due to damage, wear, or displacement of one or more parts. Another problem is that many of the compact filtering units cannot eliminate or neutralize malodorous air. Other ventilation devices cannot be hidden or made less noticeable when attached to an object. The overall appearance of the device and object thus suffer. Moreover, many previous devices are unsightly and too large to be hidden from view. Furthermore, previous devices are not generally adaptable to be attached to different objects. Moreover, many previous devices have failed to provide an effective mechanism to control the fan. Additionally, other systems are not adaptable to remove or treat malodorous air from a multitude of locations. In many instances, malodorous source generation is in an inconvenient location in which a known filtering unit would be inadequate due to the lack of any mechanism to reach to an area near the source. In addition, some areas in which it may be desired to operate such devices are not proximate to a wall power outlet or other source of electric power. Another problem with previous devices is that many use activated charcoal as a filter media. It would be desirable to provide a filter that is more effective than charcoal in the elimination of odors from air. In addition, some previous devices are ineffective in obtaining their intended purpose, eliminating or treating malodorous air. It would be desirable if these disadvantages of previous devices could be overcome.
Although a multitude of devices have been proposed for removing foul air, problems have arisen for the removal of the malodor from an interior portion of an object while circulating refreshed air. Consequently, there exists a continued need for an improved ventilating apparatus that can efficiently remove malodor from the air with an inexpensive apparatus capable of deployment with a multitude of different objects.
SUMMARY OF THE INVENTION
The present invention, in its various embodiments and features, satisfies the aforementioned needs and overcomes the above-noted shortcomings of previous devices.
An apparatus according to a first aspect of the invention functions to dissipate malodorous air. The apparatus comprises a casing, an element for removably attaching the casing to an object, a motorized fan, a conduit, an intake member, and an element for removably attaching the intake member to the object. The casing defines an inlet port and an outlet port. The motorized fan creates a partial vacuum or pressure differential that draws the air into the inlet port and exhausts the air from the outlet port. The conduit has a first end coupled to the casing's inlet port, and the intake member coupled to a second end of the conduit. The apparatus can further comprise an energy source coupled to the motorized fan. The energy source can be a battery and/or a transformer and electrical extension cord coupled to a wall outlet, for example. The motorized fan can be adaptable to selectively receive power from a battery housed within the casing or a wall outlet. In addition, the apparatus can comprise a timed duration control unit coupled to the motorized fan, that is controllable to activate the motorized fan for a period of time. The apparatus can comprise a switch coupled to the timed duration control unit, for activating the timed duration control unit to operate the motorized fan. The switch can comprise a motion or heat sensor that activates the timed duration control unit to operate the motorized fan, based on movement or heat of a person's body in proximity to the object. Alternatively, the switch can comprise a sensor for detecting pressure for activation of the timed duration control unit to operate the motorized fan, based on force applied by a person. Force can be applied by either the weight of the person's body or pressing the switch with a finger, for example. Alternatively, or in addition to the above-described features, the switch can be manipulated by a person to activate the timed duration control unit to operate the motorized fan. The apparatus can further comprise an element coupled to the switch, for removably attaching the switch to the object. The timed duration control unit can be functional to provide the energy source from an internal or external energy source. The object can be a toilet stand, cat litter box, or a waste disposal container, for example. Moreover, the apparatus can comprise a porous filter situated with respect to the casing so as to receive air from the inlet port, and a liquid or oil fragrance for application to the porous filter, for treating the air from the inlet port so as to be fragrant upon passing through the filter. The porous filter can comprise a paper, natural or synthetic fiber material, or charcoal, for example, and is absorbent to allow the liquid or oil fragrance to permeate it. The apparatus can further comprise an inlet nozzle member coupled to the casing and the conduit to duct air from the conduit to the inlet port of the casing. The inlet nozzle member can define a relatively wide opening where it meets with the casing and a relatively narrow opening where is meets with the conduit. The inlet nozzle member defines a passage between its two openings to channel air through such member. The elements used to removably attach the casing, intake member and/or switch to the object can be one or more suctions cups or hooked members, for example. The elements used to removably attached the casing, intake member and/or switch to the object can comprise one or more suction cups or hooked members, for example. The conduit can comprise a flexible hose for ducting the air from the intake member to the casing's inlet port. The apparatus can comprise a vent duct coupled to the casing to vent air from the outlet port.
An apparatus according to a second aspect of the invention comprises a casing, attachment member, motorized fan, and inlet nozzle member. The casing defines an inlet port and an outlet port. The attachment member is coupled to the casing, and is used to removably attach the casing to an object. The motorized fan creates a partial vacuum that draws the air into the inlet port and exhausts the air from the outlet port. The inlet nozzle member is coupled to the casing and defines a passage with a relatively wide opening meeting with the inlet port of the casing and a relatively narrow opening opposite the relatively wide opening. The apparatus can comprise an energy source coupled to the motorized fan. The energy source can comprise a battery and/or a transformer coupled to receive power from a wall outlet. The motorized fan is adaptable to selectively receive power from a battery housed within the casing or a wall outlet. The timed duration control unit coupled to the motorized fan, and controllable to activate the motorized fan for a period of time. The apparatus can comprise a switch coupled to the timed duration control unit, for activating the timed duration control unit to operate the motorized fan. The switch can comprise a motion or heat sensor that activates the timed duration control unit to operate the motorized fan, based on movement or heat of a person's body in proximity to the object. Alternatively, the switch can comprise a pressure sensor for activation of the timed duration control unit to operate the motorized fan, based on finger force or weight of a person's body. The switch can be manipulated by a person to activate the timed duration control unit to operate the motorized fan. The apparatus can further comprise an element coupled to the switch, for removably attaching the switch to the object. The timed duration control unit can be functional to provide the energy source from an internal or external energy source. The object to which the apparatus is attached can be a toilet stand, waste disposal container, or cat litter box, for example. The apparatus can further comprise a porous filter situated with respect to the casing so as to receive air from the inlet port, and a liquid or oil fragrance applied to the porous filter, for treating the air from the inlet port so as to be fragrant upon passing through the filter. The apparatus can further comprise a conduit having a first end coupled to the inlet nozzle member at its relatively narrow opening, an intake member coupled to a second end of the conduit, and at least one element coupled to the intake member, for removably attaching the intake member to the object. The conduit can comprise a flexible hose. The inlet nozzle member can be removably attached to the casing. The apparatus can comprise a vent duct coupled to the casing to vent air from the outlet port.
In the above-described aspects of the invention, the casing, intake member, and inlet nozzle member can be made of rigid materials such as hard plastic or metal, for example. The conduit can be a hose made of flexible rubber material or plastic material. The plastic material is optionally transparent. The attachment members, if implemented as suctions cups, can be composed of resilient, high-friction plastic material to grip the object to which they are attached. If implemented as hooked members, such elements can be composed of hard plastic or metal.
BRIEF DESCRIPTION OF THE DRAWINGS
Benefits and further features of the present invention will be apparent from a detailed description of embodiments thereof taken in conjunction with the following drawings, wherein like elements are referenced with like numbers, and wherein:
FIG. 1 is an isometric top view of an embodiment of a malodor ventilation apparatus with an intake member.
FIG. 2 is an isometric bottom view of an embodiment of a malodor ventilation apparatus with an inlet extension defined by a conduit and intake member.
FIGS. 3A , 3 B, 3 C, 3 D are bottom, front, left, and right views of an embodiment of a malodor ventilation apparatus.
FIGS. 4A and 4B are plan and rear views of an embodiment of a malodor ventilation apparatus.
FIGS. 5A and 5B are isometric views of an embodiment of a malodor ventilation apparatus with a fixed inlet nozzle.
FIGS. 6A , 6 B and 6 C are views of an embodiment of internal ventilating elements and related parts of malodor ventilation apparatus in accordance with the invention.
FIGS. 7A , 7 B and 7 C are views of an embodiment of a filter assembly of the ventilation apparatus of the invention.
FIG. 8 is a circuit diagram of the apparatus in accordance with the invention.
FIGS. 9A and 9B are two versions of the apparatus applied to use with a waste disposal container.
FIGS. 10A and 10B are two versions of the apparatus applied to use with a toilet stand.
FIGS. 11A and 11B are two versions of the apparatus applied to a cat litter box.
FIG. 12 is a partial cross-sectional view of a toilet stand showing a version of the apparatus with hook attachment member and brace.
FIG. 13 is a view of a version of the apparatus with circular intake member.
FIG. 14 is a perspective view of the apparatus with vent duct accessory.
FIG. 15 is a perspective view of the apparatus using the vent duct accessory to vent air into a wall space and/or through the wall to external air.
FIG. 16 is a perspective view of the apparatus using the vent duct accessory to vent air through a window to external air.
FIG. 17 is a perspective view of the apparatus using the vent duct accessory to vent air into a duct of a ceiling fan.
DETAILED DESCRIPTION OF THE INVENTION
The described embodiment discloses an apparatus that provides an efficient, compact, and reliable method of ventilating malodorous air from an area. An embodiment of the new and improved ventilating apparatus embodying the principle and concepts of the present invention and generally designated by the numeral 100 will be described.
Referring to FIG. 1 , an apparatus 100 of the invention generally comprises a casing 110 , an inlet nozzle member 130 , an intake member 140 , a switch 150 , and a conduit 170 . The apparatus 100 also comprises internal ventilating elements 600 that are not shown in FIGS. 1 and 2 , but are shown in FIG. 6 .
The casing 110 comprises a top casing part 120 and a bottom casing part 280 that define an enclosure to house and protect the internal ventilating elements 600 . The top casing part 120 comprises a latching mechanism 224 to snap the top casing part firmly in place with the bottom casing part 280 . An embodiment of the top latching mechanism 224 includes a plastic protrusion designed to snap into the latching receptacle 284 . Although only one latching mechanism 224 and corresponding receptacle 284 are shown in FIG. 2 , latching of the top casing part 120 to the bottom casing part 280 can be accomplished by a series of protrusions 224 that snap into corresponding latching receptacles 284 to hold the top and bottom parts 120 , 280 together. Screws 286 can further secure the top casing part 120 and the bottom casing part 280 . The screws 286 are threaded through screw holes 288 defined in the bottom casing part 280 , and screwed into the top casing part 120 to hold together the top and bottom casing parts. The internal ventilating elements 600 (see FIG. 6 ) and associated batteries for powering such elements can thus be contained and secured within the casing 110 for their protection. In addition, the casing 110 provides for a compact arrangement and attractive appearance for the apparatus 100 .
The bottom casing part 280 includes two attachment members 282 . The attachment members 282 can comprise suction cups that enable the apparatus 100 to be easily and securely placed where desired. However, the attachment members 282 can be removable from an object to which the apparatus 100 is attached so that the apparatus can be moved to another location at a later time if desired.
The bottom casing part 280 can comprise stabilization feet 290 . The stabilization feet 290 protrude from the bottom casing part 280 at spaced positions on such part to prevent wobbling and to enable the apparatus 100 to rest stably on an object. The malodor ventilation apparatus 100 can be placed inside trash receptacles, on a toilet stand, a cat litter box or wherever objectionable odors originate.
As previously mentioned, the ventilation apparatus 100 comprises the switch 150 . The switch 150 is electrically coupled to the internal ventilating elements 600 of the apparatus 100 by electrically conductive switch wires 155 . Upon activation of the switch 150 , the internal ventilating elements 600 of the apparatus 100 optionally can run for a predetermined time period from a fraction of a second to several hours or more, several minutes being sufficient for many applications. A switch suction cup 152 attached to the switch 150 allows for easy, secure, and movable placement on an object. The switch 150 can thus be conveniently located for easy activation of the unit 100 . Optionally, the switch 150 may also be a motion or heat sensor for activation of the unit 100 . Hence, the malodor ventilation apparatus 100 can be configured for multiple activation methods.
The top casing part 120 contains battery access ports 122 for easy access to insert and replace batteries as needed. The device 100 can also have an external power input plug 324 shown in FIG. 3A for operation with an external power source (not shown). Hence, the ventilation apparatus 100 can be operated to power internal ventilating parts 600 using batteries 620 and/or external power provided from a wall outlet, for example. An embodiment of the apparatus 100 comprises an intake member 140 as depicted with reference to FIGS. 1 and 2 . The intake member 140 can be used to extend the suction inlet of the apparatus 100 into an area in which the casing 110 cannot fit or in which it may not be desirable to locate the device for reasons of appearance or interference with operation of the object to which the apparatus is attached, for example. An attachment member 142 is mounted to the intake member 140 to removably attach such part to an object. The attachment member 142 can be a suction cup, for example. The extended inlet part 140 can be coupled to an inlet nozzle member 130 that communicates with the inlet port of the casing 120 . The inlet nozzle member 130 defines a sleeve 132 configured to mount tightly over the apparatus inlet lips 323 of the inlet port defined in the casing 110 shown in reference to FIG. 3 A. The inlet nozzle member 130 also has a connection nose 134 designed to form fit within the conduit 170 . The conduit 170 can be a flexible tube or hose, for example. Preferably, the conduit 170 has sufficient resilience that its internal passage is not blocked if the conduit is bent. The flexible connection hose 170 connects with the nozzle connector 160 such that it fits securely within the inside of the flexible hose 170 in airtight engagement therewith. The nozzle connector 160 also has an extended neck section 165 that fits loosely inside an outer neck ring 144 of the extended inlet part 140 . The outer neck ring 144 enables the extended inlet part 140 to rotate three-hundred-sixty degrees while maintaining airtight coupling to the nozzle connector 160 that is sufficient to ventilate malodorous air. The attachment member 142 is attached by a screw 243 to the inlet attachment member rotatable flap 245 . The inlet attachment member rotatable flap 245 is attached to the intake member 140 by a hinge 241 . The hinge 241 enables the attachment member 142 to rotate from zero to approximately one-hundred-eighty degrees about the bottom plane of the intake member 140 .
The ability of the intake member 140 to rotate around the nozzle connector 160 and the ability of the attachment member 142 to rotate relative to the part 140 provide enhanced flexibility to position the intake member 140 at a desired location to maximize the ability to draw malodorous air in proximity to its source. As shown, the extended inlet 140 provides the apparatus 100 with flexibility to acquire objectionable air from remote structures.
FIGS. 3A-3D are various views of elements of the apparatus 100 that have been previously described for the most part. Referring to FIG. 3A , the casing 110 comprises top and bottom casing parts 120 , 280 that when joined together define inlet lips 323 that engage with inlet nozzle member 130 . The inlet lips 323 surround and define the casing's inlet port 325 . Also visible in FIG. 3A are attachment members 282 mounted to bottom casing part 280 for removably attaching the apparatus 100 to an object. Further visible in FIG. 3A are battery access ports 122 that can be used to insert or extract batteries in the apparatus 100 to power the internal ventilating elements 600 . FIG. 3A also shows the switch 150 and its attachment member 152 to attach such switch to an object. Conductive wires 155 are coupled to the switch 150 and the internal ventilating elements 600 , and extend through slit 327 defined for this purpose in the top casing part 120 . FIG. 3B is a view of the bottom casing part 280 and associated elements. The bottom casing part 280 has attachment members 282 mounted thereto by screws 283 inserted in respective holes 285 defined in the bottom casing part 280 to secure the attachment members to the casing 110 . In FIG. 3C plug 324 is clearly shown in the side of the apparatus 100 . Such plug 324 can be coupled to an eight Volt power transformer, for example, to power the apparatus 100 in lieu of or in addition to battery power. In FIG. 3D the top casing part 120 defines a slit 327 through which can be passed the conductive wires 155 coupling the switch 150 to the internal ventilating elements 600 of the apparatus 100 .
In FIGS. 4A and 4B the apparatus 100 comprises a plurality of latching mechanisms 224 formed in bottom casing part 280 that engage with respective receptacles 284 defined in the top casing part 120 to hold together the top and bottom casing parts. Outlet port 413 is shown defined in the top casing part 120 . The outlet port 413 exhausts air drawn from the inlet port through the apparatus 100 by the internal ventilating elements 600 . Switch 150 with attachment member 152 and battery access ports 122 are also shown in FIGS. 4A and 4B .
In FIGS. 5A and 5B the apparatus 100 comprises an inlet nozzle member 530 that replaces the inlet nozzle member 130 , conduit 170 , and intake member 140 . The fixed inlet nozzle member 530 functions to focus the area in which the objectionable air is drawn. Additionally, the inlet nozzle member 530 protects the internal components of the malodor ventilation apparatus 100 from splash and other debris. The fixed inlet nozzle member 530 defines an internal passage extending from end 132 defining a relatively wide opening to end 534 defining a relatively narrow opening 534 . The opening of the wide end 532 can be designed to press fit onto the inlet lips 323 of casing 110 . Consequently, the fixed inlet nozzle member 530 can be easily removed for cleaning and reattached to the casing 110 .
FIG. 6 illustrates an embodiment of the internal ventilating elements 600 of the malodor ventilation apparatus 100 . The switch 150 causes the activation of a motorized fan 690 . The motorized fan 690 is powered by two “D-size” batteries 620 and/or via an external power source coupled to power the motorized fan 690 via the electric plug 324 . Two batteries 620 ′, 620 ″ operate in series to power the motorized fan 690 . More specifically, the anode of the first battery 620 ′ physically contacts a first metal spring 616 ′. The first metal spring 616 ′ is physically and electronically coupled to a first metal spring plate 614 ′. The spring plate 614 ′ is coupled via line 625 to a control unit 601 of the apparatus 100 . As shown in FIG. 6B the cathodes of the batteries 620 ′, 620 ″ have associated therewith respective battery access ports 122 . These have keys 623 on opposite sides of the ports 122 . The port 122 is positioned over the aperture 623 so that its keys 623 are inserted in respective notches 623 defined adjacent the aperture 625 in the top casing part 120 . By placing the keys 623 in the notches 625 and by rotating the ports 122 to a degree so that the keys 623 move past the notches, the keys 623 engage with the top casing part 110 and hold the ports 122 to the top casing part 120 . The ports 122 are each provided with a metal battery cover plate 622 . If the port 122 is secured to the top casing part 120 with the battery 620 ′ inside of the casing 110 , the cover plate 622 engages with the protruding cathode of the battery 620 ′ to make electrical contact therewith. The cover plate 622 further extends to and makes electrical contact with a second metal battery base plate 622 ′ when properly positioned. The second metal battery base plate 622 ′ is mounted to the top casing part 120 and is coupled via insulated conductive line 627 to the second spring plate 614 ″. The spring plate 614 ″ is coupled to the spring 616 ″ that makes physical and electrical contact with the anode of the battery 620 ″. A similar port 122 to that previously described is fitted to the top casing part 120 so that it is base plate 622 makes electrical contact with the base plate 622 ″. The base plate 622 ″ is mounted to the bottom casing part 280 and is electrically coupled to insulated conductive wire 629 . The wire 629 coupled the base plate 622 ″ to the control unit 601 . Thus, the control unit 601 receives electric power from batteries 620 ′, 620 ″.
The control unit 601 is coupled via conductive wires 631 , 633 to plug 324 . A three-volt AC-to-DC transformer or converter can be attached to a wall outlet and coupled to the plug 324 to provide electric power to the control unit 601 . The control unit 601 is also coupled to conductive wires 155 from the switch 150 . The control unit 601 can be in the form of a circuit board such as a model no. CBJFTO 1 commercially available from Products of Tomorrow, Inc. of New Jersey and Hong Kong. The control unit receives an input signal from the external switch 150 via the switch wires 155 upon activation of the switch. The control unit 601 activates the fan upon receipt of an input signal from the switch 150 . The control unit 601 can have a timer to deactivate the motorized fan 690 after a certain predetermined duration of time. Additionally, the control unit 601 can receive a signal indicating motion or heat from the switch 150 and activate the fan for a set period from which no significant motion or heat is detected. Control units 601 that are operable to control the function of a motorized fan 690 are well known in the art and can be purchased from numerous companies such as the afore-mentioned Products of Tomorrow, Inc. The control unit 601 can supply DC power to the motorized fan 690 via insulated conductive wires 635 , 637 . These wires 635 , 637 can be coupled to respective positive voltage and ground terminals 691 , 692 to supply power to the motorized fan 690 . More specifically, the motorized fan 690 comprises a fan 693 and a DC motor 695 . If the terminals 691 , 692 of the DC motor 695 receive electric power from the control unit 601 , the DC motor 695 generates magnetic fields based on the electric power to rotate its rotor 697 and thereby also the fan 693 attached to such rotor. Due to the configuration of its blades 699 , the fan 693 creates a pressure differential that draws malodorous air into the casing 110 via its inlet port 325 and through the casing 110 to the outlet port 413 where it is exhausted and dissipated.
Referring now to FIGS. 7A-7C in addition to FIGS. 6A and 6B , a filter unit 700 is physically installed in the filter chassis grove 610 defined in bottom casing part 280 . The filter unit 700 comprises a filter chassis 710 and a porous filter 715 , as shown in FIGS. 7A and 7B , respectively. The filter chassis 710 can be constructed of hard plastic and has a series of holes through which air can freely pass. A porous filter 715 is physically coupled to the filter chassis 710 , which can be accomplished by application of an adhesive, for example. The porous filter 715 is preferably a porous woven or compacted fiber fabric that can absorb liquid fragrances. The fibers composing the filter 715 can be wood pulp, cellulose, other plant, animal, and/or synthetic plastic fibers, for example. Liquid fragrances are well known in the art and can be commercially purchased at specialty shops or at large retailers such as the retailer operating under the trademark TARGET. As the air passes the porous filter 715 , the malodorous air becomes aromatized, and the refreshed air is delivered out of the export port 413 .
Referring to FIG. 8 , the control unit 601 comprises a timer 802 and a power switch 804 . The timer 802 is coupled to the activation switch 150 via wires 155 to receive an input signal generated upon activation of the switch 150 . The timer 802 is coupled to the power switch 804 , and activates such power switch in response to activation the signal from the switch 150 . Upon activation, the power switch 804 supplies DC power to the motorized fan unit 690 . The power switch 804 can be coupled to batteries 620 ′, 620 ″ or an external DC power source via the plug 324 , as previously described. Upon activation, the power switch 804 enters a conductive state and supplies DC power from the batteries 620 ′, 620 ″ or the external DC power source, or both. The power switch 804 supplies the DC power to the DC motor 695 that rotates the rotor 697 to turn the fan 693 . The fan 693 draws air into the inlet port 325 , through the fan and casing 110 to the outlet port 413 where it is expelled and dissipated.
The activation of the timer 802 by the switch 150 causes the timer to start measuring a predetermined amount of time starting from activation of the switch 150 . An event triggering the activation of the switch 150 can be either the first or last application of pressure, heat and/or motion, depending upon the nature of the switch 150 . Such time can be programmed or hardwired into the timer, and may be from one to thirty minutes, for example. The timer 802 maintains the activated state of the signal to the power switch 804 until the timer has counted out the predetermined time, at which time the timer 802 deactivates its signal to the power switch 804 . This causes the power switch 804 to enter a non-conductive state to cut off electric power to the motorized fan 690 , thereby stopping the fan 690 . Hence, power and wear on the apparatus 100 can be reduced by automatically turning off the apparatus when it is not needed.
FIG. 9A shows the apparatus 100 used with a waste disposal container 900 . The intake member 140 is attached inside container 900 with the attachment member 142 . The conduit 170 is coupled to the intake member 140 and extends to the casing 110 attached to the outside of the container 900 with the attachment members 282 and supported by stabilization feet 290 . The motorized fan 690 is coupled to receive electric power from batteries 620 ′, 620 ″ and/or via plug 342 coupled to external wall outlet 902 via a three-volt AC-to-DC converter 904 . The motorized fan 690 draws malodorous air from waste 908 via intake member 140 , conduit 170 , and inlet nozzle member 130 , and exhausts and dissipates such air via the casing's outlet port 413 . Alternatively, the intake member 140 , the conduit 170 , and the inlet nozzle member 130 can be removed, and inlet nozzle member 530 can be attached to the casing 110 , as shown in FIG. 9 B. In this case, if desired, the apparatus 100 can be attached to the inside surface of the container 900 using the attachment members 282 so that the inlet nozzle member 530 is arranged to draw malodorous air from waste 908 and to exhaust and dissipate this air, optionally after deodorization via filter 715 and volatile liquid fragrance applied thereto, from the casing's outlet port 413 .
In FIG. 10A the apparatus 100 is applied to use with a toilet stand 906 . The casing 110 of the apparatus 100 is attached to the toilet stand 906 via attachment members 282 and is stabilized by the feet 290 . As previously described, the motorized fan 690 can be powered by the batteries 620 ′, 620 ″ and/or the wall outlet 902 via the converter 904 . The casing's inlet 325 is coupled to conduit 170 , connector 160 , and intake member 140 . The intake member 140 is attached to the toilet stand 906 via the attachment member 142 that is mounted to the rotatable flap 245 that is rotated downwardly from the bottom surface of the intake member 140 . The rotatable flap 245 is thus seen to facilitate attachment of the intake member 140 to the toilet stand 906 in a location in which the casing 110 may not fit. The switch 150 is attached to the toilet stand 906 and is coupled to the internal ventilating elements 600 of the apparatus 100 . The switch 150 can be pressure-, motion- and/or heat-activated. Upon activation via the switch 150 , the apparatus 100 draws malodorous air via the intake member 140 , conduit 170 , and inlet nozzle member 130 using motorized fan 690 and dissipates same via outlet port 413 , optionally with application of deodorizing fragrance via volatile liquid applied to the filter 170 . FIG. 10B shows an alternative configuration of the apparatus 100 in which the inlet nozzle member 130 , the conduit 170 , and the intake member 140 are removed from the casing 110 of the apparatus 100 , and the inlet nozzle member 530 is attached to the casing 110 of the apparatus 100 . The apparatus 100 thus draws malodorous air via the inlet nozzle member 530 and dissipates it via the outlet port 413 , optionally with deodorization applied via volatile fragrance from the filter 715 within such apparatus.
FIG. 11A is a view of the apparatus 100 applied to use with a cat litter box 1100 . The apparatus 100 is attached to the exterior of the cat litter box 1100 with attachment members 282 and is stabilized by the feet 290 . The intake member 140 can be attached to the interior of the cat litter box with the attachment member 142 . The sensor 150 is attached to an interior surface of the cat litter box 1100 with attachment member 152 . The sensor 150 can be a motion or heat sensor, for example. In operation, if a cat enters the litter box 1100 , the motion or heat sensor 150 detects movement or heat of the cat and generates a signal that travels on conductive line 155 to the control unit 601 . In turn, the control unit 601 activates the motorized fan 690 . The motorized fan 690 creates a pressure differential that draws malodorous air through intake member 140 , conduit 170 , and inlet nozzle member 130 . The malodorous air passes through filter 715 . Optional liquid fragrance, if applied to the filter 715 , volatizes into the air passing through the filter to neutralize its scent. The air passes through the blades of the motorized fan and is expelled and dissipated via vent 413 . After a predetermined time and/or if motion or heat of the cat is no longer detected, the sensor 150 deactivates its signal to turn off the motorized fan 690 .
FIG. 11B shows an alternative configuration of the apparatus 100 in which the inlet nozzle member 130 , the conduit 170 , and the intake member 140 are removed from the casing 110 of the apparatus 100 , and the inlet nozzle member 530 is attached to the casing 110 of the apparatus 100 in replacement thereof. The apparatus 100 can be attached to the interior of the cat litter box 1100 with the attachment members 282 and is supported by the feet 290 . The sensor 150 is attached to an interior surface of the litter box 1100 with the attachment member 152 . Upon activation of the sensor 150 by movement or heat of a cat within the litter box 1100 , the motorized fan 690 is activated to draw air through inlet nozzle member 530 , optionally applies fragrance by drawing air through filter 715 treated with fragrant substance, and expels and dissipates such air through vent 413 . After cat movement or heat stops, indicating the cat has left the litter box, and/or after a predetermined time expires, the signal supplied from the sensor 150 deactivates and the motorized fan 690 stops to conserve power and reduce wear on the apparatus 100 . FIG. 12 shows an alternative configuration for the attachment member 282 . In this configuration, the attachment member 282 is a hook member that engages with the rim of a toilet bowl to hold the apparatus 100 in place against the toilet stand. The hook member extends from the inlet nozzle member 130 and is positioned so as to be under the lowered seat of the toilet stand. The apparatus 100 of FIG. 12 also comprises a brace 910 that extends from the casing 110 and contacts the side of the toilet bowl to support the apparatus 100 .
FIG. 13 shows an alternative configuration of the apparatus 100 that comprises an intake member 912 configured to draw air either partially or totally around the circumference of the toilet bowl. The intake member 912 is hollow or tube-like in configuration and defines holes at intervals along its length. The intake member 912 is coupled to communicate with the inlet nozzle member 130 of the apparatus 100 . Accordingly, if the motorized fan 690 of the apparatus 100 is activated, the partial vacuum generated by the motorized fan draws in air through the defined holes along the circumferential extent of the intake member 912 . As another alternative configuration, the intake member 912 can be horseshoe- or arc-shaped extending only partially around the circumference of the toilet bowl.
FIG. 14 shows a vent duct 920 which is an accessory for the apparatus 100 . The vent duct 920 can be coupled to any one of the configurations of the apparatus 100 disclosed herein. The vent duct 920 comprises a coupler 922 and a conduit 940 . The coupler 922 can be box-like in configuration, with a solid exterior defining an interior space and an opening 924 that communicates with the interior space. The coupler 922 has coupling members 926 fixed to the coupler 922 on opposite sides of the opening 924 . The coupling members 926 can be inserted into respective slots 928 defined in the casing 110 on opposite sides of the outlet port 413 . The coupling members 926 are resilient and have angled ends that force the coupling members 928 to move toward one another if inserted in the slots 928 . Once the angled portions of the coupling members 926 clear the surfaces of the casing 110 defining the slots 928 , they snap back to their unstressed position in which the angled portions of the coupling members 926 lock the coupler 920 to the casing 110 . At the end opposite the opening 924 , the coupler 920 has a tube extension 930 . The tube extension 930 can be inserted into conduit 940 . The conduit 940 can be composed of flexible material that stretches over and grips the tube extension 930 . Alternatively, or in addition, an adhesive can be applied to an outer surface of the tube extension 930 and/or an inner surface of the conduit's end so that the coupler 920 is fixed to the conduit 940 .
FIG. 15 is a view of the vent duct 920 applied to duct malodorous air from the outlet port 413 of the apparatus 100 through a wall plate 950 covering an opening in an interior wall of a house or building, for example. More specifically, if the apparatus 100 is activated, its motorized fan 690 draws in and drives the malodorous or treated air through the outlet port 413 into the vent duct 920 . The vent duct 920 passes through wall plate 950 and vents the malodorous or refreshed air into the wall space or entirely through the wall to be exhausted into outside air external to the house or building.
FIG. 16 is a view of the vent duct 920 applied to duct air drawn into the apparatus 100 by motorized fan 690 and driven from the outlet port 413 of the apparatus 100 through the plate 950 . In FIG. 16 , the plate 950 replaces a pane of a window 952 . The malodorous or refreshed air can thus be vented from the apparatus 100 to ambient air outside of a house or building.
FIG. 17 is a view of the vent duct 920 applied to duct malodorous or refreshed air from the outlet port 413 of the apparatus 100 through a wall plate 950 into and through a wall space to a vent duct 954 of a ceiling fan 956 . The malodorous or refreshed air can thus be drawn into the apparatus 100 and driven by the motorized fan of the apparatus to the ceiling fan 956 that expels such air from the house or building.
It should be understood that the foregoing relates only to the exemplary embodiments of the present invention, and that numerous changes may be made therein without departing from the spirit and scope of the invention as defined by the following claims. Accordingly, it is the claims set forth below, and not merely the foregoing illustration, which are intended to define the exclusive rights of the invention. | To accomplish the task of removing foul air, the malodor ventilation apparatus has attachment members such as suction cups or a hook for easy installation in different locations. The apparatus has an inlet port for the intake of objectionable air and an outlet port to expel scented refreshed air. Air is drawn into the inlet port by a motorized fan that creates a pressure differential. The objectionable air is drawn through a porous filter. The porous filter is scented by several drops of a liquid scent. This scent is volatized into the malodorous air, changing the air into a pleasing aroma. The scented air is expelled and dissipated through an outlet port of the apparatus. Alternately, the apparatus can comprise a vent duct coupled to exhaust air from the outlet port. | 4 |
[0001] The instant disclosure claims priority to Provisional Application No. 62/313,985, filed Mar. 28, 2016, the specification of which is incorporated herein in its entirety.
FIELD OF THE DISCLOSURE
[0002] The disclosure is directed generally to apparatus and methods for biological sample processing including obtaining selected materials from a biological sample. More specifically, the disclosure relates to an apparatus and methods for isolating and concentrating microorganisms of interest from a biological sample such as blood, sputum, or cerebrospinal fluid.
BACKGROUND
[0003] Rapid isolation and collection of microorganisms, such as pathogenic bacteria, from biological samples is an important aspect to clinical evaluation and testing. Accurate diagnosis and pathogen monitoring may involve obtaining a sample from a subject, for example, in the form of sputum, blood, tissue, urine, cerebrospinal fluid or other biological specimen. Extraction techniques may then be used to isolate and concentrate pathogens from the specimen. In some instances, intact pathogens may be desirably collected for culture or analysis while other approaches may enrich for nucleic acids, proteins or other biological indicators used to detect or identify the presence of a pathogen or infectious agent within the sample.
[0004] Conventional methods for collecting microorganisms from a biological sample are typically slow and lack the ability to readily isolate and separate small quantities of pathogens from larger sample volumes in which they are contained. Blood-based processing techniques may require centrifugation and withdrawal of sub-fractions from the sample to obtain crude pathogen isolates. In some conventional processing workflows, technicians must work with open sample containers and perform transfer operations manually creating potential biological and exposure hazards.
[0005] A particular problem exists when attempting to extract and analyze pathogens from biological samples where the overall amount of the sample is large or where the number of pathogens present is very small. In such circumstances, conventional processing techniques may not be able to efficiently concentrate and retain the microorganisms in a manner suitable for rapid identification. In these and other regards, the present disclosure provides significant advances in sample processing and analysis techniques that facilitate and improve microorganism isolation and identification.
SUMMARY OF THE DISCLOSURE
[0006] According to various embodiments, an apparatus and methods for rapid isolation, concentration, and purification of microbes/pathogens of interest from a raw biological sample such as blood is described. Samples may be processed directly from biological or clinical sample collection vessels, such as vacutainers, by coupling with the sample processing apparatus in such a manner that minimizes or eliminates user exposure and potential contamination issues. In various embodiments, the apparatus comprises a staged syringe or piston arrangement configured to withdraw a desired quantity of biological sample from a sample collection vessel. The sample is then mixed with selected processing reagents preparing the sample for isolation of microbes or pathogens contained therein. Sample processing may include liquefying or homogenizing non-pathogenic components of the biological specimen and performing various fluidic transfer operations induced by operation of the syringe or piston. The resulting sample constituents may be redirected to flow across a capture filter or membrane of appropriate size or composition to capture specific microbes/pathogens or other biological sample constituents. Additional operations may be performed including washing and drying of the filter or membrane by action of the syringe or piston. In various embodiments, sample backflow and cross-contamination within the device is avoided using one-way valves that direct sample fluids along desired paths while preventing leakage, backflow, and/or undesired sample movement.
[0007] The device may include a capture filter for retaining microbes/pathogens of interest allowing them to be readily separated from sample eluent or remaining fraction of the processed sample/waste. The capture filter may be housed in a sealable container and can further be configured to be received directly by other sample processing/analytical instruments for performing downstream operations such as lysis, elution, detection and identification of the captured microbes/pathogens retained on the filter/membrane.
[0008] The collector may comprise various features to facilitate automated or semi-automated sample processing and include additional reagents contained in at least one reservoir integrated into the collector to preserve or further process the isolated microbes/pathogens captured or contained by the filter/membrane. In various embodiments, the collector may contain constituents capable of chemically disinfecting the isolated microbes/pathogens or render the sample non-infectious while preserving the integrity of biological constituents associated with the microbe/pathogen such as nucleic acids and/or proteins that may be desirably isolated for subsequent downstream processing and analysis. The collector and associated instrument components may desirably maintain the sample in an isolated environment avoiding sample contamination and/or user exposure to the sample contents.
[0009] In various embodiments, this present disclosure describes an apparatus that permits rapid and semi-automated isolation and extraction of microorganisms such as bacteria, virus, spores, and fungi or constituent biomolecules associated with the microorganisms, such as nucleic acids and/or proteins from a biological sample without extensive hands-on processing or lab equipment. The apparatus has the further benefit of concentrating the microbes, pathogens, or associated biomolecules/biomaterial of interest. For example, bacteria, virus, spores, or fungi present in the sample (or nucleic acids and/or proteins associated therewith) may be conveniently isolated from the original sample material and concentrated on the filter or membrane. Concentration in this manner increases the efficiency of the downstream assays and analysis improving detection sensitivity by providing lower limits of detection relative to the input sample.
[0010] The sample preparation apparatus of the present disclosure may further be adapted for use with analytical devices and instruments capable of processing and identifying the microorganisms and/or associated biomolecules present within the biological sample. In various embodiments, the sample collector and various other components of the system can be fabricated from inexpensive and disposable materials such as molded plastic that are compatible with downstream sample processing methods and economical to produce. Such components may be desirably sealed and delivered in a sterile package for single use thereby avoiding potential contamination of the sample contents or exposure of the user while handling. In various embodiments, the reagents of the sample collector provide for disinfection of the sample constituents such that may be disposed of without risk or remaining infectious or hazardous. The sample collector provides simplified workflows and does not require specialized training or procedures for handling and disposal.
[0011] In various embodiments, the automated and semi-automated processing capabilities of the system simplify sample preparation and processing protocols. A practical benefit may be realized in an overall reduction in the number of required user operations, interactions, or potential sample exposures as compared to conventional sample processing systems. This results in lower user training requirements and fewer user-induced failure points. In still other embodiments, the system advantageously provides effective isolation and/or decontamination of a sample improving overall user safety while at the same time preserving sample integrity, for example by reducing undesirable sample degradation.
[0012] Additional objects and advantages of the disclosed embodiments will be set forth in part in the description that follows, and in part will be apparent from the description, or may be learned by practice of the disclosed embodiments. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the scope of disclosed embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] These and other embodiments of the disclosure will be discussed with reference to the following exemplary and non-limiting illustrations, in which like elements are numbered similarly, and where:
[0014] FIG. 1 illustrates an exemplary embodiment of the sample processing apparatus of the disclosure.
[0015] FIG. 2 illustrates an expanded cross-sectional view of the valve body for an exemplary sample processing apparatus of the disclosure.
[0016] FIG. 3A illustrates detail view for a piercing member and an exemplary first position to provide an automatic or predetermined multi-stage fluidic release capability according to one embodiments of the disclosure.
[0017] FIG. 3B illustrates detail view for a piercing member and an exemplary second position to provide an automatic or predetermined multi-stage fluidic release capability according to one embodiments of the disclosure.
[0018] FIGS. 4 illustrates a first step in an exemplary process where the plunger is withdrawn to introduce relative negative pressure in the sample tube.
[0019] FIG. 4B illustrates a second step in an exemplary process where the plunger is compressed to introduce relative positive pressure in the reservoirs.
[0020] FIG. 4C illustrates a third step in an exemplary process where the syringe is compressed into a final position.
[0021] FIG. 4D illustrates certain components of an exemplary embodiment of the disclosure.
DETAILED DESCRIPTION
[0022] An illustration of one embodiment of the sample processing apparatus 100 of the present disclosure is depicted in FIG. 1 . The apparatus 100 may be configured with a multi-stage syringe 110 FIG. 4A ) having an outlet that mates or joins with a syringe coupler 115 provided on a valve body 120 . The valve body 120 is further configured to mate or join with a capture tube or reservoir 125 and a sample tube or reservoir 130 via capture tube coupler 135 and sample tube coupler 140 respectively. As will be described in greater detail hereinbelow the valve body 120 comprises a sample delivery assembly having one or more valves and sample flow paths that allow sample 142 contained in a sample collection tube 130 to be withdrawn and distributed by operation of the syringe 110 .
[0023] In various embodiments, the syringe 110 may comprise a two-stage assembly having an inner plunger/piston 155 and inner barrel 160 . The inner barrel 160 may also serve as or be associated with an outer plunger/piston 165 that operates in connection with an outer barrel 170 . The outer barrel 170 mates with the valve body 120 by the syringe coupler 115 such that sample 142 may be drawn into the barrel 170 . A first plunger tip or gasket 175 separates an outer barrel reservoir 180 from and inner barrel reservoir 185 ( FIG. 2 ). Each reservoir 180 , 185 may contain various reagents and components used in sample processing.
[0024] The outer barrel reservoir 180 may contain a first processing fluid such as a liquefaction reagent 187 selected based on the sample type and when mixed with the sample 142 may result, for example, in breaking down selected constituents of the sample 142 . The constituents may include blood cells, sputum, or other components that are to be made to desirably pass through the capture tube 125 without being retained such that they may be separated from microbes/pathogens which will be retained by the sample tube 125 . The liquefaction fluid 187 may be preloaded in the reservoir 180 in a predetermined quantity such that the apparatus 100 is made ready-to-use requiring little or no significant preparation before introduction of the sample 142 . The reservoir 180 may further be sized to accommodate a selected volume of liquefaction fluid 187 and additionally provide an air volume 189 . As will be described in greater detail, providing a selected volume of air 189 facilitates sample processing such as mixing and sample distribution to other components within the apparatus 100 .
[0025] The inner barrel reservoir 185 may contain a second processing fluid such as a wash reagent 192 used to further process the sample 142 . Similar to the first processing fluid 187 , the second processing fluid 192 may be preloaded in the reservoir 185 in a predetermined quantity. The reservoir 185 may also be sized to accommodate a selected volume of air 194 facilitating sample processing and distribution.
[0026] By operation of the plunger 165 , sample 142 may be drawn from the sample tube 130 through the valve body 120 and introduced into the outer reservoir 180 where it is mixed with the first processing fluid 187 . The resulting mixture may then be expelled through the capture tube 125 into the waste receptacle 145 . As part of this operation, microbes/pathogens released or present in the sample 142 may be captured and retained on a filter/membrane (not shown in FIG. 1 ) associated with the capture tube 125 thereby separating them from the rest of the processed sample. A desirable aspect of this approach, is that significant volumes of sample can be passed through the capture tube 125 retaining microbes/pathogens contained therein and effectively concentrating or localizing them on the filter/membrane.
[0027] The volume of air 189 contained in the reservoir 170 can then be made to pass over the filter and retained microbes/pathogens to aid in removing residual first processing fluid 187 and efficiently expelling into the waste reservoir 145 . As will be described in greater detail, the air volume 189 may also provide separation between additional processing steps where the second processing fluid 192 is exposed to the sample constituents including the microbes/pathogens retained on the filter/membrane.
[0028] FIG. 2 illustrates an expanded cross-sectional view of the valve body 120 for the sample processing apparatus 100 . Channels 205 fluidically connect the sample tube 130 with the syringe 110 and the capture tube 125 . According to various embodiments, fluidic restrictors or one way valves 210 , 215 may be provided that moderate and direct the flow of sample and fluid within the channels 205 . These valves 210 , 215 may comprise a diaphragm or other device that prevents backflow into a particular component of the assembly 100 . For example, the sample tube valve 210 may permit sample (e.g. blood) to be drawn from the sample tube 130 into selected channels 205 when the plunger 155 is actuated in a first direction (e.g. fluid draw). Sample passes through the channels 205 and into the syringe reservoir 180 where it may mix with the first processing reagent 187 . The one-way capture tube valve 215 may prevent or restrict entry of fluid into the capture tube 125 during the sample fluid draw stage from the sample tube 130 .
[0029] Subsequent actuation of the inner barrel/outer plunger 160 , 165 in a second direction (e.g. fluid push) may result in the one-way valve 210 associated with the sample tube 130 remaining closed thereby preventing fluid flow into the sample tube 130 . Substantially simultaneously, the one-way valve 215 associated with the capture tube 125 may permit fluid flow into the capture tube 125 allowing processed sample (e.g. sample mixed with processing fluid) to pass through a filter/membrane 220 used to separate microbes/pathogens from the remainder of the sample eluent.
[0030] According to various embodiments, a needle or piercing member 225 may be positioned in a manner to allow penetration of the gasket 175 creating a fluidic interconnection between the first and second reservoirs 180 , 185 . Operation of the outer plunger 165 may thus first draw sample 142 from the sample tube 130 into the first reservoir 180 and upon expulsion of the sample/first processing fluid mixture through the capture tube 125 position the gasket 175 such that it engages with the piercing member 225 creating a hole or channel in the gasket 175 . Second processing fluid 192 may then be introduced into the channels 205 by operation of the inner plunger 155 which expels the second processing fluid 192 from the second reservoir 185 either into the first reservoir 180 or directly into the channels 205 .
[0031] As previously noted, the air volume 189 present in the first reservoir creates a gap that permits the first processing fluid 187 to be substantially or completely expelled from the first reservoir 180 prior to piercing of the gasket 175 and entry of the second processing fluid 192 into the first reservoir 180 and/or channels 205 . Such a configuration may be desirable to maintain separation between the two processing fluids 187 , 192 and provides a means by which to conduct substantially different steps or treatments on the sample and/or retained microbes. For example, the first processing fluid 187 may be used to liquefy the sample breaking it down into a form that allows passage through the filter 220 while the second processing fluid 192 may be subsequently introduced as a wash, preservative, or lysis agent for the microbes/pathogens retained on the filter 220 .
[0032] It will be appreciated that the configuration of the apparatus 100 desirably provides a closed or sealed environment for sample processing. Sample can be conveniently withdrawn from the sample tube 130 and a series of one or more processing steps conducted using the sample 142 with various processing fluids 187 , 192 without having to individually handle or measure the fluidic components. Operation of the assembly 100 may further be conducted manually or using an instrument or apparatus configured to impart desired mechanical drawing and pushing forces on the plunger(s) 155 , 165 . The resulting filter 220 containing isolated microbes as well as the capture sample eluent retained in the reservoir 145 may be used in further operations, processing steps, and analysis.
[0033] FIGS. 3AB illustrate further detail views for the needle or piercing member 225 and exemplary positioning and penetration of the gasket 175 to provide an automatic or predetermined multi-stage fluidic release capability for the syringe 110 . FIG. 3A illustrates exemplary positioning of the needle 225 prior to piercing the seal/gasket 175 . As indicated, the reservoirs 180 , 185 and processing reagents 187 , 192 are maintained separately before penetration of the gasket 175 . The first processing reagent 187 may further interact with the sample 142 and be expelled from the syringe 110 .
[0034] As shown in FIG. 3B , actuation or displacement of the plunger 165 is then conducted sufficient to engage the needle 225 with the gasket 175 resulting in piercing of the seal 175 and permitting the second processing fluid 192 to enter through the newly created channel. In various embodiments, the needle 225 includes a channel extending through its length for fluid passage, however, the fluid may also be allowed to escape or pass around the piercing member 225 into the first reservoir 180 directly. Further actuation or displacement of the inner plunger 155 (not shown in FIG. 3 ) permits the second processing fluid 192 to be expelled from the inner reservoir 185 .
[0035] FIGS. 4A-D illustrate operation of the sample processing apparatus 100 . As indicated by the arrows depicting fluidic movement in the valve body of FIG. 4A , sample may be withdrawn from the sample tube, pass through the one or more channels and mix with the first processing reagent in the syringe reservoir. The first processing reagent may react or interact with the sample to achieve a desired state or composition. For example, as shown in the figure, mixing of sample with the first processing reagent results in the formation of a liquefied sample suitable for passage through the sample collector. Exemplary operation of the plunger in a draw direction as indicated by the arrow in FIG. 4A introduces the sample to liquefaction fluid.
[0036] As shown in FIG. 4B , upon suitable mixing of sample and first processing fluid, the mixture may be expelled or passed through the capture tube by compression or actuation of the outer plunger. The capture filter provides a desired surface or medium by which to retain and concentrate selected components of the processed sample. For example, microbes/pathogens may be retained on a filter or membrane having suitable porosity or molecular composition to permit passage of the processed liquid sample while selectively capturing microorganisms or other desired sample constituents.
[0037] As shown in FIG. 4C , further compression or actuation of the inner plunger engages the needle with the gasket and releases the second processing fluid into the channels of the valve body. The second processing fluid release may be preceded by a flow of air through the channels resultant from the air volume contained in the first reservoir aiding in purging the first fluidic mixture from the assembly and further improving the capture or retention of desired sample constituents on the filter or membrane. Fully compressing the inner plunger purges the second processing fluid from the inner reservoir and permits its interaction with the retained sample constituents. This multi-step process allows for sequential operations to be performed on the sample, for example to capture microbes on the filter and subsequently wash or elute desired constituents from the filter.
[0038] As shown in FIG. 4D , the sample processing assembly may be configured as separable subassemblies such that the sample tube retaining desired microbes or other constituents resultant from sample processing may be conveniently and quickly removed for further processing and/or analysis. In various embodiments, the components of the apparatus are fabricated from inexpensive materials and may be configured for single use or disposable. Additionally, the separable aspects of the apparatus aid in maintaining sterility and/or preventing contamination of the collected/retained material while reducing risk of exposure to the user.
[0039] The item 127 is an optional cap for the Sample Tube. The optional cap may contain the amplification reagent (under a foil seal that is punctured upon assembly), which may attached after the capture and wash process is completed and before the Sample Tube is transferred to the instrument.
[0040] An exemplary sample processing system that may be adapted for use with the apparatus and sample capture tube of the present disclosure for automated or semi-automated sample processing is described in commonly assigned PCT Application Serial PCT/US2013/075430 (Publication #WO2014093973) entitled “METHOD FOR CENTRIFUGE MOUNTABLE MANIFOLD FOR PROCESSING FLUIDIC ASSAYS” to John Nobile, the contents of which are hereby incorporated by reference in its entirety. It will be appreciated by those of skill in the art that the methods and apparatus of the present disclosure may be adapted to other platforms and configurations for sample processing and as such other embodiments and adaptations are considered within the scope of the present teachings.
[0041] The following examples are provided to further illustrate different embodiments of the disclosure. The examples are demonstrative and non-limiting in nature.
[0042] Example 1 is directed to an apparatus to capture pathogens from a biological sample, the apparatus comprising: a valve body to fluidically couple a sample tube to each of a syringe body and a capture tube, the valve body having a sample inlet, a first outlet, a second outlet, a channel to connect the sample inlet with each of the first and the second outlets, a first one-way valve to connect the sample inlet with the channel, a second one-way valve to connect the channel to the second outlet; a syringe body having an outer barrel and an inner barrel, the outer barrel further comprising a first reservoir containing a first reagent; and a plunger piston configured to moveably couple to the outer syringe barrel, the plunger piston comprising an inner syringe barrel, and outer syringe barrel and a puncture-able separator positioned between the first and second reservoirs, the inner syringe barrel defining a second reservoir to receive a second reagent; wherein the puncture-able separator is configured to provide automatic sequential delivery of the first and second reagents.
[0043] Example 2 is directed to the apparatus of example 1, wherein the valve body is configured to receive a sample tube and fluidically connect the sample to the inlet channel.
[0044] Example 3 is directed to the apparatus of example 2, wherein the valve body further comprises a piercing member configured to pierce the puncture-able separator to thereby access the second reagent.
[0045] Example 4 is directed to the apparatus of example 3, wherein the piercing member is configured to enter the second reservoir when the outer syringe, containing the first reagent, is nearly fully displaced, and the first reservoir is substantially empty.
[0046] Example 5 is directed to the apparatus of example 4, wherein the first and second reservoirs are separated by an elastomer diaphragm.
[0047] Example 6 is directed to the apparatus of example 2, wherein the valve body further comprises at least one inlet piercing member, the inlet piercing member configured to couple through the one-way valve to the sample tube.
[0048] Example 7 is directed to the apparatus of example 2, wherein the valve body further comprises a first and a second piercing members configured to enter the sample tube, the first piercing member to fluidically couple to the channel, the second piercing member to fluidically communicate with the ambient.
[0049] Example 8 is directed to the apparatus of example 7, wherein the second piercing member further comprises a one-way valve to allow ingress of ambient air into the sample tube.
[0050] Example 9 is directed to the apparatus of example 1, further comprising a capture tube to removably connect to the valve body, the capture tube having at least one filter membrane configured such that all fluids exiting the valve body pass through the at least one membrane.
[0051] Example 10 is directed to the apparatus of example 1, wherein the first one-way valve opens under a relative negative pressure on the syringe side of the valve and closes under a relative positive pressure on the syringe side of the valve.
[0052] Example 11 is directed to the apparatus of example 1, wherein the second one-way valve opens under a relative positive pressure on the syringe side of the valve, and closes under a relative negative pressure on the syringe side of the valve.
[0053] Example 12 is directed to a method to hermetically and sequentially mix a sample with a first processing fluid to form a first mixture and wash material captured from the first mixture with a second processing fluid, the method comprising: receiving a sample vessel containing a biological sample; applying a relative negative pressure to the sample vessel to transfer at least a portion of the sample from the sample vessel to the first reservoir, allowing a portion of the sample to admix with the first processing fluid to form the first mixture; applying an external relative positive pressure to the first reservoir by applying a pressure to the second processing fluid reservoir in physical communication with the first reservoir to expel a quantity of the first mixture from the first reservoir; and continuing to apply the external pressure, causing the second processing fluid to be released from the second reservoir.
[0054] Example 13 is directed to the method of example 12, wherein the step of applying an external positive pressure to the first reservoir further exerts the external positive pressure to the first admixture.
[0055] Example 14 is directed to the method of example 12, wherein continual application of external pressure delivers the second fluid by creating an opening in a barrier between the first and second reservoirs.
[0056] Example 15 is directed to the method of example 14, wherein the opening in the barrier places the second reservoir in fluidic communication only with a fluid exit channel which leads to a capture area.
[0057] Example 16 is directed to the method of example 12, further comprising filtering the first admixture through a membrane.
[0058] Example 17 is directed to the method of example 16, wherein the step of applying a relative negative pressure further comprises purging air from the first reservoir to substantially dry the membrane after the first admixture has passed through the membrane.
[0059] Example 18 is directed to method of example 12, wherein the sample defines biological fluid that may contain pathogens therein.
[0060] Example 19 relates to an apparatus to mix a sample with a pre-defined reagent, the apparatus comprising: a syringe body having an outer barrel and an inner barrel; a plunger piston configured to moveably couple to the syringe body, the plunger piston having a reservoir and a plunger gasket, the plunger gasket to sealingly couple the plunger piston with the inner barrel of the syringe, the plunger piston further having a reservoir to receive a second reagent; and a valve body to fluidically couple to the syringe body, the valve body having an inlet, a first outlet, a second outlet, a channel connecting the inlet with the first and the second outlets, a first one-way valve connecting the inlet with the channel and a second one-way valve connecting the channel to the second outlet.
[0061] Example 20 is directed to apparatus of example 19, wherein the outer barrel mates with the valve body through syringe coupler 115 .
[0062] Example 21 is directed to the apparatus of example 19, wherein the valve body is configured to receive a sample tube and connect the sample tube to the inlet.
[0063] Example 22 is directed to the apparatus of example 19, wherein the plunger further comprises an auxiliary reservoir to receive a second processing fluid.
[0064] Example 23 is directed to the apparatus of example 22, wherein the valve body further comprises a piercing member to pierce the plunger gasket to thereby access the second reagent.
[0065] Example 24 is directed to the apparatus of example 22, wherein the piercing member is configured to extends to the auxiliary reservoir.
[0066] Example 25 is directed to the apparatus of example 22, wherein the plunger reservoir and the plunger auxiliary reservoir are separated by a diaphragm.
[0067] Example 26 is directed to the apparatus of example 21, wherein the valve body further comprises at least one inlet piercing member, the at least one inlet piercing member configured to couple the valve channel with the sample tube.
[0068] Example 27 is directed to the apparatus of example 19, further comprising a capture tube to connect the valve body to couple to the valve body, the capture tube having a filter membrane to capture at least one effluent from the second outlet of the valve body.
[0069] Example 28 is directed to the apparatus of example 19, wherein the first one-way valve opens under a relative negative pressure and closes under a relative positive pressure.
[0070] Example 29 is directed to the apparatus of example 19, wherein the second one-way valve closes under a relative negative pressure and closes under a relative positive pressure.
[0071] Example 30 is directed to a method to hermetically and sequentially mix a sample with a first processing fluid and a second processing fluid, the method comprising: receiving a sample quantity at a sample reservoir; receiving a quantity of the first processing fluid at a first reservoir and a quantity of the second processing fluid at a second reservoir, the first reservoir and the second reservoir fluidically separated by a gasket; pressurizing the sample reservoir to transfer at least a sample portion from the sample reservoir to the first reservoir and allowing the portion of the sample portion to admix with the first processing fluid to form a first mixture; exerting a first pressure on the first reservoir to expel a quantity of the first mixture from the first reservoir; exerting a second pressure on the first reservoir to introduce the second processing fluid to a portion of the first admixture to thereby form a second admixture; and exerting a third pressure on the first reservoir to expel a quantity of the second admixture.
[0072] Example 31 is directed to the method of example 30, wherein the first pressure is a relative negative pressure and the second pressure is a substantially positive pressure.
[0073] Example 32 is directed to the method of example 30, wherein the step of exerting a second pressure on the first reservoir to introduce the second processing fluid to a portion of the first admixture to thereby form a second admixture further comprises creating an opening in the gasket.
[0074] Example 33 is directed to the method of example 30, further comprising filtering the first admixture through a membrane.
[0075] Example 34 is directed to the method of example 33, wherein the step of exerting a first pressure on the first reservoir to expel a quantity of the first mixture from the first reservoir further comprises purging air from the first reservoir so as to substantially dry the membrane after the first admixture has passed through the membrane.
[0076] Example 35 is directed to the method of example 30, wherein the sample defines biological fluid having pathogens therein.
[0077] Example 36 is directed to the method of example 30, further comprising sealing the sample reservoir after the first pressure is ceased such that substantially no further sample is expelled from the first reservoir.
[0078] Example 37 is directed to the method of example 30, wherein the step of exerting a second pressure on the first reservoir to introduce the second processing fluid to a portion of the first admixture to thereby form a second admixture further comprises continuing exerting the second pressure to expel the first admixture from the second reservoir.
[0079] While the principles of the disclosure have been illustrated in relation to the exemplary embodiments shown herein, the principles of the disclosure are not limited thereto and include any modification, variation or permutation thereof. | The disclosed embodiments related to an apparatus and methods for biological sample processing enabling isolation and concentration of microbial or pathogenic constituents from the sample. Sample may be obtained directly from a specimen container, such as a vacutainer, and processed directly without risk of user exposure. The disclosed methods and apparatus provide a convenient and inexpensive solution for rapid sample preparation compatible with downstream analysis techniques. | 1 |
BACKGROUND OF THE INVENTION
The invention relates to a device for obtaining signals to be applied to the control unit of an electronic fuel injection system of an internal combustion engine from a tachometer for measuring the engine speed and a gauge for measuring the air flow supply to the engine or the intake air pressure.
Electronic fuel injection system for internal combustion engines, in various embodiments and operating on various principles, are well known. For example, articles in the Motortechnische Zeitschrift 34 (1973) 1, page 7, and 4, page 99, describe electronic gasoline injection systems operating with an airflow gauge, where the control unit is supplied with rotational speed signals obtained from ignition impulses of the engine. Articles in the Automobilitechnische Zeitschrift 72 (1971) 4, page 125; Bosch Technische Berichte 2, No. 3, November 1967, page 107; and Bosch Technische Zeitschrift 3, No. 1, November 1969, page 3, describe fuel injection systems in which the rotational speed signals are obtained by means of additional contacts on the ignition distributor. In the fuel injection systems according to the references first mentioned, the control unit forms the quotient of the airflow measurement and the speed signal to obtain a signal proportional to the injection time. However, in the systems described in the articles last mentioned, the speed is only a correction factor.
Certain vehicles equipped with fuel injection have unexplained lengthwise vehicle vibrations that appear under some operating conditions, for example in the engine brake mode or under partial load. Even more mysteriously, this vibration tendency does not occur in all vehicles of the same type and occurs in different degrees among vehicles of the same type.
As has been learned, short-term variations in the speed of the engine, such as positive or negative speed variations or irregularities, due to various causes, as for example unevennesses in the roadway or even electrical interference in the ignition from the outside, may cause changes in the injection time by way of the speed feedback in the fuel injection control unit. This leads in turn to fluctuations in the torque delivered by the engine, because of changes in the proportion of air. The extent to which such fluctuations in delivered torque manifest themselves by longitudinal vibration of the vehicle depends among other things on the elasticity in the drive train of the vehicle and, hence, on its natural frequency.
SUMMARY OF THE INVENTION
The object of the invention is to provide a device for obtaining signals for the control unit of an electronic fuel injection system, which device is free from the unwanted tendency toward torque fluctuation. The accomplishment of this object according to the invention is characterized in that at least one of the measuring means generating an analog control voltage signal is followed by a stabilizer of low-pass character for the voltage signal generated by it. The stabilizer is designed to dampen any a.c. voltage components that occur in the analog voltage signals because of non-operational influences.
It is especially desirable to have such a stabilizing means in the path of the signals both from the tachometer means and from the air measuring means. Thus, the invention in its most general form provides that those a.c. voltage components in the analog voltage signal that are generated by the measuring means in question and which are not attributable to operational influences, shall be at least damped. The stabilizing means must be designed to dampen frequencies from about 2 to 8 Hz, for such is the order of magnitude of the a.c. voltage components leading to the undesirable lengthwise vehicle vibrations. Due to the required low-pass character of the stabilizing means, however, changes in the instantaneous voltage signal due to operating maneuvers, for example changes in throttle setting, are practically undamped, apart from some distortion of the shape of the voltage rise and fall. As a result the damping provided according to the invention will not lead to any troublesome prolongation of the fuel injection system reaction time in response to control maneuvers.
The stabilizing means may be designed so that it achieves a symmetrical damping, thereby equally damping both half-waves of the a.c. voltage components to be damped. An especially desirable version of the invention, however, is characterized in that the stabilizing means is designed to dampen the a.c. voltage components asymmetrically. The asymmetry is chosen so that the resulting change in the mean analog voltage signal reaches the control unit as a signal increasing the fuel feed (fattening signal). The advantage of this arrangement lies in the fact that there is not only a damping of the opposed half-wave of the a.c. voltage component in unlike degree, but there is at the same time a shift in the mean of the a.c. voltage component due to the asymmetrical damping. This shift is utilized to obtain a signal increasing the fuel feed. Such a fattening of the mixture has the effect of eliminating the torque variations that occasion the undesirable longitudinal vehicle vibrations. In this embodiment of the invention when the a.c. voltage components first appear in the analog voltage signals emitted by either of the measuring means, signals are put into the control unit that immediately cause a fattening of the mixture which in turn counteracts the unwanted vibrations.
While this device employs a passive stabilizing means, another embodiment of the device is characterized in that there are a plurality of diodes in series, and an a.c. voltage amplifier for the a.c. voltage components is connected across at least one of them. This version thus provides an active stabilizing means. With suitable gain adjustment, it is possible to have a d.c. stabilized output voltage at the output of the stabilizing means that lies above the highest peaks of the input a.c. voltage component. In a passive stabilizing means, on the other hand, the stabilized output voltage is always lower than the highest peaks.
An especially economical embodiment with respect to the cost of parts, space and energy is distinguished in that the stabilizing means contains an RC combination as well as at least one diode in parallel with a resistance in the lengthwise branch of the RC combination. In the case of symmetrical damping of both half-waves of the a.c. voltage components, two diodes will be used with opposite polarity. With asymmetrical damping one diode is sufficient; but, it is also possible to employ two oppositely poled diodes with different value bias resistances. One of the bias resistances may have a value of zero. Independent of whether the stabilizing means is designed for symmetrical or asymmetrical damping, all a.c. voltage components with an amplitude smaller than the threshold voltage of the diode can reach the control unit only by way of the RC combination and only to an extent depending on the merit of the low pass filter. However, all voltage signals, as well as their a.c. components, whose amplitude of variation is greater than the theshold voltage of the diode in question will put the diode into the conductive state. This will produce a damping effect due to the voltage drop across the diode. In addition, if a stabilizing means with asymmetrical damping is present, e.g., where only one diode or two oppositely poled diodes with unlike bias resistances are used, there will be a displacement of the average of the a.c. voltage components, which in turn leads to a signal causing the fattening of the mixture.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other features of the present invention will be more readily apparent from the following detailed description and drawings in which:
FIG. 1 is a block diagram of the device according to the invention with circuitry for a symmetrical damping stabilizing means;
FIG. 2 represents a possible embodiment for an asymmetrical damping stabilizing means; p FIG. 3 shows a possible connection of a stabilizing means with other components of the device; and
FIG. 4 is a possible embodiment for an active stabilizing means.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
In FIG. 1 an air flow gauge 1 and a tachometer gauge 2 are shown. The tachometer receives ignition impulses, for example, by way of a contact in the distributor 3. The air flow gauge 1 in this embodiment of the invention, by way of example, contains a flap 5 that is actuated by the flow of air in the intake 4 in a known manner. The flap sets the potentiometer 6 according to the air through-put at the time. At circuit points 7 and 8 there are analog voltage signals corresponding in amplitude to the air flow and the rotational speed of the engine, respectively.
In this exemplary embodiment of the invention, stabilizing means 10 and 11 are connected between a control unit 9 and airflow gauge 1 and speed gauge 2, respectively. In principle, it is possible alternatively to provide only one of these stabilizing means. In the embodiment represented in FIG. 1 by way of example, the stabilizing means 10 is comprised of the RC element, longitudinal resistance 12 and transverse condenser 13, and two oppositely poled diodes 14 and 15 arranged in parallel with the resistance 12. Correspondingly, the other stabilizing means 11 contains a longitudinal resistance 16 and a transverse condenser 17, which together form the RC element of the low-pass filter. The two oppositely poled diodes 18 and 19 are in parallel with the longitudinal resistance 16. Thus, for both gauges there are damping means which symmetrically dampen both half-waves of the a.c. voltage components in the analog voltage signals.
Since the invention employs analog voltage signals, while at least the signals corresponding to the engine speed in question must reach the control unit 9 in the form of pulse signals, the stabilizing means 11 is followed by a means 20 that transforms the analog voltage signal available at its input into simulated ignition pulses. A schematic of such a circuit is shown as 20 in FIG. 3.
The example of FIG. 2 serves to illustrate several possibilities for the structure of the stabilizing means designated by 10 and 11 in FIG. 1. As in FIG. 1, there is an RC element, containing the resistance 21 and transverse condenser 22, connected between one of the measuring means (left-hand terminal in FIG. 2) and the control unit (righ-hand terminal). In parallel with the lengthwise resistance 21 there are first and second series circuits with diodes 23 and 24, respectively, and bias resistances 25 and 26, respectively. The two diodes 23 and 24 are oppositely directed. All of the embodiments described with respect to FIG. 2 are similar in that the resistance 21 is very great compared to the resistances 25 and 26. If resistances 25 and 26 are equal and diodes 23 and 24 are of like type, the stabilizing means will have a symmetrical damping effect. However, if resistances 25 and 26 are different, there will be different dampings of the opposed half-waves of the unwanted a.c. voltage components of the analog voltage signals that are applied to the circuit. This inequality of the resistances may be carried to the extreme of omitting one of the two resistances. It is likewise possible to dispense with one of the two diodes 23 and 24, thereby achieving the maximum asymmetry of damping.
FIG. 3 shows a block diagram of the manner in which the stabilizing means 11 in FIG. 1 or alternatively any of the forms of the stabilizing means illustrated with reference to FIG. 2, is worked into the system as a whole. The dotted line boxes in FIG. 3 indicate the rotational speed measuring means 2 and the transducer 20 of FIG. 1.
The ignition impulses at terminal a or pulses corresponding to them pass by way of the threshold circuit 30, which suppresses interference impulses, to the input of a first monostable flip-flop 31. Consequently, at the output b of the monostable flip-flop 31 there results a series of rectangular pulses with a duration t, determined by the time constant of flip-flop 31. The time interval between the pulses corresponds to the interval between individual ignition impulses.
The output pulses of the first monostable flip-flop 31 are led to OR-gate 32 and are inverted and used to actuate a first integrator 33. A prerequisite for effective operation of the device is a low level starting signal at OR-gate 32 coming from the ignition switch 42 which is also applied to OR-gate 32. The actuation of the first integrator 33, which is connected by its input terminal at the left in the diagram to a reference voltage source V ref , is thus such that the integrator 33 charges only during the period between output pulses from the first monostable flip-flop 31, and discharges during the periods of time t. The result is the voltage curve pictured over the output terminal c of the first integrator 33. During the time t, track-store element 34 holds the integrated signal value constant as indicated by the graph over terminal d. Track-store element 35, however, emits a voltage at its output terminal e, that is analogous to the rotational speed and matches the trend of the peaks of the voltage at terminal d. The peak occurring in the voltage curve at terminal d during each space of time t is held constant in element 35 until the appearance of the next pulse of duration t.
The voltage that is analogous to the speed is now passed by way of stabilizing means 11 and inverter 36 to one input of the comparator 37. The other input of comparator 37 is connected to the output of a second integrator 38. The time constants of the two integrators 33 and 38 are the same. Similar to the first integrator the second integrator is actuated from a second monostable flip-flop 40 by way of a OR-gate 39. The two flip-flops 31 and 40 have equal time constants. The output voltage of the second integrator 38, whose input is connected directly to the same reference voltage as the input of the first integrator, is pictured above terminal f. As soon as this voltage becomes greater in absolute value than the voltage supplied by way of inverter 36, the comparator 37 emits a pulse to the monostable flip-flop 40 which in turn interrupts the operation of integration in the second integrator 38 during the period of time t. The output signals of the second monostable flip-flop 40 at the same time are applied to a switchable amplifier 41, which at its output g conveys rectangular pulses to the control unit in the form of simulated ignition impulses. These impulses result from inverting and amplifying the negative voltage input to amplifier 41 in response to flip-flop 40. Consequently, the circuit of FIG. 3 first converts the ignition impulses into an analog voltage signal, then stabilizes the analog signal according to the invention, and finally converts the analog voltage signal back into the pulse signals required to actuate the control unit.
The structure of the several circuit components need not be enlarged upon, as they belong to the prior art. In this connection, reference is made to the book Electronics and Nulceonics Dictionary of Cook and Markus, 1960 and to the circuit elements of the Analog/Hybrid Computing System manufactured by Electronic Associates, Inc. of West Long Branch, N.J. In particular, elements 34, 35 and 41 can be an inverting track-store, i.e., amplifiers which will produce an inverted version of the input and will hold its output voltage when a hold signal is received.
The stabilizing means of FIG. 4 contains, as an essential component, the RC element comprised of longitudinal resistance 51 and transverse condenser 52. In parallel with the resistance 51 in this example are two series connected diodes 53 and 54. Connected between the two diodes is the output of an a.c. voltage amplifier designated generally by 55. This amplifier contains, as an essential component, a transistor 56. The analog voltage signal to be stabilized with its a.c. voltage components is supplied to transistor 56 by way of bias resistance 57 and input condenser 58. The amplified output signal is picked up by way of the output condenser 59.
The gain of the amplifier 55 is so contrived that at the output 60 of the stabilizing means, there is a stabilized voltage output greater than the highest peaks of the a.c. voltage components. Too great an elevation of the a.c. voltage component by the amplifier 55 is prevented by the additional diode 61 which is in parallel with series diodes 53 and 54 and with resistance 51. Diode 61 has a threshold higher than the threshold voltage of diodes 53 and 54, and is oppositely directed.
The unwanted a.c. voltage components are thus themselves utilized to effect an increase in the amplitude of the d.c. voltage signals to be fed to the control unit, whereby a fattening of the mixture so as to counteract the longitudinal vehicle vibrations is achieved.
While the present invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention. In particular, while there is an airflow meter in all of the exemplary embodiments, this does not preclude application of the invention to an air meter in the form of an intake pressure gauge. | A device modifies the signals for the control unit of an electronic fuel injection system of an internal combustion engine in order to reduce lengthwise vehicle vibrations. The signals are derived from a tachometer that measures the engine speed and a gauge that measures the air flow supply to the engine. The device dampens the a.c. components in the signal either symmetrically or asymmetrically. This device can be in the form of a passive RC circuit with diodes to determine the operating points or it can be an active circuit. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present invention is a continuation-in-part of a pending U.S. application Ser. No. 13/904,985 filed May 29, 2013, and incorporates at least by reference all of the disclosure of that prior application.
BACKGROUND
1. Field of the Invention
The present invention is the technical area of controlling hydraulic actuators, and pertains more particularly to precise control of movement of hydraulic cylinders and rotary hydraulic motors.
2. Description of Related Art
Hydraulic motivation of cylinders and motors is quite well-known in the art. There are always areas for improvement, however, and in the field of robotics in particular there is a need for very precise control of position and rate of change, acceleration, and force. The present invention addresses these unmet needs.
SUMMARY
A system is provided comprising a hydraulically-driven actuator having one of a rotor or a linear piston, and ports for hydraulic fluid to move the rotor or linear piston in either of two directions to different positions, an electro-mechanical sensor enabled to sense position of the rotor or linear piston, a valve having a substantially cylindrical plug in a bore of a valve body, the plug having cross bores at right angles to an axis of the plug, the cross bores aligning with passages within the valve body communicating with individual ones of a plurality of inlet and outlet ports to and from the valve body, depending on relative position of the plug in the bore of the valve body, a servo motor coupled mechanically to the cylindrical plug in a manner to move the plug around or along the axis to different positions to align individual ones of the cross bores with individual ones of the passages communicating with individual ones of the ports, and a programmable controller coupled to the electro-mechanical sensor and to the servo motor, the controller enabled to control the servo motor to accomplish programmed movement and position of the rotor or linear piston of the hydraulically-driven actuator.
In one embodiment the hydraulically-driven actuator is a linear cylinder, and the electro-mechanical sensor comprises a linear-potentiometer enabled to detect linear position of a piston within the linear cylinder. Also in one embodiment the programmable controller is enabled to determine velocity and acceleration of the piston from position information and passage of time.
Also in one embodiment the hydraulically-driven actuator is a rotary hydraulic motor, and the electro-mechanical sensor comprises a detector enabled to detect radial position of a driven rotor within the hydraulic motor.
In one embodiment the programmable controller is enabled to determine velocity and acceleration of the rotor from position information and passage of time. Also in one embodiment the servo motor is coupled to the cylindrical plug by gears to rotate the plug around the axis to different positions to align individual ones of the cross bores with individual ones of the passages communicating with individual ones of the ports. In one embodiment the servo motor is coupled to the cylindrical plug by gears and by a cam arrangement, to rotate the plug around the axis to different rotary positions and to different linear positions along the axis of the plug to align individual ones of the cross bores with individual ones of the passages communicating with individual ones of the ports.
In another embodiment the system further comprises pressure sensors in hydraulic lines proceeding from the valve to the actuator, the sensors providing information to the controller enabling pressure to be used as a variable in a program executed by the controller. Also in one embodiment the controller is coupled to a computerized appliance enabled to execute software enabling a user to prepare and upload programs for the controller to execute.
In another aspect of the invention a method is provided for controlling movement of a hydraulically-driven actuator, comprising steps of (a) connecting outlet ports of a hydraulic control valve having a valve body to ports of a hydraulically-driven actuator having one of a rotor or a linear piston, and ports for hydraulic fluid to move the rotor or linear piston in either of two directions to different positions, (b) providing an electro-mechanical sensor enabled to sense position of the rotor or linear piston, (c) moving a cylindrical plug having an axis and cross-bores substantially at right angles to the axis, by a servo motor coupled to the plug, in a bore of the valve body, to align individual ones of the cross bores with individual ones of a plurality of inlet and outlet ports to and from the valve body, depending on relative position of the plug in the bore of the valve body, (d) sensing positions of the rotor or linear piston by the electro-mechanical sensor and transmitting the position information to a programmable controller coupled to the servo motor and to the electro-mechanical sensor, and (e) controlling the servo motor to accomplish programmed movement of the rotor or linear piston of the hydraulically-driven actuator.
In one embodiment of the method the hydraulically-driven actuator is a linear cylinder, and the electro-mechanical sensor comprises a linear-potentiometer enabled to detect linear position of a piston within the linear cylinder. Also in one embodiment the programmable controller is enabled to determine velocity and acceleration of the piston from position information and passage of time. Also in one embodiment the hydraulically-driven actuator is a rotary hydraulic motor, and the electro-mechanical sensor comprises a detector enabled to detect radial position of a driven rotor within the hydraulic motor.
In one embodiment the programmable controller is enabled to determine velocity and acceleration of the rotor from position information and passage of time. Also in one embodiment the servo motor is coupled to the cylindrical plug by gears to rotate the plug around the axis to different positions to align individual ones of the cross bores with individual ones of the passages communicating with individual ones of the ports. And in one embodiment the servo motor is coupled to the cylindrical plug by gears and by a cam arrangement, to rotate the plug around the axis to different rotary positions and to different linear positions along the axis of the plug to align individual ones of the cross bores with individual ones of the passages communicating with individual ones of the ports.
BRIEF DESCRIPTION OF THE FIGURES
Detailed description of some embodiments of the invention is made below with reference to the accompanying figures, wherein like numerals represent corresponding parts of the figures.
FIG. 1 is a perspective view in one embodiment of the invention.
FIG. 2 is a top view of the embodiment of FIG. 1 .
FIG. 3 is an exploded view of the valve plug and valve body of the embodiment of FIG. 1 .
FIG. 4 is a cross-sectional perspective view of the valve body of FIG. 3 .
FIG. 5 is a top view of the valve body of FIG. 3 .
FIGS. 6, 11 and 16 are schematic side views of the valve body of FIG. 3 shown in connection with an example of hydraulic cylinder in a first open position, a closed position, and a second open position, respectively.
FIGS. 7-10 , FIGS. 12-15 and FIGS. 17-20 are cross-sectional views of the valve body of FIG. 3 taken through cross-section lines designated in FIGS. 6, 11 and 16 , showing the relative position of the valve plug vis-à-vis the valve body when the valve is in a first open position, a closed position, and a second open position, respectively.
FIG. 21 is a schematic perspective view of the system embodiment of FIG. 1 shown in electrical and fluid connection with an example of a hydraulic cylinder employing a linear detection sensor, such as a linear-potentiometer, by example.
FIG. 22 is a perspective view similar to FIG. 21 , adding additional detail concerning control mechanisms in embodiments of the invention.
DETAILED DESCRIPTION OF THE INVENTION
By way of example, and referring to FIGS. 1 and 2 , one embodiment of the present inventive multi-port valve system 10 comprises a valve 12 and a servo motor 14 within a valve body housing 34 . The system comprises a plurality of fluid ports 24 configured for the delivery of fluid to and from the valve system. In the example illustrated herein, there are four ports 24 . However, the number of ports, and the arrangement of those ports relative to each other is not limited as shown, but indeed may include more than four ports and may orient the ports to have some being parallel to each other, perpendicular to each other, or any other one of a number of possible configurations within the housing 34 .
Referring to FIG. 3 momentarily, the valve 14 comprises a valve plug 22 configured to be housed within a valve plug bore 38 within the valve body of the multi-port valve system 10 . In one embodiment, the valve plug comprises a plurality of holes 16 therethrough, where each of the plurality of holes 16 are spaced axially along the length of the valve plug 22 . At least one set of holes 16 is aligned parallel to each other (in this example of embodiment the top hole and the second from the bottom hole), while another set of holes 16 is also aligned parallel to each other (in this example of embodiment the second hole from the top and the bottom hole), but out of alignment with the first set. Of course, the set of holes may be arranged in any number of configurations and radial positions, as may be appreciated further below. And additional holes and/or sets of holes may be employed where additional fluid ports are desired for the valve to control.
With reference back to FIGS. 1 and 2 , in this embodiment, the servo motor 14 is configured to have a mechanical output which, in this case, is in the form of a servo gear 18 configured to rotate in clockwise and counterclockwise motion. Servo gear 18 is preferably positioned to be in engagement with valve gear 20 that is affixed to valve plug 22 so that rotation of the servo gear 18 causes rotation of valve gear 20 , to drive rotation of valve plug 22 . Such rotation of the valve plug 22 causes the first and second holes to come within and without of alignment with fluid pathway ports, as described below.
It should be noted that the radial size and number of teeth in the servo motor gear 18 and the valve gear 20 are set dependent upon the desired control of valve movement and the mechanical output of the servo motor. The larger or smaller the ratio between gears impacts the speed of movement of the valve. In some cases, it may be desired to have very small movement of the valve plug to correspond with fine piston movement within the hydraulic cylinder. In other cases, micro-movement control may not be necessary, so that the gear ratio may be smaller.
Importantly, it should be noted that movement of the valve plug 22 within valve plug bore 38 need not be limited to rotational movement, but indeed may comprise axial movement instead of rotational movement or in addition to rotation movement. Axial movement may be achieved via a combination of bevel gears, or a rack and pinion arrangement, for example, where the servo motor may drive axial movement of the valve plug. It may also be desired that the valve plug be spring loaded either axially or rotationally where the combination of the servo motor and the force of the spring act to control fine movement of the valve plug relative to the valve plug bore. It is contemplated that a number of possible configurations may be employed to cause the valve plug to bring into alignment certain of the valve plug holes with ports that extend radialy outward from the valve plug bore 38 , as described further below.
Regardless of how the valve plug 22 moves within valve plug bore 38 , the holes 16 are brought into and out of alignment with ports to control the flow of fluid through the valve body ports 24 in a manner that permits, at least in one application, the actuation of a hydraulic cylinder, for example. In FIG. 6 , one example of hydraulic cylinder 26 comprises a cylinder housing 44 and a piston 28 . With reference to FIG. 21 , the position of the piston 28 relative to the cylinder housing 44 is controlled by the delivery of fluid from the multi-port servo embodiment 10 of the present invention through valve body ports 24 to and from cylinder ports 46 and 48 , where the source of fluid pressure (e.g., pump—not shown) is supplied to the valve body 10 through line 54 and returned to the source of fluid pressure through line 56 , both connected to the other set of valve body ports 24 .
Referring back to FIG. 3 , the valve body 34 comprises valve port bores 36 into which valve ports 24 may be affixed (in one of numerous possible mechanical and/or adhesive connections), depending upon the material chosen for the valve ports 24 and the valve body 34 . In a high-pressure hydraulic fluid system, the valve body 34 and the valve ports 24 are both made of high strength metals capable of withstanding the high pressures associated with the control of hydraulic cylinders. As may be appreciated, the valve plug 22 comprises a generally cylindrical configuration that may include parallel surfaces and/or tapered surfaces between holes 16 , or a single or plurality of grooves along the axial length. The grooves may provide functional value of being aligned within internal collars within the valve plug bore, in some examples, or may simply reflect the addition of material around the holes for enhanced structural integrity to withstand high pressure flows.
With reference to FIGS. 4 and 5 , one example of a series of fluid pathways within the valve body housing 34 may be described, where the fluid pathways permit fluid communication between the valve ports 24 through holes 16 of valve plug 22 . In one embodiment of the multi-port valve body, the port bores comprise one bore 40 connected to one cylinder port 48 and another valve body port bore 42 connected to cylinder port 46 . Likewise, valve body port 58 is connected to the fluid delivery line 54 from the pressure source while valve body port 60 is connected to the fluid return line 56 to the pressure source. The internal pathways within the valve body housing 34 , combined with the controlled movement of the valve plug 22 within valve plug bore 38 —and the concomitant alignment of holes 16 with radial ports of the valve plug bore—permit the controlled direction of fluid from fluid delivery port 58 to either cylinder ports 40 or 42 for the alternating control of piston movement in one linear direction or the other. In the example of multi-port valve body system shown here, a plurality of bores generally aligned parallel to the valve plug bore 38 are in respective communication with a port in each of the delivery and return ports 58 and 60 , on the one hand, and a set of valve plug bore ports, on the other hand.
Referring to FIGS. 6 though 20 , the sequence of operation may be appreciated, where the relative position of the valve plug 22 (and holes 16 ) within the valve plug bore 38 is shown in three different positions: a first valve open position (shown in FIGS. 6 through 10 ), a closed position (shown in FIGS. 11-15 ), and a second valve open position (shown in FIGS. 16-20 ). Each cross-section view associated with schematic FIGS. 6, 11 and 16 show the relative position of each of the holes 16 relative to a corresponding valve plug bore port. For example, in FIG. 7 , the upper most hole is shown in fluid communication with cylinder port 40 , while the second hole from the bottom is in fluid communication with cylinder port 42 , as shown in FIG. 9 . Meanwhile, the second hole from the top and the bottom most hole are not in fluid communication with any port. The result, as shown in FIGS. 6 and 21 , is that the fluid delivery line 54 permits fluid to flow through valve body port 58 directly to valve body port 40 and then to cylinder port 48 , with the return of fluid coming from cylinder port 46 through valve body port 42 through to valve body port 60 and back to the pressure source.
With reference to FIGS. 11 through 15 , the position of valve plug 22 within valve plug bore 38 is such that none of the valve plug holes 16 are in fluid communication with any ports. Thus, the valve is essentially closed and no flow is occurring between the pressure source, the valve body and the hydraulic cylinder. It should be note that the static pressure may be such that overtime, the pressure may cause undue stress on one or more of the components. Thus, it may be desirable to include within the system a pressure-relief valve to permit the exhaust of at least some of the fluid to a sink or simply to the ambient to temporarily reduce the pressure until the valve is turned back on to the first or second valve open positions.
Referring to FIGS. 16 through 20 , relative position of the valve plug 22 and the valve plug bore 38 is shown. There, the valve plug holes 16 are aligned such the resultant flow path is shown by the arrows in FIG. 16 to reflect the flow of fluid from delivery line 54 permits to valve body port 58 directly to valve body port 42 and then to cylinder port 46 , with the return of fluid coming from cylinder port 48 through valve body port 40 through to valve body port 60 and back to the pressure source. This alternating “second” valve open position directs the piston in the opposite linear direction as results when the valve is in the “first” valve open position. Thus, reciprocating piston movement may be controlled within the hydraulic cylinder 44 to accomplish the task desired. Importantly, it should be noted that the orientation of the fluid paths and ports within the valve body example illustrated and described herein may be varied considerably and still achieve the desired fluid dynamic result.
Referring back to FIGS. 1 and 2 , as well as FIG. 21 , the automated control feature of embodiments of the present invention may be described. In that regard, embodiments of the multi-port servo valve system comprises a control circuit assembly 62 that may be affixed directly to the valve housing 34 or simply electrically connected to the valve housing in one form of the other, either wired or wirelessly. Preferably, the circuit assembly 62 comprises a controller 64 that may be programmed to designate the desired linear position of piston 28 within the cylinder housing 44 over time. In that regard, a sensor 50 is provided in association with the hydraulic cylinder 26 , either directly attached to the cylinder housing 44 or linked in some other configuration, to detect that position of the piston 28 within the housing 44 at any one moment in time. The position is continuously or periodically fed to the controller 64 so that the controller may compare in real time or periodically the actual position of the piston to the desire position of the piston. The controller is electrically connected to the servo motor, either wired or wirelessly, to direct the servo motor to actuate the valve when necessary. If the controller's programmed comparative function reveals that there is a delta between the actual and desired piston position, the servo motor may be directed to move the valve plug in one direction or the other; i.e., to a first open or second open position, to adjust the piston position accordingly. If there is no delta directed, the valve may be either actuated to a closed position or left in a closed position, depending upon where the sequence of operation is at. In one example of a sensor 50 , a linear-potentiometer may be employed. Other sensors may be employed as well to provide meaningful information about the present situation of the cylinder 26 vis-à-vis the desired situation dictated by the program entered into the controller.
Indeed, other applications are possible for the inventive embodiments of the multi-port servo valve, as described herein. For example, instead of controlling the flow of hydraulic fluid to a linear piston-style hydraulic cylinder through the use of linear position feedback, the embodiments may be employed to control the movement of a rotational cylinder, where rotational movement of a rotor in one direction or the other may be controlled through the delivery and return of pressurized fluid through embodiments of the multi-port servo valve. One example of a rotational cylinder might be a hydraulic motor configured so that the rotor rotates in a single direction, but at varying speeds and/or for varying time periods., One type of feedback sensor may be one that is configured to detect the rotational position of the rotor within its housing, or the angular velocity at any point in time.
FIG. 22 is a diagram illustrating more detail in operation and control of a hydraulic actuator in an embodiment of the invention. FIG. 22 illustrates a linear hydraulic cylinder 70 , as does FIG. 21 , but it should be apparent to the skilled person that cylinder 70 could also be a rotary actuator like a hydraulic motor.
In the arrangement of FIG. 22 piston 72 of the cylinder is driven in opposite directions by supply of hydraulic fluid under pressure from valve assembly 80 , which includes a servo motor, and is operationally identical to valve assembly 10 in FIG. 21 . Hydraulic fluid under pressure is supplied by pump 91 through conduit 78 to the valve, and depending on the rotary and linear position of valve plug 80 (equivalent to plug 22 described above, through the valve to either of conduits 76 or 77 to drive the cylinder. Cylinder 70 has a linear potentiometer 75 connected at a far end of piston 72 at element 73 , such that a signal may be generated regarding the position of the piston in the cylinder. That signal is provided via line 85 to a programmable controller 84 . Controller 84 also receives pressure signals from pressure sensors 82 and 83 in lines 76 and 77 . Controller 84 is provided with a program 95 for cylinder operation by a coupled computerized appliance 89 running SW 94 via path 93 . SW 94 provides a user with an interactive interface for preparing different programs for cylinder (actuator) operation.
Controller 84 provides signals via path 92 to operate pump 91 and via path 86 to operate the servo motor in valve assembly 80 . A user may program sophisticated programs for movement of the piston of the cylinder, or for rotation of a rotor in a rotary actuator. By virtue of the fine position control of valve plug 8 , described in detail above with reference to valve plug 22 , one may for example, position valve bores 16 (see FIGS. 3 and 7 through 10 ) relative to matching bores in the valve body, such that fine speed control is attained. For example, one may program position of valve plug 81 relative to matching bores in the valve body, such that a bore 61 is not directly aligned with the matching bore, so the area for passage of hydraulic fluid is restricted, depending on the position of the valve plug. Consider the area as the full cross-sectional area of the bore 16 when alignment is direct. Then, when the valve plug begins to turn, the area diminishes over a few degrees until the flow is completely shut off. This phenomena may be used in control to get very fine changes in rate and acceleration. The same principle works in the opposite circumstance as the plug is turned from a full off position over a few degrees to a full on position.
In some embodiments of the invention pressure information from sensors 82 and 83 may be used in programming and control to control piston movement and pressure applied, which translates to force exerted by the piston, or a rotary member of a rotary actuator. Further, in some embodiments of the invention the actuator, be it a linear cylinder or a rotary actuator, may operate one or more mechanisms for pushing or pulling a load, or for gripping an object for example. Sensor 95 in FIG. 22 is meant to represent any such sensors that may be implemented in driven mechanisms to sense force against elements manifested by movement of and contact with a portion of the actuator. Such sensors provide force data to programmable controller 84 via path 96 , and this data may be used in programming operation of the actuator.
Persons of ordinary skill in the art may appreciate that numerous design configurations may be possible to enjoy the functional benefits of the inventive systems. Thus, given the wide variety of configurations and arrangements of embodiments of the present invention the scope of the invention is reflected by the breadth of the claims below rather than narrowed by the embodiments described above. | A system has an actuator having a rotor or a linear piston, and ports for hydraulic fluid, an electro-mechanical sensor sensing position of the rotor or linear piston, a valve having a 1 plug in a bore of a valve body, the plug having cross bores aligning with passages within the valve body communicating inlet and outlet ports depending on relative position of the plug in the bore of the valve body, a servo motor to move the plug around or along the axis to different positions to align individual ones of the cross bores with individual ones of the passages communicating with individual ones of the ports, and a programmable controller coupled to the electro-mechanical sensor and to the servo motor, the controller enabled to control the servo motor to accomplish programmed movement and position of the rotor or linear piston of the hydraulically-driven actuator. | 5 |
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
This application a continuation of U.S. application Ser. No. 11/039,877, filed Jan. 24, 2005, now U.S. Pat. No. 7,931,895, which is a divisional of U.S. application Ser. No. 10/257,477, filed Jan. 14, 2003, now U.S. Pat. No. 7,579,170, which is a U.S. National Stage of International application serial number PCT/FR01/01127, filed Apr. 12, 2001, which claims priority to France application serial number 00/04,685, filed Apr. 12, 2000, all of which are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
The present invention relates to a method of obtaining and selecting monoclonal antibodies using an assay of the ADCC type, said antibodies being capable of activating Fcγ type III receptors. The invention is also directed toward monoclonal antibodies having a particular glycan structure, the cells producing said antibodies, the methods for preparing the producer cells, and also the pharmaceutical compositions or the diagnostic tests comprising said antibodies. The anti-D antibodies according to the invention can be used for preventing Rhesus isoimmunization of Rh-negative individuals, in particular a hemolytic disease of the newborn (HDN), or in applications such as Idiopathic Thrombocytopenic Purpura (ITP).
Passive immunotherapy using polyclonal antibodies has been carried out since the 1970s. However, the production of polyclonal immunoglobulins poses a problem: The immunization of volunteers was discontinued in France in 1997 because of the ethical problems that such acts present. In France, as in Europe, the number of immunized donors is too low to ensure a sufficient supply of certain antibodies, to such an extent that it proves necessary to import hyperimmunized plasma from the United States for example.
Thus, this immunoglobulin shortage does not make it possible to envisage antenatal administration for preventing HDN.
Various studies have resulted in the production of human monoclonal antibodies for the purpose of replacing the polyclonal antibodies obtained from fractionating plasmas from voluntary donors.
Monoclonal antibodies have several advantages: they can be obtained in large amounts at reasonable costs, each batch of antibodies is homogeneous and the quality of the various batches is reproducible since they are produced by the same cell line, which is cryopreserved in liquid nitrogen. It is possible to ensure the safety of the product with regard to an absence of viral contamination.
Several publications describe the production of cell lines producing human anti-Rh D monoclonal antibodies of IgG class, from B cells of immunized donors. Boylston et al. 1980; Koskimies 1980; Crawford et al. 1983; Doyle et al. 1985; Goossens et al. 1987; Kumpel et al. 1989(a) and McCann-Carter et al. 1993 describe the production of B lymphocyte lines transformed with the EBV virus. Melamed et al. 1985; Thompson et al. 1986 and McCann-Carter et al. 1993 relate to heterohybridomas resulting from B lymphocyte (transformed with EBV)×murine myeloma fusion. Goossens et al., 1987 relates to heterohybrids resulting from B lymphocyte (transformed with EBV)×human myeloma fusion. Bron et al., 1984 and Foung et al., 1987 describe heterohybrids resulting from B lymphocyte (transformed with EBV)×human-mouse heteromyeloma fusion and, finally, Edelman et al., 1997 relates to insect cells transfected with the gene encoding an anti-Rh(D) using the baculovirus system.
Among the patents and patent applications relating to such monoclonal antibodies and the lines secreting them, mention may be made of: EP 576093 (AETS (FR), Biotest Pharma GmbH (Germany); Composition for prophylaxis of the haemolytic disease of the new-born comprises two human monoclonal antibodies of sub-class IgG1 and IgG3, which are active against the Rhesus D antigen), RU 2094462, WO 85/02413 (Board of Trustees of the Leland Stanford Jr. University, Human Monoclonal Antibody against Rh (D) antigen and its uses), GB 86-10106 (Central Blood Laboratories Authority, Production of heterohybridomas for manufacture of human monoclonal antibodies to Rhesus D antigen), EP 0 251 440 (Central Blood Laboratories Authority, Human Anti-Rhesus D Producing Heterohybridomas), WO 89/02442, WO 89/02600 and WO 89/024443 (Central Blood Laboratories Authority, Human Anti-Rh (D) Monoclonal Antibodies), WO 8607740 (Institut Pasteur, Protein Performance SA, Paris, FR, Production of a recombinant monoclonal antibody from a human anti-rhesus D monoclonal antibody, production thereof in insect cells and uses thereof), JP 88-50710 (International Reagents Corp., Japan, Reagents for Determination of Blood Group Substance Rh (D) Factor), JP 83-248865 (Mitsubishi Chemical Industries Co., Ltd., Japan, Preparation of Monoclonal Antibody to Rh (D) positive Antigen); CA 82-406033 (Queens University at Kingston, Human Monoclonal Antibodies) and GB 8226513 (University College London, Human Monoclonal Antibody against Rhesus D Antigen).
While the use of monoclonal antibodies has many advantages compared to the use of pools of polyclonal antibodies, it may, on the other hand, prove to be difficult to obtain an effective monoclonal antibody. In fact, it has been found, in the context of the invention, that the Fcγ fragment of the immunoglobulin obtained must have very particular properties in order to be able to interact with and activate the receptors of effector cells (macrophage, TH lymphocyte and NK).
The biological activity of certain G immunoglobulins is dependent on the structure of the oligosaccharides present on the molecule, and in particular on its Fc component. IgG molecules of all human and murine subclasses have an N-oligosaccharide attached to the CH 2 domain of each heavy chain (at residue Asn 297 for human IgGs). The influence of this glycan-containing residue on the ability of the antibody to interact with effector molecules (Fc receptors and complement) has been demonstrated Inhibiting glycosylation of a human IgG1, by culturing in the presence of tunicamycin, causes, for example, a 50-fold decrease in the affinity of this antibody for the FcγRI receptor present on monocytes and macrophages (Leatherbarrow et al., 1985). Binding to the FcγRIII receptor is also affected by the loss of carbohydrates on IgG, since it has been described that a nonglycosylated IgG3 is incapable of inducing lysis of the ADCC type via the FcγRIII receptor of NK cells (Lund et al., 1990).
However, beyond the necessary presence of these glycan-containing residues, it is more precisely the heterogeneity of their structure which may result in differences in the ability to initiate effector functions. Galactosylation profiles which are variable depending on individuals (human serum IgG1s) have been observed. These differences probably reflect differences in the activity of galactosyltransferases and other enzymes between the cellular clones of these individuals (Jefferis et al., 1990). Although this normal heterogeneity of post-translational processes generates various glycoforms (even in the case of monoclonal antibodies), it may lead to atypical structures associated with certain pathological conditions, such as rheumatoid arthritis or Crohn's disease, for which a considerable proportion of agalactosylated residues have been demonstrated (Parekh et al., 1985).
The glycosylation profile of the purified molecule is the consequence of multiple effects, some parameters of which have already been studied. The protein backbone of IgGs, and in particular amino acids in contact with the terminal N-acetylglucosamine (GlcNAc) and galactose residues of the mannose α-1,6 arm (aa 246 and 258 of IgGs), may explain the existence of preferential structures (galactosylation), as shown in the study carried out on murine and chimeric IgGs of different isotypes (Lund et al., 1993).
The differences observed also reveal specificities related to the species and to the cell type used for producing the molecule. Thus, the conventional structure of the N-glycans of human IgGs reveals a significant proportion of bi-antennary types with a GlcNAc residue in the bisecting position, this being a structure which is absent in antibodies produced by murine cells. Similarly, the sialic acid residues synthesized by the CHO (Chinese Hamster Ovary) line are exclusively of the α-2,3 type, whereas they are of the α-2,3 and α-2,6 type with murine and human cells (Yu Ip et al., 1994). Immunoglobulin production in expression systems other than those derived from mammals may introduce much more important modifications, such as the presence of xylose residues produced by insect cells or plants (Ma et al., 1995).
Other factors, such as the cell culture conditions (including the composition of the culture medium, the cell density, the pH, the oxygenation), appear to have an effect on glycosyltransferase activity in the cell and, consequently, on the glycan structure of the molecule (Monica et al., 1993; Kumpel et al., 1994 b).
Now, in the context of the present invention, it has been found that a structure of the bi-antennary type, with short chains, a low degree of sialylation, and nonintercalated terminal mannoses and/or terminal GlcNAcs, is the common denominator for glycan structures which confer strong ADCC activity on monoclonal antibodies. A method for preparing such antibodies capable of activating effector cells via FcγRIII, in particular anti-Rh(D) antibodies, has also been developed.
Blood group antigens are classified in several systems depending on the nature of the membrane-bound molecules expressed at the surface of red blood cells. The Rhesus (Rh) system comprises 5 molecules or antigens: D, C, c, E and e (ISSITT, 1988). The D antigen is the most important of these molecules because it is the most immunogenic, i.e. it can induce the production of anti-D antibodies if Rh-D-positive red blood cells are transfused into Rh-negative individuals.
The D antigen is normally expressed in 85% of Caucasian individuals, these people are termed “Rh-positive;” 25% of these individuals are therefore Rh-negative, i.e. their red blood cells do not exhibit any D antigen. D antigen expression exhibits certain variants which may be linked either to a weak antigenic density, reference is then made to weak D antigens, or to a different or partial antigenicity, reference is then made to partial D antigens. The weak D characteristic is characterized in that it is a normal antigen, but the number of sites thereof per red blood cell is decreased more or less considerably; this characteristic is transmissible according to Mendelian laws. Partial D phenotypes have been discovered in Rh-D-positive individuals who have anti-D serum antibodies; these partial D antigens can therefore be characterized as having only part of the mosaic. Studies carried out with polyclonal and monoclonal antibodies have made it possible to define 7 categories of partial D antigens with at least 8 epitopes constituting the D antigen being described (LOMAS et al., 1989; TIPETT 1988).
The importance of anti-Rh D antibodies became apparent with the discovery of the mechanisms leading to hemolytic disease of the newborn (HDN). This corresponds to the various pathological conditions observed in some fetuses or in some newborn babies when there is a feto-maternal blood group incompatibility which is responsible for the formation of maternal anti-Rh D antibodies capable of crossing the placental barrier. In fact, fetal Rh-positive red blood cells passing into an Rh-negative mother can lead to the formation of anti-D antibodies.
After immunization of the Rh-negative mother, the IgG class anti-D antibodies are capable of crossing the placental barrier and of binding to the fetal Rh-positive red blood cells. This binding leads to the activation of immunocompetent cells via their surface Fc receptors, thus inducing hemolysis of the sensitized fetal red blood cells. Depending on the strength of the reaction, several degrees of seriousness of HDN can be observed.
An HDN diagnosis can be carried out before and after birth. Prenatal diagnosis is based on the development of the anti-D antibody level in the mother using several immunohematological techniques. Post-partum diagnosis may be carried out using an umbilical cord blood sample, analyzing the following parameters: determining the blood groups of the fetus and of the father; searching for anti-D antibodies; assaying the hemoglobin and the bilirubin.
Prophylactic treatment for HDN is currently systematically given to all women with an Rh-negative blood group who have given birth to an Rh-positive child, with injections of human anti-D immunoglobulin. The first real immunoprophylaxis trials began in 1964. For the prevention to be effective, the immunoglobulin must be injected before the immunization, i.e. within the 72 hours following the birth, and the antibody doses must be sufficient (10 μg of anti-D antibodies per 0.5 ml of Rh+ red blood cells).
Several anti-D monoclonal antibodies have been the subject of therapeutic assessment: BROSSARD/FNTS 1990 (not published); THOMSON/IBGRL 1990; KUMPEL/IBGRL 1994; BELKINA/Institute of hematology, Moscow, 1996; BIOTEST/LFB 1997 (not published). The clinical effectiveness of the antibodies in inducing clearance of Rh(D)-positive red blood cells was assessed in Rh(D)-negative volunteers.
A single IgG1 antibody showed an effectiveness equivalent to that of anti-D polyclonal immunoglobulins, but only in some patients (KUMPEL et al., 1995).
The invention proposes to provide monoclonal antibodies which reply to the abovementioned problems, i.e. antibodies selected using an assay of the ADCC type specific for the antibody and/or the antibodies having a glycan structure required for obtaining good effectiveness.
SUMMARY OF THE INVENTION
Thus, the present invention relates to a method for preparing a monoclonal antibody capable of activating effector cells expressing FcγRIII, characterized in that it comprises the following steps:
a. purifying monoclonal antibodies obtained from various clones originating from cell lines selected from hybridomas, in particular heterohybridomas, and animal or human cell lines transfected with a vector comprising the gene encoding said antibody; b. adding each antibody obtained in step a) to a different reaction mixture comprising:
the target cells for said antibodies,
effector cells comprising cells expressing FcγRIII,
polyvalent IgGs;
c. determining the percentage lysis of the target cells and selecting the monoclonal antibodies which activate the effector cells causing significant lysis of the target cells (FcγRIII-type ADCC activity).
The clones may originate from heterohybrid cell lines obtained by fusion of human B lymphocytes (originating from immunized individuals) with murine, human or heterohybrid myeloma cells, in particular the K6H6-B5 myeloma (ATCC No. CRL 1823); or else from animal or human cell lines transfected with a vector containing the gene encoding a human IgG immunoglobulin, said lines possibly being selected in particular from the CHO—K, CHO-Lec10, CHO Lec-1, CHO Pro-5, CHO dhfr-, Wil-2, Jurkat, Vero, Molt-4, COS-7, 293-HEK, YB2/0, BHK, K6H6, NSO, SP2/0-Ag 14 and P3X63Ag8.653 lines.
The polyvalent IgGs are used to inhibit the mechanism of lysis of the effector cells via FcγRI. In this method, the antibodies which exhibit an FcγRIII-type ADCC level greater than 60%, 70%, 80%, or preferably greater than 90%, are selected. The target cells can be red blood cells treated with papain. In this case, the following are deposited per well:
100 μl of purified monoclonal antibodies at approximately 200 ng/ml, 25 μl of papain-treated red blood cells, i.e. approximately 1×10 6 cells, 25 μl of effector cells, i.e. approximately 2×10 6 cells, and 50 μl of polyvalent IgGs, in particular of TEGELINE™ (LFB, France), at a concentration of between 1 and 20 mg/ml.
It is thus possible to compare the amount of target cell lysis to two positive controls consisting of a chemical compound such as NH 4 Cl and a reference antibody active in vivo, and to a negative control consisting of an antibody inactive in vivo.
It is also possible to use polyclonal antibodies of commercial origin as positive controls and a monoclonal antibody incapable of inducing clearance in vivo as a negative control.
Advantageously, this method makes it possible to prepare anti-Rh(D) monoclonal antibodies as indicated above. Rhesus D red blood cells are then used as target cells.
The invention is therefore based on developing an assay for biological activity in vitro, in which the activities measured correlate with the biological activity in vivo of the monoclonal or polyclonal antibodies already evaluated from the clinical point of view with regard to their potentiality in inducing clearance of Rh(D)-positive red blood cells in Rh(D)-negative volunteers. This assay makes it possible to evaluate the antibody-dependent lytic activity=ADCC (antibody-dependent cellular cytotoxicity) induced essentially by the Fcγ type III receptors (CD16), the Fcγ type I receptors (CD64) being saturated by the addition of human IgG immunoglobulins (in the form of therapeutic polyvalent IgGs). The FcγRIII specificity of this ADCC assay was confirmed by inhibition in the presence of an anti-FcγRIII monoclonal antibody (see FIG. 6 ). Mononuclear cells from healthy individuals are used as effector cells in an effector/target (E/T) ratio close to physiological conditions in vivo. Under these conditions, the lytic activities of the polyclonal immunoglobulins and of the anti-D monoclonal antibodies ineffective in vivo (antibody DF5, Goossens et al., 1987, and the antibodies AD1+AD3, FR 92/07893 LFB/Biotest and FOG-1, GB 2189506) are, respectively, strong and weak.
The selection of the antibodies described in the present invention was therefore carried out by evaluating their biological activity in this ADCC-type assay (see example 1).
In another aspect, the invention relates to the antibodies which can be obtained using the method described above, said antibodies exhibiting FcγRIII-type ADCC levels greater than 60%, 70%, 80%, or preferably greater than 90%, relative to the reference polyclonal. The monoclonal antibodies of the invention, directed against a given antigen, activate effector cells expressing FcγRIII, causing lysis greater than 60%, 70%, 80%, preferably greater than 90%, of the lysis caused by polyclonal antibodies directed against said antigen. Advantageously, said monoclonal antibodies are directed against rhesus D.
They may preferably be produced by clones derived from the Vero (ATCC No. CCL 81), YB2/0 (ATTC No. CRL 1662) or CHO Lec-1 (ATCC No. CRL 1735) lines and may belong to the IgG1 or IgG3 class.
The invention also relates to antibodies which have a particular glycan structure conferring FcγRIII-dependent effector activity.
Such antibodies can be obtained using a method explained above and have, on their Fcγ glycosylation site (Asn 297), glycan structures of the bi-antennary type, with short chains and a low degree of sialylation. Preferably, their glycan structure exhibits nonintercalated terminal mannoses and/or terminal GlcNAcs.
Such antibodies are more particularly selected from the forms shown in FIG. 10 .
Thus, the invention is directed toward a monoclonal antibody characterized in that it has, on its Fcγ glycosylation site (Asn 297), glycan structures of the bi-antennary type, with short chains, a low degree of sialylation, and nonintercalated mannoses and GlcNAcs with a terminal point of attachment. Said antibodies, directed against a given antigen, activate effector cells expressing FcγRIII, causing lysis greater than 60%, 70%, 80%, preferably greater than 90%, of the lysis caused by polyclonal antibodies directed against said antigen.
More particularly, the invention relates to antibodies and compositions comprising said antibodies as defined above, in which the sialic acid content is less than 25%, 20%, 15% or 10%, preferably 5%, 4%, 3% or 2%.
Similarly, the invention relates to antibodies and compositions comprising said antibodies as defined above, in which the fucose content is less than 65%, 60%, 50%, 40% or 30%. Preferably, the fucose content is between 20% and 45%, or else between 25% and 40%.
A particularly effective composition according to the invention comprises, for example, a content greater than 60%, preferably greater than 80%, for the G0+G1+G0F+G1F forms, it being understood that the G0F+G1F forms are less than 50%, preferably less than 30%.
TABLE 1
Quantification (%) of the oligosaccharide structures of the various anti-RhD antibodies
Antibodies inactive by
Antibodies active by FcRγIII ADCC
FcRγIII ADCC
R297
R270
F60
D31
HPCE-
HPCE-
HPCE-
HPCE-
HPCE-
F5
Structure
LIF
LIF
HPLCs
LIF
HPLCs
LIF
LIF
HPLCs
Fucosylated
34.3
45.9
37.2
47.7
46.6
82.0
88
100
Sialylated
1.0
2.2
4.1
9.9
19.6
47.9
52.0
17
G2S2FB
2.8
G2S2F
0.0
0.0
n.d.
4.2
0.0
11.3
11.9
4.1
G2S1FB
6.1
G2S1F
1.0
1.0
n.d.
2.7
2.5
21.4
30.5
28
G2S1
0.0
1.2
n.d.
3.0
0.0
0
0
G1S1FB
6.2
G1S1F
1.7
G2F
3.9
5.0
3.0
10.3
11.6
16.9
22.1
4.2
G2
12.1
6.1
3.3
7.0
13.3
2.0
0.0
0.0
G1FB
25.7
G1F
17.4
16.9
15
24.8
22.1
16.1
21.5
12.4
G1
26.1
11.3
21.0
22.2
22.8
0.0
0.0
0.0
G0F
12.1
23.1
19.4
5.6
10.5
1.7
3.0
0.0
G0
29.1
32.7
38.5
15.8
17.7
13.6
13.9
0.5
An alternative for specifically targeting FcγRIII consists in preparing antibodies of the “high mannose” type.
In another aspect, the invention relates to a cell producing an antibody mentioned above. It may be a hybridoma, in particular a heterohybridoma obtained with the fusion partner K6H6-B5 (ATCC No. CRL 1823); or an animal or human cell transfected with a vector comprising the gene encoding said antibody, in particular a cell derived from the Vero (ATCC No. CCL 81), YB2/0 (ATCC No. CRL 1662) or CHO Lec-1 (ATCC No. CRL 1735) lines. These cells correspond to the cell lines selected using the method according to the invention, said cells producing antibodies which have the characteristics mentioned above.
A preferred antibody according to the invention shows considerable biological activity (greater than or equal to that of the anti-Rh(D) reference polyclonal antibody) in the ADCC assay using FcγRIII-positive effector cells.
Its ability to activate FcγRIII receptors (after binding) is confirmed on in vitro models which demonstrate modification of intracellular calcium flux, phosphorylation of activation signal transduction molecules, or release of chemical mediators.
These properties are associated with a particular structure of the oligosaccharides of the N-glycosylation site of the Fc component of the antibody: presence of short chains, low degree of galactosylation, little sialylation, may have non-intercalated terminal mannoses and/or terminal GlcNAcs, for example.
This antibody has therapeutic applications: prevention of HDN, treatment of ITP in Rh(D)-positive individuals, and any other application to which the use of anti-D polyclonal immunoglobulins relates.
A preferred antibody according to the invention may also have a specificity other than anti-Rh(D) (anti-cancer cell for example). It may have the properties described above (functional activity dependent on a mechanism of binding to/activation of FcγRIII receptors, particular structure of oligosaccharides) and may be used in immunotherapy for cancers or for any other pathological condition for which a curative or preventive treatment may be carried out using a monoclonal antibody the mechanism of action of which corresponds to an activity which is functional via the FcγRIII receptor.
Another aspect relates to a pharmaceutical composition comprising an antibody according to the invention and to the use of said antibody for producing a medicinal product.
Preferably, the invention relates to the use of an anti-Rh(D) antibody described above, for producing a medicinal product intended for the prevention of Rhesus alloimmunization of Rh-negative individuals. The method of action of the anti-D immunoglobulins in vivo is specific binding of the antibodies to the D antigen of the Rh(D)-positive red blood cells, followed by elimination of these red blood cells from the circulation essentially in the spleen. This clearance is associated with a dynamic mechanism of suppression of primary immune response in the individual, and therefore prevents the immunization.
Thus, an antibody of the invention may be used prophylactically for preventing alloimmunization of Rhesus-negative women immediately after the birth of a Rhesus-positive child, and for preventing, at the time of subsequent pregnancies, hemolytic disease of the newborn (HDN); at the time of abortions or of extra-uterine pregnancies in a situation of Rhesus D incompatibility or else at the time of transplacental hemorrhages resulting from amniocentesis, from chorionic biopsies or from traumatic obstetric manipulations in a situation of Rhesus D incompatibility.
In addition, an antibody of the invention may be used in the case of Rh-incompatible transfusions with blood or labile blood derivatives.
The invention also relates to the use of an antibody of the invention for producing a medicinal product intended for therapeutic use in Idiopathic Thrombocytopenic Purpura (ITP).
The antibodies of the invention are also of use for producing a medicinal product intended for the treatment of cancers by immunotherapy, or for the treatment of infections caused by viral or bacterial pathogenic agents.
An additional aspect of the invention relates to the use of said antibodies in particular for diagnosis. The invention is therefore directed toward a kit comprising an antibody described above.
For the remainder of the description, reference will be made to the legends of the figures presented below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 : ADCC evaluation of F60 and T125 YB2/0 (R270). This figure represents the percentage lysis obtained as a function of the antibody concentration in the presence of 100 and 500 μg/well of TEGELINE™ (LFB, France). A high percentage lysis is obtained for the antibodies according to the invention F60 and T125.
FIG. 2 : Anti-D binding to the receptor (FcγRIII). A high binding index is obtained for the antibodies according to the invention F60 and T125.
FIG. 3 : Construction of the expression vector T125-H26 for expressing the H chain of T125.
FIG. 4 : Construction of the expression vector T125-K47 for expressing the L chain of T125
FIG. 5 : Construction of the expression vector T125-IG24 for expressing the whole antibody T125
FIG. 6 : ADCC inhibition in the presence of anti-FcRIII (CD16)
The ADCC assay is established according to the procedure described in §3.3 in the presence of the commercial anti-CD16 3G8 (TEBU), the action of which is to block the FcRIII receptors present on the effector cells. The final concentration of 3G8 is 5 μg/well (25 μg/ml). A control is carried out in parallel in the absence of 3G8.
The three antibodies tested are Poly-D WinRho, the antibody F60 (Pf 155 99/47) obtained according to the method described in example I, and R297 (Pf 210 01/76) obtained according to the method described in example II.
Results: an inhibition is observed in the presence of 3G8, which demonstrates that the ADCC induced by the three antibodies tested is mainly FcRIII-dependent. A slightly stronger inhibition is observed in the presence of Poly-D WinRho (83% compared to 68% and 61% inhibition for F60 and R297, respectively). This difference may be due to the presence, in the Poly-D, of non-anti-D human IgGs which will inhibit type I receptors (FCR1 or CD64) and therefore act synergistically with the anti-CD 16.
FIG. 7 : Characterization of the anti-D glycans by mass spectrometry (MS).
FIG. 8 : Comparison of the MS spectra for 8290 and DF5.
FIG. 9 : Study of the glycosylation of the anti-D D31DMM by MS.
FIG. 10 : Preferred embodiments of antibodies having a particular glycan structure conferring FcγRIII-dependent effector activity.
FIG. 11 : A preferred embodiment for producing an IgG1 possessing a Kappa light chain.
FIG. 12 : A preferred embodiment for producing an IgG3 possessing a Kappa light chain.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Example 1
Establishing a Heterohybrid Cell Line Producing an Anti-Rh(D) Antibody
1—Production of Lymphoblastoid and Heterohybrid Clones:
1.1—Lymphocyte Source:
The B lymphocyte donor is selected from anti-Rh(D) donors undergoing plasmapheresis, based on the activity of his or her anti-Rh(D) serum antibodies in the ADCC activity assay described in §33. After a whole blood donation, in 1998, the “buffy coat” fraction (leukocyte concentrate) was recovered.
1.2—Immortalization of the B Lymphocytes from the Donor
The peripheral blood mononuclear cells are separated from the other elements by centrifugation on Ficoll Plus (Pharmacia). They are then diluted to 10 6 cell/ml in IMDM containing 20% (v/v) of fetal calf serum (FCS), to which 20% of culture supernatant of the B95-8 line (ATCC-CRL1612), 0.1 μg/ml of cyclosporin A (Sandoz), 50 μg/ml of gentamycin sulfate (Life Technologies) are added, and distributed into round-bottomed 96-well plates or 24-well plates (P24 Greiner). They are then placed in an incubator at 37° C., 7% CO 2 . After 3 weeks, the presence of anti-Rh(D) antibodies is sought by ADCC.
Each one of the 16 microwells of a positive P24 plate well is transferred into a new P24 well. This enrichment is repeated after 10 to 15 days of culturing and each microwell is amplified in a P96 and then in a P24.
The positive P96 wells are taken up and amplified in a flat-bottomed P24 (Nunc). After a few days of culturing, the presence of anti-Rh(D) antibodies is sought by ADCC.
1.3—Enrichment by Immunorosetting (IR):
The cells derived from one or more P24 wells are enriched in specific cells by the formation and separation of rosettes with papain-treated Rh(D)-positive red blood cells: one volume of red blood cells washed in 0.9% NaCl is incubated for 10 minutes at 37° C. with 1 volume of papain (Merck) solution at 1/1 000th (m/v), and then washed 3 times in 0.9% NaCl. The cells were then washed once in Hanks solution, suspended in FCS and mixed with the papain-treated red blood cells in a ratio of 1 cell to 33 red blood cells. The mixture is placed in a cone-bottomed centrifuged tube, centrifuged for 5 minutes at 80 g and incubated for one hour in melting ice. The mixture is then carefully agitated and Ficoll is deposited at the bottom of the tube for separation at 900 g for 20 minutes. The pellet containing the rosettes is hemolyzed in a solution of NH 4 Cl for 5 minutes and the cells are placed in culture again in a P24 containing irradiated human mononuclear cells. After approximately 1 week, the supernatants are evaluated in CELA (paragraph 3.2) and ADCC assays for the presence of anti-Rh(D) antibodies having good activity. A further cycle of enrichment is carried out if the percentage of cells forming rosettes significantly increases compared to the preceding cycle.
1.4—Cloning of the Lymphoblastoid Cells:
The IR-enriched cells are distributed at 5 and 0.5 cells per well in round-bottomed 96-well plates containing irradiated human mononuclear cells.
After approximately 4 weeks of culturing, the supernatants from the wells containing cell aggregates are evaluated by ADCC assay.
1.5—Heterofusion:
The wells from cloning the EBV-transformed cells exhibiting an advantageous ADCC activity are amplified in culture and then fused with the heteromyeloma K6H6-B5 (ATCC CRL-1823) according to the standard PEG technique. After fusion, the cells are distributed, in a proportion of 2×10 4 cells/well, into flat-bottomed P96s containing murine intraperitoneal macrophages and in a selective medium containing aminopterin and ouabain (Sigma).
After 3 to 4 weeks of culturing, the supernatants of the wells containing cell aggregates are evaluated by ADCC assay.
1.6—Cloning of the Heterohybridomas:
Cloning by limiting dilution is carried out at 4, 2 and 1 cell/well in flat-bottomed P96s. After 2 weeks, the microscopic appearance of the wells is examined in order to identify the single clones, and the medium is then renewed. After approximately 2 weeks, the supernatants of the wells containing cell aggregates are evaluated by ADCC assay.
2—History of the Clones Selected:
2.1—Clone producing an IgG1
EBV transformation of the cells of donor d13 made it possible to select a well, designated T125 2A2, on which the following were successively carried out: 2 enrichments, 3 cycles of IR, and cloning at 5 cells/well to give 2 clones:
1) T125 2A2 (5/1)A2 from which the DNA was extracted in order to prepare the recombinant vector; 2) T125 (5/1)A2 which was fused with K6H6-B5 to give F60 2F6 and then, after 5 rounds of cloning, F60 2F6 (5) 4C4, a clone selected for constituting a cell stock prior to preparing libraries.
It is an IgG1 possessing a Kappa light chain. The method is shown in FIG. 11 .
2.2—Clone Producing an IgG3
A line producing an IgG3 was prepared according to the same method as that used to prepare the antibody of IgG1 isotype. The cells of origin originate from a donation of whole blood, from a designated donor, from which the “buffy coat” fraction (leukocyte concentrate) was recovered.
It is an IgG3 possessing a Kappa light chain. The method is shown in FIG. 12 .
3—Methods for Evaluating the Anti-Rh(D) Antibodies:
After purification by affinity chromatography on protein A sepharose (Pharmacia) and dialysis in 25 mM Tris buffer, 150 mM NaCl, pH 7.4, the concentration of the antibody T125 is determined by the ELISA technique. The biological activity in vitro is then measured by the ADCC technique.
3.1—Determination of the IgG Level and of the Isotypes by the ELISA Technique:
Total IgGs
Coating: anti-IgG (Calbiochem) at 2 μg/ml in 0.05M carbonate buffer, pH 9.5, overnight at 4° C. Saturation: dilution buffer (PBS+1% BSA+0.05% Tween 20, pH 7.2), 1 h at ambient temperature. Washing (to be renewed at each step): H 2 O+150 mM NaCl+0.05% Tween 20. Dilution of the samples, in dilution buffer to approximately 100 ng/ml and of the control range made up of LFB polyvalent human IgGs prediluted to 100 ng/ml. Incubation for 2 h at ambient temperature. Conjugate: anti-IgG (Diagnostic Pasteur) diluted to 1/5 000, 2 hours at ambient temperature. Substrate: OPD at 0.5 mg/ml (Sigma) in phosphate-citrate buffer containing sodium perborate (Sigma), 10 minutes in the dark. Reaction stopped with 1N HCl, and read at 492 nm.
Assaying of Kappa Chain
Coating: anti-Kappa (Caltag Lab) at 5 μg/ml in 0.05M carbonate buffer, pH 9.5, overnight at 4° C. Saturation: dilution buffer (PBS+1% BSA+0.05% Tween 20, pH 7.2), 1 h at ambient temperature. The washing (to be renewed at each step): H 2 O+150 mM NaCl+0.05% Tween 20. Dilution of the samples, in dilution buffer, to approximately 100 ng/ml and of the control range made up of the LFB monoclonal antibody AD3T1 (Kappa/gamma 3) prediluted to 100 ng/ml. Incubation for 2 h at ambient temperature. Conjugate: biotinylated anti-Kappa (Pierce) diluted to 1/1 000 in the presence of streptavidin-peroxidase (Pierce) diluted to 1/1 500, 2 hours at ambient temperature. Substrate: OPD at 0.5 mg/ml (sigma) in phosphate-citrate buffer containing sodium perborate (Sigma), 10 minutes in the dark. The reaction is stopped with 1N HCl, and read at 492 nm.
3.2—Specific Assaying of Anti-D by the CELA (Cellular Enzyme Linked Assay) Technique:
This method is used for specifically assaying the anti-D antibodies in particular when this involves a culture supernatant at culturing stages at which other non-anti-D immunoglobulins are present in the solution (early stages after EBV transformation).
Principle: The anti-D antibody is incubated with Rhesus-positive red blood cells and then revealed with an alkaline phosphatase-labeled anti-human Ig.
100 μl of Rh+ red blood cells at 10% diluted in Liss-1% BSA dilution buffer. Dilution of the samples, in dilution buffer, to approximately 500 ng/ml and of the control range made up of a purified monoclonal human anti-D IgG (DF5, LFB) prediluted to 500 ng/ml. Incubation for 45 min at ambient temperature. Washing (to be renewed at each step): H 2 O+150 mM NaCl. Conjugate: anti-IgG alkaline phosphatase (Jackson) diluted to 1/4 000 in PBS+1% BSA, 1 h 30 at ambient temperature. Substrate: PNPP at 1 mg/ml (sigma) in 1M diethanolamine, 0.5 mM MgCl 2 , pH 9.8. The reaction is stopped with 1N NaOH, and read at 405 nm.
3.3—ADCC Technique
The ADCC (antibody-dependent cellular cytotoxicity) technique makes it possible to evaluate the ability of the (anti-D) antibodies to induce lysis of Rh-positive red blood cells, in the presence of effector cells (mononuclear cells or lymphocytes).
Briefly, the red blood cells of an Rh-positive cell concentrate are treated with papain (1 mg/ml, 10 min at 37° C.) and then washed in 0.9% NaCl. The effector cells are isolated from a pool of at least 3 buffy-coats, by centrifugation on Ficoll (Pharmacia), followed by a step of adhesion in the presence of 25% FCS, so as to obtain a lymphocyte/monocyte ratio of the order of 9. The following are deposited, per well, into a microtitration plate (96 well): 100 μl of purified anti-D antibody at 200 ng/ml, 25 μl of Rh+ papain-treated red blood cells (i.e. 1×10 6 ), 25 μl of effector cells (i.e. 2×10 6 ) and 50 μl of polyvalent IgG (Tegeline, LFB, for example) at the usual concentrations of 10 and 2 mg/ml. The dilutions are made in IMDM containing 0.25% FCS. After overnight incubation at 37° C., the plates are centrifuged, and the hemoglobin released into the supernatant is then measured in the presence of a substrate specific for peroxidase activity (2,7-diaminofluorene, DAF). The results are expressed as percentage lysis, 100% corresponding to total red blood cell lysis in NH 4 Cl (100% control), and 0% to the reaction mixture without antibody (0% control).
The specific lysis is calculated as a percentage according to the following formula:
(
OD
sample
-
OD
0
%
control
)
×
100
OD
100
%
control
-
OD
0
%
control
=
%
ADCC
The results given in FIG. 1 show the activity of the antibody produced by the heterohybrid F60 compared to those of the reference antibodies:
the anti-Rh(D) polyclonal antibodies POLY-D LFB 51 and WinRhO W03 (Cangene)=positive controls
the monoclonal antibody DF5 (inactive in vivo on clearance of Rh(D)-positive red blood cells (BROSSARD/FNTS, 1990, not published))=negative control
the IgG1s purified (separated from the IgG3s) from the polyclonal WinRhO W03.
Two concentrations of human IgGs (Tegeline LFB) are used to show that inhibition of activity of the negative control is linked to the binding of competing IgGs to the Fcγ type I receptors.
3.4—FcγRIII(CD16)-Binding Technique:
This assay makes it possible to assess the binding of the anti-Rh(D) antibodies of IgG1 isotype to FcγRIII, and in particular to differentiate IgG3 antibodies. Given the low affinity of this receptor for monomeric IgGs, prior binding of the antibodies to the D antigen is necessary.
Principle: The antibody to be tested (anti-D) is added to membranes of Rh+ red blood cells coated with a microtitration plate, followed by transfected Jurkat cells expressing the FcγRIII receptor at their surface. After centrifugation, the “Rh+ membrane/anti-D/CD16 Jurkat” interaction is visualized by a homogeneous plating of the CD16 Jurkats in the well. In the absence of interaction, the cells are, on the contrary, grouped at the center of the well. The intensity of the reaction is expressed as numbers of +.
Method: 1) Incubation for 1 h at 37° C. of the anti-D antibody (50 μl at 1 μg/ml in IMDM) on a Capture R plate (Immunochim), and then washes in water+0.9% NaCl. Addition of CD16 Jurkat (2×10 6 cells/ml) in IMDM+10% FCS. Incubation for 20 min at 37° C. and then centrifugation and evaluation of cell adhesion (against a control range).
2) Revelation of the anti-D bound to the Capture R plates by an ELISA-type technique using anti-human IgG-peroxidase at 1/5 000 (Sanofi Diagnostics Pasteur) after having lysed the CD16 Jurkat cells with 0.2M Tris-HCl, 6M urea, pH 5.3-5.5. OPD revelation and then reading of optical density (O.D.) at 492 nm.
Expression of results: an arbitrary value of 0 to 3 is allotted as a function of the binding and of the plating of the CD16 Jurkat cells. These values are allotted at each OD interval defined (increments of 0.1). The following are plotted:
either a curve: adhesion of the Jurkat cells (Y) as a function of the amount of anti-D bound to the red blood cell membranes (X).
or a histogram of the “binding indices” corresponding, for each antibody, to the sum of each Jurkat cell binding value (0 to 3) allotted per OD interval (over a portion common to all the antibodies tested).
An example of a histogram is given in FIG. 2 .
The anti-Rh(D) antibodies of IgG1 isotype (F60 and T125 YB2/0) show a binding index close to that of the polyclonal IgG1s (WinRho), whereas the negative control antibodies DF5 and AD1 do not bind. Similarly, the antibody of IgG3 isotype (F41) exhibits a good binding index, slightly less than that of the IgG3s purified from the polyclonal Winrho and greater than that of the antibody AD3 (other IgG3 tested and ineffective in clinical trial, in a mixture with AD1 (Biotest/LFB, 1997, not published).
Example 2
Production of a Recombinant Anti-D Antibody (Ab)
1—Isolation and Amplification of the cDNAs Encoding the Heavy and Light Chains of the Ab
1.1—RNA Extraction and cDNA Synthesis
The total RNAs were extracted from an anti-D Ab-producing clone (IgG G1/Kappa) obtained by EBV transformation: T125 A2 (5/1) A2 (see paragraph 2, example 1).
The corresponding cDNAs were synthesized by reverse transcription of the total RNAs using oligo dT primers.
1.2—Amplification of the Variable Region of the Heavy Chain of T125-A2: VH/T125-A2 Sequence
The VH/T125-A2 sequence is obtained by amplification of the T125-A2 cDNAs using the following primers:
primer A2VH5, located 5′ of the leader region of the VH gene of T125-A2, introduces a consensus leader sequence (in bold) deduced from leader sequences already published and associated with VH genes belonging to the same VH3-30 family as the VH gene of T125-A2; this sequence also comprises an Eco RI restriction site (in italics) and a Kozak sequence (underlined):
A2VH5 (SEQ ID No. 1):
5′-CTCTCC GAATTC GCCGCCACC ATGGAGTTTGGGCTGAGCTGGGT -3′
antisense primer GSP2ANP, located 5′ of the constant region (CH) of T125-A2:
GSP2ANP (SEQ ID No. 2): 5′-GGAAGTAGTCCTTGACCAGGCAG-3′.
1.3—Amplification of the Constant Region of T125-A2: CH/T125-A2 Sequence
The CH/T125-A2 sequence is obtained by amplification of the T125-A2 cDNAs using the following primers:
primer G1, located 5′ of the CH region of T125-A2:
G1 (SEQ ID No. 3):
5′- C CCTCCACCAAGGGCCCATCGGTC-3′
The first G base of the CH sequence is here replaced with a C (underlined) in order to recreate, after cloning, an Eco RI site (see paragraph 2.1.1).
antisense primer H3′Xba, located 3′ of the CH of T125-A2, introduces an Xba I site (underlined) 3′ of the amplified sequence:
H3′Xba (SEQ ID No. 4): 5′-GAGAGG TCTAGA CTATTTACCCGGAGACAGGGAGAG-3'
1.4—Amplification of the Kappa Light Chain: K/T125-A2 Sequence
The entire Kappa chain of T125-A2 (K/T125-A2 sequence) is amplified from the T125-A2 cDNAs using the following primers:
primer A2VK3, located 5′ of the leader region of the VK gene of T125-A2, introduces a consensus sequence (in bold) deduced from the sequence of several leader regions of VK VH genes belonging to the same VK1 subgroup as the VK gene of T125-A2; this sequence also comprises an Eco RI restriction site (in italics) and a Kozak sequence (underlined):
A2VK3 (SEQ ID No. 5):
5′-CCTACC GAATTC GCCGCCACC ATGGACATGAGGGTCCCCGCTCA -3′
antisense primer KSE1, located 3′ of Kappa, introduces an Eco RI site (underlined):
KSE1 (SEQ ID No. 6):
5′-GGTGGT GAATTC CTAACACTCTCCCCTGTTGAAGCTCTT-3′.
FIG. 1 gives a diagrammatic illustration of the strategies for amplifying the heavy and light chains of T125-A2.
2—Construction of Expression Vectors
2.1—Vector for Expressing the Heavy Chain of T125-A2: T125-H26
The construction of T125-H26 is summarized in FIG. 2 . It is carried out in two stages: first of all, construction of the intermediate vector V51-CH/T125-A2 by insertion of the constant region of T125-A2 into the expression vector V51 derived from pCI-neo ( FIG. 3 ) and then cloning of the variable region into V51-CH/T125-A2.
2.1.1—Cloning of the Constant Region of T125-A2
The amplified CH/T125-A2 sequence is inserted, after phosphorylation, at the Eco RI site of the vector V51 ( FIG. 3 ). The ligation is performed after prior treatment of the Eco RI sticky ends of V51 with the Klenow polymerase in order to make them “blunt-ended.”
The primer G1 used for amplifying CH/T125-A2 makes it possible to recreate, after its insertion into V51, an Eco RI site 5′ of CH/T125-A2.
2.1.2—Cloning of the Variable Region of T125-A2
The VH/T125-A2 sequence obtained by amplification is digested with Eco RI and Apa I and then inserted at the Eco RI and Apa I sites of the vector V51-G1/T125-A2.
2.2—T125-A2 Light Chain Vector: T125-K47
The construction of T125-K47 is given in FIG. 4 . The K/T125-A2 sequence obtained by PCR is digested with Eco RI and inserted at the Eco RI site of the expression vector V47 derived from pCI-neo ( FIG. 5 ).
2.3—T125-A2 Heavy and Light Chain Vector: T125-IG24
The construction of T125-IG24 is illustrated diagrammatically in FIG. 6 . This vector, which contains the two transcription units for the heavy and Kappa chains of T125-A2, is obtained by inserting the Sal I-Xho I fragment of T125-K47, containing the transcription unit for K/T125-A2, at the Xho I and Sal I sites of T125-H26.
Thus, the heavy and light chains of T125-A2 are expressed under the control of the CMV promoter; other promoters may be used: RSV, IgG heavy chain promoter, MMLV LTR, HIV, β-actin, etc.
2.4—T125-A2 Heavy and Light Chain Specific Leader Vector: T125-LS4
A second vector for expressing T125-A2 is also constructed, in which the consensus leader sequence of the Kappa chain is replaced with the real sequence of the leader region of T125-A2 determined beforehand by sequencing products from “PCR 5′-RACE” (Rapid Amplification of cDNA 5′ Ends).
The construction of this T125-LS4 vector is described in FIG. 7 . It is carried out in two stages: first of all, construction of a new vector for expressing the T125-A2 Kappa chain, T125-KLS18, and then assembly of the final expression vector, T125-LS4, containing the two heavy chain and modified light chain transcription units.
2.4.1—Construction of the Vector T125-KLS18
The 5′ portion of the Kappa consensus leader sequence of the vector T125-K47 is replaced with the specific leader sequence of T125 (KLS/T125-A2) during a step of amplification of the K/T125-A2 sequence carried out using the following primers:
primer A2VK9, modifies the 5′ portion of the leader region (in bold) and introduces an Eco RI site (underlined) and also a Kozak sequence (in italics):
A2VK9:
5′-CCTACC GAATTC GCCGCCACC ATGAGGGTCCCCGCTCAGCTC -3′
primer KSE1 (described in paragraph 1.4)
The vector T125-KLS18 is then obtained by replacing the Eco RI fragment of T125-K47, containing the K/T125-A2 sequence of origin, with the new sequence KLS/T125-A2 digested via Eco RI.
2.4.2—Construction of the Final Vector T125-LS4
The Sal I-Xho I fragment of T125-KLS18, containing the modified KLS/T125-A2 sequence, is inserted into T125-H26 at the Xho I and Sal I sites.
3—Production of Anti-D Abs in the YB2/0 Line
3.1—Without Gene Amplification
The two expression vectors T125-IG24 and T125-LS4 were used to transfect cells of the YB2/0 line (rat myeloma, ATCC line No. 1662). After transfection by electroporation and selection of transformants in the presence of G418 (neo selection), several clones were isolated. The production of recombinant anti-D Abs is approximately 0.2 μg/10 6 cells/24 h (value obtained for clone 3B2 of R270). The ADCC activity of this recombinant Ab is greater than or equal to that of the poly-D controls ( FIG. 1 ). The Abs produced using the two expression vectors are not significantly different in terms of level of production or of ADCC activity.
3.2—With Gene Amplification
The gene amplification system used is based on the selection of transformants resistant to methotrexate (MTX). It requires the prior introduction of a transcription unit encoding the DHFR (dihydrofolate reductase) enzyme into the vector for expressing the recombinant Ab (SHITARI et al., 1994).
3.2.1—Construction of the Expression Vector T125-dhfr 13
The scheme shown in FIG. 8 describes the construction of the vector for expressing T125-A2, containing the murine dhfr gene.
A first vector (V64) was constructed from a vector derived from pCI-neo, V43 ( FIG. 9 ), by replacing, 3′ of the SV40 promoter and 5′ of a synthetic polyadenylation sequence, the neo gene (Hind III-Csp 45 I fragment) with the cDNA of the murine dhfr gene (obtained by amplification from the plasmid pMT2). This vector is then modified so as to create a Cla I site 5′ of the dhfr transcription unit. The Cla I fragment containing the dhfr transcription unit is then inserted at the Cla I site of T125-LS4.
3.2.2—Selection in the Presence of MTX
1st Strategy:
YB2/0 cells transfected by electroporation with the vector T125-dhfr13 are selected in the presence of G418. The recombinant Ab-producing transformants are then subjected to selection in the presence of increasing doses of MTX (from 25 nM to 25 μM). The progression of the recombinant Ab production, reflecting the gene amplification process, is followed during the MTX selection steps. The MTX-resistant transformants are then cloned by limiting dilution. The level and the stability of the recombinant Ab production are evaluated for each clone obtained. The anti-D antibody productivity after gene amplification is approximately 13 (+/−7) μg/10 6 cells/24 h.
2nd Strategy:
YB2/0 cells transfected by electroporation with vector T125-dhfr13 are selected in the presence of G418. The best recombinant Ab-producing transformants are cloned by limiting dilution before selection in the presence of increasing doses of MTX. The progression of the production by each clone, reflecting the gene amplification process, is followed during the MTX selection steps. The level and the stability of the recombinant Ab production are evaluated for each MTX-resistant clone obtained.
4—Evaluation of the Activity of the T125 Antibody Expressed in YB2/0
After purification by affinity chromatography on protein A Sepharose (Pharmacia) and dialysis into 25 mM Tris buffer, 150 mM NaCl, pH 7.4, the concentration of the T125 antibody is determined by the ELISA technique. The biological activity in vitro is then measured by the ADCC assay described above. The results are given in FIG. 1 .
Example 3
Demonstration of the Relationship Between Glycan Structure and FcγRIII-Dependent Activity
1—Cell Culture in the Presence of Deoxymannojirimycin (DMM)
Several studies describe the effect of enzymatic inhibitors on the glycosylation of immunoglobulins and on their biological activity. An increase in ADCC activity is reported by ROTHMAN et al., 1989, this being an increase which cannot be attributed to an enhancement of the affinity of the antibody for its target. The modification of glycosylation caused by adding DMM consists of inhibition of the α-1,2 mannosidase I present in le Golgi. It leads to the production of a greater proportion of polymannosylated, nonfucosylated structures.
Various anti-Rh(D) antibody-producing lines were brought into contact with DMM and the functional activity of the monoclonal antibodies produced was evaluated in the form of culture supernatants or after purification.
The cells (heterohybrid or lymphoblastoid cells) are seeded at between 1 and 3×10 5 cell/ml, and cultured in IMDM culture medium (Life Technologies) with 10% of FCS and in the presence of 20 μg/ml of DMM (Sigma, Boehringer). After having renewed the medium 3 times, the culture supernatants are assayed by human IgG ELISA and then by ADCC.
TABLE 2
Effect of culturing in the presence of DMM on the ADCC activity of
various anti-Rh(D)s
ADCC activity as % of the
Minimum dose
activity of poly-D LFB51
of DMM
Culture
Culture in the
necessary
Samples
without DMM
presence of DMM
μg/ml
F60
109
113
NT
D31
19
87
10
DF5
26
62
20
T125 RI(3)
3
72
20
T125-CHO
0
105
5
NT—not tested
Culturing in the presence of deoxymannojirimycin (DMM) brings a significant improvement to the ADCC results for the antibodies previously weakly active, produced by:
a human-mouse hybridoma
D31
a human lymphoblastoid line
DF5
a transfected murine line
T125 in CHO
The addition of DMM may make it possible to restore the ADCC activity of an antibody derived from the cloid T125=T125 RI(3) (described in example 1) and which has lost this activity through sustained culturing.
The strong activity of the antibody produced by the heterohybridoma F60 (the production of which is described in example 1) is not modified by culturing in the presence of DMM.
2—Production of Recombinant Anti-D Antibodies by Various Cell Lines:
2.1—Preparation of an Expression Vector for the Antibody DF5:
The nucleotide sequence of the antibody DF5, a negative control in the ADCC assay, is used to study the transfection of this antibody into some lines, in parallel to transfection of the antibody T125.
The sequences encoding the Ab DF5 are isolated and amplified according to the same techniques used for the recombinant Ab T125-A2.
The corresponding cDNAs are first of all synthesized from total RNA extracted from the anti-D Ab-(IgG G1/Lambda)-producing clone 2MDF5 obtained by EBV transformation. Amplification of the heavy and light chains is then carried out from these cDNAs using the primers presented below. Amplification of the variable region of the heavy chain of DF5 (VH/DF5 sequence):
primer DF5VH1, located 5′ of the leader region (in bold) of the VH gene of DF5 (sequence published: L. Chouchane et al.); this primer also comprises an Eco RI restriction site (in italics) and a Kozak sequence (underlined):
DF5VH1 (SEQ ID No. 8):
5′CTCTCC GAATTC GCCGCCACC ATGGACTGGACCTGGAGGATCCTCTT
TTTGGTGG -3′
antisense primer GSP2ANP, located 5′ of the constant region (CH) already described in paragraph 1.2 (example 2).
Amplification of the constant region CH of DF5 (CH/DF5 sequence): primers G1 and H3′Xba already described in paragraph 1.3 (example 2). Amplification of the Lambda light chain of DF5 (LBD/DF5 sequence):
primer DF5VLBD1, located 5′ of the leader region of the VL gene of DF5, introduces a consensus sequence (in bold) deduced from the sequence of several leader regions of VL genes belonging to the same VL1 subgroup as the VL gene of 2MDF5; this sequence also comprises an Eco RI restriction site (in italics) and a Kozak sequence (underlined):
DF5VLBD1 (SEQ ID No. 9):
5′CCTACC GAATTC GCCGCCACC ATGGCCTGGTCTCCTCTCCTCCTC
AC -3′
antisense primer LSE1, located 3′ of Lambda, introduces an Eco RI site (underlined):
LSE1 (SEQ ID No. 10):
5′-GAGGAG GAATTC ACTATGAACATTCTGTAGGGGCCACTGTCTT-3′.
The construction of the vectors for expressing the heavy chain (DF5-H31), light chain (DF5-L10) and heavy and light chains (DF5-IG1) of the Ab DF5 is carried out according to a construction scheme similar to vectors expressing the Ab T125-A2. All the leader sequences of origin (introduced in the amplification primers) are conserved in these various vectors.
2.2—Transfection of Various Cell Lines with the Antibodies T125 and DF5
The three expression vectors T125-IG24, T125-LS4 and DF5-IgG1 are used to transfect cells of various lines: Stable or transient transfections are performed by electroporation or using a transfection reagent.
TABLE 3
Cell lines used for the transfection of anti-Rh(D) antibodies
Name
Reference
Cell type
CHO-K1
ATCC CCL 61
Chinese hamster ovary
(epithelium like)
CHO-Lec10
Fenouillet et al., 1996,
Chinese hamster ovary
Virology, 218, 224-231
(epithelium like)
Jurkat
ATCC TIB-152
Human T lymphocyte
(T leukemia)
Molt-4
ATCC CRL 1582
Human T lymphocyte (acute
lymphoblastic leukemia)
WIL2-NS
ATCC CRL 8155
EBV-transformed human B
lymphocyte
Vero
ATCC CCL 81
African green monkey kidney
(fibroblast like)
COS-7
ATCC CRL 1651
SV40-transformed African green
monkey kidney (fibroblast like)
293-HEK
ATCC CRL 1573
Primary human embryonic
kidney transformed with
defective adenovirus 5 DNA
YB2/0
ATCC CRL 1662
Nonsecreting rat myeloma
BHK-21
ATCC CCL 10
Newborn hamster kidney
(fibroblast like)
K6H6-B5
ATCC CRL 1823
Nonsecreting human-mouse
heteromyeloma
NSO
ECACC 85110503
Nonsecreting mouse myeloma
(lymphoblast like)
SP2/0-Ag 14
ECACC 85072401
Nonsecreting mouse × mouse
hybridoma
CHO Lec-1
ATCC CRL 1735
Chinese hamster ovary
CHO dhfr
ECACC 94060607
Chinese hamster ovary
CHO Pro-5
ATCC CRL 1781
Chinese hamster ovary
P3X63 Ag8.653
ATCC CRL 1580
Nonsecreting mouse myeloma
After selection of the transformants in the presence of G418 (neo selection), several clones were isolated.
The modification of effector activity of a humanized monoclonal antibody as a function of the expressing cell has been described by CROWE et al. (1992), with the CHO, NSO and YB2/0 cell lines.
The results obtained here confirm the importance of the expressing cell line with respect to the functional characteristics of the antibody to be produced. Among the cells tested, only the Vero, YB2/0 and CHO Lec-1 lines make it possible to express recombinant anti-Rh(D) monoclonal antibodies with strong lytic activity in the ADCC assay (see example 1 and table 4).
TABLE 4 ADCC activity of the antibodies DF5 and T125 obtained by transfection into various cell lines. The results are expressed as percentage of the activity of the reference polyclonal antibody: Poly-D LFB 51 Transfected cell lines CHO- CHO- 293- K1 Lec10 Wil-2 Jurkat Vero Molt-4 COS-7 HEK YB2/0 antibodies T125 7 +/− 8 22 +/− 6 3 +/− 5 6 +/− 8 90 +/− 21 0 13 +/− 2 16 +/− 13 114 +/− 28 n = 13 n = 11 n = 12 n = 7 n = 5 n = 1 n = 4 n = 12 n = 54 DF5 NT 51 +/− 19 NT NT 72 +/− 17 NT 21 +/− 4 12 +/− 14 94 +/− 15 n = 3 n = 5 n = 4 n = 12 n = 15 Transfected cell lines CHO- SP2/0- CHO CHO P3X63A NSO BHK Lec1 Ag14 K6H6-B5 Pro-5 dhfr g8.653 antibodies T125 6 +/− 8 13 +/− 5 106 +/− 60 0 +/− 0 9 +/− 8 3 +/− 3 13 +/− 8 34 +/− 8 n = 3 n = 4 n = 4 n = 6 n = 3 n = 4 n = 12 n = 9
3—Study of the Glycan Structures
Characterization of the glycan structures of the anti-Rh-D antibody was carried out on four purified products having an ADCC activity (F60, and three recombinant proteins derived from T125) in comparison with two purified products inactive or very weakly active in the ADCC assay according to the invention (D31 and DF5).
In practice, the oligosaccharides are separated from the protein by specific enzymatic deglycosylation with PNGase F at Asn 297. The oligosaccharides thus released are labeled with a fluorophore, separated and identified by various complementary techniques which allow:
fine characterization of the glycan structures by matrix-assisted laser desorption ionization (MALDI) mass spectrometry by comparison of the experimental masses with the theoretical masses.
determination of the degree of sialylation by ion exchange HPLC (GlycoSep C)
separation and quantification of the oligosacharride forms according to hydrophilicity criteria by normal-phase HPLC (GlycoSep N)
separation and quantification of the oligosaccharides by high performance capillary electrophoresis-laser induced fluorescence (HPCE-LIF).
1) Characterization of the Glycans of Active Forms
The various active forms studied are F60 and three recombinant antibodies, R 290, R 297 and R 270, derived from T125 and produced in YB2/0. Fine characterization of the glycan structures by mass spectrometry ( FIG. 7 ) shows that these forms are all of the bi-antennary type. In the case of R 270, the major form is of the agalactosylated, nonfucosylated type (G0, exp. mass 1459.37 Da, FIG. 1 ). Three other structures are identified: agalactosylated, fucosylated (G0F at 1605.41 Da), monogalactosylated, nonfucosylated (G1 at 1621.26 Da) and monogalactosylated, fucosylated (G1F at 1767.43 Da) in minor amount. These same four structures are characteristic of R 290, F 60 and R 297 ( FIG. 1 ).
These four antibodies which are active in ADCC are also characterized by the absence of oligosaccharides having a bisecting N-acetylglucosamine residue.
Quantification of the glycan structures by the various techniques of HPLC and HPCE-LIF (table 1) confirms the presence of the four forms identified by mass: G0, G0F, G1 and G1F. The degree of sialylation is very low, in particular for the recombinant products, from 1 to 9.4%, which is confirmed by the similarity of the mass spectra obtained before and after enzymatic desilylation. The degree of fucosylation ranges from 34 to 59%.
2) Inactive Forms
The various inactive forms studied are D31 and DF5. Quantification of the glycan structures by the various chromatographic and capillary electrophoresis techniques (table 1) reveals, for these two antibodies, a degree of sialylation close to 50%, and a degree of fucosylation of 88 and 100% for D31 and DF5, respectively. These degrees of sialylation and fucosylation are much higher than those obtained from the active forms.
Characterization of the glycan structures shows that the major form is, for the two antibodies, of the bi-antennary, monosialylated, digalactosylated, fucosylated type (G2S1F, table 1). The characterization by mass spectrometry of D31 ( FIG. 7 ) reveals that the neutral forms are mainly of the monogalactosylated, fucosylated type (G1F at 1767.43 Da) and digalactosylated, fucosylated type (G2F at 1929.66 Da).
The inactive antibody DF5 is characterized by the presence of oligosaccharides having an intercalated GlcNAc residue. In particular, the mass analysis ( FIG. 8 ) reveals the presence of a major neutral form of the monogalactosylated, fucosylated, bisecting, intercalated GlcNAc type (G1FB at 1851.03 Da). On the other hand, these structural forms are undetectable or present in trace amounts on the active antibodies studied.
The ADCC activity of D31 after the action of DMM increases from 10% to 60%. The glycan structures of DMM D31 differ from those of D31 by the presence of oligomannose forms (Man 5, Man 6 and Man 7) (see FIG. 9 ).
3) Conclusion
The various active antibodies are modified on Asn 297 with N-glycosylations of the bi-antennary and/or oligomannoside type. For the bi-antennary forms, this involves short structures with a very low degree of sialylation, a low degree of fucosylation, a low degree of galactosylation and no intercalated GlcNAc.
REFERENCES
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Chouchane, L., Van Spronsen, A., Breyer, J., Guglielmi, P., and Strosberg, A D. Molecular characterization of a human anti-Rh(D) antibody with a DII segment encoded by a germ-line sequence. Eur. J. Biochem. 1; 207(3): 1115-1121 (1992).
Crawford, D. H., Barlow, M. J., Harrison, J. F., Winger, L. and Huehns, E. R. Production of human monoclonal antibody to rhesus D antigen. Lancet, i: 386-388 (1983).
Doyle, A., Jones, T. J., Bidwell, J. L. and Bradley, B. A. In vitro development of human monoclonal antibody secreting plasmacytomas. Hum. Immunol. 13: 199-209 (1985).
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Foung, S. K. H., Blunt, J. A., Wu, P. S., Ahearn, P., Winn, L. C., Engleman, E. G. and Grumet, F. C. Human Monoclonal Antibodies to Rho (D). Vox Sang. 53: 44-47 (1987).
Goossens, D., Champomier, F., Rouger, P., and Salmon, C. Human Monoclonal Antibodies against Blood Group Antigens: Preparation of a series of stable EBV immortalized B clones producing high levels of antibody of different isotypes and specificities. J. Immunol. Methods 101: 193-200 (1987).
Issitt, P. D. Genetics of the Rh Blood Group System: Some Current Concepts. Med. Lab. Sci. 45: 395-404 (1988).
Jefferis, R, Lund, J., Mizutani, H., Nakagawa, H., Kawazoe, Y., Arata, Y. and Takahashi, N. A comparative study of the N-linked oligosaccharides structure of human IgG Subclass proteins. Biochem. J., 268: 529-537 (1990).
Koskimies, S. Human Lymphoblastoid Cell Line Producing Specific Antibody against Rh-Antigen D. Scand. Immunol. 11:73-77 (1980).
Kumpel, B. M., Goodrick, M. J., Pamphilon, D. H., Fraser, I. D., Poole G. D., Morse, C., Standen, G. R., Chapman, G. E., Thomas, D. P. and Anstee, D. J. Human Rh D monoclonal antibodies (BRAD-3 and BRAD-5) Cause Accelerated Clearance of Rh D+ Red blood Cells and Suppression of Rh D Immunization in Rh D Volunteers. Blood, Vol. 86, No. 5, 1701-1709 (1995).
Kumpel, B. M., Poole, G. D. and Bradley, B. A. Human Monoclonal Anti-D Antibodies. I. Their Production, Serology, Quantitation and Potential Use as Blood Grouping Reagents. Brit. J. Haemat. 71: 125-129 (1989a).
Kumpel, B. M., Rademacher, T. W., Rook, G. A. W., Williams, P. J., Wilson, I. B. M. Galacatosylation of human IgG anti-D produced by EBV-transformed B lymphoblastoid cell lines is dependent on culture method and affects Fc receptor mediated functional activity. Hum. Antibodies and Hybridomas, 5: 143-151 (1994).
Leatherbarrow, R. J., Rademacher, T. W., Dwek, R. A., Woof, J. M., Clark, A., Burton, D. R., Richardson, N. and Feinstein, A. Effector functions of monoclonal aglycosylated mouse IgG2a; binding and activation of complement component CI and interaction with human Fc receptor. Molec. Immun. 22, 407-415 (1985).
Lomas, C., Tippett, P., Thompson, K. M., Melamed, M. D. and Hughes-Jones, N. C. Demonstration of seven epitopes on the Rh antigen D using human monoclonal anti-D antibodies and red cells from D categories. Vox Sang. 57: 261-264 (1989).
Lund, J., Takahaski, N., Nakagawa, H., Goodall, M., Bentley, T., Hindley, S. A., Tyler, R. and Jefferis, R. Control of IgG/Fc glycosylation: a comparison of oligosaccharides from chimeric human/mouse and mouse subclass immunoglobulin G5. Molec. Immun. 30, No. 8, 741-748 (1993).
Lund, J., Tanaka, T., Takahashi, N., Sarmay, G., Arata, Y. and Jefferis, R. A protein structural change in aglycosylated IgG3 correlates with loss of hu Fc□RI and Hu FcγRIII binding and/or activation. Molec. Immun. 27, 1145-1153 (1990).
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Mc Cann-Carter, M. C., Bruce, M., Shaw, E. M., Thorpe, S. J., Sweeney, G. M., Armstrong, S. S. and James, K. The production and evaluation of two human monoclonal anti-D antibodies. Transf. Med. 3: 187-194 (1993).
Melamed. M. D., Gordon, J., Ley, S. J., Edgar, D. and Hughes-Jones, N. C. Senescence of a human lymphoblastoid clone producing anti-Rhesus (D) Eur. J. Immunol. 115: 742-746 (1985).
Parekh, R. B., Dwek, R. A., Sutton, B. J., Fernanes, D. L., Leung, A., Stanworth, D., Rademacher, T. W., Mizuochi, T., Taniguchi, T., Matsuta, K., Takeuchi, F.,
Nagano, Y., Miyamoto, T. and Kobata, A. Association of rheumatoid arthritis and primary osteoarthritis with changes in the glycosylation pattern of total serum IgG. Nature, 316: 452-457 (1985).
Rothman, R. J., Perussia, B., Herlyn, D. and Warren, L. Antibody-dependent cytotoxicity mediated by natural killer cells is enhanced by castanospermine-induced alterations of IgG glycosylation. Mol. Immunol. 26(12): 1113-1123 (1989).
Shitara K., Nakamura K., Tokutake-Tanaka Y., Fukushima M., and Hanai N. A new vector for the high level expression of chimeric antibodies to myeloma cells. J. Immunol. Methods 167: 271-278 (1994).
Thompson, K. M., Hough, D. W., Maddison, P. J., Mclamed, M. D. and Hughes-Jones, N. C. Production of human monoclonal IgG and IgM antibodies with anti-D (rhesus) specificity using heterohybridomas. Immunology 58: 157-160 (1986).
Thomson, A., Contreras, M., Gorick, B., Kumpel, B., Chapman, G. E., Lane, R. S., Teesdale, P. Hughes-Jones, N. C. and Mollison, P. L. Clearance of Rh D-positive red cells with monoclonal anti-D. Lancet 336: 1147-1150 (1990).
Tippett, P. Sub-divisions of the Rh(D) antigen. Med. Lab. Sci. 45: 88-93 (1988).
Ware, R. E. and Zimmerman, S. A. Anti-D: Mechanisms of action. Seminars in Hematology, vol. 35, No. 1, supp. 1: 14-22 (1998).
Yu, I. P. C., Miller, W. J., Silberklang, M., Mark, G. E., Ellis, R. W., Huang, L., Glushka, J., Van Halbeek, H., Zhu, J. and Alhadeff, J. A. Structural characterization of the N-Glycans of a humanized anti-CD18 murine immunoglobulin G. Arch. Biochem. Biophys. 308, 387-399 (1994).
Zupanska, B., Thompson, E., Brojer, E. and Merry, A. H. Phagocytosis of Erythrocytes Sensitized with Known Amounts of IgG1 and IgG3 anti-Rh antibodies. Vox Sang. 53: 96-101 (1987). | The invention concerns a method for obtaining and selecting monoclonal antibodies by an ADDC-type test, said antibodies capable of activating type III Fcy receptors and having a particular glycan structure. The inventive anti-D antibodies can be used for preventing Rhesus isoimmunization in Rh negative persons, in particular for haemolytic disease in a new-born baby of for uses such as idiopathic thrombocytopenic pupura 9ITP. | 2 |
RELATED APPLICATIONS
[0001] This application is the division of the U.S. application of Ser. No. 12/123,710 filed May 20, 2008 which claims the benefit of U.S. Provisional Application No. 60/954,708, filed Aug. 8, 2007, which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an optical waveguide device which is widely used for optical communications, optical information processing and other general optics, and to a method of manufacturing the optical waveguide device.
[0004] 2. Description of the Related Art
[0005] In general, optical waveguide devices are configured such that light emitted from a light emitting element is transmitted through an optical waveguide (see, for example, U.S. Pat. No. 5,914,709). Such an optical waveguide device is schematically illustrated in FIG. 5 . In FIG. 5 , the optical waveguide device includes an optical waveguide provided on a substrate 10 , and a light emitting element 50 fixed to the substrate 10 by an adhesive A in spaced relation from one end of the optical waveguide. A light beam L from the light emitting element 50 is incident on one end face of a core 30 of the optical waveguide, then transmitted through the core 30 , and output from the other end face of the core 30 . In FIG. 5 , a reference numeral 20 denotes an under-cladding layer, and a reference numeral 40 denotes an over-cladding layer.
[0006] In the optical waveguide device, however, the adhesive A is liable to protrude to interfere with an optical path when the light emitting element 50 is pressed from the above for bonding thereof.
SUMMARY OF THE INVENTION
[0007] In view of the foregoing, it is an object of the present invention to provide an optical waveguide device which is free from interference with an optical path between a light emitting element and an optical waveguide thereof, and to provide a method of manufacturing the optical waveguide device.
[0008] According to a first aspect of the present invention to achieve the aforementioned object, there is provided an optical waveguide device, which comprises: a light emitting element provided on an upper surface of a first under-cladding layer; a second under-cladding layer provided on the upper surface of the first under-cladding layer, covering the light emitting element; and a core provided on an upper surface of the second under-cladding layer in a position such that light emitted from the light emitting element is incident on the core, the core being adapted to receive the emitted light through the second under-cladding layer.
[0009] According to a second aspect of the present invention, there is provided an optical waveguide device manufacturing method, which comprises the steps of: placing a light emitting element on an upper surface of a first under-cladding layer; forming a second under-cladding layer on the upper surface of the first under-cladding layer to cover the light emitting element; and forming a core on an upper surface of the second under-cladding layer in a position such that light emitted from the light emitting element is incident on the core, the core being adapted to receive the emitted light through the second under-cladding layer.
[0010] The inventors of the present invention conducted studies on the construction of the optical waveguide device to eliminate the interference with the optical path between the light emitting element and the optical waveguide in the optical waveguide device. As a result, the inventors came up with an idea of burying and fixing the light emitting element in an under-cladding underlying the core to allow the core to receive light emitted from the light emitting element through the under-cladding, and further conducted experiments and studies. Consequently, the inventors attained the present invention, in which the aforementioned object is achieved based on this idea.
[0011] In the inventive optical waveguide device, the light emitting element is provided on the upper surface of the first under-cladding layer, and the second under-cladding layer is provided on the upper surface of the first under-cladding layer, covering the light emitting element. Therefore, the light emitting element is buried and fixed in an under-cladding configured as a laminate of the first under-cladding layer and the second under-cladding layer. This obviates the use of an adhesive for the fixing of the light emitting element, or eliminates the possibility of protrusion of the adhesive from the periphery of the light emitting element if a very small amount of the adhesive is used for tentatively fixing the light emitting element on the upper surface of the first under-cladding layer prior to the formation of the second under-cladding layer. The inventive optical waveguide device ensures proper light transmission between the light emitting element and the core without the possibility that the adhesive interferes with the optical path. Further, the light emitted from the light emitting element is received on a bottom surface of the core through the second under-cladding layer, so that the core has a greater light receiving area than in the conventional case in which the light is received by the one end face of the core. Thus, the light transmission is more reliably achieved.
[0012] Particularly, one end portion of the core serves as a light receiving portion for receiving the light emitted from the light emitting element, and an end surface of the light receiving portion is inclined at an angle of 45 degrees with respect to the bottom surface of the core. Further, the light emitted from the light emitting element is projected at an angle of 45 degrees with respect to the inclined surface. In this case, the light emitted from the light emitting element is reflected on the inclined surface, whereby the optical path is efficiently deflected to extend longitudinally of the core. Thus, the light transmission efficiency is improved.
[0013] In the inventive optical waveguide device manufacturing method, the light emitting element is placed on the upper surface of the first under-cladding layer, and then the second under-cladding layer is formed on the upper surface of the first under-cladding layer to cover the light emitting element. Thereafter, the core which receives the light emitted from the light emitting element through the second under-cladding layer is formed on the upper surface of the second under-cladding layer in the position such that the light emitted from the light emitting element is incident on the core. Therefore, the inventive optical waveguide device can be provided, which ensures proper and highly reliable light transmission.
[0014] A light-receiving end surface of the core is formed inclined at an angle of 45 degrees with respect to the bottom surface of the core, and positioned so that the light emitted from the light emitting element is projected at an angle of 45 degrees with respect to the inclined surface. In this case, the light emitted from the light emitting element is reflected on the inclined surface, whereby the optical path is efficiently deflected to extend longitudinally of the core. Thus, the optical waveguide device is improved in light transmission efficiency.
[0015] Where one end portion of the core is cut by moving a blade having an edge angle of 90 degrees along a light projection axis of the light emitting element for the formation of the inclined light-receiving end surface of the core, the blade can be easily positioned. This makes it possible to accurately and easily position the inclined surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a sectional view schematically illustrating an optical waveguide device according to one embodiment of the present invention.
[0017] FIGS. 2( a ) to 2 ( f ) are explanatory diagrams schematically showing an optical waveguide device production method according to the present invention.
[0018] FIG. 3 is an explanatory diagram schematically illustrating a modification of the optical waveguide device production method.
[0019] FIG. 4 is an explanatory diagram schematically illustrating a modification of the optical waveguide device.
[0020] FIG. 5 is a sectional view schematically illustrating a conventional optical waveguide device.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0021] Embodiments of the present invention will hereinafter be described in detail with reference to the attached drawings.
[0022] FIG. 1 illustrates an optical waveguide device according to one embodiment of the present invention. In this embodiment, the optical waveguide device is provided on an upper surface of a substrate 1 . In the optical waveguide device, a light emitting element 5 is buried and fixed in an under-cladding 2 including a first under-cladding layer (lower layer) 21 and a transparent second under-cladding layer (upper layer) 22 stacked one on the other, and a core 3 serving as a path of a light beam L is provided in a predetermined pattern on an upper surface of the second under-cladding layer 22 . In this embodiment, an over-cladding layer 4 is provided which covers the core 3 . The light emitting element 5 is adapted to project the light beam L vertically upward, and one end portion of the core 3 serving as a light receiving portion is positioned just above the light emitting element 5 . An end surface 3 a of the light receiving portion is inclined at an angle of 45 degrees with respect to a bottom surface of the core 3 . In FIG. 1 , a reference character 5 a denotes a lead frame having one end portion on which the light emitting element 5 is fixed, and the other end portion provided with terminals (wiring connection portions) 5 b connected to the light emitting element 5 . Further, a reference character H denotes a cut hole which is formed by means of a rotary blade D (see FIG. 2( f )) for forming the inclined surface 3 a on the light receiving portion.
[0023] The light beam L projected vertically upward from the light emitting element 5 passes through the second under-cladding layer 22 , and is incident on a bottom surface of the one end portion of the core 3 to enter the core 3 . Then, the light beam L is reflected on the inclined surface 3 a at an angle of 45 degrees, whereby an optical path is deflected to extend longitudinally of the core 3 . Then, the light beam L travels along the length of the core 3 , and is output from the other end surface of the core 3 .
[0024] An exemplary production method for the optical waveguide device will be described.
[0025] First, a planar substrate 2 (see FIG. 2( a )) is prepared. The substrate 1 is not particularly limited, but exemplary materials for the substrate 1 include glass, quartz, silicon, resins and metals. The thickness of the substrate 1 is not particularly limited, but is typically in the range of 20 μm to 5 mm.
[0026] In turn, a first under-cladding layer 21 is formed in a predetermined region of an upper surface of the substrate 1 as shown in FIG. 2( a ). Examples of a material for the formation of the first under-cladding layer 21 include photosensitive resins, polyimide resins and epoxy resins. The formation of the first under-cladding layer 21 is achieved in the following manner. A varnish prepared by dissolving any of the aforementioned resins in a solvent is applied on the substrate 1 . The application of the varnish is achieved, for example, by a spin coating method, a dipping method, a casting method, an injection method, an ink jet method or the like. Then, the varnish is cured. Where a photosensitive resin is employed as the material for the formation of the first under-cladding layer 21 , the curing is achieved by exposing the applied varnish to radiation. An exposed portion of the varnish serves as the first under-cladding layer 21 . Where a polyimide resin is employed as the material for the formation of the first under-cladding layer 21 , the curing is typically achieved by a heat treatment at 300° C. to 400° C. for 60 to 180 minutes. The thickness of the first under-cladding layer 21 is typically in the range of 5 to 50 μm. Thus, the first under-cladding layer 21 is formed.
[0027] Next, a light emitting element 5 is placed together with a lead frame 5 a in a predetermined position on an upper surface of the first under-cladding layer 21 as shown in FIG. 2( b ). At this time, terminals (wiring connection portions) 5 b provided on the other end portion of the lead frame 5 a are positioned outward of an edge of the first under-cladding layer 21 . The placement of the light emitting element 5 may be achieved with the use of no adhesive or with the use of a very small amount of an adhesive for tentative fixing thereof. This is because the light emitting element 5 is fixed in the subsequent step (see FIG. 2( c )), in which a transparent second under-cladding layer 22 is formed on the upper surface of the first under-cladding layer 21 in the same manner as in the formation of the first under-cladding layer 21 to cover the light emitting element 5 . Examples of a material for the formation of the second under-cladding layer 22 include those employed as the material for the formation of the first under-cladding layer 21 , but a transparent one is selected from those materials. Typically employed as the light emitting element 5 is a light emitting diode, a laser diode, a VCSEL (Vertical Cavity Surface Emitting Laser) or the like.
[0028] Thus, the light emitting element 5 is buried and fixed in an under-cladding 2 configured as a laminate of the first under-cladding layer 21 and the second under-cladding layer 22 as shown in FIG. 2( c ). In this state, the terminals (wiring connection portions) 5 b of the light emitting element 5 are exposed out of an end face of the under-cladding 2 .
[0029] Subsequently, a core 3 is formed on an upper surface of the second under-cladding layer 22 as shown in FIG. 2( d ). At this time, one end portion of the core 3 is positioned just above the light emitting element 5 . A material for the formation of the core 3 is typically a photosensitive resin, which has a greater refractive index than the material for the formation of the second under-cladding layer 22 and a material for formation of an over-cladding layer 4 (see FIG. 2( e )) to be described later. The refractive index may be adjusted, for example, by selection of the types of the materials for the formation of the second under-cladding layer 22 , the core 3 and the over-cladding layer 4 and adjustment of the composition ratio thereof. The formation of the core 3 is achieved in the following manner. A varnish prepared by dissolving the photosensitive resin in a solvent is applied on the under-cladding layer 22 in the same manner as described above. The application of the varnish is achieved in the same manner as described above, for example, by a spin coating method, a dipping method, a casting method, an injection method, an ink jet method or the like. Then, the varnish is dried to form a resin layer. The drying is typically achieved by a heat treatment at 50° C. to 120° C. for 10 to 30 minutes.
[0030] Then, the resin layer is exposed to radiation through a photo mask (not shown) formed with an opening pattern corresponding to a pattern of the core 3 . An exposed portion of the resin layer serves as the core 3 after an unexposed portion removing step. More specifically, examples of the radiation for the exposure include visible light, ultraviolet radiation, infrared radiation, X-rays, α-rays, β-rays and γ-rays. Preferably, the ultraviolet radiation is used. The use of the ultraviolet radiation permits irradiation at a higher energy to provide a higher curing speed. In addition, a less expensive smaller-size irradiation apparatus can be employed, thereby reducing production costs. Examples of a light source for the ultraviolet radiation include a low-pressure mercury-vapor lamp, a high-pressure mercury-vapor lamp and an ultra-high-pressure mercury-vapor lamp. The dose of the ultraviolet radiation is typically 10 to 10000 mJ/cm 2 , preferably 50 to 3000 mJ/cm 2 .
[0031] After the exposure, a heat treatment is performed to complete a photoreaction. The heat treatment is performed at 80° C. to 250° C., preferably at 100° C. to 200° C., for 10 seconds to two hours, preferably for five minutes to one hour. Thereafter, a development process is performed by using a developing agent to dissolve away an unexposed portion of the resin layer. Thus, the remaining portion of the resin layer has the pattern of the core 3 . Exemplary methods for the development include an immersion method, a spray method and a puddle method. Examples of the developing agent include an organic solvent and an organic solvent containing an alkaline aqueous solution. The developing agent and conditions for the development are properly selected depending on the composition of the photosensitive resin.
[0032] Then, the developing agent in the remaining resin layer having the pattern of the core 3 is removed by a heat treatment. The heat treatment is typically performed at 80° C. to 120° C. for 10 to 30 minutes. The remaining resin layer thus patterned serves as the core 3 . The core 3 typically has a thickness of 5 to 30 μm, and typically has a width of 5 to 30 μm.
[0033] Then, as shown in FIG. 2( e ) r an over-cladding layer 4 is formed on the upper surface of the second under-cladding layer 22 to cover the core 3 . Examples of a material for the formation of the over-cladding layer 4 include those employed as the materials for the first and second under-cladding layers 21 , 22 . The material for the formation of the over-cladding layer 4 may be the same as or different from the materials for the formation of the first and second under-cladding layers 21 , 22 . The formation of the over-cladding layer 4 is achieved in the same manner as the formation of the first or second under-cladding layer 21 , 22 . The thickness of the over-cladding layer 4 is typically 20 to 100 μm.
[0034] Further, the terminals (wiring connection portions) 5 b of the light emitting element 5 are respectively connected to wirings 6 by a wire bonding method or the like.
[0035] Then, the one end portion of the core 3 is cut by moving a disk-shaped rotary blade D having an edge angle of 90 degrees downward toward the bottom surface of the core 3 from above the over-cladding layer 4 while rotating the rotary blade D. Thus, the core 3 has a surface 3 a inclined at an angle of 45 degrees with respect to the bottom surface of the core 3 .
[0036] Thus, the optical waveguide device (see FIG. 1 ) including the under-cladding 2 having the light emitting element 5 buried therein, the core 3 and the over-cladding layer 4 is produced on the upper surface of the substrate 1 .
[0037] In the embodiment described above, when the one end portion of the core 3 is cut, the light beam L is projected vertically upward from the light emitting element 5 as shown in FIG. 3 . At this time, the projected light may be employed as a reference, and the rotary blade D may be moved down in an arrow direction X along a light projection axis (with a rotating surface of the rotary blade D being oriented along the light projection axis) for the cutting. For the cutting, the rotary blade D is positioned so that a generally middle portion of the inclined surface 3 a to be formed intersects the light projection axis (in FIG. 3 , a widthwise center of the rotary blade D is illustrated as being offset to the left side from the light projection axis). By employing the light projection as the reference, the positioning of the rotary blade D for the cutting is facilitated, so that the inclined surface 3 a can be more accurately and easily positioned.
[0038] In the embodiment described above, the light beam is projected vertically upward from the light emitting element 5 , and the end surface 3 a of the core 3 inclined at an angle of 45 degrees is positioned just above the light emitting element 5 . However, this arrangement is not limitative. For example, the light beam may be projected obliquely upward from the light emitting element 5 , and a portion (light receiving portion) of the core 3 may be positioned with respect to the light projection axis in an optical waveguide device as shown in FIG. 4 . That is, an intermediate portion (light receiving portion) of the core 3 is positioned obliquely upward of the light emitting element 5 with respect to the light projection axis in the optical waveguide device shown in FIG. 4 . In this optical waveguide device, the light beam L is incident on the portion (light receiving portion) of the core 3 , and travels longitudinally in the core 3 while being repeatedly reflected in the core 3 . In this case, there is no need to form the inclined surface 3 a (see FIG. 1 ) on the one end portion of the core 3 .
[0039] The over-cladding layer 4 is provided in the embodiments described above (see FIGS. 1 and 4 ), but the over-cladding layer 4 is not essential. The optical waveguide device may be configured without the provision of the over-cladding layer 4 .
[0040] Next, an inventive example will be described. However, the present invention is not limited to the example.
Example
Material for Formation of First and Second Under-Cladding Layers and Over-Cladding Layer
[0041] A material for formation of first and second under-cladding layers and an over-cladding layer was prepared by mixing 35 parts by weight of bisphenoxyethanolfluorenediglycidyl ether (Component A), 40 parts by weight of 3′,4′-epoxycyclohexylmethyl-3,4-epoxycyclohexane carboxylate which is an alicyclic epoxy resin (CELLOXIDE 2021P manufactured by Daicel Chemical Industries, Ltd.) (Component 13), 25 parts by weight of (3′,4′-epoxycyclohexane)methyl-3′,4′-epoxycyclohexyl-carboxylate (CELLOXIDE 2081P manufactured by Daicel Chemical Industries, Ltd.) (Component C), and 1 part by weight of a 50% propione carbonate solution of 4,4′-bis[di(β-hydroxyethoxy)phenylsulfinio]phenylsulfide bishexafluoroantimonate (photoacid generator, Component D).
Material for Formation of Core
[0042] A material for formation of a core was prepared by dissolving 70 parts by weight of the aforementioned component A, 30 parts by weight of 1,3,3-tris{4-[2-(3-oxetanyl)]butoxyphenyl}butane and 0.5 part by weight of the aforementioned component D in 28 parts by weight of ethyl lactate.
Production of Optical Waveguide Device
[0043] The first under-cladding layer material was applied on an upper surface of a glass substrate (having a thickness of 1.0 mm) by a spin coating method, and then irradiated with ultraviolet radiation at 2000 mJ/cm 2 . Subsequently, a heat treatment was performed at 100° C. for 15 minutes, whereby a first under-cladding layer (having a thickness of 15 μm) was formed.
[0044] Next, a light emitting diode was tentatively fixed to an upper surface of the first under-cladding layer with the use of a very small amount of a UV-curable adhesive.
[0045] Then, a second under-cladding layer (having a thickness of 10 μm) was formed on the upper surface of the first under-cladding layer in the same manner as in the formation of the first under-cladding layer to cover the light emitting diode.
[0046] Subsequently, the core material was applied on an upper surface of the second under-cladding layer by a spin coating method, and dried at 100° C. for 15 minutes. In turn, a synthetic quartz photo mask having an opening pattern conformable to a core pattern was placed above the resulting core material film. After the core material film was exposed to ultraviolet radiation emitted from above at 4000 mJ/cm 2 by a contact exposure method, a heat treatment was performed at 120° C. for 15 minutes. Subsequently, a development process was performed by using a γ-butyrolactone aqueous solution to dissolve away an unexposed portion, and then a heat treatment was performed at 120° C. for 30 minutes, whereby a core (having a sectional size of 12 μm (width)×24 μm (height)) was formed.
[0047] In turn, the over-cladding layer material was applied on the second under-cladding layer to cover the core by a spin coating method, and then irradiated with ultraviolet radiation at 2000 mJ/cm 2 . Subsequently, a heat treatment was performed at 150° C. for 60 minutes. Thus, an over-cladding layer (having a thickness of 35 μm) was formed.
[0048] Then, wirings were respectively connected to terminals of the light emitting diode by a wire bonding method.
[0049] Subsequently, light was projected vertically upward from the light emitting diode and, in this state, a rotary blade having an edge angle of 90 degrees was moved down from above the over-cladding layer along a light projection axis by means of a dicing machine (Model 522 available from Disco Corporation) to cut one end portion of the core at an angle of 45 degrees with respect to a bottom surface of the core to form an inclined surface on the one end portion.
[0050] Thus, an optical waveguide device including the under-cladding having the light emitting diode buried therein, the core and the over-cladding layer was produced on the substrate.
[0051] Although a specific form of embodiment of the instant invention has been described above and illustrated in the accompanying drawings in order to be more clearly understood, the above description is made by way of example and not as a limitation to the scope of the instant invention. It is contemplated that various modifications apparent to one of ordinary skill in the art could be made without departing from the scope of the invention which is to be determined by the following claims. | An optical waveguide device which is free from interference with an optical path between a light emitting element and an optical waveguide thereof, and to provide a method of manufacturing the optical waveguide device. A light emitting element ( 5 ) is provided on an upper surface of a first under-cladding layer ( 21 ), and a second under-cladding layer ( 22 ) is provided on the upper surface of the first under-cladding layer ( 21 ), covering the light emitting element ( 5 ). A core 3 which receives light emitted from the light emitting element ( 5 ) through the second under-cladding layer ( 22 ) is provided on an upper surface of the second under-cladding layer ( 22 ). The core ( 3 ) is located in a position such that the light emitted from the light emitting element ( 5 ) is incident on the core ( 3 ). | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a National Phase Patent Application of International Application Number PCT/GB01/03274, filed on Jul. 23, 2001, which claims priority of British Patent Application Number 0017976.2, filed Jul. 22, 2000.
FIELD OF THE INVENTION
This invention relates generally to the production of X-rays, and in particular, but not exclusively it relates to a compact X-ray source.
BACKGROUND OF THE INVENTION
A typical X-ray source comprises a thermionic source (typically a heated filament), a high-voltage supply to accelerate the electrons to a high energy, and a target made of a high atomic number metal.
FIG. 1 depicts a simple schematic diagram of a very basic and conventional X-ray source, although it will be realised that, in practice, much more complex arrangements are generally used, including the use of additional electrodes and magnetic fields to control and focus the electron beam
Electrons are emitted thermionically from a hot cathode filament 30 under the action of an isolated heater supply 10 and are attracted to a metal target 70 via an intervening anode 60 . The electrons are accelerated in a beam 50 towards the target due to a high potential difference between the filament and the anode/target arrangement established by means of a high voltage supply 20 . On striking the target 70 the electrons stimulate X-ray emission by various processes, resulting in the emission of an X-ray beam 80 .
Since it is desirable for the anode and target to be at, or substantially near, ground potential, the cathode filament must be at a very high negative potential with respect to ground Moreover, the cathode filament requires several watts of power to reach operable temperatures.
FIG. 2 shows a typical X-ray source arrangement where a cathode filament 30 is heated by a voltage supplied from an isolating transformer 11 . Typically the voltage is between 2V and 6V, whilst the electrons are accelerated by a high voltage supplied from a multiplier 90 , known as a Cockcroft-Walton voltage multiplier. The high voltage maybe in the range of hundreds of kilovolts, for example 160 kV.
It is often required to construct an X-ray source that is compact, and this requirement introduces or exacerbates various problems, for example those associated with providing accurate and effective control over the electron beam current, particularly where the source is desired to be capable of operating reliably with a low radiation output, and those associated with achieving sufficient insulation between various components.
Control over the current of the electron beam 50 is usually desirable with X-ray sources in general and, in low performance X-ray sources, this is frequently achieved merely by varying the temperature of the filament; relying upon the principle that a hotter filament emits more current than does a cooler one. In higher performance systems, exemplified in very basic form in FIG. 3 , this is achieved by controlling the beam in the space charge limited regime by means of a field control electrode 40 , often referred to as a focusing cup or Wehnelt. Such a focusing cup 40 is required to be at a negative potential with respect to the cathode filament in much the same way as the grid in a thermionic triode valve. The required potential can be supplied by either an electrically isolated bias supply, or self-biasing using a feedback resistor 120 between cathode filament 30 and focus cup 40 . Current passing through the feedback resistor generates the required negative bias. However, such a negative feedback system has the drawback that it is difficult to adjust.
When conventional X-ray sources are required to operate at low electron beam current levels, a problem occurs in that electron current leakage from the cathode and focus cup becomes significant compared to the total electron beam current. Often this problem arises from cold cathode discharge (field emission), ‘surface tracking’ or other such problematic phenomena. Conventional X-ray sources measure the electron beam current with a current sensing circuit located at the end of the high voltage supply that is at ground potential (shown schematically as 25 in FIG. 4 ). A problem then arises in that any current measurement at this point in the system cannot differentiate between the actual thermionic electron beam current and the leakage current. This inability to
separate the level of current leakage from the overall current measurement leads to variations in X-ray output since accurate control over the true electron beam current is not possible. Particularly where low radiation output levels are called for, variations in the measured electron beam current due to spurious factors such as those mentioned above can have a significant and adverse effect upon the radiation output levels and stability of operation.
Another problem with conventional X-ray sources arises from the high voltages required to accelerate the electron beam. When employing such extreme potential differences, there is always a risk of an electrical discharge or breakdown. When such phenomena occur, rapidly changing electromagnetic fields arise. Such fields induce large currents to instantaneously flow within the electronic circuitry of the X-ray source, and these currents can damage or destroy circuit components leading to X-ray source failure. A common solution to this problem is to enclose all susceptible components and circuitry within a Faraday shield to protect them from any rapidly changing fields.
In known X-ray sources, the integrity of the Faraday shield is compromised by the need to leave a conduit through which power and signals can be introduced into the circuitry. The break in the shield to provide a signal path also provides a pathway for signal interference during a high voltage breakdown. The integrity of the shield is particularly compromised by the use of isolating transformers that are generally used to introduce power and signals into the Faraday shield.
The present invention arose in an attempt to address some or all of the above problems.
SUMMARY OF THE INVENTION
According to one aspect of the present invention there is provided an X-ray source comprising: a high voltage power source; a cathode filament coupled to said high voltage power source; an active variable conductance device connected between the cathode filament and the high voltage power source; means for determining the amount of current flowing into said cathode filament through said variable conductance device and for providing a signal indicative thereof; and control means for utilising said signal to control said amount of current, thereby to control the current of an electron beam emitted from said cathode.
This current control arrangement differs significantly, in concept and effect, from conventional circuit schemes, which typically employ a separate DC supply for the grid voltage, floating at cathode potential. The voltage levels of such supplies require accurate control and stabilisation. It has been proposed in U.S. Pat. No. 5,528,657 to use such a series-regulating element to control the operative high voltage (anode/cathode) level, but this document does not teach series regulated control of the grid voltage level. The present invention also differs substantially, in concept and effect, from circuit arrangements for pulsed grid X-ray tubes, such as those disclosed in Japanese patent application No. 59132599. This document teaches the use of a transistor as a switch in the grid circuit to effect fast beam-switching with minimal overshoot and distortion of the current pulse.
Preferably, the active variable conductance device is a transistor, for example either a field effect transistor (FEI) or a bipolar transistor.
The active variable conductance device may alternatively comprise one or more light dependent resistors.
The control means advantageously comprises fibre optics and electro-optical devices, or any other optical link.
By using an active variable conductance device instead of a passive resistor as in the prior art, control over the electron beam current is greatly facilitated. Preferably, an optical link is used to control the variable conductance device, thereby reducing the risk of electromagnetic interference.
In a preferred embodiment, a current detector for detecting the current flow between the high voltage supply and the cathode filament is provided, either between the output of the high voltage power supply and the active variable conductance device or between the active variable conductance device and the cathode filament.
By measuring the current at this point, rather than at the ground end of the high voltage power source, discrimination between the true thermionic emission from the filament and all other forms of leakage current becomes possible. Hence the true thermionic emission current can be measured and controlled.
In accordance with a second aspect of the present invention, there is provided an X-ray source comprising a Faraday shield, in which electrical circuitry is housed, a high voltage power supply and an isolating transformer, wherein the isolating transformer is coaxially shielded; the shielding forming a continuation of the Faraday shield.
The isolating transformer is preferably in electrical connection with both an electron accelerating means and a cathode filament transformer, or other cathode filament supply means.
The first and second aspects of the invention are valuable individually, but a preferred embodiment comprises an X-ray source including both aspects of the invention.
The invention further provides an X-ray source or apparatus including any one or more of the novel features described or claimed herein.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will now be described, by way of example only, and with reference to the accompanying schematic drawings, in which:
FIG. 1 shows a conventional X-ray source circuit arrangement;
FIG. 2 shows conventional cathode filament heating in an X-ray source incorporating a high voltage multiplier circuit and isolating heater transformer;
FIG. 3 shows an X-ray source utilising negative feedback biasing;
FIG. 4 shows an embodiment of an X-ray source in accordance with one example of the first aspect of the present invention;
FIG. 5 shows a further embodiment of an X-ray source in accordance with another example of the first aspect of the present invention;
FIG. 6 shows an embodiment of an X-ray source in accordance with one example of the second aspect of the present invention;
FIG. 7 shows a further embodiment of an X-ray source in accordance with another example of the second aspect of the present invention; and
FIG. 8 shows a preferred embodiment of an X-ray source incorporating examples of both aspects of the invention.
In all of FIGS. 1 to 7 , identical reference numbers are used throughout to indicate similar components and features. In FIG. 8 , however, features and components directly comparable with those in FIGS. 1 to 7 are given reference numbers increased by 200 over those used in the earlier figures.
DETAILED DESCRIPTION
In the conventional X-ray source shown in FIG. 1 , a cathode filament 30 is connected to an isolated power supply 10 . Encircling the cathode filament 30 , and connected to a high voltage supply 20 , is a focusing cup 40 . In operation, an electron beam 50 is accelerated through an annular anode 60 and focused onto a metal target 70 from which X-rays 80 radiate. The power supply 10 typically comprises an isolating step-down transformer (shown in FIG. 2 as 11 ), supplying around 6V to heat the cathode filament 30 .
FIG. 2 shows a conventional X-ray source including a high voltage multiplier circuit 90 connected to the focusing cup 40 . Here, an isolating transformer 11 is shown connected to the cathode filament 30 . The multiplier 90 is otherwise known as a Cockcroft-Walton voltage multiplier 90 . Most modem X-ray sources use this type of multiplier, the functioning of which is well known to persons skilled in the art.
Included in the conventional X-ray source shown in FIG. 3 is a variable feedback resistor 120 , which is connected between the cathode filament 30 and the focusing cup 40 . This configuration provides negative biasing to the focusing cup 40 , thus ensuring that it remains at a negative potential as compared to the potential of the cathode filament 30 . Biasing is essential if the focusing cup is to provide space-charge control of the electron beam current and is often alternatively provided by an isolated negative bias supply.
A problem arising from the X-ray source of FIG. 3 stems from the difficulties associated with safely and precisely varying the value of the feedback resistor in order to maintain optimal control of the beam current. An embodiment of an X-ray source in accordance with the first aspect of the invention is shown in FIG. 4 . Here, instead of a feedback resistor, an active variable conductance device 130 is employed. This device maybe a field effect transistor (FET) for example. Alternatively, a light dependent resistor (LDR) controlled by an optical link to vary the conductance can be used. Indeed, the reader will be aware that there are many other devices that may be suitable for the particular requirements of an application.
In the X-ray source of FIG. 4 , the variable conductance device 130 is a bipolar transistor, controlled (by one of a variety of known methods) by a control circuit 140 in response to control signals 150 . In the case where optical control is used, control signals 150 will be passed by one of a choice of known optical links such as a conventional fibre optic cable and transduced by suitable electro-optical devices such as light-emitting diodes (LEDs) and photodiodes. In this way it is possible to provide precise dynamic and inertialess control of the electron beam current.
In a further embodiment of an X-ray source according to the first aspect of the arrangement, as shown in FIG. 5 , a current sensing circuit 160 is employed to provide a measurable indication of the electron beam current. This circuit can include an LED, the luminance of which is directly proportional to the amplified electron beam current. The circuit generates control signals 170 that are used in feedback control of the variable conductance device 130 , through control signals 150 and associated control circuit 140 . (This feedback loop is shown schematically by the broken line 155 ). In practice, other components may be included in the feedback loop, and these components may include ground circuitry 156 , so that signal 170 returns to ground and signal 150 is transmitted from ground. The current sensing circuit 160 is shown between the high voltage supply and the active conductance device. This current sensing circuit could instead be at a position indicated by 160 A, between the active conductance device 130 and the filament 30 .
The advantage of the above embodiment is that, in measuring the current flow at a point in the circuit shown in FIG. 5 by circuit 160 (or alternatively 160 A), it is possible to differentiate accurately between the thermionic current flow and the leakage current which, as described earlier, can be influenced by many extraneous factors. Measured current values can then be used in a feedback control loop via optic link 150 to facilitate optimal adjustment of the biasing level. The current sensitive circuit 160 may take many different forms, and may be optical or electronic or otherwise. Many such means will be apparent to the skilled reader.
As discussed above, it is conventional to enclose all sensitive circuitry and components in a Faraday shield. However, it is not normally possible to completely electrically screen the components from potentially damaging electromagnetic fields, since a break in the Faraday shield is necessary to allow access to the circuit for power lines, control inputs etc.
Referring to FIGS. 6 and 7 , a transformer primary winding 180 is coupled to a transformer secondary winding 190 via a transformer core 200 . The transformer secondary winding 190 feeds power into circuitry within a Faraday shield 210 .
In an embodiment of the second aspect of the invention, a toroidal metal sheath 193 surrounds the transformer secondary winding 190 , and extends as a tube 194 from the secondary circuit 190 towards the main Faraday shield 210 . For practical shielding purposes, the toroidal sheath 193 and tube 194 form an integral part of the Faraday shield 210 . Tube 194 serves as a conduit, screening wires 195 connecting (or continuing) winding 190 to circuitry within the Faraday shield. The toroidal sheath has a discontinuity, or electrical break, 196 , preventing it from acting as a shorted turn. The discontinuity is, however, such that total shielding is still obtained.
FIG. 7 shows a variant of FIG. 6 , in which the outer coaxial conductor forms part of the secondary winding; it connects to the secondary winding at point 197 . Thus, the outer conductor forms part of the winding and its extension towards the Faraday shield.
It is to be noted that, in FIGS. 6 and 7 , only one turn is shown for the primary and secondary windings, for clarity. In practice, more than one turn may be present for either or both of these.
Referring now to FIG. 8 , there is shown a preferred embodiment of the invention in which developed forms of both aspects of the invention are incorporated into an integrated high voltage generator and x-ray source.
The electron beam is produced by thermionic emission from a cathode 230 , which is made from tungsten wire or other material typically formed into the shape of a hairpin. In order for it to emit electrons, the cathode must be heated to incandescence. The required cathode temperature is produced by resistive self-heating. Electrons are extracted from the cathode 230 by means of an electric field applied, in known manner, between the cathode 230 and an anode (not shown in FIG. 8 ). As explained previously, the arrangement is such that the anode is at ground potential and the cathode is raised to a high negative potential. The magnitude of the beam current is controlled by a “bias” voltage imposed onto an annular grid electrode or Wehnelt 240 that surrounds the cathode. The bias voltage is always negative with respect to the cathode. The bias voltage also serves to produce a focussing electric field for the emitted electron beam, thereby controlling its diameter and ultimately the size of the x-ray source. The cathode 230 and the annular grid electrode 240 are, as is conventional, maintained in vacuum; the vacuum wall being shown in part as 235 in FIG. 8 .
The grid bias voltage is obtained by a technique, known as self-bias, which is commonly used on triode devices including, in particular, electron microscopes. The electron beam current passes through a resistor connected between the grid and the cathode and develops, across the resistor, a voltage which constitutes the grid bias voltage. The system is thus self-stabilising and a separate power supply for the grid voltage is not required. The magnitude of the electron beam current depends on the size of the resistor and on physical characteristics of the gun which are geometry dependent.
In accordance with this embodiment, the resistor is replaced by a device whose resistance can be altered electronically. A preferred device is a Field Effect Transistor (FET) 330 , but the principle of operation could also be implemented using other devices, such as light dependent resistors.
The beam current flows in series through a resistor 325 , the FET 330 and a resistor 335 . A Zener diode 336 protects the FET 330 from excessive voltage.
As discussed above, this arrangement differs significantly, in both concept and effect, from conventional circuit schemes, which typically employ a separate DC supply for the grid voltage floating at cathode potential, and which may utilise a series-regulating element for voltage control and stabilisation.
In conventional x-ray generators, the beam current sensing is typically achieved by measuring the current flowing at the bottom of the diode capacitor bank forming the high voltage multiplier (often called a Cockroft-Walton multiplier). In the present system, such a high voltage multiplier 290 is employed. A conventional sense resistor 300 is also shown. However, as described above, there is a serious disadvantage to using the voltage on sense resistor 300 as the means of measuring and controlling the electron beam current; namely that the current flowing at this point may include extraneous components in addition to the true electron beam current. These extraneous currents often include currents emitted from the vacuum facing surface of the housing surrounding the filament. The locations producing such emission are known as cold cathode or field emission sites, and are well known to those skilled in the art of the design of high voltage vacuum devices. Field emission sites are unstable and can be neither predicted nor eliminated If the control signal for beam current stabilisation is derived from a sense resistor 300 then the control of the true electron beam, that is emitted thermionically from the cathode 230 , will be corrupted by the unquantifiable inclusion of extraneous currents from field emission sites. This makes stable control at low operating beam currents and high cathode voltages very difficult and degrades x-ray image quality under such conditions. The present invention permits the true current flowing from the cathode to be measured. This allows very precise control of the beam current even under usually difficult conditions, such as when operating at extreme high voltage with low beam currents, and even with field emission sites present.
The true electron beam current is sensed as a voltage across resistor 325 and is fed into an integrated circuit 361 configured as a voltage to frequency converter. The frequency output of integrated circuit 361 drives an LED 362 , which sends a frequency modulated light signal 371 down an optical fibre 355 a . At the other end of the fibre 355 a , the optical signal is incident upon a photodiode 363 . This converts the optical signal back into an electrical signal which accurately represents the measured electron beam current and is applied, via a buffer amplifier 364 , to circuitry (not shown) which interfaces in a known manner with a computer. Computer commands input by a user of the system are used to effect adjustment of the electron beam current. However, if a computer is not used, appropriate circuitry is presented at a location convenient for direct or remote manual adjustment by an operator, thus allowing the beam current to be controlled, which may be either in real time, or to predetermined values.
It is necessary to provide a feedback signal for precise closed-loop control of the beam current against the predetermined demand level selected by the operator. Advantageously, since the resistance of the FET 330 may be varied by adjusting its gate voltage, this is accomplished by means of another photodiode 365 using optical signals 351 generated by a second LED 366 ; these optical signals 351 being amplitude modulated in a sense effective to indicate any desired change of the beam current. The signals are delivered into a second optical fibre 355 b , the output of which illuminates the photodiode 365 .
Optical fibres are used to provide electrical isolation between electronic circuits at the high and low voltage ends of the high voltage multiplier 290 .
The current sensed on resistor 300 is not used for control or measurement, but may be used by circuits designed to protect the high voltage generator in the event of a fault causing excessively high current in the multiplier 290 .
Occasional electrical discharges can be expected to occur within the x-ray source. Such discharges lead to rapidly changing transient currents, and it is necessary to protect active electronic components from the potentially damaging effects of radiated and conducted electromagnetic interference generated by these transients. The electronic circuits associated with the cathode and grid are contained in a metal walled chamber 410 . The whole of this container is connected to the grid and is therefore at a very high voltage with respect to ground. This container provides very substantial screening for the sensitive circuits within it, and acts as a “Faraday shield”.
Although it does not need to be hermetically sealed, the container is constructed in such a way that its openings are of minimal size. The integrity of such a Faraday shield may be compromised by the need to bring electrical signals in and out.
In this embodiment, the power for all of the circuits within the shield is provided by a high voltage isolation transformer. The secondary winding 390 of the transformer is insulated so as to provide the required high voltage isolation, and is constructed as a co-axial system. The outer conducting member 393 of this co-axial arrangement forms a continuous extension of the main Faraday shield 410 . Furthermore, only the outer conductor of the co-axial arrangement winds around the transformer core 400 .
The inner conductor 390 emerges from a hole in the side of the outer conductor and is then joined to the end of outer conductor 393 . The length of inner conductor 390 and the size of the hole in the outer conductor 393 are kept very small. The co-axial self screening construction of the secondary winding ensures that conducted and radiated signals into the Faraday shield are so small that the reliability of the sensitive components housed within can be guaranteed.
The core 400 of the isolating transformer lies outside the boundary of the Faraday shield 410 ; only the outer co-axial member 393 of the secondary winding 390 is integrated into the continuum of the Faraday shield wall.
The Faraday shield may advantageously contain certain additional electronic circuits which might, for example, be used to monitor, control or stabilise the cathode filament voltage, current or power. Such circuitry, floating at high voltage, may also utilise fibre optics as the means of conveying signals to other electronic circuits operating near to ground potential. | A compact X-ray source is disclosed, improving controllability and insulation from unwanted high voltage effects. In one aspect, an active variable conductance device ( 130, 330 ) connected in series with the cathode is used in a closed loop, feedback arrangement to control the cathode beam current; the current flowing through the device to the cathode being directly sensed and compared with a desired current level. The result of the comparison is used to control the conductance of the device, thereby directly influencing the cathode current. A second aspect provides an extension of a Faraday cage, whereby the secondary winding of a transformer used to supply power to components within the cage is shielded within a coaxial, tubular member connected to the cage and extending outwardly from it. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a method of machining a workpiece by cooperation of a machine tool and a robot.
[0003] 2. Description of the Related Art
[0004] A machining system provided with a robot which grasps and transfers a workpiece, and places the workpiece on a jig has been known (see, for example, Japanese Unexamined Patent Publication (Kokai) No. 2009-184055). Further, a machine tool provided with a clamp mechanism for clamping a workpiece, to machine the workpiece placed on a jig has been known (see, for example, Japanese Unexamined Patent Publication (Kokai) No. 9-201742).
[0005] When a clamp mechanism presses a work piece, which has been placed on a jig, against a clamp mechanism, the portion of the workpiece, which abuts with the clamp mechanism, cannot be machined. Thus, conventionally, in order to machine this portion, another operation, for example, placing the workpiece on another jig is necessary in some cases. In this respect, a reduction of machining accuracy and production efficiency may arise.
SUMMARY OF THE INVENTION
[0006] In an aspect of the invention, a method of machining a workpiece by cooperation of a machine tool, which includes a workpiece receiving part on which the workpiece is placed and a clamp part which presses the workpiece against the workpiece receiving part, and a robot, which includes a robot hand capable of gripping the workpiece, comprises pressing the clamp part against a first portion of the workpiece and clamping the workpiece between the clamp part and the workpiece receiving part.
[0007] The method comprises moving the clamp part so as to separate away from the first portion, and releasing the workpiece from the clamp part, operating the robot so as to grip a second portion of the workpiece, which is different from the first portion, by the robot hand, and restricting a movement of the workpiece relative to the workpiece receiving part without changing a posture of the workpiece, and operating the machine tool so as to machine the first portion when restricting the movement of the workpiece relative to the workpiece receiving part.
[0008] The robot may include a force sensor which measures a force applied to the robot hand. When the second portion is gripped by the robot hand, a pressing force, by which the robot hand presses the second portion, may be controlled to a predetermined value based on the force measured by the force sensor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The above-mentioned or other objects, features, and advantages of the invention will be clarified by the following description of preferred embodiments with reference to the accompanying drawings, in which:
[0010] FIG. 1 is a block diagram of a machining system according to an embodiment of the invention;
[0011] FIG. 2 is a view of the workpiece and workpiece receiving part shown in FIG. 1 when viewed from the z-axis positive direction in FIG. 1 , in which a robot hand gripping the workpiece is indicated by a dotted line;
[0012] FIG. 3 is a flowchart of an example of an operation flow of the machining system shown in FIG. 1 ;
[0013] FIG. 4 is a flowchart of an example of the flow of step S 5 in FIG. 3 ;
[0014] FIG. 5 shows the machining system at the end of step S 4 in FIG. 3 ;
[0015] FIG. 6 shows the machining system at the time when it is determined “YES” at step S 13 in FIG. 4 ;
[0016] FIG. 7 is a view of a workpiece receiving part according to another embodiment of the invention;
[0017] FIG. 8 is a view of a workpiece receiving part according to still another embodiment of the invention;
[0018] FIG. 9 is a view of a robot hand according to another embodiment of the invention; and
[0019] FIG. 10 is a block diagram of a machining system according to another embodiment of the invention.
DETAILED DESCRIPTION
[0020] Embodiments of the invention will be described below in detail with reference to the drawings. First, with reference to FIGS. 1 and 2 , a machining system 10 according to an embodiment of the invention will be described. The machining system 10 includes a robot system 12 and a machine tool 14 .
[0021] The robot system 12 is for carrying a workpiece W into the machine tool 14 so as to place it on a workpiece receiving part 46 of the machine tool 14 , and removing the workpiece W placed on the workpiece receiving part 46 from the machine tool 14 .
[0022] The robot system 12 includes a robot controller 16 and a robot 18 . The robot controller 16 includes e.g. a central processing unit (CPU) and a memory (both are not shown), and directly or indirectly controls each component of the robot 18 .
[0023] The robot 18 is e.g. a vertical articulated robot, and includes a robot base 20 , a revolving drum 22 , a robot arm 24 , a robot hand 26 , and a force sensor 38 . The robot base 20 is fixed on a floor of a work cell. The revolving drum 22 is attached to the robot base 20 so as to revolve about a vertical axis.
[0024] The robot arm 24 includes an upper arm 28 rotatably attached to the revolving drum 22 , and a forearm 30 rotatably attached to a distal end of the upper arm 28 . A wrist 32 is provided at a distal end of the forearm 30 . The robot hand 26 is attached to the distal end of the forearm 30 via the wrist 32 .
[0025] The robot hand 26 includes a hand base 34 attached to the wrist 32 , and a plurality of fingers 36 attached to the hand base 34 so as to be able to open and close. The fingers 36 are provided at the hand base 34 so as to be movable in directions toward and away from each other.
[0026] The robot controller 16 sends a command to each servo motor (not shown) built in the robot 18 so as to operate the robot 18 , thereby the robot hand 26 is moved. Further, the robot controller 16 sends a command to each servo motor (not shown) built in the robot hand 26 so as to open and close the fingers 36 .
[0027] The force sensor 38 includes e.g. a sensor element, such as a strain gauge or displacement gauge, and detects a load applied to the finger 36 . The force sensor 38 sends data of the detected load to the robot controller 16 . For example, the force sensor 38 sends data of the load to the robot controller 16 with a predetermined period.
[0028] The machine tool 14 includes a machine tool controller 40 , a main spindle 42 , a table 44 , the workpiece receiving part 46 , and a clamp mechanism 48 . The machine tool controller 40 includes e.g. a central processing unit (CPU) and a memory (both are not shown), and directly or indirectly controls each component of the machine tool 14 .
[0029] The machine tool controller 40 is connected to the robot controller 16 so as to communicate with it. The machine tool controller 40 and the robot controller 16 execute a machining process on the workpiece W while communicating with each other. Note that, this machining process will be described later.
[0030] The main spindle 42 is provided so as to be movable in directions toward and away from the workpiece receiving part 46 (i.e., in the z-axis direction in the figures). The main spindle 42 holds a tool 50 on its distal end. The machine tool controller 40 sends a command to a servo motor (not shown) built in the main spindle 42 so as to move the main spindle 42 in the z-axis direction.
[0031] By this operation of the main spindle 42 , the tool 50 held by the main spindle 42 is also moved in the directions toward and away from the workpiece receiving part 46 (i.e., in the z-axis direction in the figures). Further, the machine tool controller 40 sends a command to a servo motor (not shown) built in the main spindle 42 so as to rotate the tool 50 to machine the workpiece W.
[0032] The table 44 includes a movable board 44 a and a movement mechanism 44 b which moves the movable board 44 a. The movement mechanism 44 b includes a servo motor and a ball screw mechanism, and moves the movable board 44 a in the x-axis direction and the y-axis direction in FIG. 1 , in accordance with a command from the machine tool controller 40 .
[0033] The workpiece receiving part 46 is fixed on the movable board 44 a of the table 44 , and moves integrally with the movable board 44 a. The workpiece receiving part 46 is formed with engagement parts 46 a for positioning the workpiece W.
[0034] In this embodiment, a plurality of engagement parts 46 a are formed so as to project from a top face 46 b of the workpiece receiving part 46 in the z-axis positive direction, and are arranged so as to surround the workpiece W as shown in FIG. 2 . The engagement parts 46 a engage an outer peripheral surface S of the workpiece W, so that the movement of the workpiece W relative to the workpiece receiving part 46 along the x-y plane is restricted.
[0035] The clamp mechanism 48 includes a clamp driving part 52 , a clamp arm 54 , and a clamp part 56 . The clamp driving part 52 includes e.g. a pneumatic or hydraulic cylinder, and drives the clamp arm 54 in the z-axis direction in accordance with a command from the machine tool controller 40 .
[0036] One end of the clamp arm 54 is fixed to the clamp driving part 52 , while the other end of the clamp arm 54 holds the clamp part 56 . The clamp part 56 is arranged so as to be separate away from the engagement parts 46 a formed at the workpiece receiving part 46 in the z-axis positive direction. The clamp part 56 is driven by the clamp driving part 52 in the z-axis direction integrally with the clamp arm 54 .
[0037] In this embodiment, the clamp part 56 is arranged so as to contact a first part P 1 of the workpiece W disposed on the workpiece receiving part 46 when the clamp part 56 is moved by the clamp driving part 52 in the z-axis negative direction. The first part P 1 is an end of the workpiece W in the z-axis positive direction, and faces the clamp part 56 .
[0038] Next, an operation of the machining system 10 will be described with reference to FIGS. 3 to 6 . The operation flow shown in FIG. 3 is started when the robot controller 16 or the machine tool controller 40 receives a machining command for machining the workpiece W from a user, host controller, or machining program.
[0039] At step S 1 , the robot controller 16 places the workpiece W on the workpiece receiving part 46 . Specifically, the robot controller 16 operates the robot 18 in accordance with a robot program so as to grip the workpiece W placed on a predetermined location by the robot hand 26 .
[0040] Then, the robot controller 16 moves the workpiece W by the robot 18 , and places it on the workpiece receiving part 46 . At this time, the engagement parts 46 a of the workpiece receiving part 46 engage the outer peripheral surface S of the workpiece W.
[0041] At step S 2 , the machine tool controller 40 operates the clamp mechanism 48 so as to clamp the workpiece W placed on the workpiece receiving part 46 by the clamp mechanism 48 . Specifically, the machine tool controller 40 sends a command to the clamp driving part 52 so as to move the clamp part 56 in the z-axis negative direction.
[0042] Consequently, as shown in FIG. 1 , the clamp part 56 contacts the first part P 1 of the workpiece W so as to press the first part P 1 in the z-axis negative direction, thereby the workpiece W is clamped between the clamp part 56 and the workpiece receiving part 46 .
[0043] At step S 3 , the machine tool controller 40 machines the workpiece W. Specifically, the machine tool controller 40 moves the main spindle 42 so as to contact the tool 50 with a portion of the workpiece W other than the first part P 1 (e.g., the outer peripheral surface S). Then, the machine tool controller 40 rotates the tool 50 , thereby the workpiece W is machined.
[0044] At step S 4 , the machine tool controller 40 moves the clamp part 56 so as to separate away from the first part P 1 of the workpiece W to release the workpiece W from the clamp mechanism 48 .
[0045] Specifically, the machine tool controller 40 sends a command to the clamp driving part 52 so as to move the clamp part 56 in the z-axis positive direction. Consequently, as shown in FIG. 5 , the clamp part 56 is separate away from the first part P 1 of the workpiece W in the z-axis positive direction.
[0046] At step S 5 , the robot controller 16 grips the workpiece W by the robot hand 26 . This Step S 5 will be described with reference to FIG. 4 .
[0047] At step S 11 , the robot controller 16 moves the robot hand 26 . Specifically, the robot controller 16 operates the robot 18 in accordance with a robot program so as to move the robot hand 26 so that the workpiece W is arranged between the opened fingers 36 .
[0048] At this time, the robot hand 26 is positioned relative to the workpiece W so that the fingers 36 face a second part P ( FIG. 2 , FIG. 5 ) of the workpiece W. The second part P 2 is a part of the workpiece W other than the first part P 1 (e.g., the outer peripheral surface S), and this second part P 2 is to be gripped by the robot hand 26 as described later.
[0049] At step S 12 , the robot controller 16 moves the fingers 36 in closing directions. Specifically, the robot controller 16 sends a command to the servo motor built in the robot hand 26 so as to move the fingers 36 in the direction toward each other.
[0050] At step S 13 , the robot controller 16 determines whether a pressing force, by which the robot hand 26 presses the second part P 2 of the workpiece W, reaches a predetermined value. Specifically, the robot controller 16 determines whether the detected load value measured by the force sensor 38 is within a predetermined range.
[0051] As described above, the force sensor 38 detects the load applied to the finger 36 . The load applied to the finger 36 correlates with a reaction force applied to the finger 36 when the fingers 36 press the second parts P 2 . Accordingly, the pressing force by which the robot hand 26 presses the second part P 2 can be estimated from the load detected by the force sensor 38 .
[0052] As an example, a relationship between the load value detected by the force sensor 38 and the pressing force by which the robot hand 26 presses the second parts P 2 is obtained in advance by means of an experimental or simulation method, and is pre-stored in the storage incorporated in the robot controller 16 .
[0053] Then, a user sets the above-mentioned predetermined range so as to include the detected load value of the force sensor 38 when the pressing force by which the robot hand 26 presses the second parts P 2 is a desired value (e.g., a range of ±1% of the detected load value corresponding to the desired pressing force).
[0054] At this step S 13 , the robot controller 16 determines whether the load value detected by the force sensor 38 is within the predetermined range. When the robot controller 16 determines that the detected load value is within the predetermined range (i.e., determines “YES”), it proceeds to step S 14 .
[0055] On the other hand, when the robot controller 16 determines that the load value detected by the force sensor 38 is out of the predetermined range (i.e., determines “NO”), it repeats step S 13
[0056] When it is determined “YES” at step S 13 , the robot hand 26 presses the second parts P 2 of the workpiece W by a desired magnitude of force. This state is shown in FIGS. 2 and 6 . Note that, in FIG. 2 , the robot hand 26 is indicated by a dotted line for the purposes of easy understanding.
[0057] As shown in FIGS. 2 and 6 , when it is determined “YES” at step S 13 , the second parts P of the workpiece W is held between the fingers 36 of the robot hand 26 in the y-axis direction, and gripped by them.
[0058] As shown in FIG. 6 , in this embodiment, the second parts P 2 are disposed in the vicinity of the end of the workpiece W in the z-axis positive direction so as to be spaced away from the engagement parts 46 a of the workpiece receiving part 46 in the z-axis positive direction. On the other hand, the engagement parts 46 a of the workpiece receiving part 46 engage the end part of the workpiece W in the z-axis negative direction.
[0059] Thus, in this embodiment, the robot hand 26 and each engagement part 46 a engage different parts of the workpiece W (i.e., the robot hand 26 engages the vicinity of the upper end of the workpiece W, while each engagement part 46 a engages the vicinity of the lower end of the workpiece W).
[0060] Due to this, it is possible to effectively restrict the movement of the workpiece W relative to the workpiece receiving part 46 along the x-y plane. Further, it is possible to effectively prevent the end part of the workpiece W in the z-axis positive direction from swinging, thereby it is possible to prevent the workpiece W from being inclined with respect to the x-y plane, during the machining process.
[0061] At step S 14 , the robot controller 16 maintains the position of the fingers 36 . For example, the robot controller 16 measures a load torque N of the servomotor for driving the fingers 36 at the time when it is determined “YES” at step S 13 , and feedback-controls the servomotor so that a load torque thereof is the measured load torque N.
[0062] By this operation, the position of the fingers 36 can be maintained, thereby the robot hand 26 can keep gripping the second parts P 2 by the desired magnitude of force.
[0063] By step S 5 shown in FIG. 4 , the robot hand 26 presses the workpiece W, which has been released from the clamp mechanism 48 at step S 4 , against the workpiece receiving part 46 , without changing the posture of the workpiece W at the end of step S 3 .
[0064] Referring again to FIG. 3 , at step S 6 , the machine tool controller 40 machines the first part P 1 of the workpiece W. Specifically, the machine tool controller 40 operates the main spindle 42 so as to press the tool 50 against the first part P 1 of the workpiece W in the z-axis negative direction. Then, the machine tool controller 40 rotates the tool 50 , thereby the first part P 1 of the workpiece W is machined.
[0065] As described above, the movement of the workpiece W in the x-y plane is restricted by the robot hand 26 and the engagement parts 46 a. In this state, the tool 50 machines the first part P 1 along with pressing the first part P i in the z-axis negative direction, by which it is possible to effectively prevent the position of the workpiece W from deviating during machining.
[0066] At step S 7 , the robot controller 16 removes the workpiece W from the machine tool 14 . Specifically, while the robot controller 16 keeps gripping the workpiece W by the robot hand 26 , the robot controller 16 operates the robot 18 in accordance with a robot program so as to move the workpiece W to a predetermined location. Then, the robot controller 16 moves the fingers 36 of the robot hand 26 in opening direction so as to release the workpiece W to the predetermined location.
[0067] At step S 8 , the robot controller 16 or the machine tool controller 40 determines whether all of workpieces have been machined. When the robot controller 16 or machine tool controller 40 determines that all of workpieces have been machined (i.e., determines “YES”), it ends the flow shown in FIG. 3 . On the other hand, when the robot controller 16 or machine tool controller 40 determines that a workpiece to be machined still remains (i.e., determines “NO”), it returns to step S 1 .
[0068] In this embodiment, after the workpiece W is released from the clamp part 56 , the robot hand 26 presses the workpiece W against the workpiece receiving part 46 without changing the posture of the workpiece W.
[0069] According to this configuration, after step S 3 , the first part P 1 , against which the clamp part 56 was butted at step S 3 , can be sequentially machined without changing the posture of the workpiece W. Accordingly, it is possible to omit operations for e.g. changing the posture of the workpiece W or setting the workpiece W to another jig after step S 3 , thereby the production efficiency can be improved.
[0070] Further, in this embodiment, while the movement of the workpiece W in the x-y plane is restricted by the robot hand 26 , the tool 50 is pressed against the first part P 1 in the z-axis negative direction to machine. According to this configuration, it is possible to effectively prevent the movement of the workpiece W in the x-axis, the y-axis, and the z-axis directions during machining.
[0071] Further, in this embodiment, the workpiece W is pressed against the workpiece receiving part 46 by the robot 18 for carrying and removing the workpiece W into and from the machine tool 14 . Due to this, the configuration of the system can be simplified.
[0072] Further, since the robot hand 26 is gripping the workpiece W at step S 5 , the machined workpiece W can be quickly removed at step S 7 by the robot 18 after the end of step S 6 . Accordingly, the work efficiency can be improved.
[0073] Note that, various types of engagement parts other than the engagement parts 46 a of the above-mentioned embodiment can be applied. FIG. 7 shows a workpiece receiving part 46 ′ according to another embodiment. The workpiece receiving part 46 ′ is formed with two engagement parts 46 a ′ arranged to be opposite to each other.
[0074] These engagement parts 46 a ′ are formed to restrict the movement of the workpiece W in the x-axis direction. In this case, at the above-mentioned step S 5 , the robot controller 16 causes the robot hand 26 to grip the second parts P 2 of the workpiece W so as to restrict the movement of the workpiece W in the y-axis direction, as shown in FIG. 7 .
[0075] Thus, in this embodiment, the robot hand 26 and the engagement parts 46 a ′ respectively restrict the movements of the workpiece W in the y-axis direction and the x-axis direction. Due to this, it is possible to restrict the movement of the workpiece W along the x-y plane.
[0076] FIG. 8 shows a workpiece receiving part 46 ″ according to still another embodiment. The workpiece receiving part 46 ″ is formed with two engagement parts 46 a ″ arranged to be opposite to each other. These engagement parts 46 a ″ are formed to restrict the movement of the workpiece W in the x-axis positive direction.
[0077] In this embodiment, at the above-mentioned step S 5 , the robot controller 16 causes the robot hand 26 to grip the second parts P 2 of the workpiece W so as to restrict the movement of the workpiece W in the y-axis direction.
[0078] In this state, the robot controller 16 moves the robot hand 26 in the x-axis positive direction so as to press the workpiece W against the engagement parts 46 a ″ in the x-axis positive direction. According to this embodiment, it is also possible to restrict the movement of the workpiece W along the x-y plane by the robot hand 26 and the engagement parts 46 a″.
[0079] Further, the robot 18 may be provided with other force sensor capable of detecting a load applied to the robot arm 24 , instead of (or in addition to) the force sensor 38 . The other force sensor can be attached to the robot arm 24 or the wrist 32 .
[0080] In this case, at the above-mentioned step S 13 , the robot controller 16 may determine whether a force by which the robot hand 26 presses the second parts P 2 reaches a predetermined value, based on the load measured by the other force sensor.
[0081] As an example, if the workpiece receiving part 46 ″ shown in FIG. 8 is applied, at the above-mentioned step S 13 , the robot controller 16 may control a force by which the robot hand 26 presses the workpiece W against the engagement parts 46 a ″ in the x-axis positive direction, based on the load measured by the other force sensor.
[0082] Further, the clamp driving part 52 may include e.g. a servomotor, other than the pneumatic or hydraulic cylinder.
[0083] Further, the workpiece W may be pressed against the workpiece receiving part only by the robot hand, without providing any engagement part on the workpiece receiving part. As an example, FIG. 9 shows a robot hand 26 ′ according to another embodiment.
[0084] The robot hand 26 ′ includes a hand base 34 and a plurality of fingers 36 ′ provided at the hand base 34 so as to open and close. The fingers 36 ′ are provided at the hand base 34 so as to move closer to and away from each other.
[0085] A gripping part 36 a ′ is formed at a portion of each finger 36 ′, against which the workpiece W′ to be gripped is butted. Each gripping part 36 a ′ has a shape corresponding to the second parts P 2 ′ of the workpiece W′. According to this embodiment, even if the engagement parts 46 a are not provided on the workpiece receiving part 46 , it is possible to restrict the movement of the workpiece W′ in the x-y plane by the robot hand 26 ′.
[0086] Further, the engagement part may be not only a projecting part projecting from the surface of the workpiece receiving part, as the above-mentioned engagement parts 46 a, 46 a ′ and 46 ″, but also a recessed part (e.g. groove) inwardly recessed from the surface of the workpiece receiving part.
[0087] Further, in the above-mentioned embodiments, the machine tool 14 includes single clamp mechanism 48 . However, the machine tool may include a plurality of clamp mechanisms.
[0088] Below, a machining system 10 ′ according to still another embodiment will be described with reference to FIG. 10 . Note that, in this embodiment, elements similar to those in the above-mentioned embodiments are assigned the same reference numerals, and the detailed descriptions thereof will be omitted.
[0089] The machining system 10 ′ differs from the machining system 10 in the configuration of the machine tool 14 ′. Specifically, the machine tool 14 ′ includes the machine tool controller 40 , the main spindle 42 , the table 44 , the workpiece receiving part 46 , a first clamp mechanism 48 a, and a second clamp mechanism 48 b.
[0090] The first clamp mechanism 48 a includes a first clamp driving part 52 a, a first clamp arm 54 a, and a first clamp part 56 a. The second clamp mechanism 48 b includes a second clamp driving part 52 b, a second clamp arm 54 b, and a second clamp part 56 b.
[0091] The configurations of the clamp driving parts 52 a, 52 b, the clamp arms 54 a, 54 b, and the clamp parts 56 a, 56 b are respectively similar to those of the clamp driving part 52 , the clamp arm 54 , and the clamp part 56 .
[0092] The first clamp part 56 a is disposed so as to contact a portion P 1 ′ of a workpiece W″ placed on the workpiece receiving part 46 . On the other hand, the second clamp part 56 b is disposed so as to contact a portion P 1 ″ of the workpiece W″.
[0093] Next, the operation of the machining system 10 ′ according to this embodiment will be described with reference to FIG. 3 . The operation of the machining system 10 ′ differs from that of the machining system 10 in the following processes.
[0094] Specifically, at step S 4 , the machine tool controller 40 sends a command to the first clamp driving part 52 a so as to move the first clamp part 56 a away from the portion P 1 ′ of the workpiece W.
[0095] Then, after executing step S 5 , at step S 6 , the machine tool controller 40 operates the main spindle 42 so as to machine the portion P 1 ′ of the workpiece W. Then, the machine tool controller 40 sends a command to the second clamp driving part 52 b so as to move the second clamp part 56 b away from the portion P 1 ″ of the workpiece W.
[0096] Then, the machine tool controller 40 operates the main spindle 42 so as to machine the portion P 1 ″ of the workpiece W. According to this embodiment, it is possible to sequentially machine the portion P 1 ′ against which the first clamp part 56 a was butted at step S 3 and the portion P 1 ″ against which the second clamp part 56 b was butted at step S 3 , without changing the posture of the workpiece W″.
[0097] Note that, regarding the operation of the machining system 10 ′, the machine tool controller 40 may move both of the first clamp part 56 a and the second clamp part 56 b away from the portions P 1 ′ and P 1 ″ of the workpiece W concurrently at step S 4 .
[0098] Note that, in the above-mentioned embodiments, the robot controller 16 and the machine tool controller 40 are provided to be independent elements separate from each other. However, a single controller which controls each component of the robot 18 and the machine tool 14 may be provided.
[0099] Although the invention has been described above through various embodiments, the embodiments do not limit the inventions according to the claims. Further, a configuration obtained by combining the features described in the embodiments of the invention can be included in the technical scope of the invention. However, all combinations of these features are not necessarily essential for solving means of the invention. Furthermore, it is obvious for a person skilled in the art that various modifications or improvements can be applied to the embodiments.
[0100] Regarding the order of operations, such as actions, sequences, steps, processes, and stages, in the devices, systems, programs, and methods indicated in the claims, specification and drawings, it should be noted that the terms “before”, “prior to”, etc. are not explicitly described, and any order can be realized unless the output of a previous operation is used in the subsequent operation. Regarding the processing in the claims, specification, and drawings, even when the order of operations is described using the terms “first”, “next”, “subsequently”, “then”, etc., for convenience, maintaining this order is not necessarily essential for working the inventions. | A method for machining a workpiece which can prevent a reduction in machining accuracy and production efficiency. The method includes pressing a clamp part against a first portion of the workpiece, to clamp the workpiece in cooperation with a workpiece receiving part, causing the clamp part to move away from the first portion, to release the workpiece, which has been clamped by the clamp part, operating the robot to cause the robot hand to grasp a second portion of the workpiece, which is different from the first portion, to restrict the movement of the workpiece relative to the workpiece receiving part without a change in the posture of the workpiece, and operating the machine tool to machine the first portion while restricting the movement of the workpiece relative to the workpiece receiving part. | 8 |
RELATED APPLICATIONS
[0001] This application claims priority from U.S. patent application Ser. No. 11/064,310, filed Feb. 23, 2005, which claims priority from U.S. Provisional Patent Application No. 60/546,859, filed on Feb. 23, 2004, and entitled “A Method of Real-time Incremental Zooming using Pointing”. This application is also related to U.S. patent application Ser. No. 10/768,432. The subject matter of each of these applications are incorporated in its entirety herein by reference.
BACKGROUND
[0002] The present invention is directed to user interfaces and more particularly, to a method of navigation and interaction with a user interface. Such interaction and navigation involve operating an input device such as a mouse, a trackball or a three-dimensional (hereinafter “3D”) pointing remote device. The operation of the input device includes at least one of point, click, scroll, etc.
[0003] User interfaces, such as graphical user interfaces (GUIs) are well known. Virtually all computers include (or, enable) a graphical user interface in order to make the interaction with the computer more “user friendly”. This is accomplished by reducing, if not eliminating, the number of keystrokes a user is required to enter in order to perform a function such as launching an application residing on the computer. An increasing number of other electronic devices, from cell phones to user controls on appliances, rely on various graphical user interfaces that facilitate a user interaction with the particular device.
[0004] Traditional methods of using a GUI (on a computer for example) include the use of an input device such as a mouse or a track ball. A movement of the mouse or the track ball results in a corresponding pointer moving on the graphical user interface. The pointer can thus be navigated to an object (represented by an icon) on the GUI that corresponds to an executable task such as launching a software application for example. Once the pointer is navigated to an icon, the corresponding task can be executed by clicking (depressing) on an actuating button that is integrated within the input device. For example, if the icon on the GUI corresponds to a word processing application, clicking on the icon results in launching the word processing application. The pointer can also be used to rapidly scroll through pages of text within a word processing document for example.
[0005] The input device can be used to perform various tasks depending on the application being executed on the computer. In a map software program (generically referred to as location information program) for example, maps of a geographic area can be displayed. While displaying a map, the actuating button of the pointer can be depressed on a particular area of the map to zoom in on the selected area to provide additional detail while displaying a smaller overall geographic area. The actuating button therefore can be used to zoom in on an area of interest.
[0006] Referring to FIG. 1 , a map of the United States 114 is illustrated. Center point 108 represents the center of bounding box 102 (which could also represent the user interface) that includes map 114 . User interface 102 can represent a window corresponding to the map software program similar to a window that represents a work area of a document in a word processing program for example. The user can then request a more detailed view of a point of interest 105 on the map (such as New York City) by moving the pointer 104 to point of interest 105 and depressing the actuating button. The points of interest displayed on a graphical user interface may be thought of as objects.
[0007] The zooming in on the point of interest (i.e. New York in this example) results in map 314 of FIG. 3A being included within user interface 102 . As illustrated, New York (point of interest 105 ) is now displayed in the center of user interface 102 . Center point 108 , still representing center of the user interface 102 (but no longer representing center of map 114 ), now coincides with point of interest 105 . The point of interest 105 and center point 108 represent the same location on map 314 .
[0008] Pointer 104 , previously pointing to the point of interest 105 (in FIG. 1 ), however remains at the same physical location within the user interface 102 but no longer points to the point of interest 105 (in FIG. 3A ). That is, the relative distance of pointer 104 with respect to the side and top of user interface 102 in FIG. 3A is identical to the relative distance of pointer 104 with respect to the side and top of user interface 102 in FIG. 1 .
[0009] If a user now wishes to zoom in further on New York, the user has to move the mouse until pointer 104 points to the point of interest 105 (or, center point 108 ) prior to depressing the actuating button. The pointer location does not coincide with or, is not synchronized to, the point of interest when zooming occurs according to current implementations. If a user wishes to zoom in a few times (to a number of zooming levels), a cumulative delay factor is introduced into the process as the pointer has to be located and moved to the point of interest for each desired zooming level. The cumulative delay factor is a sum of delays each of which is associated with having to re-centering the pointer after each zooming function.
[0010] Some embodiments provide a synchronization (or, coordination) between the zooming function and the pointer location on a user interface.
SUMMARY
[0011] Methods according to the present invention address these needs and others by providing a method for maintaining the position of pointer on a center of a graphical user interface
[0012] According to one exemplary embodiment of the present invention, a method for navigating a pointer on a graphical user interface (GUI) includes the steps of: scrolling an input device to locate the pointer corresponding to the input device on a point of interest within the GUI, depressing an actuating button associated with the input device on the point of interest, obtaining a detailed view of the point of interest while centering the point of interest on the GUI and maintaining a position of the pointer on the point of interest.
[0013] According to another exemplary embodiment of the present invention, a method of centering a pointer on a graphical user interface (GUI) includes navigating the pointer to a point of interest away from a center of the GUI, actuating a mechanism for obtaining a magnified view of the point of interest, computing a distance between a center of the GUI and a location of the point of interest, generating a detailed view of the point of interest, displaying the detailed view with the point of interest centered on the GUI and animating a movement of the pointer from the position away from the center of the GUI to the point of interest.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The accompanying drawings illustrate exemplary embodiments of the present invention, wherein:
[0015] FIG. 1 depicts a graphical user interface corresponding to an exemplary location information program;
[0016] FIG. 2 illustrates a first magnified view of a portion of the user interface of FIG. 1 in exemplary embodiment;
[0017] FIGS. 3A and 3B depicts a second magnified view of a portion of the user interfaces of FIGS. 1 and 2 ; and
[0018] FIGS. 4 and 5 illustrate methods in accordance with exemplary embodiments.
DETAILED DESCRIPTION
[0019] The following detailed description of the invention refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. Also, the following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims.
[0020] In exemplary embodiments, incremental zooming may be utilized to coordinate pointer location with a point of interest on a user interface. Referring back to FIG. 1 , a user may navigate pointer 104 to a point of interest 105 and depresses the actuating button of an input device to obtain a more detailed view of point of interest 105 . An incremental zooming may take place in a series of zooming levels from FIG. 1 to a desired zooming level for the point of interest 105 as illustrated in FIGS. 3A and 3B . The number of zooming levels may be two for example—that is, an intermediate zooming step may exist between user interface in FIG. 1 and that of FIGS. 3A and 3B . Having two zooming levels is specified for exemplary purposes; the number of zooming levels may be greater than two in preferred embodiments.
[0021] By navigating pointer 104 and depressing actuating button at the point of interest 105 on FIG. 1 , a user may identify the location for which a detailed view is desired. The detailed view may be obtained from pre-stored information contained in the software program for example; it may also be generated. The program may be stored in the computer, in a computer medium (such as a compact disc) or accessible to the computer over a network such as the internet.
[0022] A distance 106 between center 108 and point of interest 105 may be computed. A virtual line (representing 106 ) may be drawn between starting point 108 and point of interest 105 . The virtual line may represent the linear distance between points 108 and 105 of FIG. 1 . An intermediate zooming level (or step) may be illustrated in FIG. 2 . The center 108 of user interface 102 has now moved (along the virtual line representing distance 106 ) to approximately a midway point between center 108 in FIG. 1 and center 108 of FIGS. 3A or 3 B.
[0023] The center 108 of the user interface 102 remains fixed at one physical location on the interface as long as the size of the interface (represented by the window) remains constant; the geographic point represented by the center may vary based on the zooming level. For example, in FIG. 1 , center 108 may represent some point in Nebraska while center 108 of FIG. 2 may represent some point in Ohio. The pointer, designated by 104 , remains on the point of interest 105 . The original location of pointer 104 ′ (at point of interest 105 in FIG. 1 ) is also shown in FIG. 2 to distinguish exemplary embodiments over existing implementation methods.
[0024] A detailed view desired by zooming in point of interest 105 of FIG. 1 is illustrated in FIGS. 3A and 3B . A second zooming level may be illustrated with respect to FIGS. 3A and 3B . Starting from FIG. 2 , the distance represented by line 206 (which is one half of the distance 106 of FIG. 1 ) between center 108 and point of interest 105 may be reduced to zero as center 108 of FIGS. 3A and 3B coincides with point of interest 105 . As with FIG. 2 above, pointer 104 is now located over point of interest 105 in FIG. 3B . The location of pointer 104 ″ (at point of interest 105 in FIG. 2 ) is also illustrated in FIG. 3B to distinguish exemplary embodiments over existing implementation methods.
[0025] In some embodiments, the intermediate zooming level, the results of which are illustrated in FIG. 2 , may not be needed. That is, the zooming can transition from FIG. 1 to FIG. 3B . Pointer 104 would be positioned over point of interest 105 after the transition. Other embodiments may include additional zooming levels (additional to the two levels illustrated).
[0026] Centering the point of interest 105 within user interface 102 while zooming in may be achieved by combining the zooming function with a simultaneous panning function. Panning refers to translating the view in either the vertical horizontal dimensions. As a result of the panning process, the point of interest 105 coincides with center 108 of the interface 102 .
[0027] As the actuation button of the input device is depressed to achieve zooming, the point of interest 105 may move along the dotted distance line 106 to center 108 of the interface 102 . A progress of the pointer's movement along this line may be illustrated in an animated manner. In preferred embodiments, panning in order to make the point of interest 105 coincide with center 108 of user interface 102 may be completed at the same time the desired zooming level is achieved. The amount of movement (or displacement) the point of interest 105 undergoes for each zooming step may be computed. As described above, center 108 of the interface represents the point of interest as a result of this movement.
[0028] The final level of detail available for zooming in may be determined by a designer of the particular software program being used. For example, a designer of a map software program might choose to facilitate zooming in to a block level or a street level, etc. This may assist in determining the number of available zooming levels between a starting point 108 of FIG. 1 and ending point 108 of FIGS. 3A and 3B for example. The number of available zooming levels may also determine how long it takes to get from the starting point to the ending point.
[0029] While the number of zooming levels illustrated is two and one intermediate frame is illustrated in this example, a higher number of zooming levels will result in more intermediate frames being shown. If four levels are available in an embodiment, then the number of intermediate frames may be three. That is, a first intermediate frame may depict point 108 being located between point 108 of FIG. 1 and point 108 of FIG. 2 ; a second intermediate frame may be identical to FIG. 2 ; a third intermediate frame may depict point 108 being located between point 108 of FIG. 2 and point 108 of FIG. 3A (or 3 B) and a fourth frame may be identical to FIG. 3A (of 3 B). If the number of available zoom levels is N, then the number of intermediate frames may be N- 1 .
[0030] Exemplary methods may also facilitate zooming out from a point of interest. In zooming out, the pointer may remain on the point of interest but the center may no longer coincide with the pointer. In FIG. 3B for example, if zooming out is indicated via the user input device, a portion of the user interface may illustrate the Atlantic Ocean east of New York for which no data may be available. In this case, the center 108 may be moved westward while pointer 104 remains on point of interest 105 .
[0031] Each of the figures also shows a scale (designated by 112 , 212 and 312 ) to depict what one unit may represent (such as distance for example) in the corresponding figure. In some embodiments, a history of zooming levels that were illustrated (frames) may be maintained in order to enable a user to visit previous frames.
[0032] In some embodiments as described above, the animation or transition between a starting point (such as FIG. 1 ) and the ending point ( FIGS. 3A and 3B ) may occur in a linear manner. That is, if only one intermediate frame is shown, the intermediate frame may be the midway point between the starting and ending points; similarly, if three intermediate frames are shown, they may represent points that are one quarter of the way, one half of the way and three quarters of the way between the starting point and the ending point as the intermediate frames.
[0033] In other embodiments, the animation may take place at a different rate (or at a varying rate). The first few intermediate frames may be shown slowly, the next several intermediate frames may be shown at a faster rate and the last few intermediate frames may be shown slowly for example.
[0034] Exemplary embodiments may be implemented on a general purpose computer such as a desktop, a laptop, a pocket PC, personal digital assistant (PDA) or other similar devices having the processing capacity. Methods described may be encoded on a computer readable medium as a series of executable instructions or on an application specific integrated chip (ASIC).
[0035] Methods in accordance with exemplary embodiments as described above may be illustrated as process or flow charts 400 and 500 in FIGS. 4 and 5 respectively.
[0036] While the description has focused on zooming in on a map, exemplary methods may be equally applicable in other scenarios such as in virtual tour programs (i.e. real estate viewing for example) and in gaming, etc. The methods can also be used in menu selection within an entertainment/pay-per-view environment. For example, thumb nail images representing various movies available for viewing or on a pay-per-view basis may be displayed to a user on a display or screen. The user may utilize a 3D pointing device such as that developed by Hillcrest Laboratories, Inc. of Rockville, Md. to select one of the images. As a result of this selection, more detailed information corresponding to the selected image may be displayed to the user. Input devices may also include a graphic tablet, a tracking surface such as a track pad or a 3D pointing device.
[0037] The above-described exemplary embodiments are intended to be illustrative in all respects, rather than restrictive, of the present invention. Thus the present invention is capable of many variations in detailed implementation that can be derived from the description contained herein by a person skilled in the art. All such variations and modifications are considered to be within the scope and spirit of the present invention as defined by the following claims. No element, act, or instruction used in the description of the present application should be construed as critical or essential to the invention unless explicitly described as such. Also, as used herein, the article “a” is intended to include one or more items. | A method for navigating a pointer on a graphical user interface (GUI) includes the steps of: scrolling an input device to locate the pointer corresponding to the input device on a point of interest within the GUI, depressing an actuating button associated with the input device on the point of interest, obtaining a detailed view of the point of interest while centering the point of interest on the GUI and maintaining a position of the pointer on the point of interest. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to alarm systems and, more particularly, to a multi-zone alarm system for, and method of, protecting a premises from alarm events such as burglary and fire.
2. Description of the Prior Art
Conventional alarm systems have not proven to be altogether satisfactory in preventing unauthorized entry and/or in preventing fire damage to industrial and/or home premises. With the evergrowing sophistication of the intruder or arsonist, conventional alarm systems are easily compromised by short- or open-circuiting the individual alarm sensor devices.
In a typical conventional alarm system installation, a plurality of burglary-type sensors are mounted in one closed circuit loop, and a plurality of fire-type sensors are mounted in another closed circuit loop. However, the burglary sensors are all of the same type, generally series-connected normally-closed switches each having two contacts. The fire sensors are likewise all of the same type, generally parallel-connected normally-open switches each having two contacts. Each loop has its own alarm sensing element for detecting whether a burglary sensor or a fire sensor has been actuated.
In order to overcome the increasing expertise of the intruder/arsonist, more sophisticated burglary and fire sensors, such as infrared light, ultrasonic sound, microwave, have been developed. These sophisticated sensors are switches having a three-contact configuration. One contact is a common contact, and defines a normally-closed branch path with a second contact, and defines a normally-open branch path with a third contact. However, in order to install these multiple contact sensors into an existing two-wire loop, adaptors for converting a three-contact switch to a two-contact switch are needed.
The above-described installation techniques suffer from many disadvantages. First of all, it is easy to compromise the burglary sensors by simply jumping its respective two contacts. The fire sensors are easily compromised by cutting the conductors leading to its respective two contacts. A combination fire-burglary system requires two loops, two sensing elements, and extra wiring. This represents additional costs not only in duplication of parts, but also in terms of the labor required to install the extra loops around a premises. Moreover, the extra wiring increases the probability of accidental breaks, thereby leading to inadvertent tripping of the alarm by the user of the premises. Still further, the sophisticated multiple contact sensors cannot be inexpensively installed, because they require additional wiring and expensive adaptors.
SUMMARY OF THE INVENTION
1. Objects of the Invention
Accordingly, it is the general object of the present invention to overcome the aforementioned drawbacks of the prior art.
Another object of the present invention is to provide a multi-sensor alarm system in which burglary sensors of the normally-open double contact type, or of the normally-closed double contact type, or of the sophisticated multiple contact type, can all be mounted in the same two-wire closed circuit loop.
An additional object of this invention is to provide a multi-sensor alarm system in which fire sensors of the normally-open double contact type, or of the normally-closed double contact type, or of the sophisticated multiple contact type, can all be mounted in the same two-wire closed circuit loop.
Another object of this invention is to provide a multi-sensor alarm system in which both burglary and fire sensors can be mounted now in the same two-wire closed circuit loop.
Still another object of the present invention is to eliminate the necessity for mounting fire sensors in one loop and burglary sensors in another loop.
An additional object of this invention is to eliminate the necessity for using adaptors to mount multiple-contact sensors in an already existing circuit loop.
Another object of this invention is to reduce the length and cost and labor involved in installing extra circuit loops in a premises to be protected.
Still another object of this invention is to reduce the probability of accidental breaks in the circuit wiring.
A further object of this invention is to wire a premises with maximum flexibility.
Another object of the present invention is to wire a premises with an alarm system which is not restricted to the type of configuration with which the sensor is normally supplied.
Still another object of this invention is to simplify the maintenance of the alarm system.
A further object of this invention is to provide a tamper-proof multi-sensor alarm system which will alert the occupant whenever any attempt is made to bridge, jump, short, cut or open the circuit path.
An additional object of this invention is to track an intruder/arsonist during his travel throughout a premises.
Still another object of this invention is to provide a multi-sensor alarm system which will recondition itself for subsequent alarms.
Yet another object of this invention is to provide a novel method of protecting a premises.
2. Features of the Invention
In keeping with these objects and others which will become apparent hereinafter, one feature of the invention resides, briefly stated, in a multi-sensor alarm system for, and method of, protecting a premises. The invention includes an electrical circuit means for establishing a two-wire closed loop circuit path having a load impedance through which an electrical current is conducted.
Three different types of burglary and/or fire sensors are connected in the same two-wire circuit path. A first type of normally-closed sensor is actuatable from a non-alarm state to an alarm state in which the current is respectively permitted or prevented from being conducted through the first sensor. A second type or normally-open sensor is actuatable from a non-alarm state to an alarm state in which the current is respectively prevented or permitted from being conducted through the second sensor. A third type is a multiple contact switch which defines two branch paths. One is normally-closed, and the other is normally-open in the non-alarm state. In the alarm state, the condition of the branch paths reverses.
Each sensor is operative to differently change the current and voltage characteristics of the two-wire circuit path. An alarm means is operative to sense each differently changed circuit characteristic, and to generate an alarm signal when any of the sensors is in its respective alarm state.
Hence, in accordance with the invention, a single two-wire circuit path is required to only accommodate all the various types of burglary sensors, or all the various types of fire sensors, or both the fire and the burglary sensors together. It is no longer necessary to restrict a single two-wire circuit path to only burglary sensors of a single type, or to only fire sensors of a single type; nor is it any longer necessary to mount sensors in different loops, thereby reducing the additional wiring and installation costs. The frequency of accidental breaks in the circuit path is reduced. The alarm system is not restricted to any particular type of contact configuration with which the sensor is normally supplied. Adaptors are no longer needed to accommodate the more sophisticated multiple contact sensors. Maintenance throughout the alarm system is greatly improved. A premises can be wired with maximum flexibility. The alarm system is tamper-resistant, because it will alert the occupant to any attempt to bridge, jump, short, cut or open the circuit path.
Still another feature of the invention is that the individual sensors are mounted in the circuit path such that one sensor can be actuated even after another sensor has already been actuated and has remained in its respective alarm state. Even if one sensor is of the automatically-resetting type and has returned to its non-alarm state, the other sensors are still operational to generate subsequent alarm signals.
The independent operation of the sensors can be used to track the course of an intruder through the premises. This information can be useful to law enforcement personnel.
The novel features which are considered as characteristic of the invention are set forth in particular in the appended claims. The invention itself, however, both as to its contruction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an electrical circuit schematic diagram of one embodiment of the multi-sensor alarm system in accordance with the present invention; and
FIG. 2 is another embodiment of the multi-sensor alarm system in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, reference numeral 10 generally identifies the multi-sensor alarm system for, and method of, protecting a premises in accordance with this invention. The system 10 basically comprises a sensor circuit 12 and an alarm circuit 14 which are electrically interconnected at terminals 16,18. At least one, and preferably a plurality of sensor devices, are electrically connected in the sensor circuit 12. The individual sensor devices, as described below, may all be of one type, or may all be of a different type, or may constitute various types in the same sensor circuit. All of the sensor devices of whatever type are distributed at desired locations of a premises to be protected.
As shown in FIG. 1, three different types of sensor devices are connected in the same single sensor circuit 12, which can serve as either a burglary-detection circuit only, or as a fire-detection circuit only, or as a combination burglary- and fire-detection circuit. However, this is not intended to be self-limiting on the invention in any way, because it is to be expressly understood that more than one sensor circuit, and that any number and type of sensor devices, are intended to be within the spirit of this invention. As described below in connection with FIG. 2, a plurality of independent sensor circuits, each connected to its own respectively-associated alarm circuit, can be utilized. In that case, one sensor circuit can be provided with a plurality of sensor devices which are all of one type; another sensor circuit can be provided with a plurality of sensor devices which are all of a different type; and still another sensor circuit can be provided with a plurality of sensor devices which are all of still a different type.
Reference numeral 20 identifies a type A sensor which is commonly, but not exclusively, used to detect burglary events. Type A sensors can be generally represented as two-contact switches whose contact configuration is of the normally-closed type. The type A sensor permits an electrical current to pass therethrough in its normally-closed (non-alarm) state. However, upon actuation, the type A sensor assumes an open (alarm) state and prevents the electrical current from being conducted therethrough. Typical examples of normally-closed type A burglary sensors are lead window foils, magnetic door switches, vibration detectors (tremblers), mercury window switches, etc. A typical example of a normally-open burglar sensor is a floor mat switch.
Reference numeral 22 identifies a type B sensor which is commonly, but not exclusively, used to detect fire events. Type B sensors can be generally represented as two-contact switches whose contact configuration is of the normally-open type. The type B sensor prevents an electrical current from passing therethrough in its normally-open (non-alarm) state. However, upon actuation, the type B sensor assumes a closed (alarm) state and permits the electrical current to pass therethrough. Typical examples of type B normally-open fire sensors are thermal detectors, rate of rise detectors, rate anticipation detectors, light refraction smoke detectors, product of combustion detectors, infrared detectors, etc.
Reference numeral 24 identifies a type C sensor which is commonly used to detect either burglary or fire events. Type C sensors can be generally represented as three- (or more) or multiple contact switches which have two branches. In its non-alarm state, the type C sensor permits an electrical current to pass through one of its branches, but prevents the electrical current from conducting through the other. In its alarm state, the type C sensor prevents the current from passing through the first-mentioned one branch and permits the current to pass through the second-mentioned other branch. Type C sensors, therefore, have a normally-closed and normally-open contact configuration in its non-alarm state, and the inverse contact configuration in its alarm state. Type C sensors are generally associated with the more sophisticated burglary detectors which are currently being sold. Typical examples of type C burglary sensors are of the infrared light type, the ultrasonic sound type, the microwave type, the seismic type, etc. However, it is to be expressly understood that any of the above-mentioned sensors, i.e. fire as well as burglary, are sold with contact configurations of the C type.
The system 10 includes electrical circuit means for establishing a two-wire closed loop circuit path in which all of the sensors 20,22,24 are electrically connected. An electrical current I 1 is conducted along the circuit path which starts from negative terminal 26 of a DC power supply along conductor 30 to terminal 18, and thereupon along conductor 32 through an end-of-line load resistor R 1 . The current I 1 returns along conductor 34 to terminal 16, and thereupon through various circuit components, e.g. L 1 , R 4 , D 1 , along conductor 36 to the positive terminal 28 of the DC power supply.
As noted above, the sensors 20,22,24 are mounted in the above-described closed loop circuit path. Normally-closed sensor 20 is connected in series with the load resistor R 1 ; normally-open sensor 22 is connected in parallel across the load resistor R 1 ; and sensor 24 is connected in cascade relative to the load resistor R 1 ; that is, one normally-closed branch is connected in series with the load resistor, whereas the other normally-open branch is connected in parallel across the load resistor. It is noted that sensor 20 is located nearest to the load resistor, that sensor 22 is located furthest from the load resistor, and that sensor 24 is located intermediate the sensors 20,22.
When normally-closed sensor 20 detects an alarm event, the sensor 20 opens, and the current I 1 no longer flows through the load resistor R 1 . Put another way, an open circuit condition appears across terminals 16, 18.
When normally-open sensor 22 detects an alarm event, the sensor 22 closes, and the current no longer flows through the load resistor, but instead flows through the sensor 22 itself. Similarly, when sensor 24 detects an alarm event, the sensor 24 changes from its illustrated condition, and produces a short circuit across the load resistor. Put another way, a short circuit condition appears across terminals 16, 18 when either sensor 22 or 24 is actuated.
It will be observed that no matter whether sensor 20, or 22, or 24 is actuated, the electrical characteristics of the sensor circuit 12, as measured at terminal 16 and 18, is changed. The change in the voltage and current parameters is different for the sensor 20, as contrasted to the change for the sensors 22 or 24.
In accordance with this invention, the alarm circuit 14 is operative to sense either of these differently changed electrical characteristics of the sensor circuit 12, and then to generate an alarm signal when any of the sensors have been actuated from their illustrated non-alarm states to their respective alarm states upon respective detection of an alarm event, such as burglary or fire situations.
The alarm circuit 14 includes a radio frequency choke L 1 for minimizing radio interference; and an pnp transistor TR connected in the circuit path in which the sensors are located, and operative for sensing the differently changed voltage and current parameters of the sensor circuit 12. Biasing resistor R 2 is connected between the collector and the positive power terminal 28; biasing resistor R 3 is connected between the emitter and the negative power terminal 26; biasing resistor R 4 is connected between the base and the positive terminal 28. Resistor R 5 is a decoupling resistor. The load resistor R 1 is likewise a biasing resistor, because it is located in the transistor biasing network; specifically, one side of the load resistor is connected to resistor R 3 and the other side of the load resistor is connected to the junction 38 between resistors R 4 and R 5 .
All of the biasing resistors R 1 , R 2 , R 3 , R 4 , are selected to bias the transistor TR into a "just-turned-on" or equilibrium condition. The transistor is a switching element which can be switched between a fully-on (saturated) condition and a fully-off (cut-off) condition. All the biasing resistors are chosen to establish the equilibrium condition somewhere between the saturated and cut-off conditions. A balance is obtained whereby an increase in voltage at base terminal 38 will drive the transistor into saturation, or conversely a decrease in voltage at base terminal 38 will drive the transistor into cut-off.
The equilibrium condition is adjustably set, either by careful selection of the biasing resistors, or by making any one or more of the biasing resistors a potentiometer, and therefore adjustable. For example, end-of-line resistor R 1 may be adjustable. Typically, the end-of-line resistor measures 2500 ohms.
Also connected between the collector and the base of the transistor is a light-emitting diode D 1 . Diode D 1 serves as a supervisory means for constantly monitoring the status of the sensors in the sensor circuit, as described below.
In order to more particularly set forth the illustrated normal equilibrium condition, let us assume for the sake of convenience that the voltage across power terminals 26,28 is approximately 15 volts DC. The biasing resistors R 1 -R 4 bias the transistor such that the base input voltage 38 is on the order of 8.5 volts. The collector output voltage at terminal 40 is on the order of 7.5 volts. The current I 2 passing through the supervisory diode D 1 is just enough to dimly light it. All the sensors are in their respective non-activated states.
Now, if sensor 20 opens and produces an open circuit across terminals 16, 18, then the base input voltage will suddenly increase from 8.5 v towards 15 v. The transistor will be driven into cut-off, and cause the collector output voltage to suddenly fall from 7.5 v towards 0 v. The current I 2 will concomitantly suddenly decrease and cause the supervisory diode D 1 to be extinguished.
Alternatively, if either sensor 22 or sensor 24 closes and produces a short circuit across terminals 16, 18, then the base input voltage will suddenly decrease from 8.5 v towards 0 volts. The transistor will be driven into saturation and cause the collector output voltage to suddenly rise from 7.5 v towards 15 volts. The current I 2 will concomitantly suddenly increase and cause the supervisory diode D 1 to emit much more light than before.
Hence, the transistor detects either open- or short-circuits across terminals 16, 18; that is, the same transistor can detect whether the current and voltage parameters of the sensor circuit are less than, or greater than, the predetermined equilibrium current and voltage parameters. At the same time, a user can visually check the light output of the supervisory diode to determine whether the sensors are still in their non-alarm states (diode dim), or whether the normally-closed sensor has been actuated to its alarm state (diode extinguished), or whether the normally-open sensors have been actuated to their alarm states (diode very bright).
The alarm circuit 14 includes a timer 44 operative for generating the alarm signal for a predetermined time period which is independent of any other time interval. The timer 44 is preferably an integrated chip type No. 555 which has eight terminals. Terminal 1 is grounded. Terminal 2 is an input terminal for receiving an electrical input timer signal generated from the collector output voltage of the transistor. Terminal 3 is an output terminal for supplying the alarm signal. Terminal 4 is connected to the positive terminal 28. Terminal 5 is connected to the negative terminal 26 through the decoupling capacitor C 5 . Terminal 6 is connected to the negative terminal 26 through the time constant capacitor C 6 . Terminal 7 is directly connected to terminal 6, and is connected to the wiper arm of time constant potentiometer R 10 . Terminal 8 is connected to one end of the potentiometer R 10 , and is also directly connected to terminal 4. The resistance of potentiometer R 10 and the capacitance of capacitor C 6 determine the time constant of the independent time period of the timer. The potentiometer R 10 serves as the means for adjusting the time duration of this time period. Typically, the time constant is set for about 15 seconds.
The timer 44 will produce the alarm signal at the output terminal 3 for the predetermined time period whenever a negative-going signal is applied at input terminal 2. It will be recalled that the collector output voltage at terminal 40 either decreases (sensor 20) or increases (sensors 22,24). Hence, it is necessary to modify the voltage at terminal 40 so that there is a negative-going signal in all cases.
The processing means for modifying the collector output voltage includes a charging-discharging processor sub-circuit which comprises a resistor R 8 and a capacitor C 1 connected in parallel with each other. A voltage divider constituting resistors R 6 and R 7 is connected between the positive and negative power terminals 28, 26. The sub-circuit is connected between terminals 40,42; the terminal 42 is located at the junction between the resistors R 6 , R 7 . The current-limiting resistor R 9 connects terminal 42 to the input timer terminal 2. A capacitor C 2 for minimizing radio frequency interference is connected between input terminal 2 and terminal 26.
In the aforementioned equilibrium position, 15 volts is present across the power terminals, and 7.5 volts is present at voltage divider terminal 42. This 7.5 volts represents a substantially constant biasing or reference value for the output of the processor sub-circuit. The quiescent collector output voltage value is also about 7.5 volts, and therefore very little, if any, current is applied to the timer input terminal 2. The timer is turned off. Put another way, the timer generates a non-alarm signal at output terminal 3.
Now, if the collector output voltage at terminal 40 suddenly increases from 7.5 volts towards 15 volts, then the voltage at terminal 42 likewise suddenly increases, and thereupon discharges back to 7.5 volts. A negative-going signal is generated at the trailing edge of the voltage waveform at terminal 42.
Conversely, if the collector output voltage at terminal 40 suddenly decreases from 7.5 volts towards 0 volts, then the voltage at terminal 42 likewise suddenly decreases, and thereupon charges back to 7.5 volts. A negative-going signal is generated at the leading edge of the voltage waveform at terminal 42.
In either case, a negative-going signal is applied to timer input terminal 2 to thereby generate a timer output signal at timer output terminal 3. The timer output signal generally has a voltage amplitude of about 9-9.5 volts. The timer output signal is conducted to an alarm relay RLY which has a relay coil L 2 and normally-open relay contacts 46,48. The alarm signal energizes the coil L 2 and is operative to close the contacts, to thereby generate the alarm signal which is conducted to the alarm device. The alarm device can be connected to a distant monitoring station via radio, phone lines, or other means.
The back electromotive force caused by collapse of the magnetic field in the relay coil L 2 is smoothed by diode D 3 which is connected across the latter. The capacitor C 3 serves to filter and smooth out any voltage spikes.
An alarm indicator means or light-emitting diode D 2 is operative for visually indicating the generation of the alarm signal. The diode D 2 is actuatable from its non-activated OFF-state to its activated ON-state whenever the alarm signal is generated. A latching means or silicon controlled rectifier SCR is operative for maintaining the diode D 2 in the ON-state whenever the alarm signal is generated.
In the equilibrium condition, the output timer terminal 3 is connected to the gate of the SCR through a decoupling resistor R 10 . The gate bias resistor R 11 is operative to bias the gate voltage to be at a value less than its threshold value, e.g on the order of 2.0 volts. The gate capacitor C 4 serves to minimize line transients.
A manually-resettable normally-closed switch SW is connected between the positive terminal 28 and the anode of diode D 2 . The cathode of diode D 2 is connected in series with a current-limiting resistor R 12 , which in turn is connected to the anode of the SCR. The cathode of the SCR is connected to the negative terminal 28.
In operation, whenever a timer output signal is generated, a voltage larger than the threshold voltage is applied to the gate of the SCR, thereby turning the latter on. The SCR stays on, even after the timer output signal has terminated, because current is still flowing through the SCR. The SCR can only be turned off by resetting the switch SW, i.e. by interrupting the current flow through the SCR.
The light-emitting diode D 2 emits a red-colored light in its ON-state. In its OFF-state, the diode D 2 is extinguished. By contrast, the light-emitting diode D 1 emits a green-colored light when it is either dimly or brightly lit. The different colors serve to distinguish the diodes and their different functions.
It will therefore be seen that type A and/or type B and/or type C sensors or any combinations thereof can be connected in the same two-wire closed loop, and that any shorting or opening of any of the contacts will be sensed to thereby generate an alarm signal.
Furthermore, the actuation of one sensor does not mean that the other sensors will automatically be rendered inoperative. For example, if sensor 20 is actuated, then, after its alarm signal has expired fifteen seconds later, the sensor circuit is still operative, because either sensor 24 or sensor 22 can still be actuated. After another 15 second delay, either sensor 22 or 24 can still later be actuated if they are of the automatically-rearming type and have returned to their non-alarm state, whether or not sensor 20 remains in the alarm state or returns to the non-alarm state. Put another way, sensor 20 need not be of the automatically-rearming type.
In a preferred installation technique, sensor 20 is a perimeter-type sensor, i.e. a sensor which is arranged at the exterior parts of a premises to be protected. For example, perimeter-type sensors protect doors and windows. Sensor 24 is preferably a room- or area-type sensor of the automatically-rearming type for protecting interior room areas of the premises. For example, area-type sensors protect wide zones of coverage, like carpets, interior room doors, etc. Sensor 22 is preferably an interior-type sensor of the automatically-rearming type for protecting items located in the rooms of the premises. For example, a safe can be protected by sensor 22. Inasmuch as an intruder will trip sensors 20,24 and 22 in that order, and that each of these sensors can still be actuated even if the perimeter sensor 20 remains in its alarm state, it will be possible to track the course of the intruder through the premises with the multi-zone alarm system of this invention. Of course, if all the sensors are of the automatically-rearming type, it doesn't matter what the order of tripping the sensors will be.
In the event that any one of the sensors is of the automatically-resetting type and returns to its non-alarm state at any time other than during the timing cycle, the processor sub-circuit also acts as a buffer circuit to absorb any contact activity. Thus, the R 8 -C 1 sub-circuit serves to introduce a slight time delay which prevents the timer 44 from retriggering.
Turning now to FIG. 2, another embodiment of this invention comprises connecting all the burglary sensors in one sensor circuit, all the fire sensors in another sensor circuit, and all other sensors, e.g. water temperature sensors, in still another sensor circuit. By segregating the burglary, fire and water temperature sensors, each type of alarm can be readily distinguished from the others.
As described above, burglary sensors typically have normally-closed double contact configurations. However, this is not necessarily so, because some burglary sensors have normally-open double contact configurations, e.g. floor mat switches, and the more sophisticated burglary sensors have multiple contact configurations. Nevertheless, all of these different contact configurations can all be mounted in the same sensor circuit 12a which is operative for exclusively detecting burglary events.
In analogous manner, fine sensors can have double- or triple-contact configurations, and can either be normally-open (UL approved) or normally-closed (UL non-approved). All of these different contact configurations can all be mounted in the same sensor circuit 12b which is operative for exclusively detecting fire events.
Also, in analogous manner, water temperature or the like sensors can be of normally-open or normally-closed type, or have multiple contact configurations. These sensors are all mounted in the same sensor circuit 12c which is exclusively operative for detecting that particular alarm event, e.g. water overheating or freezing.
As shown in FIG. 2, the burglary, fire and water temperature sensor circuits 12a, 12b, 12c are each provided with their own respective alarm circuit 14a, 14b, 14c which are analogous to the above-described alarm circuit 14. One alarm indicator is sufficient, or if desired, separate alarm indicators can be utilized.
Still another feature of the invention is a trouble indicator circuit connected with the fire sensor circuit 12b. It is desirable to alert the fire department of a fire event only when a short-circuit is established across terminals 16,18 of the two-wire closed fire loop. If an open-circuit or break is made across terminals 16,18 of the fire loop, then it is not desired to alert the fire department, but instead, to locally alert the occupant that there is "trouble" in the fire loop.
The trouble alarm circuit is roughly analogous to the alarm circuit 14 of FIG. 1, except that resistor R 2 is removed, and that terminal 38 is directly connected to terminal 40, thereby shorting out the transistor TR. In this modified configuration, a closure of the fire sensor in the fire loop will produce a negative-going signal at terminal 42 for the timer 44, because the voltage at terminal 38 will suddenly decrease from about 8.5 v towards 0 volts. As before, the negative-going signal fed to the timer will generate the fire alarm signal.
However, an open or break in the fire loop will not produce a negative-going signal at terminal 42, because the voltage at terminal 38 will rise from 8.5 v towards 15 v and remain at 15 v for as long as the fire loop is open. This positive-going signal is used as a trigger input for an additional trigger signal processing circuit which will generate a trouble signal which is distinctive from the aforementioned alarm signal. The trouble signal is locally annunciated, either auditorily and/or visually, and is generally not transmitted to the fire department station.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the types described above.
While the invention has been illustrated and described as embodied in a multi-sensor alarm system and method of protecting a premises, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can by applying current knowledge readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention and, therefore, such adaptations should and are intended to be comprehended within the meaning and range of equivalence of the following claims. | A multi-sensor alarm system and method of protecting a premises include at least one sensor circuit and an alarm circuit which together establish a two-wire closed loop electrical circuit path in which a wide variety of alarm sensors are accommodated. The sensors include two-contact configurations which are normally-closed or normally-open, as well as multiple-contact configurations which are characterized by both normally-closed and normally-open contacts. Each sensor differently changes the electrical parameters of the circuit path; and the alarm circuit includes a transistor which senses each parameter change, and a timer which generates an alarm signal whenever any of the sensors is actuated. Opening or closing the circuit path at any point therein will cause the alarm signal to be generated. A status indicator constantly monitors and supervises the status of the sensors in the circuit path. An alarm indicator is latched to the ON-state to constantly indicate the fact that the alarm signal has been generated. A manual-reset switch returns the alarm indicator to its OFF-state. The alarm system reconditions itself such that more than one sensor can be tripped, no matter whether the particular sensor is of the non-resettable or of the automatically-resetting type. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates to a bike locking mechanism; more specifically, the present invention relates to separate front and rear bike locks and the combination of a front and rear bike lock working together.
BACKGROUND OF THE INVENTION
[0002] EP Application Pub. EP 0 192 467 Published 27.08.86 Application 86301139.1 filed 19.02.86
[0003] The aforementioned European Patent Application described a novel locking mechanism that teaches a rack key locking system as described below.
[0004] The publication refers to improvements in a rack and pinion system for activating lock cylinder units.
[0005] This enables the lock cylinder unit to be retained against rotating movement by a plurality of discs oscillating about its shaft and provided with a toothed section, a segmented area of each of them being housed in openings at corresponding points of a fixed sleeve of the cylinder unit. The said discs are disposed in plates radial to the cylinder unit shaft, secured at their axial ends to circular supports.
[0006] The release position of the lock cylinder unit, so that it can rotate freely, is obtained by inserting, axially to the cylinder unit, the corresponding key provided with a plurality of racks disposed longitudinally at at least one of the faces of its polygonal profile, which racks are capable of meshing with the corresponding teeth of the discs; causing them to rotate to a maximum penetration position of the key at which segmented offsets of the discs coincide with the open-in6s of the fixed sleeve. At this position there are no means for retaining the cylinder unit against rotation.
[0007] Each of the discs is impelled by a spring which maintains it in an angular position fixed by a butt, in order to enable insertion of the key and so that the initial tooth of each of its racks impinges correctly on the first tooth of the disc, without causing any obstruction or blocking between teeth.
[0008] The wide range of lock cylinder units and corresponding keys is achieved by varying the number of teeth of at least one of the key racks, since this has a bearing on the final position adopted by the corresponding disc, and therefore its segmented offset, enabling the cylinder unit to rotate freely, should be placed at a different position. According to the teachings herein, and to highly increase the different combinations of lock cylinder units and keys, the pitch of at least one of the rack and pinion gears must differ from that of the rest. Further, the teeth of at least one of the key racks can be disposed in a lineally offset position from those of the rest.
[0009] According to the teachings herein, the discs provided with a toothed area are preferably placed at both sides of the radial plates, oscillating about a common shaft which passes through them, the said discs being angularly positioned so that the first tooth, on which the key impinges, is firmly positioned by the said butt, close to the shaft of the lock cylinder unit and coinciding therefore with that of the operating key. In accordance with this arrangement of the discs, the racks of the key will be positioned in pairs, their teeth having the same or a different pitch, as well as also slight-ly offset, as already indicated.
[0010] The disc support plates are preferably arranged according to two perpendicular planes, so that their inner edges are close to the shaft, emerging from the discs, wherefore the key will adopt a general square section and will be provided with four longitudinal notches constituting the guiding means for the insertion thereof, since the longitudinal edges of the said support plates slide there along.
[0011] FIG. 1 is an elevational view of one of the support plates of the partially toothed discs, corresponding to a position at which the lock cylinder unit is retained against rotation, and also showing the key of the actuating system of the teachings herein.
[0012] FIG. 2 is a section on line A-B of FIG. 1 .
[0013] FIG. 3 is a fragmentary perspective view showing the fastening of the radial support plates of the discs to end circular supports, thereby determining the solid frame of the lock cylinder unit.
[0014] FIG. 4 is a cross-section of the lock cylinder unit of FIG. 3 , including the discs and the fixed sleeve of the cylinder unit.
[0015] FIG. 5 is a partial section of the operating key of the teachings herein.
[0016] FIG. 6 is a section on line C-D of FIG. 5 .
[0017] FIG. 7 is a perspective view of the fixed sleeve of the lock cylinder unit, illustrating the openings constituting the means for retaining the cylinder unit against rotation.
[0018] Referring to the drawings, it can be seen that the rack and pinion system for activating lock cylinder units is comprised of a plurality of discs 1 provided at a partial area of their periphery with teeth 2 , each one of which has a segmented offset defining a straight line 3 at a relative position with respect to the teeth 2 , some discs differing from others. The discs 1 are preferably disposed in pairs and are rotatably supported at both sides of a plurality of support plates 4 disposed radially to the shaft of the lock cylinder unit, which plates are fixed at their ends 5 to axially-holed circular supports 6 . According to a preferred embodiment of the teachings herein, there are four radial support plates 4 disposed according to two perpendicular planes, although any other arrangement having a higher or lesser number of support plates and preferably arranged in a uniform angular position could be adopted.
[0019] Referring to FIG. 3 , the support plates 4 are fixed to the circular supports 6 provided with the axial hole 7 , the assembly being secured by screws 8 passing through holes 9 of a member 10 placed in a backed relation with the outer face of the inner circular support 6 , and through corresponding holes 11 of said circular supports 6 , the end of said screws 8 en-engaging in threaded holes of another end member 12 placed in a backed relation with the outermost circular support 6 and provided with the axial hole 13 for inserting the key 14 .
[0020] The assembly of elements through which the screws 8 pass, forms a compact assembly constituting the rotary frame of the lock cylinder unit.
[0021] According to FIGS. 1 and 2 , each support plate 4 includes two discs 1 backed to their faces and oscillating about a common shaft 15 which passes through the support plate 4 . The shaft 15 is retained against axial movement since its ends are provided with annular slots 16 into which the end lugs 17 and 18 of one of the ends of abutting members 19 are introduced, the opposite end of which is secured to the support plate 4 by means of a pin 20 .
[0022] Each abutting member 19 therefore has the dual purpose of, on the one hand, preventing the common shaft 15 , for turning two discs 1 , from emerging and, on the other hand, fixing the angular position of the teeth 2 of the disc 1 , when the pivot 21 emerging from the outer face of the disc 1 , since it is aided by a spring 22 , contacts its edge radially furthermost from the shaft of the cylinder unit.
[0023] According to FIG. 1 , each disc 1 has an area in the form of a circular segment 23 which emerges from the radially furthermost longitudinal edge 24 of the support plate 4 . Upon insertion of the key 14 through the opening of the end member 12 of the lock cylinder unit, the first tooth 25 of the corresponding rack 26 , provided longitudinally in the key 14 and cap-able of meshing with the teeth 2 of the corresponding disc 1 , impinges on the first tooth 2 thereof, causing an angular displacement of the disc in which, at the position corresponding to that of maximum penetration of the key 14 , the segmented offset 3 of the disc 1 occupies the position shown at 27 in FIG. 1 , at which it is joined to the upper edge 24 of the support plate 4 .
[0024] As can be seen from FIGS. 4 and 7 , as long as the lock is not activated by the corresponding key, the discs 1 present a circular segment 23 , emerging from its support plate 4 , this circular segment 23 being housed in the corresponding housing 28 made in the direction of the generators of a sleeve 29 of the cylinder unit frame, which remains fixed and therefore stationary with respect to the cylinder unit, thereby constituting the blocking means for the lock.
[0025] The housings 28 of the fixed sleeve 29 are formed of rectangular windows uniformly arranged on the circular periphery of the sleeve. In the embodiment shown in the figures, they are arranged in pairs, there-fore forming, between each two consecutive pairs, a small stiffening partition 30 which insures the entire stable position and a maximum resistance against a possible fraudulent action due to the rotation of the cylinder unit.
[0026] Referring to FIG. 4 , the eight discs 1 are partially housed in the corresponding housings 28 of the sleeve 29 , the cylinder unit therefore being retained against rotation or being encountered at a block-ing position. FIG. 4 also illustrates that the free edge 24 of the support plate 4 is positioned close to the inner surface of the sleeve 29 , whereas its innermost edge is very close to the lock cylinder unit.
[0027] According to FIGS. 5 and 6 illustrating the key, it can be seen that the profile has a polygonal shape, adapted to the number of support plates 4 of the cylinder unit shaft, said profile having a like number of notches 31 defining guiding means for the insertion of the key, since the innermost edge of the support plates 4 is housed in said notches 31 (see FIGS. 1 and 4 ). At the maximum insertion position of the key 14 , that is when the front end 32 thereof butts against the end member 10 of the lock cylinder unit, all the segments 3 or offsets of the discs 1 are positioned according to the dotted line 27 of FIG. 1 , prolonging from the upper edge 24 of the support plates 4 , where-by the housings 28 of the sleeve 29 of the cylinder unit are free from the disc 1 , thereby eliminating the blocking means for the lock cylinder unit to turn freely.
[0028] Each of the racks 26 disposed in the key 14 has a different number of teeth 25 , so that, until the maximum insertion position of the key is reached, a different angular displacement will be produced in each one of the discs, or at least in some of them, wherefore the segmented offset 3 of each of the discs 1 is made at a relative position in accordance with the angular magnitude of the rotation. Apart from the different number of teeth of the racks 26 of the key 14 , the pitch of the rack and pinion gear of some of the discs 1 and their respective rack 26 can also vary, end further, although all the racks have the same pitch, the teeth of some of them can be offset from the teeth of others, enabling the number of possible combinations in the formation of the range of locks to be highly increased and preventing the same manufactured unit from being repeated.
[0029] Since the teeth of the racks 26 intervening in the rotation of the respective discs 1 are those positioned close to the end 32 for the insertion of the key, the said racks can depart from the same front surface 33 close to the widening 34 for securing the key, since this arrangement is not related to the functioning.
[0030] As can be seen from FIG. 4 , the fixed sleeve 29 of the lock cylinder unit is, in turn, covered with another steel sleeve 35 which conceals the housings 25 of the former, to prevent access to the discs 1 as well as a fraudulent action.
[0031] Upon extraction of the key 14 , all the discs 1 recover their original position to enable the key 14 to be re-inserted by means of springs 22 .
[0032] If a key 14 differing from that corresponding to the cylinder unit, because it has a different gear pitch or an offset arrangement of the racks, is inserted, the assembly will normally be blocked because of jamming, and it will not be possible to completely insert the key or to extract it thereafter, if insertion has been forced. In the case of a very simple arrangement of racks and partially toothed discs, even though the key could be completely inserted, one area of each of the discs will always be housed in the corresponding housing of the fixed sleeve, therefore preventing the cylinder unit from rotating freely, which effect is achieved only when the corresponding key is inserted and all the discs rotate in the adequate angular magnitude.
Bike Locks
[0033] Bike locks come in a variety of sizes and shapes. The most reliable and effective tend to be those locks that are least portable and most expensive. Amongst the various types of existing bike locks are the U-locks and D-locks, chain, cable, wheel and locking skewers.
[0034] The so-called U-lock is a rigid metal ring that is formed like the letter U. A crossbar portion attaches to the U part of the lock. The attachment of the crossbar portion makes the entire device appear to be in the shape of a letter D. In order to secure the bike a user attaches it to some other object, such as a bike rack, parking meter or a flagpole or similar structure.
[0035] A chain lock has a predetermined length of chain that has a lock attached at a link of the chain; the lock is typically a combination or key based lock. If there is sufficient length the chain can pass through both wheels, the bike frame and fix it to an immovable object such as a rack, pole or meter. Since chains are easy to manipulate and rearrange around objects, they are easier to lock about then the D locks.
[0036] Another type of bike locking mechanism is a cable lock. These share some similarities to chain locks in that they have a locking mechanism attached to a length of flexible material. Cable locks usually have a lock already permanently integrated with the cable so as to ensure proper attachment of the bike. Alternatively, a length of cable with loops on both ends is used to thread the lock therethrough. The main advantage of cable locks over chains is that they are more portable then chain locks.
[0037] Next, a wheel lock also known as an O-lock or ring-lock, is a low security mechanism mounted on the frame that prevents motion of the rear wheel by moving a metal rod through the bike spokes to prevent rotation of the aforementioned.
[0038] Finally, locking skewers replace the existing quick release skewers on a bicycle's wheels and seat post clamp.
[0039] A criminal with a cutting mechanism can simply break the chain, cable, metal part and pedal away or load the bike in the back of a truck and drive away. Thus, cable, chain, D, skewer and wheel locking mechanisms are easily breakable by a delinquent and do not provide sufficient protection for the bicycle. Accordingly, there needs to be some solution to overcome the aforementioned problem.
SUMMARY OF THE INVENTION
[0040] The present invention overcomes the deficiencies of the known art and the problems that remain unsolved by providing the following:
[0041] A bicycle locking system comprising:
[0042] a deadbolt lock attached to
[0043] a tubular member of the bicycle.
[0044] In another aspect, a rotating member situated within the tubular member.
[0045] In another aspect, a perforation on one side of the tubular member.
[0046] In another aspect, a first perforation in the rotating member.
[0047] In another aspect, a second perforation in the rotating member.
[0048] In another aspect, wherein the first and second perforation are disposed on opposite sides of the rotating member.
[0049] In another aspect, wherein the first and second perforation are disposed at angle apart from each other on the rotating member.
[0050] In another aspect, wherein the angle creates a chord between the first and second perforation.
[0051] In another aspect, wherein the tubular member is the head tube of the bike.
[0052] In another aspect, a bike locking mechanism comprising:
a bike having a top tube and a linear frictional member attached at an end of the top tube.
[0056] In another aspect, a deadbolt lock attached to the linear frictional member.
[0057] In another aspect, wherein the deadbolt lock further comprises: a bolt exiting the locking mechanism.
[0058] In another aspect, wherein the bolt exiting the locking mechanism further comprises an end plate.
[0059] In another aspect, further comprising a rubber device attached to the end plate.
[0060] In another aspect, a bike locking apparatus comprising:
a bike having a top tube and a front locking device inserted within the top tube.
[0064] In another aspect, a rear locking device inserted within the top tube and operable in conjunction with the front locking device.
[0065] In another aspect, wherein the front locking device further comprises:
a rack and pinion system.
[0067] In another aspect, wherein the rear locking device further comprises:
a rack and pinion system.
[0069] In another aspect, wherein the front locking device and the rear locking device further comprise:
a top rack associated with one device and bottom rack associated with the other device.
[0071] In another aspect, a pinion attached to and operable from a keyed locking mechanism to rotatable actuate the bottom and top rack devices.
[0072] These and other aspects, features, and advantages of the present invention will become more readily apparent from the attached drawings and the detailed description of the preferred embodiments, which follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0073] The preferred embodiments of the invention will hereinafter be described in conjunction with the appended drawings provided to illustrate and not to limit the invention, in which:
[0074] FIG. 1 presents an elevational view of one of the support plates of the partially toothed discs, corresponding to a position at which the lock cylinder unit is retained against rotation, and also showing the key of the actuating system of the EP patent publication of the prior art.
[0075] FIG. 2 is a section on line A-B of FIG. 1 of the EP patent publication of the prior art.
[0076] FIG. 3 is a fragmentary perspective view showing the fastening of the radial support plates of the discs to end circular supports, thereby determining the solid frame of the lock cylinder unit of the EP patent publication of the prior art.
[0077] FIG. 4 is a cross-section of the lock cylinder unit of FIG. 3 , including the discs and the fixed sleeve of the cylinder unit of the EP patent publication of the prior art.
[0078] FIG. 5 is a partial section of the operating key of the teachings of the prior art.
[0079] FIG. 6 is a section on line C-D of FIG. 5 of the EP patent publication of the prior art.
[0080] FIG. 7 is a perspective view of the fixed sleeve of the lock cylinder unit, illustrating the openings constituting the means for retaining the cylinder unit against rotation of the EP patent publication of the prior art.
[0081] FIG. 8A presents a side view of a novel front lock according to an embodiment. FIG. 8B presents a view of a novel front bike lock according to an embodiment. FIG. 8C presents an isometric view of a portion of the tubular structure of the bike having holes for practicing an embodiment. FIG. 8D presents a top cross section view of the top portion of the holysmoke. FIG. 8E shows an assembled cross section of the front tubular structure of a novel front bike lock according to an embodiment. FIG. 8F shows a novel front lock once the bolt or pin has been extended according to an embodiment.
[0082] FIG. 9A presents a side view of a novel bicycle rear lock according to an embodiment. FIG. 9B illustrates a rear view of a novel rear bike lock according to an embodiment. FIG. 9C illustrates a retracted bolt locking arm of a novel rear bike lock according to an embodiment. FIG. 9D shows an extended bolt locking arm of a novel rear bike lock according to an embodiment.
[0083] FIG. 10A presents an isometric side view of a barrel of a novel bike lock according to an embodiment showing the toothed gear at the end of the barrel for turning the front and rear racks. FIG. 10B shows a side view of interior side wall of a bike tube having a protrusion forming a rotational axis for the barrel and toothed gear. FIG. 10C illustrates a right side view of a set of front and rear racks of a novel bike lock according to an embodiment. FIG. 10D shows a left cross section view of a set of front and rear racks inside a top tube of a novel bike lock according to an embodiment. FIG. 10E shows a left cross section side view of a bike showing the rack mechanism inside of a top tube for a novel bike lock according to an embodiment. FIG. 10F shows a front bolt lock of a novel bike lock according to an embodiment as the locking mechanism enters the front tube walls. FIG. 10G illustrates a left side isometric view of tubular device having a rack used to create a front lock according to an embodiment. FIG. 10H shows a left side isometric view of a tubular device having a rack used to make a rear lock in combination with a friction member according to an embodiment. FIG. 10I is a swivel joint for a rear friction lock according to an embodiment. FIG. 10J is a side view of a friction member according to an embodiment.
[0084] Like reference numerals refer to like parts throughout the several views of the drawings.
DETAILED DESCRIPTION
[0085] The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the disclosure and are not intended to limit the scope of the disclosure, which is defined by the claims. For purposes of description herein, the terms “upper”, “lower”, “left”, “rear”, “right”, “front”, “vertical”, “horizontal”, and derivatives thereof shall relate to the invention as oriented in the individual figure. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.
[0086] The following is a detailed description as to the embodiments herein. What is proposed is a deadbolt locking system of the front wheel, friction lock of the back wheel and a combination rack and pinion system of the front and rear wheels.
[0087] FIG. 8A presents a side view of a novel front lock according to an embodiment. A top tube 37 of a bike is integrated with the an external portion of head tube 38 of a bike as shown; similarly, a down tube of a bicycle is integrated with a side of a bottom portion of a head tube 38 . The head tube 38 has a hollow passageway 39 running through it. A deadbolt lock 40 is integrated on the side of the head tube 39 so that it juts out the side of the head tube 39 . Optionally, the deadbolt lock 40 is situated underneath the top tube 37 and above the down tube 36 for a more streamlined appearance.
[0088] FIG. 8B presents a view of a novel front bike lock according to an embodiment. The bike deadbolt lock 40 is integrated with the side of the head tube 38 using welds or screw locked mounts 44 . A key lock 43 is found in the deadbolt lock as shown; locking the system requires the bolt 42 made from a suitable metal to proceed through a cavity in the head tube passing into a central cavity 39 of the head tube 38 . Optionally, the other side of the head tube has a depression 41 for reception of the bolt that further strengthens the locking of the bike wheel.
[0089] FIG. 8C presents an isometric view of a portion of the tubular structure of the bike having holes for practicing an embodiment. The top tubular portion of the holysmoke 45 has two holes 46 through it arranged in a pair. The holes are arranged offset from the center of the circle such that they are less than 180 degrees apart from the adjacent hole; when set in the bike, the holysmoke 45 is set with a predetermined angle and distance to the first hole 46 from a centerline through a cross section of it. The holes are arranged so that when the wheel of the bike is turned a deadbolt locking mechanism is inserted within the two holes 46 through corresponding holes in the head tube 38 .
[0090] FIG. 8D shows a top cross section top view of the top portion of the holysmoke 45 according to an embodiment showing corresponding holes 46 offset from the center of the circular holysmoke.
[0091] FIG. 8E shows an assembled cross section of the front tubular structure of a novel front bike lock according to an embodiment. A head tube 38 having a hole and a depression therein is concentrically arranged along with a top tubular structure of a holy smoke 45 . The holy smoke 45 has two perforations along its surface that permit access from the outside to the shaft or cavity therein. It should be apparent that the holysmoke is arranged with these perforations arranged at a predetermined angle from a pair of axes drawn therein; thus, a plane representing the front bike wheel 48 and bike wheel rear portion 47 are situated at a predetermined number of degrees from the first hole adjacent to that plane. A deadbolt bike lock 40 side integrated in the head tube 38 of a bicycle has a key activated port 43 . The deadbolt bike lock 40 has screw mounts with locking screws and or weld points 44 ; alternatively, the entire device is an integral structure with the head tube. The bolt of the deadbolt lock 40 proceeds through a passageway in the head tube 38 and on through the holes in the holysmoke 45 when extended. The arrangement of the holes thereby avoids the dipstick within the head tube that is not shown but understood to be concentrically arranged therein.
[0092] FIG. 8F shows a novel front lock once the bolt or pin has been extended according to an embodiment. In this drawing, the deadbolt has been extended through the perforation in the head tube 38 on through a first perforation in holysmoke 45 through a second perforation therein and on into a depression on the other side of the head tube 38 . Optionally, the bolt is only long enough to make it through the second perforation and not into the depression; a final option is that the bolt can only make it through the first perforation. Each of these steps provides less protection but also more flexibility for designers seeking to make changes in bike design.
[0093] FIG. 9A presents a side view of a novel bicycle rear lock according to an embodiment. A rear locking mechanism 900 is shown attached to a bicycle. A first tubular member 53 or solid rod made from a suitable metal is attached to the rear portion of the bike between the stays at a juncture 51 there between where the two stays become one. This tubular member is attached by welding or screw mounts to a deadbolt key lock mechanism 52 . The deadbolt 49 itself proceeds out from the locking mechanism and ends in friction member 50 formed of a rubber material adhesively and mechanically forced onto a T shaped top plate. The rubber material itself has a cut out that closely matches this shape so that it can be mounted thereon.
[0094] FIG. 9B illustrates a rear view of a novel rear bike lock according to an embodiment. The tubular member or rod 53 is shown attached to a juncture 51 between the stays. The tubular member or rod is integrated with a deadbolt locking or attached thereto. This locking mechanism has a deadbolt 49 that proceeds out therefrom and ends on a friction rubber member 50 attached to a T shaped end of the deadbolt 49 .
[0095] FIG. 9C illustrates a retracted bolt locking arm of a novel rear bike lock according to an embodiment. The tubular member or rod 53 is shown attached to a key activated deadbolt mechanism 52 with a retracted deadbolt 49 .
[0096] FIG. 9D shows an extended bolt locking arm of a novel rear bike lock according to an embodiment. The tubular member or rod 53 is shown attached to a key activated deadbolt mechanism 52 with a extended deadbolt 49 .
Dual Front and Rear Locking Mechanism
[0097] FIG. 10A presents an isometric side view of a barrel of a novel bike lock according to an embodiment showing the toothed gear at the end of the barrel for turning the front and rear racks. Barrel 35 is a cylinder or sleeve that surrounds the mechanisms as taught in the prior art patent EP Application Pub. EP 0 192 467 Published 27.08.86, Application 86301139.1 filed 19.02.86; it should be understood that the teachings found in the background of the invention are herein utilized to make a rotatable bike locking rack and pinion system as taught in the following description. The mechanism of that patent operates the same here except several modifications are made to it so that a bike rack and pinion lock mechanism can be made to work.
[0098] FIG. 10B shows a side view of interior side wall of a bike tube having a protrusion forming a rotational axis for the barrel and toothed gear. The sleeve or barrel 35 has its external surface welded into a hole on one side of the top tube 37 of a bike; this prevents the barrel or sleeve from turning. Member 10 is modified to have teeth that rotate in union with support 6 that it is attached to. The back part of the member 10 has a hollow area that closely matches a metal protrusion welded to the inside surface of the top tube; this metal protrusion is welded or integral with the top tube inner surface, at its bottom to the inner surface of the top tube on the opposite side of the hole where is welded the outside of sleeve 35 . Using physical force the cylindrical hollow side of member 10 is forced onto this protrusion so that it can rotate thereon.
[0099] FIG. 10C illustrates a right side view of a set of front and rear racks of a novel bike lock according to an embodiment. Rotating member's 10 teeth are arranged within two sets of teeth 58 disposed on two toothed racks 56 , 57 ; in this fashion the rotation of the member 10 acts as a pinion to move the top and bottom racks 56 , 57 . The toothed racks are metal rods horizontally extending from two other metal rods 54 , 55 or cylinders that operate within the top tube to open and close a dual operating locking mechanism.
[0100] FIG. 10D shows a left cross section view of a set of front and rear racks inside a top tube of a novel bike lock according to an embodiment. The top tube 37 of a bicycle has two toothed racks 56 , 57 that are metal rods horizontally extending from two other metal rods 54 , 55 or cylinders that operate within the top tube to open and close a dual operating locking mechanism.
[0101] FIG. 10E shows a left cross section side view of a bike showing the rack mechanism inside of a top tube for a novel bike lock according to an embodiment. This view further shows how the rear cylinder or rod 55 extends toward a hole between the stays at the rear end of the bicycle. The rod or cylinder 55 ends in a joint 59 that has recesses for holding a curved swivel mechanism that actuates the friction brake at the back end of the bicycle.
[0102] FIG. 10F shows a front bolt lock of a novel bike lock according to an embodiment as the locking mechanism enters the front tube walls. A bolt or pin integrally formed form cylinder or rod 54 proceeds parallel and out therefrom at its front portion. When a key is turned opening the locking mechanism situated in the midst of the top tube the lock activates the sliding mechanism within the top tube moving the rack forward. Then, the pin or bolt enters a hole in the head tube and further on into the first perforation in the holy smoke thus locking the bike in place. It can proceed further to a depression 41 on the other side of the tube as in the front lock embodiment of FIG. 8D-F .
[0103] FIG. 10G illustrates a left side isometric view of tubular device having a rack used to create a front lock according to an embodiment. The tubular device 54 has a rack 57 at one end having teeth 58 and a pin or bolt at the other end jutting forwards and in parallel with the rest of the device 54 .
[0104] FIG. 10H shows a left side isometric view of a tubular device having a rack used to make a rear lock in combination with a friction member according to an embodiment. The tubular device 55 or rod has a rack 56 disposed on its forward portion having a set of teeth 58 . At the other end or rear portion of the tubular member 55 there is a fixed hinge set between two holders 59 . The two holders are integrated with the fixed hinge or swivel point 59 .
[0105] FIG. 10I is a swivel joint for a rear friction lock according to an embodiment. FIG. 10I is a swivel joint or juncture having two sides and a hinge there between. The two portions of the juncture 59 are integrated with the hinge axis fixed there between.
[0106] FIG. 10J is a side view of a friction member according to an embodiment. Braking member 61 is primarily formed of a rod or hollow metallic member having a T-shaped end 63 at one end. This T-shaped member 63 is surrounded by a rubber portion that is adhesively and physically locked in place thereon to make frictional contact with the rear tire of a bike. On the other side of braking member 61 is a curved swivel joint or mechanism that has two protruding curves that are welded together at manufacture. Of course the welding happens after the jaw formed by the two curves has been loaded onto the hinge 59 located at the end of cylinder or rod 55 ; the two ends are brought together and welded together at that time.
[0107] Finally, stops 64 are found on opposite sides of the braking member 61 ; these are protrusions that act in combination with a locking plate 65 to ensure that the member 61 can proceed no further outside of top tube 37 . The locking plate is a simple piece of metal having a perforation that permits the member 61 to slide therethrough but does not permit it to proceed further then stops 64 . The locking plate is made from a strip of material that is cut, bent and situated about member 61 ahead of the stops 64 then bent again into place and all ends are welded together and the edges thereof are welded to the perforation's edges between the stays. Of course, another solution envisions two precut pieces of material being brought together and welded to the perforation between the stays after loading the member and other components into place.
[0108] All components are metallic unless otherwise indicated; further, suitable replacement materials having properties similar to metals can also be utilized. The above described embodiments are merely exemplary illustrations of implementations set forth for a clear understanding of the principles of the invention. Many variations, combinations, modifications or equivalents may be substituted for elements thereof without departing from the scope of the invention. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed as the only modes contemplated for carrying out this invention, but that the invention will include all the embodiments falling within the scope of the appended claims. | A deadbolt lock is utilized to lock a turned wheel in place at an angle from its ordinary orientation. Perforations in the holy smoke tube match perforation in the head tube whereupon the bolt from the keyed lock may be inserted upon turning of a key. A rear wheel friction lock is provided having a member having a deadbolt lock that extends a frictional rubber device to make contact and block further rotation of the tire. Finally, a dual rack and pinion system has a key lock activated pinion articulating oppositely operating rack members; a pin or bolt lock blocks front tire and wheel movement and a hinged friction lock blocks rear tire and wheel motion. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to a method and apparatus for automatically removing filler thread from a multi-end yarn tape and for thereafter taking up the individual yarn ends on corresponding take-up spools.
The deweaving technique of this invention was developed primarily for use with a continuous run dyeing process; however, it may be used with any yarn processing method which utilizes a plurality of yarn ends held together in a flat package by a filler thread, called a "lease", which essentially weaves the yarn ends together. A multi-end yarn tape yarn construction of this type is particularly useful in continuous run bath dyeing where the tape is run through a dying apparatus in which one or more dyes are applied to the yarn by a roller application technique.
In a multi-end yarn tape, a plurality of yarn ends, for example, 40 to 80 ends, of approximately equal length are woven together in the form of a tape by the leasing or filler thread. This tape forming technique is described in U.S. Pat. No. 3,605,225, issued Sept. 20, 1971 to K. H. Gibson et al. A problem which has developed in using multi-end yarn tapes of this type and which has inhibited the use of such tapes in continuous-run dyeing is that it has been necessary to remove the filler or leasing thread by hand. This is an extremely time-consuming operation which has led many dyers to stay away from the use of such tapes. Moreover, even after the tape has been deleased by hand, it has then been necessary to perform several different operations separately. For example, after the leasing thread has been removed, the ends are separated on a machine which runs each yarn end into a separate container. These containers are then transferred to a winding apparatus which takes the yarn out of the container and winds it onto a spool. If the yarn wound on this spool does not have the required degree of uniformity for shipment, it must then be taken to another winder which winds the yarn end onto a further spool or a cone with the degree of uniformity suitable for shipping to the customer.
The present invention was designed to overcome the former difficulties in manual deleasing and to eliminate at least some of the steps in the above-described operation. With the use of this invention, the continuous-run dyeing techniques have become both practical and economically feasible.
SUMMARY OF THE INVENTION
The multi-end yarn tape is threaded onto the deweaving apparatus and the filler thread is wound onto a Gilbos winder modified to provide a motor speed control based on the tension on the filler thread. The yarn tape follows a path which takes it first through an overhead channel, then around a first guide which reverses the direction of tape movement, around tension members, and over a kiss roll which applies an antistatic emulsion. Downstream of this point, the filler thread is separated and is wound onto the Gilbos winder, passing first through a large eye connected to a microswitch control rod which provides on/off control of the winder motor. (In a modified version, this control rod may be connected to a rheostat to provide continuous motor control.) After passing through the eye, the filler thread passes through a guide hole on the winder and then around various tension members, including a sensor bar which shuts off the winder when the filler thread breaks. The several yarn ends continue across the top of the frame to another set of tension members, and then onto a winding frame which contains at least as many take-up spools as there are yarn ends. In one version of the machine, there are up to 80 take-up locations.
BRIEF DESCRIPTION OF THE DRAWING
FIGS. 1A and 1B show side and top views, respectively, of the deweaving apparatus;
FIG. 2 shows a portion of the take-up frame and rollers;
FIG. 3 is a block diagram of the electrical circuit of this invention; and
FIG. 4 shows details of the motor control devices.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The deweaving or deleasing apparatus, shown in FIGS. 1A and 1B, comprises an open box-like framework 20 having a pair of front legs 22 and a pair of back legs 24; a top pair of parallel frame members 26, 26' rest on legs 22 and 24 and extend rearwardly of back legs 24. The yarn tape feed section of the apparatus includes a channel member 28 mounted to one side of the framework 20 and slightly below top members 26, 26'. A yarn guide member 30 is mounted to and slightly below the rearward end of members 26, 26'. Also mounted to members 26, 26' are a first pair of tension bars 32, 32', a fluid application roller 34, which may be positively driven by a motor 33, a second set of tension bars 36, 36', and a further pair of over-and-under yarn guides 38, 38', the latter being mounted at the front end of the framework 20.
A multi-end yarn tape 42 having a filler thread 44 woven therethrough in the manner described in U.S. Pat. No. 3,605,225 is supplied to the input end of the channel guide 28 through a guide ring 29 from a storage bin 43. The use of the storage bin is merely representative; the yarn tape supplied to the deweaving machine could be taken directly from the output of a preceding yarn treating station to maintain continuity of operations. From the channel guide 28, the yarn is passed under and around guide 30 to reverse its direction of travel, between over-and-under tension bars 32, 32' and over application roller 34. This latter roller sits partially immersed in a trough 35 containing an antistatic emulsion. As the yarn tape 42 passes over the roller 34, the emulsion is applied to the tape to prevent a static electric charge from accumulating on the yarn ends as they are wound onto take-up spools. Motor 33 may, in addition to driving roller 34, act as a pump to supply emulsion fluid from container 37 to trough 35.
A thread take-up apparatus comprising a Gilbos winder 40 is mounted between the front legs 22 of framework 20 and below the upper frame members 26. The motor drive control circuit of the winder is modified for use in this invention in a manner described below. Downstream of the roller 34, the filler thread 44 is separated from the yarn tape in the filler thread deweaving or removal region (defined between points A and B in FIG. 1B) and passed through a large eye ring 46 mounted on the end of an arm 47 which is connected to the Gilbos winder motor drive circuit. The location on the yarn tape where the end of the filler thread is pulled out of the tape will, for convenience, be referred to hereafter as the "removal point". This removal point moves back and forth within the filler thread removal region as a function of the relative winder and yarn tape speeds. Downstream of the removal point, the filler thread 44 is passed through a hole in a guide member 48, under a limit switch tension bar 50 and onto the takeup spool 52 of the winder. The yarn tape, downstream of the removal point, is trained around over-and-under tension bars 36, 36' and over-and-under guides 38, 38' to be taken up separately on individual take-up spools.
The take-up section includes a take-up frame 54 on which are mounted sets of rollers 56, 58. Rollers 58 need not have the same length as rollers 56; in one embodiment they are in fact approximately five times the length of a roller 56. For convenience, however, they may be considered as roller pairs. Yarn takeup spools 60 are provided to separately take up the individual yarn ends following removal of the filler thread from the tape. Each spool 60 rests on a corresponding pair of rollers 56, 58 and is driven by the frictional engagement of spool 60 with roller pairs 56, 58. This frictional drive arrangement is an important feature of this invention as will be made clear below. As shown in FIG. 2, the roller pairs are arranged in columns and rows and are driven by motor 62 through any known drive transmission mechanism, such as a gearchain drive arrangement. The roller pairs are geared such that rollers 56, which have cammed surfaces to guide the yarn ends onto the spools 60 evenly, have a higher rotational velocity than do rollers 58, which are smooth surfaced. It was determined that the cammed rollers 56 should rotate about 5-15% faster than the smooth rollers 58; preferably the ratio V c :V s is on the order of 13:12, where V c is the rotational velocity of the cammed roller 56 and V s is the rotational velocity of the smooth roller 58. It was found that this velocity relationship is desirable to keep the spool 60 properly seated in engagement with its roller pair.
Mounted on the frame 54 is a yarn guide having a plurality of comb-like members 63. Also mounted on the frame 54 are guide bars 65. Yarn ends passing through the guide paths of comblike members 63 are trained under and around a guide bar 65 so that a yarn end will pass over the cammed surface of a roller 56 at the proper angle of wrap, which is preferably on the order of about 120°; the distance from guide bar 65 to the center of the corresponding roller 56 is about 24 inches.
The electrical system for the apparatus of this invention is shown in FIGS. 3 and 4. FIG. 3 shows the overall block diagram of the electrical system. The roller pairs 56, 58 are driven by a 5 HP D.C. motor 62 coupled to a D.C. drive controller 64. The Gilbos winder 40 is driven by a 1 HP D.C. motor 66 coupled to a D.C. drive control 68. In the disclosed embodiment, the motor control unit 64 is a Model WER ES-125 packaged drive made by Wer Industrial, a division of Emerson Electric Company. The motor control unit 68 is the Cadet Series 330B SCR adjustable speed drive system, available commercially from Morse Chain, a division of Borg-Warner Corporation. For use in this invention, the Wer Electrostat and Morse Cadet controllers have been modified as shown in FIG. 4. (The terminal numbers indicated in FIG. 4 correspond to the similarly numbered terminals indicated in the schematics of the Wer "Electrostat 125" instruction manual, dated February, 1974 and the Morse "Cadet Series" operating manual, dated December, 1972.)
The ES-125 controller has a RUN switch which, when engaged, permits the motor 62 to accelerate to the speed set by the operator. As modified for this invention, a limit switch 641, connected to and operated by tension bar 50, is interposed in series with the RUN switch to automatically shut down the motor 62 if a break should occur in the filler thread as it is being wound onto the Gilbos winder 40. Limit switch 641 remains closed as long as the tension bar 50 is held up by tension on the filler thread being wound onto the winder take-up spool 52. When a break occurs in the filler thread, tension on the bar 50 is relaxed and switch 641 opens to shut down the yarn take-up motor 62. Connected to terminals 10 and 12 of the RUN start circuit of the ES-125 controller is a 24-volt D.C. relay coil 642 having at least three sets of contacts 642a, 642b and 642c. As long as the take-up motor 62 is in the RUN state, and limit switch 641 is closed, coil 642 remains energized. Contacts 642a will be closed to energize the emulsion pump relay 341 (and thus motor 33) to pump emulsion fluid into the emulsion roller trough 35. At the same time, contacts 642b close and 642c open to permit winder motor 66 to be controlled by means of the speed control potentiometer R201 in the Morse Cadet D.C. drive controller 68.
The Morse drive controller 68 is modified as shown in FIG. 4 by the addition of a lease limit switch 681. Opening and closing of limit switch 681 is controlled by the movement of the eye 46 and rod 47; switch 681 opens (as shown in FIG. 4) to shut off motor 66 when sufficient tension is applied by the filler thread 44 against eye 46 (i.e. when the removal point of the thread 44 on the yarn tape 42 is adjacent point A). This occurs when the filler thread is being removed from the tape at too fast a rate relative to the rate at which the yarn tape is being pulled through the deweaving apparatus.
When limit switch 641 opens upon the occurrence of a break in the filler thread 44 being wound onto the winder spool 52, relay 642 is de-energized and contacts 642b and 642c return to the states shown in FIG. 4 to cut off winder motor 66. In the embodiment described above, the lease limit switch 681 controlled by the loop 46 provides only on/off control of the winder motor 66. This control may be modified by replacing the limit switch 681 with a potentiometer arrangement to provide continuous winder motor speed control, from fully on to fully off, as a direct function of the tension imparted by the filler thread 44 to the loop 46.
In operation, the take-up spools 60 draw the yarn tape out of the storage bin 44, through the deweaving apparatus and onto the spools 60. At the same time, the filler thread 44 is drawn out of the yarn tape 42 by the winder 40.
Key aspects of this invention reside in 1) the speed relationship amoung the take-up spools 60 taking up the individual yarn ends of tape 42 and 2) the speed relationship of the take-up spools 60 to the take-up of the filler thread 44 on spool 52. It is found that when the yarn tape 42 is made up with the filler thread 44 in the manner disclosed in the aforementioned Gibson et al patent, some of the yarn ends are longer than others. Over the total length of the yarn tape, the differential between yarn ends within the tape can run to several feet or more. The yarn end take-up system of this invention allows each end to be individually taken up at its own speed so that the overall speed of the yarn tape as it moves through the deweaving apparatus remains relatively constant.
As noted above, each take-up spool 60 merely rests on the two rollers 56 and 58 and is caused to rotate by the frictional drive imparted by these two rollers. The rotational speed of a given spool 60 is determined by the back tension on that spool applied by the yarn end being wound thereon; the greater the tension on the yarn end, the slower the take-up spool will rotate. Thus a longer yarn having some slack as compared to the other ends within the tape will impart less tension to its take-up spool, thereby permitting that spool to rotate faster than the spools taking up the shorter ends. The longer end is therefore taken up faster and in essence catches up with the shorter ends, thereby maintaining the desired uniform tension throughout the system and the uniform velocity of the tape.
After the operator initially threads each yarn end onto its appropriate take-up spool 60 and the filler thread onto the take-up spool 52 of the winder, he manually sets the initial speed of the yarn take-up spool driving motor 62 which provides the positive drive for pulling the tape through the deweaving apparatus. The tape speed is maintained relatively constant by virtue of the frictional drive on the individual yarn end take-up spools as described above. At the same time, he sets the initial or nominal speed of the winder take-up motor 66. The speed at which the filler thread 44 is taken up on the winder spool varies as a function of the tension on the filler thread. In the deweaving or filler thread removal region, defined between points A and B in FIG. 1B, the tension on thread 44 decreases as the point where the thread 44 is removed from the tape 42 moves from point A to point B; that is, the tension on thread 44 decreases as the speed at which the tape 42 moves increases relative to the speed at which the thread 44 is removed from the tape. The nominal winder speed is set by taking into consideration the following factors: The maximum take-up speed of the filler thread 44 onto the winder spool 52 must be greater than the speed at which the tape moves through the deweaving region but must not be so great that the removal point occurs upstream of point A. The minimum take-up speed of the winder 40 must not be so low that the removal point moves downstream of point B.
When the filler thread is being taken up too rapidly, that is, it is being pulled out of the tape near the beginning of the deweaving region (adjacent point A), the thread 44 engages eye 46 causing rod 47 to open limit switch 681 to shut off the winder motor. Winder roll 52 does not stop immediately but continues, through inertia, to rotate at a continuously decreasing rotational velocity. The take-up speed of the thread 44 is therefore decreased relative to the tape speed; the removal point of the filler thread from the tape then moves with the tape in the direction from A to B. As the tension imparted by the filler thread 44 on loop 46 thus decreases, the limit switch 681 closes and the winder motor 66 starts up again to increase the speed at which the filler thread is removed from the tape. The nominal filler thread take-up speed is set by the operator relative to the yarn tape speed so that the removal point does not go beyond end point B of the deweaving region.
Although the principles of the present invention have been described above in relation to a particular embodiment, it will be understood that this description has been provided merely by way of example; the scope of the invention is limited solely by the hereafter appended claims. | Disclosed is a method and apparatus for removing a filler thread from a multiple end yarn tape. The yarn tape containing a filler thread is passed over an elongated framework which defines a filler thread removal region. In this region the filler thread is removed from the tape and taken up on a Gilbos winder. The yarn ends are separated downstream of the removal region and wound up on separate take-up spools resting on pairs of driven rollers; the take-up spools are frictionally driven by the positively driven rollers. Means are provided to adjust the speed of the Gilbos winder relative to the yarn tape speed to maintain the removal point of the filler thread from the tape within the defined thread removal region. Further means are provided to shut down the entire apparatus when a break in the filler thread being removed from the yarn tape is detected. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] Not Applicable.
BACKGROUND OF THE INVENTION
[0003] a. Field of the Invention
[0004] This invention relates to the control of hydrocarbon production using plunger lift systems. More specifically, it relates to controllers using measurements of conditions in subsurface wells to operate non-linear artificial intelligence processes to sequence the operation of plunger lift devices.
[0005] b. Discussion of the Prior Art
[0006] The control of oil and gas production wells are an on-going concern of the petroleum industry due, in part, to the monetary expense involved as well as the risks associated with environmental and safety issues.
[0007] In many hydrocarbon wells, that is gas and oil wells, as described in greater detail below, fluids accumulate within the well casing and production string which block the flow of the formation gas or oil into the borehole, and such accumulations reduce the production of hydrocarbons from the well. As used herein, “fluids” primarily refers to a combination of naturally occurring liquids and emulsions, including water, oil, paraffin or combinations thereof. As fluids accumulate within the well casing and production string, often referred to as “tubing string” or “tubing”, the production of hydrocarbons from the well may diminish, and may ultimately fail due to the effect of pressure buildup of such fluids on the formation. Currently, the state-of-the art technique for removing accumulated fluids from the well casing and production string is through the use of plunger lift systems.
[0008] State-of-the art plunger lift production systems include a cylindrical plunger. In such a system, the cylindrical plunger normally resides at the bottom of the borehole, and is sized to travel through the production string extending from a location adjacent to the producing formation down in the bottom of the borehole upward to the surface equipment located at the hydrocarbon receiving end of the borehole. In general, fluids in the borehole that inhibit the flow of hydrocarbons out of the formation tend to collect in the lower portion of the production string. Periodically, a valve, typically a motor valve, in the production string at the surface of the well is opened at the surface. This allows accumulated reservoir pressure within the well to drive the plunger up the production string. The small clearance between the plunger and the well production string is such that the plunger carries with it to the surface a load of accumulated blocking fluids. The accumulated fluids are then ejected out of the top of the well, thereby allowing hydrocarbons to flow more freely from the formation into the well bore and be delivered to a distribution system at the surface. After the flow of gas has once again been restricted due to the further accumulation of fluids downhole, the surface valve of the well is closed, and the plunger, due to its own weight, then falls back down the production string to the bottom of the borehole. While the valve is so closed, the pressure within the well generally increases again. If the pressure is allowed to build to a strong enough level, the pressure will be strong enough to lift the plunger and another load of fluids to the surface of the well when the valve is reopened.
[0009] In plunger lift production systems, there is a requirement for the periodic operation of a motor valve at the surface of the wellhead to control the flow of fluids from the well to assist in the production of hydrocarbons and removal of fluids from the well. These motor valves are conventionally controlled by timing mechanisms and are currently programmed in accordance with principles of reservoir engineering, which determine the length of time that a plunger lift control valve should be either “closed” and restricted from the flowing of gas or liquids to the surface, and the time the plunger lift control valve should be “opened” to more freely produce.
[0010] If the plunger lift control valve is left opened or closed for too long of a time, there will be a loss of well production and the producing formation may be damaged. Furthermore, pressure buildup within a well can cause the plunger to rise to the surface at excessive speeds, which can cause serious damage to the surface components of the well and cause hydrocarbons and fluids from the well to leak into the surrounding environment. Not only does this present a safety risk to workers at the surface of the well, but it also presents serious environmental concerns. It is therefore seen that control of the plunger lift control valve is critical to maintain proper pressure and production balance within the well by avoiding having it be open or closed for too long or too short of a time.
[0011] It is extremely impractical to manually open and close the plunger lift control valve for each well. As a consequence, automatic controllers are currently used to open and close the motor valve. Generally, the criterion used in most systems for operation of the plunger lift control valve is strictly one of the elapse of pre-selected time periods. In most systems, measured well parameters, such as pressure and temperature, can be used to override the timing cycle in special conditions.
[0012] For example, in the patent prior art, U.S. Pat. No. 4,150,721 (Norwood) discloses a battery operated gas well controller system which utilizes digital logic circuitry to operate a well in response to a timing counter and certain measured well parameters. U.S. Pat. Nos. 4,352,376 and 4,532,952 (Norwood) disclose similar controllers comprising the use of a microprocessor. U.S. Pat. No. 4,354,524 (Higgins) discloses a pneumatic timing system which uses injected gas to artificially lift liquids to a well surface. U.S. Pat. No. 4,355,365 (McCracken) discloses a system for electronically operating a well in accordance with timing techniques wherein the well is allowed to flow for a pre-selected period of time and then closed for a second pre-selected period of time to effect the production from the well. U.S. Pat. No. 4,921,048 (Crow) discloses an electronic controller which detects the arrival of a plunger and monitors the time required for the plunger to make each trip to the surface. U.S. Pat. No. 5,146,991 (Rogers, Jr.) discloses a plunger lift well which evaluates plunger lift speed. U.S. Pat. No. 5,878,817 (Stastka) discloses a controller which opens the plunger lift control valve based on the measurement of the pressure difference between the gas in the tubing line and the pressure of gas in the sales line, and in addition uses the speed of the plunger to adjust valve operation. Similarly, U.S. Pat. No. 6,595,287 (Fisher) controls valve operation based on the pressure difference between sales line pressure and well casing pressure. U.S. Pat. No. 5,984,013 (Giacomino) uses plunger arrival time to adjust the subsequent valve opening and closing times.
[0013] It is currently observed that relatively simple, timed intermittent operation of plunger lift control valves is often not adequate to control outflow so as to optimize hydrocarbon production from wells. As a consequence, sophisticated computerized controllers positioned at the surface of production wells have been used for control of devices, such as the plunger lift control valves. Additional systems have been developed that relate to: (1) surface controller systems using a surface microprocessor; and (2) downhole controller systems which are initiated by surface control signals.
[0014] Surface controller systems generally teach computerized systems for monitoring and controlling a gas/oil production well whereby the control electronics is located at the surface and communicates with sensors and electromechanical devices near the surface. An example of this system is disclosed in U.S. Pat. Nos. 4,633,954 (Dixon) and 4,685,522 (Dixon), which describe a fully programmable microprocessor controller which monitors downhole parameters, such as pressure and flow, and controls the operation of gas injection to the well, outflow of fluids from the well, or shutting in of the well to maximize output. Another example of a controller system of this type is disclosed in U.S. Pat. No. 5,132,904 (Lamp), which further describes a feature where the controller includes serial and parallel communication ports through which all communications to and from the controller pass. Hand held devices or portable computers capable of serial communication may access the controller. A telephone modem or telemetry link to central host computer may also be used to permit several controllers to be accessed remotely. It is well recognized that petroleum production wells using surface based controllers will have increased production efficiencies and lower operating costs than downhole microprocessor controllers.
[0015] In general, although controller systems have become much more complex, they still do not fully optimize well production and often require a great deal of operator inputs. What is needed is a plunger lift system that optimizes the open and close cycles of the motor valve based on minimal input. Additionally, well operation and production varies between different wells and can even change from cycle to cycle within the same well. For example, the gas pressure within a well will vary from well to well and can significantly change during the life of that well. Because each well will have its own unique properties, the automatic controller closing and opening the plunger lift control valve must be suitable for use on a wide variety of wells and be flexible enough to adjust to the changes that often occur during the life of the well to provide ongoing optimum production. Ideally, the operation of a plunger lift control valve by an automatic controller system would be able to approximate the operation of a controller system by an ever present and vigilant human operator.
SUMMARY OF THE INVENTION
[0016] The present invention teaches an automatic controller system and methods for controlling plunger assisted gas and/or oil wells. As detailed below, limited operator entry is required as the controller system calculates values used to control the plunger lift control valve of the well and optimize production. The controller system contains a microprocessor and memory, wherein the microprocessor utilizes a non-linear artificial intelligence process that controls when the well is closed and open, and determines the optimal operational plunger lift control valve cycles. As used herein, the term microprocessor is meant to include general-purpose microprocessors, microcontrollers, Digital Signal Processors (DSP), electronic data processing computers of all kinds, and combinations thereof. In one embodiment, the present invention provides a microprocessor that requires minimal operator input and utilizes Zadehan logic to optimize well operation after the required inputs are entered. Zadehan logic is also referred to as “fuzzy logic”.
[0017] Zadehan logic and fuzzy logic sets are viewed as a mathematical formalism for the representation of uncertainty. Contrary to their name, the laws of fuzziness are not vague, but rather describe complex real systems operation with linguistic variables that may have varying membership functions and slope. Typically, spreadsheets are used to define the variables and degree of membership of external events. Graphs define the slope of the terms used for inputs and output data. The final system is compiled for compact representation of the complex system to be embedded in microprocessor firmware. Such use of Zadehan logic, or fuzzy logic, is well known in the art and is widely used in programmable controllers of all types, for example, see: (International Electrotechnical Commission (2000) International Standard, Programmable controllers-Part 7: Fuzzy control programming; Liu et al. (2005), “A probabilistic fuzzy logic system for modeling and control,” IEEE Transactions on Fuzzy Systems 13(6):848-859; Gaweda et al. (2003), “Data-driven linguistic modeling using relational fuzzy rules,” IEEE Transactions on Fuzzy Systems 11(1):121-134; Joo et al. (1999), “Hybrid state-space fuzzy model-based controller with dual-rate sampling for digital control of chaotic systems,” IEEE Transactions on Fuzzy Systems 7(4):394-408).
[0018] As described in greater detail below, a gas or oil well utilizing an embodiment of the present invention comprises tubing, often in the form of a production string, positioned within a well casing; a plunger positioned within the production string, wherein the plunger is moveable within the production string; a plunger arrival sensor at the lubricator; a plunger lift control valve connected to the production string and the sales line; and, in some cases optional pressure sensors located at the annulus of the well casing, and a hydrocarbon take-off line, commonly referred to as a “sales line”. The plunger lift control valve is operated to change the valve between a closed and an open position in response to a microprocessor in the operation of the present invention, as further detailed below.
[0019] Such a well using a plunger lift system operates using a series of cycles. As used herein, the term “operating cycle” refers to a repeating process of closing the plunger lift control motor valve to build sufficient pressure to lift the plunger to the surface followed by opening the plunger lift control valve to collect the oil and/or gas hydrocarbons from the well. Typically, each operating cycle comprises at least a close cycle, an open cycle, an afterflow cycle, and a fall cycle, as detailed immediately below.
[0020] The “close cycle” refers to the cycle during normal well operation wherein the plunger is at the bottom of the production string and the plunger lift control valve is closed, thereby preventing fluids and hydrocarbons within the production string from flowing to the surface of the well. When in a close cycle, the pressure within the well will generally increase. Preferably, the duration of the close cycle, also referred to herein as the “close time”, is as short as possible, but still allows for enough pressure to build so as to push the plunger to the surface during an open cycle. That is, when the plunger lift control valve is opened, the time period referred to herein as the “open cycle”, the plunger and the fluids that have accumulated in the production string above the plunger will rise to the surface of the well. The duration of the open cycle, also referred to herein as the “open time”, should be long enough to ensure the plunger rises to the surface and is detected by the controller system. Once the fluids reach the surface of the well, they can be collected into a separator and hydrocarbons can more freely flow through the production string to the sales line. The period of time during which a well is producing the desired gaseous hydrocarbons is referred to as the “afterflow cycle”. Preferably, the duration of each afterflow cycle, also referred to herein as the “afterflow time”, is as long as possible for optimized well production. In typical operation, the well will proceed through a close cycle, followed by an open cycle, then an afterflow cycle, and then a “fall cycle” during which the plunger falls to the bottom of the production string. After the fall cycle, the well repeats the process starting with another close cycle.
[0021] In the practice of the process of the present invention, well parameters entered by an operator, measurements of the current well conditions, previous well measurements, and trends are assigned a value and applied to the Zadehan logic engine, which is stored on the microprocessor, to calculate the value of modifications required for improved cycle time and hydrocarbon production time.
[0022] In one embodiment of the invention, the minimal operator inputs required by the microprocessor controller system comprise the well depth, an initial close time required to recharge the well after a plunger arrives to the surface, and an initial afterflow time to allow collection of hydrocarbons after the plunger arrives to the surface of the well. From the required operator inputs, the Zadehan logic engine of the microprocessor will calculate the time required for the plunger lift control valve to be opened, fall time required for the plunger to fall to the bottom of the well, and backup time required to build up the pressure in the well should a plunger fail to reach the surface of the well. The various cycle times are then adjusted by the Zadehan logic of the microprocessor, preferably to reduce the time the plunger lift control valve is closed and increase the afterflow time when the desired hydrocarbons are collected. Non-linear pressure limits can be calculated and used after adjustment of the cycles to form an optimized closed loop system. In one embodiment, the microprocessor uses a high pressure limit and low pressure limit as additional parameters.
[0023] In one embodiment, the invention provides a method for optimizing the operation of a well having a plunger lift control valve connected between the production string of the well and the sales line, wherein a controller system is able to open and close the motor valve according to values stored on the controller system memory. The method comprises entering a predetermined value for well depth, close time, and afterflow time into the controller system memory, and conducting one or more operating cycles wherein the controller opens and closes the motor valve to allow fluids or gasses to flow through the sales line. The controller system automatically calculates the open time based on the entered predetermined values. Each operating cycle comprises entering a closed cycle for a period of time equal to the initial close time; opening the plunger lift control valve and entering an open cycle for a period of time equal to the calculated open time allowing fluids to be artificially lifted which allows the fluids to flow into the sales line; and entering an afterflow cycle for a period of time equal to the afterflow time and allowing gases to flow into the sales lines during the afterflow cycle. After one or more successful operating cycles, the Zadehan logic of the microprocessor controller system adjusts the close time and afterflow time based on current well conditions and previous well measurements. Subsequent adjusted operating cycles are conducted using the adjusted close time and afterflow time.
[0024] In a further embodiment, the close time is adjusted by the Zadehan logic engine after a number of operating cycles have been run using the initial close time and initial afterflow time. After there have been a number of successful operational cycles using the adjusted close time, the afterflow time is adjusted. After a number of successful operating cycles have been run using the adjusted afterflow time and close time, the controller system adjusts the afterflow time again using the Zadehan logic engine. This second adjustment is also referred to as the fine adjust.
[0025] The pressures in the sales line, well casing and production string can also be used by the Zadehan logic engine to open and close the plunger lift control valve. For example, the controller system can terminate a close cycle and enter an open cycle when the pressure in the well casing (also called the well annulus) exceeds the pressure in the sales line by a predetermined amount. The Zadehan controller system can also terminate an afterflow cycle when the current pressure in the well annulus is less than the minimum recorded well annulus pressure by a predetermined amount. The Zadehan controller system can also terminate an afterflow cycle when the current pressure in the sales line is less than the minimum recorded pressure at the well annulus by a predetermined amount.
[0026] The objects of the present invention will become apparent to those skilled in the art from the following detailed description and accompanying drawings, showing the contemplated novel construction, combination, and elements as herein described, and more particularly defined by the appended claims, it being understood that changes in the precise embodiments to the herein disclosed invention are meant to be included as coming within the scope of the claims, except insofar as they may be precluded by the prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate complete preferred embodiments of the present invention according to the best modes presently devised for the practical application of the principles thereof, and in which:
[0028] FIG. 1 shows a diagrammatic side view, partially in cross-section, of a well utilizing a plunger lift system that is connected to and operated by a Zadehan controller system of the present invention;
[0029] FIG. 2 shows a keypad of a Zadehan controller system in one embodiment of the invention used for operator entry and review of well data;
[0030] FIG. 3 illustrates an overview of the operator entry used with a Zadehan controller system of the present invention;
[0031] FIG. 4 illustrates an overview of the firmware modification control section used in a controller system of the present invention; and
[0032] FIG. 5 and FIG. 5A illustrates an overview of the firmware run time network used in a controller system of the present invention.
DETAILED DESCRIPTION
[0033] FIG. 1 shows one embodiment of the present invention with a well that has a plunger lift system. As shown, well casing 22 extends from the earth surface down into an oil-gas formation 14 . The production string 20 is a series of connected elongated hollow tubes within well casing 22 that extends from wellhead 21 at the surface down to the bottom or near the bottom of well casing 22 . Production string 20 is open at its lower end allowing fluids and hydrocarbons in the well casing 22 to enter the production string 20 . Plunger 17 is disposed within production string 20 , and is designed to move from the bottom of production string 20 to lubricator 5 which is located at the top of production string 20 . At or near the bottom of production string 20 is a lower bumper spring 18 , which catches and stops plunger 17 as it travels to the bottom of production string 20 . An upper bumper spring 4 above the lubricator 5 stops plunger 17 as it is pushed through production string 20 to the surface by the pressure of the flow of hydrocarbons from oil-gas formation 14 .
[0034] The top of production string 20 is connected to a master valve 12 . When maintenance and repair of the system is required, master valve 12 is used to shut off the flow of hydrocarbons and thereby the pressure for maintenance and repair of the system. Above master valve 12 are a plunger catcher 6 and a lubricator 5 . The plunger catcher 6 can be engaged by an operator to catch plunger 17 after it is caused to rise within production string 20 to lubricator 5 . An upper bumper spring 4 is attached to the lubricator 5 by threads and can be unscrewed using handles 3 . When the upper bumper spring 4 is removed, the plunger 17 can be removed and repaired, replaced, or inspected for damage.
[0035] Upper flow outlet 7 and lower flow outlet 8 connect a sales line 15 to the lubricator 5 , such that sales line 15 is in fluid communication with production string 20 . By “fluid communication”, it is meant that fluids and hydrocarbons can flow from the production string 20 into the sales line 15 through upper flow outlet 7 and lower flow outlet 8 . As is well known in the art, the other end of sales line 15 is attached to one or more separators (not shown) used to separate the fluids from the hydrocarbons. Shut-in valve 9 may be used to shut down flow through sales line 15 for maintenance.
[0036] The flow of fluids and hydrocarbons through sales line 15 is regulated by plunger lift control valve 10 , which is connected to controller system 200 , as further detailed and explained below, through motor valve connecting tubing 11 . At the heart of the present invention, controller system 200 contains a microprocessor which calculates when plunger lift control valve 10 should be opened and closed. The controller system 200 uses an art known actuator (not shown), such as a solenoid valve or a pilot latch valve, to open and close the plunger lift control valve 10 . When the controller system 200 activates plunger lift control valve 10 to an open position, and if there is sufficient pressure in production string 20 , plunger 17 will be pushed from the lower bumper spring 18 at the oil-gas formation 14 and be pushed to the surface lifting accumulated fluids into sales line 15 . A plunger arrival sensor 2 detects when plunger 17 arrives at lubricator 5 and relays this information to controller system 200 . Plunger arrival sensor 2 can be electronic or mechanical. Additional monitoring devices, such as annulus pressure sensor 1 and sales line pressure sensor 19 , relay pressure information to controller system 200 . Gas from the well casing 22 is used by the controller 200 to mechanically control the open/close state of the motor valve 10 . Gas from the well casing 22 is delivered to the controller system 200 through controller gas supply line 13 . A regulator 16 attached to controller gas supply line 13 reduces the gas pressure to manageable levels, typically to approximately 25 PSI.
[0037] Controller system 200 includes a keypad and an alpha-numeric display 201 to allow for operator input. Keypads and displays suitable for use with this invention are well known in the art. FIG. 2 shows a typical keypad and display 201 located within controller system 200 described in FIG. 1 and herein below. The alpha-numeric display 201 shows operator entries, current cycle in use, in addition to well history items. Well history can be displayed by depressing or continuously depressing history key 205 for different well history items. History items may include, but are not limited to, total sales time, total close time, total open count, number of successful and failed plunger arrivals, plunger run times, and various recorded pressures. Depressing the history key 205 again after the last well history item is displayed will return to the current cycle display. Well depth, initial close time, and initial afterflow times are entered while the controller system 200 is in operator set mode. Operator set mode is entered by depressing the set key 207 . While in operator set mode, close times and afterflow times are entered by depressing the hours key 202 , minutes key 203 , and seconds key 204 . In one embodiment, well depth is entered by depressing the hours key 202 to add 10,000 feet increments, the minutes key 203 to add 100 feet increments, and the seconds key 204 to add 1 foot increments. Alternatively, the add/subtract key 206 will add or subtract time or feet when the hours key 202 , minutes key 203 , or seconds keys 204 are depressed. In one embodiment, the plunger lift control valve 10 can be manually opened and closed by an operator by depressing the manual key 208 .
[0038] FIG. 3 illustrates firmware stored within the microprocessor of controller system 200 of the present invention. The completed operator entry items 301 are processed by the microprocessor to generate the calculated and adjusted values 302 , which are stored in nonvolatile memory. The operator entry items 301 include well depth, initial close time, and initial afterflow time. Calculated and adjusted values 302 include the open time, backup time, and fall time. Determining the desired open time and fall time for a well are based on methods known in the art and can be modified by the experience and judgment of the well operator. Primarily, the open time and fall time depend on the well depth. The open time should be long enough to ensure the plunger 17 has enough time to rise to the surface and be detected by the plunger arrival sensor 2 . The fall time should be long enough to ensure that the plunger 17 has enough time to return to the bottom of the production string 20 before the plunger lift control valve 10 is reopened. Methods for determining backup time are also known in the art. Backup time can vary according to the characteristics of each well and the judgment of the well operator, but the backup time will always be greater than the close time. In one embodiment, the backup time is approximately 1½ to 2½ times the close time.
[0039] The microprocessor also calculates the adjustments to the afterflow time and close time, and determines the parameters used to enter the shut in cycle 305 when a dry plunger is detected. A dry plunger means that the plunger 17 reached the top of the production string 20 without any accompanying fluids. This scenario is not within the normal operation of the well and may indicate that the plunger 17 is not reaching the bottom of the production string 20 during the fall cycle 309 . This is a dangerous situation because a dry plunger can hit the upper bumper spring 4 at a much higher velocity than normal which can damage or rupture the top of the well. Typically, plunger 17 speed is not directly measured. Instead, an abnormally short plunger arrival time is assumed to indicate excessive plunger speed and a dry plunger. If the plunger arrival time is less than a time limit corresponding to the safest maximum plunger speed, the controller system will close plunger lift control valve 10 and enter the shut in cycle 305 .
[0040] During a normal operating cycle, the microprocessor enters the close cycle 303 . “Close” refers to the state of the plunger lift control valve 10 as controlled by the microprocessor. A timeout of the close cycle 303 or a high pressure signal from the annulus pressure sensor 1 will cause the microprocessor to enter the open cycle 306 and open the plunger lift control valve 10 . When the plunger arrival sensor 2 detects a normal plunger arrival, the plunger lift control valve 10 remains open. The microprocessor then enters the afterflow cycle 308 and hydrocarbons can more freely flow from production string 20 into sales line 15 . The microprocessor remains in the afterflow cycle 308 until a timeout of the cycle or a low pressure signal is received from annulus pressure sensor 1 or sales line pressure sensor 19 . During the afterflow cycle 308 , hydrocarbons are collected through the sales line 15 .
[0041] If the afterflow cycle 308 ends as the result of a timeout, the microprocessor enters the plunger fall cycle 309 . During the fall cycle 309 , plunger lift control valve 10 is closed and plunger 17 is given sufficient time to return to lower bumper spring 18 at the bottom of the production string 20 . At the end of the plunger fall cycle 309 , the microprocessor enters the next normal close cycle 303 . If the afterflow cycle 308 ends as a result of a low pressure signal, the microprocessor enters the fall cycle 309 and the motor valve 10 is closed. Close cycle 303 or afterflow cycle 308 may be adjusted by the microprocessor to account for the low pressure signal.
[0042] If the plunger arrival sensor 2 does not detect the arrival of the plunger 17 during the open cycle 306 , the microprocessor will timeout and enter the backup cycle 307 . The backup cycle 307 closes the motor valve 10 to allow a sufficient pressure to build within production string 20 and allow plunger 17 to arrive at the surface on the next open cycle 306 . If a dry plunger is detected, the microprocessor will enter into the shut in cycle 305 . This is an abnormal condition and requires an operator entry to leave the cycle and resume operation. It may be prudent at this time to check plunger 17 for damage before continuing operation. During the backup cycle 307 , plunger fall time cycle 309 , and shut in cycle 305 , the microprocessor closes the motor valve 10 .
[0043] In terms of environmental safety, detecting a dry plunger and entering the shut in cycle 305 is a very useful feature because it prevents damage to the well and prevents leaks to the environment. In a further embodiment, the controller system 200 also monitors the sales line pressure to determine if the sales line 15 has a leak or a break. If the sales line pressure sensor 19 detects a drop in pressure indicative of a leak or a break, the controller system 200 will enter the shut in cycle 305 .
[0044] FIG. 4 illustrates firmware stored on the microprocessor in one embodiment of the present invention. The firmware optimizes well production by adjusting the close time 402 and afterflow time 401 . The microprocessor utilizes a non-linear Zadehan logic engine 400 , previously referred to in the art as a “fuzzy logic” engine, to adjust the close time 402 and afterflow time 401 . Because well operation is non-linear, the optimization process is also non-linear. The current operating cycle has the highest priority in altering well operation while previous cycles have a lower priority. The Zadehan logic engine 400 reduces the close time 401 until it reaches the optimal time period. Conversely, afterflow time 401 is extended to increase hydrocarbon production until it also reaches its optimal time period. If a specific afterflow time 401 , close time 402 or well condition corresponds to a failed plunger arrival, the microprocessor will adjust the close time 402 or afterflow time 401 to avoid repeating the same conditions.
[0045] It should be noted that the controller system of the present invention does not adjust the close time or afterflow time based on whether well characteristics such as the plunger arrival time or plunger speed fall within a predetermined range. Instead, the present invention compares well characteristics exhibited during the current operating cycle to previous cycles and adjusts the close time and afterflow time based on the trends exhibited by the well during its operation. Trend information is typical of how humans evaluate a series of recorded numbers or graphical information.
[0046] Controller system 200 uses a number of recorded variables to adjust the close time 402 and afterflow time 401 . In one embodiment of the invention, the Zadehan logic engine 400 adjusts the close time and afterflow time based on pressure, plunger count, plunger trend, plunger fail, high to low transition count, high to low transition trend, and combinations thereof.
[0047] Plunger trend is the determination of whether the plunger arrival time in the current cycle is faster, slower or the same compared to the plunger arrival time in the previous cycle. The microprocessor in controller system 200 records plunger trend as an integer which is incremented or decremented according to whether the current plunger time is greater or lesser than the previous plunger time. A plunger trend over several cycles showing a steady, consistent plunger arrival time is an indication of stability in the close time and afterflow time adjustments.
[0048] Plunger count is the total number of plunger arrivals. Plunger fail is when the controller system 200 fails to detect the successful arrival of the plunger 17 at the lubricator 5 during the open cycle.
[0049] During normal operation, the pressure within a well casing 22 will drop when the well switches to from a close cycle to an open cycle. The time it takes for the pressure in well casing 22 to complete the transition from the higher pressure of the close cycle to the lower pressure of the open cycle is known as the high to low transition time, or HL count. HL count will vary from well to well, and will most likely vary within the same well from one close-open cycle to the next. Generally, a lower HL count is preferable to a high HL count. More important is the trend of whether the HL count is increasing, decreasing or the same from one run to the next. The controller system 200 records the high to low transition trend (HL trend) as an integer, which is incremented or decremented according to whether the HL count has increased or decreased from the last cycle. An HL trend indicating that the HL count is decreasing can be an indication that the adjustments to the well cycles are having a desired effect. An HL trend indicating that the HL count is remaining stable is an indication of well optimization.
[0050] Pressure information is recorded at various operating cycle boundaries and is used for cycle limits. Minimum and maximum values with various time limits are selected to insure well stability and optimization.
[0051] In one embodiment, as shown in FIG. 4 , the Zadehan logic engine 400 reduces the close time 402 in a series of operating cycles until a failed plunger arrival is detected. The close time 402 is then increased sufficiently so that plunger 17 successfully arrives at the top of the production string 20 . The Zadehan logic engine 400 then adjusts the afterflow time 401 in the subsequent operating cycles until the well operation is stable. Typically, the afterflow time 401 is increased to allow for the greatest amount of gas production that still results in stable well operation.
[0052] After afterflow time 401 is adjusted, the well is allowed to operate without additional adjustments in order to allow the well to stabilize. After a consecutive number of successful operating cycles during which no additional adjustments are made, the Zadehan logic engine 400 will fine adjust 403 the afterflow time 401 and, if necessary, the close time 402 and then stop adjusting (represented by the done step 404 ). Once the fine adjust 403 step has been completed, the well will operate according to the adjusted afterflow time 401 and adjusted close time 402 to provide improved hydrocarbon production from that well. Additionally, well casing 22 and production string 20 pressure limits may be used to open and close the plunger lift control valve 10 during this time if necessary. The optimization process can be restarted with a new operator entry at controller system 200 . All of the related variables are saved in the nonvolatile memory of the microprocessor, allowing restarting at the same adjustment setting.
[0053] The pressure difference between production string 20 and well casing 22 during the operating cycle can be used as further indicator of well optimization. The production string 20 pressure and well casing 22 pressure will be very close to the same and will rise and lower uniformly on each cycle if efficient well operation is being achieved. The pressures will never match exactly because the production string 20 will never be completely free of fluids. Generally in an efficient plunger lift well, the production string pressure will be approximately 80-85% of the well casing pressure. In a further embodiment, the controller system 200 records the pressure difference between the well casing 22 and the production string 20 . The Zadehan logic engine 400 will adjust or stabilize the afterflow time 401 and close time 402 based on how closely the production string pressure resembles the well casing pressure.
[0054] FIG. 5 and FIG. 5A illustrates a Run Time Network (RTN) used in a controller system 200 of the present invention. The RTN shell 501 evaluates the current cycle state, selecting a new state if required. The cycle state may be the close state 502 , shut in state 503 , open state 504 , afterflow state 505 , backup state 506 , or fall state 507 . Each second 508 the current main timer 509 and well history timers 510 are adjusted and updated in the microprocessor memory. If the current cycle is the afterflow cycle 511 , that cycle is also adjusted. A low pressure input inhibited 512 during the initial change to the afterflow cycles is also adjusted and updated. The display 521 is alphanumeric and displays operator entry, current cycle information, and well history. External inputs are recorded and used by the RTN shell 501 to select the current cycle. When the keypad is active 523 the firmware decodes 524 the keypad input and the proper response is initiated. The display 521 will shut off to conserve power after a predetermined time, say about 4.25 minutes as shown in FIG. 5A , has elapsed after the last key pad activity 525 . Any subsequent keypad activity will cause the display 521 to be turned back on.
[0055] Now, with the system of the present invention in mind, in one embodiment of the present invention, an operator initially, for example, enters predetermined values for well depth, initial close time and initial afterflow time into the controller system 200 microprocessor memory through a keypad, such as described with respect to FIG. 2 , above. The microprocessor of the controller system 200 will calculate the open time, fall time and backup time. The controller system 200 will enter a close cycle 303 for a period of time equal to the initial close time. During the close cycle 303 , the plunger lift control valve 10 is closed and the plunger 17 remains at the bottom of the production string 20 . The pressure within the well casing 22 will increase during the close cycle 303 . Upon timeout of the close cycle 303 or a high pressure signal from the annulus pressure sensor 1 , the controller system 200 will terminate the close cycle 303 , enter the open cycle 306 , and open the plunger lift control valve 10 . Once the plunger lift control valve 10 is opened, the built up pressure will lift plunger 17 and the fluids that have accumulated above plunger 17 to the surface and into the sales line 15 . Plunger arrival sensor 2 connected to controller system 200 will detect when plunger 17 arrives at the surface. Upon timeout of the open cycle 306 , the controller system 200 enters the afterflow cycle 308 , during which the motor valve 10 remains open and hydrocarbons can more freely flow through production string 20 into sales line 15 . Controller system 200 remains in the afterflow cycle 308 until a timeout of the cycle or a low pressure signal is received from the annulus pressure sensor 1 or sales line pressure sensor 19 . After the afterflow cycle 308 is terminated, controller system 200 closes the plunger lift control valve 10 and enters the close cycle 303 for the next operating cycle. When plunger lift control valve 10 is closed, plunger 17 will return to the bottom of the production string 20 and remain there until the next open cycle 306 .
[0056] During successive operating cycles, the controller system 200 will gradually decrease the close time 402 until a failed plunger arrival is detected. The controller system 200 will then enter a backup cycle 307 and increase the close time 402 so that sufficient pressure is built up in production string 20 to cause a successful plunger arrival. Controller system 200 , utilizing Zadehan logic, adjusts the afterflow time 401 in subsequent operating cycles with variables such as pressure, plunger count, plunger fall, plunger trend, high to low transition count, and high to low transition trend. Plunger trend, high to low transition count, and high to low transition trend have not been used in previous control systems to optimize well operation. After the afterflow time 401 has been adjusted, the well is allowed to operate without additional adjustments in order to allow the well to stabilize. After a consecutive number of successful operating cycles during which no additional adjustments are made, the controller system 200 will fine adjust 403 the afterflow time 401 , and the close time 402 if necessary to provide improved hydrocarbon production. It should be noted that previous control systems also do not allow the well to stabilize between adjustment periods, and it has been determined that lack of adjustment can prevent optimal well operation. After the controller system 200 fine adjusts the afterflow time 401 and close time 402 , the well is allowed to operate without additional adjustments.
[0057] All references cited herein are hereby incorporated by reference in their entirety to the extent that there is no inconsistency with the disclosure of this specification. All headings used herein are for convenience only. All patents and publications mentioned in the specification are indicative of the levels of skill of those skilled in the art to which the invention pertains, and are herein incorporated by reference to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated by reference. References cited herein are incorporated by reference herein in their entirety to indicate the state of the art as of their publication or filing date and it is intended that this information can be employed herein, if needed, to exclude specific embodiments that are in the prior art.
[0058] Having now fully described the present invention in some detail by way of illustration and examples for purposes of clarity of understanding, it will be obvious to one of ordinary skill in the art that the same can be performed by modifying or changing the invention within a wide and equivalent range of conditions, formulations and other parameters without affecting the scope of the invention or any specific embodiment thereof, and that such modifications or changes are intended to be encompassed within the scope of the appended claims. | A microcontroller system for oil and gas wells using a plunger lift device, which responds to the variations in well production and operation. The system requires minimal operator input, and is able to calculate the operational cycles and adjustments to maximize well production and maintain environmental safety using non-linear artificial intelligence processes. | 4 |
[0001] The present invention refers to a method of infiltrating enamel, in particular for the prevention and/or treatment of carious lesions. The present invention further refers to a kit for carrying out said method of infiltrating enamel, which comprises a conditioner comprising hydrochloric acid and an infiltrant comprising at least one low viscous dental resin.
FIELD OF THE INVENTION
[0002] In industrial countries, about 98% of the adult population exhibits one or more carious lesions or are already provided with fillings. Any carious lesion which eventually may lead to cavitation is initiated by demineralization of the hard tooth substance. At an early stage, referred to as “initial enamel caries”, the tooth surface remains intact without visible signs of erosion but the demineralized area below the surface becomes more and more porous.
[0003] Today, the only non-operative ways to treat approximal caries are to enhance remineralization by application of fluorides and to arrest lesion progress by improvement of patient's oral hygiene. While smooth surfaces of the tooth are more susceptible for improved cleaning strategies, approximal surfaces are particularly difficult to clean. Nevertheless, remineralization in approximal lesions that have reached the dentin seems to be hardly achievable, since several clinical studies showed that from this threshold a visible cavitation of the lesion is established in most cases (Rugg-Gunn, A J. Approximal carious lesions. A comparison of the radiological and clinical appearances. Br Dent J, 1972, 133:481-484; De Araujo, F B et al. Diagnosis of approximal caries: radiographic versus clinical examination using tooth separation. Am J Dent, 1992, 5:245-248; Ratledge et al. A clinical and microbiological study of approximal carious lesions. Part 1: The relationship between cavitation, radiographic lesion depth, the site-specific gingival index and the level of infection of the dentine. Caries Res, 2001, 35:3-7). Moreover, in vitro studies even found many cavitations in lesions confined to enamel. A cavitated enamel lesion cannot be cleaned sufficiently by the patient and will progress (Marthaler, T M and Germann, M. Radiographic and visual appearance of small smooth surface caries lesions studied on extracted teeth. Caries Res, 1970, 4:224-242; Kogon, S L et al. Can radiographic criteria be used to distinguish between cavitated and noncavitated approximal enamel caries? Dentomaillofac Radiol, 1987, 16:33-36). Therefore, if a cavitation occurs even at such an early stage of the caries process, a remineralization seems very unlikely under clinical conditions. This could explain clinical findings, that fluoridation and improved oral hygiene can only slow down the progression of approximal caries but are not capable of reversing it (Mejare, I et al. Caries development from 11 to 22 years of age: A prospective radiographic study. Prevalence and distribution. Caries Res, 1998, 32:10-16).
[0004] Once a cavitation has developed, invasive methods of treatment are generally indicated. However, drilling out carious tooth material is always accompanied by the removal of non-carious, i.e. sound, hard tooth substance. In approximal carious lesions which are difficult to reach, the ratio of carious and intact substance being removed is particularly unfavorable. Moreover, the connection between an inserted filling and the endogenous tooth material is susceptible for carious lesions itself, and renewal of fillings due to the ageing process leads to further removal of sound tooth material. Therefore, methods of treating caries at an early stage, and in particular approximal initial carious lesions, are highly desirable in order to prevent later requirement for invasive procedures.
[0005] One apparent indication of initial enamel caries are white spot lesions. Such a lesion is characterized by a loss of mineral in the bulk of enamel, whereas the surface of the lesion remains relatively intact (so-called “pseudo-intact surface layer”). A promising approach of non-operative dentistry might be the sealing of enamel lesions with low viscous light curing resins such as dental adhesives and fissure sealants. The tiny pores within the lesion body act as diffusion pathways for acids and minerals and, therefore, enable the dissolution of enamel at the advancing front of the lesion. The aim of the proposed regimen is not only to seal the surface but to infiltrate these pores, thereby withdrawing the lesion body from further attack. Moreover, after curing the resin material, a mechanical support of the fragile enamel framework in the lesion will be achieved.
[0006] The idea to arrest caries by sealing with low viscous resins has been followed in a few in vitro experiments since the seventies of the last century (Robinson, C et al. Arrest and control of carious lesions: A study based on preliminary experiments with resorcinol-formaldehyde resin. J Dent Res, 1976, 55:812-818; Davila, J M et al. Adhesive penetration in human artificial and natural white spots. J Dent Res, 1975, 54:999-1008; Gray, G B and Shellis, P. Infiltration of resin into white spot caries-like lesions of enamel: An in vitro study. Eur J Prosthodont Restor Dent, 2002, 10:27-32; Garcia-Godoy, F et al. Caries progression of whit spot lesions sealed with an unfilled resin. J Clin Pediatr Dent, 1997, 21:141-143; Robinson, C et al. In vitro studies of the penetration of adhesive resins into artificial caries-like lesions. Caries Res, 2001, 35:136-141; Schmidlin, P R et al. Penetration of a bonding agent into de- and remineralized enamel in vitro. J Adhes Dent, 2004, 6:111-115). It could be shown that sealants penetrate the body of artificial lesions up to 95% (Gray, G B and Shellis, P. Infiltration of resin into white spot caries-like lesions of enamel: An in vitro study. Eur J Prosthodont Restor Dent, 2002, 10:27-32), and reduce the accessible pore volumes within the lesions significantly (Robinson, C et al. In vitro studies of the penetration of adhesive resins into artificial caries-like lesions. Caries Res, 2001, 35:136-141). Moreover, it has been observed that sealants are capable to inhibit further lesion progress under demineralizing conditions (Robinson, C et al. Arrest and control of carious lesions: A study based on preliminary experiments with resorcinol-formaldehyde resin. J Dent Res, 1976, 55:812-818; Garcia-Godoy, F et al. Caries progression of whit spot lesions sealed with an unfilled resin. J Clin Pediatr Dent, 1997, 21:141-143; Robinson et al. In vitro studies of the penetration of adhesive resins into artificial caries-like lesions. Caries Res, 2001, 35:136-141).
[0007] However, one of the problems in sealing natural enamel lesions is that “pseudo-intact surface layers” have higher mineral contents compared to carious bodies of lesion. As a consequence, these layers inhibit the penetration of the lesion body by the sealing material and may even function as a barrier. In the end, the surface layer may be superficially sealed, but the carious body may be insufficiently penetrated by the resin. At worst, the carious process further proceeds below the “seal”.
[0008] Efforts have been made to enhance the penetration of an enamel lesion. In an in vitro model, extracted bovine incisors were treated to produce an intact surface layer, a body of lesion and a progressive demineralization front. It has been shown that a 5-second etching of those artificially induced lesions with phosphoric acid resulted in deeper penetration depths (Gray, G B and Shellis, P. Infiltration of resin into white spot caries-like lesions of enamel: An in vitro study. Eur Prosthodont Restor Dent, 2002, 10:27-32). Thus, such a pre-treatment or “conditioning” of an enamel area by etching could also improve the penetration of sealant in vivo. However, artificially induced enamel lesions differ from natural lesions in that they comprise regular and relatively thin “pseudo-intact surface layers”. Natural enamel lesions, in contrast, usually show higher mineralized surface layers of varying thickness. Thus, conditioning with phosphoric acid, although demonstrated as successful in vitro, must not necessarily provide for a benefit in vivo.
[0009] Nevertheless, an in vivo study reported that the application of a conventional adhesive onto enamel lesions pre-treated with phosphoric acid gel resulted in retardation of caries progression compared to controls (Ekstrand et al. Caries Res, 2004, 38:361). However, patients were monitored for two years only and diagnosis was done by x-raying, a rather insensitive method for analyzing successful penetration. Therefore, the results of this study should be regarded with some caution, as even the authors concede. Moreover, it remains unclear whether this initial success would be seen after longer periods since the rather superficial “seal” might be destroyed due to the physical load in vivo.
[0010] Thus, there is still a strong need for an improved non-operative procedure of treating initial enamel lesions in order to inhibit caries progression.
[0011] It is therefore an object of the present invention to provide for a method and means enabling improved resin penetration of initial enamel lesions.
SUMMARY OF THE INVENTION
[0012] The object of the present invention is solved by a method of infiltrating enamel, comprising the following steps:
(a) exposing an enamel area to be infiltrated to a conditioner comprising hydrochloric acid; (b) exposing the enamel area conditioned in step (a) to an infiltrant; (c) curing the infiltrant.
[0016] In one embodiment, the conditioner is based on a gel comprising about 1-30% (w/w) of hydrochloric acid.
[0017] In a preferred embodiment, the conditioner is based on a gel comprising about 5-15% (w/w) of hydrochloric acid.
[0018] In a further embodiment, the conditioner further comprises additives selected from the group comprising glycerol, highly dispersed silicon dioxide and methylene blue.
[0019] In one embodiment, the infiltrant comprises at least one low viscous resin.
[0020] In a preferred embodiment, the low viscous resin is selected from the group comprising bis-GMA, 2,2-bis[4-(2-hydroxy-3-methacryloxypropoxy)phenyl]propane; bis-PMA, propoxylated bisphenol-A-dimethacrylate; bis-EMA, ethoxylated bisphenol-A-dimethacrylate; bis-MA, bisphenol-A-dimethacrylate; UDMA, 1,6-bis(methacryloxy-2-ethoxycarbonylamino)-2,4,4-trimethylhexan; UPGMA, urethane bisphenol-A-dimethacrylate; TEGDMA, triethylene glycol dimethacrylate; TEGMMA triethylene glycol monomethacrylate; TEEGDMA, tetraethylene glycol dimethacrylate; DEGDMA, diethylene glycol dimethacrylate; EGDMA, ethylene glycol dimethacrylate; DDDMA, 1,10-decanediol dimethacrylate; HDDMA, 1,6-hexanediol dimethacrylate; PDDMA, 1,5-pentanediol dimethacrylate; BDDMA, 1,4-butanediol dimethacrylate; MBDDMA ½, BDDMA-methanol-adduct ½; DBDDMA ½, BDDMA-auto-adduct ½; PRDMA, 1,2-propanediol dimethacrylate; DMTCDDA, Bis(acryloxymethyl) triclodecane; BEMA, benzyl methacrylate; SIMA, 3-trimethoxysilane propylmethacrylate; SYHEMA ½, ½- cyclohexene methacrylate; TYMPTMA, trimethylolpropane trimethacrylate; MMA, methyl methacrylate; MAA, methacrylic acid; and HEMA, 2-hydroxyethyl methacrylate.
[0021] In a particularly preferred embodiment, the low viscous resin is selected from the group comprising polymethacrylic acid and derivatives thereof.
[0022] In a most preferred embodiment, the low viscous resin is selected form the group comprising bis-GMA, 2,2-bis[4-(2-hydroxy-3-methacryloxypropoxy)phenyl]propane; UDMA, 1,6-bis(methacryloxy-2-ethoxycarbonylamino)-2,4,4-trimethylhexan; TEGDMA, triethylene glycol dimethacrylate; and HEMA, 2-hydroxyethyl methacrylate.
[0023] In a further embodiment, the infiltrant further comprises additives selected from the group comprising CQ, camphoroquinone; BL, benzil; DMBZ, dimethoxybenzoin; CEMA, N-(2-cyanoethyl)N-methylanilin; DMABEE, 4-N,N-diethylaminobenzoic acid ethyl ester; DMABBEE, 4-N,N-diethylaminobenzoic acid butyl ethoxy ester; DMABEHE, 4-N,N-diethylaminobenzoic acid 2-ethylhexyl ester; DMAEMA, N,N-diethyl aminoethyl methacrylate; DEMAEEA, N,N-(bis-ethylmetacrylate)-2-ethoxyethylamine; HMBP, 2-hydroxy-4-methoxy benzophenone; TINP, 2(2′-hydroxy-5′-methylphenyl) benzotriazol; TIN326, Tinuvin 326; TIN350, Tinuvin 350; Tin328, Tinuvin 328; HQME, hydroxyquinone monomethyl ester; BHT 2,6-di-t-butyl-4-methyl phenol; MBP 2,2-methylene-bis(6-t-butylphenol); MBEP, 2,2-methylenebis(6-t-butyl-4-ethylphenol); BPE, benzoic acid phenylester; MMMA, methyl methacrylate methanol adduct; CA, camphoric anhydride; HC ½, 2(3)-endo-hydroxyepicamphor; TPP, triphenyl phosphane; TPSb, triphenyl stibane; DMDDA, dimethyl dodecylamine; DMTDA, dimethyl tetradecylamine; DCHP, dicyclohexyl phthalate; DEHP, bis-(2-ethylhexyl) phthalate; and formaldehyde.
[0024] The object of the present invention is further solved by a use of a method of infiltrating enamel according to any of the preceding claims for the prevention and/or treatment of a carious lesion in a subject in need thereof.
[0025] In one embodiment, the subject is a mammal, preferably human.
[0026] The object of the present invention is also solved by a kit for infiltrating enamel, comprising at least the following:
[0027] (a) a conditioner comprising hydrochloric acid;
[0028] (b) an infiltrant.
[0029] In one embodiment, the conditioner is based on a gel comprising about 1-30% (w/w) of hydrochloric acid.
[0030] In a preferred embodiment, the conditioner is based on a gel comprising about 5-15% (w/w) of hydrochloric acid.
[0031] In a further embodiment, the conditioner further comprises additives selected from the group comprising glycerol, highly dispersed silicon dioxide and methylene blue.
[0032] In one embodiment, the infiltrant comprises at least one low viscous resin.
[0033] In a preferred embodiment, the low viscous resin is selected from the group comprising bis-GMA, 2,2-bis[4-(2-hydroxy-3-methacryloxypropoxy)phenyl]propane; bis-PMA, propoxylated bisphenol-A-dimethacrylate; bis-EMA, ethoxylated bisphenol-A-dimethacrylate; bis-MA, bisphenol-A-dimethacrylate; UDMA, 1,6-bis(methacryloxy-2-ethoxycarbonylamino)-2,4,4-trimethylhexan; UPGMA, urethane bisphenol-A-dimethacrylate; TEGDMA, triethylene glycol dimethacrylate; TEGMMA triethylene glycol monomethacrylate; TEEGDMA, tetraethylene glycol dimethacrylate; DEGDMA, diethylene glycol dimethacrylate; EGDMA, ethylene glycol dimethacrylate; DDDMA, 1,10-decanediol dimethacrylate; HDDMA, 1,6-hexanediol dimethacrylate; PDDMA, 1,5-pentanediol dimethacrylate; BDDMA, 1,4-butanediol dimethacrylate; MBDDMA ½, BDDMA-methanol-adduct ½; DBDDMA ½, BDDMA-auto-adduct ½; PRDMA, 1,2-propanediol dimethacrylate; DMTCDDA, bis(acryloxymethyl) triclodecane; BEMA, benzyl methacrylate; SIMA, 3-trimethoxysilane propylmethacrylate; SYHEMA ½, ½-cyclohexene methacrylate; TYMPTMA, trimethylolpropane trimethacrylate; MMA, methyl methacrylate; MAA, methacrylic acid; and HEMA, 2-hydroxyethyl methacrylate.
[0034] In a particularly preferred embodiment, the low viscous resin is selected from the group comprising polymethacrylic acid and derivatives thereof.
[0035] In a most preferred embodiment, the low viscous resin is selected form the group comprising bis-GMA, 2,2-bis[4-(2-hydroxy-3-methacryloxypropoxy)phenyl]propane; UDMA, 1,6-bis(methacryloxy-2-ethoxycarbonylamino)-2,4,4-trimethylhexan; TEGDMA, triethylene glycol dimethacrylate; and HEMA, 2-hydroxyethyl methacrylate.
[0036] In a further embodiment, the infiltrant further comprises additives selected from the group comprising CQ, camphoroquinone; BL, benzil; DMBZ, dimethoxybenzoin; CEMA, N-(2-cyanoethyl)N-methylanilin; DMABEE, 4-N,N-diethylaminobenzoic acid ethyl ester; DMABBEE, 4-N,N-diethylaminobenzoic acid butyl ethoxy ester; DMABEHE, 4-N,N-diethylaminobenzoic acid 2-ethylhexyl ester; DMAEMA, N,N-diethyl aminoethyl methacrylate; DEMAEEA, N,N-(bis-ethylmetacrylate)-2-ethoxyethylamine; HMBP, 2-hydroxy-4-methoxy benzophenone; TINP, 2(2′-hydroxy-5′-methylphenyl) benzotriazol; TIN326, Tinuvin 326; TIN350, Tinuvin 350; Tin328, Tinuvin 328; HQME, hydroxyquinone monomethyl ester; BHT 2,6-di-t-butyl-4-methyl phenol; MBP 2,2-methylene-bis(6-t-butylphenol); MBEP, 2,2-Methylenebis(6-t-butyl-4-ethylphenol); BPE, benzoic acid phenylester; MMMA, methyl methacrylate methanol adduct; CA, camphoric anhydride; HC ½, 2(3)-endo-hydroxyepicamphor; TPP, triphenyl phosphane; TPSb, triphenyl stibane; DMDDA, dimethyl dodecylamine; DMTDA, dimethyl tetradecylamine; DCHP, dicyclohexyl phthalate; DEHP, bis-(2-ethylhexyl) phthalate; and formaldehyde.
[0037] The object of the present invention is also solved by a use of a kit for infiltrating enamel for the prevention and/or treatment of a caries lesion in a subject in need thereof.
[0038] In one embodiment, the subject is a mammal, preferably human.
[0039] The object of the present invention is also solved by a method for preparing the kit.
[0040] The object of the present invention is also solved by the use of hydrochloric acid for the manufacture of a medical product for the prevention and/or treatment of a carious lesion.
[0041] In one embodiment, the medical product is based on a gel comprising about 1-30% (w/w) of hydrochloric acid.
[0042] In a preferred embodiment, the medical product is based on a gel comprising about 5-15% (w/w) of hydrochloric acid.
[0043] In a further embodiment, the medical product further comprises additives selected from the group comprising glycerol, highly dispersed silicon dioxide and methylene blue.
[0044] The object of the present invention is also solved by a method for manufacturing the medical product.
[0045] The object of the present invention is also solved by an infiltrant comprising at least one low viscous resin.
[0046] In one embodiment, the low viscous resin is selected from the group comprising bis-GMA, 2,2-bis[4-(2-hydroxy-3-methacryloxypropoxy)phenyl]propane; bis-PMA, propoxylated bisphenol-A-dimethacrylate; bis-EMA, ethoxylated bisphenol-A-dimethacrylate; bis-MA, bisphenol-A-dimethacrylate; UDMA, 1,6-bis(methacryloxy-2-ethoxycarbonylamino)-2,4,4-trimethylhexan; UPGMA, urethane bisphenol-A-dimethacrylate; TEGDMA, triethylene glycol dimethacrylate; TEGMMA triethylene glycol monomethacrylate; TEEGDMA, tetraethylene glycol dimethacrylate; DEGDMA, diethylene glycol dimethacrylate; EGDMA, ethylene glycol dimethacrylate; DDDMA, 1,10-decanediol dimethacrylate; HDDMA, 1,6-hexanediol dimethacrylate; PDDMA, 1,5-pentanediol dimethacrylate; BDDMA, 1,4-butanediol dimethacrylate; MBDDMA ½, BDDMA-methanol-adduct ½; DBDDMA ½, BDDMA-auto-adduct ½; PRDMA, 1,2-propanediol dimethacrylate; DMTCDDA, bis(acryloxymethyl) triclodecane; BEMA, benzyl methacrylate; SIMA, 3-trimethoxysilane propylmethacrylate; SYHEMA ½, ½-cyclohexene methacrylate; TYMPTMA, trimethylolpropane trimethacrylate; MMA, methyl methacrylate; MAA, methacrylic acid; and HEMA, 2-hydroxyethyl methacrylate.
[0047] In a preferred embodiment, the low viscous resin is selected from the group comprising polymethacrylic acid and derivatives thereof.
[0048] In a particularly preferred embodiment, the low viscous resin is selected form the group comprising bis-GMA, 2,2-bis[4-(2-hydroxy-3-methacryloxypropoxy)phenyl]propane; UDMA, 1,6-bis(methacryloxy-2-ethoxycarbonylamino)-2,4,4-trimethylhexan; TEGDMA, triethylene glycol dimethacrylate; and HEMA, 2-hydroxyethyl methacrylate.
[0049] In a further embodiment, the infiltrant further comprises additives selected from the group comprising CQ, camphoroquinone; BL, benzil; DMBZ, dimethoxybenzoin; CEMA, N-(2-cyanoethyl)N-methylanilin; DMABEE, 4-N,N-diethylaminobenzoic acid ethyl ester; DMABBEE, 4-N,N-diethylaminobenzoic acid butyl ethoxy ester; DMABEHE, 4-N,N-diethylaminobenzoic acid 2-ethylhexyl ester; DMAEMA, N,N-diethyl aminoethyl methacrylate; DEMAEEA, N,N-(bis-ethylmetacrylate)-2-ethoxyethylamine; HMBP, 2-hydroxy-4-methoxy benzophenone; TINP, 2(2′-hydroxy-5′-methylphenyl) benzotriazol; TIN326, Tinuvin 326; TIN350, Tinuvin 350; Tin328, Tinuvin 328; HQME, hydroxyquinone monomethyl ester; BHT 2,6-di-t-butyl-4-methyl phenol; MBP 2,2-methylene-bis(6-t-butylphenol); MBEP, 2,2-Methylenebis(6-t-butyl-4-ethylphenol); BPE, benzoic acid phenylester; MMMA, methyl methacrylate methanol adduct; CA, camphoric anhydride; HC ½, 2(3)-endo-hydroxyepicamphor; TPP, triphenyl phosphane; TPSb, triphenyl stibane; DMDDA, dimethyl dodecylamine; DMTDA, dimethyl tetradecylamine; DCHP, dicyclohexyl phthalate; DEHP, bis-(2-ethylhexyl) phthalate; and formaldehyde.
[0050] The object of the present invention is further solved by a method for preparing an infiltrant.
[0051] The term “exposing” as used herein refers to any procedure by which the enamel is provided with the conditioner or the infiltrant. Mostly, an exposure will be achieved by simple application, e.g. by spreading. For that purpose, the kit may additionally comprise one or more devices suitable for supporting the application, e.g. a brush, a sponge, a tissue, a pipette, a syringe or such.
[0052] It is considered by the present invention that the conditioner may be removed prior to application of the infiltrant. Thus, the kit may additionally comprise any device for that purpose.
[0053] It is further considered by the present invention that surplus infiltrant may be removed. Thus, the kit may additionally comprise any device for that purpose.
[0054] Preferably, the conditioner is allowed to remain applied for about 90-120 seconds, more preferably, the conditioner is allowed to remain applied for about 120 seconds.
[0055] Preferably, the infiltrant is allowed to remain applied for up to about 120 seconds, more preferably, the infiltrant is allowed to remain applied for about 120 seconds.
[0056] Preferably, the infiltrant is applied twice.
[0057] An “enamel area to be infiltrated” preferably is an area comprising a carious lesion. However, in order to prevent such lesions, i.e. for prophylaxis, any carious damage may be also absent in this area.
[0058] The conditioner may alternatively be based on an aqueous solution or may also be embedded in a plaster.
[0059] It is also considered by the present invention that the conditioner may additionally comprise phosphoric acid up to about 40% (w/w), preferably in the range of about 20% to 37% (w/w).
[0060] “Curing of the infiltrant” is preferably achieved by light-induced polymerization.
[0061] To enable access to the approximal surface, a separation of the carious teeth could be performed using orthodontic elastics. This technique is well documented for diagnostic purposes.
[0062] The resins according to the present invention are further considered for use as dental adhesives and/or fissure sealants.
[0063] Said resins cited above may be used, e.g. within the infiltrant of the present invention, either separately or in any combination thereof.
[0064] In conclusion, the present invention provides for an improved penetration of initial enamel lesions by an infiltrant. Within the prior art, methods of sealing enamel are available which, however, bear the risk of only superficially sealing the “pseudo-intact surface layer” but leaving the body of lesion insufficiently penetrated by the resin. Using the method and means, e.g. the conditioner and/or the low viscous resins, according to the present invention, occlusion of the body of lesion becomes possible.
[0065] First, by exposing an enamel area to be infiltrated to the conditioner comprising hydrochloric acid, the “pseudo-intact surface layer” is removed such that infiltration of carious areas by the infiltrant is greatly facilitated. Second, the resins cited above exhibit very low viscosity properties, and thus the infiltrant readily reaches the pores of the lesion to occlude them.
[0066] By using the method and means according to the present invention, invasive treatment of an enamel lesion may be prevented or at least delayed. Due to the non-operative character of the sealing procedure, the patient's compliance will be greatly enhanced. The method is well practicable with low costs. Finally, the inventive method may represent a therapeutic link between pure prophylaxis and invasive treatment of caries.
[0067] As used in this specification and the appended claims, the singular forms “a”, “an”, and “the” include plural reference unless the context clearly dictates otherwise.
DETAILED DESCRIPTION OF THE INVENTION
[0068] In the following, the invention should be further illustrated by making reference to FIGS. 1-3 and to Examples 1 and 2.
[0069] FIGS. 1-3 show results obtained by the Confocal Laser Scanning Microscope (CLSM) imaging technique.
[0070] FIG. 1 shows an initial enamel carious lesion after conditioning with 37% of phosphoric acid gel for 30 seconds.
[0071] FIG. 2 shows an initial enamel carious lesion after conditioning with 15% hydrochloric acid gel for 120 seconds.
[0072] FIG. 3 shows a partially infiltrated initial enamel carious lesion.
EXAMPLES
Example 1
Effect of the Pre-treatment with a Conditioner Comprising Hydrochloric Acid
[0000] 1. Material and Methods
[0000] 1.1 Sample Preparation
[0073] Extracted human molars and premolars, showing approximal white spots were cut across the demineralizations. One-hundred-twenty lesions confined to the outer enamel were selected. The cut surface as well as half of each lesion, thus serving as control, was covered with nail varnish. Subsequently, the lesions were etched with either phosphoric (37%) or hydrochloric (5% or 15%) acid gel for 30 to 120 seconds (n=10).
[0000] 1.2 Visualization
[0074] The specimens were dried for 5 minutes in a silicone hose, closed at one end with a stopper, and separated with silicone rings. Subsequently, Spurr's resin (Spurr, A R. A low-viscosity epoxy resin embedding medium for electron microscopy. J Ultrastruct Res, 1969, 26:31-43), labeled with 0.1 mmol/l of the fluorescent dye Rhodamine B Isothiocyanate (RITC), was doused over the specimens and the hose was closed with another stopper. The resin was cured in an autoclave (Ivomat IP3; Ivoclar Vivadent, Schaan, Liechtenstein) at 0.8 MPa and 70° C. for 8 hours. Under this pressure, the very low viscous resin penetrated into the remaining pores of the lesion. After curing, the specimens were cut, fixed on object holders, parallelized and polished up to 4000 grit (Exakt Mikroschleifsystem; ExaktApparatebau). This infiltration technique was termed VIsualisation by Resin INfiltration (VIRIN).
[0000] 1.3 CLSM Imaging
[0075] The specimens were studied using a Confocal Laser Scanning Microscope (CLSM) (Leica TCS NT; Leica, Heidelberg, Germany). The excitation light was generated with an Ar/Kr-Laser and had a maximum wavelength at 560 nm. The images were recorded in fluorescent mode. The emitted light was conducted through a 590 nm long pass filter to make sure that only fluorescent light was detected and reflected light was suppressed. Specimens were observed with a 40× objective using oil immersion. The observed layer was approximately 10 μm below the surface. Laser beam intensity and photo multiplier amplification were kept constant during the investigation. The images (250×250 μm) were taken with a resolution of 1024×1024 pixels and 256 pseudo color steps (red/black) and analyzed using the ImageJ Program (NIH; Rockville Pike, Md., USA).
[0000] 2. Results
[0076] The thickness of the surface layers in the control and the etched parts as well as the erosions in the sound and diseased tissues were measured. Etching with H 3 PO 4 gel for 30 seconds did not alter the thickness of the surface layer significantly (p>0.05; t-test). However, the surface layer reduction was significantly increased in lesions etched with 15% HCl gel for 90 seconds compared to those etched with H 3 PO 4 gel for 30 seconds or 90 seconds (p<0.05; ANOVA). No significant differences in the depths of erosion in the lesions compared to sound enamel could be observed (p>0.05; t-test).
[0077] In FIG. 1 , it is shown that pre-treatment of initial enamel carious lesions with 37% of phosphoric acid gel for 30 seconds resulted in only insufficient etching of the “pseudo-intact surface layer”. Thus, this kind of pre-treatment is not capable of destabilizing the surface layer to an extent necessary for optimal penetration of the infiltrant. In consequence, sealing will be only superficial. Incomplete infiltration, however, does not protect from organic acids and dissolution of enamel and erosion will further proceed. In FIG. 2 , it is shown that pre-treatment with 15% of hydrochloric acid gel for 120 seconds resulted in complete removal of the “pseudo-intact surface layer”.
[0078] It can be concluded that a reliable reduction of the surface layer can be achieved by etching with 15% hydrochloric acid gel for 90-120 seconds.
Example 2
Penetration of Infiltrant in the Presence or Absence of a “Pseudo-Intact Surface Layer”
[0000] 1. Material and Methods
[0079] Natural enamel lesions were etched with 15% hydrochloric acid for 30 seconds. Several experimental infiltrants and the commercial adhesive Excite (Vivadent, Schaan, Lichtenstein), respectively, each labeled with the fluorescent dye RITC, were applied on the lesions using a micro brush. After a penetration time of 120 seconds the overlying material was wiped away using a cotton roll and the resins were light cured for 15 seconds (Translux CL; Heraeus Kulzer). The preparation for the CLSM observation was carried out as described above, except that the embedding resin was labeled with the fluorescent dye Fluoresceine Isothiocyanate (FITC). The CLSM observation was carried out as described above except that the double fluorescence mode was used for RITC/FITC observation.
[0000] 2. Results
[0080] In FIG. 3 , it is shown that enamel areas covered by a “pseudo-intact surface layer” (A, dark surface zone) are not penetrated by the infiltrant (arrows). In contrast, in the absence of this layer (B) the infiltrant readily has penetrated the area below (double-arrow).
[0081] Thus, in areas where the “pseudo-intact surface layer” was removed by the etching gel, an infiltration of the lesion could be achieved. In areas where the “pseudo intact surface layer was not completely removed by the conditioning agent no significant infiltration of the lesion was observed.
[0082] All patents, patent applications, provisional applications, and publications referred to or cited herein are incorporated by reference in their entirety, including all figures and tables, to the extent they are not inconsistent with the explicit teachings of this specification.
[0083] It should be understood that the examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this application. | The present invention refers to a method of infiltrating enamel, in particular for the prevention and/or treatment of carious lesions. Said method of infiltrating enamel comprises the steps of (a) exposing an enamel area to be infiltrated to a conditioner comprising hydrochloric acid; (b) exposing the enamel area conditioned in step (a) to an infiltrant comprising at least one low viscous dental resin; and (c) curing the infiltrant. The present invention further refers to a kit for carrying out said method. | 0 |
TECHNICAL FIELD OF THE INVENTION
[0001] The technical field of this invention is the area of exchange of video and particularly video messaging and video answering.
BACKGROUND OF THE INVENTION
[0002] Current technology is sufficient to permit real time video conferencing. However, despite the state of technology, video conferencing has never been widely used. A number of factors which combine to prevent widespread use of video conferencing. These include the cost necessary to provide high quality video. Typical video conferencing terminals cost more than $200 using current technology. Existing implementations of video conferencing are geared toward the personal computer as the hub device. These systems typically rely on analog modem technology. The picture quality is perceived as poor, typically providing ¼ or ⅛th Sif and frame rates in the region of 7 to 13 frames per second. This quality video handles motion poorly, producing a jerky feeling to the display. Video conferencing also provides a number of additional issues. Typically a video conference must be prearranged so that all parties are available at the time of the video conference. This causes problems, who wants to gather the family in front of a personal computer to call grandma. Video conferencing produces additional latency issues. Video phones have much the same disadvantages as video conferencing. In addition, there is the interruption factor, who wants to answer the video phone when they just got out of the shower?
SUMMARY OF THE INVENTION
[0003] This invention is a method of video messaging. A transmission station records a video message in digital form and transmitting it to a predetermined reception station. The reception station stores the received video message in a nonvolatile memory. At a time other than reception of the video message, the reception station displays the stored video message to a user. The video message may be encoded at the transmission station and decoded at the reception station.
[0004] The transmission station may transmit a digital attachment file with the video message. The attachment file is stored upon reception like the video message. The reception station presents the attachment file in a manner perceivable by a user at a time other than reception of the video message. This attachment may be a word processing document, a spreadsheet document, a digital still picture or a video clip. In this case, the reception station preferably runs a compatible application program. This attachment may be a audio file which is optionally encoded prior to transmission. In this case the reception station generates an aurally perceivable replication of the original audio file.
[0005] The reception station uses any suitable display, such as a cathode ray tube, a liquid crystal display, a plasma discharge display or any of the various types of projection displays. In the preferred embodiment, the reception station uses a television receiver to display the video message. In this case, the reception station outputs a television signal modulated according to the transmission standard of the television receiver. Video messages may be archived at the reception station using a video cassette recorder or other storage medium.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] These and other aspects of this invention are illustrated in the drawings, in which:
[0007] [0007]FIG. 1 illustrates a block diagram of an exemplary embodiment of the hardware used to practice this invention;
[0008] [0008]FIG. 2 illustrates a flow chart of the video message transmission process; and
[0009] [0009]FIG. 3 illustrates a flow chart of the video message reception process.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0010] Current technology permits a variation on video conferencing and video phone that is advantageous over those techniques. This technology includes: the greatly expanded use of the Internet; familiarity with e-mail applications; current investments in video delivery over phone lines, such as Microsoft WebTV and AOL-TV; the proliferation of digital video recording devices, such as TiVo; the availability of digital camera and photo services; and the emergence of digital video cameras. This technology infrastructure permits two advantageous video applications. The first application is video messaging. Video messaging is the digital recording and transmission, such as via Internet, of video messages. Video messaging permits high picture quality and full screen video. Video messaging can be accomplished with current technologies. A particular advantage of video messaging is that latency is no longer an issue. The second application is video answering machine. A video answering machine replicates a digitally recorded video message which can be transmitted, such as via the Internet, stored on a fixed disk drive and played back at the user's convenience. Thus a person does not have to worry about answering a video phone when she is wearing her curlers, bathrobe and slippers. Additionally, the recipient does not have to be at home to receive the message.
[0011] There are two main applications for video messaging. Video messaging essentially is the delivery of a message that includes video and audio content. This transmission may be over the Internet. This technique is analogous to email. Attachments could be added to the video message. These attachments could be content from analog or digital video cameras, digital still cameras, photo CDs or other video generating or storage media as well as any other digital content. The second application is used in conjunction with video conferencing. A video answering machine provides the ability to leave a video message, when the person you want to video conference with is not available. This is much like the telephone answering machines or voice mail used today.
[0012] Current technology permits support of video conferencing capabilities. Other technologies have been developed that allow digital recording of video content. This latter capability is currently being used only for the recording of cable TV or satellite TV programming. Neither of these current applications take full advantage of technology such as the Internet. Neither of these current technologies operate like what people use today, such as email.
[0013] The proposed video messaging is non-interactive. Non-interactive, digitized messages can be easily sent over the Internet and buffered or stored. The video quality can be enhanced over that currently provided by video conferencing, since there is not the huge bandwidth requirement necessary for interactive video. Latency is not an issue in video messaging, because this application technology is not interactive. The recipient does not have to be present to participate. The video message can be digitally stored, such as in a hard disk drive, at the receiving end and played back whenever the recipient desires. The recipient does not have to be home. Further, it doesn't matter if the recipient is not properly dressed to receive a video conference. The recipient can reply or forward the video message when and as they desire.
[0014] [0014]FIG. 1 illustrates a block diagram of an exemplary embodiment of the hardware used to practice this invention. FIG. 1 illustrates a transmission station including digital video camera 101 , digital still camera 102 , microphone 103 , analog video camera 104 , television receiver 105 and transmission appliance 110 . FIG. 1 illustrates a reception station including reception appliance 130 , television receiver 141 and video cassette recorder 143 . Transmission appliance 110 and reception appliance 130 could each be a stand alone apparatus, a personal computer or a resident gateway providing Internet connection, server and networking capability to plural computers in the home. Not illustrated in FIG. 1 is an input device to receive user commands for the transmission station and the reception station. This could be any input device known in the prior art such as: a keyboard; a keypad; a pointing device like a mouse, a joystick or a track ball; and a touch screen display integral with or separate from television receiver 105 .
[0015] Video message transmission takes place in a manner outlined in FIG. 2. FIG. 2 illustrates only the general outline of this process. Those skilled in the art would realize that a practical application would require some provision to receive user inputs and commands, such as to initiate video recording, specify the reception station and the like. Program 200 executes on central processing unit 111 of transmission appliance 110 . Initially, program 200 continually tests to determine if a video message is to be recorded (decision block 201 ). Some form of user input would generally be required to initiate this process. Alternatively, central processing unit 111 could be programmed to initiate video recording and transmission upon detection of a predetermined event or set of events, such as expiration of a time period, detection of some external event by a sensor or the like. If not (No at decision block 201 ), then program 200 repeats this block. If so (Yes at decision block 210 ), then program 200 controls recording the video message (processing block 202 ). FIG. 1 illustrates alternate hardware for recording the video message. The video message could be captured by digital video camera 101 . Such cameras typically include an integral microphone for capturing audio corresponding to the video. This combined video and audio is transmitted to buffer 116 within transmission appliance 110 . Digital video cameras typically employ some type of broadband transmission such as 10Bt Ethernet or IEEE 1394, commonly known as FireWire. This connection could also be by way of a Universal Serial Bus (USB) or any other medium providing acceptable transmission bandwidth. Buffer 116 provides temporary storage of the received signal from digital video camera 101 until it can be stored in hard disk drive 114 . This data may also be intermediately stored in memory 112 prior to storage in hard disk drive 114 . As an alternative, the video message could be captured by analog video camera 104 . FIG. 1 illustrates microphone 103 separate from analog video camera 104 . Analog video cameras of the type proposed typically include an integral microphone as described above with regard to digital video camera 101 . However, even with an integral microphone, such an analog video camera typically supplies separate audio and video baseband signals as shown in FIG. 1. This differs from the typical digital video camera which supplies a combined digital analog and video signal. The respective audio and video baseband signals are supplied to analog to digital converter 118 in transmission appliance 110 . Analog to digital converter 118 converts the respective audio and video baseband signals into digital data streams. These digital data streams are stored in hard disk drive 114 as previously described and optionally may be buffered and temporarily stored in memory 112 .
[0016] Program 200 next encodes the digital video data (processing block 203 ). Such data encoding reduces the amount of data that must be transferred to the reception station. Central processing unit 111 recalls the digital video data from hard disk drive 114 , encodes it with the selected algorithm and stores the resultant encoded digital video data on hard disk drive 114 . Several video encoding standards are known in the art. The MPEG2 (Motion Pictures Expert Group) standard is one of the many standards suitable for this invention. Note that the video data transmission does not need to be in real time as the video is generated. Central processing unit 111 may employ more time for data encoding than the run time of the video message. Following encoding and storage of the encoded file, the original, unencoded digital video data may be discarded to save disk space within hard disk drive 114 . Alternatively, the encoded video data need not be stored on hard disk drive 114 but may be simultaneously transmitted via communications interface 113 as it is encoded. Storage is probably necessary if there are to be any attachments described later.
[0017] Program 200 next determines whether any other data is to be attached to the video message (decision block 204 ). If not (No at decision block 204 ), then program 200 sends the message (processing block 205 ). This will be further described below. If so (Yes at decision block 205 ), then program 200 inputs and processes the attachment (processing block 205 ). An attachment could be text file from another source, a digital still picture from digital still camera 102 by way of buffer 117 or an audio file by way of microphone 103 and analog to digital converter 118 . These files may also be encoded using central processing unit 111 . The JPEG (Joint Picture Expert Group) standard is a suitable standard for digital still pictures. Several audio encoding standards exist, the MPEG layer 3 standard, known as MP 3 , is a suitable standard for this invention. As described above in conjunction with digital video data, once encoded the original, unencoded data may be discarded to save space on hard disk drive 114 .
[0018] The digital video message and any attached file is then transmitted (processing block 206 ). A number of transmission methods are feasible. It is preferable in this invention to use a broadband connection to the Internet 120 for this transmission. A cable modem or a digital subscriber line (DSL) connection are suitable for this invention. Central processing unit 111 controls transfer of the desired data from hard disk drive 114 to Internet 120 via communications interface 113 . Communications interface 113 services any required connection and log on protocols, designation of the destination and then supplies the data to the transmission medium. If the transmission is to be via the Internet, the user of the transmission station must prearrange a relationship with an Internet service provider (ISP) to complete the connection to Internet 120 . Communications interface 113 controls transmission of the video message with any attachments for later review at the reception station.
[0019] At the transmission station, a video message may be reviewed on television receiver 105 . This may occur in real time as the video message is produced via digital video camera 101 or analog video camera 104 , or following storage and encoding of the video message. TV encoder 115 receives the video data and produces an appropriate signal for viewing by television receiver 105 . In the case of review of encoded data, such as stored on hard disk drive 114 following encoding, central processing unit 111 preferably decodes the data or controls decoding of the data. In this case the decoding preferably takes place in real time as the video is viewed. TV encoder 115 produces a signal compatible with television receiver 105 . Television receivers used in North America employ the National Televison Standards Committee (NTSC) standard to receive broadcast signals. Apparatus, such as video cassette recorders or video game consoles, which use a television receiver as a display typically modulate the video and audio signals on a carrier according to the NTSC standard at a frequency within the tuning range of the television receiver. Analog video cameras such as analog video camera 104 typically produce a signal compatible with the NTSC standard. In this case, TV encoder 115 need only recover the original input signal. Digital video camera 101 may employ a differing encoding standard. In this case, TV encoder 115 also needs to transcode the digital video signal to the NTSC standard.
[0020] Video message reception takes place in a manner outlined in FIG. 3. As described above in conjunction with FIG. 2, a practical application would require a manner to be responsive to user commands. Program 300 executes on central processing unit 131 of reception appliance 130 . Initially, program 300 includes a polling loop including decision blocks 301 , 303 , 308 and 314 . A negative answer to each of these queries remains in this polling loop. A positive answer to one of these queries branches to a service routine. Following execution of the corresponding service routine, program 300 returns to the polling loop.
[0021] Program 300 checks to determine if a video message is received (decision block 301 ). In the preferred embodiment, reception appliance 130 is connected to Internet 120 via communications interface 133 . The nature of communications interface 133 depends upon the type of connection to Internet 120 . A dial-up connection via an ordinary telephone line requires communications interface 133 to place a telephone call on the line to the ISP of the user, connect to the ISP server and establish a connection. This process typically includes entry of a user identification and password. In such a case, the determination that a video message has been received will only occur following logging on to Internet 120 via communications interface 133 and the user's ISP. In the case of a DSL or cable modem connection, the connection to Internet 120 is always live and no such log on is required. In this case, determining that a video message has been received may take place on an interrupt basis. Alternatively, communications interface 133 may periodically poll a particular location where the user's ISP stores such messages prior to download. The nature of the reception depends upon the type of transmission medium used in a manner well known to those skilled in the art.
[0022] Upon determining a video message has been received (Yes at decision block 301 ), program 300 stores the video message and any attachments in non-volatile memory (processing block 302 ). Memory is classified as non-volatile if data is not lost upon removal of electrical power. In the preferred embodiment the video message is transferred from communications interface 133 to hard disk drive 134 and optionally may be buffered in memory 132 . Following this storage, program 300 produces a “message received” indication” (processing block 303 ). Reception appliance 130 preferably produces a user indication that a video message has been received. This user indication could be by a visual message displayed via television receiver 141 , an audio alarm produced by the audio channel of television receiver 141 or a separate audio channel (not shown) or any other type of visual or audible indicator. Following indication that a message has been received, program 300 returns to the polling loop at decision block 301 .
[0023] If a video message has not been received (No at decision block 301 ), program checks to determine if the user desires to view a previously received and stored video message (decision block 304 ). As noted above, reception appliance 130 preferably provides an indication to the user when such a video message has been received. If this is the case (Yes at decision block 304 ), then the desired video message is recalled (processing block 305 ). This process preferably takes place by soliciting user input as to which video message to view. It is known in the art to provide a visual menu enabling such user selection. This video menu could be displayed via television receiver 141 in a manner that will be described below. Following recall of the selected video message, program 300 decodes the digital video data (processing block 306 ). This process is the reverse of the encoding process 203 of program 200 . The result is recovery of the original video recorded at the transmission station. This decoded video data is supplied to TV encoder 135 for display via television receiver 141 (processing block 307 ). There are several alternatives for this procedure. In a first alternative, the encoded video data can be recalled from hard disk drive 134 , decoded by central processing unit 131 and supplied to TV encoder 135 in real time as the video message is viewed. This requires that central processing unit 131 has the computation capacity to perform the decoding in real time, as fast as data is streaming from hard disk drive 134 to TV encoder 135 . Typical video encoding standards do not require as intensive computation for decoding as for encoding. In a second alternative, the decoding can take place slower than real time. In this case, encoded video data is recalled from hard disk drive 134 and decoded by central processing unit 131 at a rate slower than needed to view the video. Decoded video data from central processing unit 131 is then stored at another location on hard disk drive 134 . Following decoding of all or part of the video message, central processing unit 131 controls recall of the decoded video data from hard disk drive 134 and routes this data to TV encoder 135 . TV encoder 135 operates similarly to TV encoder 115 previously described. TV encoder 135 receives the decoded video data and generates a signal compatible with the technical standard of television receiver 141 . Program 300 tests to determine the end of the video message (decision block 308 ). Upon detection of the end of the video message (Yes at decision block 308 ), program 300 resets the message received indicator (processing block 309 ). Thereafter, program 300 returns to the polling loop at decision block 301 .
[0024] If the user does not select viewing a previously stored video message (No at decision block 304 ), then program 300 checks to determine if the user wants to access an attachment (decision block 310 ). In the preferred embodiment the same menu system used to select accessing a video message alerts the user to the presence of one or more video message attachments and permits the user to select accessing any such attachments. If the user selects accessing a video attachment (Yes at decision block 310 ), program 300 recalls the selected video attachment (processing block 311 ). Such video attachments are preferably stored on hard disk drive 134 . Upon such recall, program 300 checks to determine if the video attachment is encoded (decision block 312 ). Recall from the above description that encoding of video attachment is optional. Generally picture and audio attachments would be encoded while other attachments, such as text, spreadsheet or computer presentation files would not be encoded. If encoded (Yes at decision block 312 ), central processing unit 131 would identify the proper encoding standard and decode the attachment (processing block 313 ). If not encoded (No at decision block 312 ), program 300 would skip this step.
[0025] Following any needed decoding, program 300 transfers the attachment data to TV encoder 135 (processing block 314 ). The manner of this access depends upon the nature of the attachment. Data files such as text, spreadsheet or presentation data should be displayed in the manner of its originating application. Accordingly, hard disk drive 134 should store a compatible application to enable central processing unit 131 to open and make visible the attachment data. In the case of a picture, such as taken by digital still camera 102 , hard disk drive 134 should store a picture viewing program permitting central processing unit 131 to format the picture data for viewing via television receiver 141 . Large pictures may either be shrunk by reducing picture resolution for display of the whole picture on television receiver 141 or the picture viewing application programmed to permit viewing less than all the picture and scrolling to view other parts. In the preferred embodiment audio files are accessed via television receiver 141 . Central processing unit 131 supplies the audio data to TV encoder 135 in a manner like the soundtrack of a video message. TV encoder 135 generates a signal to television receiver 141 with audio data modulation in the same manner as the soundtrack of a video message. Using this technique no additional audio system is required. Alternatively, reception appliance 130 could be constructed with a separate audio channel (not shown) including a digital to analog converter, an audio amplifier and a speaker.
[0026] Following accessing the attachment, program 300 tests to determine if the attachment is complete (decision block 315 ). This may be the end of an audio file of the user deciding to end a text, spreadsheet or picture viewing program. Program 300 remains in decision block 315 if the attachment is not compete (No at decision block 315 ). Upon detecting the end of the attachment (Yes at decision block 315 ), program 300 returns to the polling loop at decision block 301 .
[0027] If program 300 has not received an input video message, the user does not select viewing a video message or attachment (No at decision blocks 301 , 304 and 310 ), program 300 checks to determine if the user wants to archive a previously received video message (decision block 316 ). It is well known that video data files are very large. Attempting to archive video messages in hard disk drive 134 would quickly fill the available storage space. In the preferred embodiment video messages are archived using video cassette recorder 143 . As known in the art, a video cassette recorder includes: a television receiver to receive and demodulate broadcast or cable cast television signals: a video record/playback tape transport; and a signal generator similar to TV encoders 115 and 135 which supplies a modulated signal within the reception band of television receiver 141 . Because a single video cassette can store several hours of video, this is a convenient way to archive video messages.
[0028] If the user indicates archiving a video message (Yes at decision block 316 ), then program 300 recalls the video message to be archived (decision block 317 ) in the same fashion as processing block 305 . Program 300 then decodes the video message (processing block 318 ) in the same fashion as processing block 306 . The decoded video is supplied to TV encoder 135 (processing block 319 ) in the same fashion as processing block 307 . Program 300 starts video cassette recorder 143 in record mode (processing block 320 ). Thereafter program 300 waits until the end of the video message (processing block 321 ) in the same fashion as decision block 308 . As previously described above, this process may involve real time decoding or the decoded video may be temporarily stored in hard disk drive 134 for later supply to TV encoder 134 . Following the end of the video message (Yes at decision block 321 ), program 300 stops the recording of video cassette recorder 143 (processing block 322 ). Note that the record start and stop may be performed manually by the operator with cues from reception appliance 130 or reception appliance 130 may perform this automatically under direction of central processing unit 131 . After stopping recording by video cassette recorder 143 (processing block 322 ), program 300 returns to the polling loop at decision block 301 .
[0029] Program 300 illustrates that video message input and access are separate processes that cannot take place simultaneously. Depending on the capacity of reception appliance 130 , it is feasible to receive and store a new video message (blocks 301 , 302 , 303 and 304 ) while simultaneously viewing a video message (blocks 304 , 305 , 306 , 307 , 308 and 309 ), accessing an attachment (blocks 310 , 311 , 312 , 313 , 314 and 315 ) or archiving a video message (blocks 316 , 317 , 318 , 319 , 320 , 321 and 322 ). In this event the reception and storing of a video message proceeds autonomously while the user requests the other process. | In a method of video messaging a transmission station ( 110 ) records a video message in digital form and transmitting it to a predetermined reception station ( 130 ). The reception station ( 130 ) stores the received video message in a nonvolatile memory ( 134 ). At a time other than reception of the video message, the reception station ( 130 ) displays the stored video message to a user. The video message may be encoded at the transmission station ( 110 ) and decoded at the reception station ( 130 ). The transmission station ( 110 ) may transmit a digital attachment file with the video message, such as a word processing document, a spreadsheet document, a digital still picture, an audio file or a video clip. The reception station ( 130 ) preferably uses a television receiver ( 141 ) to display the video message. Video messages may be archived at the reception station ( 130 ) using a video cassette recorder ( 143 ). | 7 |
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