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This application claims the benefit of U.S. Provisional Application Ser. No. 61/278,745, filed Oct. 9, 2009 titled “Easily-Changed Panels for Galley Inserts in Aircraft or Other Vessels,” the entire contents of which are hereby incorporated by reference.
FIELD OF THE INVENTION
Embodiments of the present invention relate generally to panel inserts for aircraft that can be easily changed, as well as components on the aircraft that are specifically designed to receive and cooperate with such panel inserts. Particular embodiments are designed for use in aircraft galleys and other locations on an aircraft or other passenger transport vehicle or vessel.
BACKGROUND
A number of food service and other components/hardware items are located in an aircraft galley. For example, an aircraft galley typically includes at least a water boiler, a beverage/food chiller, an oven, and a trash compactor. It may also include a coffee maker, storage cabinets or closets, trolleys/food service carts, and a number of other service and storage items/areas.
Traditionally, galley equipment has a single paint color or decorative laminate affixed to the front surface that faces that galley work area. The surface is intended to be generally neutral or to match the color of other decorative materials in the area. Once such equipment is installed, changing the colors or laminate materials is expensive and usually requires re-certifying the entire component with appropriate authorities or airframe manufacturers.
As airlines are moving more toward an integrated design approach in their galleys (as well as other areas on the aircraft), it is desirable that the galley components present a unified and harmonized look and feel. For example, if the door panels of all of the components have a similar color or finish, similar design, a unified graphic design, or an otherwise clean and uncluttered look, then the galley is much more visually appealing to travelers and airline attendants than if the door panels are a hodge-podge of colors and designs. Additionally, components that are located in an aircraft galley may initially all be purchased from one supplier so that they have a cohesive look and feel, although it is more often the case that varying components are purchased from a number of separate suppliers. This may result in the galley having a disjointed look and feel, which prevents the airline from projecting a unified and cohesive look in the galley area.
Moreover, even if the component door panels initially present a unified look (e.g., a similar color scheme or décor) when installed, over time, they may become scratched, dented, gummed with stickers or sticky notes (used to identify the food items located inside the component), marred, or otherwise damaged. This results in a galley that appears messy and unkempt. Travelers often pass by and through the galley areas. Thus, presenting a unified, uncluttered, and elegant look to the galley helps the airline project a professional and calming atmosphere. Damage to component door panels can interfere with this goal.
The present inventors have also identified a separate need, wherein airlines may wish to replace component doors that are not necessarily damaged, but to provide artwork, a billboard effect, decorative items, graphics, promotional, “white board” (easily erasable, marking board), or other functional or ornamental indicia across the galley area. These options are described in more detail below.
In the past, replacement of component panel doors has entailed removing the entire component (the oven, the chiller, or so forth) and installing a completely new component or unit. This can be expensive, wasteful, and time-consuming. Alternatively, just the door of the particular component may be removed and replaced, which is also expensive and time-consuming. A further option has been to non-removeably adhere (glue, bolt, or otherwise permanently secure) a separate, new panel to the component door. All of these options are expensive and time-consuming, requiring tools, downtime of the aircraft, and skilled maintenance personnel in order to effect the replacement or change. In short, these options are not optimal ways to achieve the desired results.
Another challenge that arises when components on an aircraft are replaced is that each and every time a part is changed or installed on the aircraft, it must receive a new part number and be independently Federal Aviation Administration (FAA) certified. This is in part to ensure that the parts meet non-flammability, smoke, and other FAA requirements. This additional certification can be expensive and time-consuming. There is thus a need for an improved system for replacing component door panels on aircraft and other passenger transport vehicles or vessels.
BRIEF SUMMARY
Airlines may wish to refresh the look of their galleys or other cabin areas from time to time. With the current approach to decorative finishes and laminates on galley components, the entire unit (or at least the door of the unit) would need to be upgraded or replaced. This typically requires wholly new certification of the entire galley component equipment. Accordingly, the present inventors have developed a system that provides a cohesive, harmonized look to aircraft galleys and other aircraft areas. The system allows airlines to easily change the decorative front fascia of galley (and other) airline components, even while the components are installed on the aircraft. The replacement is accomplished without the use of tools or extensive manual effort by providing replaceable and interchangeable panels for use on aircraft. The panel system also helps enhance the aesthetic value of the aircraft cabin and galley environment. Just the decorative or aesthetic quality finish may be replaced from unit to unit (or from door to door or from panel to panel), and the airline may select from a family of panel insert designs.
For example, embodiments described allow the airline to quickly and easily change panel inserts so that they match collectively across an entire galley or other area. Alternative embodiments allow the airline to display significantly larger advertising, logos, or other large surface area designs across an entire galley in order to achieve a billboard effect, rather than be restricted to designs on a single component. If a galley component is broken and needs to be removed from the aircraft, the panel insert may be quickly and easily transferred from the broken component to the replacement component, without having an unmatching component in the interim. Alternatively, the airline may simply wish to refurbish all component doors with a different color or design, and do so without extreme expense, down-time or regulatory considerations. At least one embodiment of the system described herein thus provides the option of a single certification step, wherein the system or family of panel inserts is initially certified, such that once installed, the entire component does not need to be re-qualified or certified.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a front plan view of an aircraft galley featuring one family of billboard panel inserts.
FIG. 2 shows a front plan view of an aircraft galley featuring an alternate family of billboard panel inserts.
FIG. 3 shows a front plan view of an aircraft galley featuring a cohesive family of billboard panel inserts positioned on upper and lower components, and illustrates an example of how they may be interchanged.
FIG. 4 shows a plurality of side perspective views of aircraft galley equipment components featuring single, replaceable, alternate colored panel inserts.
FIG. 5 shows a side perspective view of an aircraft galley equipment component door without having a panel insert positioned thereon.
FIG. 6 shows a side perspective view of the aircraft galley equipment component door of FIG. 5 having a panel insert positioned thereon.
FIG. 7 shows one embodiment of a securing system for securing an insert panel.
DETAILED DESCRIPTION
Embodiments of the present invention provide a system of airline component door panel inserts that provide a cohesive, harmonized look to aircraft galleys and other aircraft areas. It may often be the case that damaged component doors need to be replaced, but airlines may also wish to use various embodiments described herein in order to provide a fresh new look to a galley area or other area on-board the aircraft. There is provided a system of easily-changeable panel inserts that may be removed, replaced, and interchanged relatively easily without specific tools or skilled maintenance personnel on the aircraft. The panel system helps enhance the aesthetic value of the aircraft cabin and galley environment. The system also provides the option of a single certification step, wherein the system of panel inserts is initially certified, and then, once installed, the component does not need to be re-certified.
As shown in FIGS. 1-3 , various embodiments of the panel inserts 10 described herein may feature imprinted graphics, promotional indicia, decorative items, airline logos, advertisement material, artwork, visual indicia (including, for example, exit directional information), or any other design elements. In one embodiment, a family 12 of multiple panels 10 may each have a different design element or visual indicia or printed material (such as part of a photo, a letter, a logo, or any other feature) that collectively forms a billboard effect or a mural when positioned and viewed together. These panel inserts may be referred to as billboard panels 13 , and this term is intended to refer to and include one or more panel insert(s) having any type of pattern, picture, text, printing, logo, photo, design, symbol, or any other visual indicia adhered to, printed on, or otherwise displayed by the panel insert.
For example, the family 12 of panels together may create a visually appealing scene, such as a photograph or picture of one of the destinations to which the airline travels, as shown in FIG. 1 . Each panel may have a portion of the scene thereon, such that when installed or properly positioned, the panels collectively form a continuous visual effect, much like a mural. In another example shown in FIGS. 2 and 3 , each panel has a portion of an airline name, airline logo, or other promotional item or service, such that when installed or properly positioned, the panels collectively form a desired, continuous visual effect.
Other embodiments provide panel inserts that do not present a collective design, but that match a related color scheme or provide a generally muted design or pattern (rather than a series of graphics on two or more panels intended to be viewed as a billboard). These embodiments may be referred to as single panels 14 . As such, single panels 14 do not need to be installed as part of a family of panels in order to be visually appealing, but can instead be installed individually and in no particular order. Examples of such features are shown in FIG. 4 . Non-limiting examples include a stainless steel finish, a glossy or matte color finish, a fabric-type material, a wood-like or wood finish, laminate, vinyl, leather (real or faux), metals (e.g., aluminum), ceramics, plastics (e.g., polycarbonate), glass, bendable glass, whiteboard material, chalkboard finish, or any other appropriate material that would enhance the décor of an aircraft interior or provide a functional advantage or look over the currently-installed door panels. The panels may feature a single solid color, one or more colors, or an individual repeating pattern (e.g., stripes, dots, chevrons, triangles, or any other design). One example could be a leather-like or wood-like finish that may have a grain or a textured appearance, but does not necessarily feature graphics or textual indicia. Another example could be a repeating shape design. In short, the installation of such single panels 14 does not require any order or sequence in order to present a unified look.
Any and all of the above visual options for either a billboard panel 13 or a single panel 14 will collectively be referred to as an “aesthetic quality.” In order to lower inventory and provide enhanced options, it is possible that each of the front and back surfaces of the panel insert may feature an aesthetic quality. In one example, a front surface of the panel features a solid color and the back surface features a portion of scenery or a logo. Airline personnel may desire to interchange one option for another quickly and easily.
Panel inserts 10 may be attached or otherwise secured to any appropriate cabin surface. Although installation and use is described throughout with a particular emphasis for use in an aircraft galley and on galley component doors, it should be understood that the panel inserts may be installed on any appropriate cabin surface. For example, the panel inserts may be secured to component door(s) anywhere on the aircraft (such as oven door, chiller door, trash compactor door, boiler door, or so forth), storage cabinet door(s), lavatory door(s), overhead compartment door(s), galley cart/trolley or other food service cart, coat closet door(s), cockpit door(s), divider panel(s), tray table(s), seat back(s), exit row panels(s), or any other appropriate aircraft surface. In short, instead of only replacing damaged panels, an airline may also desire to periodically change the doors of its galley components, its lavatory doors, its closet doors, or any other space in the cabin interior in order to provide a different look and feel of the galley or other airline areas. Any and all of these options will be collectively referred to as a “receiving surface.” For example, the airline may wish to provide artwork, a billboard scenery effect, the airline name, logo, or other promotional indicia in the galley or anywhere on the aircraft. The airline may instead wish to a club-like feel and provide a leather or wood panel look, or it may wish to provide a contemporary modern feel and use a stainless finish in the galley or other airline areas.
Generally, the panel inserts are configured and designed to be removeably and releaseably secured or fixed to a receiving surface 16 . Removal and replacement of the panel insert does not require any special tools. In a specific embodiment, the receiving surface 16 has a first securing mechanism 18 that is intended to cooperate with a second, corresponding securing mechanism 20 on the panel insert 10 . The panel inserts 10 may be secured to the receiving surface 16 by cooperation between the first and second securing mechanisms, collectively referred to as a “securing system” 22 . The panel inserts 10 are not adhesively bonded or otherwise permanently secured to the receiving surface 16 , but instead, securing system 22 provides an easily-releasable and easily-changeable system for the panel inserts 10 .
In one embodiment, the securing system is a channel (or groove or slot) and edge cooperation. The panel insert 10 has one or more edges 24 that may slide into a slot, channel, pocket, or groove 26 on receiving surface. For example, as shown in FIG. 5 , a galley component door 28 is shown as having a channel 26 along its top portion 30 and along one side edge 32 . Channel may also be positioned along the bottom portion. Channel 26 may be formed as an overhang portion at the top of the receiving surface 16 (here, shown as a door 28 ), integral with the receiving surface, or it may be formed as a separate channel that is installed separately on receiving surface. Although not shown, channel 26 may alternatively be positioned along both sides and along the bottom of the receiving surface. Channel 26 may be continuously formed or it may simply be provided as a portion (e.g., a portion of a channel or of the door) positioned along receiving surface.
In use, edge 24 of panel insert 10 is slid into the channel 26 . If channel 26 is positioned along the top, bottom, and one side edge of surface 16 as shown, then the panel insert edge 24 may be inserted from the opposite side edge (the side edge without the channel). If channel is positioned along both side edges and along the bottom of surface, then the panel insert edge 24 may be inserted from the top. Other insertion options, directions, and channel positions are also possible and considered within the scope of this invention.
One optional feature (particularly if the channel is provided as a separate channel portion) is a similarly-shaped trim edge 34 . Trim edge may be provided as a strip that is similar in geometry or the same geometry as the other three edges, so that when it is installed, trim edge provides a “picture frame” look. Examples of trim edges 34 are shown in FIGS. 6 and 7 . In one embodiment, trim edge is an approximately 0.06×0.3×18″ plastic strip attached to panel insert 10 . Once installed, it may provide a continuous “picture frame” look around all four sides of the panel. It should be understood, however, that trim edge may be made of any appropriate material. One visually appealing effect is provided if the trim piece is of a similar material as the panel insert.
Upon insertion of the panel insert 10 , the trim edge 34 may be removeably secured along the open edge where the panel was inserted in order to complete the look, as well as prevent inadvertent sliding of the panel insert. Trim edge 34 may snap onto the panel, be secured around the non-received panel edge (i.e., the edge that does not cooperate with the channel 26 ), it may be received in channel, or may be secured in any other appropriate manner.
The dimensions of channel may be any appropriate size, as long as it is slightly larger than the edge of panel, such that panel may slide into and be received in channel. In a specific embodiment, the width of the channel is about 0.030 inches and the thickness of the decorative panel is about 0.020 inches. These are provided as examples only and are not intended to limit this disclosure in any way. In another specific embodiment, the size of the panel insert is about 24 inches to about 24 inches, more particularly about 20 inches to about 20 inches, even more particularly about 17 to about 11 inches, and even more particularly about 17.6 inches to about 11.1 inches. It should be understood that the panel insert may be any appropriate dimension, however. For example, if used to cover a lavatory or cockpit door, it should accordingly be appropriately sized. Other dimensions and sizes can be understood and determined based on the intended use for panel insert.
In an alternate embodiment, the securing system is a bump (or raised protrusion) and recess cooperation. One of the panel insert 10 or the receiving surface 16 has a bump 36 and the other of the panel insert or the receiving surface has a recess 38 . In use, the bump 36 mates with the recess 38 . For example, as shown in FIG. 7 , if the bump 36 is located on the receiving surface 16 , it mates with a recess on the back of panel insert. If the bump is located on the pack of panel insert, it mates with a recess on receiving surface. This allows panel insert to easily snap onto and off of receiving surface without the use of specific tools.
Any other connection or securing systems may be used in conjunction with the embodiments described herein. Any system that will removeably or interchangeably secure the panel inserts to a aircraft receiving surface is considered within the scope of this invention. For example, the securing system may be a ball and detent system, a dove-tail connection, a J-lock system, a magnetic system, a snap system, a hinged system (wherein a panel insert can have one or more pegs that are inserted into holes resembling hinge elements on the receiving surface and swung closed) a clip system, hook and loop (e.g., Velcro™) or any other appropriate system.
Another feature provided is the ability to obtain a single certification for the panel inserts, such that once certified by the FAA, the panel inserts can be removed and replaced without additional re-certification for each part. In one proposed approach, the panel inserts are designated as trim to the component to which they are intended to be releaseably secured. The process includes certifying and qualifying a first a panel insert having one color or design, but then allowing that panel insert to be interchangeable with any number of second panel inserts from the family 12 without a new certification process. Thus, after an airline installs qualified and certified unit, component or piece of equipment, it is free to replace the panel inserts with any other panel insert in the family (e.g., a billboard panel 13 or a single panel 14 or any other option) having a different color or design without having to create a new unit part number and subsequently re-qualify or certify the unit, component or piece of equipment. In short, this option allows the fit, form, and function of the panel inserts to be pre-qualified with the FAA for the entire family of interchangeable panel inserts, without obtaining new parts numbers for each panel. Additionally, qualified and certified equipment may be shipped with a panel insert (showing a different design or color than the panel insert that went through the original certification) without having to obtain new part numbers. Materials, colors, dimensions, construction parameters, and any other parameter that must be qualified of certified for safety and other FAA reasons will all be certified initially and then panel inserts from the family will be easily replaceable without further regulatory efforts.
Changes and modifications, additions and deletions may be made to the structures and methods recited above and shown in the drawings without departing from the scope or spirit of the invention and the following claims. | Embodiments of the present invention provide a system that provides a cohesive, harmonized look to aircraft galleys and other aircraft areas. The system allows airlines to easily change the decorative front fascia of galley (and other) airline components, even while the components are installed on the aircraft. The replacement is accomplished without the use of tools or extensive manual effort by providing replaceable and interchangeable panels for use on aircraft or other passenger transport vehicles or vessels. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a dot line printer including a printing unit making a reciprocating motion and a shuttle unit making a motion in a direction opposite thereto.
2. Description of the Related Art
A dot line printer apparatus performs printing while a printing unit makes a rectilinear reciprocating motion. Then, when completing one-line printing, the consecutive printing is carried out by feeding a sheet in a direction orthogonal thereto. This printing unit has a plurality of dot elements and is therefore large in weight. Hence, the apparatus oscillates due to the reciprocating motions of the printing unit.
For preventing this phenomenon, in the apparatus, provided is a shuttle unit making a motion in a direction opposite to that of the printing unit. The motion of this shuttle unit takes a balance with the motion of the printing unit. The oscillations of the apparatus can be thereby prevented. In the dot line printer equipped with the shuttle unit making the motion in this opposite direction, the reciprocating motion is required to increase in terms of velocity.
FIG. 8 is a perspective view showing the prior art. FIG. 9 is a sectional view of the prior art.
As illustrated in FIGS. 8 and 9, a balance shuttle unit 9 is provided in a face-to-face relationship with a printing shuttle unit 8.
The printing shuttle unit 8 includes a printing unit 80 having a plurality of dot printing elements. This printing unit 80 is mounted on a shuttle frame 81 moving along a shuttle shaft 85. The printing unit 80 is constructed such that a plurality of wire dot element strings each having a plurality of vertically arranged wire dot elements are arrayed at a predetermined interval.
Coils 82 are provided under this shuttle frame 81 through a yoke 86. A magnet 84 is attached to a base frame (yoke) 83 in a face-to-face relationship with this coil 82. Note that the numeral 87 designates a guide roller for the reciprocating motion, and 88 represents a balance weight.
On the other hand, the balance shuttle unit 9 has a balance weight unit 90 for taking a balance in terms of weight with the printing unit 80. This balance weight unit 90 is mounted on a shuttle frame 91 moving along a shuttle shaft 95. Coils 92 are provided under this shuttle frame 91 through a yoke 96. A magnet 94 is attached to a base frame (yoke) 93 in the face-to-face relationship with the coils 92. Note that the numeral 97 denotes a guide roller for the reciprocating motion.
This printing mechanism is based on the principle that the printing unit 80 is reciprocated by a linear motor. That is, the shuttle unit 81 to which the coils 82 are fixed makes the reciprocating motion in the direction right-angled to a feeding direction of a sheet 71. With this motion, the wire dot printing elements of the printing unit 80 are driven toward a platen 70, thus effecting the printing on the sheet 71.
According to a kinetic principle of the linear motor, an electric current flows across the coils 82 in a magnetic field generated by a permanent magnet 84 disposed under the coils 82. With this operation, the shuttle unit 81 fitted with the coils 82 makes a motion according to the Fleming's left-hand rule.
On the other hand, the balance shuttle unit 9 makes a motion in a direction opposite to that of the printing shuttle unit 8 on the basis of the same principle as that of the printing shuttle unit 8. This offsets an inertial moment of the printing shuttle unit 8, thereby preventing the oscillations.
An improvement of this printing speed entails a speed-up of the reciprocating motion of the printing unit. For this purpose, there are considered a method of reducing a load on the linear motor by decreasing weights of members for making the reciprocating motion and a method of increasing an output of the linear motor.
The former method requires reductions in weight of the coils 82, 92, the shuttle frames 81, 91 and the coil bases 86, 96. Reducing the weights of the coils 82, 92 leads to down-sizing of the coils 82, 92. However, this brings about a drop of output of the linear motor, and therefore the coils can not be reduced in weight. Further, the shuttle frame 81 is hard to extremely decrease in weight because of bearing a printing reaction and, besides, actualizing the stable reciprocating motion.
Moreover, according to the prior art, the coil bases 86, 96 serves as the yokes. For this reason, the coil base is required to have a minimum plate thickness enough not to saturate a magnetic flux of the magnet. Accordingly, this conduces to a problem in which the weight of the coil base is hard to decrease.
On the other hand, increasing the output of the linear motor involves enlarging the coils or the magnet. Consequently, there arises a problem in which the apparatus augment in size.
Besides, according to the prior art, the printing shuttle unit 8 and the balance shuttle unit 9 are disposed facing each other through the sheet, resulting in such a problem that the size of the apparatus increases.
SUMMARY OF THE INVENTION
It is a primary object of the present invention to provide a dot line printer capable of speeding up a reciprocating motion of a printing unit.
It is another object of the present invention to provide a dot line printer capable of decreasing a movable unit of a reciprocating motion mechanism in weight.
It is still another object of the present invention to provide a dot line printer capable of decreasing a plate thickness of a coil base.
It is a further object of the present invention to provide a dot line printer capable of restraining oscillations due to the reciprocating motion.
It is a still further object of the present invention to provide a dot line printer capable of attaining down-sizing of the apparatus.
To accomplish the objects given above, according to one aspect of the present invention, a dot line printer comprises a printing shuttle unit making a reciprocating motion to perform dot printing and a balance shuttle unit making a motion in a direction opposite to the kinetic direction of the printing shuttle unit. The printing shuttle unit includes a first magnetic circuit having a first magnet and a first yoke that are disposed in a face-to-face relationship and a first coil base plate disposed in a magnetic gap of the first magnetic circuit and provided with first coils. The printing shuttle unit further includes a printing unit having a plurality of dot printing elements, a printing shuttle frame mounted with the printing unit and a pair of first connecting arms for connecting the first coil base plate to the printing shuttle frame. The balance shuttle frame includes a second magnetic circuit having a second magnet and a second yoke that are disposed in the face-to-face relationship, a second coil base plate disposed in a magnetic gap of the second magnetic circuit and provided with second coils and a balance unit for taking a balance with the printing unit. The balance shuttle unit further includes a shuttle frame mounted with the balance unit and a pair of second connecting arms for connecting the second coil base plate to the shuttle frame.
According to the above aspect of the present invention, the coil base plate of the shuttle unit does not function as a yoke. Then, a yoke fixed otherwise is provided. This coil base plate is fitted with a shuttle frame by use of the connecting arms. Therefore, the coil base plate may have a thickness enough to bear the coils. With this construction, the movable unit of the shuttle unit can be reduced in weight. Accordingly, the printing unit is capable of making the high-speed motion, and this leads to the high-speed printing.
Further, according to another aspect of the present invention, a dot line printer for performing dot printing on a sheet comprises a printing shuttle unit making a reciprocating motion to perform the dot printing and a balance shuttle unit provided under the printing shuttle unit and making a motion in a direction opposite to the kinetic direction of the printing shuttle unit.
According to this aspect of the present invention, the balance shuttle unit is provided under the printing shuttle unit, and the apparatus can be therefore made compact. Further, the magnets each undergoing the reaction of the reciprocating motion are disposed close to each other, and, besides, the movable units of the two shuttles are also close to each other. Hence, the oscillations exerted on the apparatus as a whole can be restrained. The high-speed motion can be therefore attained.
Other features and advantages of the present invention will become readily apparent from the following description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate presently preferred embodiments of the invention, and together with the general description given above and the detailed description of the preferred embodiments given below, serve to explain the principle of the invention, in which:
FIG. 1 is a perspective view showing one embodiment of the present invention;
FIG. 2 is a side view of one embodiment of the present invention;
FIG. 3 is a front view of one embodiment of the present invention;
FIG. 4 is a fragmentary view illustrating a shuttle unit of FIG. 2;
FIG. 5 is a perspective view illustrating a magnetic circuit;
FIG. 6 is a front view showing a printing shuttle frame of FIG. 1;
FIG. 7 is a fragmentary perspective view illustrating a shuttle frame of FIG. 2;
FIG. 8 is a perspective view showing the prior art; and
FIG. 9 is a sectional view showing the prior art.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a perspective view of one embodiment of the present invention. FIG. 2 is a side view of one embodiment of the present invention. FIG. 3 is a front view of one embodiment of the present invention. FIG. 4 is a fragmentary view illustrating a shuttle unit. FIG. 5 is a perspective view illustrating a magnetic circuit. FIG. 6 is a front view showing a printing shuttle frame of FIG. 1. FIG. 7 is a perspective view illustrating the shuttle frame of FIG. 1.
As illustrated in FIG. 1, a dot line printer is constructed of a printing shuttle unit 2 mounted with a printing unit 1 and a balance shuttle unit 11 provided under this printing shuttle unit 2. This printing unit 1 is equipped with a plurality of dot printing elements. This printing unit 1 is, as known well, constructed such that a plurality of wire dot element strings each having a plurality of wire dot elements arranged in one line are arrayed at a predetermined pitch. And an unillustrated platen is provided in a face-to face relationship with the printing unit 1.
As shown in FIGS. 6 and 7, the printing shuttle unit 2 includes a shuttle frame 3 moving along a shuttle shaft 10, This shuttle frame 3 is mounted with the printing unit 1. Also, the shuttle frame 3 is provided with guide rollers 8 for reciprocating motions. Further, a coil base plate 4 is composed of a light-weight non-magnetic material.
This coil base plate 4 has a multiplicity of coils 5 provided on its rear surface. A pair of connecting arms 9 are fastened to both edges of the coil base plate 4 with screws. These connecting arms 9 are fastened to both edges of the shuttled frame 3 with screws. Accordingly, as illustrated in FIG. 6, the shuttle frame 3, the pair of connecting arms 9 and the coil base plate 4 are combined to constitute a box structure.
On the other hand, the balance shuttle unit 11 includes, as illustrated in FIG. 7, a shuttle frame 13 moving along a shuttle shaft 20. This shuttle frame 13 is mounted with a balance weight unit 26. The shuttle frame 13 is also provided with guide rollers 18 for the reciprocating motions. Further, the coil base plate 14 is a light-weight non-magnetic material.
This coil base plate 14 has a multiplicity of coils 15 provided on its surface. A pair of connecting arms 19 are fastened to both edges of the coil base plate 14 with screws. These connecting arms 19 are fastened to both edges of a shuttle frame 13 with screws. Accordingly, similarly, the shuttle frame 13, the pair of connecting arms 19 and the coil base plate 14 are combined to constitute a box structure.
Next, a structure of the magnetic circuit will be explained. As illustrated in FIGS. 4 and 5, the magnetic circuit includes a holding block 25 taking an E-shape in section. This holding block 25 has an upper arm 25-1, an intermediate arm 25-2 and a lower arm 25-3. Gaps between these arms 25-1, 25-2 and 25-3 are fixed.
A first yoke 28-1 is provided on the lower surface of the upper arm 25-1. A yoke 6 and a first permanent magnet 7 are provided on the upper surface of the intermediate arm 25-2 in a face-to-face relationship with the first yoke 28-1. Further, a yoke 16 and a second permanent magnet 17 are attached to the lower surface of the intermediate arm 25-2. A second yoke 28-2 is attached to the upper surface of the lower arm 25-3 in the face-to-face relationship with the second permanent magnet 17.
As illustrated in FIG. 4, the first arm 25-1 of the holding block 25 is inserted between the shuttle frame 3 of the printing shuttle unit 2 and the coil base plate 4. The second arm 25-2 of the holding block 25 is inserted between the coils 5 of the printing shuttle unit 2 and the coils 15 of the balance shuttle unit 12. The third arm 25-3 of the holding block 25 is inserted between the shuttle frame 13 of the balance shuttle unit 12 and the coil base plate 14.
With this arrangement, the section goes as illustrated in FIG. 2, while the front goes as shown in FIG. 3. That is, in the printing shuttle unit 2, the coils 5 provided on the first coil base plate 4 are positioned in the magnetic gap between the first yoke 28-1 and the first permanent magnet 7. Further, in the balance shuttle unit 12, the coils 15 provided on the second coil base plate 14 are positioned in the magnetic gap between the second yoke 28-2 and the second permanent magnet 17.
Thus, the balance shuttle unit 12 is disposed in a symmetric position of the printing shuttle unit 2 with respect to the holding block 25 of the magnetic circuit. Therefore, a shuttle mechanism hitherto requiring a broad packaging area can be packaged in a compact way. Further, the permanent magnets 7, 17 each undergoing reaction of the reciprocating motion are disposed in close proximity to each other, and, besides, the reciprocating motion parts of the two shuttle units 2, 12 are also close to each other. Oscillations exerted on the apparatus as a whole are thereby restrained. A high-speed motion can be therefore attained.
The two shuttle units 2, 12 include the movable coil units and the magnetic circuits that are separated from each other. Therefore, the movable coil unit can be structured such that the coil base plate is attached to connecting arms at both edges of the shuttle frame, and the coils are fitted onto the coil base plate.
This coil base plate does not serve as a yoke, and hence there is no necessity for providing a yoke having a plate thickness enough not to saturate a magnetic flux of the magnet. Accordingly, the coil base plate can be decreased in thickness. Further, this coil base plate is formed of a non-magnetic material such as aluminum, stainless steel, etc. and thus can be reduced in weight.
Besides, the coil base plate is not attracted by the magnet, and, therefore, a strength of the coil base plate with respect to an attracting force of the magnet can be ignored. From the above-mentioned, the coil base plate can be thinned, resulting in obtaining a light-weight coil base plate. Therefore, the movable unit of the shuttle unit can be reduced in weight. Accordingly, the reciprocating motion of the printing unit can be speeded up.
Further, as illustrated in FIG. 4, since the printing shuttle 2 unit and the balance shuttle unit 12 are structured in such a way that the coil movable units and the magnetic circuits are separated from each other, the coil unit itself does not undergo an influence of the magnet at all. Hence, the coils can be attached and detached when replaced in a maintenance work or the like.
As shown in FIG. 4, in the magnetic circuits of the two shuttle units, i.e., the printing shuttle unit 2 and the balance shuttle unit 12, the block 25 mounted with magnet fitting bases 6, 16 and yoke plates 28-1, 28-2 each bearing a face-to-face relationship therewith is formed in the E-shape. A flatness of the fitting surface thereof can be thereby secured. This makes it possible to uniformize a gap in a linear motor. A more constant speed-up is also attainable.
Further, the movable coil unit has such a box structure that the coil base plate is attached to the connecting arms at both edges of the shuttle frame, and therefore an enhancement of the strength of the shuttle frame can be actualized. The light-weight shuttle frame can be thereby obtained.
In addition, the shuttle frames, the connecting arms and the movable coil units of the two shuttle units are commonized, and, hence, it is possible to decrease costs and improve an assembling property.
In addition to the embodiment discussed above, the present invention can be modified as follows. First, although the holding block assuming the E-shape is employed, the configuration of the holding block is not confined to this shape. Second, the printing unit including the wire dot printing elements has been exemplified, however, the present invention is applicable to printing units having other types of dot printing elements.
The present invention has been discussed so far by way of the embodiment but can be carried out in a variety of modifications within the range of the gist of the present invention. These modifications are not excluded from the scope of the present invention.
As explained above, according to the present invention, the coil movable units and the magnetic circuits of the shuttle units are separated from each other, and hence the coil movable units can be reduced in weight. For this reason, the reciprocating motion of the printing unit can be speeded up. Further, the maintenance work is also facilitated. Moreover, since the printing shuttle unit and the balance shuttle unit are provided up and down, the packaging area can be set compact. | Disclosed is a shuttle mechanism of a dot line printer including a printing shuttle unit making a reciprocating motion to perform dot printing and a balance shuttle unit making a motion in a direction opposite to the kinetic motion of the printing shuttle unit. This shuttle mechanism is constructed of a linear motor in which a movable unit for the reciprocating motion and a magnetic circuit are separated. With this construction, the movable unit can be decreased in weight. Therefore, the high-speed reciprocating motion can be made, and high-speed printing is thereby attainable. The balance shuttle unit is disposed under the printing shuttle unit. The apparatus can be thereby made compact. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This present invention relates to a personal computer and, more particularly, to an apparatus for sensing system bus clock speed and processor power supply voltage within a personal computer motherboard to which a microprocessor is delegated for connection.
2. Description of the Related Art
A personal computer is generally know to comprise, at a minimum, an execution unit, memory and various input/output ports. The execution unit is often referred to as a microprocessor, and the microprocessor is typically linked to the memory via a system bus. The system bus, sometimes referred to as a local bus, links address and data information sent between the microprocessor and memory. The system bus can also link the microprocessor, or memory, to various other subsystems, some of which are arranged on a single printed circuit board. The singular printed circuit board is often referred to as a motherboard.
A typical motherboard housed within a personal computer comprises one or more layers of printed conductors extending at least partially across the motherboard. The printed conductors surface at localized regions of the motherboard. Those regions allow connection of integrated or discreet devices using various connection techniques, such as plug-and-socket, wire wrap, or solder.
A substantial percentage of motherboards manufactured today can be reconfigured. Specifically, modern motherboards come equipped with numerous switches or jumpers which can alter the operation of one or more subsystems arranged thereon. For example, the clocking speed of the system bus can be modified by connecting a jumper across two pins extending from the motherboard. The power supply voltage supplied to a microprocessor can also be changed, for example, by connecting a jumper or actuating a switch. It is therefore necessary when modifying signals within printed conductors of a motherboard that the operator know which jumper to connect or which switch to activate.
Typical motherboards have numerous switches and jumpers, wherein the particular switch and jumper of interest must be identified in order to reconfigure, e.g., the system bus frequency or the processor supply voltage. Generally speaking, a motherboard is manufactured so that it can accommodate dissimilar microprocessors, or microprocessors which respond to differing system bus frequencies or power supply voltages. When assembling a personal computer, it would be desirable to quickly identify the particular jumper or switch of interest so that operation of the motherboard can be made compatible with the desired microprocessor. Once the settings are located, the motherboard can readily be altered to match the specification of a microprocessor which will thereafter be coupled to the motherboard. A mechanism for quickly identifying the jumpers or switches of interest is therefore desired so as not to damage a microprocessor subsequently linked to the motherboard.
SUMMARY OF THE INVENTION
The problems outlined above are in large part solved by a system for detecting jumper and switch settings (i.e., motherboard operation) prior to coupling a microprocessor to the motherboard. The present system employs a probe and a display remotely linked to the probe. The probe contains sensors which respond to signals within the motherboard during times when the probe connects to printed conductors embodying those signals. According to one embodiment, the sensors are designed to detect the system bus frequency and power supply voltage "seen" by a microprocessor-to-be-connected thereto. Accordingly, the probe may couple to a localized area (of socket) of the motherboard on which a microprocessor is designed for coupling.
The desirability of determining power supply voltage and system bus frequency resides in the variability at which numerous microprocessors can operate. The present system, for example, can determine if the system bus has been selected to run at 50 MHz, 60 MHz, 66 MHz, or 75 MHz. A microprocessor most certainly would fail if the system bus reads 75 MHz, but the microprocessor is designed only to handle, e.g., a 66 MHz system bus frequency. Therefore, it is beneficial to know the current clocking speed of the system bus and/or change that clocking speed prior to connecting the microprocessor. Likewise, the core section of a modern microprocessor is designed to operate at a voltage ranging, e.g., anywhere from less than 2.5 volts to greater than 3.6 volts. Knowing the voltage arising from the motherboard would be beneficial in determining if that voltage is compatible with the to-be-used microprocessor. If the voltage is dissimilar from the microprocessor specification, then the motherboard voltage can be changed by identifying the switch of interest and actuating that switch.
The probe and sensor of the present system is therefore designed not only to determine the current system bus frequency and voltage applied to the microprocessor core, but also to determine a clock multiplier setting and the voltage applied to the input/output portion of the microprocessor. Knowing the clock multiplier setting will therefore determine the differential between the system bus frequency and the internal microprocessor clocking frequency. Accordingly, the combination of system bus frequency and clock multiplier readings indicate the frequency at which the microprocessor will be operating once is it connected. If the microprocessor cannot operate at the frequency chosen, then the jumpers or switches which modify the system bus frequency and/or the clock multiplier setting can be changed.
Broadly speaking, the present invention contemplates a mechanism for detecting electronic signals. The mechanism comprises a printed circuit board having a power conductor and a clocking conductor. The power and clocking conductors are designed for powering and strobing an integrated circuit arranged upon the printed circuit board. The power and clocking conductors may be designed to embody signals which power a microprocessor core section and clock a system bus connected to the microprocessor, respectively. The mechanism also includes a probe releasibly coupled to a socket. The socket receives terminal ends of the power and clocking conductors. A detection circuit is included within the probe, wherein the detection circuit is brought in operable communication with the power and clocking conductors for determining a voltage within the power conductor and a clocking frequency within the clocking conductor. A visual display is remotely coupled to the detection circuit for illustrating the current voltage level and clocking frequency. Preferably, the printed circuit board comprises a motherboard. The socket can be either an arrangement of solder and/or wire wrap connections, or a receptacle into which a male end can be frictionally engaged. The visual display includes a first set and a second set of light emitting diodes (LEDs). Each of the first set of LEDs is responsive to a unique, predefined range of voltage, whereas each of the second set of LEDs is responsive to a unique, predefined range of the clocking frequency.
The present invention further contemplates a frequency detection circuit. The detection circuit includes a counter coupled to count a set of clocking cycles from among a plurality of clock cycles existing within a clocking signal. A timer is coupled to produce a timed output value which terminates after at least two of the set of clock cycles. A latch is coupled to receive this set of clock cycles during times when the timed output value is present. The latch produces a frequency detection output signal dependent upon the number of clock cycles which exist before the timed output value is terminated. The frequency detection circuit is preferably designed to detect the clock frequency of a system bus to which a microprocessor can be connected. The timed output value terminates after a variable number of clock cycles to indicate a clocking signal frequency in the range between, for example, 50 MHz to 75 MHz.
The present invention yet further contemplates a voltage detection circuit. The detection circuit is adapted to detect voltages within a conductor born as a terminal end within a socket. A probe is releasibly coupled to the socket. The probe comprises a plurality of pairs of comparators connecting in parallel. Each pair of comparators includes two mutual connections comprising a non-inverting input of one comparator connected to an inverting input of the other comparator. A reference voltage is connected to one of the two mutual connections and the voltage to be detected is connected to the other of the two mutual connections. Further, a plurality of conductors is connected to the output of the respective plurality of comparators, wherein only one of the plurality of conductors bears the voltage to be detected. Preferably, the voltage detection circuit detects voltage within a motherboard used to supply power to a microprocessor core section. The voltage to be detected activates a light emitting diode next to indicia indicating a detected voltage amount. A light emitting diode is therefore dedicated to a specific range of voltages, and a plurality of light emitting diodes are used to indicate separate and distinct voltage ranges.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages of the present invention will become apparent to those skilled in the art upon reading the following description of the preferred embodiments and upon reference to the accompanying drawings in which:
FIG. 1 is a block diagram of a system for determining motherboard operation according to the present invention;
FIG. 2 is a block diagram of various voltages supplied to operate the probe and remote module of FIG. 1;
FIG. 3 is a plan diagram of LEDs arranged across a remote module, each of which are uniquely illuminated in response to activation of an on/off switch also arranged on the remote module;
FIG. 4 is a circuit schematic of a frequency detection circuit used in determining the clocking frequency of a system bus within the motherboard to which a microprocessor can be coupled;
FIG. 5 is a circuit schematic of a voltage detection circuit used in determining a voltage of a power supply conductor within the motherboard to which a microprocessor can be coupled;
FIG. 6 is a circuit schematic of a first set of LEDs within the remote module responsive to the voltage detected; and,
FIG. 7 is a circuit schematic of a second set of LEDs within the remote module responsive to the clocking frequency detected.
While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now to the drawings, FIG. 1 illustrates a system 10 for determining operation of a printed circuit board (PCB). Preferably, PCB is a motherboard configured within the chassis of a personal computer. PCB 12 preferably comprises one or more dielectrically spaced layers, each of which comprise numerous printed conductors. Those conductors embody numerous signals, including a signal indicative of a system bus frequency (SYS CLK), a processor core voltage (VCC SN), a processor input/output voltage (VCC I/O), and clock multiplier signal voltage (BF0, BF1 and BF2). The signals of interest needed for detection by probe 14 can be contacted by a series of receptors 16 extending from probe 14. Receptors 16 align with and contact corresponding conductors within PCB 12. Preferably, receptors 16 align with terminal ends of the conductors, those terminal ends accumulated within, for example, a socket 18. Socket 18 occupies a relatively small portion of one surface of PCB 12. Socket 18 preferably comprises a plurality of mating receptors (not shown) arranged to electrically communicate with receptors 16 such that a plurality of electrical connections can be releasably made between probe 14 and socket 18. According to one embodiment, receptors 16 align with pins normally associated with a microprocessor, and that pins of interest within the microprocessor are substituted by corresponding receptors of probe 14. Thus, system clock, processor core and input/output voltages, ground, and clock multiplier pins extending from probe 14 match the arrangement at which those pins would normally extend from a microprocessor into socket 18.
Probe 14 includes not only receptors 16, but also one or more detection circuits electrically connected to receptors 16. The detection circuits, according to one embodiment, comprise a voltage detection circuit and a frequency detection circuit. The voltage detection circuit senses processor core voltages delivered by socket 18, and labeled as VCC SN. Similarly, the frequency detection circuit senses the frequency of system clock (SYS CLK) delivered from socket 18. The voltage detection circuit dispatches a voltage upon one of a plurality of voltage output conductors 20 dependent upon the amount of voltage detected within VCC SN. Similarly, the frequency detection circuit outputs a voltage upon output frequency conductors 22 dependent upon the frequency of SYS CLK. The clock multiplier signals BF0, BF1 and BF2 are dispatched directly to clock multiplier outputs 24. Conductors 20, 22 and 24 are preferably covered within a ribbon cable extending between probe 14 and remote module 26. Contained within remote module 26 are a series of light emitting diodes (LEDs). The pattern in which the LEDs illuminate is dependent upon which conductor of conductors 20, 22 and 24 receive an illumination voltage.
Power necessary to operate remote module 26 and detectors within probe 14 arise from one of possibly three sources. Firstly, power can be supplied from a supply 30 within the personal computer. Supply 30 generates voltages needed to connect, for example, devices normally associated with a personal computer such as a disk drive, CD ROM, etc. Supply 30 generates, for example, 5.0 V and 12.0 V from a four-pin adapter well know in the art. Secondly, power can arise from PCB 12. Specifically, PCB 12 contains a conductor which carries the input/output voltage of an input/output section of the microprocessor (VCC I/O). VCC I/O is typically around 3.3 volts, which can be converted to any voltage necessary to operate module 26 or detectors within probe 14. Thirdly, power can arise from a battery 32 within remote module 26. The battery (or batteries) are preferably housed within remote module 26, wherein their voltage is carried to probe 14 via a conductor within the ribbon cable. More specifically, battery voltage and various other power supply voltages are linked between probe 14 and remote module 26, and are converted within probe 14 as shown in further detail in FIG. 2.
Referring to FIG. 2, the voltage within battery 32 may be enhanced according to one embodiment so that a 9.0 V output is converted to 12.0 V as shown in the circuit schematic represented as numeral 34. Thus, a voltage regulator 36 can be used to decrease the normally 12.0 V output from supply 30 (shown in FIG. 1) and from the 12.0 V stepped-up from the 9.0 V battery supply. Regulator 36 is contained within probe 14 to convert the 12.0 V amounts to a 5.0 V voltage compatible with the various detection circuits within probe 14 and the LEDs within remote module 26. Similarly, the 3.3 V from VCC I/O is increased by converter 38 to a 5.0 V level. The various voltages (12.0 V and VCC I/O) arising from battery 32, power supply 30 and PCB 12 (shown in FIG. 1) are coupled by conductors 40 and 42. The output from a regulator 36 or converter 38 (shown in FIG. 2) is preferably 5.0 V, which is connected between probe 14 and remote module 26 via conductor 44 (shown in FIG. 1).
FIG. 3 illustrates the arrangement of LEDs 27 across an outer surface of remote module 26. Importantly, next to each LED is indicia which identifies various operating characteristics of conductors within PCB 12. Importantly, those characteristics indicate the environment in which a microprocessor connectable to socket 18 is expected to endure. FIG. 3 illustrates an example of four similar system bus clocking frequencies, three clock multiplier settings, and eight processor core power settings. It is recognized, however, that the face of remote module 26, and the arrangement of LED can be modified to accommodate more or less than the number of LEDs and the indicia shown in FIG. 3. For example, more than four system bus setting LEDs can be utilized, and the indicia next to each LED can be changed to indicate a frequency dissimilar to that shown.
Turning now to FIG. 4, a frequency detection circuit 46 is shown according to one embodiment. Detection circuit 46 includes a clock divider circuit 48 made up of a pair of D-type flip flops 48a and 48b. The clocking input of flip-flop 48a is connected to receive the system bus clocking signal (SYS CLK). The complimentary output of flip-flop 48a is fed back to the D input so that flip-flop 48a transition on the following edge of each SYS CLK cycle. The clocking input of flip-flop 48b receives the true output from flip-flop 48a, and the feedback arrangement of flip-flop 48b affords an output which transitions at each falling edge of the output signal emanating from flip-flop 48a. Accordingly, the arrangement of flip-flops 48a and 48b produces a clocking signal input to counter 50 that is preferably one quarter the clocking frequency of SYS CLK. Counter 50 is connected such that a count occurs during each clock cycle and once a series of counts have been achieved, a carry signal is output from ripple carry out (RCO) pin. The carry output preferably occurs after the sixteenth cycle, and is referenced as numeral 52. Accordingly, counter 50 counts a set of clock cycles from among a plurality of clock cycles existing within SYS CLK. A timer 56 is coupled to produce a timed output value upon conductor 58. The duration of timed output value is set based on the ratio of resistors 60 and capacitors 62 externally connected to timer 56. Preferably, the ratio of resistors and capacitors produces a timed output value which exceeds at least two pulses of carry signal 52. Accordingly, D-type flip-flop 64 produces a signal on conductor 66 which is synchronized with the transitions of carry output signal 52. Signal within conductor 66 is maintained in a monostable state based on the arrangement of a series of one-shot inverters 68 and AND gate 69 ensures a timed output value within conductor 70 of a duration greater than at least two clock cycles within conductor 52 but preferably less than 16 clock cycles, according to one preferred embodiment. Thus AND gate 74 produces a series of clock signals, the number of which is dependent on the duration of the timed output value within conductor 70. The number of clock cycles determine which output from latch/registers 76 will be active. Register 76 include a series coupled pair of eight bit parallel-out serial shift registers 76a and 76b. Output from the eighth bit of register 78a is fed to the inputs of registers 76b to continue registering up to 16 bits. The ninth and tenth bit outputs are fed to OR gate 78.
The operation of detection circuit 46 is predicated on the ratio of clock signals within SYS CLK to the timed output value from timer 56. If SYS CLK is relatively slow, fewer numbers of clock transitions will occur within the timed output value. In this instance, maybe only the ninth or tenth bit will be set rather than continuing until possibly the fourteenth or fifteenth, etc. A logic one value output from OR gate 78 indicates SYS CLK set at, for example, 50 MHz. If SYS CLK is faster, then register 76 will indicate a higher order bit set prior to termination of the timed output value. For example, a higher SYS CLK frequency will set bit twelve, thirteen or fifteen indicating, for example, 60 MHz, 66 MHz, or 75 MHz, respectively. Registers 76 latches the particular output value at the termination of the timed output value, and maintains that latched value until the timed output value is reasserted.
Referring to FIG. 5, a voltage detection circuit is shown. Detection circuit 80 exists within the detection unit of probe 14, and is coupled to receive the processor core voltage (VCC SN) delivered from PCB 12. Circuit 80 is also coupled to receive a regulated/converted 5.0 V from either power supply 30, VCC I/O or battery 32. The 5.0 V amount is reduced to differing amounts dependent upon the resistor values of voltage divider networks 82a-82d. A variable resistor (or potentiometer) 84 may be coupled to complete the resistor divider network by varying the amount of resistance within each potentiometer, the voltage existing between the fixed and variable resistor will correspondingly change. A potentiometer need not be used in all cases, however. In some instances, the resistor pair values can be fixed dissimilar from each other, such as those used in forming voltage dividers 82a and 82d. In other cases, the resistance can vary in one resistor within a pair of voltage divider resistors, such as the case in voltage dividers 82b and 82c. The fixed and variable resistance values are established so as to form a voltage less than 5.0 V at a node between the resistor pairs. In the example shown in FIG. 5, a separate and unique voltage is produced at a node between voltage divider resistor pairs for each voltage divider 82a, 82b, 82c and 82d. Those values can be arbitrarily chosen and are shown according to one example as 3.6 V, 3.5 V, 3.4 V and 3.3 V, respectively. The voltages so produced pass through a low frequency pass filter 86a-86d to form reference voltages denoted as REF36, REF35, REF34 and REF33, respectively. Filter 86 ensures a substantial amount of noise once the reference voltages are removed from the input of voltage comparators 90a-90h. Comparators 90 are arranged into a plurality of pairs of comparators connected in parallel. A first pair shown as 90a and 90b, has two mutual connections. A first mutual connection is coupled to receive a reference voltage from voltage divider 82a. A second mutual connection is coupled to receive VCC SN. The inverting and non-inverting inputs are connected so that if VCC SN exceeds REF36 (e.g., 3.6 V) then the output from comparator 90a will transition to a logic high value, but the output from comparator 90b will transition to a logic low value. On the other hand, if VCC SN is less than REF36, then the output from comparator 90a will transition to a logic low value while the output from comparator 90b will transition to a logic high value.
The output from comparator 90b is logically ORed with the output of comparator 90c. The logic OR coupling produces a logic high value at OUT35 with output from both the comparator 90b and 90c being active high. This occurs when VCC SN is less than REF36 but is greater than REF35. If, for example, REF36 represents 3.6 V and REF35 represents 3.5 V, then OUT35 will be active high when VCC SN is within the range between 3.5 and 3.6 V.
The OR connection from outputs of comparators 90b and 90c is continued through comparators 90d and 90e, comparators 90f and 90g, etc. Thus, OUT34 is active if both comparator 90d and 90e is active, and OUT36 is active if both comparator 90f and 90g are active. In the embodiment shown in FIG. 5, examples of reference voltages 3.6 V, 3.5 V, 3.4 V and 3.3 V produce separate distinct output signals from detector circuit 80 relative to those reference voltages. Thus, conductor OUTGREATER36 is active when VCC SN is greater than 3.6V. OUT35 is active if VCC SN is between 3.5 V and 3.6 V. OUT34 is active is VCC SN is between 3.4 V and 3.5 V. OUT33 is active if VCC SN is between 3.0 V and 3.4 V.
FIG. 5 illustrates, for sake of brevity, five output conductors, each carrying a separate and distinct voltage. It is recognized, however, that more than five output conductors can be used. For example, the connection can be continued almost indefinitely with additional voltage dividers, low-pass filters and comparators to form additional output signals having voltages different from those shown. For example, circuit 80 can be extended to produce REF28, REF26 and REF24. REF28, in combination with REF33 produce a window which activates OUT29. Likewise, REF26, in combination with REF28, produce OUT27 from a comparator (not shown). Still further, REF24, in combination with REF26 produce a signal OUT25 from the output of a comparator (not shown).
FIG. 5 illustrates an example of several reference voltages and several corresponding output voltages if VCC SN falls within a window between a pair of reference voltages. The reference voltages shown are only for sake of example. Given the exemplary reference voltages, a VCC SN which exceeds 3.6 V will produce an output signal upon a conductor OUTGREATER36 and not produce signals on the other output conductors. The same applies if VCC SN is less than 3.6 V, in which case the voltage upon VCC SN is dependent upon the particular window (or range) in which it falls between specified reference voltages. If VCC SN is less than 2.5 V, then an output voltage will appear only upon output conductor OUTLESS25. All of the various voltage comparators 90 can be found within an integrated circuit. The output of the integrated voltage comparators are open collector outputs and are driven to ground if the input to the inverting input is more positive than input to the non-inverting input. Conversely, the output is driven high if the non-inverting input is more positive than the inverting input.
FIGS. 6 and 7 illustrate circuitry within the remote module. FIG. 6 depicts an LED 27a which emits a light if a signal transferred thereto has a logic high value. Thus, FIG. 6 illustrates one of the possible four conductors output from the frequency detection circuit 46, shown in FIG. 4. The output conductor can be either the 50 MEN, 60 MEN, 66 or 75 MHz conductor. It is recognized that the circuit shown is repeated for each output conductor. For sake of brevity, only one output conductor is shown and is recognized to be either the 50, 60, 66 or 75 MHz conductor. It is further recognized that the conductor of FIG. 6 is repeated for each output of detection circuit 46.
FIG. 7 depicts one conductor of possibly numerous conductors output from voltage conductor circuit 80. It is recognized that the conductor, and LED 27b is repeated for each output conductor. Whenever the voltage upon the output conductor transitions to a high voltage value, then inverter 96 will cause LED 27b to illuminate. The resistance values for the resistors shown in FIG. 7 as well as the resistor shown in FIG. 6 will vary depending upon the amount of current needed to activate and deactivate LEDs 27a and 27b.
It will be appreciated to those skilled in the art having the benefit of this disclosure that this invention is believed to be capable of activating a separate and distinct LED based upon a frequency detected within a system bus clocking conductor or a voltage detected within a processor core power supply conductor. Both the system bus clocking conductor and the power supply core conductor are configured within any PCB to which a microprocessor can be attached. Accordingly, the present invention is used to determine operation of the motherboard at a socket source prior to connecting the microprocessor. The motherboard operation can be changed after detection by the present detection system by actuating switches or coupling jumpers. The present invention is therefore believed to have benefit is locating the switch and jumper locations necessary to change motherboard signals and to therefore ensure compatibility to a microprocessor being coupled. The number of LEDs used to signal system bus setting, or processor core VCC SN will vary, and therefore, the number presented therein is not to limit the present invention. The detection circuits can therefore be expanded, the timed output value duration can be modified, the reference voltages changed, and the LED indicia on the remote module modified depending upon the breadth at which the detection circuits must operate to ascertain various motherboard configurations. Accordingly, various modifications and changes may be made without departing from the spirit and scope of the invention as set forth in the claims. It is intended that the following claims be interpreted to embrace all such modifications and changes. The specification and drawings are to be regarded in an illustrative rather than a restrictive sense. | One or more detection circuits are provided for determining the operation of a motherboard prior to placing a microprocessor upon that motherboard. The detection circuit determines a particular way in which the motherboard is configured by ascertaining, for example, a power supply voltage and a clocking frequency output from the motherboard. A probe is used, in combination with the detector circuits, to determine motherboard operation at a socket to which, for example, a microprocessor can be coupled. Jumpers or switches upon the motherboard can be readily found by activating a switch and looking for a response upon the detection circuit output. If a response is not found, the jumper or switch is returned, and another jumper or switch is activated. Once the jumper or switch used for changing system clock speed and/or processor voltage is located, then a display is read as to those parameters to ensure the parameters match the processor specification. Reading the motherboard configuration and/or reconfiguring the motherboard to a different operation parameter proves beneficial in ensuring its output compatibility to a microprocessor to be inserted upon the motherboard socket. | 6 |
FIELD OF THE INVENTION
The present invention relates to 4-aminopyridine derivatives represented by the general formula (I): ##STR2## where R 1 is a hydrogen atom, a hydroxyl group, a linear or branched lower alkyl group or a cycloalkyl group which may be substituted by a hydroxyl group, a lower alkoxy group, a lower alkyl or a cycloalkyl group which contains a carbonyl group, a morpholino group or a group --NH--B (where B is a lower alkyl group, a cycloalkyl group or a phenyl group); R 2 and R 3 which may be the same or different each represents a hydrogen atom, a lower alkyl group or a loweralkylcarbonyl group, or when taken together, form an azacycloalkyl group, a morpholino group or an N-methylpiperazinyl group together with the nitrogen atom; R 4 and R 5 each represents a hydrogen atom, or when taken together with the ring A, form a quinoline ring or a 5,6,7,8-tetrahydroquinoline ring, provided that when each of R 1 , R 4 and R 5 is a hydrogen atom. R 2 and R 3 are neither a hydrogen atom nor a methyl group at the same time, and when R 1 is a hydrogen atom and R 4 and R 5 taken together with the ring A form a quinoline ring. R 2 and R 3 are neither a hydrogen atom nor an ethyl group at the same time. The present invention also relates to an acid addition salts of said 4-aminopyridine derivatives.
BACKGROUND OF THE INVENTION
With the progress of "aging society", the population of aged persons has recently increased and the increase in the number of senile diseases is correspondingly rapid. Among various senile diseases, dementia is of particular importance since the mechanism of its occurrence has not been fully unravelled and it can be fatal depending on its severity. Under these circumstances, the advent of an effective therapeutic agent for senile dementia is strongly desired.
Numerous studies on senile dementia have been conducted to date. The phenomena that have been reported to occur in patients with senile dementia include impairment of the central cholinergic nervous function on account of decreases in the number of choline acetyltransferase (CAT) and acetylcholinesterase (AChE) which are enzymes that synthesize and decompose, respectively. acetylcholine known to be the transmitter of cholinergic neurons (see British Medical Journal, 2: 1457-1459, 1978; Brain, 107: 507-518, 1984; Journal of the Neurological Sciences, 57: 407-417, 1982; and Lancet, 2: 1403, 1976) and impairment of the central noradrenergic nervous function (see British Medical Journal, 282: 93-94, 1981). Researchers are making active efforts to develop drugs that are suitable for the symptomatic treatment of these phenomena.
SUMMARY OF THE INVENTION
Under the circumstances described above, the present inventors undertook intensive studies in order to develop a therapeutic agent effective in reactivating the nervous function impaired by senile dementia. As a result, they found that compounds represented by the general formula (I) exhibited unique pharmacological effects in that they activated the nervous function of animals and accelerated their mnemonic and learning performance. The present invention has been accomplished on the basis of this finding.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows mean correct response vs the dose of a compound of the present invention administered to rats under a radial-arm maze task in Test Example 6.
DETAILED DESCRIPTION OF THE INVENTION
The compounds of the general formula (I) are novel and may be prepared by the following methods (a)-(h). the choice of which depends on R 1 in the general formula (I).
(a) If R 1 is a branched lower alkyl group or a cycloalkyl group substituted by a hydroxyl group, or if it is a lower alkyl group or a cycloalkyl group containing a carbonyl group, the following procedure is taken: a starting compound represented by the general formula (II): ##STR3## (where R A and R B each represents a hydrogen atom or, when taken together with the ring A, form a quinoline ring; X is a halogen) is reacted with an enamine corresponding to the end compound thereby introducing a substitute on both 2 and 3 positions, and subsequently the nitro group on 4 position is reduced, optionally followed by further reduction. The reaction with enamine is performed in an inert solvent such as chloroform or methylene chloride and the enamine to be used corresponds to the end compound as exemplified by 1-(N-morpholino)cyclohexene. The reaction temperature ranges from 20° to 80° C. and is preferably room temperature. The reduction of the nitro group on 4 position involves an ordinary reduction reaction and may be accomplished by hydrogenation in the presence of a catalyst such as palladium-on-carbon, Raney nickel or Raney cobalt. The reduction reaction is performed in an inert solvent such as tetrahydrofuran or an alcohol. A compound of the general formula (I) wherein R 4 and R 5 combine with the pyridine ring to form a 5,6,7,8 -tetrahydroquinoline ring is obtained by performing further reduction in an acidic solvent such as trifluoroacetic acid or acetic acid in the presence of a reduction catalyst such as platinum dioxide or Raney nickel.
(b) If R 1 is a branched lower alkyl group or a cycloalkyl group, a compound of the general formula (II) is reacted with an enamine and the nitro group on 4 position is reduced as in (a). The resulting compound of the general formula (III): ##STR4## (where Rc is a lower alkyl group or a cycloalkyl group containing a carbonyl group; R A , R B , R 2 and R 3 are each the same as defIned above) is reacted with a compound of the general formula Y--NHNH 2 (where Y is a paratoluenesulfonyl group or a hydrogen atom) in a solvent such as alcohol at 20°-80° C., preferably at room temperature. By subsequent reaction with a reducing agent such as NaBH 4 , LiAlH 4 or BH 3 , a compound of the general formula (I) is obtained. By performing further reduction which is optional, a 5,6,7,8-tetrahydroquinoline based end compound can be obtained.
(c) If R 1 is ##STR5## the following scheme may be employed: ##STR6## (where R 2 , R 3 , R A , R 3 and X have the same meanings as defined above: ##STR7## denotes a phenyl or cyclohexyl group).
The conversion from the general formula (II) to (IV) is carried out by reacting the compound (II) with a corresponding amine in an inert solvent such as tetrahydrofuran or an alcohol, preferably at room temperature. The conversion from the general formula (IV) to (V) is carried out using phenyl isocyanate in a solvent such as dimethylformamide or dimethyl acetamide. The reaction temperature is in the range of 50°-100° C., preferably 80° C. The conversion from the general formula (V) to (VI) involves an ordinary step of reduction and may be accomplished by hydrogenation in the presence of a catalyst such as palladium-on-carbon. Raney nickel or Raney cobalt. The reduction reaction is performed in an invert solvent such as tetrahydrofuran or an alcohol, preferably at room temperature. By further reducing the compound of the general formula (VI) with a suitable catalyst such as platinum dioxide or Raney cobalt, an end compound wherein R 1 is ##STR8## or a 5,6,7,8-tetrahydroquinoline based compound is obtained (general formula (VII)).
(d) If R 1 is --NH--RD (RD is a lower alkyl group), the following scheme may be employed: ##STR9## (where R 2 , R 3 , R A , R B , R D and X are the same as defined above).
The conversion from the general formula (II) to (IV) is carried out as in (c). The conversion from the general formula (IV) to (VIII) is carried out by reacting the compound of formula (IV) with RD--NCO (where RD is a lower alkyl group) in a sealed tube. The reaction is performed in an inert solvent such as dimethylformamide at 100°-150° C., preferably at 130° C., for a period of 4-10 hours, preferably 6 hours. Conversion from the general formula (VIII) to (IX) may be accomplished by reducing the nitro group as in (a)-(c). If desired further reduction may be performed by treatment with a suitable catalyst such as platinum dioxide or Raney cobalt and this leads to the production of an end compound of the general formula (X).
(e) If R 1 is a lower alkoxy group, the following scheme may be employed: ##STR10##
The conversion from the general formula (II) to (IV) is carried out as in (c). The conversion from the general formula (IV) to (XI) may be carried out in the usual manner and an α-oxy form (XI) can be obtained in high yield treatment with acetic anhydride in pyridine used as a solvent. The reaction is performed at a temperature in the range of 60°-100° C., preferably at 80° C., and is completed in 1-8 hours. This reaction may also be performed with p-toluenesulfonyl chloride or chloroform used as a solvent. Conversion from the general formula (XI) to (XIl) is performed by reacting the compound of (XI) with (R E ) 3 OBF 4 (R E is a lower alkyl group such as methyl or ethyl) or AgBF 4 R E X (R E has the same meaning as defined above) under cooling with ice in a nitrogen stream. The reaction is performed over 4-7 days in a solvent such as chloroform or methylene chloride. Conversion from the general formula (XII) to (XIII) and from (XIII) to (XIV) is performed by reduction reaction in the same manner as already described.
(f) If R 1 is a hydrogen atom, a linear lower alkyl group or a hydroxyl-substituted linear lower alkyl group, the following scheme may be employed: ##STR11## (where R 2 , R 3 , R A , R B and X have the same meanings as defined above).
The conversion from the general formula (II) to (IV) is carried out as in (c). Conversion from the general formula (IV) to (XV) is accomplished by reduction reaction which is performed in the presence of a catalyst such as Raney nickel in a solvent such as tetrahydrofuran or an alcohol, preferably at room temperature. The reaction may also proceed in the presence of an iron catalyst in a solvent such as acetic acid or trifluoroacetic acid at a temperature of 90°-100° C. If desired further reduction may be performed with a suitable catalyst such as platinum dioxide, thereby producing an end compound of the general formula (XVI).
(g) If R 1 is a hydroxyl group, the following scheme may be employed: ##STR12## (where R 2 , R 3 , R A , R B and X have the same meanings as defined above).
The conversion from the general formula (II) to (IV) and from (IV) to (XI) is performed as described above. Conversion from the general formula (XI) to (XVII) is performed as already-described in connection with the reaction for reducing the nitro group and may be accomplished by reduction in the presence of a catalyst such as palladium-on-carbon or Raney nickel. If desired, further reduction may be performed to obtain an end compound represented by the general formula (XVIII).
(h) If R 1 is a morphlino group, the following scheme may be employed: ##STR13## (where R 2 , R 3 , R A , R B and X have the same meanings as defined above).
The conversion from the general formula (II) to (IV) is performed as in (C). Conversion from the general formula (IV) to (XIX) is performed by reaction with an enamine having a morpholino group such as 1-(N-morphlino)cyclohexene and an acylating agent such as benzoyl chloride, tosyl chloride or an acid anhydride such as acetic anhydride in an inert solvent such as chloroform or methylene chloride. The reaction temperature is in the range of 0°-10° C. and the reaction time is in the range of 3-24 hours, preferably 12 hours. The enamine is added in an amount of 1.5-3 equivalents, preferably 2 equivalents, and the acylating agent is added in an amount of 0.5-2 equivalents, preferably 1 equivalent.
Conversion from the general formula (XIX) to (XX) involves the usual practice of reduction as describe above and may be accomplished by hydrogenation in the presence of a catalyst such as palladium-on-carbon. Raney nickel or Raney cobalt.
The compounds of the general formula (I) thus obtained exhibit excellent activity in accelerating mnemonic and learning performance and improving the brain function in small doses and hence are useful as pharmaceutical drugs.
The compounds of the general formula (I) may be converted to acid addition salts as required. If such acid addition salts are to be used in medical applications, any pharmaceutically acceptable salt forming acids may be used. Specific examples include organic acids such as citric acid, fumaric acid, maleic acid and tartaric acid, and inorganic salts such as hydrochloric acid, hydrobromic acid, nitric acid and sulfuric acid.
The following examples and test examples are provided for the purpose of further illustrating the present invention but are in no way to be taken as limiting.
EXAMPLE 1
Preparation of 4-amino-3-morpholino-2-(2'-oxycyclohexyl)quinoline Compound No. 3):
(a) 3-Bromo-4-nitroquinoline-N-oxide (2.69 g, 0.01 mol) and 1-(N-morpholino)cyclohexene (4.18 g. 0.02B mol) were dissolved in B0 ml of chloroform and the mixture was stirred at room temperature for 4 days. After distilling off the chloroform under vacuum, the residue was subjected to extraction with benzene. Following washing with water and drying, the benzene was distilled off under vacuum and ethanol was added to the residue, whereupon crystal was precipitated. The resulting crystals were recrystallized from ethanol to obtain 3-morpholino-4-nitro-2-(2'-oxocyclohexyl)quinoline in an amount of 2.g7 g (yield. 04g).
(b) 3-Morpholino-4-nitro-2-(2'-oxocyclohexyl)quinoline (2.00 g. 0.00B mol) was dissolved in tetrahydrofuran (10 ml) and subjected to reduction in the presence of 10g palladium-on-carbon (0.3 g). After completion of the reaction, the palladium-on-carbon catalyst was filtered off and the mother liquor was concentrated. Following purification by chromatography on an alumina column using chloroform as a developing solvent, recrystallization from ethanol was performed, whereupon 4-amino-3-morpholino-g-(2'-oxocyclohexyl)quinoline was obtained in an amount of 0.94 g (yield, 46%).
EXAMPLE 2
Preparation of 4-amino-g-(2.-hydroxycyclohexyl)-3-morpholino-5,6,7,8-tetrahydroquinoline (Compound No. 0):
The 4-amino-S-morpholino-2-(2'-oxocyclohexyl)quinoline (0.8 g, 0.0024 mol) obtained in Example 1-(b) was dissolved in 10 ml of trifluoroacetic acid and subjected to reduction in the presence of platinum (IV) dioxide (0.g g). After completion of the reaction, the platinum dioxide was filtered off and the mother liquor was concentrated. Following purification by chromatography on an alumina column using chloroform as a developing solvent, recrystallization from benzene/n-hexane was performed, whereupon 4-amino-2-(2'-hydroxychlorohexyl)-3-morpholino-5,6,7,8-tetrahydroquinoline was obtained in an amount of 0.69 g (yield, 85%).
EXAMPLE 3
Preparation of 4-amino-2-cyclohexyl-3-morpholinoquinoline (Compound No. 18):
(a) The 4-amino-3-morpholino-2-(2'-oxocyclohexyl)quinoline (1.0 g, 0.0031 mol) obtained in Example 1-(b) and p-toluenesulfonyl hydrazide (0.72 g, 0.0039 mol) were dissolved in 10 ml of methanol and the solution was stirred at room temperature for 4 hours, whereupon gradual crystallization occurred. The crystals were recovered by filtration under vacuum and washed with methanol to obtain 2-(4'-amino-3'-morpholinoquinolyl)-1-tosylhydrazonocyclohexane in an amount of 0.65 g (yield, 43%).
The 2-(4'-amino-3'-morpholinoquinolyl)-1-tosylhydrazonocyclohexane (0.65 g, 0.0013 mol) was suspended in methanol (30 ml) and 1.0 g of sodium borohydride was gradually added under cooling with ice. Thereafter, the mixture was heated under reflux on an oil bath for 5 hours. Methanol was distilled off from the whole reaction mixture under vacuum and the residue was subjected to extraction with chloroform. The chloroform layer was washed with water, dried with anhydrous sodium sulfate and subjected to isolation and purification steps on an alumina column, thereby obtaining 4-amino-2-cyclohexyl-3-morpholinoquinoline in an amount of 0.31 g (yield. 78%).
EXAMPLE 4
Preparation of 4-amino-2-cyclohexyl-3-morpholino-5,6,7,8-tetrahydroquinoline (Compound No. 10):
The 4-amino-cyclohexyl-S-morpholinoquinoline (0.31 g. 0.001 mol) obtained in Example 3-(b) was dissolved in 10 ml of trifluoroacetic acid and subjected to reduction in the presence of platinum (IV) dioxide (0.3 g). After completion of the reaction, the platinum dioxide was filtered off and the mother liquor was concentrated. Following purification by chromatography on an alumina column using chloroform as a developing solvent, recrystallization from benzene/n-hexane was performed, whereupon 4-amino-2-cyclohexyl-3-morpholino-5,6,7,8-tetrahydroquinoline was obtained in an amount of 0.25 g (yield, 83%).
EXAMPLE 5
Preparation of 4-amino-2-anilino-3-morpholinoquinoline (Compound No. 13):
(a) 3-Bromo-4-nitroquinoline-N-oxide (10 g, 0.037 mol) was dissolved in tetrahydrofuran and after adding morpholine (8.1 g. 0.093 mol). the mixture was stirred at room temperature, whereupon gradual crystallization occurred. Tetrahydrofuran was distilled off from the whole reaction mixture under vacuum and the residue was dissolved in chloroform. The chloroform layer was washed with water and dried with form under vacuum, the residue was washed with a small amount of ethanol and recovered by filtration under vacuum, whereupon 3-morpholino-4-nitroquinoline-N-oxide was obtained in an amount of 10 g (yield, 98%).
(b) The 3-morpholino-4-nitroquinoline-N-oxide (3 g, 0.011 mol) was suspended in dimethylformamide (40 ml) and following addition of phenyl isocyanate (3.4 g, 0.029 mol), the mixture was added on an oil bath at 80°-90° C. for ca. 3 hours. The reaction mixture was totally charged into water and subjected to extraction with chloroform. The chloroform layer was washed with water and dried with anhydrous sodium sulfate. After the chloroform was distilled off under vacuum, the residue was subjected to recrystallization with ethanol. The resulting crystal was recovered by filtration under vacuum to obtain 2-anilino-3-morpholino-4-nitroquinoline in an amount of 2.95 g (yield, 77%).
(c) The 2-anilino-3-morpholino-4-nitroquinoline (2.9 g, 0.0083 mol) was dissolved in tetrahydrofuran (10 ml) and subjected to reduction in the presence of 10g palladium-on-carbon (0.3 g). After completion of the reaction, the palladium-on-carbon catalyst was filtered off and the mother liquor was concentrated. Following purification by chromatography on an alumina column using chloroform as a developing solvent, recrystallization from methanol was conducted to obtain 4-amino-2-anilino-3-morpholinoquinoline in an amount of 1.89 g (yield, 69%).
EXAMPLE 6
Preparation of 4-amino-2-anilino-3-morpholino-5,6,7,8-tetrahydroquinoline (Compound No. 15):
The 4-amino-2-anilino-3-morpholinoquinoline (1.8 g, 0.0055 mol) obtained in Example 5-(c) was dissolved in trifluoroacetic acid (10 ml) and subjected to reduction in the presence of platinum (IV) dioxide (0.3 g). After completion of the reaction, platinum dioxide was filtered off and the mother liquor was concentrated. Following purification by chromatography on an alumina column using chloroform as a developing solvent, recrystallization from benzene was performed, whereupon 4-amino-2-anilino-3-morpholino-5,6,7,8-tetrahydroquinoline was obtained in an amount of 0.58 g (yield, 32%).
EXAMPLE 7
Preparation of 4-amino-2-ethylamino-3-morpholinoquinoline (Compound No. 43):
(a) The 3-morpholino-4-nitroquinoline-N-oxide (3 g, 0.011 mol) obtained in Example 5-(a) was dissolved in dimethylformamide (40 ml) and following the addition of ethyl isocyanate (2.7 g, 0.038 mol), the suspension was heated in a sealed tube on an oil bath at 130° C. for ca. 6 hours. The mixture was totally charged into water and subjected to extraction with chloroform. The chloroform layer was washed with water, dried with anhydrous sodium sulfate and concentrated under vacuum. Following isolation by chromatography on a silica gel column (solvent: 5% methanol/chloroform). recrystallization from ethanol was performed, whereupon 2-ethylamino-3-morpholino-4-nitroquinoline was obtained in an amount of 2.1 g (yield, 64%).
(b) The 2-ethylamino-3-morpholino-4-nitroquinoline (2.0 g, 0.0066 mol) was dissolved in tetrahydrofuran (10 ml) and subjected to reduction in the presence of 10g palladium-on-carbon (0.3 g). After completion of the reaction, the palladium-on-carbon catalyst was filtered off and the mother liquor was concentrated. Following purification by chromatography on an alumina column using chloroform as a developing solvent, recrystallization from ethanol gas conducted, whereupon 4-amino-2-ethylamino-3-morpholinoquinoline was obtained in an amount of 1.2 g (yield, 67%).
EXAMPLE 8
Preparation of 4-amino-2-ethoxy-3-morpholinoquinoline (Compound No. 38):
(a) The 3-morpholino-4-nitroquinoline-N-oxide (4 g, 0.015 mol) obtained in Example 5-(b) was dissolved in acetic anhydride (20 ml) and pyridine (20 ml) and the solution was heated on an oil bath at 80° C. for 3 hours. Excess acetic anhydride and pyridine were distilled off from the whole reaction mixture in vacuum and the residue was washed with ether to obtain 3-morpholino-4-nitro-2-quinolone in an amount of 3.5 g (yield, 88%),
(b) The 3-morpholino-4-nitro-2-quinoline (3.5 g, 0.013 mol) was suspended in methylene chloride (200 ml). To the ice-cooled suspension, 25 ml of a solution of triethyl oxonium tetrafluoroborate in methylene chloride was added in a nitrogen stream and the mixture was stirred at room temperature for 7 days. The whole portion of the mixture was poured into 50% aqueous potassium carbonate and the resulting mixture was subjected to extraction with chloroform. The chloroform layer was washed with water and dried with anhydrous sodium sulfate. Upon isolation and purification by chromatography on a silica gel column (solvent: chloroform), 2-ethoxy-3-morpholino-4-nitroquinoline was obtained in an amount of 1.3 g (yield, 34%).
(c) The 2-ethoxy-3-morpholino-4-nitroquinoline (1.2 g, 0.004 mol) was dissolved in tetrahydrofuran (10 ml) and subjected to reduction in the presence of 10g palladium-on-carbon (0.3 g). After completion of the reaction, the palladium-on-carbon catalyst was filtered off and the mother liquor was concentrated. Following purification by chromatography on an alumina column using chloroform as a developing solvent, recrystallization from chloroform gas performed to obtain 4-amino-2-ethoxy-3-morpholinoquinoline in an amount of 0.7 g (yield, 60%).
EXAMPLE 9
Preparation of 4-amino-3-piperidino-2-(2'-oxocyclohexyl)quinoline (Compound No. 7):
(a) 3-Bromo-4-nitroquinoline-N-oxide (10 g, 0.037 mol) and 1-(N-piperidino)cyclohexene (15.4 g, 0.093 mol) were dissolved in chloroform (100 ml) and the solution was stirred at room temperature for 2 days. The chloroform was distilled off under vacuum and the residue was subjected to extraction with benzene. Following washing with water and drying, benzene was distilled off under vacuum and the residue was purified and isolated by chromatography on a silica gel column using chloroform as a developing solvent. By recrystallization from ethanol, 3-piperidino-4-nitro-2-(2'-oxocyclohexyl)quinoline was obtained in an amount of 9 g (yield, 68%).
(b) The 3-piperidino-4-nitro-2-(2'-oxocyclohexyl)quinoline (8.5 g, 0.024 mol) was dissolved in tetrahydrofuran (50 ml) and subjected to reduction in the presence of 10g palladium-on-carbon (1.2 g). After completion of the reaction, the palladium-on-carbon catalyst was filtered off and the mother liquor was concentrated. Following purification by chromatography on an alumina column using chloroform as a developing solvent, recrystallization from ethanol was conducted to obtain 4-amino-3-piperidino-2-(2'-oxocyclohexyl)quinoline in an amount of 6.1 g (yield, 74%).
EXAMPLE 10
Preparation of 4-amino-2-hydroxy-3-morpholinoquinoline (Compound No. 27):
(a) The 3-morpholino-4-nitroquinoline-N-oxide obtained in Example 5-(a) was dissolved in acetic anhydride (16 ml) and pyridine (16 ml) and the solution was heated on an oil bath at 80° C. for 1 hour. Excess acetic anhydride and pyridine were distilled off under vacuum from the whole reaction mixture and the residue was dissolved in chloroform, followed by washing with 10% NaHCO 3 . The insoluble matter was recovered by filtration under vacuum, dissolved in acetone and treated with charcoal. The chloroform layer was dried with anhydrous Na 2 SO 4 and CHCl 3 was distilled off under vacuum. The residue was combined with the charcoal treated (insoluble) matter and washed with ethanol to obtain 2-hydroxy-3-morpholino-4-nitroquinoline in an amount of 3.5 g (yield, 44%).
(b) The 2-hydroxy-3-morpholino-4-nitroquinoline (1.5 g, 0.0054 mol) was dissolved in a mixed solvent of methanol and tetrahydrofuran and subjected to catalytic reduction in the presence of 10g palladium-on-carbon. After completion of the reaction, the palladium-on-carbon catalyst was filtered off and the mother liquor was concentrated. Following purification by chromatography on an alumina column using chloroform as a developing solvent, recrystallization from chloroform was conducted to obtain 4-amino-2-hydroxy-3-morpholinoquinoline in an amount of 0.9 g (yield, 63%).
EXAMPLE 11
Preparation of 4-amino-3-piperidinoquinoline (Compound No. 1):
(a) 3-Bromo-4-nitroquinoline-N-oxide (10 g, 0.037 mol) was dissolved in tetrahydrofuran (100 ml). To the solution, piperidine (7.9 g, 0.093 mol) was added and the mixture was stirred at room temperature until gradual crystallization occurred. Tetrahydrofuran was distilled off from the whole reaction mixture under vacuum and the residue was dissolved in chloroform. The chloroform layer was washed with water and dried with anhydrous sodium sulfate. After distilling off the chloroform under vacuum, the residue was washed with a small amount of ethanol and recovered by filtration under vacuum to obtain 4-nitro-3-piperidinoquinoline-N-oxide in an amount of 6.0 g (yield, 59%).
(b) The 4-nitro-3-piperidinoquinoline-N-oxide (4 g, 0.015 mol) was dissolved in a mixed solvent of methanol and tetrahydrofuran (50 ml) and subjected to catalytic reduction in the presence of purified Raney nickel (2 ml). Upon isolation and purification by chromatography on an alumina column (developing solvent: CHCl 3 ), 4-amino-3-piperidinoquinoline was obtained in an amount of 2.1 g (yield, 63%).
EXAMPLE 12
Preparation of 4-amino-3-ethylamino-2-morpholinoquinoline (Compound No. 52):
(a) 3-Bromo-4-nitroquinoline-N-oxide (10 g, 0.037 mol) was dissolved in tetrahydrofuran (100 ml). To the solution, ethylamine (5.96 g, 70% in H 2 O) was added and the mixture was stirred at room temperature for 1 hour. Tetrahydrofuran was distilled off under vacuum from the whole reaction mixture and the residue was dissolved in chloroform. The chloroform layer was washed with water and dried with anhydrous sodium sulfate. Upon isolation and purification by chromatography on a silica gel column using chloroform as a developing solvent, 3-ethylamino-4-nitroquinoline-N-oxide was obtained in an amount of 5.4 g (yield, 62%).
(b) The 3-ethylamino-4-nitroquinoline-N-oxide (1 g, 0.004 mol) was dissolved in chloroform (15 mol). To the ice-cooled solution, 1-(N-morpholino)-cyclohexene (1.7 g) and benzoyl chloride (0.7 g) were added dropwise. The mixture was restored to room temperature and stirred overnight. Following addition of water, the mixture was stirred for about 1 hour and washed with water. Thereafter, the CHCl 3 layer was separated and dried with anhydrous Na 2 SO 4 . Upon isolation and purification by chromatography on a silica gel column using chloroform as a developing solvent. 3-ethylamino-2-morpholino-4-nitroquinoline was obtained in an amount of 0.7 g (yield, 54%).
(c) The 3-ethylamino-2-morpholino-4-nitroquinoline (0.7 g, 0.0023 mol) was dissolved in a mixed solvent of methanol and tetrahydrofuran (15 ml) and subjected to catalytic reduction in the presence of 10g palladium-on-carbon (0.3 g), thereby obtaining 4-amino-3-ethylamino-2-morpholinoquinoline in an amount of 0.5 g (yield, 79%).
The compounds prepared in Examples 1-12 and other compounds of the general formula (I) are characterized in Table 1 below, wherein "Q" in the "R 4 , R 5 " column means that R 4 and R 5 taken together with the ring A form a quinoline ring; "T" means that R 4 and R 5 taken together with the ring A form a 5,6,7,8-tetrahydroquinoline ring; and "P" means that R 4 and R 5 each represents a hydrogen atom.
TABLE 1__________________________________________________________________________ ##STR14##Comp. m.p.No. R.sub.1 R.sub.2 R.sub.3 R.sub.4 .R.sub.5 (°C.) NMR salt__________________________________________________________________________1 H ##STR15## Q 255-257 1.36-2.27(6H,m), 2.72-3.26(4H,m ), 5.32(2H,bs), 7.11-8.03(4H,m) , 8.56(1H,s) 2HCl2 H ##STR16## Q 113-114 2.32(3H,s), 2.35-3.20(8H,m), 5.30(2H,bs), 7.11-8.12(4H,m), 8.49(1H,s)##STR17## ##STR18## Q 195-196 1.50-2.87(8H,m), 3.01(4H,m), 3.79(4H,m), 4.12(1H,dd), 5.10(2H,bs), 7.15-8.05(4H,m)4 CH.sub.2 OH H H Q 242-244 3.41(1H,b), 4.85(2H,b), 5.11(2H,bs), 7.04-8.49(4H,m), 8.06(2H,bs)5 CH.sub.2 OH H COCH.sub.3 Q 218-224 2.08(3H,s), 3.26(1H,b), (dec.) 4.46(2H,bs), 6.31(2H,bs), 7.05-8.30(4H,m), 8.86(1H,bs)6##STR19## ##STR20## T 247-248 1.45-3.37(21H,m), 3.63-3.95(4H, m), 4.09(1H,s), 4.79(2H,bs), 7.50(1H,bs)7##STR21## ##STR22## Q 192-194 1.50-1.90(6H,m), 1.90-2.80(8H,m ), 2.80-3.25(4H,m), 4.12(1H,dd), 5.12(2H,bs), 7.15-8.05(4H,m)8 CH.sub.3 ##STR23## Q 270-280 (sublimable) 2.87(3H,s), 2.90-4.44(8H,m), 5.10(2H,bs), 7.49-8.31(4H,m)9##STR24## ##STR25## T 220- 223 1.32-3.00(27H,m), 4.08(1H,s), 4.72(2H,bs), 7.56(1H,bs)10 CH.sub.3 ##STR26## T 133-134 1.65-2.88(8H,m), 2.42(3H,s), 3.10-4.21(8H,m), 4.67(2H,bs)11##STR27## ##STR28## Q 205-208 0.98(3H, t), 1.51(3H,d), 2.17-2.59(2H,q), 2.66-3.98(8H,m ), 3.92-4.39(1H,q), 5.35(2H,bs), 7.13-8.01(4H,m)12##STR29## ##STR30## Q -- --13##STR31## ##STR32## Q 224-225 2.51-3.79(4H,m), 3.70-4.11(4H,m ), 5.59(2H,bs), 6.70-7.97(9H,m) , 8.51(1H,bs)14 H ##STR33## Q 168-170 2.21-3.15(4H,m), 3.16-4.07(4H,m ), 5.30(2H,bs), 7.16-8.09(4H,m) , 8.56(1H,s)15##STR34## ##STR35## T 184-186 1.62-2.86(8H,m), 2.90-3.62(4H,m ), 3.63-3.99(4H,m), 4.08(2H,bs), 6.66-8.01(6H,m)16##STR36## ##STR37## T 189-191 1.02-3.46(22H,m), 3.50-4.24(5H, m), 5.74(2H,bs), 6.69(1H,bs)17 H ##STR38## T 136-138 1.67-3.20(12H,m), 3.70-4.05(4H, m), 4.43(2H,bs), 7.92(1H,s)18##STR39## ##STR40## Q 195-196 1.11-2.12(10H,m), 2.53-4.25(9H, m), 5.30(2H,bs), 7.12-8.02(4H,m )19##STR41## ##STR42## T 191-193 1.10-3.07(22H,m), 3.10-4.11(5H, m), 4.59(2H,bs)20 H ##STR43## Q 263-264 (dec.) 2.04-2.37(4H,m), 3.82-4.18(4H,m ), 5.01(2H,bs), 7.35-8.51(5H,m)21 H H ##STR44## Q -- --22##STR45## CH.sub.2CH.sub.3 CH.sub.2CH.sub.3 Q 192-193 1.02(6H,t), 1.50-2.90(8H,m), 2.80-3.31(4H,m), 5.17(2H,bs), 7.19-8.02(4H,m)23##STR46## CH.sub.2CH.sub.3 CH.sub.2CH.sub.3 T 123-125 1.01(6H,t), 1.20-3.38(21H,m), 4.02(1H,s), 4.70(2H,bs), 7.75(1H,bs)24##STR47## CH.sub.2CH.sub.3 CH.sub.2CH.sub.3 Q 280-285 (dec.) 1.03(6H,t), 1.20-3.70(15H,m), 5.23(2H,bs), HCl0-8.00(4H,m)25##STR48## CH.sub.2CH.sub.3 CH.sub.2CH.sub.3 T 265-270 (sublimable) 1.01(6H,t), 1.10-3.35(22H,m), 3.40-3.86(1H,m), 4.57(2H,bs)26##STR49## ##STR50## Q 131-132 1.09-2.47(16H,m), 2.64-3.39(5H, m), 5.30(2H,bs), 7.06-7.97(4H,m )27 OH ##STR51## Q 283-284 2.91-4.20(8H,m), 6.11(2H,bs), 6.72-8.05(4H,m), 11.15(1H,bs)28##STR52## ##STR53## T 144-146 1.01-3.45(28H,m), 4.20-4.51(1H, m), 5.30(2H,bs)29##STR54## CH.sub.2 CH.sub.2 CH.sub.3 CH.sub.2 CH.sub.2 CH.sub.3 Q 176-177 0.64-1.10(6H,m), 1.10-3.40(6H,m ), 3.85-4.30(1H,dd), 5.18(2H,bs), 7.13-8.07(4H,m)30##STR55## CH.sub.2 CH.sub.2 CH.sub.3 CH.sub.2 CH.sub.2 CH.sub.3 T 123-124 0.52-1.10(6H,m), 1.20-3.25(26H, m), 4.11(1H,bs), 6.72(2H,bs)31##STR56## CH.sub.2 CH.sub.2 CH.sub.3 CH.sub.2 CH.sub.2 CH.sub.3 Q 129-130 0.67-1.03(6H,m), 1.10-2.30(14H, m), 2.60-3.35(5H,m), 5.22(2H,bs), 7.03-7.99(4H,m)32##STR57## CH.sub.2 CH.sub.2 CH.sub.3 CH.sub.2 CH.sub. 2 CH.sub.3 T 119-120 0.71-1.05(6H,m), 1.10-2.57(22H, m), 2.60-3.23(5H,m), 4.52(2H,bs)33##STR58## CH.sub.2 CH.sub.3 CH.sub.2 CH.sub.3 Q 153-155 0.88-1.27(6H,t), 2.95-3.30(4H,q ), 3.97(1H,bs), 4.46(2H,bs), 6.75-8.28(9H,m)34##STR59## CH.sub.2 CH.sub.3 CH.sub.2 CH.sub.3 T 224-226 1.04-(6H,t), 1.51-2.03(4H,m), 2.12-2.84(4H,m), 2.97-3.65(4H,q ), 7.20-8.35(7H,m), 12.97(1H,bs) 2HCl35##STR60## ##STR61## Q 119-121 1.34-2.06(6H,m), 2.77-3.34(4H,m ), 4.49(2H,bs), 6.78-8.06(9H,m) , 8.33(1H,bs)36##STR62## ##STR63## T 270 (dec.) 1.69-3.21(24H,m), 3.62-4.22(6H, m), 4.41-4.58(1H,m), 7.84(1H,b) 2HCl37##STR64## ##STR65## T 215-218 0.98(3H,t), 2.39(3H,d), 1.60- 4.36(21H,m), HCl1(2H,bs)38 OCH.sub.2 CH.sub.3 ##STR66## Q 149-151 1.45(3H,t), 2.32-4.09(2H,m), 4.33-4.68(2H,q), 5.19(2H,bs), 7.03-7.75(4H,m)39##STR67## ##STR68## Q 132-134 0.65-2.20(10H,m), 2.61-4.22(9H, m), 5.29(2H,bs), 7.25-8.01(4H,m )40##STR69## ##STR70## T 178-179 0.67-1.12(3H,m), 1.30-1.55(3H,d ), 1.61-4.16(21H,m), 6.82(2H,bs)41##STR71## ##STR72## T 137-140 1.54-3.33(20H,m), 3.60-4.05(5H, m), 4.47(2H,bs)42 OCH.sub.2 CH.sub.3 CH.sub.2 CH.sub.3 CH.sub.2 CH.sub.3 Q 167-169 1.08(6H,t), 1.47(3H,t), (dec.) 3.31(4H,q), 4.83(2H,q), 7.12-7.89(4H,m), 8.10(2H,bs)43 NHCH.sub.2 CH.sub.3 ##STR73## Q 152-153 1.24(3H,t), 2.61-3.93(10H,m), 5.44(2H,bs), 5.65(1H,bs), 6.81-7.89(4H,m)44 OCH.sub.2 CH.sub.3 ##STR74## Q 168-170 1.40-2.06(9H,m), 2.10-3.61(4H,m ), 4.63-5.03(4H,q), 6.96-7.72(4 H,m), 8.11-8.5(2H,m)45 NHCH.sub.2 CH.sub.3 ##STR75## Q 99-100 1.29(3H,t), 1.30-2.18(6H,m), 2.71-3.35(4H,m), 3.30-4.11(2H,m ), 4.25-4.92(2H,bs), 5.21-5.70( 1H,b), 6.80-7.99(4H,m)46 NHCH.sub.2 CH.sub.3 ##STR76## Q 99-101 1.23(3H,t), 1.84-2.31(4H,m), 3.02-3.38(4H,m), 3.38-3.87(2H,m ), 4.44(2H,bs), 5.10(1H,m), 6.82-7.78(4H,m)47 OCH.sub.2 CH.sub.3 COCH.sub.3 CH.sub.2 CH.sub.3 Q 117-119 1.10(3H,t), 1.34(3H,t), 1.82(3H,s), 3.43-3.89(2H,m), 4.25-4.69(2H,q), 4.99(2H,bs), 7.05-7.84(4H,m)48##STR77## ##STR78## Q 205-207 0.80-1.15(3H,m), 1.21-2.06(10H, m), 2.54-3.53(4H,m), 3.67-4.12( 2H,m), 6.52-6.98(2H,bs), 6.99-8.67(4H,m)49##STR79## ##STR80## P 175-176 1.10-2.80(8H,m), 2.94(4H,m), 3.72(4H,m), 3.91(1H,dd), 6.34-8.00(2H,ABq)50##STR81## ##STR82## P 154-155 1.30-1.81(6H,m), 1.81-2.70(8H,m ), 2.70-3.20(4H,m), 3.94(1H,dd) 4.51(2H,bs), 6.33-8.00(2H,ABq)51##STR83## CH.sub.2 CH.sub.3 CH.sub.2 CH.sub.3 P 146-147 1.00(6H,t), 1.35-2.66(8H,m), 2.86(4H,q), 3.85(1H,dd), 4.53(2H,bs), 6.31-8.04(2H,ABq)52##STR84## H CH.sub.2 CH.sub.3 Q 89-90 1.19(3H,t), 1.57-2.20(4H,m), 2.51-2.90(4H,m), 4.10-4.91(5H, m), 7.00-8.45(4H,m)__________________________________________________________________________ (dec.) denotes decomposition point.
Test Example 1
Inhibition of Acetylcholinesterase Activity:
Acetylcholinesterase activity was assayed in accordance with the method of S. H. Sterri and F. Fonnum described in European Journal of Biochemistry, 91: 215-222, 1978. The method consisted of incubating 0.5 μU of authentic acetylcholinesterase (ECS, 1,1,7) (Sigma, No. C-2888) at 30° C. for 15 minutes in a 20 mM sodium phosphate buffer (pH 7.4). with 1.3 mM [1 -14 C] acetylcholine (0.025 μCi) being used as a substrate. Selected compounds of the general formula (I) were added at a concentration of 1 μM to the reaction solution and the resulting effect on enzymatic activity was evaluated.
The result was obtained as the average of three measurements and shown in Table 2 in terms of percentage, with the activity for the case where no drum compound was added being taken as 100.
TABLE 2__________________________________________________________________________Compound InhibitionNo. Structure Concentration rate (%)__________________________________________________________________________None -- -- 100 2 ##STR85## 1 μM 27.1 6 ##STR86## 1 μM 36.9 7 ##STR87## 1 μM 38.1 9 ##STR88## 1 μM 38.815 ##STR89## 1 μM 37.216 ##STR90## 1 μM 25.919 ##STR91## 1 μM 21.825 ##STR92## 1 μM 30.128 ##STR93## 1 μM 22.232 ##STR94## 1 μM 28.735 ##STR95## 1 μM 28.341 ##STR96## 1 μM 4.2__________________________________________________________________________
As Table 2 shows, the tested compounds of the present invention have a strong power to inhibit acetylcholin-esterase activity and hence are expected to stimulate the cholinergic function of the central nervous system. This will justify the anticipation that the compounds of the general formula (I) according to the present invention will be useful in the treatment of dementia of Alzheimer type which is accomplished by an observable damage specific to central cholinergic neurons (P. J. Whitehouse et al., Science, 215, 1237-1239, 1982).
Test Example 2
Inhibition of Catecholamine Uptake:
A crude synaptosomal fraction (P2) was obtained from the brain of rats (F344/C rj ) in the usual manner. In accordance with the method of S. H. Snyder and J. T. Coyle described in Journal of Pharmacology and Experimental Therapeutics, 165(1), 78-86, 1969, the fraction P2 was incubated in a Krebs-Henseleit bicarbonate buffer solution at 37° C. for 10 minutes together with 50 nM 3 H-norepinephrine (0.25 jμCi). Thereafter, the uptake of norepinephrine into the synaptosomes was measured by the filtration method. Selected compounds were added at a concentration of 1 μM to the solution being incubated and their effect on norepinephrine uptake was examined. The control drug was tetrahydroaminoacridine (THA).
The results are shown in Table 3 in terms of percentage, with norepinephrine uptake in the absence of drug compounds being taken as 100.
TABLE 3__________________________________________________________________________Compound InhibitionNo. Structure Concentration rate (%)__________________________________________________________________________None -- -- 100 1 ##STR97## 1 μM 69.1 6 ##STR98## 1 μM 82.6 7 ##STR99## 1 μM 79.0 9 ##STR100## 1 μM 69.415 ##STR101## 1 μM 85.416 ##STR102## 1 μM 88.119 ##STR103## 1 μM 83.223 ##STR104## 1 μM 73.724 ##STR105## 1 μM 68.225 ##STR106## 1 μM 75.326 ##STR107## 1 μM 68.228 ##STR108## 1 μM 85.230 ##STR109## 1 μM 76.932 ##STR110## 1 μM 73.234 ##STR111## 1 μM 80.039 ##STR112## 1 μM 71.943 ##STR113## 1 μM 78.845 ##STR114## 1 μM 79.852 ##STR115## 1 μM 79.8control ##STR116## 1 μM 84.6__________________________________________________________________________
As Table 3 shows, in most of the cases examined, the tested compounds of the present invention exhibited a stronger activity than THA which is known as an effective drug against senile dementia. This result shows that the compounds of the present invention have a strong power to stimulate catecholaminergic neurons in the central nervous system, thus clearly demonstrating their utility as drugs in the treatment of neural and mental disorders.
Test Example 3
Improvement of memory and Learning Ability Tested by Passive Avoidance Response:
Four groups of male ICR mice (10-14 weeks old). each consisting of 10 animals, were used in the experiment. Except for one control group, the mice were administered with selected compounds of the present invention. The experimental chamber consisted of a light and a dark compartment and an electric current shock source was connected to the floor grid in the dark compartment.
The experimental sessions consisted of acclimation. acquisition, and retention trials and were performed for B days, one trial per day. In the acclimation trial, animals were placed in the light compartment of the experimental chamber and left there for 5 minutes to acclimate them to the apparatus. In the acquisition trial which was conducted on the 2nd day, the animals were placed in the light compartment and when they entered the dark compartment, they were confined and given an a.c. electric shock (1 mA) through the floor grid for 10 seconds. In the retention trial which was conducted 24 hours after the acquisition trial, the animals were placed in the light compartment of the chamber and the step-through latency (i.e., the time required for the animals to enter the dark compartment) was measured. A physiological saline solution was administered at the acclimation trial to all of the animals. At the acquisition trial, selected compounds were administered in amounts of 10 μg/kg of body weight (1 ml/100 g). The control group was administered the same amount of physiological saline solution 60 minutes before the start of the trial. All administrations were intraperitoneal.
The results are shown in Table 4 below.
TABLE 4__________________________________________________________________________Compound dose Step throughNo. Structure (μ/kg i.p.) latency (sec)__________________________________________________________________________None -- -- 41.9 ± 10.2 2 ##STR117## 10 92.1 ± 13.5 6 ##STR118## 10 144.8 ± 45.1 7 ##STR119## 10 104.1 ± 28.5 9 ##STR120## 10 54.4 ± 7.213 ##STR121## 10 100.2 ± 17.815 ##STR122## 10 80.4 ± 14.616 ##STR123## 10 102.1 ± 22.318 ##STR124## 10 116.4 ± 29.219 ##STR125## 10 107.1 ± 29.922 ##STR126## 10 144.8 ± 25.524 ##STR127## 10 94.2 ± 14.732 ##STR128## 10 109.7 ± 16.639 ##STR129## 10 108.3 ± 16.040 ##STR130## 10 113.1 ± 29.643 ##STR131## 10 109.1 ± 13.444 ##STR132## 10 90.4 ± 12.445 ##STR133## 10 70.7 ± 6.850 ##STR134## 10 83.4 ± 14.8__________________________________________________________________________
As Table 4 shows, the step-through latency of the control group which was 41.9±10.2 jwas significantly delayed by the tested compounds of the present invention, which hence were found to be effective in promoting memory and learning performance.
Test Example 4
Inhibition of Catecholamine Uptake:
The uptake of dopamine into synaptosomes was measured by repeating the procedure of Test Example 2 except that 50 nM 3 H-norepinephrine (0.25 μCi) was replaced by 15 nM 3 H-dopamine (0.68 μCi). The control drug was tetrahydroaminoacridine (THA). The result is shown in Table 5 in terms of percentage, with dopamine uptake in the absence of drugs being taken as 100.
TABLE 5__________________________________________________________________________Compound InhibitionNo. Structure Concentration rate (%)__________________________________________________________________________None -- -- 100 7 ##STR135## 1 μ M 86.4 9 ##STR136## 1 μ M 78.623 ##STR137## 1 μ M 83.024 ##STR138## 1 μ M 59.625 ##STR139## 1 μ M 76.426 ##STR140## 1 μ M 55.428 ##STR141## 1 μ M 80.530 ##STR142## 1 μ M 79.232 ##STR143## 1 μ M 71.034 ##STR144## 1 μ M 84.845 ##STR145## 1 μ M 82.349 ##STR146## 1 μ M 67.552 ##STR147## 1 μ M 57.8control ##STR148## 1 μ M 91.5__________________________________________________________________________
As Table 5 shows, the tested compounds of the present invention had a stronger activity than THA indicating together with the results shown in Test Example 2 their great ability to stimulate catecholaminergic neurons in the central nervous system. The compounds of the present invention are therefore anticipated to prove useful as a drug in the treatment of neural and mental disorders.
Test Example 5
Inhibition of Monoamine Oxidase (MAO):
A crude synaptosomal fraction (P2) was obtained from the brain of rats (F344/C rj ) in the usual manner and homogenized to perform MAO activity measurements. The substrate was 12 μM [ 14 C]-serotonin in the case of MAO-A activity measurements, and 5 μM [ 14 C]-2-phenethylamine in the case of MAO-B activity measurements. In accordance with the method of R. J. Wurtman and J. Axelrod described in Biochemical Pharmacol. 12, 1489-1440, 1963, the homogenates were incubated in 100 mM phosphate buffer (pH 7.4) at 37° C. for 20 minutes and the effect of adding selected compounds at a concentration of 10 μM was evaluated. The results are shown in Table 8.
TABLE 6__________________________________________________________________________Compound Concen- Inhibition rate (%)No. Structure tration MAO-A MAO-B__________________________________________________________________________None -- -- 100 100 ##STR149## 10 μ M 44.1 82.97 ##STR150## 10 μ M 58.7 87.59 ##STR151## 10 μ M 59.4 89.449 ##STR152## 10 μ M 54.5 71.252 ##STR153## 10 μ M 0.0 63.0control ##STR154## 10 μ M 60.8 90.3__________________________________________________________________________
As Table 6 shows, the tested comPounds of the present invention were capable of inhibiting both MAO-A and MAO-B. with their ability to inhibit MAO-A being particularly great. Therefore, the compounds of the present invention are anticipated to exhibit stimulatory effect on monoaminergic neurons in the central nervous system, thereby proving useful in the treatment of neural and mental disorders caused by the functional impairment of such neurons.
Test Example 6
Effect on Performance in a Radial-Arm Maze Task:
In accordance with the method described by Thomas, J. W. et al. in Brain Research, 321, 91-102, 1984, 0.05 nmol of AF64A picryl sulfonate (hereunder abbreviated as AF64AP) was injected into the both sides lateral cerebral ventricles of male rats (F344) that had been made to acquire the ability to solve a radial-arm maze problem in accordance with the method of Olton and Samuelson (Olton, D. S. and Samuelson. R. J., J. Exp. Psychol., 2, 97-116, 1976), so as to impart a damage specific to the hippocampal cholinergic system. The mnemonic ability of the rats was evaluated with the number of correct responses (i.e.. the number of different arms selected in the first 8 choices) being used as a measure of their performance. The rats treated with AF64AP were found to have suffered significant memory impairment compared to the control group.
The treated animals were administered orally a vehicle on day 1, 3 and 5, Compound No. 7 on day 2, 4 and 6 (the dose was 3, 10 and 30 mg/kg on day 2, 4 and 6, respectively), and thereafter checked for their ability to solve a radial-arm maze problem. On each day when the performance subsequent to the administration of Compound No. 7 was compared with the control data (obtained by vehicle administration on the previous day) by a paired t-test, a statistically significant increase in the number of correct responses was observed at 10 mg/kg (p<0.05; n=6) and 30 mg/kg (p<0.05; n=6). The results are shown in FIG. 1, with the control data for the first and last days of the test being designated by V. Chance level of correct responses defined by Spetch, M. L. and Wilkie, D. M., Behavior Research Methods and Instrumentations. 12, 377-378, 1980, was expressed by dashed line. All the control data obtained in the test were stable since there was no significant difference among the control data.
The results described above and depicted in FIG. 1 show that the compounds of the present invention will prove effective in improving the cognitive ability of patients suffering from Alzheimer's disease and other types of dementia which are characterized by extensive damage to the central cholinergic system. | 4-aminopyridine derivatives represented by the general formula: ##STR1## [wherein R 1 is a hydrogen atom, a hydroxyl group, a linear or branched lower alkyl group or a cycloalkyl group which may be substituted by a hydroxyl group, a lower alkoxy group, a lower alkyl or a cycloalkyl group which contains a carbonyl group, a morpholino group or a group --NH--B (where B is a lower alkyl group, a cycloalkyl group or a phenyl group); R 2 and R 3 which may be the same or different each represents a hydrogen atom, a lower alkyl group or a loweralkylcarbonyl group, or when taken together, form an azacycloalkyl group, a morpholino group or an N-methylpiperazinyl group together with the nitrogen atom; R 4 and R 5 each represents a hydrogen atom, or when taken together with the ring A, form a quinoline ring or a 5,6,7,8-tetrahydroquinoline ring, provided that when each of R 1 , R 4 and R 5 is a hydrogen atom, R 2 and R 3 are neither a hydrogen atom nor a methyl group at the same time, and when R 1 is a hydrogen atom and R 4 and R 5 taken together with the ring A form a quinoline ring, R 2 and R 3 are neither a hydrogen atom nor an ethyl group at the same time], and an acid addition salts of said 4-aminopyridine derivatives. These compounds are useful as active ingredients in pharmaceutical compositions for improving psychoneural function, especially in the treatment of Alzheimer type dementia and promotion of mnemonic and learning performance. | 2 |
RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application 60/820,079, filed Jul. 21, 2006.
FIELD OF THE INVENTION
[0002] This invention relates to distributed database queries in a multi-tier environment.
BACKGROUND
[0003] Modern client applications such as web browsers and really simple syndication (RSS) readers request information in the Hypertext Markup Language (HTML) or Extensible Markup Language (XML) from a single web server using the hypertext transfer protocol (HTTP), a lightweight and simple protocol where individual transactions return individual results. With large-scale databases such as search engines, however, computing the result of the request is an expensive operation that is best addressed by multiple back-end computers and the task of distributing the work and responding to the request with a unified response requires a middle tier system that must act as an intermediary, distributing the request to the back-end systems and consolidating the results in a consistent manner for delivery to the client.
[0004] The activity of consolidating the asynchronous results returned by the back-end into a consistent, logical, and valid set of data for consumption by the client is a challenging task. Each back-end system will be returning the results in a piecemeal fashion, often returning a subset of the results after some delay. The middle tier must combine these individual results together so that each is kept whole and distinct from other results but appear to be a part of a single result set, and the entire result set must comply with the syntactic requirements of the output format (be valid XML or HTML). A common solution to this is to have the middle tier accumulate the results from each back-end and, once a complete result is accumulated, send that accumulated result to the client,
[0005] In the ease of result sets that require consolidation or ordering or other operations, the middle tier may need to accumulate all results from all back-ends before delivering the results to the client. This is, in and of itself, time and resource intensive and requires a considerably large computing system.
[0006] The protocol between the middle tier and the back-end may be proprietary and hidden from the clients.
Current State of the Art: Sequence of Events
[0007] Step 1: Referring to FIG. 1A , the client 12 , usually a desktop environment such as a web browser, RSS reader, XML application, etc, requests data from the middle tier 14 with query parameters defining the type of information that is being requested. The middle tier connects to the databases 16 and hands off the request information relevant to find the information requested.
[0008] Step 2: Referring to FIG. 1B , the backend database systems begin to return results out of the sort order. In this example, the middle tier 14 accumulates the results until all databases 16 have returned their results in order to sort those results. Database 4 has indicated that it has no results. The client 12 has yet to receive any results.
[0009] Step 3: Referring to FIG. 1C , further results arrive from other databases 16 and databases indicate that they have returned all results they have available.
[0010] Step 4: Referring to FIG. 1D , all backend database systems complete and indicate the end to their individual results.
[0011] Step 5: Referring to FIG. 1E , the results are sorted and delivered to the client, completing the response to the request. The client 12 receives no data from the server (beyond, perhaps, status or other keep-alive messages) until this step.
DESCRIPTION OF THE DRAWINGS
[0012] For a fuller understanding of the nature and advantages of the present invention, as well as the preferred mode of use, reference should be made to the following detailed description read in conjunction with the accompanying drawings.
[0013] FIGS. 1A-E are graphic depictions of data request processing.
[0014] FIG. 2 illustrates a network architecture, in accordance with one embodiment.
[0015] FIG. 3 shows a representative hardware environment associated with a user device of FIG. 2 , in accordance with one embodiment.
[0016] FIGS. 4A-D are graphic depictions of data request processing according to an embodiment.
DETAILED DESCRIPTION
[0017] The following description is the best mode presently contemplated for carrying out the present invention. This description is made for the purpose of illustrating the general principles of the present invention and is not meant to limit the inventive concepts claimed herein. Further, particular features described herein can be used in combination with other described features in each and any of the various possible combinations and permutations.
[0018] The following description is presented to enable any person skilled in the art to make and use the invention and is provided in the context of particular applications of the invention and their requirements. Various modifications to the disclosed embodiments will be readily apparent to those skilled in the art and the general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the present invention. Thus, the present invention is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein.
[0019] In particular, various embodiments of the invention discussed below are implemented using the internet as a means of communicating among a plurality of computer systems. One skilled in the art will recognize that the present invention is not limited to the use of the Internet as a communication medium and that alternative methods of the invention may accommodate the use of a private intranet, a Local Area Network (LAN), a Wide Area Network (WAN) or other means of communication. In addition, various combinations of wired, wireless (e.g., radio frequency) and optical communication links may be utilized.
[0020] The program environment in which a present embodiment of the invention is executed illustratively incorporates one or more general-purpose computers or special-purpose devices such hand-held computers. Details of such devices (e.g., processor, memory, data storage, input and output devices) are well known and are omitted for the sake of clarity.
[0021] It should also be understood that the techniques of the present invention might be implemented using a variety of technologies. For example, the methods described herein may be implemented in software running on a computer system, or implemented in hardware utilizing either a combination of microprocessors or other specially designed application specific integrated circuits, programmable logic devices, or various combinations thereof. In particular, methods described herein may be implemented by a series of computer-executable instructions residing on a storage medium such as a carrier wave, disk drive, or computer-readable medium. Exemplary forms of carrier waves may be electrical, electromagnetic or optical signals conveying digital data streams along a local network or a publicly accessible network such as the Internet. In addition, although specific embodiments of the invention may employ object-oriented software programming concepts, the invention is not so limited and is easily adapted to employ other forms of directing the operation of a computer.
[0022] The invention can also be provided in the form of a computer program product comprising a computer readable medium having computer code thereon. A computer readable medium can include any medium capable of storing computer code thereon for use by a computer, including optical media such as read only and writeable CD and DVD, magnetic memory, semiconductor memory (e.g., FLASH memory and other portable memory cards, etc.), etc. Further, such software can be downloadable or otherwise transferable from one computing device to another via network, wireless link, nonvolatile memory device, etc.
[0023] FIG. 2 illustrates a network architecture 100 , in accordance with one embodiment. As shown, a plurality of remote networks 102 are provided including a first remote network 104 and a second remote network 106 . Also included is at least one gateway 107 coupled between the remote networks 102 and a proximate network 108 . In the context of the present network architecture 100 , the networks 104 , 106 may each take any form including, but not limited to a local area network (LAN), a wide area network (WAN) such as the Internet, etc.
[0024] In use, the gateway 107 serves as an entrance point from the remote networks 102 to the proximate network 108 . As such, the gateway 107 may function as a router, which is capable of directing a given packet of data that arrives at the gateway 107 , and a switch, which furnishes the actual path in and out of the gateway 107 for a given packet.
[0025] Further included is at least one data server 114 coupled to the proximate network 108 , and which is accessible from the remote networks 102 via the gateway 107 . It should be noted that the data server(s) 114 may include any type of computing device/groupware. Coupled to each data server 114 is a plurality of user devices 116 . Such user devices 116 may include a desktop computer, lap-top computer, hand-held computer, printer or any other type of logic. It should be noted that a user device 117 may also be directly coupled to any of the networks, in one embodiment.
[0026] A database 120 or series of databases 120 may be coupled to one or more of the networks 104 , 106 , 108 . It should be noted that additional databases and/or components thereof may be utilized with, or integrated into, any type of network element coupled to the networks 104 , 106 , 108 . In the context of the present description, a network element may refer to any component of a network.
[0027] FIG. 3 shows a representative hardware environment associated with a user device 116 of FIG. 2 , in accordance with one embodiment. Such figure illustrates a typical hardware configuration of a workstation having a central processing unit 210 , such as a microprocessor, and a number of other units interconnected via a system bus 212 .
[0028] The workstation shown in FIG. 3 includes a Random Access Memory (RAM) 214 , Read Only Memory (ROM) 216 , an I/O adapter 218 for connecting peripheral devices such as disk storage units 220 to the bus 212 , a user interface adapter 222 for connecting a keyboard 224 , a mouse 226 , a speaker 228 , a microphone 232 , and/or other user interface devices such as a touch screen and a digital camera (not shown) to the bus 212 , communication adapter 234 for connecting the workstation to a communication network 235 (e.g., a data processing network) and a display adapter 236 for connecting the bus 212 to a display device 238 .
[0029] The workstation may have resident thereon an operating system such as the Microsoft Windows® Operating System (OS), a MAC OS, or UNIX operating system. It will be appreciated that a preferred embodiment may also be implemented on platforms and operating systems other than those mentioned. A preferred embodiment may be written using JAVA, XML, C, and/or C++ language, or other programming languages, along with an object oriented programming methodology. Object oriented programming (OOP), which has become increasingly used to develop complex applications, may be used.
[0030] In small installations it may be beneficial to enable direct communications to a single back-end system or enable more intelligent clients to communicate to all of the back-end systems directly (acting much like this middle tier.) In order to facilitate multiple configurations of this type, a preferred embodiment uses XML at each stage of communication.
[0031] In configurations where the client is burdened with other duties, or where the middle tier is an appliance with limited resources (memory, compute power), embodiments of the present invention may change the paradigm of the middle tier so that it does not need to accumulate results from the back-end systems. In cases where the results simply need to be accumulated and delivered, not ordered or consolidated, the approach is a mechanism of signaling between the back-end and the middle tier so that the middle tier does not need to accumulate data and would, instead, await a signal from a back-end that, a completed result is available and switch to the next input. If data is not available or the signal of completion is set, the middle tier moves to the third source and so on. To switch among sources, signals and patterns are decoded from the stream or any other method for notify the middle tier.
[0032] The balance of the multiplexer is defined by identifying statistically or any other approach on the likely size of a packet from a data source. Estimation of the packet size, the available bandwidth and middle tier computational capabilities, the total number of sources could be identified as:
[0000] [Total Number of Sources]×[Likely Packet Size/sec]=MIN {[Middle tier CPU], [Bandwith]} (units Bytes/sec)
[0033] When a result is available from any of the back-end systems, the middle tier will simply stream the result from the back-end to the client knowing that the result is complete and available for delivery. This “signal” channel would be a second HTTP connection between the middle tier and the back-end, with the “data channel” being a standard HTTP connection for the request and results. Upon delivery of a result over the data connection, the back-end would send the number of bytes in that result over the signal channel indicating how much must be relayed by the middle tier in order to deliver a complete result to the client. The signal channel can also be used to monitor the quality and other status indicators so that in the case where the back-end system is overburdened and will not be able to respond in a timely fashion, the middle tier system can use a redundant fallback system and/or return partial results with an indication of the status to the client.
High-Performance Multiplexing Architecture: Sequence of Events
[0034] Step 1: Referring to FIG. 4A , the client 402 makes a request of the middle tier 404 and that middle tier connects to the databases 406 and hands off the request information relevant to find the information requested. The request may be submitted by any client application, including web browsers and really simple syndication (RSS) readers requesting information in the HyperText Markup Language (HTML) or Extensible Markup Language (XML), typically performed at a user's request. Other examples of client applications include automated programs such as, but not limited to, data mining programs, applications containing pointers to data in one or more of the databases, etc. The query may any type of request, including, but not limited to, keyword search request, specific filename request, file or data type request, file size-based request, partition-specific request, etc.
[0035] Step 2: Referring to FIG. 4B , the backend database systems 406 begin to return results out of the sort order. In this example, the middle tier 404 immediately relays each result to the client 406 as they are received (often not in any particular order). The client may have the option, as it receives these results, to perform its own sort operation as results are received. Many user interfaces allow for progressive updates of the results as they arrive, providing immediate feedback to the user. The results may be any kind of results, including but not limited to entire files, file name, paths or pointers to files, portions of files, specific types of files, etc.
[0036] Step 3: Referring to FIG. 4C , further results arrive from other databases 106 and databases indicate that they have returned all results they have available.
[0037] Step 4: Referring to FIG. 4D , all backend database systems 406 complete and indicate the end to their individual results. The middle tier 404 indicates an end of results to the client 402 and the client is free to do with the data what it wishes. This may include outputting the results to a visual display device displaying a graphical user interface.
[0038] The following description illustrates various features which may be implemented in embodiments of the present invention. It should not be implied that any particular feature or combination of features is necessary or required to be present in any embodiments of the present invention, but rather that various embodiments may include one or more of the following features in any combination.
[0039] One purpose of the system or method according to an embodiment and API is to enable users to retrieve specific and precise information from within the contents of documents spread across disparate systems. A user can use a browser and appropriate syntax to create a custom application focused on local and general needs, with minimal effort. Using the system or method according to an embodiment may provide developers with the ability to:
Use a standard set of programming patterns and practices Query unstructured information in data repositories based on both contest and content Re-compose new documents from the results of the queries Publish information to the ‘Subscribers,” using queries to combine relevant information from different sources into custom documents.
[0044] The system preferably enables:
Users to select and integrate contents from proprietary electronic information software systems using a standard browser Both end users and industry Developers to use a custom UI in their web browsers to execute features of a system or method according to an embodiment Developers to design queries that require the existing systems to share information in a way not possible now Users to ‘subscribe’ to new documents created by the queries, receiving a new one when the basic information is updated.
OVERVIEW OF A PREFERRED EMBODIMENT
[0049] Assumptions and Constraints
[0050] The system or method according to an embodiment may be designed to function as a ‘universal interface,’ if the categories of assumptions shown below are met.
Security Assumptions
[0000]
Two-way encryption and other security measures are in place.
The environment includes the latest security patches on browser clients and relevant web servers.
The Developer has the appropriate network; and server permissions, knows the names of the development server and how to specify the location of other components in the development environment.
Computing Environment Assumptions
[0000]
The Administrator has enabled functioning WebDAV client (typically a Microsoft Web Folder) so the information can reach the DAV service on the server.
Development Process Assumptions
[0000]
The Developer bases the query on proper syntax for EXtensible Markup Language (XML).
The Developer applies the appropriate user-defined XML query command functions to filter out redundant data, navigate through the XML tree structures, and yield a more precise search result.
The Developer applies the appropriate XSLT style sheet to transform the node sets from the query into the desired XML/HTML format.
Constraints
[0058] Restraints may include:
[0059] 1. ASYNCHRONOUS: must be used with all queries.
[0060] 2. KEYWORDS: requires the use of spaces, not underscores
[0061] 3. XML:
Use CDATA to ‘escape’ special characters so they can be used in XML
[0063] 4. SENSITIVTY:
XML is designed for use with queries of XML files, with the following constraints:
XML is case sensitive XML does support attributes in XML tags The system or method may not require the use of quotation marks for strings and extra space at the end of a string XML requires the use of XML FORMAT QUERY EXCEPTION: do not use XML FORMAT QUERY when querying non-XML files.
How To Create Welt Formed Queries
HTTP and HTTP-DAV Transactions
Types of Transaction
[0070] The system architecture according to one embodiment may permit the following types of asynchronous transactions:
[0071] OPTIONS, GET, HEAD, POST, PUT, DELETE, MKCOL, MOVE, COPY, PROPFIND, NAS.0, NAS.1, LOCK, UNLOCK, PROPPATCH
[0072] OPTIONS methods to access the available options *
[0073] GET to fetch resources *
[0074] HEAD to verify if resource exists
[0075] POST to submit resources
[0076] PUT to submit a resource *
[0077] DELETE to delete a resource
[0078] MKCOL to create a collection (directory or folder)
[0079] MOVE to rename a resource
[0080] COPY to copy a resource
[0081] PROPFIND to fetch property definition of a resource in XML *
[0082] NAS.0 and NAS.1 Neighborhood registry with other devices
[0083] LOCK to lock a resource temporarily
[0084] UNLOCK to unlock a resource temporarily
[0085] PROPPATCH to patch a resource properties (disabled)
Transaction Criteria
[0086] Select the appropriate type of asynchronous transaction based on the following user requirements:
Fundamentally to get or submit information that my system indicates is or Is not the database. Find information related to my scope that has been deleted. Find information from either of the above options, but return it to me combined into a highly formatted new document, including HTML, Macromedia Flash, Word documents, Excel documents, or PowerPoint documents. Find information from either of the first two options, but return it to me as a functioning webpage with internal links Other requirement, such as record identifier Other requirement, such as another type of format for the results These transaction are W3C Standard for the exception of NAS.0 and NAS.1
Options
Purpose
[0094] This section specifies the discovery methods for the set of methods, headers, and content-types ancillary to HTTP/1.1 for the management of resource properties, creation and management of resource collections, namespace manipulation, and resource locking (collision avoidance).
[0095] The following table sets forth illustrative syntax:
[0000]
TABLE 1
Syntax
Request
HTTP Header
OPTIONS / HTTP/1.1
Accept: */*
Connection: keep-alive
Content-Length: 0
Host: www.sciencegate.com:80
User-Agent: WebDAVFS/1.3.1 (01318000)
Darwin/8.5.0 (Power Macintosh)
Response Failed Authentication
HTTP/1.1 401 Authorization Required
Date: Wed, 07 Jun 2006 08:42:36 PDT
Server: Fastxi/2.7 Science Gate Bay (Unix)
WWW-Authenticate: Basic Realm=“directory/”
Content-Length: 0
Content-Type: text/plain; charset=ISO-8859-1
Connection: close
Response Passed Authentication
HTTP/1.1 200 OK
Date: Wed, 07 Jun 2006 08:42:40 PDT
Server: Fastxi/2.7 Science Gate Bay (Unix)
Allow:
OPTIONS,HEAD,GET,PUT,DELETE,MKCOL,MOVE,
COPY,PROPFIND,PROPPATCH,LOCK,UNLOCK
DAV: 2
MS-Author-Via: DAV
Content-Length: 0
Content-Type: text/plain; charset=ISO-8859-1
Connection: close
Instruct to Initiate Transaction
[0000]
Do not omit this required syntax.
Begin HTTP discovery request with this syntax.
More Information
[0098] See http://www.w3.org/Protocols/ for more information, and which is herein incorporated by reference.
Propfind
Purpose
[0099] This section specifies the resource discovery, content and content-types ancillary to HTTP/1.1 for the management of resource properties, creation and management of resource collections, namespace and manipulation.
[0100] The following table sets forth illustrative syntax:
[0000]
TABLE 2
Syntax
Request
HTTP
PROPFIND / HTTP/1.1
Header
Accept: */*
Authorization: Basic bWFsdWY6bWFsdWY=
Connection: keep-alive
Content-Length: 161
Content-Type: text/xml
Depth: 0
Host: www.sciencegate.com:80
User-Agent: WebDAVFS/1.3.1 (01318000)
Darwin/8.5.0 (Power Macintosh)
Response
HTTP/1.1 207 Multi-Status
Date: Wed, 07 Jun 2006 08:42:40 PDT
Server: Fastxi/2.7 Science Gate Bay (Unix)
DAV: 2
MS-Author-Via: DAV
Content-Length: −1
Content-Type: text/plain; charset=ISO-8859-1
Connection: close
<?xml version=“1.0” encoding=“utf-8” ?>
<D:multistatus xmlns:D=“DAV:”>
<D:response>
<D:href>http://www.sciencegate.com:80/</D:href>
<D:propstat>
<D:prop>
<D:creationdate></D:creationdate>
<D:getlastmodified>Wed, 25 Jan 2006 21:48:06
PST</D:getlastmodified>
<D:resourcetype>
<D:collection></D:collection></D:resourcetype>
<D:contenttype></D:contenttype>
<D:getcontentlength>238</D:getcontentlength></D:prop>
<D:status>HTTP/1.1 200 OK</D:status>
</D:propstat>
</D:response>
</D:multistatus>
Instruct to Initiate Transaction
[0000]
Do not omit tins required syntax.
Begin HTTP resource discovery with this syntax.
More Information
[0103] See http://www.w3.org/Protocols/ for more information, and which is herein incorporated by reference.
Put, MKCOL, Move and Delete
Purpose
[0104] This section specifies the methods for the management of resource properties, creation and management of resource collections, namespace manipulation.
[0105] The following table sets forth illustrative syntax.
[0000]
TABLE 3
Syntax
Request
HTTP
PUT /myfilename.xml HTTP/1.1
Header
Accept: */*
Authorization: Basic bWFsdWY6bWFsdWY=
Connection: keep-alive
Content-Length: 0
Host: www.sciencegate.com:80
User-Agent: WebDAVFS/1.3.1 (01318000)
Darwin/8.5.0 (Power Macintosh)
Response
HTTP/1.1 201 Created
Date: Wed, 07 Jun 2006 08:42:41 PDT
Server: Fastxi/2.7 Science Gate Bay (Unix)
Location: http://www.sciencegate.com:80/myfilename.xml
Content-Length: 0
Content-Type: text/plain; charset=ISO-8859-1
Connection: close
Instruct to Initiate Transaction
[0000]
Do not omit this required syntax.
Begin HTTP resource manipulation with this syntax.
More Information
[0108] See http://www.w3.org/Protocols/ for more information, and which is herein incorporated by reference.
Get
Purpose
[0109] This section specifies the methods for the management of resource properties, creation and management of resource collections, namespace manipulation.
[0110] The following table sets forth illustrative syntax:
[0000]
TABLE 4
Syntax
Request
HTTP Header
Get /myfilename.xml HTTP/1.1
Accept: */*
Authorization: Basic bWFsdWY6bWFsdWY=
Connection: keep-alive
Host: www.sciencegate.com:80
User-Agent: WebDAVFS/1.3.1 (01318000)
Darwin/8.5.0 (Power Macintosh)
Response
HTTP/1.1 200 OK
Date: Wed, 07 Jun 2006 08:42:41 PDT
Server: Fastxi/2.7 Science Gate Bay (Unix)
DAV: 2
MS-Author-Via: DAV
Content-Length: 0
Content-Type: text/plain; charset=ISO-8859-1
Connection: close
Instruct to Initiate Transaction
[0000]
Do not omit this required syntax.
Begin HTTP resource access with this syntax.
More Information
[0113] See http://www.w3.org/Protocols/ for more information, and which is herein incorporated by reference.
How To Create Well Formed Queries
XML Query
Types of Searches
Types of Searches
[0114] The system architecture may permit the following types of searches:
Is inherently GET or POST method Starts with an /ofxi! URL Request method XML tag search only search (node) XML text search only search (data) Combined node and data search XML pattern recognition combination search XML attribute search Range value search UI Processing on the query options (client side)
Search Selection Criteria
[0124] Select the appropriate type of system or method based on the following user requirements:
Find information that my system indicates is already in a database. Find information related to my scope that has been deleted. Find information from either of the above options, but return it to me combined into a highly formatted new document, including HTML, Macromedia Flash, Word documents, Excel documents, or PowerPoint documents. Find information from either of the first two options, but return it to me as a functioning webpage with internal links Other requirement, such as record identifier Other requirement, such as another type of format, for the results
Creating Well-Formed Queries
Well-Formed Query
[0000]
All queries must conform to the syntax recognizable by the system.
Note: The items are separated by | require the Developer to make a selection between the items shown
The full syntax for creating a query is as follows:
[0000]
BASIC QUERY SYNTAX
http://<server_address>/
ofxi?{[node=<node and attibute keys>]|
[&data=<keys>]}|
[&udri=<unique database record identifier >]
ADVANCED QUERY SYNTAX
http://<server_address>/
ofxi?{[node=<node and attribute keys>]|
[&data=< keys>]}|
[&modx=<xml pattern matching>]}|
[&udri=<unique database record identifier >]
Query Conventions
Query Syntax Conventions
[0134] The syntax may include the following conventions:
[0000]
TABLE 5
Expression
Meaning
Free Text
Key words used as required constant
Text between < >
Value substituted by actual value
Text between [ ]
Parameter for range evaluation
Text between { | }
Split text from UDRI
Text between “ “
Treat text as whole object
Note:
the | symbol indicates optional choices and should not be included in the text of the query because the query will not execute.
[0135] Note: a comma separates elements in the results field so that the query will operate in an Oracle environment
Before You Begin
[0136] Developers should obtain the required information to compose a well-formed query:
the source of the information, expressed as a fully qualified path the content and context to search the key word filtering requirements for the elements in an ‘advanced search’ the required format for displaying the results the need for post query processing, either on the server or the user's client desktop.
Annotated Command Reference
Introduction to Command Reference
Annotated Command Reference
[0142] Each Query command component has its own section.
[0143] Each includes the following contents:
Component name and spelling Syntax Instructions to create Cautions Notes Best Practices Links to further information component Examples.
HTTP[S]://
Purpose
[0152] Starting the query with http[s]://
Indicates you are using the Secure Hypertext Transfer Protocol and will run the query in a browser. Enables the system or method to send and receive a query request to or from a central or remote location at any time, anywhere around the world.
[0155] The following table sets forth illustrative syntax:
[0000]
TABLE 6
Syntax
http[s]://
Instruct to Initiate Transaction
[0000]
Do not omit this required syntax.
Begin each query with this syntax.
More Information
[0158] See http://www.w3.org/Protocols/ for more information, and which is herein incorporated by reference.
Server_address
Purpose
[0159] Use the Server_address parameter to:
To identify the server in your work location that functions as the “host” and to specify the port on which this server communicates. To use the correct port and ensure security for communications between the server and the rest of the a networked computing infrastructure.
[0162] The following table sets forth illustrative syntax:
[0000]
TABLE 7
Syntax
<server_address>
——————————————————————————
Instruct to Specify Host Name
[0000]
Do not omit this required syntax.
Replace “server_address” with the name of the server
EXAMPLES
[0165] Because XML queries are used for applications, see the section that contains Customer-specific examples.
XSLT
Purpose
[0166] Use the /xslt parameter to:
To specify that the results of the query must be transformed from XML format, using a specific style sheet. To specify post-processing of the query results, in this case on the Server.
[0169] The following table sets forth illustrative syntax:
[0000]
TABLE 8
Syntax
/xslt/
Instruct to Produce XML Output
See Also &sxslt
[0170] The &sxslt parameter specifies server-side post-processing of the query
EXAMPLES
[0171] Because queries are used in applications, see the section that contains Customer-specific examples.
Node
Purpose
[0172] Use the node portion of the query syntax to specify Key Words to set:
either node, data or modx or a combination of the three.
[0175] If there is more than one context, use the syntax &node
[0176] The following table sets forth illustrative syntax:
[0000]
TABLE 9
Syntax
{[node=<node keys>]& [data =<data keys>]}
——————————————————————————
Scope of Search
[0000]
Currently, the “depth” of the search will find only the parent and all its children.
The syntax combines both the node and data qualifier.
If you do not specify a specific key word for “keys,” then the query will return all the nodes and their descendents, within the specified scope
DATA is case sensitive
Instruct to Define the Scope of the XML
[0000]
Do not omit the node qualifier.
The data qualifier is optional.
Replace “node keys” qualifier text with any full or partial element, attribute or tag names on which to base the search.
Replace “data keys” qualifier text with a keyword for the search to return all the tag nodes that contain the keyword within their text.
Caution
[0185] The following cautions apply to this portion of the query:
Use the [ ] notation characters, omitting the | after making a selection. The [ ] pattern in node is pattern ranger specifier. Checkpattern recognition section. Replace the underscore with either a space character or the %20 characters. Replace the = symbol with %3D characters.
EXAMPLES
[0188] Because XML queries are used for applications, see the section that contains Customer-specific examples.
Data
Purpose
[0189] Use data to create a combined node and data searches
[0190] The following table sets forth illustrative syntax:
[0000]
TABLE 10
Syntax
node=<node keys>&data=<data keys>
——————————————————————————
Instruct to Create a Combined Node and Data Search
[0000]
Do not omit the data qualifier.
To create a combined node and data search, use the ampersand before data
DATA is not case sensitive
EXAMPLES
[0194] Because XML queries are used for applications, see the section that contains Customer-specific examples.
MODX
Purpose
[0195] Use the modx parameter to:
Define an extended XML pattern search Increase the complexity of the query and or pattern.
Best Practice
[0000]
Using the modx parameter is a best practice recommendation for database usage.
modx is particularly useful if information is xml segmented and the desired result is composition.
[0200] The following table sets forth illustrative syntax:
[0000]
TABLE 11
Syntax
[modx=< xml pattern> ... text pattern ...
[nested xml pattern]</>]
——————————————————————————
More Information
[0201] For more information, please see
[0202] http://www.ietf.org/html.charters/webday-charter.html
[0203] http://www.webdav.org
Instruct to Set the Modx Pattern
[0000]
Combine a node and node searches with “< >” xml delimiters. In tag attributes definitions follow xml specifications.
Use this option to perform database searches to a specific collection of information.
Relation to WebPAV
[0000]
The system or method preferably complies with the WebDAV standard so thai standard UI interface can drag and drop information into what appear to be folders on their desktops.
When that happens, the documents and XML documents are parsed, and stored in the database.
This process enables full text searches and makes the ‘upload’ process to the server invisible to the user
Caution
[0209] The following cautions apply to this portion of the query:
Use the [ ] notation characters, omitting the | after making a selection. The [ ] pattern in node is pattern ranger specifier. Checkpattern recognition section. Replace the underscore with either a space character or the %20 characters. Replace the = symbol with %3D characters.
A.XSL, with Stylesheet
Purpose
[0212] Use the A.xsl stylesheet file to:
Transform the output of a standard node, data and modx query to a display that includes all the search terms in highlights, all the sections with content that match the search terms as a separate paragraph, and links to the source files.
[0214] Note: This style sheet (A.XSL) will work with any query combinations.
[0215] The following table sets forth illustrative syntax:
[0000]
TABLE 12
——————————————————————————
Syntax
http://127.0.0.1/ofxi?xslt=/home/
style1.xsl&node=name&data=anderson
——————————————————————————
Instructions
[0216] If customizing this example for your own use, replace the following:
127.0.0.1 with your server address name with your node to be searched anderson with your data to be searched stylel.xsl with the path to the location of your stylesheet on your server.
Node and Data Query
Purpose
[0221] Use the node and data portion of the query to:
Obtain both specific contents of documents within a specific context scope expressed in the default syntax.
[0224] The following table sets forth illustrative syntax:
[0000]
TABLE 13
——————————————————————————
Syntax
http://127.0.0.1/ofxi?xslt=/home/
style1.xsl&node=name&data=anderson
——————————————————————————
Instructions
[0225] If customizing this example for your own use, replace the following:
127.0.0.1 with your server address name with your node to be searched the key word anderson with the name of your data to be searched
Job Aid: Detailed Samples for Customers
Purpose
How to Use
[0000]
The following section contains detailed examples for typical business cases your customers may require
Use them as starting points in developing requirements for custom queries
Collect feedback and report back to your manager and the developer community
Add your own, using this format as a template
Example 1
[0233] In the following example, the system or method found information originally stored as a transformed the information into xml and presented the results as a web page in ‘raw’ format.
[0000]
TABLE 14
Example 1
Sample Ouput in Raw Format for a list of multiple files associated with a
Query.
Query
http://127.0.0.1/ofxi?node=Abstract&data=safety
Note: the output contains more information;
Output
<?xml version=\″1.0\″?>
<fx:uri name=″nlm.xml″ date=″″ user=″nlm″ size=″174928″/>
<fx:ofx udrx=″0000014000000100101940″/>
< department=”medicine” serial=”ABC.345.XY”>
<AbstractText>
The technique of early extubation after coronary artery
bypass grafting is increasing in popularity, but its
and effect on myocardial ischaemia remain to be
established ...
</AbstractText>
</Abstract>
<fx:uri name=″arts.xml″ date=″″ user=″artist″ size=″1728″/>
<fx:ofx udrx=″0000014000000100101940″/>
< number=”12345”>
<Art>
Abstract Art is art that is not an accurate representation
of a form or object...
</Art>
</Abstract>
<fx:uri name=″doc.doc″ date=″″ user=″facility″ size=″4928″/>
<fx:ofx udrx=″0000014000000100101940″/>
<![CDATA We consider the of the population is at risk]]>
Example 2
[0234] In the following example, the system or method found information originally stored as a transformed the information into xml and presented the results as a web page in ‘raw’ format.
[0000]
TABLE 15
Example 2
Sample Output in Raw Format for a list of multiple files associated
with a Query.
Query
http://127.0.0.1/
ofxi?node=Abstract_and_Department=medicine
Note: the query contains an algebraic operator “_and_.” More
information on the algebra is in later sections.
Output
<?xml version=\″1.0\″?>
<fx:uri name=″nlm.xml″ date=″″ user=″nlm″ size=″174928″/>
<fx:ofx udrx=″0000014000000100101940″/>
< serial=”ABC.345.XY”>
<AbstractText>
The technique of early extubation after coronary artery
bypass grafting is increasing in popularity, but its safety and
effect on myocardial ischaemia remain to be established ...
</AbstractText>
</Abstract>
Example 3
[0235] In the following example, the system or method found information originally stored as a transformed the information into xml and presented the results as a web page in ‘raw’ format.
[0000]
TABLE 16
Example 3
Sample Output in Raw Format for a list of multiple files associated with a
Query.
Query
http://127.0.0.1/ofxi?data=safety_or_establish*
Note: the query contains an algebraic operator “_or_.” More
information on the algebra is in later sections.
Output
<?xml version=\″1.0\″?>
<fx:uri name=″nlm.xml″ date=″″ user=″nlm″ size=″174928″/>
<fx:ofx udrx=″0000014000000100101940″/>
<Abstract department=”medicine” serial=”ABC.345.XY”>
<AbstractText>
The technique of early extubation after coronary artery
bypass grafting is increasing in popularity, but its ␣
and effect on myocardial ischaemia remain to be
...
</AbstractText>
</Abstract>
Example 4
[0236] In the following example, the system or method found information originally stored as a transformed the information into xml and presented the results as a web page in ‘raw’ format.
[0000]
TABLE 17
Example 4
Sample Output in Raw Format for a list of multiple files associated with a
Query.
Query
http://127.0.0.1/ofxi?modx=
<Abstract _and — department=”medicine”>
<AbstractText>safety _and — established</></>
Note: the query contains an algebraic operator “_and — ” More
information on the algebra is in later sections.
Output
<?xml version=\″1.0\″?>
<fx:uri name=″nlm.xml″ date=″″ user=″nlm″ size=″174928″/>
<fx:ofx udrx=″0000014000000100101940″/>
< department=”medicine” serial=”ABC.345.XY”>
<AbstractText>
The technique of early extubation after coronary artery
bypass grafting is increasing in popularity, but its
and effect on myocardial ischaemia remain to be
...
</AbstractText>
</Abstract>
Algebra
Purpose
[0237] The World-Wide Web Consortium (W3C) promotes XML and related standards, including XML Schema. The albebra is a formalization over XML. A formal semantics based on these ideas is part of the official algebra specification, one of the first uses of formal methods by a standards body. XML features both named and structural types, with structure based on tree grammars. The operators are:
_and — _or — _sub —
[0241] The following table sets forth illustrative syntax:
[0000]
TABLE 18
————————————————————————
Syntax
SET { key [operater ]key }
————————————————————————
Instructions
http://127.0.0.1/
ofxi?node=Abstract_and_Department=medicine
Note:
the query contains an algebraic operator “_and_.” The default white space is an “_or_” operator.
UDRI Universal Database Record Identifier
Description
[0242] Universal Database Record Identifier (UDRI) is intended to be a subset to the Uniform Resource Locator (URL) and provide an extensible means for identifying universally database records. This specification of URI syntax and semantics is derived from concepts introduced by the World Wide Web global information initiative, and is described in “Universal Resource Identifiers [RFC1630].
UDRI Syntax
[0243] The UDRI syntax is a scheme derived from URI. In general, absolute URI are written as follows:
[0000] <scheme>:<scheme-specific-part>
[0244] An absolute URI contains the name of the scheme being used (<scheme>) followed by a colon (“:”) and then a string (the <scheme-specific part>) whose interpretation depends on the scheme.
Example 5
Query
[0245] http://127.0.0.1/ofxi!udrx=0000014000000100101940
[0246] Note: the query contains a unique identifier to the record.
[0247] The following table sets forth illustrative ouptut:
[0000]
TABLE 19
Output
<?xml version=\″1.0\″?>
<fx:uri name=″nlm.xml″ date=″″ user=″nlm″ size=″174928″/>
<fx:ofx udrx=″0000014000000100101940″/>
< department=”medicine” serial=”ABC.345.XY”>
<AbstractText>
The technique of early extubation after coronary artery bypass
grafing is increasing in popularity, but its and effect on
myocardial ischaemia remain to be ...
</AbstractText>
</Abstract>
Unexpected Results
Symptom
[0248] One example is an error in the style sheet thai prevents the expected output from formatting correctly.
More Symptoms
[0000]
The results should be xml but are not
The results are not a recomposed document, but should be
The layout is not correct
Parts of the expected contents are missing
The titles and the contents do not match the content requested
Solution
[0000]
Check the version of the Query being used.
Check the syntax of the query
Check the full path to the required information source
Check the full path to the required output file
Check the syntax inside the associated style sheet or template
Check the configuration file/scripts such licensing keys
Check permission on data and data access
Check log files for errors
Check Access Control
Check the server publishing the results for outages.
[0264] While various embodiments have been described above, it should be understood that they have been presented by way of example only, and not limitation. Thus, the breadth and scope of a preferred embodiment should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents. | A method for querying a database comprises receiving a query from a client, querying a plurality of databases, receiving replies from the databases, relaying the replies from the databases to the client as they are received from the databases. A system for querying a database comprises a client, a plurality of databases, and a query dispatcher receiving a query from the client, querying the plurality of databases, receiving replies from the databases, relaying the replies from the databases to the client as they are received from the databases. | 7 |
This application is a continuation of International Application No. PCT/AT2006/000270, filed Jun. 29, 2006.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an article of furniture comprising a furniture carcass and a first and at least one second drawer displaceable relative to the furniture carcass, wherein in the closed position of the two drawers the front panel of the first drawer substantially completely covers the front panel or the front wall of the second drawer.
2. Description of the Related Art
Items of furniture of that kind describe inter alia what are referred to as internal extension portions, the front panel or the front wall of which is disposed behind a larger or upwardly extended front panel of a front extension portion. When an internal extension portion is fitted into an article of furniture in the form of a cabinet, the front extension portion always has to be opened first so that the internal extension portion becomes accessible and can also be opened. Often those internal extension portions, for aesthetic reasons or reasons of space, do not have any handle or grip whereby the operating option is restricted. If, in addition, the internal extension portion is arranged directly beneath a transverse member, an intermediate panel portion or under additional internal extension portions, there is no comfortable and convenient possible way of opening the internal extension portion. If, moreover, the internal extension portion is provided with a closure mechanism, which in its closed position acts on the internal extension portion with a retaining force for keeping it closed, actuation is in addition impractical as the opening movement against a spring force is made considerably more difficult.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to propose an article of furniture of the general kind set forth in the opening part of this specification, which offers a user a high level of operating comfort.
In accordance with the invention in an advantageous configuration that is achieved in that the first and the at least one second drawer have an ejection device for moving the drawers from the closed position into an open position and that arranged between the two ejection devices is a switching element which couples the two ejection devices in a first switching position and uncouples them in a second switching position.
If the ejection device acts, for example, on the second drawer (internal extension portion), it can be conveniently moved into an open position without any need for the user to grip behind the internal extension portion for that purpose. If the ejection device acts on the first drawer (front extension portion), it can be selectively coupled to or not coupled to the internal extension portion, by a preferably mechanical coupling means.
In order to promote the ejection movement of the drawer it can also be provided that at least one ejection device has a drive device, preferably at least one spring or at least an electric motor, by which an ejection element is or can be acted upon for ejection of the drawer. In order to avoid the drawer abruptly springing open, it can also be desirable for the relative movement between the ejection device and the drawer or the guide rails thereof to be damped by means of a damping device.
An embodiment of the invention provides that the first drawer and the at least one second drawer have a separate ejection device for moving the drawers from a closed position into an open position. In that way the extension movements can be controlled independently of each other. An advantageous configuration provides in that respect that the ejection device of the first and the at least one second drawers are coupled so that the ejection device of the second drawer can be triggered by way of the ejection device of the first drawer. In that case, the at least two ejection devices can be electrically or mechanically coupled together so as to afford a very wide range of triggering and switching combinations. A configuration in that respect can be such that disposed between the two ejection devices is a switching element which couples the two ejection devices in a first switching position and uncouples them in a second switching position. In that case, the switching element can be either in the form of a mechanical switch or—in accordance with a further embodiment—it can be in the form of a logic circuit for interlinking digital signals in accordance with the rules of Boolean algebra.
A further embodiment of the invention provides that at least the first drawer has a first limit position which corresponds to the closed position of the first drawer and the first drawer is movable starting from that limit position by the application of pressure in the closing direction thereof into a second limit position which is further into the furniture carcass. In that case, the configuration can be such that an ejection device is of such a configuration that it moves the drawer from the second limit position into an open position. Fitments of that kind are known as touch-latch fitments which are actuated by the drawer being pushed in by a predetermined distance in order then to be moved into an open position by a force storage device (spring device, fluid damper, electric motor).
Alternatively or as a supplemental consideration, it may also be advantageous if the at least first drawer has a limit position which corresponds to the closed position of the drawer and the first drawer is movable starting from that limit position by applying a pulling force into an open position, wherein the ejection device is inactive. If the first drawer (front extension portion) is activated by way of a pulling pulse, in that case preferably only the front extension portion is extended as the ejection device of the internal extension portion does not receive a switching pulse. In that situation, the internal extension portion can selectively remain in the closed position or selectively be activated by manually applying pressure or a pulling force to the front panel thereof.
In accordance with a further embodiment of the invention it can be provided that the article of furniture has a control and/or a regulating device for selectively moving the drawers. In that case for example selective activation, the moment in time of actuation and/or the movements of the drawer can be controlled separately or in all possible combinations. In that connection, it may be desirable if the ejection device has at least one electric switch which is activatable by the application of a pulling force or a pushing force to the drawer, wherein the signals thereof can be passed to the control and/or regulating device. In that respect, the electric switch can be in the form of a microswitch, the switching pulses of which are passed to an address decoder for programmed actuation of the individual ejection devices. By way of example the arrangement can be such that the control and/or regulating device is so designed that it does not activate the ejection device of the at least second drawer (internal extension portion) when a pressure is preferably applied once to the first drawer (front extension portion). In other words, the internal extension portion, when pressure is applied once to the front panel of the front extension portion, is not extended while the front extension portion alone moves into the open position. A further embodiment can be such that the control and/or regulating device is so designed that it activates the ejection device of the at least second drawer (internal extension portion) when pressure is preferably applied twice in succession to the first drawer (front extension portion) within a predetermined or predeterminable period of time. In other words, in the case of a “double click” on the front extension portion, both the front extension portion and also the internal extension portion are moved into an open position. In an advantageous development it can also be provided that the control and/or regulating device is so designed that it does not activate the ejection device or devices when a pulling force is applied to the first drawer. It is to be noted in that respect that a very wide range of switching options are possible in this connection, for one of ordinary skill in the art dealing with this object.
In accordance with a preferred development of the invention it can be provided that the article of furniture has a releasable coupling device for temporarily coupling the two drawers. The additional arrangement of that releasable coupling device in combination with at least one ejection device for the drawer affords additional possible combinations. In that respect, it can be advantageous if the at least second drawer is movable at least from the completely closed position into an open position by the releasable coupling device. In this connection, it is desirable if the releasable coupling device has two or more, preferably preselectable, modes of operation. The possibility of adjusting the releasable coupling device can provide that for example the first drawer (front extension portion) can be opened, in which case in accordance with the two modes of operation it is possible selectively to establish whether the at least second drawer (internal extension portion) does or does not also perform the movement of the front extension portion. In that respect, it is advantageous if the releasable coupling device is arranged or designed in such a way that the drawers can be uncoupled, preferably in a common open position thereof, so that each drawer can be actuated in itself alone.
In regard to the releasable coupling device many different configurations can be implemented in a manner with which the man skilled in the art will be familiar. In an embodiment it can be provided that the releasable coupling device is preferably operative between the rear side of the front panel of the first drawer and between the front side of the front panel or front wall of the at least second drawer. In the simplest case it may be desirable if the releasable coupling device has a mechanical latching connection (for example at least one spring-loaded latching element).
An alternative embodiment can also provide that at least one, preferably spring-loaded, spring buffer and/or at least one spacer portion, preferably comprising a damping material, is or are arranged between the front panel of the first drawer and the front panel or front wall of the second drawer. That arrangement means that it is possible to effectively prevent hard impact of the front panel of the first drawer against the front panel or front wall of the second drawer so that the banging noises which occur in that case are substantially reduced.
Finally, in an embodiment of the invention it can be provided that at least one of the drawers has a retraction device by which the drawer is movable into the closed limit position, wherein preferably the last closing travel to the completely closed position thereof takes place in a damped fashion. In that respect, each drawer of the article of furniture can be equipped with a retraction device of that kind, which reliably move the drawers into the closed limit position. Usually, retraction devices of that kind are also provided with a damping device which damps the movement of the drawer over the last closing range so that it is not retracted into the carcass of the article of furniture with too much momentum. In that respect fluid dampers, for example linear or rotational dampers, can advantageously be used as the damping devices.
BRIEF DESCRIPTION OF THE DRAWINGS
Further details and advantages of the invention are described in greater detail hereinafter by means of the specific description with reference to the drawings in which:
FIG. 1 shows a perspective view of an embodiment of an article of furniture according to the invention, wherein the article of furniture has a front extension portion and two internal extension portions disposed therebehind,
FIG. 2 shows a further embodiment of the invention with a releasable coupling device between the lower internal extension portion and the front extension portion and with a spring buffer between the upper internal extension portion and the front extension portion, and
FIGS. 3 a - 3 d show various embodiments of the triggering and coupling options between an internal extension portion and the front extension portion.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows an embodiment of an article of furniture 1 according to the invention as a perspective view. The article of furniture 1 which is in the form of a cabinet has a carcass 2 in which a first drawer 3 (front extension portion) with an upwardly extended front panel 3 ′ is displaceable. Also, disposed in the carcass 2 are a second and a third drawer 4 and 5 (internal extension portions), the front walls 4 ′ and 5 ′ of which in the closed position of the drawers 3 , 4 , 5 are behind the upwardly extended front panel 3 ′ of the front extension portion 3 . In order to open the two internal extension portions 4 and 5 , the front extension portion 3 always has to be opened first, which makes it more difficult to operate the drawers 3 , 4 and 5 . For that purpose provided on the rear wall 8 (only partially shown) of the article of furniture are three separate ejection devices 9 , 9 ′ and 9 ″, the ejection elements 9 a , 9 a ′ and 9 a ″ of which preferably act on the respective rear walls of the individual drawers 3 , 4 and 5 so that the drawers 3 , 4 and 5 , starting from the closed position, are accelerated, overcoming the mass inertia thereof, so that the drawers 3 , 4 and 5 can be moved into an open position. The ejection devices 9 , 9 ′ and 9 ″ preferably include a spring device (not shown) or, in accordance with an alternative embodiment, at least one electrical drive unit so that a torque is applied to the respective ejection elements 9 a , 9 a ′ and 9 a ″. The rear wall of the respective drawers 3 , 4 and 5 is suitable in particular for the force of the ejection elements 9 a , 9 a ′ and 9 a ″ to act thereon, in which case the free ends of the ejection elements 9 a , 9 a ′ and 9 a ″ bear in the closed limit position against the respective rear walls of the drawers 3 , 4 and 5 . In principle the ejection devices 9 , 9 ′ and 9 ″ can also act at another location of the article of furniture, for example on the extension rails thereof which are disposed at both sides of the drawers 3 , 4 and 5 .
The separate ejection devices 9 , 9 ′ and 9 ″ which in accordance with an embodiment of the invention can be coupled by at least one switching element afford various possible combinations which are described in greater detail in the Figures hereinafter. In order still further to enlarge the possible combinations of the drawers 3 , 4 and 5 , there are provided releasable coupling devices for selectively or temporarily coupling an internal extension portion 4 , 5 to the front extension portion 3 so that, in an outward movement of the front extension portion 3 , an internal extension portion 4 , 5 also moves therewith or does not move therewith. The releasable coupling device includes substantially hook-shaped entrainment elements 10 b and 11 b respectively, and coupling elements 10 a and 11 a . The hook-shaped entrainment elements 10 b and 11 b are disposed in the region of the front walls 4 ′ and 5 ′ and can be releasably coupled to the coupling elements 10 a and 11 a of the front panel 3 ′. In that respect it may desirably be provided that the entrainment elements 10 b and 11 b and/or the coupling elements 10 a and 11 a have at least two operating positions, wherein in a first operating position the entrainment elements 10 b and 11 b automatically latch to the coupling element 10 a and 11 a respectively when the front extension portion 3 is brought together with the internal extension portions 4 , 5 while in a second operating position no latching occurs between the entrainment elements 10 b and 11 b and the coupling elements 10 a and 11 a . In that connection, it is desirable if the entrainment element 10 b and 11 b respectively has an adjustment option by which the two operating positions can be activated, for example by manual actuation. That can be affected by either the entrainment elements 10 b and 11 b respectively, or the coupling elements 10 a and 11 a respectively, being adapted to be rotatable through 180° so that coupling is activated in one position and is deactivated in the position of being turned through 180°.
FIG. 2 shows a slight modification to the embodiment of FIG. 1 . The structure of the article of furniture 1 is identical to that of FIG. 1 , with the exception that no coupling option is provided for the upper internal extension portion 5 or the front wall 5 ′ thereof, to the upwardly extended front panel 3 ′ of the front extension portion 3 . In the illustrated embodiment provided on the rear side of the front panel 3 ′ of the front extension portion 3 is a spring buffer 12 which in the closed position of the two drawers 3 and 5 bears against the front wall 5 ′ of the upper internal extension portion 5 . In that way, the spring buffer 12 prevents unwanted panel impact in respect of the front panel 3 ′ when the drawer 3 is closed. The spring buffer 12 can be replaced by a spacer portion preferably formed from a damping material with rubber-elastic properties.
FIGS. 3 a - 3 d show various embodiments of the triggering and coupling options by means of a simplified view of the front extension portion 3 and an internal extension portion 4 , as a side view. FIG. 3 a shows the front extension portion 3 with its upwardly extended front panel 3 ′ which in the closed position of the drawers 3 and 4 substantially completely covers the front wall 4 ′ of the internal extension portion 4 . Provided at the rear wall 8 of the article of furniture 1 are two separate ejection devices 9 and 9 ′, the ejection elements 9 a and 9 a ′ of which act on the respective drawer rear wall. In the illustrated embodiment, it is provided that the front extension portion 3 has a first limit position which corresponds to the closed position of the front extension portion 3 and that the front extension portion 3 is movable from that setting by the application of pressure in the closing direction thereof into a second limit position which is disposed inwardly of the carcass 2 so that the ejection element 9 a of the ejection device 9 can be acted upon by pressure applied to the front extension portion 3 . In the illustrated embodiment the ejection devices 9 and 9 ′ are not coupled and there is not a releasable coupling option as between the front panel 3 ′ and the front wall 4 ′. The opening process for the drawers 3 , 4 takes place in mutually independent fashion, that is to say the internal extension portion 4 can only be extended after the front extension portion 3 has been deliberately moved into an open position by way of the ejection device 9 . Subsequently, the internal extension portion 4 can be moved into the open position after separate activation of the ejection device 9 ′.
FIG. 3 b shows an alternative embodiment of the invention as a side view. In contrast to FIG. 3 a , the internal extension portion 4 or the front wall 4 ′ thereof is coupled by way of a releasable coupling device 11 to the front panel 3 ′ of the front extension portion 3 . The releasable coupling device 11 comprises the entrainment element 11 b shown in FIG. 1 , and the coupling element 11 a . The releasable coupling device 11 is preferably operative between the rear side of the front panel ( 3 ′) of the first drawer ( 3 ) and between the front side ( 4 ′) of the front panel or front wall of the at least second drawer ( 4 ) and preferably has two preselectable modes of operation, wherein in a first mode of operation the two drawers 3 and 4 are coupled together and in a further mode of operation they are not coupled. If the ejection device 9 of the front extension portion 3 is activated—for example by applying a manual pressure or pulling force to the front panel 3 ′—then the internal extension portion 4 , in a situation involving active coupling of the releasable coupling device 11 , moves together with the front extension portion 3 out of the carcass 2 . If the releasable coupling device 11 is not active, separate activation of the internal extension portion 4 (also by applying pressure or a pulling force to the front panel 4 ′) can be effected for moving it from its closed limit position into an open position.
FIG. 3 c shows a further embodiment of the invention. A spring buffer 12 , as shown in FIG. 2 , or a spacer portion is operative between the front panel 3 ′ of the front extension portion 3 and the front wall 4 ′ of the internal extension portion 4 . When a pressure is applied to the front panel 3 ′ the drawer 3 —starting from the illustrated limit position corresponding to the closed position of the front extension portion 3 —will be moved into a second limit position which is further into the carcass 2 so that pressure is also applied to the ejection element 9 a . Pressure is also applied to the ejection element 9 a ′ of the ejection device 9 ′ by the spring buffer 12 or the spacer portion so that this leads to joint triggering of the two ejection devices 9 and 9 ′. In that case, it can be provided that when a pulling force is applied to the front panel 3 ′, only the ejection device 9 of the front extension portion 3 is activated. The internal extension portion 4 can be activated independently of the front extension portion 3 by way of pressure or pulling pulses applied to its front panel 4 ′.
FIG. 3 d shows a further embodiment of the invention. The illustrated Figure diagrammatically shows a switching element 13 operative between the two ejection devices 9 and 9 ′. The switching element 13 has at least two switching positions, wherein the switching element 13 couples the two drawers 3 and 4 in a first switching position and uncouples them in a second switching position. When the ejection device 8 of the front extension portion 3 is activated the internal extension portion 4 also moves or does not move with the front extension portion 3 , depending on the respective switching position.
The switching element 13 can also be part of a program logic of a control and/or regulating device 14 by which the at least two ejection devices 9 and 9 ′ are selectively controllable and actuatable. Various triggering pulses can be implemented by preferably manually applying a pulling and/or pressing force to the front panel 3 ′ of the front extension portion 3 . In that respect, it can be provided for example that the ejection device 9 ′ of the internal extension portion 4 is not activated when pressure is preferably applied once to the front panel 3 ′ of the front extension portion 3 . In an advantageous development, it can also be the case that the ejection device 9 ′ is activated upon preferably two successive applications of pressure to the front panel 3 ′ of the front extension portion 3 within a predetermined or predeterminable period of time.
The invention is not limited to the illustrated embodiments by way of example but embraces or extends to all technical equivalents which can fall within the scope of the appended claims. The positional references adopted in the description such as for example up, down, lateral and so forth refer to the directly described and illustrated Figure and in the event of a change in position are to be correspondingly applied to the new position. The activation options described in respect of the individual ejection devices are to be interpreted only by way of example as a large number of further possible options are to be implemented for one of ordinary skill in the art concerned with the technical object here. | A piece of furniture with a furniture body and a first and at least one second drawer, displaceable relative to the furniture body, the front panel of the first drawer essentially completely covering the front panel or front wall of the second drawer in the closed position for both drawers, characterized in that the first and the at least one second drawer comprise an opening device for displacing the drawers from a closed position to an open position and a switch element is provided between both opening devices which couples both opening devices in a first switch position and uncouples the same in a second switch position. | 0 |
TECHNICAL FIELD
[0001] The present invention relates to technologies for prohibiting unnecessary delivery of electronic mail (email) to users.
RELATED ART
[0002] In recent years, some types of emails, such as ‘junk’ emails or advertising emails, have become a serious problem for users, who do not wish to receive such emails.
[0003] The email server apparatus disclosed in patent publication JP H10-161949A, 1) stores keywords sent from an email user; 2) determines, when receiving an email addressed to the user, whether the received email contains any of the stored keywords; and 3) delivers the received email to the user when the received email contains any of the stored keywords. Using such an email server apparatus, a user is able to configure the server apparatus not to deliver emails which contain no pre-stored keywords.
[0004] However, even if such an email server apparatus is employed, there exists a problem that an unwanted email may contain one or more of the pre-stored keywords, and may, therefore, still be delivered to the user, depending on the keyword settings. There exists a further problem that it is difficult properly for an email user who receives many emails to set keywords such that only desired email is delivered to the user.
SUMMARY OF INVENTION
[0005] The present invention provides a server apparatus which has:
[0006] a receiving means for receiving email;
[0007] a storage means for storing, in association with an email address, screening data for screening the email;
[0008] a determining means for
determining an email address indicating an addressee from the email received by the receiving means, reading from the storage means the screening data associated with the determined email address, determining whether to deliver the email to the addressee based on the read screening data, and outputting a determination result;
[0013] a reporting means for reporting information indicating the result determined by the determining means to the determined email addressee if the result is “not deliver”; and
[0014] a delivery means for delivering the received email to the determined email addressee if the result is “deliver”.
[0015] According to the present invention, it is preferable that:
[0016] the receiving means has a clock means for obtaining a current time;
[0017] the storage means stores data indicating a trial period; and
[0018] the delivery means delivers the received email to the determined email addressee while the current time obtained by the clock means is within the trial period, even if the determination result is “not deliver”. The present invention is further characterized by a reporting means reporting the determination result to the sender of the received email when the email address determined by the determining means is a user's first email address.
[0019] The present invention is further characterized by the determining means storing a history of the determination results in the storage means, in association with the determined email address; and by the reporting means reporting the history of the determination results to the determined email address.
[0020] The present invention is further characterized by
[0021] the storage means storing an order of priority in association with the delivery screening data and an order of priority in association with the non-delivery screening data, respectively, if the screening data includes both delivery screening data for screening email to be delivered and non-delivery screening data for screening email not to be delivered;
[0022] the determining means outputting the determination result of “deliver”, if received email contains only delivery screening data;
[0023] outputting the determination result of “not deliver” if received email contains only non-delivery screening data;
[0024] reading from the storage means the order of priority for the screening data contained in the received email if the screening data includes both delivery screening data and non-delivery screening data, and outputting the determination result of “deliver” if the screening data with the highest order of priority is delivery screening data, and outputting the determination result of “not deliver” if the screening data with the highest order of priority is non-delivery screening data.
[0025] Further, it is preferable that the order of priority for delivery screening data and the order of priority for non-delivery screening data be stored for each email address.
[0026] The present invention is further characterized by the storage means storing one or more screening data candidates in association with category information; the server apparatus further having a sending means for sending category information on a plurality of screening data candidates to a communication terminal capable of receiving email; the receiving means receiving an email address assigned to a user of the communication terminal and sent from the communication terminal along with the category information selected by the user of the communication terminal from among the category information on a plurality of screening data candidates sent by the sending means and sent from the communication terminal; and the storage means storing, in association with the email address received by the receiving means, one or a plurality of screening data candidates associated with the category information received by the receiving means.
[0027] The present invention is further characterized by the storage means storing screening data candidates, if the received email contains the screening data candidate in a case that the email address determined by the determining means is a second email address.
[0028] It is further preferable that morphological analysis be performed to determine whether screening data candidates are included in the received email.
BRIEF DESCRIPTION OF DRAWINGS
[0029] FIG. 1 is a view showing an entire configuration of a communications system according to an embodiment of the present invention.
[0030] FIG. 2 illustrates subscriber data stored in a subscriber database device 500 according to an embodiment of the present invention.
[0031] FIG. 3 is a view showing a configuration of an email server apparatus 600 according to an embodiment of the present invention.
[0032] FIG. 4 illustrates content of a data table TB 1 .
[0033] FIG. 5 illustrates content of a character string table TB 2 .
[0034] FIG. 6 illustrates content of a history table TB 3 .
[0035] FIG. 7 is an example of a valid/invalid setting screen.
[0036] FIG. 8 is an example of a character string registration screen.
[0037] FIG. 9 is a flowchart showing a processing procedure for a CGI setting program according to an embodiment of the present invention.
[0038] FIG. 10 is a flowchart showing a processing procedure for a CGI character string registration program according to an embodiment of the present invention.
[0039] FIG. 11 is a flowchart showing a flow of a process when an email server apparatus receives email according to an embodiment of the present invention.
[0040] FIG. 12 is a flowchart showing a flow of a character string registration process according to an embodiment of the present invention.
[0041] FIG. 13 is a flowchart showing a flow of a test process according to an embodiment of the present invention.
[0042] FIG. 14 is a flowchart showing a flow of an email screening process according to an embodiment of the present invention.
[0043] FIG. 15 is a flowchart showing a flow of a history output process according to an embodiment of the present invention.
[0044] FIG. 16 is an example of a screen displayed immediately after a mobile phone 700 launches browser software.
[0045] FIG. 17 is an example of a screen wherein the mobile phone 700 displays a list of received email.
[0046] FIG. 18 is an example of a screen wherein the mobile phone 700 displays a received email.
[0047] FIG. 19 is an example of a screen wherein the mobile phone 700 displays a forwarding screen for an email.
[0048] FIG. 20 is a view showing an example of an expression used by the email server apparatus during a test process according to an embodiment of the present invention.
[0049] FIG. 21 is a view showing an example of an expression used by the email server apparatus during the test process according to an embodiment of the present invention.
[0050] FIG. 22 is a view showing an example of a body of an email.
[0051] FIG. 23 is a view showing an example of an expression used by the email server apparatus during an email screening process during a trial period according to an embodiment of the present invention.
[0052] FIG. 24 is a view showing an example of an expression used by the email server apparatus during an email screening process during a trial period according to an embodiment of the present invention.
[0053] FIG. 25 is an example of a screen wherein the mobile phone 700 displays a list of received emails.
[0054] FIG. 26 is an example of a screen wherein the mobile phone 700 displays a received email.
[0055] FIG. 27 is an example of a screen wherein the mobile phone 700 displays a forwarding screen for an email.
[0056] FIG. 28 is a view showing an example of an expression used by the email server apparatus during a character string registration process according to an embodiment of the present invention.
[0057] FIG. 29 is a view showing an example of a history of undelivered email generated by the email server apparatus according to an embodiment of the present invention.
[0058] FIG. 30 is an example of a registered character string confirmation screen according to a variation of the present invention.
[0059] FIG. 31 is an example of a screen wherein the mobile phone 700 displays a list of character strings for screening registered in the email server apparatus 600 .
[0060] FIG. 32 is an example of a character string deletion screen according to a variation of the present invention.
[0061] FIG. 33 is an example of a screen displayed according to a variation of the present invention.
[0062] FIG. 34 is an example of a reception rejection test screen according to a variation of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0063] Below is a description of an embodiment according the present invention, referring to the drawings.
[0000] A. Configuration
[0000] A-1. Communication System 10
[0064] FIG. 1 shows an entire configuration of a communications system 10 used together with an email server apparatus 600 according to an embodiment of the present invention.
[0065] The communications system 10 has a plurality of personal computers PC 100 , Internet 200 which is connected to each PC 100 , a mobile packet communications network 300 which is connected to the Internet 200 , and a plurality of mobile phones 700 covered by the mobile packet communications network 300 . To keep the drawing simple, only one mobile phone 700 and one PC 100 are illustrated in FIG. 1 .
[0066] The PC 100 is a personal computer which can connect to the Internet 200 . The PC 100 includes packet communications functionality and functionality for sending and receiving email according to a protocol such as SMTP (Simple Mail Transfer Protocol) or POP (Post Office Protocol). The PC 100 stores an email address “aaa@gxyz.cojp” granted to a user of the PC 100 .
[0067] The Internet 200 is connected to email server apparatuses, which are not illustrated. The PC 100 sends and receives email to and from the email server apparatuses.
[0068] The mobile packet communications network 300 provides packet data communications services to persons subscribed to a data communications service (hereafter referred to as “subscribers”) offered by a communications provider which operates the mobile packet communications network 300 (hereafter referred to as “communications provider”). The mobile packet communications network 300 has a gateway server apparatus 400 which is connected to the Internet 200 shown in FIG. 1 , a subscriber database device 500 and the email server apparatus 600 which are connected to the gateway server apparatus 400 , and wireless base stations, switching devices connected to the wireless base stations, and gateway switches connected to the switching devices and fixed-line telephone networks, which are not illustrated.
[0069] The gateway server apparatus 400 reciprocally converts protocols between the protocol used within the mobile packet communications network 300 and TCP/IP (Transmission Control Protocol/Internet Protocol) used in the Internet 200 .
[0070] As shown in FIG. 2 , the subscriber database device 500 stores subscriber data including names, a terminal identifier and telephone number for the mobile phone being used, an email address, and a residential address, for each subscriber. The subscriber's email address is assigned by the communications provider.
[0071] The email server apparatus 600 includes WWW (World Wide Web) server functionality, in addition to email server functionality. The email server apparatus 600 further includes functionality for screening emails containing character strings specified by the subscriber and prohibiting the screened emails from being delivered to the mobile phone 700 used by the subscriber. The email server apparatus 600 is described in greater detail below.
[0072] The mobile phone 700 includes a function for performing packet communications via the mobile packet communications network 300 , a function for executing email software for sending and receiving email, and a function for performing communications in accordance with HTTP (Hyper Text Transfer Protocol) by executing WWW browser software (hereafter referred to as “browser software”) which can interpret text files written using CHTML (Compact Hyper Text Markup Language) (hereafter referred to as “CHTML files”). The mobile phone 700 stores a terminal identifier “MS0001” for identifying the mobile terminal device 700 and an email address, for example “ichiro@abc.nejp,” assigned to the user of the mobile phone 700 .
[0000] A-2. Mail Server Apparatus 600
[0073] FIG. 3 shows a configuration of an email server apparatus 600 . As shown in FIG. 3 , the email server apparatus 600 has a bus 601 , a communication unit 602 which is connected to the bus 601 , an operating unit 603 , a display unit 604 , a clock unit 605 , a storage unit 606 , a ROM (Read Only Memory) 607 which stores initialization software, etc., for initializing each portion of the email server apparatus 600 , a RAM (Random Access Memory) 608 , and a CPU (Central Processing Unit) 609 .
[0074] The bus 601 performs data transmission with each portion connected to the bus 601 .
[0075] The communication unit 602 is connected to a gateway server apparatus 400 via a communication line. The communication unit 602 is used when the email server apparatus 600 communicates with other devices.
[0076] The operation portion 603 has a keyboard and a mouse. When the operating unit 603 is operated, signals are supplied to the CPU 609 in response to the operation.
[0077] The display unit 604 has an LCD panel and control circuitry thereof. The display unit 604 displays characters, graphics, menu screens, etc., in the LCD panel under control from the CPU 609 .
[0078] The clock unit 605 supplies information indicating current date and time to the CPU 609 .
[0079] The storage unit 606 is configured such that it has a device for permanent storage of data, such as, for example, a hard disk device. The storage unit 606 stores a data table TB 1 , a character string table TB 2 , a history table TB 3 , a first CHTML file and a first CGI (Common Gateway Interface) program, a second CHTML file and a second CGI program, email server software, and general WWW server software, etc. The storage unit 606 includes a mailbox for storing email for every email address assigned to the subscriber. Once power is supplied from a power source, the CPU 609 reads the initialization software stored in the ROM 607 and initializes each portion of the email server apparatus 600 , using the RAM 608 as a work area. Once initialization of each portion is finished, the CPU 609 reads and launches the email server software and WWW server software stored in the storage unit 606 .
[0080] As shown in FIG. 4 , the data table TB 1 associates valid/invalid setting data, character strings (hereafter referred to also as “character strings for screening”), and a trial period due date with email addresses assigned to subscribers, and stores this data. The CPU 609 refers to the data table TB 1 when determining whether to deliver received email to the subscriber. The valid/invalid setting data is data for setting email screening to valid or invalid. If the valid/invalid setting data is set to valid, the email server apparatus 600 screens received email to be delivered and email not to be delivered, and deletes email not to be delivered from the area where it is temporarily stored. The character strings for screening are character strings used when screening email to be delivered and email not to be delivered to the subscriber. The trial period due date is the final date of a fixed period, after which screening process of email is prevented from operating fully, even if the valid/invalid setting data is set to valid by the subscriber. The period will be referred to as a “trial period” hereafter.
[0081] As shown in FIG. 5 , the character string table TB 2 stores character strings for screening, extracted through analysis of unwanted bulk email and unsolicited email advertisements by the communications provider and registered in advance. The character string table TB 2 is used when the subscriber registers character strings for screening in the data table TB 1 .
[0082] As shown in FIG. 6 , the history table TB 3 associates email addresses of email addressees to whom an email is determined not to be delivered with the reception date, subject line, and email address of the sender of the email, and stores this information.
[0083] The first CHTML file (hereafter referred to as the “settings file”) is written such that a valid/invalid setting screen is displayed, which has a “Set” button, valid/invalid radio buttons, and a textbox BX 11 , as shown in FIG. 7 , when the settings file is interpreted by the browser software operating in the mobile phone 700 . The first CGI program (hereafter referred to as the “CGI setting program”) is a CGI program which causes the CPU 609 to execute a process shown in FIG. 9 . The settings file is specified by, for example, the URL (Uniform Resource Locator) “http://www.abc.ne.jp/settei.html”. The CGI setting program is specified by, for example, the URL “http://www.abc.nejp/settei.cgi”. When the “Set” button shown in FIG. 7 is clicked, the settings file is written such that an HTTP request is sent with the URL of the CGI settings file, etc., as parameters. The settings file and CGI setting program are used when the subscriber registers valid/invalid setting data to the data table TB 1 .
[0084] Specifically, when the CPU 609 receives an HTTP request containing a URL for the settings file from the mobile phone 700 , it reads the settings file specified in the URL from the storage unit 606 . The CPU 609 generates an HTTP response including the read settings file and sends the generated HTTP response to the mobile phone 700 via the communication unit 602 . When, in the mobile phone 700 displaying a valid/invalid setting screen such as that shown in FIG. 7 , an email address is entered into the textbox BX 11 , one of the valid/invalid radio buttons is selected, and the operation of clicking the “Set” button (hereafter referred to as “clicking the button”) is performed, the browser software sends an HTTP request with the URL of the CGI setting program, the entered email address, and the valid/invalid setting data as parameters. When the CPU 609 receives the HTTP request, it launches the CGI setting program specified by the URL and performs the process shown in FIG. 9 .
[0085] The second CHTML file (hereafter referred to as the “character string registration file”) is written such that a character string registration screen is displayed which has a “Register” button and textboxes BX 21 and BX 22 , as shown in FIG. 8 , when the character string registration file is interpreted by the browser software operating in the mobile phone 700 . When the “Register” button in FIG. 8 is clicked, the character string registration file is written such that an HTTP request and the URL of the CGI character string registration file, etc., are sent as parameters. The second CGI program (hereafter referred to as the “CGI character registration program”) is a CGI program which causes the CPU 609 to execute a process shown in FIG. 10 . The character string registration file is specified by, for example, the URL “http://www.abc.ne.jp/toroku.html”. The CGI character string registration program is specified by, for example, the URL “http://www.abc.nejp/toroku.cgi”. The character string registration file and CGI character string registration program are used by the subscriber when registering character strings for screening. Specifically, when the CPU 609 receives an HTTP request containing a URL for the character string registration file from the mobile phone 700 , it reads the character string registration file specified in the URL from the storage unit 606 . The CPU 609 generates an HTTP response including the read character string registration file and sends the generated HTTP response to the mobile phone 700 via the Communication unit 602 . When, in the mobile phone 700 displaying a character string registration screen such as that shown in FIG. 8 , an email address is entered into the textbox BX 21 , a character string is entered into the textbox BX 22 , and the “Register” button is clicked, the browser software sends an HTTP request with the URL of the CGI character string registration program and the entered email address and character string as parameters. When the CPU 609 receives the HTTP request, it launches the CGI character string registration program specified by the URL and performs the process shown in FIG. 10 .
[0086] The email server software is software that causes the CPU 609 to execute the processes shown in FIG. 11 through FIG. 15 . FIG. 11 shows a flow of an entire process performed by the CPU 609 when an email is received. As shown in FIG. 11 , the CPU 609 performs a process in accordance with the email address (hereafter referred to as the “destination email address”) that indicates the addressee of the received email. If the CPU 609 determines that the destination email address is an email address for registration assigned to the email server apparatus 600 for registering character strings for screening, for example “toroku@abc.nejp”, then it performs the character string registration process shown in FIG. 12 . If the CPU 609 determines that the destination email address is a trial email address assigned, to the email server apparatus 600 , for testing the function of screening email, for example “test@abc.nejp”, then it performs the test process shown in FIG. 13 . If the CPU 609 determines that the destination email address is not either of the email addresses described above assigned to the email server apparatus 600 , then it executes the email screening process shown in FIG. 14 . The CPU 609 also executes the history output process shown in FIG. 15 when it detects that the month has changed. Each process is described in detail below.
[0000] B. Operating Example of the Mail Server Apparatus 600
[0000] B-1. Operations in Trial Period Setting Process
[0087] When the screen in FIG. 16 is displayed on the LCD display of the mobile phone 700 , if a user of the mobile phone 700 (hereafter referred to simply as the “user”) enters the URL for the settings file “http://www.abc.ne jp/settei.html” in a textbox BX 31 in FIG. 16 and clicks a “Display” button, the mobile phone 700 generates an HTTP request including the URL of the entered settings file and sends it to the email server apparatus 600 .
[0088] When, in the email server apparatus 600 , the CPU 609 receives the HTTP request via the Communication unit 602 , it reads the settings file specified by the URL of the settings file included in the HTTP request from the storage unit 606 , generates an HTTP response including the read settings file, and sends it to the mobile phone 700 via the Communication unit 602 .
[0089] When the mobile phone 700 receives this HTTP response, it extracts the settings file included in the HTTP response, interprets the extracted settings file, and displays the screen shown in FIG. 7 to the LCD display. When the user enters his/her assigned email address “ichiro@abc.nejp” in the textbox BX 11 in FIG. 7 , selects “valid” from the valid/invalid radio buttons, and clicks the “Set” button, the browser software generates an HTTP request containing data indicating “valid,” the URL of the CGI setting program, and the entered email address, and sends it to the email server apparatus 600 .
[0090] When, in the email server apparatus 600 , the CPU 609 receives the HTTP request via the Communication unit 602 , it reads the CGI setting program specified by the URL of the CGI setting program contained in the HTTP request from the storage unit 606 and executes the read CGI setting program ( FIG. 9 ). The CPU 609 extracts the email address “ichiro@abc.nejp” contained in the HTTP request (step SA 1 ). Since data indicating “valid” is contained in the HTTP request, the CPU 609 sets to “valid” the “valid/invalid setting data” field in the data table TB 1 corresponding to this email address (step SA 2 ). The CPU 609 obtains information indicating the current date from the clock unit 605 , calculates, from the obtained current date, a date which is the ending date for the trial period (in this example, one week ahead), associates the calculated date with the email address, and sets it in the “trial period due date” field in the data table TB 1 corresponding to the email address (step SA 3 ).
[0091] By this process, the “valid/invalid setting data” field in the data table TB 1 is validated, and the date is set in the “trial period due date” field.
[0000] B-2. Operation 1 of Registering Character Strings for Screening
[0092] When the screen in FIG. 16 is displayed in the LCD display of the mobile phone 700 , if the user enters the URL for the character string registration file “http://www.abc.ne.jp/toroku.html” in the textbox BX 31 shown in FIG. 16 and clicks the “Display” button, the mobile phone 700 generates an HTTP request containing the URL of the entered character string registration file and sends it to the email server apparatus 600 .
[0093] When, in the email server apparatus 600 , the CPU 609 receives the HTTP request, it similarly reads the character string registration file from the storage unit 606 and sends an HTTP response including the read character string registration file to the mobile phone 700 .
[0094] When the mobile phone 700 receives the HTTP response, it displays the screen shown in FIG. 8 on the LCD display. When the user enters the email address “ichiro@abc.nejp” in the textbox BX 21 in FIG. 8 and “futures trading” in the textbox BX 22 and clicks the “Register” button, an HTTP request is generated including the email address entered in textbox BX 21 , the character string entered in textbox BX 22 , and the URL of the CGI character string registration program, and is sent to the email server apparatus 600 .
[0095] When, in the email server apparatus 600 , the CPU 609 receives the HTTP request, it reads the CGI character string registration program from the storage unit 606 and executes it ( FIG. 10 ). The CPU 609 extracts the email address “ichiro@abc.nejp” included in the HTTP request (step SB 1 ). When the CPU 609 searches the data table TB 1 based on the email address and finds the appropriate email address, it registers the character string “futures trading” included in the HTTP request in the “character string” field in the data table TB 1 corresponding to the email address (step SB 2 ).
[0096] In this fashion, character strings for screening are registered in the data table TB 1 .
[0000] B-3. Operations in Test Process
[0097] As shown in FIG. 17 , when a list of received emails is displayed in the LCD display of the mobile phone 700 , if the user performs the operation of selecting an email with the subject line “strike it rich”, the mobile phone 700 displays the selected email in the LCD display as shown in FIG. 18 . When the user clicks a “Forward” button in FIG. 18 , the mobile phone 700 displays a forward screen shown in FIG. 19 in the LCD display for the selected email.
[0098] When the user enters the email address “test@abc.nejp” in a textbox BX 41 shown in FIG. 19 to use the test function, and clicks the “Send” button in FIG. 19 , the mobile phone 700 generates an email by writing the email address “ichiro@abc.nejp” assigned to the user and stored in the mobile phone 700 itself to the FROM field in the email headers, setting the entered email address for test as an recipientaddressee, and setting the content of the received email as the body, and sends it to the email server apparatus 600 .
[0099] When, in the email server apparatus 600 , the CPU 609 receives the email via the communication unit 602 , as shown in FIG. 11 , the email address specified as the recipientaddressee of the received email (hereafter referred to as the “destination email address”) is determined regarding whether it is the email address “toroku@abc.nejp” for registration (step SC 1 ). In this example, the destination email address is “test@abc.nejp”, so the determination in step SC 1 is “No.” Next, the CPU 609 determines whether the destination email address is the email address “test@abc.nejp” for testing (step SC 3 ). In this example, the destination email address is “test@abc.nejp”, so the CPU 609 determines “Yes” in step SC 3 and executes the test process (step SC 4 ).
[0100] Next, the test process operation in the email server apparatus 600 is described in detail, referring to FIG. 13 .
[0101] The CPU 609 extracts the email address “ichiro@abc.nejp” indicating the sender from the FROM field in the email header of the received email (hereafter referred to as the “sender email address”). The CPU 609 searches the data table TB 1 based on the extracted sender email address and reads the registered character string “futures trading” associated with the email address (step SE 1 ).
[0102] When the CPU 609 has read the character string for screening from the data table TB 1 , it determines whether the extracted character string for screening “futures trading” is present in the subject line or body of the received email (step SE 2 ). As shown in FIG. 19 , in this example the character string for screening “futures trading” is included in the body of the received email, so the CPU 609 determines that the received email is not to be delivered and generates an email, adding an expression along the lines of “not delivered” indicating the determination result, as shown in FIG. 20 , to the body of the received email (step SE 3 ). If the character string for screening “futures trading” is not included in the body of the received email, the CPU 609 determines that the received email is to be delivered and generates an email, adding an expression indicating the determination result that the message is to be “delivered”, as shown in FIG. 21 , to the body of the received email.
[0103] The CPU 609 stores the generated email in a mailbox identified by the extracted sender email address “ichiro@abc.nejp” (step SE 4 ) and sends an incoming notification to the mobile phone 700 , which is the sender, to report that an email has been stored in the mailbox (step SE 5 ).
[0104] When the mobile phone 700 receives the incoming notification, it generates an email request including its own terminal identifier “MS0001” and sends it to the email server apparatus 600 , requesting the email server apparatus 600 to send the generated email stored in the mailbox.
[0105] When, in the email server apparatus 600 , the CPU 609 receives this email request, it searches through the subscriber database device 500 based on the terminal identifier “MS0001” included in the email request, and reads the stored email address “ichiro@abc.ne.jp” which is associated with this terminal identifier. The CPU 609 reads the generated email stored in the email box identified by the read email address and sends it to the mobile phone 700 .
[0106] When the mobile phone 700 receives the generated email, it emits a sound alert to let the user know that the email has been received. Thereafter, when the user performs the operation of displaying the email, the mobile phone 700 displays the email to which the determination result has been added in the LCD display.
[0107] In this manner, the user can verify whether an email will be delivered or rejected by sending an email to an email address used for testing.
[0000] B-4. Operations in Email Screening Process during the Trial Period
[0108] As shown in FIG. 11 , when, in the email server apparatus 600 , the CPU 609 receives an email whose subject line is “looking for email friends” and whose body is the content illustrated in FIG. 22 , it determines whether the destination email address of the received email is “toroku@abc.nejp” (step SC 1 ). In this example, the destination email address is “ichiro@abc.nejp”, so the CPU 609 determines “No” in step SC 1 . Next, the CPU 609 determines whether the destination email address is “test@abc.nejp” (step SC 3 ). In this example, the destination email address is “ichiro@abc.nejp”, so the CPU 609 determines “No” in step SC 3 and executes the email screening process (step SC 5 ).
[0109] Next, the email screening process in the email server apparatus 600 during the trial period is described in detail, referring to FIG. 14 .
[0110] The CPU 609 extracts the destination email address “ichiro@abc.nejp” from the received email and reads the valid/invalid setting data corresponding to the extracted destination email address from the data table TB 1 . The CPU 609 determines whether the valid/invalid setting data is set to valid (step SF 1 ), and since it is set to “valid” in this example (step SF 1 Yes), it executes the processes from step SF 2 onward.
[0111] Next, the CPU 609 obtains the current date when the email was received (e.g., “Feb. 12, 200X) from the clock unit 605 , and reads the trial period due date (e.g., “Feb. 17, 200X”) corresponding to the destination email address from the data table TB 1 . The CPU 609 determines whether the trial period is valid based on whether the obtained current date has reached the trial period due date (step SF 2 ). In this example, the current date has not reached the trial period due date, so the CPU 609 determines that the trial period is valid (step SF 2 : Yes) and reads the character string for screening corresponding to the extracted destination email address from the data table TB 1 . The CPU 609 screens received email into items to be delivered and items not to be delivered based on whether the read character string for screening is written in the email (step SF 3 ). In this example, the character string for screening “futures trading” is not written in the received email whose destination email address is “ichiro@abc.nejp”, so the CPU 609 screens this email as an item to be delivered and generates an email in which expressions indicating that the “trial period is active” as exemplified in FIG. 23 and suggesting that character strings for screening can be registered (hereafter also referred to as the “message”) are added to the body of the received email (step SF 4 ). If the character string for screening is written in the received email, the CPU 609 screens the email as an item not to be delivered and generates an email in which an expression indicating that the “trial period is active” as exemplified in FIG. 24 is added. The CPU 609 stores the generated email in a mailbox identified by the destination email address “ichiro@abc.nejp” (step SF 5 ) and sends an incoming notification to the mobile phone 700 , which is the sender, to report that an email has been stored in the mailbox (step SF 6 ). When the mobile phone 700 receives this incoming notification, it performs the same process as described in B-3 and receives the email from the email server apparatus 600 . When the mobile phone 700 receives the email, it emits a sound to let the user know that the email has been received. Thereafter, when the user performs the operation of displaying the email, an email to which expressions have been added indicating that the “trial period is active” and suggesting that character strings for screening can be registered, is displayed on the LCD display.
[0000] B-5. Operation 2 of Registering Character Strings for Screening
[0112] An email server apparatus 600 according to the present embodiment may also perform a registration operation different from the registration operation for character strings for screening described in B-2. This is described below.
[0113] As shown in FIG. 25 , when a list of received emails is displayed on the LCD display of the mobile phone 700 , if the user performs an operation of selecting an email with the subject line “looking for email friends” received during the trial period, the mobile phone 700 displays the selected email on the LCD display as shown in FIG. 26 . When the user clicks a “Forward” button in FIG. 26 , the mobile phone 700 displays a forwarding screen shown in FIG. 27 on the LCD display for the selected email.
[0114] When the user enters the email address “toroku@abc.nejp” for registration in a textbox BX 51 shown in FIG. 27 , to register a character string for a screening function and clicks the “Send” button shown in FIG. 27 , the mobile phone 700 generates an email by writing the email address “ichiro@abc.ne jp” assigned to the user and stored in the mobile phone 700 to the FROM field in the email headers, setting the entered email address for registration as an addressee, and setting the content of the received email as the body, and sends it to the email server apparatus 600 .
[0115] When, in the email server apparatus 600 , the CPU 609 receives the email, as shown in FIG. 11 , it determines whether the destination email address of the received email is the email address “toroku@abc.nejp” for registration (step SC 1 ). In this example, the destination email address is “toroku@abc.nejp”, so the CPU determines “Yes” in step SC 1 and executes a character string registration process (step SC 2 ).
[0116] Next, the character string registration process operation in the email server apparatus 600 is described in detail, referring to FIG. 12 .
[0117] The CPU 609 breaks down the text in the received email into minimum unit character strings using morphological analysis (step SD 1 ). The CPU 609 determines whether a character string identical to any of the broken down character strings is registered in a character string table TB 2 (step SD 2 ). In this example, the CPU 609 determines “Yes,” since the character string “email friend”, which is written in the body of the received email, is registered in the character string table TB 2 shown in FIG. 5 .
[0118] When the CPU 609 determines “Yes” in step SD 2 , it reads the character string for screening “email friend” as identical to the broken down character string from the character string table TB 2 , associates the sender email address “ichiro@abc.nejp” extracted from the FROM field in the email headers of the received email, and registers this character string for screening to data table TB 1 (step SD 3 ). Next, the CPU 609 generates an email including the character string for screening exemplified in FIG. 28 and an expression reporting the registration thereof (step SD 4 ), stores this email in the mailbox identified with the sender email address (step SD 5 ) and sends an incoming notification to the mobile phone 700 which is the sender (step SD 6 ). When the mobile phone 700 receives this incoming notification, it performs the same process as described in B-3 and receives the email from the email server apparatus 600 . When the mobile phone 700 receives the email, it emits a sound to let the user know that the email has been received. Thereafter, when the user performs the operation of displaying the email, the character string for screening and the email reporting the registration thereof are displayed in the LCD display.
[0000] B-6. Operations in Email Screening Process after Expiration of the Trial Period
[0119] As shown in FIG. 11 , when, in the email server apparatus 600 , the CPU 609 receives an email whose subject line is, for example, “looking for email friends”, whose body is the content illustrated in FIG. 22 , and whose destination email address is “ichiro@abc.nejp”, this destination email address is neither an email address for registration nor an email for testing, so a determination of “No” is made at both step SC 1 and step SC 3 , and the email screening process (step SC 5 ) is executed.
[0120] Next, the email screening process in the email server apparatus 600 after the trial period is terminated is described in detail, referring to FIG. 14 .
[0121] The CPU 609 extracts the destination email address “ichiro@abc.nejp” from the received email and reads the valid/invalid setting data corresponding to the extracted destination email address from the data table TB 1 . The CPU 609 determines whether the valid/invalid setting data is set to valid (step SF 1 ), and since it is set to “valid” in this example (step SF 1 : Yes), it executes the processes from step SF 2 onward.
[0122] Next, the CPU 609 obtains the date when the email was received (e.g., “Feb. 19, 200X) from the clock unit 605 , and reads the trial period due date (e.g., “Feb. 17, 200X”) corresponding to the destination email address from the data table TB 1 . The CPU 609 determines whether the trial period is valid based on whether the obtained current date has reached the trial period due date (step SF 2 ). In this example, the CPU 609 determines that the trial period is terminated, since the current date falls after the expiry date of the trial period (step SF 2 : No).
[0123] In this example, the trial period has terminated, so the CPU 609 reads the character strings for screening “futures trading” and “email friend” corresponding to the received destination email address “ichiro@abc.nejp” from the data table TB 1 . The CPU 609 determines whether the read character strings for screening are written in the received email (step SF 7 ). In this example, the character string for screening “email friend” is contained in the received email, so the CPU 609 determines that this email is an item not to be delivered (step SF 7 : Yes).
[0124] When the CPU 609 determines “Yes” in step SF 7 , it extracts the subject line, sender email address, and destination email address from the email headers of the received email. The CPU 609 associates the subject line, sender email address, and reception date with the destination email address of the received email and stores them in a history table TB 3 as shown in FIG. 6 (step SF 8 ). The CPU 609 deletes the email by not storing it in a mailbox (step SF 9 ).
[0125] In this manner, after the trial period is terminated, emails containing character strings for screening are no longer delivered to the mobile phone 700 .
[0000] B-7. Operations in History Output Process
[0126] The history output operation in the email server apparatus 600 is described in detail, referring to FIG. 15 .
[0127] In the email server apparatus 600 , the CPU 609 obtains the current date on a regular basis from the clock unit 605 , thereby monitoring the changing of the months. When the CPU 609 detects that the month has changed, it reads from a history table TB 3 a subject line “looking for email friends” from emails that were not delivered to email address “ichiro@abc.nejp”, a sender email address “aaa@abc.cojp”, and a reception date “Jan. 19, 200X”, for example (step SG 1 ). From the data read from the history table TB 3 , the CPU 609 generates an email in a list format shown in FIG. 29 (step SG 2 ). The CPU 609 stores it in a mailbox identified by the email address “ichiro@abc.nejp” (step SG 3 ) and sends an incoming notification to the mobile phone 700 (step SG 4 ). When the mobile phone 700 receives this incoming notification, it performs the same process as described in B-3 and receives the email from the email server apparatus 600 . When the mobile phone 700 receives the email, it emits a sound to let the user know that the email has been received. Thereafter, when the user performs the operation of displaying the email, the mobile phone 700 displays a list of emails that were not delivered in the LCD display.
[0128] As described above, by use of the email server apparatus 600 according to the present embodiment, a user of a mobile phone 700 can set up a screening process for email based on a test process and a history output process, and, accordingly, the user of the mobile phone 700 can repeatedly consider and register character strings for screening so that only necessary email is delivered.
[0129] It is generally believed that few people want to receive so-called junk email or unsolicited email advertisements, so when a contract regarding use of a data communication service provided by a mobile packet communications network 300 is entered into, a majority of email users prefer that the valid/invalid setting data be set to valid as a default setting, before setting the valid/invalid setting data to valid. However, there may be some email users who wish to receive emails such as unsolicited email advertisements and unwanted bulk email. If a trial period were not provided, subscribers could use the data communication service after entering into a subscription contract, but at the same time unsolicited email advertisements and unwanted bulk email would no longer be delivered, which would not be a desirable situation for people actually wishing to receive unsolicited email advertisements and unwanted bulk email. However, since a trial period is provided in the present embodiment, unwanted bulk email, etc., is delivered for a fixed period of time for people wishing to receive this type of email. As shown in FIG. 23 and FIG. 24 , determination results of email screening and notices regarding screening of emails are added to emails delivered during the trial period, so the email server apparatus 600 informs users who wish to receive unwanted bulk email that a process for screening email is performed. This allows users wishing to receive email generally referred to as unwanted bulk email to modify the valid/invalid setting data and receive email generally considered to be unwanted bulk email.
[0000] C. Variations
[0130] (1) An email server apparatus 600 sends a mobile phone 700 an HTML file for displaying on a screen of the mobile phone a list of category names such as “adult”, “futures trading”, etc. The mobile phone 700 sends the email server apparatus 600 information indicating categories specified by a user from among the categories displayed on the screen. The email server apparatus 600 may associate a plurality of character strings with the categories and store them in a single operation in a data table TB 1 .
[0131] (2) It is also possible to deliver only emails which contain registered character strings for screening. It is also possible to set whether to deliver or not to deliver based on registered character strings for screening.
[0132] (3) It is also possible to set individually for each character string for screening whether the character string is to be used for determining whether to deliver or not to deliver. Further, it is also possible to allow the setting of an order of priority among a plurality of registered character strings for screening, and, for example, to determine whether to deliver an email based on this order of priority, in a case that an email is received which contains both character strings the screening of which result in a determination to deliver and character strings the screening of which result in a determination not to deliver.
[0133] (4) It is also possible to register information indicating character encoding, and to have only email in which registered character encodings are used delivered.
[0134] (5) It is also possible to use other methods in combination, such as a method in which emails from sender email addresses with specified domain names are not delivered or a method in which emails with specified sender email addresses are delivered, etc.
[0135] (6) If this technology is applied to an email server apparatus for personal computers, for example, it is possible to deliver email which has been screened to ordinary personal computers.
[0136] (7) It is also possible that the email server apparatus 600 registers character strings for screening by considering frequencies of appearance of character strings, if character strings are registered by performing of morphological analysis on emails.
[0137] (8) It is also possible to set valid/invalid data for character strings such as, for example, “unsolicited advertisement *” which are used in unnecessary emails in a complex manner, and register them as character strings for screening.
[0138] (9) It is also possible for the email server apparatus 600 to perform the trial period setting process and character string for screening registration process as a single series of processes.
[0139] (10) It is also possible for the email server apparatus 600 to send the mobile phone 700 a list of character strings for screening registered in a character string table. Specifically,
[0140] (11) The email server apparatus 600 may store a third HTML file (hereafter referred to as a “character string verification file”) for displaying the screen shown in FIG. 30 in browser software and a CGI program (hereafter referred to as a “CGI list display program”) for displaying character strings for screening registered in the email server apparatus 600 in the browser software. When the mobile phone 700 sends the email server apparatus 600 an HTTP request including a URL for the character string verification file, the email server apparatus 600 sends an HTTP response including the character string verification file to the mobile phone 700 . When the mobile phone 700 receives the HTTP response, it interprets the included third HTML file and displays the screen in FIG. 30 in the LCD display. When the user enters an assigned email address in a textbox BX 61 shown in FIG. 30 and clicks a “Display List” button, the mobile phone 700 sends the email server apparatus 600 an HTTP request containing the entered email address and a URL for the CGI list display program. When the email server apparatus 600 receives the HTTP request, it executes the CGI list display program. Next, the email server apparatus 600 extracts character strings for screening stored in the data table TB 1 associated with the email address contained in the HTTP request, and generates a fourth HTML file for displaying the extracted character strings in list format in the browser software. The email server apparatus 600 sends the mobile phone 700 an HTTP response containing the generated file. The HTML file contained in the HTTP response received by the mobile phone 700 is interpreted by the browser software, and the mobile phone 700 displays a list of character strings for screening, shown in FIG. 31 , to the LCD display.
[0141] By this process, the user can verify the character strings for screening stored in the email server apparatus 600 via the LCD display of the mobile phone 700 .
[0142] It is also possible that deletion and additional registration of character strings for screening stored in the email server apparatus 600 can be performed from the list display shown in FIG. 31 . Specifically, the email server apparatus 600 may store a fifth HTML file (hereafter referred to as a “character string deletion file”) for displaying the screen shown in FIG. 32 in browser software and a CGI program (hereafter referred to as a “CGI character string deletion program”) for deleting character strings for screening registered in the email server apparatus 600 . The fourth HTML file contains a link to the character string deletion file associated with a “Delete” button shown in FIG. 31 . When the user clicks the “Delete” button shown in FIG. 31 , the mobile phone 700 generates an HTTP request containing the URL of the character string deletion file, and sends the generated HTTP request to the email server apparatus 600 . When the email server apparatus 600 receives the HTTP request, it sends an HTTP response containing the character string deletion file to the mobile phone 700 . When the mobile phone 700 receives the HTTP response, it interprets the included fifth HTML file and displays the screen shown in FIG. 32 . When the user enters his or her assigned email address in a textbox BX 71 shown in FIG. 32 and a character string to delete in a textbox BX 72 and clicks the “Delete” button, the mobile phone 700 sends the email server apparatus 600 an HTTP request containing the entered email address, a URL for the CGI character string deletion program, and the entered character string. When the email server apparatus 600 receives the HTTP request, it executes the CGI character string deletion program. Next, the email server apparatus 600 deletes from the data table TB 1 the character string contained in the HTTP request associated with the email address contained in the HTTP request. In this fashion, the user of the mobile phone 700 can delete unnecessary character strings for screening from the list of character strings for screening stored in the email server apparatus 600 .
[0143] (12) It is also possible to send only character strings for screening to the email server apparatus 600 when using the test function, and return a result regarding how an email containing the character strings for screening is determined.
[0144] (13) It is also possible for the history table TB 3 to store the body texts of undelivered emails. In this case, it is also possible to select and receive emails stored in the history table TB 3 .
[0145] (14) It is also possible for the user to access the email server apparatus 600 and see a history of undelivered email at any time. It is also possible to change the schedule for sending the history of undelivered email. It is also possible to view the history of undelivered email using browser software using a CGI program, etc.
[0146] (15) It is also possible to send the results of the test process or email screening process in a separate email.
[0147] (16) It is also possible, with regard to text added to emails during the trial period, to add a text informing the user that the email server apparatus 600 is capable of screening email. It is also possible to provide a method for forcibly terminating the trial period, using a CGI program, etc., for people who do not require the trial period.
[0148] (17) It is also possible to rewrite server software stored in the storage unit 606 . For example, it is possible to store the server software on a storage medium such as a CD-ROM (Compact Disc Read Only Memory), etc., insert this CD-ROM in a CD-ROM drive provided at the email server apparatus 600 , cause the server software to be read, and thus install the server software. Possible storage media include DVD-ROMs, IC cards with built-in flash ROM, computer disks, etc. It is also possible to download and install the server software from a server apparatus connected to the Internet.
[0149] (18) It is also possible, when using the test function, to perform tests by sending emails newly written by the user.
[0150] (19) If the language used for writing the email is, for example, English, spaces between character strings may be used to extract character strings.
[0151] (20) It is also possible to create an email by combining an expression indicating the result of the test process or email screening process during the trial period with a report of the result from the subject line of a received email, and to send this to the mobile phone 700 .
[0152] (21) It is also possible for the gateway server apparatus 400 to act as an email server apparatus 600 . It is also possible for the gateway server apparatus 400 to act as a subscriber database device 500 .
[0153] (22) The subscriber database device 500 associates terminal identifiers, assigned telephone numbers, and email addresses of mobile phones 700 being used with subscribers' names and stores this data. It is also possible, when the mobile phone 700 sends the email server apparatus 600 valid/invalid setting data and/or character strings for screening, to send the terminal identifier stored in the mobile phone 700 instead of an email address, and for the email server apparatus 600 to read the email address associated with the received terminal identifier of the mobile phone 700 and stored in the subscriber database device 500 , and store the valid/invalid setting data and/or character string, associating this with the read email address. By this process, the user of the mobile phone 700 does not need to enter an email address every time he or she registers a valid/invalid setting and/or character strings. It is also possible for the mobile phone 700 to store the telephone number assigned to the user and to send the stored telephone number.
[0154] (23) It is also possible for the email server apparatus 600 to send the mobile phone 700 a sixth HTML file for displaying the screen shown in FIG. 33 when it receives an HTTP request, and for the mobile phone 700 to display the screen shown in FIG. 33 by having browser software interpret the sixth HTML file. It is also possible, when the user clicks the “Next” button shown in FIG. 33 , for the mobile phone 700 to obtain the character string registration file described above from the email server apparatus 600 and to display it. By this process, by making it possible to scroll through screens in order, the user does not need to remember or enter individual URLs for pages for registering character strings every time, making use of the mobile phone 700 easier for the user.
[0155] The email server apparatus 600 stores a seventh HTML file for displaying the screen shown in FIG. 34 and a CGI program (hereafter referred to as a “CGI test program”) for sending the mobile phone 700 the determination result for text entered in a textbox BX 82 shown in FIG. 34 . It is also possible for the email server apparatus 600 to execute the CGI character string registration program when it receives an HTTP request and to send the seventh HTML file to the mobile phone 700 . In this fashion, the screen shown in FIG. 34 is displayed in the mobile phone 700 after the email server apparatus 600 registers character strings for screening. When the user enters his or her assigned email address in a textbox BX 81 shown in FIG. 34 , and verification text in a textbox BX 82 , and clicks the “Test” button, the mobile phone 700 sends the email server apparatus 600 an HTTP request containing a URL for the CGI test program and the entered email address. It is also possible for the email server apparatus 600 to execute the CGI test program when it receives the HTTP request, determine the text contained in the received HTTP request, and send the determination result to the mobile phone 700 . By this process, the user can set valid/invalid, and register character strings to complete test reception rejection in order. | Character strings for selecting received emails are registered in an email server apparatus ( 600 ). When receiving an email addressed to the user of a mobile phone ( 700 ), the email server apparatus ( 600 ) uses the character strings to select the email. When it is during a trial period, the email server apparatus ( 600 ) delivers the received email with a selection result addressed thereto. When it is after the trial period, the email server apparatus ( 600 ) retains, as a history, information about the received email, and periodically transmits the history to the mobile phone ( 700 ). | 7 |
RELATED APPLICATIONS
[0001] The present application claims the priority of the German Patent Application No. 10 2006 062 129.8 of Dec. 22, 2006, the disclosure of which is herewith incorporated herein by reference. This application is also a divisional of U.S. patent application Ser. No. 12/003,094 filed Dec. 20, 2007, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention refers to a self-propelled road milling machine, especially a cold milling machine, as well as a methods for measuring the milling depth.
[0004] 2. Description of Related Art
[0005] With such road milling machines, the machine frame is supported by a track assembly comprising wheels or caterpillar tracks connected to the machine frame through lifting columns, the lifting columns allowing to maintain the machine frame in a horizontal plane or in parallel to the ground or under a predetermined longitudinal and/or transversal inclination.
[0006] A milling roll for working a ground or traffic surface is supported at the machine frame.
[0007] Near the front end sides of the milling roll height-adjustable side plates are provided as edge protectors at an outer wall of the road milling machine, which side plates, in operation, rest on the ground or traffic surface at the lateral non-milled edges of the milling track. Behind the milling roll, seen in the travelling direction, a height-adjustable stripping means is provided which, in operation, may be lowered into the milling track formed by the milling roll to strip off milling material remaining in the milling track. Further, the road milling machine has a control means for controlling the milling depth of the milling roll.
[0008] It is a problem with known road milling machines that the milling depth can not be controlled accurately enough and that, for this reason, the milling depth has to be measured repeatedly by hand during the milling operation. Especially in cases where a hard traffic surface, e.g. concrete, is milled, the tools are worn heavily so that the milling depth set is corrupted by the decreasing diameter of the cutting circle. For example, the wear of the tools, when milling concrete, can cause a difference in the milling radius of 15 mm after only a few 100 m, so that the measuring of an adjustment of side plates, for example, with respect to the machine frame is not sufficiently accurate. If the milling depth is insufficient, a time-consuming reworking of the milling track has to be carried out. Should the milling track be too deep, more building material has to be applied afterwards in order to achieve the desired ground or traffic surface level.
SUMMARY OF THE INVENTION
[0009] It is an object of the present invention to improve the accuracy of measuring the milling depth during the operation of a road milling machine and to thereby minimize deviations from a predetermined milling depth.
[0010] The invention advantageously provides that at least one measuring means detects the lifting of a first sensor means resting on the ground or traffic surface and/or the lowering of a second sensor means to the bottom of the milling track, the lifting or lowering being effected in correspondence with the present milling depth. From the measured values supplied by the at least one measuring means, the control means can determine the milling depth at the level of the measuring means of the milling roll or the second sensor means.
[0011] Here, the measurement is effected preferably at the level of the stripping means arranged closely behind the milling roll, or immediately behind the stripping means, if a separate sensor means is provided.
[0012] Using the stripping means as a sensor means is advantageous in that no measuring errors are caused by some unevenness in the milling track. It is another advantage that the stripping means is protected against wear at its bottom edge.
[0013] As an alternative, the control means can use the measurement values of the at least one measuring means to determine the current milling depth of the milling roll at the level of the milling roll axis. Preferably, this is done by a calculation that may also take into account an inclined position of the machine frame.
[0014] The measuring means are preferably formed by position sensing means. In one embodiment it is provided that the first sensor means is formed by at least one of the side plates arranged on either side at the front sides of the milling roll so as to be height-adjustable and pivotable with respect to the machine frame. The side plates rest on the ground or traffic surface or are pressed against these, so that a change of their position relative to the machine frame during operation allows for an exact detection of the milling depth, if a measurement of the change of the position of a second sensor means is performed additionally in the milling track relative to the machine frame.
[0015] Also for side plates, there is an advantage that their bottom edges are protected against wear.
[0016] Here, the measuring means may comprise cable lines coupled with the side plates and/or the stripping means, and associated cable-line sensors as the position sensors which measure the changes of the position of the side plates and the stripping means relative to the machine frame or the relative displacement of at least one of the side plates in relation to the stripping means or the second sensor means.
[0017] Preferably, the cable lines coupled with the side plates and the stripping means are arranged transversely to the milling track in a substantially vertical plane extending approximately at the level of the stripping means.
[0018] Hereby, it can be avoided that a measurement error is caused by using different reference planes for the measurement at the side plates with respect to the measurement at the stripping plate.
[0019] To achieve this, it may be provided that a cable line is coupled on the one hand with the stripping means and, on the other hand, with at least one of the side plates via a guide roller, such that a cable-line sensor immediately measures the milling depth, e.g. at the guide roller.
[0020] In another alternative it may be provided that the side plate has a respective measuring means at the side edges facing the side plates, which measures the relative displacement of the stripping means with respect to the at least one adjacent side plate or the relative displacement of at least one side plate with respect to the stripping means.
[0021] According to another alternative embodiment, the stripping means may include at least one height-adjustable beam as the first sensing means, which is guided vertically and linearly in the stripping means and extends transversely to the travelling direction, said beam resting on the ground or traffic surface beside the milling track, the position of the beam relative to the stripping means, preferably with respect to height and/or inclination, being measurable by the measuring means.
[0022] Due to gravity, the side plates may rest on the edges of the ground or traffic surface beside the milling track milled by the milling machine, or they may alternatively be pressed on the edges by hydraulic means.
[0023] The stripping means may also be pressed on the surface of the milling track using hydraulic means.
[0024] The hydraulic means for pressing the side plates on the ground or traffic surface or for pressing the stripping means on the bottom of the milling track may comprise integrated position sensing systems.
[0025] For lifting or lowering the side plates and/or the stripping means, a plurality of, preferably two respective piston/cylinder units with integrated position sensing systems may be provided, whose position sensing signals are used by the control means to calculate the current milling depth from the relative difference between the positions of the stripping means and the at least one first sensor means.
[0026] The control means that receives the position sensing signals from the measuring means is adapted to automatically control the lifted condition of the rear lifting columns, seen in the travelling direction, to establish parallelism between the machine frame and the ground or traffic surface at a desired milling depth.
[0027] The side plates resting on the traffic surface so as to be pivotable with respect to the machine frame may comprise measuring means spaced apart in the travelling direction, the control means being capable to measure the longitudinal and/or the transversal inclination of the machine frame with respect to the ground or traffic surface from the difference between the measurement signals from the side plates and the stripping means.
[0028] The front and/or rear lifting columns may include a position sensing system to detect the lifted condition. The control means that receives the position sensing signals from the measuring means can control the condition of all lifting columns such that the machine frame has a predetermined inclination or a predetermined travel-distance-dependent transverse inclination across the travelling direction.
[0029] Preferably, the current set value for the milling depth of the milling roll is adjusted using the front lifting columns.
[0030] The following is a detailed description of a preferred embodiment of the invention with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1 shows a cold milling machine.
[0032] FIG. 2 illustrates a first sensor means attached to the stripping plate.
[0033] FIG. 3 shows two piston/cylinder units for lifting or lowering the stripping plate of a stripping means.
[0034] FIG. 4 illustrates an optical device for measuring the positional difference between the side plates and the stripping means.
[0035] FIG. 5 shows a cable line measuring means provided between the side plates and the stripping means.
[0036] FIG. 6 illustrates a preferred embodiment.
[0037] FIGS. 7 a, b, c are schematic illustrations of the measurement error occurring at the stripping plate of the stripping means in the absence of parallelism between the machine frame and the ground or traffic surface.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] The road milling machine illustrated in FIG. 1 comprises a machine frame 4 supported by a track assembly having two front chain tracks 2 and at least one rear chain track 3 . The chain tracks 2 , 3 are connected with the machine frame 4 via lifting columns 12 , 13 . It is understood that wheels may be used instead of the chain tracks 2 , 3 .
[0039] Using the lifting columns 12 , 13 , the machine frame 4 can be lifted or lowered or moved to take a predetermined inclined position with respect to the ground or traffic surface 8 . The milling roll 6 supported in the machine frame 4 is enclosed by a roll case 9 which is open at the front, seen in the travelling direction, towards a conveyor belt 11 that conveys the milled material in a front part of the machine frame 4 to a second conveyor means 13 . The second conveyor means 13 with which the milled material may be delivered onto a truck, for example, is not fully illustrated in FIG. 1 because of its length. Behind the milling roll 6 , a height-adjustable stripping means 14 is arranged which, in operation, has a stripping plate 15 engage into the milling track 17 formed by the milling roll 6 and strip the bottom of the milling track 17 so that no milled material is left in the milling track 17 behind the stripping plate.
[0040] Above the milling roll 6 , a driver's stand 5 with a control panel for the vehicle operator is provided for all control functions of the driving and milling operations. It also includes a control means 23 for controlling the milling depth of the milling roll 6 .
[0041] The side plates 10 , arranged on either side near the front end of the milling roll 6 , and the stripping means 14 are provided with measuring means 16 that allow the determination of the current milling depth at the level of the stripping means 14 or the calculation of the milling depth at the level of the rotational axis of the milling roll. Here, the milling depth is determined in a plane orthogonal to the ground or traffic surface, which plane is parallel to the rotational axis of the milling roll and includes the rotational axis.
[0042] The position of a first sensor means, e.g. the side plates 10 , on the ground or traffic surface 8 and/or the lowering of a second sensor means, e.g. the stripping means, can thus be detected. Measuring means 16 , preferably formed by position sensing means, measure the displacements of the sensor means, e.g. the side plates 10 or a beam 20 or the stripping plate 15 , with respect to the machine frame 4 or relative to each other.
[0043] The embodiment illustrated in FIG. 2 shows a beam 20 as the sensor means, resting on the ground or traffic surface 8 and guided at the stripping plate 15 of the stripping means in a slot 24 extending linearly and orthogonally to the bottom edge 19 of the stripping plate 15 . It is understood that two mutually parallel slots 24 can be provided in the stripping plate 15 or that the beam 20 , serving as the sensing means, can be guided in a different manner so as to be height-adjustable at the stripping means 14 . The measuring means 16 , provided in the form of a position sensing means, detects the displacement of the beam 20 with respect to the stripping means 14 . Should two horizontally spaced slots 24 be used, it is possible to separately detect the milling depth on the left side of the milling track 17 and on the right side of the milling track 17 . Moreover, this offers the possibility to determine an inclination of the machine frame 4 with respect to the ground or traffic surface 8 .
[0044] FIG. 3 illustrates another embodiment wherein the stripping plate 15 of the stripping means 14 can be lifted or lowered by means of hydraulic means. The hydraulic means are formed by piston/cylinder units 26 , 28 with an integrated position sensing system. This means that the piston/cylinder units 26 , 28 not only allow for the stroke movement of the stripping means, but moreover generate a position signal.
[0045] As is evident from FIG. 3 , the piston/cylinder units 26 , 28 have one end connected to the machine frame 4 and the other end connected to the stripping plate 15 .
[0046] FIG. 4 illustrates an embodiment, wherein the relative movement between the side plates 10 and the stripping plate 15 is measured directly in order to detect the milling depth of the milling track 17 . To achieve this, elements 38 , 40 of the measuring means 16 are provided, e.g., at the side plates 10 and opposite thereto at the stripping plate 15 , which elements allow for the detection of the relative displacement of the stripping plate 15 with respect to the side plates 10 . This displacement corresponds to the milling depth s in FIG. 4 . For example, such a measuring means, which measures relative displacements, may be formed by an optical system, e.g. by reading a scale with an optical sensor, or by an electromagnetic or inductive system.
[0047] As an alternative and as illustrated in FIG. 5 , the relative position sensing system between the side plates 10 and the stripping plate 15 may also be formed by a cable line 22 in combination with a cable-line sensor 21 . the cable line 22 is coupled with the stripping plate 15 of the stripping means 14 on the one hand and, on the other hand, with at least one of the side plates 10 via a guide roller 35 , so that the signal from the cable-line sensor 21 can immediately indicate the value of the current milling depth.
[0048] The side plates 10 themselves can be used as first sensor means by monitoring their position with respect to the machine frame 4 or the second sensor means by means of a cable line and a cable-line sensor or by means of piston/cylinder units 30 , 32 with integrated position sensing means.
[0049] For example, the measuring means can also measure the displacement of the side plates 10 with respect to the machine frame 4 . Should two measuring means be used, one in front of the side plates 10 and one behind the same, seen in the travelling direction, it is also possible to determine the longitudinal inclination of the machine frame 4 with respect to the ground or traffic surface 8 or to also determine the transverse inclination of the machine frame 4 by a comparison of the measured values for both side plates 10 on both sides of the milling roll 6 .
[0050] FIG. 6 illustrates a preferred embodiment, wherein cable lines 22 comprising cable-line sensors 21 mounted to the machine frame 4 are arranged on both sides of the stripping means 15 . On either side of the machine, the side plates 10 are also provided with cable lines 22 and cable-line sensors 21 fastened at the machine frame 4 . The milling depth s is determined from the difference between the measured values of the cable-line sensors 21 for the side plates 10 and the cable-line sensors 21 of the stripping means 15 . Here, the measurement should preferably be made in the same substantially vertical plane in order to avoid measurement errors.
[0051] FIGS. 7 a to 7 c illustrate the cable-line sensors 21 for the side plates 10 and the stripping plates 14 , the drawings only indicating one cable-line sensor 21 , since the cable-line sensors are arranged one behind the other in substantially the same plane.
[0052] FIGS. 7 a, b, c are to illustrate the case where the ground or traffic surface 8 is not parallel to the machine frame 4 , the measured milling depth value indicated by the measuring means having to be corrected because of an angle error, because a longitudinal inclination of the machine frame 4 corrupts the measurement signal at the level of the stripping plate 15 or a second sensor means near the stripping means 14 . Due to the fixed geometrical relations, i.e. the distance of the stripping plate 15 from the rotational axis of the milling roll 6 , the measured milling depth value can be corrected, knowing the angular deviation from the horizontal in the travelling direction, and the current milling depth at the level of the milling roll axis can be calculated. The angular deviation in the travelling direction may be determined, for example, from the position of the lifting columns 12 , 13 of the caterpillar track assemblies 2 , 3 or the piston/cylinder units 30 , 32 .
[0053] It is further evident from FIGS. 7 a to c , to which extent the side plates 10 are pivotable with respect to the machine frame 4 . Since the piston/cylinder units 30 , 32 are also provided with position sensing systems, these measuring signals may be used as an alternative to cable-line sensors 21 to determine the distance of the side plates 10 from the machine frame 4 .
[0054] FIG. 7 c illustrates the position of the at least one side plate 10 for a ground-parallel position of the machine frame 4 . The stripping plate 15 illustrated in FIGS. 7 a to 7 c is located at the roll case 9 , so that the distance of the stripping plate 14 from the rotational axis to the milling roll 6 can be determined unambiguously in order to allow for a calculation of the milling depth correction should the machine frame 4 not be parallel to the ground.
[0055] The control means 23 can calculate the current milling depth at the level of the milling roll axis from the position sensing signals received, and it can possibly also generate a control signal for a vertical adjustment of the milling roll 6 .
[0056] Preferably, the control means 23 can automatically control the lifted condition of the at least one rear lifting column 13 , seen in the travelling direction, to establish parallelism between the machine frame 4 and the ground or traffic surface 8 or to the horizontal plane or to a predetermined desired milling plane.
[0057] Although the invention has been described and illustrated with reference to specific embodiments thereof, it is not intended that the invention be limited to those illustrative embodiments. Those skilled in that art will recognize that variations and modifications can be made without departing from the true scope of the invention as defined by the claims that follow. It is therefore intended to include within the invention all such variations and modifications as fall within the scope of the appended claims and equivalents thereof. | A method is provided for measuring the milling depth of a road milling machine, the machine being operative to mill a ground surface with a milling roller lowered to a milling depth to create a milling track, the machine including at least one side plate located to at least one side of the milling roller to engage an untreated ground surface, and the machine including a stripping plate operative to be lowered onto the milling track generated by the milling roller. The method includes measuring the milling depth of the milling track, the measuring including detecting a measurement value of a ground engaging sensor engaging the milling track. | 4 |
This FWC application is a continuing application or continuation application of the prior application above identified, namely Ser. No. 602,936, filed Apr. 23, 1984 abandoned.
FIELD OF THE INVENTION
The present invention relates to disposable beverage brewing filter sheets. More particularly, the invention relates to a nested stack of filter sheets having special folding which forms a grippable strip. Additionally the invention includes a packaging arrangement for such filter sheets, as well as a bracket for holding the package or container as a dispenser for the sheets. Further includes is a refillable dispenser. Still further, the invention embraces a new method for preparing a beverage brewing apparatus for brewing.
The automatic drip coffee maker has become the common beverage brewing apparatus for home and commercial usage in preparing coffee. The apparatus specifically includes a basket lined with a disposable filter to contain ground coffee, tea or the like and supported so as to permit hot water to be run through the coffee in the basket, a lower vessel for collecting the brewed coffee as it drains from the basket, a warmer plate beneath the lower vessel, and a means for adding hot water to the upper basket. Such coffee makers are marketed for home use under various trade names, e.g., Mr. Coffee, manufactured by North American Systems Incorporated of Bedford Heights, Ohio, or Bunn, manufactured by Bunn-o-Matic Corporation of Springfield, Ill.
The filter sheets required for such coffee makers are generally marketed in nested stacks which has posed a problem for the consumer or user in separating individual filter sheets from the stack for use. The problem arises from the clinging of individual sheets to each other within the stack. Conventionally, the use of two hands is required to separate a single end filter sheet from the stack; and fingernail insertion at the exposed edge of the sheets of the stack is commonly used. This effort requires exposing and handling the entire nested stack and furthermore, may still be unsuccessful for separating a single filter sheet.
Heretofore all known attempts for solving the foregoing problem have dealt with edge treatment, that is, addition or creation of a structure at the edges per se of the filter sheets. Such approach conforms to that which experience has taught, namely, the edge insertion of a fingernail for separation of a sheet from the stack. Not only are edge treatments or structures economically unfeasible from a manufacturing standpoint, they also require the user or consumer to visually inspect and locate the edge structure as a preliminary to the separation step.
SUMMARY OF THE INVENTION
The present invention provides an entirely new approach for the separation of discrete filter sheets from a nested stack, namely an approach which does not rely upon attacking the problem by concentrating on edges of the sheets. Indeed, the approach of the invention permits quick and reliable separation of a single sheet from a nested stack without requiring the use of two hands and without the necessity for visual inspection of details of the nested stack. It provides a nested stack of disposable beverage brewing filter sheets that are easily separable and economically feasible to manufacture.
Further provided is a container for the nested stack which protects the stack and is convertible to a dispenser which facilitates the removal of individual filter sheets at will.
Further provided is a long life reuseable bracket to hold the package in a desirable spacial locale and facilitate removal of individual filter sheets from the package.
The invention also embraces, as a preferred option, a refillable fixture having dispenser features.
Still further the present invention provides a method for preparing a beverage brewing apparatus for the brewing operation, conveniently and more quickly than is presently known.
An especially preferred feature of the invention is a nested stack of bowl-like disposable beverage brewing filter sheets. Each preferred filter sheet has two substantially parallel adjacent folds in opposite direction relative to each other. The folds are preferably sharp creases that generally lie flat and do not interlock with other sheets in the stack. The folds form a grippable strip (e.g., a pleat) for single hand grasping to pull and remove a single sheet from the stack.
The nested stack may be packaged or placed in a container that has a removable panel. Removing the panel provides an opening for grasping of the strip, e.g., as at the bottom wall of an end filter sheet, without the necessity of visually locating the strip. The container is slideably receivable by a holding bracket, which may be mounted in a desirable locale, such as on a wall, under a cupboard or on or under a countertop near a coffee maker. The bracket allows access to the container's opening and reliable single hand removal of an individual filter sheet. For bulk size quantities of filter sheets, the nested stack may be marketed in a plastic or paper bag and placed by the user in a refillable dispenser.
With the foregoing constructions and arrangements, a new method is provided for preparing a beverage brewing apparatus for brewing, wherein single hand removal of discrete filter sheets from a nested stack comprises the key step.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one filter sheet according to the invention;
FIG. 2 is a schematic cross section along lines 2--2 of FIG. 1;
FIG. 3 is a schematic cross section of a nested stack;
FIG. 4 is a perspective view of the nested stack;
FIG. 5 is a perspective view of a package comprising a container convertible to a dispenser, illustrated with its access panel removed and a portion of the container partially cut away to expose the nested stack within the container;
FIG. 6 is a schematic cross section of a mounted bracket, with the container in the bracket, the container being shown partially cut away to expose the nested stack and an end filter in an early stage of being removed therefrom by fingers;
FIG. 7 is a exploded perspective view of major elements of a beverage brewing apparatus having the filter of the invention;
FIG. 8 is a schematic cross section of a modified form of filter sheet according to the invention;
FIG. 9 is a schematic cross section of another modified form;
FIG. 10 is a horizontally exploded perspective view of a mounting means and a cylindrical dispenser of the invention, the dispenser being partially cut away to show an opening in the bottom wall;
FIG. 11 is a vertically exploded perspective view of a mounting means and a refillable dispenser, the dispenser being partially cut away to show an opening in the bottom wall;
FIG. 12 is a perspective view of a brewing apparatus having two alternative forms of refillable dispensers for filter sheets of the invention, one dispenser being on a side panel and another mounted below a base panel.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Refering first to FIGS. 1 and 2, the filter sheet, generally indicated by numeral 10, may be made of paper or any other suitable material having a porous nature. The sheets have a bowl-like shape with a bottom wall 12 and a side wall 14 that is corrugated, such as by vertical striations, flutings, folds, or the like. The dimensions of any filter sheet 10 are suitably determined by various brewing basket size and shape characteristics. That is, the filter sheets may be round, square, oval or of other configuration. In addition, the filter sheets may be large or small.
A first fold 16 is made generally near or along a bisecting or a center diameter line across a sheet. This fold 16 lies transversely to a vertical axis 22 such as shown by a dash line in FIG. 2. Fold 16 is in the form of a creased edge. A second crease or fold 18, in opposite direction relative to fold 16, is made in substantial proximity or near first fold 16 and preferably parallel to it. Fold 18 is in the form of a creased edge similar to fold 16. The folds generally lie flat so that the sheet material adjacent the folds lies upon the folds. For clarity of illustration, however, the attached figures show the folds slightly open or raised. The folds 16 and 18 form a grippable strip 20 of Z-shaped transverse cross section.
The strip 20 functions as a grippable strip. A fingertip or fingernail can easily be inserted under a fold, without the need for visual inspection. The fold is easily pinched between fingertips for removing the sheet 10 from a nested stack 26 such as shown in FIGS. 3 and 4. The pinching of the strip 20 is easily accomplished at any point along the strip including, as preferred, the portion of the strip in the bottom wall 12, as shown in FIG. 6. It is this feature which for the first time allows discrete filter sheet removal from a nested stack in a manner readily overcoming the tendency of the sheets to cling to each other and without any handling of ther sheets of the stack.
Either fold 18 or 20 may be made first. The respective folds are preferably 0.5 cm to 1.5 cm (1/4 to 1/2 inch) from each other. Grippable strips 20 may be formed in filter sheets 10 by folding machinery before or after the sheets are individualized by cutting from a roll of filter sheet material or the like. However, the strips are preferably formed before the sheets are formed into their bowl-like shape.
As shown in FIGS. 3 and 4. the stack 26 has a solid bowl-like shape with its wall thickness dependent on the number of filter sheets in the stack. The sheets are nested snugly within one another with all surfaces, except for the exposed surface ends of the stack, in contact with each other. The folds (i.e., grippable strips 20) of adjacent sheets of the stack are not interlocked. However, the corrugated-type shape of the side walls contributes to the sidewall corrugated interlocking between the filter sheets. Any attempt to remove a single filter sheet is hampered by the sheets clinging to each other.
In this invention, however, separation of an individual filter sheet from the stack begins from bottom wall 12 and not from an edge of an end filter sheet 28, as the invention is preferrably practiced. The grippable strip 20 in end filter sheet 28 is readily accessible within the cavity recess of the stack. By preferably gripping and pulling strip 20 with fingertips at bottom wall 12 within the cavity recess end of the stack, the breaking or peeling away of the end filter sheet 28 from stack 26 begins in the center of the filter sheet and radiates outward uniformly peeling the end filter sheet away from side walls 14 of the nested stack. This is an especially interesting feature of the invention, since the clinging effect between the sheets is least between the flat bottom walls 12 and greatest between the interlocked and corrugated walls 14 within the nested stack 26.
One preferred packaging arrangement for the nested stack as shown in FIG. 5 has a container 30, which is of a size slightly larger than the stack. The container encloses the nested stack 26 and is designed to carry the stack with minimum volume space requirements and to protect the nested stack from crushing in shipment and storage. It may be made of cardboard, plastic, stainless steel or any suitable rigid material. A removable access panel 32 in wall 34 of the container opposes the interior bottom wall 12 in the cavity recess of the stack. The periphery or outline of panel 32 may be scored, perforated or otherwise weakened to form a line of severance about it so as to facilitate its removal. Upon removal of access panel 32, this novel arrangement allows access of fingers through opening 36 for gripping strip 20 in bottom wall 12 of end filter sheet 28 in the cavity recess of the stack without removal of the stack from the container. Preferably by this arrangement, the nested stack is never removed from container 30, thus insuring cleanliness of the filter sheets and no handling of those sheets not immediately needed for brewing purposes. The preferable size of opening 36 should be adequate to allow comfortable insertion of fingertips to grasp a grippable strip 20 for removal of a single filter sheet, but at the same time inadequate for removal of the stack. Remainder of wall 34 provides the means for holding and supporting the nested stack at its edges within the container as solely end filter sheet 28 is pulled and removed.
Bracket 38, as illustrated in FIG. 6, is mounted under a cabinet 40 by adhesives or conventional screws and has an elongated configuration, generally C-shape in cross section. Opposing side walls 44 extend from base wall 42 and have inwardly extending lips 46 at their opposing edges from base wall 42. Bracket 38 may have a stop member or back wall to restrict movement of container 30 as it is inserted in bracket 38 and thus prevent container 30 from sliding through the bracket. The bracket is preferably made of plastic, metal or any other relatively rigid material so as to be sturdy and have a long and reuseable life. Base wall 42 may be mounted on a desirable surface, such as a wall, under or on a countertop, cabinet, cupboard or the like. Container 30 is slideably received into bracket 38 and held by opposing side walls 44 and supported by inwardly extending lips 46. Preferably, opening 36 of container 30 is not obstructed by the lips 46 so as to insure easy finger access within the container. Dimensions of bracket 38 are dependent upon the dimensions of container 30, which may also vary for different filter sheet configurations. The preferred bracket orientation holds container 30 so that opening 36 is facing downward to keep dust and air particles from settling upon the exposed end filter sheet and thus futher contribute to the keeping of the nested stack clean.
In operation, fingers, such as a thumb and forefinger, reach inside the opening of the container or dispenser. Because the strip preferably runs across the center of bottom wall 12, a fingertip simply feels for fold 16 of grippable strip 20 and grasps such strip with fingertips or fingernails. Strip 20 is then pulled, removing the end filter sheet from the nested stack.
Once a single filter sheet has been obtained, it may be inserted within the brewing basket with strip 20 (folds 16 and 18) intact, or the sheet may be stretched out to remove or flatten the folds 16 and 18 and thereby remove the grippable strip. If folds 16 and 18 are to be removed from bottom wall 12, the bowl-like shape may be oval in overall configuration if desired, so as to allow for expansion into a round bowl-like shape before insertion into a round brewing basket. The filtration process however, will not be hampered by leaving strip 20 intact.
Using the new constructions and arrangements aforediscussed, an improved method for preparing a brewing apparatus for brewing, as shown in FIG. 7, with a speed and convenience not heretofore realized, includes the steps of removing a single filter sheet 10 from a nested stack 26 by inserting fingers of one hand into container 30 about the stack to grasp strip 20 at a location other than at the edge of the sheet, pulling strip 20 with fingertips to remove a single filter sheet 10 from the stack 26 without distrurbing or touching the other sheets within the stack, and lining the brewing basket with the removed single filter sheet.
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. More than one grippable strip may be placed in the filter sheet. For example, variations as shown in FIGS. 8 and 9 may have the strips 24 and 25, or 24'0 and 25', in converse or mirror image relationship extending away from the recess cavity or toward the recess cavity respectively. In effect, a single grippable strip of dove tail configuration in transverse cross section may be employed. Further, folds 16 and 18 forming strip 20 may be made along a line or section of a sheet other than at a bisecting or center diameter line across the sheet. Additionally, the folds need not be perfectly parallel to each other. In still another variation, strips 20 may or may not be nested in parallel alignment to each other within the stack. They may be randomly oriented, or aligned, as desired, as shown in FIGS. 3 and 4.
Commercial users of brewing apparatuses prefer purchasing bulk quantities of filter sheets. Such quantities of the nested stacks of this invention may be packaged and marketed in plastic or paper bags. FIG. 10 illustrates one variation of a permanent fixture that takes the form of a refillable cylindrical dispenser 48 with a removeable cap 50 to allow access into the cylinder for loading nested stacks therein. Cap 50 alternatively may be hingedly attached to cylinder 48. Opening 52, in bottom wall 54, is preferably similar to opening 36 of container 30. The dispenser is suitably made of relatively rigid material, such as plastic or metal. Dispenser 48 has preferably 2 vertically aligned capped pins or knobs 56 outwardly extending from its side wall. Bracket 58 is preferably of rigid material and is attached to a mounting surface 62, such as a wall, with screws 64. It has matching key hole slots 66 for receiving the corresponding capped pins 56 as the mounting points for refillable cylindrical dispenser 48.
Dispenser 68, as shown in FIG. 11, is another variation of a permanent refillable dispenser. It is box-shaped in configuration with its top wall or cover 70 hinged at 71 and mounted under a surface 72 in a manner comparable to the key hole slot 74 and capped pin 76 arrangement used in mounting the cylindrical dispenser 48. However, other mounting arrangements may be employed; and adhesive mounting is suitable. Top wall 70 and box part 68 have co-acting clasp components 78 and 79 for fastening together and thus holding dispenser 68 in a closed position. Upon disengagement of the clasp, dispenser part 68 swings downwardly to allow access for loading nested stacks therein. Opening 80, in bottom wall 82, is comparable to opening 36 of container 30.
A commercial brewing apparatus 84, as shown in FIG. 12, is preferably equipped with a permanent refillable dispenser 86 mounted on the brewing apparatus itself, such as on a side wall 88. Dispenser 86 has a hinged top wall 90 for providing access within the dispenser to load nested stacks therein. Similarly, opening 92 provides access for removal of discrete filters from the stack. Another variation of a dispenser embraced by this invention is a drawer 94 which is held by cooperative side parts at the juncture between the drawer and bottom panel 96 of the apparatus. Pulling drawer 94 outwardly allows access for loading nested stacks therein. An opening in its bottom wall provides for discrete removal of filters from the stack.
The illustrated embodiments should be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than to the foregoing description to indicate the scope of the invention. | A nested stack of bowl-like disposable beverage brewing filter sheets. Each filter sheet has two adjacent folds in opposite direction forming a grippable strip for removing discrete sheets from the stack. A container for the nested stack has a removable panel for exposing the grippable strip of the outermost sheet for easy finger gripping and discrete removal of the sheet. The container is slideably receivable in a bracket adapted to hold it as a dispenser. Refillable dispensers are also disclosed.
A method for preparing a beverage brewing apparatus for brewing comprises the steps of grasping with fingers of one hand the strip of the outermost filter sheet at a location other than at the edge of the sheet, pulling the filter sheet as a discrete entity from the stack, and lining the brewing basket with the single filter sheet in preparation for brewing. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of my previously allowed U.S. Patent application, Ser. No. 940,787, filed Sept. 8, 1978 and now U.S. Pat. No. 4,221,121. That application in its entirety is hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention pertains to lock systems with multiple levels of keys.
2. The Prior Art
The subject matter of the parent patent application is a lock system consisting of cylinder locks and appertaining flat keys in which laterally oriented blocking elements are positioned in laterally oriented bores of the rotary cylinder. Said blocking elements sense the profile thickness of an inserted key and, given a predetermined profile thickness, are forced far enough outwardly that their outer ends are level with the perimeter of the cylinder. If the inserted key has a reduced or non-existent profile, an unfilled space is left at the end of the bore. After an initial rotation of the cylinder, a housing pin can fall into the unfilled end of a lateral bore and block further rotation of the cylinder. The fundamental inventive idea therein is that a higher order key exhibits a flat coordination notch at the sensing location of the blocking elements and also exhibits at least one rib at the area of the flat side adjacent thereto. The rib extends laterally from the profile of the key. The rib or ribs are adapted to displace the blocking elements into the position in which they release the cylinder. Further, a lower order key is provided at the same sensing location of the blocking elements with a deep coordination notch, whereby there are no rib or ribs extending laterally from the profile of the key. The core pin allocated to said coordination notch has an upper offset piece and an appertaining shank whose diameter corresponds to the thickness of the lateral ribs of the higher order key at the sensing location, whereby this shank, just like the ribs, is adapted to displace the blocking elements into the position which releases the cylinder.
A significant feature of the subject matter of the invention of the parent patent application consists therein that the blocking elements are formed of blocking pins which exhibit offset sensing ends whose thickness corresponds to the length of the offset core pin piece in addition to its point, and that the diameter of the pin shanks corresponds to that of the allocated housing pin.
A lock system is achieved by means of the invention of the parent patent application in which the higher order keys are largely secured against copying. In order to make such a higher order key from a lower order key, in contrast to standard copying methods based on removal of material, material would have to be applied in order to fill the deep notch of the lower order key in the direction of a flat notch and the formation of one or more lateral profile ribs.
Protection against copying flat keys provided with profile is already the subject matter of the German LP No. 2,059,523 whose main inventive idea is to be viewed therein that at least one additional longitudinal rib projecting beyond the lateral surface of the flat key is provided, by means of which additional longitudinal rib an additional locking blocking pin is actuated. The lock can be actuated when the additional longitudinal rib exhibits a predetermined height which displaces the additional blocking pin far enough toward the outside of the cylinder that it completely fills its cylinder core bore in addition to a preceding counter-sink which may be present. The blocking pin so displaced does not allow the allocated housing pin to spring into the bearing bore of the blocking pin or, respectively, the counter-sink after an initial rotation of the cylinder core and prevent further rotation of the cylinder core.
According to a further feature of the lock device of the German LP No. 2,059,523, two additional longitudinal ribs are provided which project from the opposite lateral faces of the flat key and are each sensed by an additional blocking pin.
As in the subject matter of the parent patent application, the advantage connected with this key is that the key is protected against copying since its manufacture from commercially available blanks requires the addition of material in order to be able to form the additional longitudinal ribs projecting over the key profile. This feature, as already explained, represents a departure from the usual copying method by means of removal of material and which is very difficult for an unauthorized copier.
In order to make the lock device of the German LP No. 2,059,523 tamper-proof by preventing the additional blocking pins, which sense the additional longitudinal ribs from being rendered ineffective by means of manipulation, a lock device consisting of a rotary cylinder lock and an appertaining flat key has been proposed by the German LP No. 2,441,362. The lock of the German '362 patent proceeded from the fact that additional one-piece blocking pins can be arranged in the cylinder core of the lock and at least one additional longitudinal rib projecting laterally from the surface of the flat key is provided at the lateral face of the flat key. The additional longitudinal rib is sensed by the additional blocking pins. These pins, given a flat key which fits, lie in the separating line between the cylinder core and the cylinder housing with its end face facing away from the key channel and allow the continued rotation of the cylinder core after an initial rotation. The primary inventive idea in this case consists of the use of safety blocking pins arranged in front of, as viewed from the key bit, the additional blocking pins. These safety blocking pins sense the recesses of the additional longitudinal ribs and which are opposite the locking recesses, grooves or the like in the cylinder housing. It is these locking recesses, grooves or the like that the safety blocking pins enter when they assume their blocking position.
The resistance to tampering achieved with this lock device is first based on the fact that the safety pins seated in front of the additional blocking pins no longer allow displacement of the additional blocking pins toward the outside of the cylinder by means of a tool. Further, it is based on the fact that every positional displacement of the safety pins toward the outside by means of a tool or the like effects entry of these pins into their housing bores which results in the immediate blocking of the cylinder core against rotation.
The above inventions reveal ways of making keys nonduplicatable and making the locks functioning with them tamper-proof. In the subject matter of the parent patent application as well as in that of the German LP No. 2,059,523, the protection against duplication of keys is achieved in that an addition of material is required in order to duplicate the keys. In the subject matter of the German LP No. 2,411,362, the lock's resistance to tampering is achieved in that safety blocking pins are connected in front of the blocking pins sensing the additional longitudinal rib of the key, whereby the additional longitudinal rib consists of a sequence of elevations and depressions, i.e., is modulated as to height.
SUMMARY OF THE INVENTION
The object of the present invention is to create a lock suitable for the construction of a lock system. The lock very inexpensively is to ensure an increase of the combination of keying possibilities as well as a very significant increase in its resistance to tampering.
In our parent patent application, the higher order key exhibits a flat coordination notch at the sensing location of the blocking elements as well as rib rising above the profile of the key at the lateral side area adjacent thereto. That rib, given a predetermined height, forces the blocking elements into their release position. The lower order keys are provided with a deeper coordination notch at the same sensing location such that the rib rising above the profile is lacking. The core pin allocated to the coordination notches exhibits an upper offset piece of smaller diameter and an appertaining, thicker shank whose diameter equals the thickness of the lateral ribs of the higher order key at the sensing location. This shank, just like said ribs, is adapted to force the blocking elements into the cylinder release position.
In combination with a lock of the type shown in our parent application, in the present invention at least two additional discontinuous longitudinal ribs are provided on at least one lateral side of the key. These additional longitudinal ribs cooperate with blocking elements in front of which, as viewed from the key bit, or adjacent to which safety pins are connected which sense the adjacent recesses or interruptions in the additional discontinuous profile ribs.
In the present invention, the higher order keys are equipped with a greater plurality of profile ribs than the lower order keys and the main or master key is equipped with the greatest possible plurality of profile ribs.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional planar view taken essentially perpendicular through a cylinder lock, incorporating principles of the present invention, adjacent a selected cylinder pin with a higher order key inserted therein.
FIG. 2 is a sectional planar view taken essentially perpendicular through a cylinder lock, incorporating principles of the present invention, adjacent a selected cylinder pin with a lower order key inserted therein.
FIG. 3 is a top, fragmentary planar view showing the location of a pair of blocking pins and a pair of safety pins in the unlocked condition.
FIG. 4 is a perspective view of a fragment of a master key according to the present invention.
FIG. 5 is a top, fragmentary planar view showing the key of FIG. 4 inserted into a corresponding lock with two sets of blocking pins and two sets of safety pins all of which are unlocked.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Not by way of limitation but by way of disclosing the best mode of practicing our invention and by way of enabling one of skill in the art to practice our invention, FIGS. 1 to 5 disclose one embodiment of our invention.
FIG. 1 indicates a lock L with a housing 1 and a cylinder 2. The lock L has a key channel 3 into which a master key 4 is introduced. The key 4 exhibits a profile with profile grooves preferably designed rectangularly and profile ribs 12, 13 and 17, 18 on each lateral side. The profile ribs l2, 13, 17, 18 are sensed by means of blocking pins or elements 7, 8 and 21, 22. The pins 7, 8, 21 and 22 are seated in cylinder core bores 5, 6 and 123, 124 which terminate in counter-sinks 24, 25 and 26, 27 into which a housing pin 15 can drop after a short cylinder core rotation when the countersinks 24, 25 are not filled out by end regions 7a, 8a, 21a and 22a of the blocking pins 7, 8, 21 and 22. The blocking pins 7, 8 each have a sensing end 7b, 8b. Each sensing end 7b, 8b has a smaller diameter than the remainder of the pin 7, 8.
The core pin 10 located in a cylinder boring 9 can cooperate with a coordination notch 11 in the main or master key 4 at the sensing location of the blocking pins 7, 8. The pin 10 has an upper contracted neck section 10a with a tip 10b which is adapted to drop into the coordinating notch 11 made available to it.
The profile ribs 12, 13 and 17, 18 project laterally from the key profile and are adapted to force the blocking pins 7, 8 and 21, 22 toward the outer surface 19 of the cylinder 2 such that the outer ends 7a, 8a, 21a and 22a of said blocking pins essentially coincide with the cylinder perimeter 19. Thus, the appertaining housing pin 15 is prevented from dropping into one of the counter-sinks 24 through 27 after the initial rotation of the cylinder core 2.
A disk 16 is located between the core pin 10 and the housing pin 15. The function of the disk 16 shall be described in greater detail in conjunction with FIG. 2.
In FIG. 2, the lock of FIG. 1 is shown with a lower order key 4a introduced into the lock channel 3. The lower order key 4a has a deep coordination notch 14 at the sensing location of the blocking pins 7, 8. The coordination notch 14 causes the core pin 10 to rise significantly higher than was the case with the flat notch 11 of the higher order key 4 of FIG. 1. The core pin 10 is driven by a compression spring not shown here which forces the housing pin 15 inwardly toward the cylinder 2.
Due to the higher movement of the pin combination 10, 16, 15, into the bore 9, the larger diameter section of the core pin 10 moves adjacent the sensing ends 7a, 8a of the blocking pins 7, 8. The profile ribs 12, 13 of the higher order key 4 are omitted at this location because of the deep coordination notch 14 of the lower order key 4a. The function which the profile ribs 12, 13 had on the key 4 to force the blocking pins 7, 8 outwardly is assumed by the shank of the core pin 10 which has been lifted up. Since this shank exhibits a diameter corresponding to the thickness of the profile ribs, it causes the blocking pins 7, 8 to be displaced toward the outside perimeter 19 and into their alignment position.
A lock system constructed with locks and keys of the type described above has the advantage that the keys are largely secured against duplication. The proper addition of material at the location of the deep coordination notch 14 on a lower order key 4a in order to produce the higher order key 4 of FIG. 1 is difficult.
Additionally, the locks can also be made tamper-proof, as a lock L1 of FIG. 3 reveals. The embodiment of FIG. 3 prevents the blocking pins 7, 8 from being forced far enough toward the outer perimeter 19' of the cylinder 2' by means of a tool or the like so that they align with the perimeter 19' to prevent the entry of the housing pin situated in this plane of the lock into one of the counter-sinks placed in front of the blocking pin bores as the result of such tampering.
According to FIG. 3, the resistance to tampering is achieved by modulating the height of the profile ribs 12, 13. In FIG. 3, the ribs 12, 13 exhibit a sequence of elevations and depressions 121, 131. The blocking pins 7, 8 sense the elevations (normal profile rib height) 12, 13. As viewed from the key bit, safety pins 28, 29 are placed in front of the pins 7, 8. The safety pins 28, 29 which sense the depressions 121, 131 are seated in cylinder core bores 30, 31 which are located opposite bores 32, 33 in the housing 1'. Any attempt to align the blocking pins 7, 8 due to simulation of the profile ribs 12, 13 will drive the safety pins 28, 29 laterally into the borings 32, 33 and lock the cylinder 2' from rotating in the housing 1'. This result can be avoided only if the depressions 121 and 131 are properly located adjacent the projections 12, 13.
It is proposed to provide the tamper-proof lock, exhibiting keys which are secured against duplication to the highest degree, with a significantly higher locking security and range of variation than was the case up to now in that at least two additional discontinuous longitudinal ribs provided on at least one lateral side of the key. These additional discontinuous longitudinal ribs cooperate with blocking elements which are preceded, as viewed from the key bit, by safety pins which sense the recesses or interruptions of the additional profile ribs.
A correspondingly equipped key K is illustrated in FIG. 4. On the flat side visible in the drawing, are two discontinuous profile ribs R1, R2 which are split up into rib pieces or, segments by depressions or interruptions. Rib R1 includes elements 34, 36 and 38 which are separated by depressions 35 and 37. Rib R2 includes elements 39, 41, 43 which are separated by depressions 40 and 42. The rib members or segments 34, 36, 38, 39, 41 and 43 are sensed by blocking pins shown as arrows 50, 52, 54, 55, 57 and 59, which completely correspond to the blocking pins 7, 8, 21 and 22 of FIGS. 1 through 3. The depressions 35, 37, 40 and 42 are sensed by safety pins which are indicated by means of arrows 51, 53, 56 and 58. If the key K has the same structure on its other flat side and if one assumes five coordination notches with corresponding tumblers at the narrow side of the key, then one obtains 25 sensing locations per lock. This number of sensing locations provides an increased resistance to duplication of the keys, particularly of the higher order keys, as well as resistance to tampering with the locks in a lock system based on these locks.
FIG. 5, a top view of the key K, shows the arrangement of the profile rib members 34, 36 and 38 and interruptions 35, 37 on the key as well as the sensing elements 50-53 engaging thereon.
It follows from the structure of the lock system described herein that the higher order keys must exhibit a greater plurality of discontinuous profile ribs than the lower order keys and that the main or master key is equipped with the greatest or, respectively, greatest possible plurality of profile ribs.
While various modifications or changes might be suggested by those skilled in the art, it will be understood that we wish to include within the claims of the patent warranted hereon all such modifications and changes as reasonably come within our contribution to the art. | A key for use in a hierarchal lock system with an elongated body and selectively spaced notches cut on an elongated edge of the body. Two rows of discontinuous rib members are attached to each side of the elongated body of the key. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 61/200,564, filed Dec. 1, 2008, and entitled Thermal Deicer, the entire disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to electrically powered heating elements, and more particularly to heating elements used to supply heat to a vehicle surface to melt snow and ice.
BACKGROUND OF THE INVENTION
[0003] During winter months, snow and ice buildups on vehicle surfaces cause various problems with performance and safety of those vehicles. This is especially true of tractor trailer trucks, where snow and ice build up on their roofs and other horizontal surfaces while these vehicles are parked. If this accumulated material is not removed, chunks of ice and snow can loosen and fall onto automobiles and other vehicles traveling behind the tractor trailers. The results can vary from minor damage to vehicles, to smashed windshields, accidents, and even possibly to deaths. While some truck stops have brushes or scrapers to help remove snow and ice build-up, these are not 100% successful—especially when an ice bond has formed on the metal surface of the vehicle. Such a bond is readily formed in freezing temperatures as the ice and snow negate most heat normally present in the tractor trailer roof's exterior surface.
SUMMARY OF THE INVENTION
[0004] The heating element structure of the present invention employs electrical resistance foils to provide a heat source to a vehicle surface to raise that surface to a temperature sufficient to melt snow and ice, to thereby break the bond formed by the snow and ice with that surface. With respect to tractor trailer roofs, the present invention involves installing a heater on the inside of the trailer roof, thereby providing a heat sufficient to melt snow and ice. The heating system of the present invention is capable of operating while the tractor trailer is in a stationary position, as well as operating while the tractor trailer is in route to its destinations.
[0005] The present invention is not limited to truck roofs and to the safety issues discussed above. Other surfaces of vehicles for which accumulated snow or ice can result in safety or performance concerns can benefit from this invention. By way of examples, this invention is applicable to various surfaces on airplanes, construction vehicles, and military vehicles.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The following detailed description will be better understood when read in conjunction with the appended drawings, in which there is shown one or more of the multiple embodiments of the present disclosure. It should be understood, however, that the various embodiments of the present disclosure are not limited to the precise arrangements and instrumentalities shown in the drawings.
[0007] In the Drawings:
[0008] FIG. 1 a is perspective bottom surface view showing the overall appearance of the heating elements located in a section of the roof of a trailer, according to one embodiment of the invention;
[0009] FIG. 1 b is a partially cut-away view of the embodiment of the invention depicted in FIG. 1 a;
[0010] FIG. 2 is a perspective bottom surface view showing the overall appearance of the heating mats positioned in a trailer roof in a manner that creates two stages or zones;
[0011] FIG. 3 depicts a typical heating element pattern layout according to a further embodiment of the invention;
[0012] FIG. 4 a and FIG. 4 b illustrate additional embodiments of the invention depicting means for protecting the heating sections on the inside roof of a trailer;
[0013] FIGS. 5 a and 5 b are schematic diagrams related to an embodiment of the invention;
[0014] FIGS. 6 a - d depict various views of a control box of the heating element circuitry for one embodiment of the invention; and,
[0015] FIG. 7 is a cross sectional view of the heating element and related layers according to one embodiment of the invention.
DETAILED DESCRIPTION
[0016] Certain terminology is used herein for convenience only and is not to be taken as a limitation on the embodiments of the present disclosure. In the drawings, the same reference letters are employed for designating the same elements throughout the several figures.
[0017] The present invention is an electrically powered heating system capable of sufficient heat for use in the melting of ice and snow. In one embodiment of the invention, the system is essentially a low-watt density electrically resistive heater, thermostatically controlled, that can be powered from a generator or a 120 volt plug-in power source. In a further embodiment of the invention, for use in a truck trailer, the generator can be mounted on either the truck cab or the trailer itself. The heating system is designed in such a way that the heating elements employed are flexible and moisture proof as to prevent various types of failure.
[0018] In an embodiment for use on a surface such as a truck trailer, the actual heating element is a stamped foil approximately 1 Mil thick, custom designed in a way that the stamped pattern produces an ohmic value of 30 Ohms per 20″×93″ section. This allows for a low watt density heat to be directly applied to the underside of the roof to maintain a level of warmth to keep the trailer roof sufficiently warm to melt ice and snow but not excessively hot to waste energy or to cause damage to the roof structure. The stamped foil heating element can be cupro-nickel, nickel chrome, aluminum, or any electrically conductive material in a flat foil form. A further embodiment of the invention has the heating elements laminated onto a clear plastic or Mylar sheet to produce an evenly heated waterproof and moisture-proof heater.
[0019] FIG. 1 a is a perspective bottom surface view showing the overall appearance of the heating elements located in a section of the roof 110 of a trailer. As is well-known and illustrated in FIG. 1 a , such trailers typically contain stiffener ribs 115 approximately every 25″ on center, commencing at 10″ from the end of the trailer. As illustrated, heating sections or mats 120 , each approximately 10″ wide, are positioned in the gaps between these ribs 115 , with two mats 120 positioned in each of the 20″ wide gaps. Each of the mats runs the approximate interior width of the trailer, which is indicated as being 93″ in the figure. The invention is not limited to these dimensions as it is envisioned that alternative embodiments of the invention would be capable of being employed in various size trailers (e.g., narrow, wider, longer) as well as various other types of vehicles.
[0020] FIG. 1 b is a partially cut-away view of the trailer embodiment depicted in FIG. 1 a . As illustrated, the mat heaters 120 are attached to the underside of the trailer roof 110 by high-temperature double sided tape 125 . High-temperature double sided tape 125 is also used to secure an insulation layer 130 , approximately 1″ thick in this particular embodiment, to the underside of the mat heaters 120 . In a further embodiment, an overlay protector 135 is then fastened to the underside of the insulation (e.g., by stainless screws 140 in this embodiment) to prevent damage to the heating structure.
[0021] FIG. 2 is a perspective bottom surface view showing the overall appearance of the heating mats positioned in a trailer roof 110 in a manner that creates two zones, Stage 1 and Stage 2. As illustrated and as previously described above, heating mats 120 run the approximate entire width of the trailer in the spaces between the trailer ribs 115 , with a pair of mats 120 positioned in each of the 20″ wide gaps. As indicated by lines L 1 , L 2 , and N, these mats are electrically connected in two stages. These stages, Stage 1 and Stage 2, work off of a timer (not shown). Thus in operation, Stage 2 heater elements will be in an OFF state while Stage 1 heater elements are in an ON state, and vice versa. In one embodiment of the invention, this switching between stages occurs every 10 minutes. Each pair of low-watt density heater mats 120 produces 480 watts on 120 volts. Thus for the trailer embodiment depicted in FIG. 2 , the Stage 1 heating sub-system, comprising 11 pairs of heater mats 120 , will produce 5280 watts; and the Stage 2 heating sub-system, comprising 12 pairs of heater mats 120 , will produce 5760 watts. With this structure and a timer cycling between the two stages, the system is capable of being run off either a 120 volt supply while at a truck stop, or off a 7.5 KW generator mounted on the vehicle (tractor or trailer) during driving times.
[0022] FIG. 3 depicts a heating element pattern layout according to a further embodiment of the invention. In particular, FIG. 3 illustrates the sectioning of pairs of heating mats 120 into three sections width-wise and the use of buss bars to maintain the proper wattage. In particular, by cutting away the buss bar, the heating elements are changed from parallel to series to obtain the desired wattage, i.e. 480 watts on 120 volts.
[0023] FIGS. 4 a and 4 b illustrate additional embodiments of the invention depicting means for protecting the heating sections on the inside roof 110 of a trailer. In particular, ⅜″ or ½ ″ plywood, aluminum or stainless overlay, or plastic overlay protectors can be used as the overlay protector 135 illustrated in FIG. 4 a . FIG. 4 b depicts further embodiments in which strips 410 , running lengthwise down the trailer, are utilized as various additional means for providing protection to the heating sections. These strips 410 can be made from various materials, to include, aluminum, stainless steel, or wood.
[0024] FIG. 5 is a schematic diagram of an embodiment of the invention. As illustrated, the system employs a non-reversing contactor with 120V coil. As illustrated and as described previously above, this invention employs pairs of heating mats (e.g., 1 H 1 and 1 H 2 ) arranged in two stages. Only one stage is energized at a given time. With this arrangement, the maximum wattage (i.e., the stage 2 heating mats) required is 5760 watts. Accordingly, the system will run off either a 120 volt supply at the dock or it can run off a 7.5 KW generator mounted on the truck.
[0025] The schematic diagrams of FIGS. 5 a and 5 b illustrate various additional features of this embodiment of the invention. These include GF protection and use of shut off switches which trigger when the ambient temperature is above a settable threshold (e.g., 50° F.) or when the heating element has exceeded a settable threshold (e.g., 110° F.).
[0026] FIGS. 6 a - d depict various views of a control box of the heating element circuitry according to an embodiment of the invention. In particular, FIG. 6 a depicts the hinge cover, while FIG. 6 b depicts the back panel. Various lights, terminals, connections and functional elements are illustrated in FIGS. 6 a - d , and identified in the following tables:
[0000]
BILL OF MATERIALS
ITEM
QTY.
MANUFACTURER & DESCRIPTION
PART#
1
1
HOFFMAN JUNCTION BOX, NEMA 4X, STAINLESS
A-1614CHNF
STEEL, 14″ × 12″ × 6″, HINGE COVER
2
1
HOFFMAN BACK PANEL, STEEL
A-12P10
3
4
S&S CONTACTORS, 2-POLE, 70AMP RATED WITH
D3P75A120
A 120 VOLT COIL NON-REVERSING
4
2
PAK-STAT ELECTRONIC THERMOSTAT,
P-14A0318
0-150 DEG. F. 1-S.P.S.T. 15 AMP SWITCH
5
1
FUJI ELECTRONIC TEMPERATURE TIMER WITH
MS4SH-AP-
MANUAL ADJUSTMENT, DUAL RELAY CUTOUT,
ADC
DUAL RELAY OUTPUT
6
1
FUKI SOCKETS, 11-PIN, TERMINALS ON FRONT
TP411X
7
1
LOVATO LED PILOT LIGHTS, 120 VOLT, “WHITE”
8 LP2T 1LE8
8
2
LOVATO LED PILOT LIGHTS, 120 VOLT, “RED
8 LP2T 1LE4
9
10
MARATHON TERMINAL BLOCKS, 60 AMP, 600
6G38 TS DIN
VOLT RATED, BOX TYPE
10
1
BUSSMAN FUSE HOLDER, 1-POLE, 30A, 250 V
S-8301-1
11
1
BUSSMAN FUSE, 1-AMP, 250VAC
ABC2
12
2
WIRING, LUGS, LABELS, RING LUGS, ETC.
A/R
13
2
GROUND LUGS
TAG-1
14
2
THERMOCOUPLE, TYPE “J”, 4″ PROBE WITH
MI-J-4-120
10 FT. STAINLESS STEEL BRAIDED LEAD
15
2
GROUND FAULT-SHUNT TRIP RELAY,
AGI-NOAC-
30MA, 120VAC
120
16
2
MARINCO PANEL MOUNTED WEATHER TIGHT
301ELRV
120 VOLT CONNECTORS SERIESED TOGETHER
LOCATED ON THE CONROL BOX FOR 120 VOLT
GENERATOR HOOK-UP
17
2
MARINCO PANEL MOUNTED WEATHER TIGHT
301ELRV
120 VOLT CONNECTORS SERIESED TOGETHER
[0000]
NAME PLATE BILL OF MATERIALS
REF
DESCRIPTION
SIZE
COLOR
A
THERMAL DE-ICER
4 × 1½
WHITE
ROOF HEATING SYSTEM
B
PROCESS CONTROL
2½ × ¾
WHITE
C
HEATER HIGH-LIMIT
2½ × ¾
WHITE
D
HOTFOIL - EHS INC.
3 × 2
WHITE
2960 EAST STATE STREET EXT.
HAMILTON, NJ 08619
609-588-0900
E
POWER-ON LIGHT
2 × ⅝
WHITE
F
HEATER-ON LIGHT
2 × ⅝
WHITE
[0027] It should be noted that FIG. 6 c illustrates weather tight 120 volt connectors 16 located on the control box 2 itself. FIG. 6 d shows a further embodiment of the invention whereby 120 volt connectors 17 are separate from the control box 2 (e.g., are located on the rear of the trailer).
[0028] FIG. 7 depicts layers used in the construction of the heating mat according to one embodiment of the invention. In this embodiment, aluminum foil approximately 1 Mil thick is used as the heating element 740 . This foil 740 is encapsulated into a pressure sensitive nylon coating 730 that is 0.5-1.0 Mil thick that is then used to bond the nylon carrier to a polyester carrier layers 720 , each not less than 4 Mil thick. This polyester carrier 720 is self-adhesive and allows the two carriers 720 to essentially become one structure. Self adhesive coatings 710 are then applied to the top and bottom of the structure, the coatings each being no less than 0.5 Mil thick and having dual adhering sides. At the top of the resulting structure, the respective adhesive coating will bond directly to the vehicle surface to be heated (e.g., a trailer roof 110 ). At the bottom of the resulting structure, the respective adhesive coating will bond to an insulation layer (e.g., layer 130 ). In the construction process, once the layers are arranged in the above manner, the structure is slightly heated and then rolled together to remove most air trapped between the layers and also to seal the layers together.
[0029] It should be noted that the control embodiments of the present disclosure may be implemented with any combination of hardware and software. If implemented as a computer-implemented apparatus, the present disclosure is implemented using means for performing all of the steps and functions described above.
[0030] While specific embodiments have been described in detail in the foregoing detailed description and illustrated in the accompanying drawings, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure and the broad inventive concepts thereof. It is understood, therefore, that the scope of the present disclosure is not limited to the particular examples and implementations disclosed herein, but is intended to cover modifications within the spirit and scope thereof as defined by the appended claims and any and all equivalents thereof. | A heating element employs electrical resistance foils to provide a uniform heat that is used to prevent snow and ice from accumulating on the surfaces of vehicles. | 7 |
This application is a continuation-in-part of application Ser. No. 08/517,379 filed Aug. 21, 1995 now U.S. Pat. No. 5,839,946. This application also claims benefit to U.S. Provisional application No. 60/073,824 filed Feb. 5, 1998, which is a 371national stage entry of PCT/US 96/11696 filed Jul. 15, 1996.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to the art of continuous ambulatory peritoneal dialysis ("CAPD") support undergarments. The invention particularly relates to an undergarment which comfortably holds in place a CAPD catheter, and can be worn around the abdomen or hips of a CAPD patient, thus allowing versatility in the concealment of the CAPD catheter while achieving a greater sense of confidence and self-esteem for the CAPD patient.
As is known to those familiar with continuous ambulatory peritoneal dialysis, a surgically implanted catheter provides an opening through which dialysis solution can be instilled into the abdominal cavity of a peritoneal dialysis patient. The surgically implanted catheter is normally fabricated from a soft, flexible tube material. When not being used to introduce or remove fluid, the catheter is capped or otherwise closed off at its end. Since movement of the external portion of the catheter can cause irritation and infection at the exit site, the protruding catheter needs to be secured against the patient's body, thus providing greater protection and comfort.
2. Description of the Related Art
To Applicants' knowledge, the typical CAPD patient secures the protruding catheter to their body by utilizing adhesive tape. To access the catheter, the tape must be removed and then reapplied upon completing the dialysis procedure. This repeated removal and reapplication of adhesive tape causes severe irritation and pain in many CAPD patients.
Several prior U.S. patents provide belts for securing to the CAPD patient the implanted peritoneal dialysis catheter exiting from the abdomen of the patient. For example, U.S. Pat. No. 4,955,867, issued to Endo, discloses a peritoneal dialysis catheter protector belt comprising a fabric or paper belt or band, which may be disposable, and which is adapted to be fastened around the abdomen of a patient adjacent to the protruding end of a peritoneal dialysis catheter. The belt is equipped with an open-ended pouch which is located on the outer surface of the belt and into which the end of the catheter may be inserted to enclose and protect the end of the catheter and to prevent it from dangling. The belt is not designed to be worn over, and thus cover, the catheter exit site. Moreover, the patent fails to specifically define any fabrics which may be used to fabricate the belt. Further, Applicants have found that a belt having a single pouch on the outer surface of the belt allows the catheter to work its way out of the pouch as the patient moves about throughout the day. This being due to the fact that the pouch fails to hold the catheter in position against the patient's body.
U.S. Pat. No. 5,468,229, issued to Chandler, discloses a belt for a peritoneal dialysis patient having an aperture for receiving and orienting the protruding portion of an implanted catheter toward a plurality of holders along a outer portion of the belt. Chandler broadly discloses that the belt may be made of an elastic material and is designed so that the catheter is fed through an aperture on the inner surface of the belt and exits the aperture at an outer surface and is then placed into a plurality of holders located on the outside of the belt. Although the belt can be worn over the catheter exit site, the patent requires that the patient feed the catheter through the aperture to the outer surface of the belt, where it is secured. The patent broadly discloses that the belt can be fabricated from "an elastic material", but fails to specifically identify such material.
U.S. Pat. No. 5,496,282, issued to Militzer et al., discloses a belt for stabilizing an implanted peritoneal dialysis catheter exiting from the abdomen of a user. The belt includes a body of elasticized fabric designed to encircle the patient, and includes two fasteners with hook and pile features, and a receptacle located on the outer surface of the belt. The belt also includes two fasteners for securing the catheter to the outer portion of the belt. The belt is not designed to be worn over the catheter exit site. Further, although the belt is disclosed as including an elastic material, the patent fails to specifically identify such material.
The subject matter of each of the above U.S. patents is herein incorporated by reference.
It is an object of the present invention to overcome the deficiencies of the prior art by providing a catheter support undergarment which is manufactured from carefully selected expandable material. The undergarment also provides for extremely easy and convenient use by providing a pocket on the inner surface of the undergarment and a fastening and unfastening means which is located at the patient's side when the undergarment is worn. This allows the patient to easily insert the catheter into the pocket and simply wrap the ends of the undergarment around either their waist or hips and attach the ends together at their side. Many CAPD patients are elderly and may have difficulty fastening an undergarment at the back and also may have difficulty feeding the catheter through an aperture or the like to a pocket or securing means on the outer surface of the garment. By locating the pocket at the inner surface of the undergarment, the undergarment also serves to hold the catheter in place against the patient's body. Also, by providing the pocket on the inner surface of the undergarment, the patient is able to completely cover the catheter exit site, thus protecting the site from rubbing against outer garments, belts and the like, while at the same time providing a layer of fabric between the patient's skin and the catheter.
SUMMARY OF THE INVENTION
In accordance with aspects of this invention, it has been found that a catheter support undergarment may be provided for a peritoneal dialysis patient wherein the undergarment comprises a pocket portion located on the inner surface of the belt as well as a first end portion and a second end portion, each having thereon proximate the distal edge of the end portion, cooperating attaching means, such as hook and loop fastening materials. The first and second end portions of the undergarment are provided such that one end portion is shorter in length than the other end portion so that when the undergarment is placed in position such that the catheter is placed within the pocket, the distal edge of each end portion will be located on one side of the patient.
As is well known to those in the art, during treatments, the peritoneal dialysis patient experiences a certain degree of swelling, which results in an expanding waistline. The undergarment of the present invention is able to adjust to this changing condition by fabricating the undergarment from a material capable of easily expanding and contracting, thus comfortably conforming to the changing waistline of the patient during the time the solution dwells in the peritoneal cavity, yet remain tight enough against the body to hold the catheter in place.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective representation of the undergarment of the present invention showing the inner surface of the undergarment;
FIG. 2 is perspective representation of the belt of the present invention, showing the outer surface of the undergarment.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with the present invention, an undergarment is provided which is capable or supporting and substantially completely covering the catheter of a CAPD patient. The undergarment comprises an expandable material having an inner surface, an outer surface, a first end portion and a second end portion. The inner surface of the belt is provided with a pocket for receiving the catheter. The first end portion and the second end portion of the undergarment are designed so that one end portion is longer in length than the other, such that when the undergarment is positioned on and wrapped around the patient, the first and second end portions of the undergarment will be located on the side of the patient. A better understanding of the invention will be apparent with reference to the Figures.
FIG. 1 is a perspective view of the inner surface of the undergarment 10 of the present invention. As can be seen, the undergarment 10 is provided with a pocket 14 located at the inner surface 13 of the undergarment. The undergarment additionally includes a first end portion 11 and a second end portion 12. The first end 11 is provided with a distally located fastening means 15. The second end portion 12 is provided with a distally located corresponding fastening means 16. In FIG. 1, first end portion 11 is shown as being shorter in length than second end portion 12, such that when the catheter is inserted into pocket 14 at the front of the patient, end portion 12 will wrap substantially around one side and the back of the patient to come into engagement with first end portion 11 wherein the preferred fastening means comprising a hook and loop fastening system enables the patient to easily fasten the undergarment at the patient's side.
FIG. 2 is a perspective view of the front side 17 of the undergarment 10 of the present invention. Again, this embodiment shows first end portion 11 being somewhat shorter in length than second end portion 12 such that when positioned on the patient, the end portions will come together on the side of the patient where they may be easily fastened by the hook and loop fastening means shown in the figures.
Although specifically shown in the figures as hook and loop fasteners, the fastening mechanism utilized in the present invention could be any suitable securing means which allows the patient to easily engage and disengage the undergarment. For example, suitable fastening means include, but are not limited to, buttons, snaps, buckles, re-usable adhesive tape, etc.
The undergarment is constructed of an expandable material which is capable of conforming to the ever changing waistline of the CAPD patient, yet provide necessary support to hold the catheter in place against the patient. Particularly preferred materials include fabric blends and more particularly fabric blends which include at least some spandex fiber. A particularly preferred spandex is LYCRA ® spandex which is available from the DuPont Company.
Additionally, preferred materials which can be utilized in conjunction with spandex include, for example, cotton and/or nylon. In a preferred embodiment the undergarment comprises at least about 10 volume percent spandex. In one preferred embodiment the material comprises a fabric blend of about 10 volume percent spandex and about 90 volume percent cotton. In another preferred embodiment the undergarment comprises about 10 volume per cent spandex and about 90 volume per cent nylon. In a further preferred embodiment, the undergarment comprises about 10 volume percent spandex and about 90 volume percent of a combination of nylon and cotton.
By carefully choosing the proper fabric blend, which includes in a preferred embodiment at least some spandex, an undergarment can be provided with very desirable properties. Spandex has the ability to stretch to about five times its initial length and virtually instantaneously return to its original shape. By blending at least some spandex with either, for example cotton and/or nylon, a very desirable CAPD catheter support undergarment is obtained.
By utilizing at least some spandex, an undergarment is provided which easily conforms to the expanding waistline of the CAPD patient and is additionally very durable and comfortable. The undergarment can be worn in the shower and holds up well under repeated washings and drying. Since the undergarment is provided, in a preferred embodiment, by blending or weaving fabrics together by any known technique, the belt is easily manufactured to the various waist sizes of various patients. Additionally, the undergarment can be fabricated at a very low cost.
The pocket of the undergarment is designed to be sufficiently large as to substantially completely enclose the catheter, thus protecting the catheter from contacting and rubbing against the patient's clothes and skin. This assures the patient that the cap (or other means for closing off the catheter) of the catheter will not work its way free from rubbing against either the outer clothes or the skin of the patient.
As stated above, the pocket is located at the inner surface of the undergarment. In one embodiment the pocket is formed by attaching additional material, such as by sewing, to the inner surface material of the undergarment. When attaching the additional material, a portion of the additional material is not attached to the inner surface of the undergarment, thus forming the opening of the pocket to allow for placement of the catheter therein. In a second embodiment, the pocket may be formed by cutting or slicing a slit in the inner surface of the undergarment to form an opening between material forming the outer surface of the undergarment and material forming the inner surface of the undergarment. Other methods of forming a pocket at the inner surface of the undergarment should now be apparent to those skilled in the art.
In an additionally preferred embodiment, the pocket portion of the undergarment is provided to have a width wider than the width of the first and second end portions of the undergarment. Preferably the pocket portion has a width of about two inches and the end portions are provided in widths of about one inch. This provides for increased comfort of the patient since the pocket portion of the undergarment needs only be wide enough to comfortably secure and enclose the catheter. The end portions need only be provided in widths sufficient to secure the undergarment in place.
While the preceding description is merely exemplary in nature, many variations will become apparent to those of skill in the art. Such variations, of course, are included within the spirit and scope of this invention as defined by the following claims. | This invention relates to a continuous ambulatory peritoneal dialysis catheter support undergarment which allows for easy use and comfortable wearing by the patient. Additionally, the undergarment is versatile in that it may be worn virtually undetectable under clothing and is also designed to be sufficiently durable to withstand many washing and drying cycles. The belt also is capable of conforming to the ever changing waistline of a continuous ambulatory peritoneal dialysis patient. | 0 |
BACKGROUND OF THE INVENTION
Successful growing of grass turf or sod on a commercial scale requires the covering of seedling grass with a special textile netting designed for this purpose. The netting is stretched over the growing area which may be many acres and is engaged with rigid members inserted in the soil at regular intervals around the margin of the plot. The inserting operation when carried out manually is extremely laborious and costly. Accordingly, it is the objective of the invention to eliminate this manual labor and reduce the cost of inserting the rigid members into the soil at regular intervals through provision of a simplified and compact self-contained automatic inserting machine which may be tractor drawn and can derive its power from the power take-off shaft of the tractor and from the tractor electrical system. Ideally, the invention is realized in a continuously moving machine which travels at a speed approximating 11/4 to 11/2 miles per hour and automatically inserts elongated rigid members into the soil vertically at a rate of twenty-two per minute which results in a uniform spacing of the members of approximately four feet apart.
The member inserting machine in essence comprises a wheeled frame adapted to be drawn by a tractor, a movable carriage on the frame adapted to move horizontally forwardly and rearwardly thereon, a member delivery and inserting mechanism and a member supply hopper on the carriage bodily moving therewith, and power drive means for the carriage and the member inserting and delivery mechanism including the ground wheels of the frame, gearing between such wheels and the carriage, and a single inserting power cylinder whose movements are transmitted mechanically to a delivery plunger for the members which are held in a storage hopper on the carriage. The inserting cylinder for the members receives motive fluid from a reservoir on the wheeled frame through a pump connected with the power take-off shaft of the tractor and solenoid operated valve electrically coupled with switches in a control box on the wheeled frame. Cooperative timing switches and an electrical clutch initiating and terminating rearward carriage movement and provided.
Additional features and advantages of the invention over the known prior art will become apparent during the course of the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation of a rigid member inserting machine according to the invention.
FIG. 2 is a perspective view of an elongated rigid member.
FIG. 3 is a plan view of the machine.
FIG. 4 is an enlarged fragmentary longitudinal vertical section taken on line 4--4 of FIG. 3.
FIG. 5 is an enlarged transverse vertical section taken on line 5--5 of FIG. 3.
FIG. 6 is a horizontal section taken on line 6--6 of FIG. 5.
FIG. 7 is a perspective view of a delivery plunger for inserted members.
FIG. 8 is a rear elevation of a wheeled frame and associated parts forming the body portion of the machine.
FIG. 9 is an enlarged fragmentary vertical section taken on line 9--9 of FIG. 8.
FIG. 10 is an enlarged fragmentary vertical section taken on line 10--10 of FIG. 3.
FIG. 11 is a view similar to FIG. 10 with cooperative parts shown in different operative positions from the positions shown in FIG. 10.
FIG. 12 is a fragmentary vertical section taken on line 12--12 of FIG. 10.
FIG. 13 is a fragmentary perspective view of carriage drive components.
FIG. 14 is a fragmentary perspective view of a timer cam and associated elements.
FIG. 15 is an electrical and fluid schematic depicting the relationship of components in the operational cycle of the machine.
DETAILED DESCRIPTION
Referring to the drawings in detail wherein like numerals designate like parts, a machine for automatically inserting elongated rigid members in the ground at regular intervals comprises a horizontal wheeled frame 20 forming the body portion of the machine and including a forward draft tongue 21 adapted to be coupled to the drawbar 22 of a farm tractor 23 having a power take-off shaft 24.
The frame 20 is supported at its rear end by ground wheels 25 on a transverse axle 26 held in bearings 27 depending from the sides of frame 20. Above the axle 26 is a rigid transverse cross beam 28 whose opposite ends are rigid with side parallel channel members 29 of the frame 20.
Mounted for fore and aft movement on the frame 20 in accordance with an important aspect of the invention is an underslung transverse carriage 30 consisting of a bottom sturdy transverse horizontal channel 31 having side upstanding vertical arms 32 rigidly attached thereto. The tops of the arms 32 on their outer sides have carriage plates 33 rigidly secured thereto, the plates 33 carrying pairs of horizontally spaced guide rollers 34 which rollingly engage the channels 29.
The carriage 30 is biased toward a forward position on the wheeled frame 20 by opposite side retractile springs 35 connected between the plates 33 and a forward cross beam 36 of the frame 20. At proper times, the carriage 30 is propelled rearwardly on the channels 29 of frame 20 by drive chains 37 engaged with rear sprockets 38 secured to a horizontal transverse shaft 39 held in bearings 40 seated on the cross beam 28. The chains 37 are similarly engaged with front sprockets 41 mounted on another transverse shaft 42 held in bearings 43 on upright frame members 44.
The opposite end terminals of chains 37 are connected at 45, FIGS. 4 and 13, to fixed lugs 46 on the plates 33. Power to drive the carriage 30 rearwardly on the frame 20 against the biasing force of springs 35 is produced by the forward rolling of the two ground wheels 25 whose axle 26 has a sprocket 47 secured thereto between one wheel 25 and the adjacent bearing 27. An endless chain 48 engaged with sprocket 47 is also engaged with a sprocket 49 carried by an elevated shaft 50 parallel to the axle 26 and above the frame 20 and somewhat rearwardly of the axle 26, as best shown in FIG. 4.
The shaft 50 which is supported by a bearing 51 atop the beam 28 near its outer end is further supported near the center of the machine by a member 52 welded to the beam 28. At its inner end, the shaft 50 is connected to the input rotary part of a conventional electric clutch 53' whose output rotary part when the clutch is energized and engaged drives a short shaft 53a carrying a sprocket 53 engaged by a chain 54 which engages another sprocket 55 on the shaft 39 near the center of the machine. The two shafts 39 and 50 are at the same elevation and are parallel.
A comparatively short timer shaft 56 below the shaft 50 and parallel therewith is journaled in a bearing 57 secured to an arm 58 fixed to the bottom of beam 28, FIG. 14. The arm 58 also mounts an electrical timing switch 59 on one side thereof, whose actuator 60 is tripped by rotation of a single lobe timing cam 61 on shaft 56. The timer shaft 56 is driven by a sprocket 62 engaged with the chain 48 which is also engaged with driving sprocket 47 and overhead sprocket 49 on clutch shaft 50.
It can be seen that when the electric clutch 53' is de-energized and disengaged during forward movement of the machine, rotation of the ground wheels 25 will impart no rotation through the clutch to the chain 54 and shaft 39. Consequently, there will be no movement of the carriage 30 rearwardly on the frame 20, and such rearward movement will occur only when the electric clutch 53' is engaged, as will be further discussed.
In accordance with another major feature of the invention, cyclically operated means to automatically insert rigid elongated members into the ground at regular intervals is bodily mounted on the carriage 30 to reciprocate therewith. Each inserted member may comprise a 6" long by 1/2" diameter tube 63 shown in FIG. 2. Other types of members can be inserted by the machine.
The above inserting means on the carriage 30 comprises a supply hopper 64 for a large number of the members 63 in parallel stacked relationship. The floor 65 of hopper 64 slopes, FIG. 12, so that one member 63 will always gravitate to the lower corner of the hopper whose opposite side walls 66 have a through opening 67 at this corner through which each lowermost member 63 may be moved or pushed axially by a delivery plunger 68 into a positioning trough 69 at the outlet side of the hopper 64. The hopper is based on legs 70 rising from the member 31 of carriage 30.
The positioning trough 69 includes a horizontal floor 71 immediately beneath the hopper 64 and in fact comprised of the lower corner of the hopper. The floor or wall 71 leads to a curved descending wall 72, in turn leading to a descending vertical guide portion 73 of the trough 69 having a weak flapper valve 74 at its lower end to temporarily arrest downward movement of each member 63 until the latter is positively acted on by a vertical reciprocatory driving or inserting plunger 75.
It may be understood in FIGS. 10 and 11 that when each member 63 in succession at the bottom corner of the hopper 64 is advanced by the plunger 68 through opening 67 onto the curved wall 72, the member will slide and topple by gravity into the vertical portion 73 of trough 69 and will rest on the flapper element 74 in a vertical position until the inserting plunger rod 75 descends to push the member 63 into the soil at the moment when the carriage 30 is stationary relative to the ground at the rear end of its travel on the frame 20.
The two plungers 68 and 75 have their movements coordinated with each other and also with the fore and aft movement of the carriage 30. The plunger 75 is moved vertically by a single power cylinder 76 supported by an adjacent post 77 rising from the carriage member 31. This post carries at least one guide element 78 for the vertical plunger 75 whose lower end portion must enter the descending vertical section 73 of the trough 69 with some precision.
The vertical plunger rod 75 is mechanically linked to the horizontal plunger 68 by a chain 79 having one end attached as at 80 to the plunger rod 75. The chain 79 engages a guide sprocket 81 supported by a post 82 rising from carriage member 31. The chain engages another sprocket 83 carried by a shaft 84 projecting laterally from a square cross section carriage bar 85 for plunger 68. The carriage bar 85 is supported horizontally and movably on V-rollers 86 supported on posts 87 rising from the member 31. The carriage bar 85 and plunger 68, which are integrally connected, are biased to a retracted position by a spring 88, as best shown in FIG. 6. A control switch 89, whose purpose will be described, is attached to carriage member 32 with its actuator in the path of movement of carriage bar 85 so that the switch will be tripped when plunger 68 is fully retracted from the hopper 64, FIG. 6. It may be seen that when the vertical plunger rod 75 descends under influence of power cylinder 76 to insert a member 63 in the ground, FIG. 10, simultaneously the return spring 88 will cause retraction of plunger 68 to the position shown in FIG. 6 and also in FIG. 10, the other end of the chain 79 being attached at 90 to the post 87. When the plunger rod 75 rises or is retracted by the piston in cylinder 76, as shown in FIG. 11, the horizontal plunger 68 will simultaneously be thrust forwardly with the guided carriage bar 85 to eject one of the members 63 from the bottom of the hopper 64 into the holding and positioning trough 69, as previously described.
For the sake of safety, opposite side screen guards 91 mounted on the wheeled frame 20 enclose the chain gearing components at the opposite sides of the machine.
The tractor power take-off shaft 24 drives a hydraulic pump 92 which receives fluid through a line 93 from a tank 94 fixed on the frame 20. The pump delivers pressurized fluid through a line 95 to the inlet of a two position solenoid valve 96 shown in FIGS. 3 and 15. This valve delivers and returns fluid through two lines 97 and 98 depending on the setting of the valve to fittings on the cylinder 76 which is a double-acting cylinder. There is also a filter 99 connected in a return line 100 leading from the two-way valve 96 through a cooler 101 and back to the tank 94 by means of a line 102.
A low pressure sensor 103 and a higher pressure sensor 104 are connected through the two-way valve 96 and through the lines 97 and 98 with the high and low pressure ends of cylinder 76. The greater pressure in the cylinder 76 will be above its piston 76' when a member 63 is being driven downwardly into the ground by the plunger rod 75. A lower pressure in the cylinder below the piston 76' is sufficient to retract the plunger rod 75. The low and high pressure sensors 103 and 104 are connected through lines 105' and 105a with low and high pressure switches 105 and 106, respectively, both located in a control box 107 on the frame 20. These two switches, in turn, are electrically connected by wires 108 and 109 with the two solenoids 110 and 111 of two-way spool valve 96.
The solenoids 110 and 111 are connected through wires 112 and 113 with the switch 89 at the rear end of carriage bar 85 carrying plunger 68 and with the conventional DC battery 114 of tractor 23, which battery is series connected with the timer switch 59 operated by cam 61.
One terminal of switch 59 is connected through a wire 115 and another wire 116 with the stationary terminals of pressure switches 105 and 106. Another wire 117 electrically connects the timer switch 59 with a terminal of the electric clutch 53' which controls the rearward movement of carriage 30 on the wheeled frame 20 against the force of return springs 35. The other terminal of electric clutch 53' is connected by a wire 118 with a terminal of switch 89, as shown in FIG. 15.
An optional feature of the invention is to provide a furrow-forming disc 119 depending from the frame 20 forwardly of the vertical plunger rog 75 to continuously cut a narrow furrow or slit in the soil in order to clear it of rocks and other obstructions which would impede the driving of the rigid members 63 into the soil.
Summary of Operations
The machine is pulled forwardly continuously by tractor 23 at a speed of about 11/4 MPH. The power take-off shaft 24 will continuously drive the pump 92 and electrical power is supplied to the system shown in FIG. 15 by the tractor battery 114.
The continuous rotation of ground wheels 25 forwardly through the gearing shown in FIG. 4 causes continuous rotation of timer shaft 56 and cam 61 as well as clutch shaft 50. If the clutch 53' is de-energized, there is no rotation of shaft 39 and therefore no movement of carriage 30, as previously explained.
The rotating cam 61 will trip or close switch 59 and, through wire 115, switch 105 and wire 108, solenoid 110 of valve 96 is energized shifting the valve spool to its second position whereby the pump 92 delivers pressurized fluid to the top of cylinder 76, driving the vertical plunger rod 75 down to insert a member 63 held in the vertical portion 73 of trough 69 into the ground, FIG. 10. Simultaneously, the spring 88 retracts plunger 68 to the reloading position relative to the hopper 64 and another member 63 drops into the horizontal lower corner of the hopper, FIGS. 10 and 12, ready for the next cycle.
Simultaneously with the closing of switch 59 to energize solenoid 110, the electric clutch 53' is energized and engaged to transmit power to the carriage drive shaft 39, thereby causing the carriage to begin moving in a reverse direction relative to the forwardly moving frame 20. This carriage movement occurs while plunger rod 75 is descending.
The switch 89 at the rear of retracting carriage bar 85 will be opened to cause a brief interruption of hesitation of the carriage 30 in its rearward movement, after which the carriage continues rearwardly until reaching the end of its travel. The carriage is returned forwardly by springs 35.
Responding to high pressure above the piston 76' when the member 63 is inserted in the ground through pressure sensor 104, the switch 106 will be closed while switch 105 opens. Through wire 109, solenoid 111 is energized shifting the valve spool to the position shown in FIG. 15 where the pump 92 can deliver fluid through line 97 to the bottom of cylinder 76, retracting and elevating plunger rod 75. When this occurs, the plunger 68 travels forwardly, being driven by chain 79 attached to plunger rod 75, and plunger 68, FIG. 11, advances another element 63 into the positioning trough 69 where such element or member topples into the vertical tubular portion 73 of the chute ready for the next insertion when plunger rod 75 descends.
At the moment of insertion into the ground, the carriage 30 at the rear end of its travel is stationary relative to the ground resulting in each member 63 being driven vertically to the desired depth while the machine moves forwardly without interruption. When moving at a speed not exceeding 11/2 MPH, the machine will insert approximately twenty-two objects per minute with consistent precision and uniformity and regular spacing. The entire operation is automatic resulting in a savings of much time and labor. The spacing between inserted members 63 can be varied by changing the diameter of sprocket 49.
It is to be understood that the form of the invention herewith shown and described is to be taken as a preferred example of the same, and that various changes in the shape, size and arrangement of parts may be resorted to, without departing from the spirit of the invention or scope of the subjoined claims. | A continuously slowly moving machine automatically inserts rigid elongated members in the ground at regular intervals along the perimeter of a large field to facilitate anchoring a taut textile net placed over seedling grass. Several thousand of the members must be inserted around the perimeter of a typical turf-growing plot at a spacing of a few feet apart. Ground wheels of a moving frame generate movement of a carriage which travels horizontally on the moving frame rearwardly and forwardly. The carriage supports the inserting mechanism for the members which includes a single inserting upright cylinder and a connected coordinated delivery plunger for each member advancing each member to a ready vertical position beneath the rod of the cylinder. When the carriage is at the rear of its travel relative to the moving frame substantially at zero ground speed, a member is inserted in the soil by the rod of the cylinder accompanied by simultaneous retraction of the delivery plunger. The several machine movements are precisely timed and coordinated. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] None.
BACKGROUND OF THE INVENTION
[0002] The present invention generally relates to smoking product holders, and particularly to a holder that releasably attaches to the top of a beverage container.
[0003] Frequently, individuals that enjoy smoking tobacco products such a cigars, cigarettes, or tobacco vaporizers commonly referred to as e-cigarettes or digital vapor cigarettes smoke their chosen tobacco product while also consuming beverages. For example, some smokers may find that certain beverages—such as scotch, bourbon, or beer—provide a complimentary flavor that enhances the enjoyment of their preferred tobacco products when the beverage and the tobacco products are consumed together.
[0004] Unfortunately, when enjoying a smoking product and a beverage at the same time, the individual may find that both of his or her hands are occupied—one with the beverage, and the other with the smoking product. Additionally, since both the beverage and the smoking product are easily portable, the individual may find himself or herself in a place far from an ashtray but needing to free one or both hands to attend to another task. Since smoking products generate heat and can damage the surfaces of furniture or counter tops if placed directly thereon, it may be advantageous to provide a holder upon which to rest the smoking product such that it is elevated above the surface of furniture or counter tops.
[0005] Additionally, individuals may find themselves in a social setting where others may also be consuming beverages and/or smoking products. If the individual momentarily sets his or her beverage and/or smoking product aside in next to beverages or smoking products belonging to others, the individual may be confused as to which beverage or smoking product belongs to whom. Thus, it may be advantageous to provide a structure that keeps and individual's beverage and smoking product together in one place, in order to avoid confusion and the dreaded loss of a partially-consumed beverage or smoking product.
[0006] Given the foregoing, it would be desirable to provide a structure which addresses these and other deficiencies so that an individual may more thoroughly enjoy his or her beverage and smoking product.
SUMMARY
[0007] One object of the invention may comprise providing a holder for an elongated smoking product comprises a base portion and a cradle portion connected to said base portion; the base portion further comprises a generally vertical recess defined within the base portion; wherein the cradle is capable of receiving and supporting the elongated smoking product; and wherein the recess is capable of receiving therewithin an end of a generally cylindrical drink container such that the holder is releasably fixed to the generally cylindrical drink container.
[0008] Another object of the invention may comprise providing a holder for an elongated smoking product, comprising a base portion, and a cradle portion connected to the base portion; the base portion further comprising a generally vertical recess defined within the base portion; the cradle portion further comprising a generally horizontal, upward-opening longitudinal channel; wherein the longitudinal channel is capable of receiving therewithin an elongated smoking product so as to support the elongated smoking product in an elevated position above the base portion; and wherein the recess is capable of receiving therewithin an end of a generally cylindrical drink container such that the holder is releasably fixed to the generally cylindrical drink container.
[0009] Still another object of the invention may comprise providing a holder for an elongated smoking product, comprising a base portion and a cradle portion connected to the base portion; the base portion having a generally cylindrical vertical recess defined within the base portion; the cradle portion further comprising a generally horizontal upward-opening longitudinal channel; wherein the longitudinal channel is capable of receiving therewithin the elongated smoking product so as to support the elongated smoking article in an elevated position above the base portion; and wherein the recess further comprises a generally vertical recess wall, the recess wall further comprising at least one resilient retaining member, wherein the at least one resilient retaining member releasably engages an exterior surface of a generally cylindrical drink container received within the vertical recess such that the holder is releasably fixed to the generally cylindrical drink container.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] In order that the invention may be better understood, embodiments of the beverage container mounted holder for smoking products and methods of use thereof in accordance with the present invention will now be described by way of examples. These embodiments are not to limit the scope of the present invention as the invention is capable of other embodiments and of being practices or of being carried out in various ways.
[0011] FIG. 1 illustrates a first perspective view of an embodiment of the present invention;
[0012] FIG. 2 illustrates a second perspective view of an embodiment of the present invention;
[0013] FIG. 3 illustrates a perspective view of an embodiment of the present invention being used to hold a smoking product and being attached to a beverage container; and
[0014] FIG. 4 illustrates a perspective view of an embodiment of the present invention being attached to a beverage container.
DETAILED DESCRIPTION
[0015] The present invention now will be described more fully hereinafter with reference to the accompanying drawings, which form a part hereof, and which show, by way of illustration, specific exemplary embodiments by which the invention may be practiced. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete and convey the scope of the invention to those skilled in the art. Among other things, the present invention may be embodied as methods or devices. The following detailed description is, therefore, not to be taken in a limiting sense.
[0016] It is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. Throughout the specification and the claims, the following terms take the meanings explicitly associated herein, unless the context clearly dictates otherwise. The phrase “in one embodiment” or “in some embodiments” or “in a preferred embodiment” as used herein does not necessarily refer to the same embodiment, though it may. Furthermore, the phrase “in another embodiment” as used herein does not necessarily refer to a different embodiment, although it may. Thus, as described below, various embodiments of the invention may be readily combined, without departing from the scope or spirit of the invention. In addition, the phrase “present invention” or “object of the present invention” does not necessarily refer to nor is intended to limit the invention to the specific embodiment or feature described.
[0017] In addition, the use of “including,” “comprising,” or “having” and variations thereof herein is mean to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms “connected,” “coupled,” “mounted,” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings. In addition, the terms “connected” and “coupled” and variations thereof are not restricted to physical or mechanical connections or couplings.
[0018] Additionally, as used herein, the term “or” is an inclusive “or” operator, and is equivalent to the therm “and/or,” unless the context clearly dictates otherwise. The term “based on” is not exclusive and allows for being based on additional factors not described, unless the context clearly dictates otherwise. Throughout the specification, the meaning of “a,” “an,” and “the” include plural references. The meaning of “in” includes “in” and “on.”
[0019] Referring now to FIG. 1 , an embodiment of the smoking product holder 10 may comprise a base 20 and a cradle 40 . The smoking product holder 10 may be formed of various materials, such as lightweight metallic or lightweight plastimerics or polymerics which should provide some level of stiffness without being so rigid as to break during normal use. In the embodiment shown in FIG. 1 , base 20 and cradle 40 are connected to each other by an intermediate connection 60 .
[0020] In one embodiment, base 20 defines a bottom surface 22 and a top surface 24 , an exterior wall 26 therebetween, and a generally vertical axis AV. In the embodiment shown in FIG. 1 , base 20 is a generally cylindrical; however, it may be any suitable shape such as a rectangular, hexagonal, hemispherical, or the like.
[0021] In a preferred embodiment, Base 20 further defines a vertical recess 30 therewithin, which has a recess opening 32 defined within bottom surface 22 , a recess wall 36 extending generally vertically upward parallel to axis AV towards top surface 24 . In one embodiment, recess wall 36 may optionally terminate at a recess ceiling 34 , located vertically intermediate recess opening 32 and base top surface 24 along axis AV. In another embodiment, recess 30 may extend along the entire height of base 20 such that recess wall 36 originates at bottom surface 22 and terminates at top surface 24 .
[0022] Referring now to both FIGS. 1 and 2 , in a preferred embodiment cradle 40 defines a floor 42 that is connected to base 20 by connection 60 such that cradle 40 is positioned vertically distal from base bottom surface 22 . In the embodiment shown cradle floor 42 is connected to base top surface 24 by intermediate connection 60 shown as a generally vertical pedestal; however in other embodiments cradle floor 42 and base top surface 24 may be connected integrally, welded, or connected by other means, such as a bendable flex-arm or the like. Additionally, in still other embodiments, cradle 40 may be connected to base exterior wall 26 and extend generally horizontally outward from base 20 or, alternatively, cradle 40 may extend angularly upward from base 20 .
[0023] In one embodiment, cradle 40 defines a generally horizontal longitudinal axis AL ( FIG. 1 ) and may have a longitudinal channel 46 running along axis AL and opening generally vertically upward. Cradle 40 may also have two spaced-apart sidewalls 44 , 45 that depend generally upward from floor 42 . In this embodiment, Floor 42 and sidewalls 44 , 45 are preferably all oriented generally parallel to longitudinal axis AL and together define longitudinal channel 46 . In the embodiment shown in FIGS. 1 and 2 , floor 42 and sidewalls 44 and 45 are arranged such that longitudinal channel 46 has a generally U-shaped profile; however, in other embodiments, longitudinal channel 46 may have alternative profile shapes, such as the V-shaped longitudinal channel shown in the embodiment illustrated in FIG. 4 , a square profile shape, a semi-circular profile shape, or other appropriate profile shapes.
[0024] Turning to FIG. 3 , in a preferred embodiment, base 20 is dimensioned such that recess opening 32 and recess wall 36 are sized appropriately to releasably accept an end of a beverage container 70 such that holder 10 is releasably fixed to the beverage container. As shown in the embodiment represented in FIG. 3 , beverage container 70 is a typical beer bottle; however, it should be understood that in other embodiments base 20 , recess opening 32 , and recess wall 36 may all be sized such that recess 30 ( FIGS. 1 and 2 ) is capable of releasably accepting a variety of different sized beverage containers, including but not limited to aluminum cans, rocks glasses, tumblers, or wine bottles. In yet another embodiment, base 20 may be formed at least in part from a resilient material such as an elastomeric polymer that allows recess opening 32 and recess wall 36 to resiliently deform so as to accommodate a variety of different sized beverage containers. In still another embodiment, base 20 may be adjustable so as to accept a wide variety of different sized beverage containers.
[0025] Additionally, in a preferred embodiment cradle 40 is dimensioned such that longitudinal channel 46 is sized appropriately to releasably receive a generally cylindrical elongated smoking product 80 such that the smoking product's longitudinal axis AS is oriented generally parallel to longitudinal axis AL of channel 46 . In the embodiment illustrated in FIG. 3 , cradle 40 is sized appropriately to receive a smoking product 80 represented as a cigar having having a large bore diameter D; however, in other embodiments, longitudinal channel 46 may be sized appropriately to receive a cigarette, an e-cigarette, or other smoking product having a smaller bore diameter than the smoking article 80 depicted in FIG. 3 . In an other embodiment, cradle 40 may be sized appropriately such that channel 46 may receive a variety of different smoking articles having a diverse range of bore diameters.
[0026] Turning to FIG. 4 , another embodiment of holder 110 is shown, having a recess wall 136 may optionally define a circumferential resilient retaining member 138 positioned vertically intermediate recess opening 132 and recess ceiling 134 . In one embodiment, retaining member 138 may be a resiliently deformable ridge running along a sufficient portion of recess wall 136 such that retaining member 138 releasably engages a lip 72 from finish region 74 of a traditional bottle 70 . As bottle finish region 74 is inserted into vertical recess 130 , lip 72 impinges upon and thereby compresses retaining member 138 . Once finish region is inserted sufficiently far into recess 130 that lip 72 slips past retaining ring 138 , the retaining member resiliently returns to its normal size and shape and thereby forms a compression fit against finish region 74 that releasably secures holder 110 to bottle 70 . While not shown in the figures, it should be apparent that in embodiments in which the holder 110 is sized such that recess 130 may accommodate other kinds of beverage containers, retaining member 138 may releasably secure holder 110 to the flange portion of an aluminum can's top or form a compression fit against other beverage containers, such as screw-top bottles, tumblers, or rocks glasses.
[0027] The foregoing description of several embodiments and aspects of the invention has been presented for purpose of illustration only. It is not intended to be exhaustive or to limit the invention to the precise steps and/or forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention and all equivalents be defined by the claims appended hereto. | A holder for an elongated smoking product comprises a base portion and a cradle portion connected to said base portion; the base portion further comprises a generally vertical recess defined within the base portion; wherein the cradle is capable of receiving and supporting the elongated smoking product; and wherein the recess is capable of receiving therewithin an end of a generally cylindrical drink container such that the holder is releasably fixed to the generally cylindrical drink container. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Benefit is claimed of International Patent Application No. PCT/US2013/068802 which was filed Nov. 1, 2013 and of U.S. Provisional Patent Application No. 61/721402 which was filed Nov. 1, 2012. Both above-mentioned applications are entitled “Bottle Filling/Capping Methods and Apparatus” and their disclosures are hereby incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] The invention relates to bottle filling/capping. More particularly, the invention relates to methods and apparatus for positioning, a bottle neck during filling and/or capping.
[0003] An exemplary bottle filling/capping method and apparatus is illustrated in the context of a laundry detergent bottle. However, it may apply to other bottles.
[0004] In an exemplary bottle filling/capping process, bottles move along a flowpath through a series of operations. Exemplary operations may include filling, cap applying, labeling, inspection, and the like.
[0005] These may be further subdivided. For example, with laundry detergent bottles, capping may, involve a two-step process of first installing a spout fitment and then installing a cap. Alternatively, the spout fitment may be installed prior to filling. One exemplary group of bottles is shown in US Pre-Grant Publication No. 2009/0101682A1, the disclosure of which is incorporated by reference in its entirety as if set forth at length.
[0006] At various points along the flowpath, the bottles may need to be precisely positioned. One example involves positioning the bottle at capping where filled bottles (optionally with spout fitments preinstalled) receive caps and the caps are screwed down. More particularly, the cap may be screwed to a pre-installed spout fitment or the spout fitment with cap pre-installed may be screwed onto the bottle or snapped onto the bottle. In yet further variations, spout fitment pre-installation may be internal so that the cap screws onto the bottle.
[0007] To the extent that the bottles are not centered relative to the cap being delivered, the cap may fail to be properly installed and may damage the bottle and/or foul the assembly line. It is, therefore, desirable that the capping station precisely register the bottle relative to the cap being installed.
[0008] For registering the bottles, it is known to use a guide wheel having a circumferential array of guide members for engaging the bottle. The wheel rotates with the flowpath passing tangentially by or around the wheel so that at least one guide member may engage a bottle adjacent one or more associated capping tools. Exemplary capping tools each comprise one or more actuators for downwardly inserting the cap and rotating the cap to tighten it.
[0009] The exemplary guides have recesses nearly semicircular in planform (e.g., a circular are in the vicinity of 180°).
SUMMARY OF THE INVENTION
[0010] One aspect of the disclosure involves a bottle handling apparatus for handling bottles of a nominal neck radius. The apparatus has a carrier and a plurality of bottle guides mounted to the carrier and each comprising a bottle-engaging recess. The bottle-engaging recess comprises means for accommodating necks of different eccentricities.
[0011] A further embodiment may additionally and/or alternatively include the means comprising a central concave region of a radius of curvature less than the nominal neck radius and regions outboard of the central region on opposite sides thereof having less concavity than the central region.
[0012] A further embodiment may additionally and/or alternatively include the means comprising means for providing two circumferentially-spaced contact locations 80-100° from each other with a circular neck of said nominal neck radius.
[0013] A further embodiment may additionally and/or alternatively include the means comprising means for providing two circumferentially-spaced contact locations separated by a non-contact gap of at least 45° with a circular neck of said nominal neck radius
[0014] A further embodiment may additionally and/or alternatively include a method for using the apparatus. The method comprises: passing a plurality of the bottle bodies along a flowpath; and actuating the carrier to engage the guides to the bottle bodies as the bottle bodies in the flowpath pass the carrier, the engagement engaging the bottle neck to the guide recess.
[0015] A further embodiment may additionally and/or alternatively include the engagement providing two circumferentially-spaced contact locations 80-100° from each other with a circular neck of said nominal neck radius.
[0016] A further embodiment may additionally and/or alternatively include a circumferential outer rail providing a third contact location.
[0017] A further embodiment may additionally and/or alternatively include the engagement providing two circumferentially-spaced contact locations separated by a non-contact gap of at least 45° with a circular neck of said nominal neck radius.
[0018] A further embodiment may additionally and/or alternatively include the actuating comprising rotating the carrier.
[0019] A further embodiment may additionally and/or alternatively include aligning the guide to a chuck.
[0020] A further embodiment may additionally and/or alternatively include: as a first bottle passes through the apparatus, there are two spaced-apart contact locations with the guide; as a second bottle passes through the apparatus, the second bottle neck having a greater eccentricity than the first bottle neck, there are two contact locations with the guide shifted outward along the guide recess; and as a third bottle passes through the apparatus, the third bottle neck having a greater eccentricity than the second bottle neck, there are two contact locations with the guide shifted further outward along the guide recess.
[0021] A further embodiment may additionally and/or alternatively include the second bottle having at least 5% eccentricity and a center of the second bottle shifts radially relative to a center of the first bottle by no more than 2% of a nominal neck diameter of the first bottle, more particularly, no more than 1%.
[0022] Another aspect of the disclosure involves a bottle handling apparatus for handling bottles of a nominal neck ( 70 ) radius. The apparatus comprises: a carrier; and a plurality of bottle guides mounted to the carrier and each comprising a bottle-engaging recess, wherein the bottle-engaging recess comprises: a central concave first region of a radius of curvature less than the nominal neck radius; and second regions outboard of the central region on opposite sides thereof being less concave than the central region.
[0023] A further embodiment may additionally and/or alternatively include: the second regions have curvature magnitude at least 5 times the nominal neck radius; and the second regions are positioned to contact the neck for eccentricities from zero (circularity) to at least 5% (more particularly at least 10% or at least 15%).
[0024] A further embodiment may additionally and/or alternatively include the second regions outboard having curvature magnitude at least 10 times the nominal neck radius.
[0025] The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is a partial, partially schematic, view of a prior art filling/capping line.
[0027] FIG. 2 is a view of a prior art bottle guide which may be applied as a modification to the line of FIG. 1 .
[0028] FIG. 3 is a top plan view of a first inventive guide.
[0029] FIG. 4 is a side view of the guide of FIG. 3 .
[0030] FIG. 5 is a first photograph of a capping line including the guide of FIG. 3 .
[0031] FIG. 6 is a second photograph of the line of FIG. 4 .
[0032] FIG. ; 7 is a third photograph of the line of FIG. 4 .
[0033] FIG. 8 is a plan view of a second inventive guide.
[0034] FIG. 9 is a side view of the guide of FIG. 8 .
[0035] FIG. 10 is a side view of an alignment mandrel or positioning a guide.
[0036] Like reference numbers and designations in the various drawings indicate like elements.
DETAILED DESCRIPTION
[0037] FIG. 1 shows filling/capping system 20 comprising a filling station (filler) 22 and a capping station (capper) 24 . Bottles 50 move in a downstream direction 500 along a bottle flowpath 502 through the system. The exemplary capping station 24 includes a rotating wheel or star 30 mounted for rotation about an axis 510 . The exemplary wheel is known as a star with perimeter protrusions 32 defining perimeter pockets 34 for engaging bottle necks as the bottles move along the line. Bottle body 52 ( FIG. 5 ) bases may be accommodated in pockets (not shown) in conveyors at one or more locations along the bottle flowpath between the inlet 26 and outlet 28 .
[0038] The exemplary capping station 24 further includes a perimeter rail 40 limiting potential outward radial excursions of the bottle (e.g., due to, vibration, centrifugal force, or the like). One or more additional stations may have similar stars and rails. These include an exemplary in-feed station 44 upstream, an exemplary discharge station 46 at the outlet, and an exemplary transfer station 48 between the filler and the capper. In this exemplary embodiment, and as discussed below, the star of the capper is placed higher than the other stars so that the capper star engages a bottle neck whereas the other stars engage bottle shoulders. The filler may also include such features. The star direction of rotation is such that the bottles moving along the perimeter move downstream along the bottle flowpath.
[0039] FIG. 2 shows a bottle neck guide 60 . A circumferential array of such neck guides may be mounted to the capper wheel 30 as a carrier in lieu of projections 32 . The exemplary neck guide 60 may be formed of a metallic plate (e.g., stainless steel or, aluminum) and has an exemplary radially outwardly-open semi-circular recess 62 for receiving the bottle neck. The exemplary semi-circular recess 62 is of essentially the same radius of curvature as the bottle neck is. For example, an exemplary neck outer diameter (OD) of one nominal bottle size is 2.800 inches.
[0040] FIG. 2 also shows the bottle neck 70 . It also shows a bottle mold parting plane 520 . This exemplary bottle also has a pair of diametrically opposed neck lugs 72 protruding from the outer circular surface 74 of the neck above the guide (and from a flange 76 ). The surface 74 below the flange is shown in broken lines and may be of like diameter or slightly smaller or larger than above the flange.
[0041] FIG. 2 also shows a bottle neck center 522 (and neck central vertical axis) and a vertical radial plane 524 which intersects the wheel rotational axis 510 and intersects the bottle neck central vertical axis 522 . The parting plane 520 is circumferential/tangential relative to the wheel axis of rotation 510 .
[0042] With exemplary nearly semicircular guide recesses, problems arise with bottle necks departing from perfect or near-perfect circularity. The neck may have a designed nominal size (diameter or radius). However, artifacts of the molding process will cause a spectrum of departures from perfect circularity for a given nominal neck size. One typical artifact is that the neck planform/cross-section will be somewhat elliptical, lengthening along the mold parting plane and narrowing transverse thereto. The overall circumference may remain essentially the same as that of the nominal perfect circle but the planform will be longer than the nominal diameter parallel to the mold parting plane and smaller than the nominal diameter transverse to the parting plane (e.g., along the minor axis of the ellipse).
[0043] The eccentricity, will cause the center of the neck (axis 522 and parting plane 520 ) to shift radially outward of the guide. This may cause misalignment of the bottle with the capping chuck/clutch. As the chuck descends and attempts to install the cap, it may fail and/or may damage the bottle, spill material, or, the like.
[0044] Accordingly, FIGS. 3 and 4 show a revised guide 100 configured to be relatively insensitive to neck, eccentricity. FIG. 3 shows the circular neck of nominal neck outer diameter (OD) surface 74 . Necks of progressive eccentricities are shown as 74 ′, 74 ″, and 74 ″′. In this implementation, the eccentric necks are shown as elliptical with the major axis in the parting plane and tangentially oriented. Artifacts of molding will typically register the eccentricity with the parting plane and, more particularly, will cause the major axis to typically be along the parting plane. However, it is seen that the exemplary guide may, reduce sensitivity even where the minor axis is tangential. The tangential orientation of the axis will typically result from the registering of the base of the bottle in its pocket. For example, the exemplary bottle base may be of elongate cross-section (e.g., a rounded rectangle or a near ellipse). The pocket may be complementary to this so that the bottle is always registered with its parting plane tangential when fully seated in the guide or at least when first engaged by the chuck.
[0045] The exemplary guide may, as in the prior art, be formed of sheet metal (e.g., aluminum or stainless steel) and has an exemplary thickness between an upper face 102 and a lower face 104 of an eighth of an inch (0.13 inch).
[0046] The exemplary outward end of the guide 100 defines a recess 110 . An exemplary recess 110 is symmetric across the radial, plane 524 which also forms a center plane of the guide. The recess 110 transitions from a relatively tight inboard/proximal concave region 112 (having relatively low radius of curvature) to an intermediate region 114 having much higher magnitude radius of curvature and finally transitioning to a distal region 116 . The exemplary intermediate region is essentially straight but may have slight convexity. This transitions to the distal region which is convex but of lesser magnitude of radius of curvature. For example, this radius of curvature may transition through several steps and may include a lateral portion 118 of relatively tight convexity merely to avoid puncturing or damaging bottles during transfer to the associated guide.
[0047] For example, relative to the nominal bottle radius, the exemplary radius of curvature along the region 112 (or some portion thereof) may be at least about 10% less, more particularly, at least about 20% less, or at least about 30% less. In this example, the radius of curvature along the region 112 is 34% less than the nominal bottle radius. Along the region 114 , the recess is straight or nearly straight over a substantial distance. Two approximately straight regions 120 are at an exemplary angle 0 of about 90° (more broadly, 80°-100°). For various bottle eccentricities (e.g., with eccentricities shown of up to about 16% for the neck OD 74 ″′), the two contact points of the neck OD surface will fall along this region.
[0048] FIG. 3 shows contact points/locations 122 A and 122 B for the circular neck and the shifted contact locations of the more eccentric necks shifted slightly radially outward along the regions 114 . Exemplary radius of curvature magnitude along the regions 114 is substantially greater than that of the nominal neck (e.g., more than twice or more than five times or more than ten times).
[0049] FIG. 3 further shows a first pair of mounting features 130 A, 130 B on either side of the plane 524 and a second pair of mounting features 132 A and 132 B spaced inward thereof. The first mounting features are elongate slots parallel to the plane 524 . The second features are holes. In mounting the guide to the wheel (carrier 140 of FIG. 5 ), the guide lower surface may be placed atop the wheel upper surface. Fasteners (e.g., socket head cap screws) may be placed through the holes 130 A, 130 B into threaded bores in the wheel. The guide may be radially shifted to a desired position and the fasteners tightened or further tightened. For example, in one method of positioning, a bottle is placed in its pocket and the guide is shifted radially to make initial contact with the bottle while the bottle is maintained vertical. At this point of contact, the fasteners may be tightened. If it is desired to further secure the guide (e.g., after any test runs), the holes 132 A, 132 B may be used as guides to drill into the plate and insert set screws or pins to fix the guide position.
[0050] In yet another alternative, positioning is not via a bottle but via a mandrel 300 ( FIG. 10 ) inserted into a chuck 402 of the capper 400 . The mandrel may have a surface positioned to be contacted by the guide recess when the guide is in a desired alignment. The mandrel may have portions 310 312 , 314 of different diameter corresponding to different bottle nominal neck diameters or separate mandrels may, be used for different bottles.
[0051] Yet alternative alignment techniques may be used.
[0052] FIGS. 5-7 show various stages of movement of the capper wheel (carrier 140 ) and actuation of the capper chucks to install caps 54 to bottle bodies 52 . The rotation actuates the guides to engage the passing bottles. In this exemplary implementation, a slightly different guide 180 is shown having the regions 114 and 116 but lacking a curved central region 112 and smooth continuously curving transitions to the regions 114 . Instead, the central region 182 is machined out as an approximate right channel for ease of manufacture. Because this region forms a non-contact gap with the nominal neck, its exact geometry is not important. In this particular implementation, the bottle necks have the OD surface 74 immediately below radially protruding circular flange 76 . The lugs 72 protrude upward from the flange along the neck portion. Immediately above the lugs 72 , there is an external thread for receiving an internal thread the spout fitment. In this example, the capper installs a spout fitment 56 . The spout fitment may already have the cap 54 screwed into the spout fitment.
[0053] The capper chucks 402 are actuated by a downward movement and rotation to thread the spout fitment onto the bottle. Registration of the bottle base in its pocket helps allow the spout fitment to be tightened down.
[0054] FIGS. 8 and 9 show an alternate guide 200 which may, be otherwise similar to the guide 100 but with different mounting features. The exemplary mounting features comprise a central slot elongate along the, plane 524 and a pair of parallel elongate slots 204 A and 204 B on either side thereof. Slots 204 A and 204 B receive protruding portions of pins or set screws pre-installed on the capper wheel. These help maintain alignment. The slot 202 receives a fastener (e.g., socket head cap screw) which extends into a threaded bore in the guide. The axes of the pins and screw may be shifted away from each other at separation distance S 1 allowing the plate to, slide along a range of motion between a first extreme wherein the, pins and screws are at outboard/distal ends of the associated slots and a second extreme wherein they are at proximal/inboard ends of the slots. This allows tightening via a single fastener. As with the other guide, there might be further features for more permanently, positioning
[0055] One or more embodiments of the present invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, when applied to the remanufacture or reengineering of a given system, or to use with a given bottle, details of the system or bottle may influence details of any particular implementation. Accordingly, other embodiments are within the scope of the following claims. | A bottle handling apparatus handles bottles ( 50 ) of a nominal neck ( 70 ) radius. The apparatus has a carrier ( 140 ) and a plurality of bottle guides ( 100; 180; 200 ) mounted to the carrier and each comprising a bottle-engaging recess ( 110 ). The bottle-engaging recess accommodates necks of different eccentricities. | 1 |
TECHNICAL FIELD
[0001] The present invention relates to a drip irrigation tube.
BACKGROUND ART
[0002] Drip irrigation methods are known as one of plant cultivating methods. In the drip irrigation methods, a drip irrigation tube is disposed on the soil, and irrigation liquid such as water and liquid fertilizer is slowly supplied from the drip irrigation tube into the soil on which plants are planted, for example. The drip irrigation methods can minimize the liquid consumption, and therefore have increasingly attracted attention in recent years.
[0003] Such a drip irrigation tube typically has a tube and a dripper. Typically, the dripper supplies the irrigation liquid in the tube to the soil at a set rate at which the irrigation liquid drips into the soil. Known examples of the dripper include a dripper which is disposed in such a manner as to stick into a tube from outside, and a dripper which is bonded on an inner wall of a tube.
[0004] The latter dripper has, for example, a channel including a pressure reduction channel that allows liquid, which has flowed from the inside of the tube to the dripper, to flow toward an ejection port opening at a tube wall of the tube while depressurizing the liquid; and a diaphragm that changes the volume of a part, of the channel, where the depressurized irrigation liquid flows in accordance with the liquid pressure in a tube space. The dripper is composed of three members, i.e., a base part bonded to the inner wall of the tube, a coating part disposed on the base part, and a diaphragm disposed between the two members. The base part includes a chimney part having I-shaped cross-sectional shape, for example. The chimney part pushes the wall of the tube from inside. Cutting both the chimney part and the part pushed by the chimney part allows the ejection port to be formed. Further, the chimney part secures a space which serves as a channel of liquid at the ejection port (see, e.g., PTL 1).
[0005] The drippers can suppress variations in the ejection amount of the irrigation liquid regardless of changes in liquid pressure in the tube space. Further, liquid ejected from the ejection port is more likely to drip from the tip of the chimney part. Accordingly, the liquid is more likely to be supplied to the soil immediately below the ejection port. Therefore, the dripper is advantageous from the perspective of growing multiple plants uniformly.
CITATION LIST
Patent Literature
PTL 1
[0006] U.S. Pat. No. 8,302,887
SUMMARY OF INVENTION
Technical Problem
[0007] The drip irrigation tube is sometimes disposed such that the ejection port faces upward, in order to prevent the soil from attaching to the periphery of an opening of the ejection port to clog the ejection port. When the drip irrigation tube is disposed such that the ejection port faces upward, liquid ejected from the ejection port sometimes runs along the outer wall of the tube in the longitudinal direction of the tube and drips at a position distant from the ejection port to be absorbed into the soil. Therefore, it is desired to supply liquid ejected from the drip irrigation tube to the soil at an intended rate from an intended position at which the ejection port is formed, regardless of the orientation of the ejection port, of the drip irrigation tube, on the soil.
[0008] An object of the present invention is to provide a drip irrigation tube capable of supplying liquid in the tube to the soil from the ejection port or a position in the vicinity of the ejection port in the longitudinal direction of the tube.
Solution to Problem
[0009] A drip irrigation tube according to the present invention includes: a tube to which liquid is supplied; an ejection port allowing communication between an inside and an outside of the tube for ejecting the liquid from the inside of the tube; and guide parts for guiding the liquid in a circumferential direction of the tube, provided circumferentially at two locations, for each ejection port, on an outer circumferential surface of the tube such that the ejection port is interposed in a longitudinal direction of the tube.
Advantageous Effects of Invention
[0010] Since the drip irrigation tube according to the present invention has the guide part, the flow of liquid running along the outer wall of the tube in the longitudinal direction of the tube is retained at the guide part. Thus, the liquid is likely to be accumulated at the guide part, and the accumulated liquid is likely to be guided downward along the guide part to drip from the guide part. Therefore, according to the drip irrigation tube of the present invention, it is possible to supply liquid in the tube to the soil from a position at least in the vicinity of an ejection port in the longitudinal direction of the tube, even when the liquid ejected from the ejection port runs in the longitudinal direction of the tube.
BRIEF DESCRIPTION OF DRAWINGS
[0011] FIG. 1A is a schematic plan view of a drip irrigation tube according to Embodiment 1 of the present invention, and FIG. 1B is a cross-sectional view of the drip irrigation tube cut along line A-A in FIG. 1A ;
[0012] FIG. 2 illustrates an enlarged cross-section of a dripper in the drip irrigation tube according to Embodiment 1;
[0013] FIG. 3A illustrates an upper surface, a front surface, and a side surface of the dripper according to Embodiment 1, and FIG. 3B illustrates a bottom surface, the front surface and the side surface of the dripper of Embodiment 1;
[0014] FIG. 4A to FIG. 4D are a plan view, a front view, a bottom view and a side view of the dripper according to Embodiment 1, respectively;
[0015] FIG. 5A to FIG. 5D are a plan view, a front view, a bottom view and a side view of a dripper body according to Embodiment 1, respectively;
[0016] FIG. 6A to FIG. 6D are a plan view, a front view, a bottom view and a side view of a movable part according to Embodiment 1, respectively;
[0017] FIG. 7A is a side view schematically illustrating a state before the movement of the movable part of the dripper according to Embodiment 1, and FIG. 7B is a side view schematically illustrating a state after the movement of the movable part of the dripper;
[0018] FIG. 8A is a cross-sectional view schematically illustrating the dripper according to Embodiment 1 cut along line A-A in FIG. 4C before the movement of the movable part, and FIG. 8B is a cross-sectional view schematically illustrating the dripper cut along line A-A in FIG. 4C after the movement of the movable part;
[0019] FIG. 9A is a cross-sectional view of the drip irrigation tube according to Embodiment 1 cut along line A-A in FIG. 1A , schematically illustrating liquid being ejected from the drip irrigation tube disposed such that ejection ports face downward, and FIG. 9B is a front view schematically illustrating liquid being ejected from the drip irrigation tube according to Embodiment 1 disposed such that ejection ports face upward;
[0020] FIG. 10A is a schematic front view of a drip irrigation tube according to Embodiment 2 disposed such that ejection ports face upward, and FIG. 10B schematically illustrates liquid being ejected from the drip irrigation tube;
[0021] FIG. 11A is a schematic front view of a drip irrigation tube according to Embodiment 3 of the present invention, and FIG. 11B is a schematic front view of a drip irrigation tube according to Embodiment 4 of the present invention;
[0022] FIG. 12A illustrates an upper surface, a front surface, and a side surface of a dripper according to Embodiment 5 of the present invention, and FIG. 12B illustrates a bottom surface, the front surface and the side surface of the dripper;
[0023] FIG. 13A to FIG. 13D are a plan view, a front view, a bottom view and a side view of the dripper according to Embodiment 5, respectively;
[0024] FIG. 14A is a cross-sectional view schematically illustrating the dripper according to Embodiment 5 cut along line A-A in FIG. 13C before the movement of the movable part, and FIG. 14B is a cross-sectional view schematically illustrating the dripper cut along line A-A in FIG. 13C after the movement of the movable part; and
[0025] FIG. 15A is a schematic front view of a drip irrigation tube according to Embodiment 6 or 7 disposed such that ejection ports face upward, FIG. 15B schematically illustrates liquid being ejected from the drip irrigation tube according to Embodiment 6, and FIG. 15C schematically illustrates liquid being ejected from the drip irrigation tube according to Embodiment 7.
DESCRIPTION OF EMBODIMENTS
[0026] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.
Embodiment 1
[0027] FIG. 1A is a schematic plan view of a drip irrigation tube according to Embodiment 1 of the present invention, and FIG. 1B is a cross-sectional view of the drip irrigation tube cut along line A-A in FIG. 1A . Drip irrigation tube 100 is composed of tube 110 , drippers 120 , ejection ports 130 , and guide parts 140 .
[0028] Tube 110 is made of, for example, polyethylene, and dripper 120 is made of, for example, polypropylene.
[0029] Drippers 120 are disposed at a predetermined interval (e.g., 200 to 500 mm) in the axis direction of tube 110 . Each dripper 120 is fixed on the inner wall of tube 110 by welding. Dripper 120 is disposed at a position where dripper 120 covers ejection port 130 of tube 110 . Specifically, dripper 120 is disposed such that an ejection part thereof described below covers ejection port 130 .
[0030] Ejection port 130 is a through hole extending through the tube wall of tube 110 . The hole diameter of ejection port 130 is, for example, 1.5 mm. Ejection port 130 is typically formed after dripper 120 is welded.
[0031] Guide part 140 is a different diameter part having an outer diameter different from the outer diameter of the tube. Guide part 140 is disposed at two locations, for single ejection port 130 (a part at which ejection port 130 is to be formed if ejection port 130 has not been formed yet), such that ejection port 130 is interposed between guide parts 140 in the longitudinal direction of tube 110 . That is, each ejection port 130 is disposed between two guide parts 140 in the longitudinal direction.
[0032] The distance from ejection port 130 to guide part 140 is preferably as short as possible, from the perspective of dripping liquid ejected from ejection port 130 from a position near ejection port 130 to the soil. From such a perspective, the distance from ejection port 130 to guide part 140 is preferably 10 to 100 mm, and more preferably 10 to 50 mm. The distance from ejection port 130 to guide part 140 may be constant or different. Note that the distance from ejection port 130 to guide part 140 is the shortest distance from the center of ejection port 130 to guide part 140 in the longitudinal direction.
[0033] Each guide part 140 is provided circumferentially in the circumferential direction of tube 110 on the outer circumferential surface of tube 110 . Guide part 140 constitutes a part having an outer diameter larger than the outer diameter of tube 110 on the outer circumferential surface of tube 110 . Guide part 140 is formed, for example, by winding an adhesive tape.
[0034] Guide part 140 has an outer diameter larger than the outer diameter of tube 110 . Guide part 140 forms a step difference on the outer circumferential surface of tube 110 . The half value of the difference obtained by subtracting the outer diameter of tube 110 from the outer diameter of guide part 140 (height difference equivalent to one step difference; hereinafter, also referred to as “height”) is, for example, 2 mm. The height of guide part 140 can be appropriately determined within such a range as to bring a function of guiding liquid described below downward along the circumferential direction of tube 110 (hereinafter, also referred to as “drip-facilitating function”). The height of guide part 140 is preferably 0.5 to 5 mm, and more preferably 0.5 to 3 mm, from the above-mentioned perspective. The height of guide part 140 may be constant, different, an average value, or the minimum value.
[0035] The width of guide part 140 (length of guide part 140 in the longitudinal direction of tube 110 ) is, for example, 3 mm. The width of guide part 140 can be appropriately determined within a range smaller than the distance between adjacent ejection ports 130 in the longitudinal direction of tube 110 . The width of guide part 140 is preferably 1 to 20 mm, and more preferably 2 to 10 mm, from the above-mentioned perspective. The width of guide part 140 may be constant, different, an average value, or the minimum value.
[0036] Liquid in tube 110 is ejected from ejection port 130 by dripper 120 at a set rate. First, the configuration and function of dripper 120 will be described below.
[0037] FIG. 2 illustrates an enlarged cross-section of the dripper in the drip irrigation tube according to the present embodiment. FIG. 3A illustrates an upper surface, a front surface, and a side surface of the dripper according to the present embodiment, and FIG. 3B illustrates a bottom surface, the front surface and the side surface of the dripper according to the present embodiment. FIG. 4A to FIG. 4D are a plan view, a front view, a bottom view and a side view of the dripper according to the present embodiment, respectively.
[0038] Dripper 120 has dripper body 121 and movable part 122 engaged with dripper body 121 , as shown in FIG. 2 . Dripper 120 forms a liquid channel which is independent from the inner space of tube 110 and allows the inner space of tube 110 to communicate with ejection port 130 . The channel includes inflow part 124 , pressure reduction channel 125 and ejection part 126 . Inflow part 124 communicates with the inner space of tube 110 through inflow ports 123 . Pressure reduction channel 125 is formed by fitting a projection of movable part 122 described below with an open part of dripper body 120 described below.
[0039] A depression (also referred to as “top surface side recess”) is formed on the upper surface (top surface) of dripper 120 , and a plurality of protrusions 1201 are disposed in the top surface side recess, as shown in FIGS. 3A and 4A . Protrusions 1201 extend in transverse direction Y of dripper 120 and are arranged in parallel in longitudinal direction X of dripper 120 . Both ends of protrusion 1201 are apart from side walls of the top surface side recess in Y direction. The height of protrusion 1201 is, for example, 0.5 mm, and the interval between protrusions 1201 (the distance between the axes of protrusions 1201 ) is, for example, 0.5 mm
[0040] A plurality of inflow ports 123 are disposed on the bottom of the top surface side recess at one end part in X direction, as shown in FIGS. 3B and 4C . Inflow ports 123 are disposed in lines along protrusions 1201 (in Y direction). Inflow port 123 is a hole extending through the bottom of the top surface side recess and allows the upper side of dripper 120 to communicate with inflow part 124 . The hole diameter of inflow port 123 is, for example, 0.3 mm
[0041] As shown in FIGS. 3B and 4C , each of inflow part 124 and ejection part 126 is a rectangular depression (also referred to as “bottom surface side recesses”) which is recessed from the bottom surface of dripper body 121 and is disposed at each end part of dripper body 121 . The height of inflow part 124 (the depth of the bottom surface side recess at one end side in X direction) is, for example, 1.0 mm, and the height of ejection part 126 (the depth of the bottom surface side recess at the other end side in X direction) is, for example, 1.0 mm
[0042] Pressure reduction channel 125 allows inflow part 124 to communicate with ejection part 126 , as shown in FIG. 4C . The shape of pressure reduction channel 125 in plan view is a zigzag shape. The zigzag shape is formed by alternately disposing protrusions each having a substantially triangular shape and protruding from side walls of pressure reduction channel 125 in the longitudinal direction of pressure reduction channel 125 . The protrusion is formed such that the tip end of the protrusion does not go beyond the central axis of pressure reduction channel 125 in plan view. Both end parts of pressure reduction channel 125 are formed only with dripper body 121 , and the other part of pressure reduction channel 125 is formed by fitting a projection of movable part 122 together with an open part formed in dripper body 121 ( FIGS. 4B and 4C ).
[0043] FIG. 5A to FIG. 5D are a plan view, a front view, a bottom view and a side view of the dripper body according to the present embodiment, respectively.
[0044] Dripper body 121 is made of, for example, polypropylene. Dripper body 121 has first end part 1211 , second end part 1212 and connecting part 1213 as shown in FIGS. 5A to 5C . First end part 1211 includes the top surface side recess, protrusions 1201 , inflow ports 123 and inflow part 124 . Second end part 1212 includes the top surface side recess, protrusions 1201 and ejection part 126 .
[0045] Further, first end part 1211 and second end part 1212 have elastic supporters 1214 and 1215 , respectively, at both end parts of first end part 1211 and second end part 1212 . Both elastic supporters 1214 and 1215 are disposed at relatively high positions on upper surface (top surface) side relative to the center of dripper body 121 in the height (thickness) direction. Elastic supporter 1214 is a plate-shaped elastic member protruding from an end surface of first end part 1211 on second end part 1212 side. Elastic supporter 1215 is a plate-shaped elastic member protruding from an end surface of second end part 1212 on first end part 1211 side. The upper surface (top surface) of each of elastic supporters 1214 and 1215 is parallel with the top surface of dripper body 121 . An inclining surface inclined from top surface side to the bottom surface side is formed at the tip of the upper surface (top surface) of each of elastic supporters 1214 and 1215 .
[0046] Connecting part 1213 connects first end part 1211 with second end part 1212 . The shape of connecting part 1213 in plan view is a substantially cross shape formed by cutting out a rectangle having a shape substantially the same as the shape of elastic supporters 1214 and 1215 in plan view from every corner of a rectangle, as shown in FIGS. 5A and 5C . Connecting part 1213 has a bottom surface on the same plane as the bottom surfaces of first end part 1211 and second end part 1212 , as shown in FIG. 5B . The thickness (height) of connecting part 1213 is less than half the height of dripper body 121 , and slightly larger than the height of pressure reduction channel 125 . The height of connecting part 1213 is, for example, about 1.3 times as large as the height of pressure reduction channel 125 .
[0047] Connecting part 1213 includes open part 1216 which opens to the inner space of tube 110 except for both end parts of pressure reduction channel 125 . The shape of open part 1216 in plan view is the same as the zigzag shape of pressure reduction channel 125 , as shown in FIGS. 5A and 5C . Open part 1216 is configured of a cut extending through connecting part 1213 in the thickness direction of connecting part 1213 .
[0048] FIG. 6A to FIG. 6D are a plan view, a front view, a bottom view and a side view of a movable part according to the present embodiment, respectively.
[0049] Movable part 122 is made of, for example, polypropylene. Movable part 122 has pressure receiving part 1221 , spacer 1222 , engaging part 1223 and projection 1224 , as shown in FIGS. 6A to 6D . Pressure receiving part 1221 forms the top surface of movable part 122 . Pressure receiving part 1221 includes the depression, and protrusions 1201 . The shape of pressure receiving part 1221 is substantially rectangular, but every corner is slightly cut out by a rectangle. The length of the cutout in X direction is several millimeters, and the length of the cutout in Y direction is substantially the same as the length of elastic supporter 1215 in Y direction. End parts of pressure receiving part 1221 in Y direction have a linear cut formed in X direction from each cutout.
[0050] Spacer 1222 is disposed on the bottom surface side of pressure receiving part 1221 . The shape of spacer 1222 in plan view is rectangular. The length of spacer 1222 in X direction is less than the distance between the tip ends of elastic supporters 1214 and 1215 of dripper body 121 , and the length of spacer 1222 in Y direction is substantially the same as the length of pressure receiving part 1221 in Y direction. The thickness of spacer 1222 is substantially the same as the thickness of elastic supporters 1214 and 1215 . Spacer 1222 is disposed at a center of movable part 122 in X direction where spacer 1222 does not touch the tip end of elastic supporter 1214 or elastic supporter 1215 .
[0051] Engaging part 1223 is connected to the bottom surface side of spacer 1222 . The shape of engaging part 1223 in plan view is rectangular. An inclining surface inclined from bottom surface side to the top surface side is formed at both ends of the bottom surface of engaging part 1223 in X direction. The length of engaging part 1223 in X direction is substantially the same as the length of the remaining part of pressure receiving part 1221 in X direction after the cutout at the both end parts. The length of engaging part 1223 in Y direction is substantially the same as the length of pressure receiving part 1221 in Y direction.
[0052] Projection 1224 is a part connected to the bottom surface side of engaging part 1223 as shown in FIGS. 6B and 6D . The shape of projection 1224 in plan view is the same as the shape of open part 1216 of dripper body 121 in plan view as shown in FIG. 6C . The protruding height of projection 1224 is the sum of a movable distance of movable part 122 and an additional distance a. The movable distance is a distance from the bottom surface of spacer 1222 to the top surface of connecting part 1213 of dripper body 121 , and is 0.5 mm for example. The distance a is a distance for slightly fitting the head of projection 1224 with open part 1216 for the positioning of projection 1224 , and is about 0.25 mm for example.
[0053] Dripper 120 is assembled by disposing movable part 122 on connecting part 1213 and by pushing movable part 122 into connecting part 1213 . In response to the pushing, elastic supporters 1214 and 1215 are bent, and the inclining surfaces of the tips of engaging part 1223 slide on the inclining surfaces of the tips of elastic supporters 1214 and 1215 , and thus, elastic supporters 1214 and 1215 are fit in the gap between pressure receiving part 1221 and engaging part 1223 . As a result, elastic supporters 1214 and 1215 support pressure receiving part 1221 , and engage with engaging part 1223 . Movable part 122 is thus supported in dripper body 121 with the elasticity of elastic supporters 1214 and 1215 in a movable manner Projection 1224 of movable part 122 covers open part 1216 from above and is slightly fit with open part 1216 of dripper body 121 . With this fitting, pressure reduction channel 125 is formed.
[0054] FIG. 7A is a side view schematically illustrating a state before the movement of the movable part of the dripper according to the present embodiment, and FIG. 7B is a side view schematically illustrating a state after the movement of the movable part of the dripper. FIG. 8A is a cross-sectional view schematically illustrating the dripper according to the present embodiment cut along line A-A in FIG. 4C before the movement of the movable part, and FIG. 8B is a cross-sectional view schematically illustrating the dripper cut along line A-A in FIG. 4C after the movement of the movable part.
[0055] When a sufficient pressure is not exerted on pressure receiving part 1221 , movable part 122 does not move as shown in FIGS. 7A and 8A . In this case, height h 0 of pressure reduction channel 125 (the distance from the bottom surface of connecting part 1213 to the head of projection 1224 ) is 0.75 mm for example. The cross-sectional area of pressure reduction channel 125 has a maximum value in this case.
[0056] When a sufficient pressure is exerted on pressure receiving part 1221 , movable part 122 is biased to the bottom surface side of dripper 120 and elastic supporters 1214 and 1215 supporting movable part 122 are bent as shown in FIGS. 7B and 8B . Movable part 122 thus moves toward the bottom surface side to allow projection 1224 to slide further into open part 1216 . Height h 1 of pressure reduction channel 125 in this case is smaller than h 0 and 0.25 mm for example.
[0057] When the pressure on pressure receiving part 1221 is released, movable part 122 slides on open part 1216 upward with the elasticity of elastic supporters 1214 and 1215 , and the height of pressure reduction channel 125 increases. In this case, the height of pressure reduction channel 125 is h 0 . Thus, movable part 122 slides forward or backward on open part 1216 in accordance with the pressure on pressure receiving part 1221 , and the height (cross-sectional area) of pressure reduction channel 125 changes.
[0058] The operation of dripper 120 in drip irrigation tube 100 will be described. Liquid is supplied in drip irrigation tube 100 in FIG. 2 . The liquid flows in X direction. The liquid fills gaps between protrusions 1201 . Protrusions 1201 are arranged in parallel in the longitudinal direction (direction X) on the top surface of dripper 120 , and gaps are formed between the both ends of protrusions 1201 in Y direction and side walls of the top surface side recess. With this configuration, the gaps between protrusions 1201 are not completely clogged even when a floating object such as a fallen leaf in the liquid sticks to the top surface of dripper 120 . Thus, the gaps to which inflow ports 123 open between protrusions 1201 are filled with liquid at all times. In this manner, protrusions 1201 provide a function as a filter.
[0059] Inflow ports 123 are through holes formed in dripper body 121 made of polypropylene; therefore, inflow ports 123 have water repellency specific to polypropylene. When liquid pressure is at a specific value (e.g., 0.005 MPa, which is also referred to as “burst pressure”) or higher, the liquid filling the gaps overcomes the liquid surface tension of the water repellency, and flows into inflow part 124 from inflow ports 123 . In this manner, inflow ports 123 provide a low-pressure stopping function to inhibit the inflow of liquid whose pressure is lower than a specific value. The low-pressure stopping function can be adjusted by the hole diameter, pitch, number, open part shape, length (thickness of the bottom of the top surface side recess) of inflow ports 123 , and the like.
[0060] Liquid having a pressure equal to or higher than the burst pressure flows into inflow part 124 , and then flows through pressure reduction channel 125 . The liquid flowing through pressure reduction channel 125 is depressurized by pressure drop which is caused by the shape of pressure reduction channel 125 in plan view (zigzag shape). The depressurized liquid is received in ejection part 126 . The liquid received in ejection part 126 is ejected from ejection port 130 . The liquid ejected from ejection port 130 drips from drip irrigation tube 100 into the soil, for example.
[0061] When the liquid pressure in drip irrigation tube 100 is in a range from the burst pressure to a specific pressure higher than the burst pressure (e.g., 0.05 MPa, which is also referred to as “movement starting pressure”), movable part 122 does not move. This is because the elasticity of elastic supporters 1214 and 1215 overcome the liquid pressure on pressure receiving part 1221 . During this time, the liquid ejection rate from ejection port 130 is substantially constant at a set rate.
[0062] When the liquid pressure in drip irrigation tube 100 is equal to or higher than the movement starting pressure, the pressure on pressure receiving part 1221 overcomes the elasticity of elastic supporters 1214 and 1215 , and movable part 122 moves in accordance with the pressure toward the bottom surface side of dripper 120 in a range of less than 0.5 mm. As a result, the height of pressure reduction channel 125 becomes, for example, 0.5 mm, and the amount of liquid flowing through pressure reduction channel 125 is limited. In this manner, the increase of a liquid flow rate due to the pressure increase is offset by the decrease of the liquid flow rate caused by reduction of the cross-sectional area of pressure reduction channel 125 , and thus a supply rate of the liquid to ejection part 126 is maintained at a substantially constant rate. Consequently, the ejection rate of the liquid from ejection port 130 is substantially maintained at the above-mentioned set rate.
[0063] When the liquid pressure in drip irrigation tube 100 is equal to or higher than a specific pressure which is larger than the movement starting pressure (e.g., 0.1 MPa, which is also referred to as “maximum movement pressure”), movable part 122 is further biased by the liquid pressure. As a result, the height of pressure reduction channel 125 minimized (to the above-described fu, e.g., 0.25 mm), and the amount of the liquid flowing through pressure reduction channel 125 is further limited. In this manner, the increase of a liquid flow rate due to the further pressure increase is offset by the decrease of the liquid flow rate caused by the further reduction of the cross-sectional area of pressure reduction channel 125 and thus the supply rate of the liquid to ejection part 126 is still maintained at a substantially constant rate. Consequently, the ejection rate of the liquid from ejection port 130 is substantially maintained at the above-mentioned set rate.
[0064] Next, the functions of guide part 140 will be described.
[0065] FIG. 9A is a cross-sectional view of drip irrigation tube 100 cut along line A-A in FIG. 1A , schematically illustrating liquid 150 being ejected from drip irrigation tube 100 disposed such that ejection port 130 faces downward, and FIG. 9B is a front view schematically illustrating liquid 150 being ejected from drip irrigation tube 100 disposed such that ejection port 130 faces upward.
[0066] Typically, liquid 150 ejected from ejection port 130 is accumulated at the opening of ejection port 130 and drips. Liquid 150 is ejected from ejection port 130 at a set rate, and thus drips into the soil or the like at a properly set rate.
[0067] When drip irrigation tubes 100 is obliquely disposed partially or entirely, liquid 150 ejected from ejection port 130 runs along the lowest part of tube 110 and flows toward one side along the longitudinal direction of tube 110 , as shown in FIG. 9A . The flow of liquid 150 along the lowest part is blocked by guide part 140 . Liquid 150 is supplied to guide part 140 at the above-mentioned set rate, and liquid 150 blocked at guide part 140 drips at the above-mentioned set rate from guide part 140 due to its own weight.
[0068] When drip irrigation tube 100 is disposed such that ejection port 130 opens upward, liquid 150 ejected from ejection port 130 is accumulated at the opening of ejection port 130 , as shown in FIG. 9B . Liquid 150 accumulated at the opening may flow vertically downward from the opening along the outer circumferential surface of tube 110 in one case, whereas in another case liquid 150 may run along the highest part of tube 110 to flow toward one side along the longitudinal direction of tube 110 . The flow of liquid 150 along the highest part is blocked by guide part 140 .
[0069] Liquid 150 is supplied to guide part 140 at the above-mentioned set rate. Therefore, liquid 150 blocked at guide part 140 flows downward on the outer circumferential surface of tube 110 along guide part 140 due to its weight. Thus, liquid 150 is guided to the lowest part of tube 110 , and drips from the lowest part of tube 110 at the above-mentioned set rate. As described above, guide part 140 exhibits a drip-facilitating function of guiding liquid 150 flowing along the longitudinal direction of tube 110 to allow liquid 150 to drip into the soil from guide part 140 .
[0070] Drip irrigation tube 100 according to the present embodiment has guide part 140 , as described above. Thus, according to drip irrigation tube 100 , it is possible to supply liquid 150 in tube 110 into the soil from guide part 140 positioned in the vicinity of ejection port 130 in the longitudinal direction of tube 110 at a rate set by dripper 120 , even when liquid 150 ejected from ejection port 130 runs in the longitudinal direction of tube 110 .
[0071] Further, guide part 140 forms a step difference on the outer circumferential surface of tube 110 . Thus, liquid 150 being blocked is subjected to stronger influence of surface tension at the edge of the step difference. Accordingly, guide part 140 which forms the step difference can further prevent liquid 150 from flowing further in the longitudinal direction of tube 110 beyond guide part 140 . Therefore, guide part 140 is more effective from the perspective of enhancing the above-mentioned drip-facilitating function.
[0072] Dripper 120 according to the present embodiment includes, as described above, dripper body 121 forming a channel having a part of pressure reduction channel 125 (open part 1216 ) opened to the inner space of tube 110 , and movable part 122 disposed to cover open part 1216 from the space side and be movable forward or backward in open part 1216 in accordance with the liquid pressure in drip irrigation tube 100 . Thus, dripper 120 can suppress changes in the ejection amount due to the increase of the pressure of liquid flowing into dripper 120 . Therefore, dripper 120 can eject liquid at a constant flow rate regardless of the change in the pressure.
[0073] Further, dripper 120 can be composed with only two members, i.e., dripper body 121 and movable part 122 .
[0074] As described above, conventional drippers are formed by assembling the three members, and thus an assembly error may occur in the drippers. In particular, the assembly error in the diaphragms may cause variations in operation of the diaphragms, and variations in the ejection amount of irrigation liquid.
[0075] Further, while the dripper is typically formed of an inexpensive resin such as polypropylene, the diaphragm is made of a more expensive elastic material member such as a silicone rubber film. Use of such different materials has a room for improvement in terms of reduction of a material cost.
[0076] In some situation, several hundreds of drippers are disposed in one drip irrigation tube, and in that case pressure drop of the irrigation liquid is large when the drippers bonded on the inner wall of the tube are large. For this reason, in the case where a long drip irrigation tube is used, the pressure for supplying liquid to the tube is required to be high, and as a result the liquid ejection amount of the drippers may be unstabilized. Therefore, it is desired to reduce the size of the drippers from the perspective of suppressing the pressure drop of the liquid in the tube.
[0077] Further, a dripper which can be produced with a single inexpensive material and a smaller number of components is desired from the perspective of suppressing the material cost and the production cost of the dripper.
[0078] Dripper 120 is capable of stabilizing the ejection amount of irrigation liquid and reducing production cost, and is configured for the purpose of providing a drip irrigation tube having the dripper. As described above, dripper 120 can be composed with only two members, i.e., dripper body 121 and movable part 122 , and thus the size (thickness) of dripper 120 can be further reduced in comparison with conventional drippers composed of three members and having a diaphragm.
[0079] Since the size of drippers 120 can be further reduced, drippers 120 can further suppress an increase of liquid pressure drop in tube 110 in comparison with the conventional drippers. As a result, the liquid in drip irrigation tube 100 can be conveyed farther with a low pressure. Therefore, the present embodiment can provide an effect of ejecting liquid at a stable amount even when longer drip irrigation tube 100 is used.
[0080] Dripper 120 can further reduce material cost and production cost (assembling cost) in comparison with the conventional drippers.
[0081] Dripper body 121 further including inflow ports 123 having the low-pressure stopping function is more effective from the perspective of further suppressing the pressure of the liquid flowing into dripper 120 from the inside of drip irrigation tube 100 for the purpose of efficient use of the liquid.
[0082] Dripper 120 does not have a diaphragm in ejection part 126 ; therefore, no diaphragm would be damaged when forming ejection port 130 of drip irrigation tube 100 after welding dripper 120 . This means the pressure regulation function of dripper 120 would not be impaired even when ejection port 130 is formed after welding dripper 120 . The present embodiment thus can produce drip irrigation tube 100 more easily, and further enhance the reliability of drip irrigation tube 100 .
[0083] Dripper body 121 has inflow part 124 and ejection part 126 connected to each other only with pressure reduction channel 125 . This makes it possible to reduce the length of dripper body 121 in X direction. Dripper 120 is thus advantageous also from the perspective of reduction in the size of dripper 120 in X direction.
Embodiment 2
[0084] FIG. 10A is a schematic front view of a drip irrigation tube according to Embodiment 2 disposed such that ejection ports face upward, and FIG. 10B schematically illustrates liquid being ejected from the drip irrigation tube. Drip irrigation tube 200 according to the present embodiment is configured in the same manner as drip irrigation tube 100 according to Embodiment 1 except that for the mode of the guide part.
[0085] Drip irrigation tube 200 includes tube 210 , drippers 120 and guide parts 240 . Tube 210 is configured in the same manner as tube 110 except that guide parts 240 are formed in place of guide parts 140 .
[0086] Guide part 240 is a recess provided circumferentially on the outer circumferential surface of tube 210 . The positions of guide parts 240 in the longitudinal direction of tube 210 are the same as the positions of guide parts 140 in tube 110 . The depth of guide part 240 may be constant, different, an average value, or the minimum value.
[0087] The width of guide part 240 is, for example, 3 mm, and the depth of guide part 240 is, for example, 0.1 mm Guide part 240 is formed by cutting with a cutter, for example.
[0088] The width of guide part 240 can be appropriately determined within a range smaller than the distance between ejection ports 130 in the longitudinal direction of tube 210 . The width of guide part 240 is preferably 1 to 20 mm, and more preferably 2 to 10 mm, from the perspective of enhancement of drip-facilitating function brought by the occurrence of capillary phenomenon of liquid 150 flowing into guide part 240 .
[0089] The depth of guide part 240 can be appropriately determined within a range smaller than the wall thickness of tube 210 . The depth of guide part 240 is preferably 10 to 50% of the wall thickness of tube 210 , and more preferably 25 to 50% thereof, from the perspective of durability of tube 210 . The depth of guide part 240 is preferably 0.02 to 0.1 mm, and more preferably 0.05 to 0.1 mm, from the perspective of enhancement of drip-facilitating function due to the occurrence of capillary phenomenon.
[0090] When drip irrigation tube 200 is disposed such that ejection port 130 faces upward, liquid 150 ejected from ejection port 130 and flowing in the longitudinal direction of tube 210 to reach guide part 240 is subjected to the occurrence of stronger surface tension at the edge of a step difference formed by guide part 240 . Accordingly, the flow of liquid 150 in the longitudinal direction is blocked by guide part 240 , and liquid 150 stays on the outer circumferential surface of tube 210 at guide part 240 .
[0091] Staying liquid 150 flows downward on the outer circumferential surface of tube 210 along guide part 240 . Alternatively, liquid 150 flows into guide part 240 . When capillary phenomenon occurs to liquid 150 flowing into guide part 240 , the flow of liquid 150 is accelerated in the circumferential direction of tube 210 . Then, liquid 150 flows downward in guide part 240 and in the vicinity thereof along guide part 240 . Thus, due to the drip-facilitating function of guide part 240 , liquid 150 is guided to the lowest part of tube 210 , and drips from the lowest part of tube 210 at the above-mentioned set rate.
[0092] In drip irrigation tube 200 , guide part 240 can generate at the step difference stronger surface tension in the longitudinal direction of tube 210 for liquid 150 having reached guide part 240 from ejection port 130 . Accordingly, it is possible to enhance the effect of blocking the flow of liquid 150 in the longitudinal direction more than drip irrigation tube 100 according to Embodiment 1. In addition, liquid 150 flowing into guide part 240 is more likely to flow downward in guide part 240 in the circumferential direction of tube 210 than drip irrigation tube 100 . When guide part 240 has such a width as to generate the capillary phenomenon of liquid 150 , the flow of liquid 150 in guide part 240 is further accelerated. Thus, guide part 240 is more effective from the perspective of enhancement of the drip-facilitating function.
Embodiments 3 and 4
[0093] FIG. 11A is a schematic front view of a drip irrigation tube according to Embodiment 3 of the present invention, and FIG. 11B is a schematic front view of a drip irrigation tube according to Embodiment 4 of the present invention. Drip irrigation tube 300 according to Embodiment 3 and drip irrigation tube 400 according to Embodiment 4 are both configured in the same manner as drip irrigation tube 100 according to Embodiment 1 except for the mode of the guide part.
[0094] Drip irrigation tube 300 includes tube 310 , drippers 120 and guide parts 340 . Tube 310 is configured in the same manner as tube 110 except that guide parts 340 are formed in place of guide parts 140 . Further, drip irrigation tube 400 includes tube 410 , drippers 120 and guide parts 440 . Tube 410 is also configured in the same manner as tube 110 except that guide parts 440 are formed in place of guide parts 140 . Guide parts 340 in the longitudinal direction of tube 310 and guide parts 440 in the longitudinal direction of tube 410 are both positioned at two locations, for single ejection port 130 , such that dripper 120 is interposed therebetween in the longitudinal direction of tubes 310 and 410 , respectively.
[0095] Guide part 340 is a swelling provided circumferentially on the outer circumferential surface of tube 310 , as shown in FIG. 11A . The variation in the surface shape of the swelling is continuous in the longitudinal direction of tube 310 . The height of guide part 340 is, for example, about 2 mm, and the width of guide part 340 is, for example, about 3 mm. The height of guide part 340 is the distance from the outer circumferential surface of tube 310 to the apex of the swelling in the radial direction of tube 310 (h 1 in FIG. 11A ). The width of guide part 340 is a length of a portion, which traverses guide part 340 , of a straight line along the longitudinal direction of tube 310 on the outer circumferential surface of tube 310 (w 1 in FIG. 11A ). Guide part 340 is formed, for example, by intermittently reducing the extrusion rate of extrusion molding in producing tube 310 .
[0096] Guide part 440 is a depression provided circumferentially on the outer circumferential surface of tube 410 , as shown in FIG. 11B . The variation in the surface shape of the depression is continuous in the longitudinal direction of tube 410 . The depth of guide part 440 is, for example, about 0.1 mm, and the width of guide part 440 is, for example, about 3 mm. The depth of guide part 440 is the distance from the outer circumferential surface of tube 410 to the bottom of the depression in the radial direction of tube 410 (d 2 in FIG. 11B ). The width of guide part 440 is a length of a portion, which traverses guide part 440 , of a straight line along the longitudinal direction of tube 410 on the outer circumferential surface of tube 410 (w 2 in FIG. 11B ). Guide part 440 is formed, for example, by intermittently increasing the extrusion rate of extrusion molding in producing tube 410 .
[0097] When drip irrigation tube 300 is disposed such that ejection port 130 faces upward, liquid 150 having reached guide part 340 from ejection port 130 along the longitudinal direction of tube 310 is blocked by blocking effect due to the swelling of guide part 340 . Accordingly, liquid 150 staying on the outer circumferential surface of tube 310 flows downward along guide part 340 . Thus, liquid 150 is guided to the lowest part of tube 310 by the drip-facilitating function of guide part 340 , and drips from the lowest part at the above-mentioned set rate.
[0098] When drip irrigation tube 400 is disposed such that ejection port 130 faces upward, liquid 150 flowing along the longitudinal direction of tube 410 from ejection port 130 to reach guide part 440 flows into guide part 440 , and stays there. Thus, the flow of liquid 150 in the longitudinal direction on the outer circumferential surface of tube 410 is blocked by blocking effect due to the depression. Liquid 150 staying at guide part 440 flows downward in guide part 440 . Thus, liquid 150 is guided to the lowest part of tube 410 by the drip-facilitating function of guide part 440 , and drips from the lowest part at the above-mentioned set rate.
[0099] Thus, drip irrigation tube 300 according to Embodiment 3 and drip irrigation tube 400 according to Embodiment 4 are both capable of facilitating the drip of liquid 150 in guide parts 340 and 440 , respectively.
Embodiment 5
[0100] Embodiment 5 is the same as the above-mentioned Embodiment 1 except for the structure of the dripper. A dripper according to the present embodiment is different from the dripper of Embodiment 1 in that the dripper further has a communication channel for connecting a pressure reduction channel with an ejection part, and that a movable part changes the cross-sectional area of the communication channel. The configurations same as those of Embodiment 1 are given the same symbols as those of Embodiment 1, and the description thereof is omitted.
[0101] FIG. 12A illustrates an upper surface, a front surface, and a side surface of the dripper according to the present embodiment, and FIG. 12B illustrates a bottom surface, the front surface and the side surface of the dripper. FIG. 13A to FIG. 13D are a plan view, a front view, a bottom view and a side view of the dripper according to the present embodiment, respectively.
[0102] Dripper 220 according to the present embodiment is composed of dripper body 221 and movable part 222 . Dripper body 221 has first end part 2211 , second end part 1212 and connecting part 2213 . First end part 2211 includes inflow ports 123 , inflow part 124 and pressure reduction channel 225 . Pressure reduction channel 225 is configured with a groove recessed from the bottom surface of dripper body 221 . The shape of pressure reduction channel 225 in plan view is the same as the shape of pressure reduction channel 125 in plan view.
[0103] Connecting part 2213 is formed in the same manner as connecting part 1213 except that connecting part 2213 includes open part 2216 , a part of linear shaped communication channel 226 in plan view other than the both ends of communication channel 226 , which opens to the inner space of tube 110 ; and that the shape of bottom surface of connecting part 2213 in plan view is rectangular. Open part 2216 is configured of a cut (slit) extending through connecting part 2213 in the thickness direction of connecting part 2213 . The shape of open part 2216 in plan view is linear.
[0104] Movable part 222 is formed in the same manner as movable part 122 except for projection 2224 . The shape of projection 2224 in plan view is the same as the shape of open part 2216 in plan view, as shown in FIG. 13C . Projection 2224 covers open part 2216 from above and partially fits with open part 2216 , and thus communication channel 226 for connecting pressure reduction channel 225 to ejection part 126 is formed.
[0105] FIG. 14A is a cross-sectional view schematically illustrating the dripper according to the present embodiment cut along line A-A in FIG. 13C before the movement of the movable part, and FIG. 14B is a cross-sectional view schematically illustrating the dripper cut along line A-A in FIG. 13C after the movement of the movable part.
[0106] In the same manner as movable part 122 in Embodiment 1, movable part 222 slides at open part 2216 forward or backward from the bottom surface side of dripper 220 in a distance in accordance with the pressure on pressure receiving part 1221 to change the height (cross-sectional area) of communication channel 226 in a range of h 0 to h 1 , for example, from 0.25 to 0.75 mm in accordance with the pressure.
[0107] The present embodiment provides the same effects as those of Embodiment 1. Since dripper 220 according to the present embodiment further has communication channel 226 , dripper 220 can change a cross-sectional area of a part whose shape is simpler than that of pressure reduction channel 225 in the channel formed with dripper 220 . The shape of projection 2224 of movable part 222 in plan view thus can be further simplified. Therefore, the present embodiment is more effective from the perspective of simplifying the production of movable part 222 and assemblage of dripper 220 .
Embodiments 6 and 7
[0108] FIG. 15A is a schematic front view of a drip irrigation tube according to Embodiment 6 or 7 of the present invention disposed such that ejection ports face upward, FIG. 15B schematically illustrates liquid being ejected from the drip irrigation tube according to Embodiment 6, and FIG. 15C schematically illustrates liquid being ejected from the drip irrigation tube according to Embodiment 7. Drip irrigation tube 600 according to Embodiment 6 and drip irrigation tube 700 according to Embodiment 7 are configured in the same manner as drip irrigation tube 100 according to Embodiment 1 except for the mode of the guide part.
[0109] Drip irrigation tube 600 is configured in the same manner as drip irrigation tube 100 according to Embodiment 1 except that guide parts 640 are formed on the outer circumferential surface of tube 110 in place of guide parts 140 . Further, drip irrigation tube 700 is configured in the same manner as drip irrigation tube 100 according to Embodiment 1 except that guide parts 740 are formed on the outer circumferential surface of tube 110 in place of guide parts 140 .
[0110] Guide part 640 is a part having been subjected to a water-repellent treatment on tube 110 . Guide part 640 has higher water repellency than the outer wall of tube 110 , and is composed of a water-repellent coating film, for example. Examples of the water-repellent coating film include silicone resin coating film and fluorine resin coating film. Guide part 740 is a part having been subjected to a hydrophilic treatment on tube 110 . Guide part 740 has higher hydrophilicity than the outer wall of tube 110 , and is formed by irradiation of UV-rays, for example. The width of guide parts 640 and 740 are, for example, 3 to 20 mm
[0111] When drip irrigation tube 600 is disposed such that ejection port 130 faces upward, liquid 150 ejected from ejection port 130 flows in the longitudinal direction of tube 110 to reach guide part 640 , as shown in FIG. 15B . The flow of liquid 150 in the longitudinal direction is blocked by guide part 640 having water repellency. Liquid 150 stays on the outer circumferential surface of tube 110 at guide part 640 , and then flows downward on the outer circumferential surface of tube 110 along guide part 640 . Thus, liquid 150 is guided to the lowest part of tube 110 by the drip-facilitating function of guide part 640 , and drips from the lowest part of tube 110 at the above-mentioned set rate.
[0112] When drip irrigation tube 700 is disposed such that ejection port 130 faces upward, liquid 150 ejected from ejection port 130 flows in the longitudinal direction of tube 110 to reach guide part 740 , as shown in FIG. 15C . Since the outer wall of tube 110 has lower hydrophilicity than guide part 740 , the flow of liquid 150 having reached guide part 740 in the longitudinal direction of tube 110 is blocked by a boundary between guide part 740 and the outer wall of tube 110 . Then, liquid 150 having reached guide part 740 flows along guide part 740 , which is more hydrophilic than the outer wall of tube 110 . In this manner, liquid 150 is guided in the circumferential direction of tube 110 , and flows downward on the outer circumferential surface of tube 110 along guide part 740 . Thus, liquid 150 is guided to the lowest part of tube 110 by the drip-facilitating function of guide part 740 , and drips from the lowest part of tube 110 at the above-mentioned set rate.
[0113] Both guide parts 640 and 740 do not require substantial thickness. Thus, it is possible to dispose them on a tube regardless of the thickness of the tube wall. In addition, since the outer diameter of tube 110 is constant, stress is unlikely to focus on guide parts 640 and 740 . Therefore, guide parts 640 and 740 are more effective from the perspective of suppressing the rupture of tube 110 at a guide part due to stress focusing on the guide part in such cases of storing tube 110 in a wound state or drawing tube 110 when tube 110 is laid.
[0114] While the embodiments of the present invention have been described hereinabove, the scope of the present invention is not limited thereto.
[0115] For example, tube 110 may be a seamless tube, or a tube made by joining slender sheet(s) along the longitudinal direction.
[0116] The ejection port may be a gap formed, at a joint part of the sheet(s), to allow communication between the inside and the outside of tube 110 , or a pipe sandwiched by the sheet(s) at the joint part. Further, the shape of the ejection port in the axis direction can be appropriately determined within such a range as to enable the ejection port to eject liquid in tube 110 at an intended rate, and does not need to be linear. Examples of the tube capable of ejecting liquid from the ejection port at the intended rate include a tube having ejection ports each having a specific hole diameter, and a tube in which the pressure reduction channel is formed at the joint part through the joint of the sheet(s) each having a depression, which serves as the pressure reduction channel, formed on the surface of the sheet.
[0117] While a dripper is disposed in the tube in the above-mentioned embodiments, no dripper needs to be disposed if an ejection port can discharge liquid in tube 110 at an intended rate. While a dripper is disposed such that the inflow part is located on the upstream side in the liquid flow direction in the tube when the dripper is disposed in tube 110 , the dripper may be disposed such that the inflow part is located on a downstream side. The orientations of the drippers may be identical to each other or different from each other.
[0118] While the low-pressure stopping function based on dripper body material (polypropylene) is imparted to the dripper in the above-mentioned embodiments, the low-pressure stopping function may be imparted to the dripper by forming a burr protruding to the inner space of the tube from the open part edge on the top surface side of an inflow port, or by covering the open part edge and internal wall of the inflow port with a hydrophobic film. The low-pressure stopping function can be further enhanced by combining multiple methods of imparting the low-pressure stopping function.
[0119] While the same material (polypropylene) is used for the dripper body and the movable part in the embodiments, different materials may be used.
[0120] Methods other than the method of changing the height of the pressure reduction channel or the communication channel may be employed to change the cross-sectional area of the channel formed in the dripper. For example, the cross-sectional area may be changed using a straightening plate or a baffle plate which is movable forward or backward in the pressure reduction channel or the communication channel
[0121] While the movable part is moved forward or backward in the open part of the dripper body with plate springs formed on the dripper sides in accordance with the liquid pressure in the tube in the above-mentioned embodiments, any other means may be employed to move the movable part in accordance with the pressure. For example, it is also possible to move the movable part forward or backward in the open part by employing a movable part composed of an elastic body and expanding or contracting the elastic body in accordance with the pressure.
[0122] This application claims priority based on Japanese patent Application No. 2013-196945, filed on Sep. 24, 2013, the entire contents of which including the specification, the drawing and the abstract are incorporated herein by reference.
INDUSTRIAL APPLICABILITY
[0123] According to the present invention, it is possible to provide a drip irrigation tube capable of dripping liquid to be dripped from the vicinity of an ejection port. Also, it is possible for the present invention to easily provide a drip irrigation tube suitable for dripping liquid to be dripped at a proper rate using the pressure of the liquid. Therefore, further widespread use of such tube in the technical field of drip irrigations and endurance tests where a long term dripping is required can be expected, and further development in the technical field can be expected.
REFERENCE SIGNS LIST
[0000]
100 , 200 , 300 , 400 , 600 , 700 Drip irrigation tube
110 , 210 , 310 , 410 Tube
120 , 220 Dripper
121 , 221 Dripper body
122 , 222 movable part
123 Inflow port
124 Inflow part
125 , 225 Pressure reduction channel
126 Ejection part
130 Ejection port
140 , 240 , 340 , 440 , 640 , 740 Guide part
150 Liquid
226 Communication channel
1201 Protrusion
1211 , 2211 First end part
1212 Second end part
1213 , 2213 Connecting part
1214 , 1215 Elastic supporter
1216 , 2216 Open part
1221 Pressure receiving part
1222 Spacer
1223 Engaging part
1224 , 2224 Projection | The drip irrigation tube ( 100 ) comprises a tube ( 110 ), drippers ( 120 ), and guides ( 140 ). With respect to individual discharge openings ( 130 ), the guides ( 140 ) are disposed on both sides of the discharge opening ( 130 ) in the longitudinal direction of the tube ( 110 ). The guides ( 140 ) protrude from the outer circumferential surface of the tube ( 110 ). The guides ( 140 ) intercept the flow of liquid from the discharge openings ( 130 ) in the longitudinal direction and guide same vertically downward. The liquid is dripped on the soil from the discharge openings ( 130 ) or the vicinity of the discharge openings ( 130 ). | 8 |
TECHNICAL FIELD OF THE INVENTION
[0001] This invention relates in general to the field of solid and hollow cylinders, such as risers, hoses, pilings and pipes immersed in a fluid subject to relative motion between the cylinder and the fluid. In particular, the invention relates to a device and mechanism and method for reducing vortex-induced vibration caused by relative movement of water past a cylinder and also to a cylindrical assembly incorporating the inventive mechanism.
BACKGROUND OF THE INVENTION
[0002] Without limiting the scope of the invention, its background will be described primarily with reference to offshore risers used in sub-sea production wells as an example. Submerged cylindrically-shaped objects, such as risers, spars, or other elongated cylindrical structures used for under-sea oil or gas production, pumping, or loading are often exposed to relative movement of a body of fluid, particularly moving sea currents. Such elongated cylindrical structures are common in offshore petroleum exploration, production and transportation. Sometimes such elongated cylindrical structures extend from the surface to hundreds of meters below the surface, as in the case of spar platforms for production. Sometimes the cylindrical structures extend from the seabed thousands of meters upward toward the surface and into sea currents, as in offshore production risers, loading and unloading risers or hybrid risers for petrochemical production or transport. Cylindrical riser structures may support on their exterior or encase one or more pipelines or risers extending from the seabed to a drilling or production platform, to a ship or to another offshore structure or vehicle. Such risers or cylindrical riser support structures are continuously exposed to ocean currents that produce vortexes or vortices that tend to travel downstream with the current as the water moves around and past the risers. These vortices produce oscillating “lift” forces on the cylindrical structure as a result of vortex shedding and the spanwise, or lengthwise, coherence of the vortex shedding can produce substantial cumulative lift force on the elongated cylindrical structure. The effect is particularly adverse in the case of a cylindrical riser support column extending several hundreds of meters in the path of the current.
[0003] The lift forces due to vortex shedding act generally normal to the axis of the cylindrical structure and flow direction. As a vortex is produced and then separated in a “sheet” from the cylindrical surface along the length or span of the cylinder exposed to the current, the lift force can be significant and destructive. The vortices are swirling currents that repeatedly shed from the cylinder, sometimes called “Von Karman Vortex Sheets” and produce vortex-induced vibration. The vibratory movement or vortex-induced vibration (VIV) Von Karman Vortex caused by the repeated sheet separation from the cylinder is sometimes called “Aeolian Vibration.” This vortex-induced vibration creates cyclic stresses on the cylindrical structure that may be too small to cause immediate fracture, but upon constant repetition may weaken or damage the riser through material fatigue or stress-induced fracture. In certain relatively common current situations, a resonant vibration can be created, causing repetitive forces in phase with the vibratory motion that can overstress the cylindrical structure to potentially catastrophic failure.
[0004] In the past, fins protruding from the peripheral surface of the cylinders exposed to the current or other fluid movement, as in production riser situations, were used to reduce the adverse effect of such vortex formation and vortex sheet shedding. For example, helically-arranged vortex-shedding ribs, or strakes, have been designed to be installed on submerged risers exposed to ocean currents. In one prior device, such strakes are to be incorporated as components of a flexible wrap or panel to be disposed about and secured to the submerged riser. Typically the strakes are to be clamped to the riser prior to its being submerged. Such strakes could be formed by pairs of clamping flanges mounted along the adjacent edges of elongated parallelogram-shaped wrap segments. The wrap segments could be positioned side-by-side, twisting around the outer surface of the riser, and then bolted to engage at the clamp flanges, forming a helical strake extending in a spiral around and along the length of the cylindrical structure that will be exposed to moving current.
[0005] In another design, one or more ribs or strakes could be attached vertically or diagonally on a flat, rectangular panel of flexible wrapping material. The wrapping material would be dimensioned to encircle, by itself, an elongated segment of a single riser, piling, pipe or other cylindrical object. Clamping flanges were to be mounted along opposed vertical edges of the rectangular panel. The clamping flanges were to be brought together and clamped, thereby stretching the panel to wrap securely around and frictionally embrace the outer surface of the riser. A plurality of such wrapped panels with ribs or strakes were to be clamped in deployed positions, along the length of the cylindrical structure such that the strakes were aligned at either end of adjacent panels in a helical configuration encircling the wrapped riser structure.
[0006] It is difficult to transport, handle and install a cylindrical riser support structure having protruding strakes. Further, it has been found that installation underwater at the riser site is extremely difficult and usually impractical. It has been found that fabrication of a cylindrical riser structure with a protruding strake of a prior design is costly. Additionally, it has been found that the protruding strake on a cylindrical riser support structure increases the viscous drag of the water against the riser assembly, thereby risking greater stress and requiring increased size and strength for the riser support design.
[0007] In certain riser installations, a polymeric coating and, in particular, a polymeric foam layer is applied to the exterior surface of the risers and the riser support cylinder to provide protection from the undersea environment and advantageously to provide buoyancy to the assembly. The riser itself may be composed of a metal or a composite material. The riser support structure is normally a metal support cylinder with the metal or composite cylindrical riser pipe lines and polymeric foam coating material attached to the surface of the metal cylinder to facilitate maintaining the riser and support structure in an upright position by reducing the combined mass density (i.e., by adding buoyancy). It has been found that securing strakes, of any prior known design, to the exterior of a layer of polymeric foam is difficult. For example, clamping of strakes to the polymeric surface often fails due to insufficient compression strength of the foam. Particularly, in the case of a polymeric foam coating or bundle on the riser or riser support cylinder, clamping tension may not be sufficient to maintain the strakes in a secure position. Excessive clamping tension can significantly reduce the buoyancy by crushing the foam layer.
[0008] A need has therefore arisen for a device, mechanism and method to reduce, resist or suppress vortex induced vibration (VIV), or the effect of VIV on submergible cylinders such as risers and riser support columns, without requiring the attachment of a protruding strake. A need has also arisen for a submergible riser assembly with a VIV reduction mechanism attached that is easy to transport, easy to handle and easy to install and that is not costly to fabricate. In addition, a need has arisen for such a VIV reduction mechanism for fluid immerse cylindrical structures and assemblies, including submergible riser assemblies that does not significantly increase the viscous drag of moving fluid or moving water against the immersed cylinder or submerged riser assembly.
SUMMARY OF THE INVENTION
[0009] The present invention disclosed herein comprises a device, mechanism and method for use in a generally cylindrical assembly that is resistant to vortex-induced vibration when immersed in a moving fluid. The generally cylindrical assembly of the present invention, and particularly in the case of a cylindrical riser assembly, is easy to transport, handle and install and is not costly to fabricate. In addition, a feature of one embodiment of a cylindrical assembly according to certain inventive aspects of the present invention is that the cylindrical assembly is submergible in a body of water and resists or reduces vortex-induced vibration (VIV) and does not significantly increase the viscous drag of the fluid or water moving past the cylindrical assembly.
[0010] The vortex induced vibration (VIV) reduction mechanism of the present invention and the submergible cylindrical assembly of the present invention having such VIV reduction mechanism combined therewith effectively reduce the adverse effect of vortex-induced vibration when positioned in a flowing body of fluid such as water. The VIV reduction mechanism comprises a generally cylindrical column having a central axis, an outer surface, a wall thickness and a length. A pattern is cut or formed into the outer surface of the generally cylindrical column to selectively decrease the distance of the outer surface from the central axis. The pattern may be formed with a plurality of columnar sections each having a notch cut into the outer surface. A plurality of columnar sections are placed in series or stacked along the length of the cylindrical column. The notch of each columnar section is positioned in a selected circumferential angular relationship with the notch of each other columnar section and extends partially along the length of the column, thereby selectively reducing the thickness of the wall and producing a discontinuity in the outer cylindrical surface at selected positions. The angular position of each notch or of each reduced thickness portion of a wall around the circumference of the generally cylindrical column sections is differently selected along the length of the column. The selected angular positions provide a pattern of discontinuities on the generally cylindrical outer surface of the column. It will be understood that for a solid cylinder the wall thickness is nominally equal to the nominal radius. For a riser support column comprising a hollow cylinder encased in a polymeric or foam material, the wall thickness is less than the nominal radius. Selectively decreasing the distance from the axis to the surface might also be considered the same as reducing the wall thickness at selected locations or in a desired pattern. The reduced radius or reduced wall thickness preferably provides a sharp discontinuity in the surface.
[0011] Preferably, the discontinuities will be selectively and appropriately positioned in a pattern, desirably a helical pattern, along the length of the column so that the VIV effect of vortex sheet separation from the cylindrical column is reduced. Forming or approximating a helical shaped discontinuity along the length of the cylindrical structure exposed to moving current facilitates reduction of VIV, or at least reduces its negative effects in the cylindrical structure. The discontinuity acts to shed the vortex at different times at different segments along the length of the cylinder. The various vortex-created lift forces are out of phase from each other and thus are out of phase with the oscillation that the forces would otherwise cause in the cylindrical structure at any given time. The “out of phase” forces tend to cancel each other out. Thus, the vibratory effect of vortex-induced lift forces on the cylinder are reduced.
[0012] The abrupt reduction in thickness or the formation of a sharp discontinuity in the outer surface is generally accomplished using variously shaped notches or grooves. Preferably, notches or grooves having sharp corners have been found to be useful, such as a right angle triangular-shaped notch, an equilateral triangular-shaped notch, a rectangular-shaped notch, or other angular polygon. The notches or reduced thickness areas causing discontinuities in the outer surface of the cylindrical structure are either formed in a substantially continuous helical pattern or formed with segments of notches that are rotated to different angular positions at regular intervals along the length of the cylindrical structure. By forming relatively short segments of longitudinal notches and sequentially rotating each notch consistent angular amounts (between 10° and 90°) at regular intervals of length (between about 0.1 and 10 times the diameter), a long helical shape is approximated by the plurality of rotated notches or grooves. A series of partially rotated column sections, each column section having vertical or slightly angled notches or grooves may be provided along the length of the cylindrical column structure. By rotating the column sections at the time they are affixed to the support cylinder, a helically shaped groove is approximated by vertically elongated notches. A better approximation of a helical groove may be formed by a series of columnar sections having angled notch segments aligned end to end by rotating the columnar sections.
[0013] A generally cylindrical column structure to which the present inventive VIV reduction mechanism is to be applied according to the disclosure herein, might typically be a support structure for drilling risers or production risers. It will be understood that this is by way of example only of the cylindrical structure to which the VIV reduction device and mechanism is applied. The resulting inventive VIV reduced cylindrical assembly may also be used for other cylindrical structures; i.e., it may be a drilling riser, a production riser, a hybrid riser and/or any number of other elongated cylindrical structures that may be subjected to the adverse effects of VIV. The cylindrical structure may comprise a solid metal outer surface or may comprise a composite material on which a VIV reduction mechanism is secured or formed. The VIV reduction mechanism may be notches or grooves formed in the solid surface. Preferably notches or grooves in helical pattern may be formed into a composite polymeric material or a polymer foam material secured, attached or formed onto the surface of a generally cylindrical support structure such as a riser support cylinder or cut or molded into the surface of a generally cylindrically shaped polymer foam material attached on the outer surface of any immersed cylindrical structure. The VIV reduction mechanism may also be formed in a composite structure with notches, grooves or other discontinuity formed into the outer surface or into the wall thickness, as described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The foregoing objects, advantages, and features, as well as other objects and advantages, will become apparent with reference to the description, claims and drawings below, in which like numerals represent like elements and in which:
[0015] [0015]FIG. 1 is a schematic perspective, partially cutaway view, depicting various undersea uses of cylindrical columns in moving fluid (i.e., vertical cylindrical columns in horizontal water currents).
[0016] [0016]FIG. 2 is a schematic depiction of a cylindrical riser bundle support assembly provided with an upper buoyancy can, and a cylindrical support structure for the bundle of tubular risers with the cylindrical support structure having applicants' VIV suppression invention applied to the cylindrical exterior surface;
[0017] [0017]FIG. 3 is a schematic depiction of a hybrid riser assembly having a cylindrical riser support structure with a portion thereof having, for additional buoyancy, substantially cylindrical foam to which applicants' inventive VIV suppression device has been applied;
[0018] [0018]FIG. 4 is a schematic depiction of a representative segment of the upper enhanced buoyancy portion of the substantially cylindrical riser structure of FIG. 3 in which a plurality of risers are held together supported by a central support cylinder in segmented foam quadrants clamped in a substantially cylindrical shape and having segments of applicants' VIV reduction devices applied and clamped to the exterior of the enhanced buoyancy foam riser bundle;
[0019] [0019]FIG. 5 is a schematic cross-sectional depiction of one embodiment of applicants' inventive VIV reduction device and mechanism in which four sections of the VIV suppression device are depicted for clamping around a riser, two of which in each cylindrical segment have a notch or sharp discontinuity formed therein with each notch at concentric opposed locations, the junctions at each end each section being concentric with the other ends and of the same width so that clamping engagement results in a smooth transition between one half and the other;
[0020] [0020]FIG. 6 shows an embodiment of the VIV suppression device in which four discontinuities or four notches or four “step notches” are formed in four quadrants of the VIV columnar segments;
[0021] [0021]FIG. 7 shows an embodiment similar to FIG. 6, except that each VIV reduction columnar segment is divided into two substantially identical pieces. The cut can be anywhere in the segment;
[0022] [0022]FIG. 8 shows another embodiment similar to FIG. 7, except that each VIV reduction columnar segment is divided into four identical pieces which lock each other together. This embodiment will allow the load on the notches to be better distributed along the entire length of the segment.
[0023] [0023]FIG. 9 shows the arrangement of the segments and notches depicted in FIGS. 6 - 8 in the longitudinal direction. For clarity only one notch on each columnar segment is shown.
[0024] FIGS. 10 - 13 show cross-sections of the segments of FIG. 9 taken along the lines 10 - 10 , 11 - 11 , 12 - 12 , and 13 - 13 , respectively.
[0025] [0025]FIG. 14 shows another arrangement of the notches depicted in FIGS. 6 - 8 in the longitudinal direction. In this embodiment, successive notches form a spiral line. For clarity, only one notch on each columnar segment is shown.
[0026] FIGS. 15 - 18 show cross-sections of the segments of FIG. 14 taken along the lines 15 - 15 , 16 - 16 , 17 - 17 and 18 - 18 , respectively.
[0027] [0027]FIG. 19 shows another embodiment in which the outline of the columnar segment is not a circle, with the phantom line in the drawing showing a circle (that is not part of a structure) for comparison. At one side, the surface extends beyond the circular phantom line and at the other side it is inside the circular phantom line. The notch arrangement of successive segments in the longitudinal direction can be the same as depicted in FIGS. 9 and 14.
[0028] [0028]FIG. 20 shows another embodiment similar to FIG. 19, except that the columnar VIV reduction segment is divided into two identical pieces. The notch arrangement of successive segments in the longitudinal direction can be the same as depicted in FIGS. 9 and 14.
[0029] [0029]FIG. 21 shows another embodiment of a segment that has a notch of a different shape. The notch arrangement in the longitudinal direction can be the same as depicted in FIGS. 9 and 14.
[0030] [0030]FIG. 22 is a side view of longitudinally arranged segments with triangular notches. The triangular notches cover entire cylindrical surface and in the longitudinal direction, the notches forming spiral (helical) lines.
[0031] [0031]FIG. 23 is a cross-sectional view of one of the segments of FIG. 22, taken along the line 23 - 23 .
[0032] [0032]FIGS. 24 and 25 show another embodiment where the cross section of the segment is an ellipse and the angular orientation of the long axis of each rotates, as shown in the cross-section in FIG. 25, to form a spiral (twisted) shape.
[0033] [0033]FIGS. 26 and 27 show another embodiment where the cross section is a triangle with rounded corners. The angular orientation of each triangle rotates, as shown in the cross-section in FIG. 27, to form a spiral (twisted) shape.
[0034] [0034]FIGS. 28 and 29 show another embodiment where the cross section is a square with rounded corners. The angular orientation of the square rotates, as shown in FIG. 29, to form a spiral (twisted) shape.
[0035] [0035]FIGS. 30 and 31 show another embodiment where the cross section is an ellipse. The angular orientation of the long axis of the ellipse rotates, as shown in FIG. 31, to form a discontinuous stepped pattern.
[0036] [0036]FIGS. 32 and 33 show another embodiment where the cross section is a triangle with rounded corners. The angular orientation of the triangle rotates, as shown in FIG. 33, to form a discontinuous stepped pattern.
[0037] [0037]FIGS. 34 and 35 show another embodiment where the cross section is a square with rounded corners. The angular orientation of the square rotates, as shown in FIG. 35, to form a discontinuous stepped pattern.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applications for the inventive concepts which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention and do not delimit the scope of the invention.
[0039] Referring to FIG. 1, which is a schematic depiction of floating production systems on the sea surface 10 and extending from the seabed 12 through a distance of ocean, including a portion 14 having sea currents and a portion 15 without significant sea currents. Examples of various ocean equipment to which the invention may be usefully applied are depicted, including a sea floor drilling rig 16 , a ship 18 , a columnar-supported drilling platform 20 , a floating production platform 22 and a spar platform 24 , as well as a collection vessel 26 . Risers 28 are shown extending from the seabed 12 to the collection ship 18 where hydrocarbons are pumped on board from the risers and transported to an appropriate port facility where similar risers may offload the petroleum products to a refinery. The drilling or production platform 20 is schematically depicted with a drill casing 30 extending to the floor surface and also support legs 32 on which the drilling or production platform is secured to the sea floor 12 .
[0040] The spar platform hull 24 is supported on a large cylindrical spar hull 40 having a heavy end 39 and an upwardly buoyant end 37 so that the platform 24 is floating in a desired position and may be anchored in position with mooring lines 41 . Top tension risers and steel catenary riser pipes 42 extend upward to the spar platform 24 and through or about the spar hull 40 to the production platform 24 . The collection vessel 26 is shown receiving hydrocarbon from a hydrocarbon collection system 44 for sub-sea wells on the seabed 12 and providing the produced hydrocarbons through upwardly extending risers 46 and also collecting hydrocarbons from the well 16 through elongated recovery pipes 48 that may extend flexibly along the seabed 12 and upward to collection vessel 26 .
[0041] The foregoing floating production systems are depicted by way of background so that uses of the inventive VIV reduction mechanism according to various embodiments of the present invention may be more fully understood as to the wide ranging applications to riser cylinders drill casings, riser support columns, pipes, platform legs, cylindrical spars and other similar immersed cylindrical structures.
[0042] With reference to FIG. 2, a production/transport vessel 50 , in this case a ship 50 , is shown in position for receiving hydrocarbons above a buoyancy canister 52 attached to a riser support cylinder 54 so that the riser support cylinder 54 may be held upright and having a connection in 53 held adjacent to the sea surface 10 . Depicted in FIG. 2 is one embodiment of VIV reduction mechanism 56 attached along a length 14 exposed to current 58 that is depicted as horizontal arrows 58 . In shallow waters, the current 58 may extend from the sea surface 10 to the seabed 12 , however, in deep waters as is often the case, the current 58 may extend a length 14 that may be several hundred to several thousand meters deep. In situations where the sea depth is thousands of meters, there will also be a length 15 of riser 54 that is not exposed to any significant current. In situations where no VIV reduction mechanism 56 is applied to the cylindrical riser support, the current 58 will form vortexes or a sheet of vortex material along substantially the entire length 14 exposed to the current 58 . With vortex reduction mechanisms 56 applied to riser support structure 54 , the vortices 60 a, b, c, d, e, f, and g will each shed from the column surface at different times and/or different locations such that the lifting force at each longitudinal position along the riser support structures is out of phase with the oscillation of the entire riser 54 thereby canceling out the vibration. This effectively reduces the vibration.
[0043] The vessel 50 is shown held in place with anchor cable 62 attached to sea anchors 64 so that the conduits 66 from the connection head 53 to the production vessel 50 are retained in a relatively stable position. The VIV reduction mechanism 56 applied along cylindrical riser 54 comprises a plurality of VIV reduction column segment 70 . These have been labeled starting at the topmost as VIV reduction column segment 70 a with the next columnar segment 70 b, 70 c and etc. Each columnar segment is rotated relative to the next such that a sharp notches, grooves or discontinuities 72 a, b, c, d, e, etc. are provided in each columnar segment.
[0044] Advantageously, the discontinuity areas are rotated angularly with each successive columnar segment to a different angular position relative to the adjacent columnar segments. Desirably, for example, segment 70 b is rotated an angle of between about 10° and 90° relative to segment 70 a. Also desirably segment 70 c is also rotated to the same angular amount relative to 70 b as 70 b is rotated relative to 70 a. Thus, a consistent rotational interval is provided along each VIV reduction column segment.
[0045] As will be described more fully below, the column segments may have an axial length that is between about ½ times the diameter to about 10 times the diameter. In particular, it has been discovered that columnar segments having a length of approximately 1½ times the diameter each rotated about 30° relative to each other will advantageously break up the vortex sheet. Vortex shedding at one column will be out of phase with the next so that vortex induced lifting forces are out of phase and cancel each other. By rotating each columnar segment, a consistent rotational angle between about 10 and 90°, a helical design is approximated. Each VIV reduction columnar segment may comprise one or a plurality of longitudinal VIV reduction discontinuities. Generally speaking, the greater number of discontinuities per columnar segment, the longer the columnar segment may be and still have a desired VIV reduction effect. Various embodiments, constructions and manufacturing of VIV reduction columns will be discussed more fully below with reference to FIGS. 5 - 43 .
[0046] Turning now to FIG. 3, which is a configuration of hybrid riser, an additional application of the inventive VIV reduction mechanism may be more fully understood in connection with a support riser 76 having structural steel pipe inside the bundle, by which a plurality of riser pipes 68 may be supported vertically upward from the seabed 12 to a position close to sea surface 10 , for providing flexible riser 82 connection to floating platform 74 . In this embodiment, the VIV reduction mechanism 77 comprises of a plurality of VIV reduction columnar segments, 78 a, b, c, and d etc., each having a VIV reduction notch 84 a, b, c, and d etc. preferably a plurality of angled notches or discontinuities 84 a, b, c, and d etc. The angle of the notch relative to the longitudinal axis of a columnar segment 78 , desirably provides a segment of a helical notch 84 . Adjacent VIV reduction columnar segments 78 a and b are each simultaneously merged and are each rotated relative to each other at appropriate angular interval so that the notches 84 a and 84 b are lined end to end form a cylindrical notch comprised of a plurality of segments 84 b, c, d, e, f, g, and etc. The number of columnar segments required to provide the VIV reduction system along the length of riser support 76 that is exposed to currents will depend upon the depth of the currents and the length of each columnar segment.
[0047] In the embodiment shown in FIG. 3, additional buoyancy polymeric foam segments 80 a, b, c and etc. are also provided secured to the cylindrical riser support structure 76 toward the top thereof where it may be tethered through cables 88 to a production platform 74 floating on the sea surface 10 . A connection head 90 is provided by which the risers 68 are in fluid communication with flexible risers 82 to provide hydrocarbons to the surface vessel.
[0048] Referring now to FIG. 4, one embodiment of a riser support column with risers encased in a foam retaining material is schematically depicted with a partial perspective view of one portion of a riser support cylinder assembly having foam material in cylindrical quadrants encasing a plurality of risers and further providing additional buoyancy VIV reduction mechanisms clamped around the periphery of the cylindrical foam structure. Particularly, a metal cylinder 102 provides the main riser support and a plurality of petroleum recovery risers 104 a, 104 b, 104 c, 104 d are provided along with control cables 106 a and 106 b as well as additional pressurizing pipes 108 a, b and 108 c and d as well as gas recovery pipes 110 a and 110 b ( 110 b not shown in FIG. 4). The VIV columnar segments 70 a, 70 b, 70 c and 70 d are shown constructed of four VIV reduction column sections, the risers, conduits and control cables extending along the length of support cylinder 102 being are encased within four molded polymeric foam sections 120 , 122 , 124 and 126 making up each of the columnar segments 70 a, 70 b, 70 c and 70 d. Adjacent ones of sections 120 , 122 , 124 and 126 , need not be the same cross-sectional shape, although it is preferred that respectively opposing sections, i.e., 120 and 126 , and 122 and 124 , be the same shape as their opposed section. These sections are respectively “split” at junctions 146 and 148 (not shown if FIG. 4, see FIG. 5) for petroleum recovery risers 104 a, 104 b, 104 c and 104 d and include half-circle cutouts for these risers. Sections 122 and 126 include outwardly open cut-outs for cables 106 a and 106 b, and sections 120 and 124 include inwardly open cut-outs for gas recovery lines 110 a and 110 b. The construction of these sections will be more fully understood with reference also to FIG. 5 which is a cross-sectional view of VIV reduction riser assembly according to FIG. 4 taken along section line 5 - 5 . two of which 128 and 130 .
[0049] Each VIV reduction segment 70 a, 70 b, 70 c and 70 d has a discontinuity 132 a, 132 b, 132 c and 132 d in its outer surface, and a corresponding discontinuity 132 a′, 132 b′, 132 c′ and 132 d′ on the outer surface of its back side. As depicted in FIG. 4, each of these discontinuities comprises a substantially radially directed face 134 extending inward from the exterior surface 142 , a distance approximating between {fraction (1/10)}th and {fraction (3/10)}ths the diameter thereby decreasing the wall thickness of VIV reduction columnar half 130 as depicted at 136 . A substantially flat surface 140 is formed projecting substantially at right angles to face 134 thereby providing a right triangular notch 132 . Subsequent columnar segments 70 a, 70 b and 70 c also have a similar notches 132 a, 132 b and 132 c, respectively. In the embodiment depicted in FIGS. 4 and 5, two opposed ones of the four columnar segments also has a discontinuity or a notch 132 formed in its face. These sections are clamped using clamps 142 and 144 to securely hold the additional buoyancy foam, into which the VIV reduction mechanism has been formed, onto the exterior of the cylindrical riser assembly 80 . At junctions 146 and 148 (not shown in FIG. 4, see FIG. 5) between the sections, the wall thickness of the adjacent VIV reduction column sections is the same.
[0050] Referring to FIG. 5 that is a cross-sectional view of the VIV reduction riser assembly of FIG. 4, it can be seen that the VIV reduction columns according to this embodiment have substantially concentric notches at opposite sections where the thickness of the wall is reduced an equivalent amount D on each side and the wall thickness progressively increases from that notch 132 toward the opposing section, where the diameter continues to increase until the second notch 132 on that opposing section is reached. Again, the discontinuity wall thickness is decreased the distance D and again the wall thickness progressively increases past the junction 148 until the subsequent notch 132 on the other side is reached. Similar structure is provided with respect to each of the VIV reduction columnar segments 70 a, 70 b, 70 c and 70 d, in which successive segments are mounted sequentially adjacent to each other except rotated a predetermined angular interval between zero and 90°. It has been found that rotation of approximately 30° provides good VIV reduction, thus discontinuity 132 b is offset from the prior discontinuity 132 by an angle of approximately 30°. Subsequent columnar segment 70 c is likewise formed with four sections. The foam segments of these successive of these columnar segments are molded such that each successive discontinuity 132 is rotated about 30°. with respect to the next. It has further been found that the length 144 of each columnar segment 170 a, b, c, etc. may be desirably about 1.5 times the nominal diameter of the VIV reduction columnar segments.
[0051] Turning now to FIG. 6, a cross-section another embodiment of the VIV suppression device surrounding a pipe 108 ′ is depicted having four discontinuities or “notches” 158 , 159 , 160 and 161 formed in four quadrants of the VIV columnar segment. The eccentric exterior shape retains or approximates a substantially cylindrical columnar shape. In this embodiment, the VIV suppression device may conveniently be molded onto the pipe, or slipped onto its end prior to installation of the pipe.
[0052] [0052]FIG. 7 shows an embodiment similar to FIG. 6, except that each VIV reduction columnar segment is divided into two substantially identical pieces, to facilitate assembly. The cuts 163 and 164 can be anywhere in the segment.
[0053] [0053]FIG. 8 shows another embodiment similar to FIG. 7, except that the discontinuities 158 , 159 , 160 and 161 are, for example, at or near the junctions between each quadrant. In this embodiment, each VIV reduction columnar segment is divided into four identical pieces which lock each other together at zig-zag split lines 166 , 167 , 168 , 169 . This embodiment permits the load on the notches to be better distributed along the entire length of the segment.
[0054] [0054]FIG. 9 is a schematic depiction of a VIV reduction mechanism 180 formed of a plurality of VIV reduction columnar segments 181 a, b, c, d, e, f, g, h, i, j, k and l stacked in an elongated column each having a longitudinal discontinuity 182 in the form of notches 182 a, b, c, d, e, f, g, h, i, j, k and l. For clarity only one notch on each columnar segment is shown. Each columnar segment is rotated 30° degrees relative to each other. By sequentially rotating the columnar segments 181 , the notches 182 are arranged in a pattern that approximates a helical pattern. The rotation angle of 30° provides twelve columnar segments for one complete helical rotation of the vertical notch positions.
[0055] [0055]FIGS. 10, 11, 12 and 13 are schematic cross-sectional views taken at section lines at 10 - 10 , 11 - 11 , 12 - 12 and 13 - 13 , respectively. Each cross-sectional depiction represents 90° rotation or each third one of the columnar sections each rotated 30°. In FIG. 10 an indication of a perspective view is depicted in phantom lines in combination with the solid line cross-sectional view to assist in visualization of the construction of the discontinuity or notch 182 a. Although the embodiment depicted shows a cross-section of a substantially cylindrical column segment that is slightly eccentric rather than perfectly cylindrical, the construction may be understood in terms of a nominal diameter D represented by numeral 184 . Referring again to FIG. 9 the height of each column 185 is conveniently in a range of between one half times D to about five times D, to permit offsetting of the discontinuities by the desired rotation angle, however, the ratio is not critical to the invention. Longer columnar segments might be used, for example, where a plurality of notches 182 are formed in each columnar segment rather than the single notch as depicted in FIGS. 9 through 13. The notch or discontinuity has a substantially flat face 183 that provide a corner along the length of 185 of the column. The face has a depth B represented by numeral 187 into the eccentric surface of the cylindrical column 181 a. Depth B consist of a portion C represented by numeral 188 that accomplishes the eccentricity of the columnar segment and the remainder which corresponds to the reduction in the radius less than the nominal diameter D. The size of the notch depends upon the specific conditions of use. Of course, the rotation need not be 30 degrees, as any offset sufficient to create any pattern of notches effective to diminish VIV will suffice. Again with reference also to FIGS. 10, 11, 12 and 13 each of which depicts a cross-sectional view of the VIV reduction mechanism 190 at Section lines 10 - 10 , 11 - 11 , 12 - 12 , and 13 - 13 , respectively. In the embodiment depicted in FIGS. 19 through 13 as more specifically set forth with reference to FIGS. 10 and 11, the cylindrical columnar segments 192 have a diameter D represented by numeral 194 . The longitude and the length of each column is between one-half times D and five times D as represented by reference rule 195 . The discontinuity or notch 192 a has a flat face 193 that is radiantly aligned with the central axis of the VIV columnar segment 191 a and has a flat surface 195 projecting at right angles from face 193 . This produces a sharp exterior corner at 198 that facilitate initiation of the shear shedding as discussed previously. The depth of the phase B represented by numeral 197 may be in the range of 0.1 to 0.3 times the diameter D. The face 195 has a width A represented by numeral 196 that may be in the range of 0.3 to 0.8 times the nominal diameter D.
[0056] [0056]FIG. 14 depicts a side view of sequentially arranged segments with notches formed at an angle into the outer surface of the VIV reduction device, so that when the segments are successively arranged, the notches form a substantially longitudinally continuous spiral notch. Each columnar segment rotate at 30° relative to the other as with 90 degrees of rotation. The arrangement of each third segment is depicted in cross-sections in FIGS. 15, 16, 17 and 18 .
[0057] [0057]FIG. 19 shows another embodiment in which the outline of the columnar segment is not exactly a circle; i.e., it is somewhat spiral-shaped. The phantom line 199 in the drawing shows a circle but is not part of a structure. At one side of the surface extends beyond the circular phantom line and at the other side it is inside the circular phantom line. The notch sequential off-setting arrangement in the longitudinal direction can be the same as depicted in FIGS. 9 and 14; i.e., approximately 30 degrees..
[0058] [0058]FIG. 20 shows another embodiment similar to FIG. 19, except that the columnar VIV reduction segment is divided into two identical pieces at cut lines 163 ′ and 164 ′. The notch arrangement in the longitudinal direction can be the same as depicted in FIGS. 9 and 14; i.e., approximately 30 degrees.
[0059] [0059]FIG. 21 shows another embodiment that has a notch 158 ″ of a different shape; i.e., a square. The notch arrangement in the longitudinal direction can be the same as depicted in FIGS. 9 and 14. Although only one notch 158 ″ is depicted, four or any number could be used, as in FIGS. 9 and 14.
[0060] [0060]FIG. 22 is another embodiment which has a cross section as shown in FIG. 23. The triangular notches 300 cover entire cylindrical surface and in the longitudinal direction, the notches form spiral (helical) lines.
[0061] This embodiment uses a VIV reduction mechanism in which a plurality of V-type notches 300 are equilateral triangles are formed into the surface of the substantially cylindrical column. Again the star-shaped cross-section of FIG. 23 continuously spirals along the length of the column depicted in FIG. 23. This may be created by a long columnar section longer than the one-half to ten times the diameter columns that might be more appropriate with vertically aligned notches. However for ease of manufacture and for clamping onto cylindrical risers or cylindrical riser support structures or the like columnar sections might still be used and alignment will be easily accomplished because of the uniform star shape provided by the plurality of V-shaped notches.
[0062] [0062]FIG. 24 and 25 show another embodiment where the cross section 250 is slightly twisted, an ellipse, successive segments being offset about 45 degrees so the long axis of the ellipse “spirals,” as shown in FIG. 25, to form a spiral (twisted) shape.
[0063] [0063]FIGS. 26 and 27 show another embodiment where the cross section 255 is a slightly twisted triangle with rounded corners. Successive segments are offset about 45 degrees, the direction of the triangle, as shown in FIG. 27, to form a spiral (twisted) shape.
[0064] [0064]FIGS. 28 and 29 show another embodiment where the cross section is a square with rounded corners. The angular orientation of the square rotates, as shown in FIG. 29, to form a spiral (twisted) shape.
[0065] [0065]FIGS. 30 and 31 show another embodiment where the cross section is an ellipse. The angular orientation of the long axis of the ellipse rotates as shown in FIG. 31, to form a discontinuous stepped pattern.
[0066] [0066]FIGS. 32 and 33 show another embodiment where the cross section is a triangle with rounded corners. The angular orientation of the triangle rotates, as shown in FIG. 33, to form a discontinuous stepped pattern.
[0067] [0067]FIGS. 34 and 35 show another embodiment where the cross section is a square with rounded corners. The angular orientation of the square rotates, as shown in FIG. 35, to form a discontinuous stepped pattern.
[0068] While this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description. It is, therefore, intended that the appended claims encompass any such modifications or embodiments. Other alterations and modifications of the invention will likewise become apparent to those of ordinary skill in the art upon reading the present disclosure, and it is intended that the scope of the invention disclosed herein be limited only by the broadest interpretation of the appended claims to which the inventors are legally entitled. | A mechanism to be applied to an exterior surface of a cylindrical structure for reduction of the effect of Vortex Induce Vibration (VIV) in the cylindrical structure when immersed in flowing fluid. The mechanism is provided with a generally cylindrical column having a central axis, an interior surface corresponding in size and shape to the exterior surface of the cylindrical structure to which the mechanism is to be applied and an outer surface defining a wall thickness. A reduced wall thickness is formed into the outer surface in a pattern to produce a discontinuity that interrupts the lengthwise coherence of vortex shedding of moving fluid from the outer surface when the cylindrical column is attached to the exterior of the cylindrical structure in the flowing fluid. The effect of VIV on the cylindrical structure is effectively reduced.
A submergible cylindrical assembly for positioning in a flowing body of water and having enhanced resistance to vortex induced vibration is disclosed. The cylindrical assembly comprises a cylinder having an axis, an outer surface and a wall thickness. The cylinder has a pattern cut into the outer surface thereof that selectively reduces the wall thickness of the cylinder such that the formation of vortices is reduced, thereby reducing or eliminating the lift force on the cylinder and reducing or eliminating the vortex induced vibration that may weaken or damage the cylinder. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to the treatment of "sour" petroleum and coal liquefaction hydrocarbons containing hydrogen sulfide and other organosulfur compounds such as thiols and thiocarboxylic acids, and more particularly, to improved methods of treating such streams by using aminocarbinols.
Petroleum and synthetic coal liquefaction crude oils are converted into finished products in a fuel products refinery, where principally the products are motor gasoline, distillate fuels (diesel and heating oils), and bunker (residual) fuel oil. Vacuum distillation towers separate the crude into narrow boiling fractions. The vacuum tower cuts deeply into the crude while avoiding temperatures above about 800° F. which cause thermal cracking. A catalytic cracking unit cracks high boiling vacuum gas oil into a mixture from light gases to very heavy tars and coke. In general, very heavy virgin residuum (average boiling points greater than 1100° F.) is blended into residual fuel oil or thermally cracked into lighter products in a visbreaker or coker.
Overhead or distillate products in the refining process generally contain very little, if any, hydrogen sulfide (H 2 S), but may contain sulfur components found in the crude oil, including mercaptans and organosulfides. However, substantial amounts of hydrogen sulfide, as well as mercaptans and organosulfides, are found in the vacuum distillation tower bottoms, which may be blended into gas oils and fuel oils. In addition, hydrogen sulfide is produced during catalytic cracking or coking of higher boiling fractions and vent streams from those operations and from other refining operations must be treated to remove the hydrogen sulfide.
As employed in this application, "hydrocarbons" is meant to include the unrefined and refined hydrocarbonaceous products derived from petroleum or from gasification or liquefaction of coal, both of which contain sulfur compounds. Thus, the term "hydrocarbons" includes, particularly for petroleum based fuels, sour natural gas, casinghead gas, wellhead condensate, and crude oil which may be contained in storage facilities at the producing field and transported from those facilities by barges, pipelines, tankers, or trucks to refinery storage tanks, or, alternatively, may be transported directly from the producing facilities through pipelines to the refinery storage tanks. The term "hydrocarbons" also includes refined products, interim and final, produced in a refinery, including distillates such as gasolines, distillate fuels, oils, and residual fuels.
Hydrogen sulfide in natural gas or in refinery gases or which collects in vapor spaces above confined hydrogen sulfide containing hydrocarbons (for example, in storage tanks or barges) is poisonous, in sufficient quantities, to workers exposed to the hydrogen sulfide. Mercaptans are strongly malodorous. Refined fuels must be brought within sulfide and mercaptan specifications for marketability. In the processing of hydrocarbons, it is desirable to eliminate or reduce atmospheric emissions of noxious hydrogen sulfide, mercaptan or other sulfhydryl compounds associated with sulfur containing hydrocarbons, in order to improve environmental air quality at refineries.
Numerous proposals have been made to sweeten sour distillate products and to scrub hydrogen sulfide from sour gases by treatment with a variety of amine derivatives or other additives. Disclosures illustrative of these are contained in U.S. Pat. Nos. 4,997,630 (methyldiethanolamine); U.S. Pat. No. 4,978,512 (reaction product of monoethanolamine and formaldehyde); U.S. Pat. Nos. 4,957,715; 4,883,601; 4,764,354; 4,575,455; 4,557,991 (alkanolamines generally); U.S. Pat. No. 4,551,158 (methyldiethanolamine); U.S. Pat. No. 4,421,725(tertiary alkanolamine); and other processes involving the use of alkanolamines: U.S. Pat. Nos. 4,406,868; 4,205,050; 4,096,085; 4,085,192; 4,079,117; 3,685,960; 3,681,015; 3,516,793; 2,600,328; and 2,589,450. In gas scrubbing where alkaline aqueous scrubbing solutions normally are employed, alkanolamines are employed because of their solubility in water and alkalinity. In U.S. Pat. No. 4,405,585, a sterically hindered secondary aminoether alcohol was employed to selectively scrub hydrogen sulfide gas from a gaseous mixture of hydrogen sulfide and CO 2 . Dimethylaminoethanol and dimethylisopropanolamine were employed in U.S. Pat. Nos. 4,490,275 and 4,430,196 to neutralize acidic components in petroleum refining units. U.S. Pat. No. 5,030,762 suggests a quaternized adduct of formaldehyde and a secondary amine is useful for absorption of sulfur compounds produced by combustion of hydrocarbon materials.
The prior art relating to the treatment of sour petroleum oils also includes methods in which choline base has been employed to treat sour heavy fuel oils to maintain the hydrogen sulfide content in the atmosphere above or associated with such oils at levels within acceptable limits to avoid health hazards to personnel, as disclosed in U.S. Pat. No. 4,867,865. Choline base also has been used to treat gasoline and other motor fuels to remove organosulfur compounds such as thiols, thiolcarboxylic acids, disulfides and polysulfides, as disclosed in U.S. Pat. No. 4,594,147.
The use of choline base for these purposes has its drawbacks. Choline base itself has a strong unpleasant odor, and at low mix conditions has limited oil solubility. In the presence of water, choline base, like the alkanolamines described above, tends to seek the water in preference to oil, and does not distribute easily and thoroughly in oil without high mixing conditions. For example, it is recommended added by injection into the suction side of the product pump. Especially, this is a problem with fuel oils and residual oils. These heavy, high boiling fuels do not normally flow well at ambient temperatures, and heating at temperatures above about 140° F. and high mix conditions are necessary to mix choline base into them. High mix conditions do not always exist, or may not be feasible, and a better way to treat hydrocarbons remains a challenge in order to reduce hazards of hydrogen sulfide exposure to workers, to bring fuels within sulfide or mercaptan specifications, and to eliminate or reduce atmospheric emissions of noxious hydrogen sulfide, mercaptan or other sulfhydryl compound odors associated with such fuels for improved environmental air quality.
SUMMARY OF THE INVENTION
In accordance with this invention, a new method is provided for sweetening hydrocarbons which contain at least hydrogen sulfide (H 2 S) and may also contain organosulfur compounds having a sulfhydryl (--SH) group, also known as a mercaptan group, such as, thiols (R--SH, where R is hydrocarbon group), thiol carboxylic acids (RCO--SH), and dithio acids (RCS--SH). Such oils are treated with an effective sweetening and hydrogen sulfide vapor quantity reducing amount of an aminocarbinol of the formula
R.sub.2 N--CH(--R.sup.1)OH
wherein R 1 is hydrogen or a hydrocarbyl or inertly substituted hydrocarbyl and each R is independently hydrocarbyl or inertly substituted hydrocarbyl or both R groups are collectively a divalent hydrocarbon or ether radical combined with the nitrogen of the aminocarbinol to form a heterocyclic ring represented by the formula
(--R--R--)>N--CH(--R.sup.1)OH.
The aminocarbinols used in this treatment are suitable for treating all hydrocarbons, but especially are useful for treating sour gases and high boiling, heavy residual fuels under low mix conditions. Preferred treatment temperatures are from ambient to about 400° F.
Such aminocarbinols may also be used to reduce hydrogen sulfide vapor in vapor spaces above confined oils to acceptable limits by treating such oils with an effective hydrogen sulfide quantity reducing amount of such aminocarbinols. Such treatment is effective where the hydrogen sulfide level above the liquid petroleum hydrocarbon to be treated is between 10 ppm to 100,000 ppm.
Such aminocarbinols may also be used to reduce noxious atmospheric odors of hydrogen sulfide, mercaptans and other sulfhydryl compounds from oils by treating such products with an effective odor reducing amount of such aminocarbinols.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In accordance with this invention, the aminocarbinol may have the formula R 2 N--CH 2 OH. Aminocarbinols of this formula suitably include ones in which R is an alkyl, cycloalkyl, aryl, arylalkyl or alkaryl group; for example, where R is an alkyl group, aminocarbinols include dimethylaminocarbinol, methylethylaminocarbinol, methylpropylaminocarbinol, diethylaminocarbinol, ethylpropylaminocarbinol, ethylbutylaminocarbinol, di-isopropylaminocarbinol, dibutylaminocarbinol, dipentylaminocarbinol, dihexylaminocarbinol, dioctylaminocarbinol and dicocoaminocarbinol. Where R is a cycloalkyl group, the aminocarbinols include dicyclopentylaminocarbinol and dicyclohexylaminocarbinol. Where R is an aryl group, the aminocarbinols include diphenylaminocarbinol, methylphenylaminocarbinol and ethylphenylaminocarbinol. Where R is an alkarylgroup, the aminocarbinols include dibenzylaminocarbinol, methylbenzylaminocarbinol and di-(p-methylphenyl)-aminocarbinol.
Aminocarbinols of the formula (--R--R--)>N--CH 2 OH suitably include pyrrolidinocarbinol, piperidinocarbinol and morpholinocarbinol.
In the above examples, R 1 of the formula
R.sub.2 N--CH(--R.sup.1)OH
is hydrogen. R may also be an alkyl, cycloalkyl, aryl, arylalkyl or alkaryl group. Suitably, an alkyl group is a C 1 -C 5 group, an cycloalkyl is a cyclopentyl or cyclohexyl group, an aryl is a phenyl group, an arylalkyl is a benzyl group and an alkaryl group is an alkyl substituted phenyl group; an example in which R 1 is phenyl and both R groups are collectively a divalent ether radical combined with the nitrogen of the aminocarbinol is 1-morpholino, 1-phenylmethanol.
The aminocarbinols of this invention are suitably produced by contacting an aldehyde with a secondary amine, preferably at a high enough temperature to cause the amine and aldehyde to react in a short time. Higher temperatures require use of higher pressure equipment to retain higher vapor pressures where one or both of the amine or aldehyde is in the vapor phase. Preferably, the temperature of reaction is from about ambient temperature to about 80° C., more preferably, from about 20° C. to about 50° C. The secondary amine can be added as a gas or liquid, according to the particular amine. When added as a gas, it preferably is bubbled into a solution of the aldehyde. Preferably, a slight excess of aldehyde to amine is employed, i.e., from about 2:1 down to about 1:1, the more preferred ratio being from about 1.3:1 to about 1:1. A slight excess of amine is desired to minimize the concentration of unreacted aldehyde in the final product. Unreacted amine and aldehyde do not interfere with the hydrogen sulfide abatement reactions involved in this invention, and, accordingly, the purity of the product is not critical. However, an adduct of the secondary amine and aldehyde greater than 50% is desirable for economic reasons.
To sweeten a hydrocarbon, the molar amount of aminocarbinols of this invention added to the sour hydrocarbon is directly proportional to the molar amounts of hydrogen sulfide, mercaptans or other organosulfur compound(s) having a sulfhydrylgroup which are present in the hydrocarbon. For oils, aminocarbinol suitably is mixed in the oil at temperatures at which the oil is flowable for ease of mixing until reaction with hydrogen sulfide or with sulfhydryl-containing organosulfur compounds has produced a product with sulfhydryls removed to an acceptable or specification grade oil product. To reduce hydrogen sulfide in the vapor space above confined oils to within acceptable limits, preferably an amount of the aminocarbinol of this invention directly proportional to the amount of hydrogen sulfide present in the vapor space is employed to treat the oil.
To reduce noxious atmospheric odors of hydrogen sulfide, mercaptans and other organosulfhydryl compounds from oils, effective odor reducing amounts of the aminocarbinol are used to treat the oil. Such amounts are in direct proportion to the concentration of sulfhydryl groups. Without being bound to a particular explanation for the mechanism by which the aminocarbinol of this invention react with the sulfhydryl groups, it is believed that the reaction generally may be described as follows:
R.sub.2 N--CH(--R.sup.1)OH+H.sub.2 S→R.sub.2 N--CH(--R.sup.1)SH+H.sub.2 O (1)
R.sub.2 N--CH(--R.sup.1)SH+R.sub.2 N--CH(--R.sup.1)OH→(R.sub.2 N--CH(--R.sup.1)--).sub.2 S+H.sub.2 O (2)
or
(--R--R--)>N--CH(--R.sup.1)OH+H.sub.2 S→(--R--R--)>N--CH(--R.sup.1)SH+H.sub.2 O (1)
(--R--R--)>N--CH(--R.sup.1) SH+(--R--R--)>N--CH(--R.sup.1)OH→(--R--R--)>N--CH(--R.sup.1)--S--CH(--R.sup.1)--N<(--R--R--)+H.sub.2 O (2)
The reaction proceeds more quickly at elevated temperatures and the oil may have a temperature of up to about 400° F. without significant loss of activity of the tertiary aminocarbinol treating agent. Hydrogen sulfide contents of up to about 100,000 ppm in oil may be treated satisfactorily in accordance with this method.
The following examples illustrate the use of four aminocarbinols employed to treat crude stocks spiked with hydrogen sulfide.
EXAMPLE I
Hydrogen sulfide laden vacuum tower bottoms fuel from a West Coast (U.S.) refinery was added to a container containing dibutylaminocarbinol in a predosed quantity. The container was closed, and the closed container was heated for two hours at 180° F. The vapor space in the container was then analyzed using a Drager tube, with the following results versus a blank of the same fuel heated identically.
TABLE 1______________________________________ DOSE H.sub.2 S LEVELADDITIVE (ppm-w) (ppm-v)______________________________________Blank -- 1,200Dibutylamino carbinol 250 620______________________________________
This data shows dibutylaminocarbinol is effective to reduce H 2 S content in the head space of a container holding an H 2 S laden fuel.
EXAMPLE II
Vacuum tower bottoms fuel from a Gulf Coast (U.S.) refinery was collected in a dibutylaminocarbinol predosed Welker H 2 S testing and mixing unit. Another sample of the same fuel was collected in a Welker unit predosed with aqueous choline base (40% choline base). The dosed samples and an undosed blank sample of the same fuel were heated at 180° F. for two hours and the vapor space of each was then analyzed with Drager tubes, with the following results:
TABLE 2______________________________________ DOSE H.sub.2 S LEVELADDITIVE (ppm-w) (ppm-v)______________________________________Blank -- 50040% Choline base 50 15040% Choline base 100 75Dibutylamino carbinol 100 150Dibutylamino carbinol 150 <50______________________________________
This data also shows dibutylamino carbinol is effective to reduce H 2 S content in the head space of a container holding an H 2 S laden fuel.
EXAMPLE III
A solution containing dibutylaminocarbinol was used in a bubble cap plate tower test module to scrub a sour gas. The test gas composition comprised 2,000 ppm H 2 S, 1% CO 2 and the balance, methane. The bubble tower had a 1.25" inner diameter and a gas dispersion disc dimension of 35 microns. Gas flow rate in the tower was 5.5 standard cubic feet per hour (scfh) at a test pressure of 20 psig and test temperature of 75° F. The scrubbing solution was 100 gm of a 10% solution of dibutylaminocarbinol. The solution was placed in the bubble tower, the test gas was flowed through the bubble tower at 5.5 scfh, and H 2 S in the outlet gas from the bubble tower was measured using Drager tubes. The data collected follows:
TABLE 3______________________________________ Time Outlet Gas Minutes H.sub.2 S (ppm)______________________________________ 0 0 5 0 10 3 15 3 20 5 25 10 30 20______________________________________
From the data in Table 3, an aminocarbinol in accordance with the present invention is seen useful to scrub sour gas.
EXAMPLE IV
Gulf Coast Visbreaker resid in nitrogen sparged septum bottles was used to evaluate the test aminocarbinol compound produced according to this example. All measurements were made at 140° F. The hydrogen sulfide was determined by gas chromotography with a flame photometric detector which is specific for sulfur containing molecules.
An aminocarbinol was synthesized by reacting 55.01 g benzaldehyde with 45.11 g morpholine over a five minute period. The reaction mixture exothermed to 71° C. The product was confirmed by NMR to be 1-morpholino, 1-phenylmethanol. A dose response curve was generated by sequentially adding larger doses of the product compound to 69.43 g of test fuel oil in a septum bottle. The H 2 S in the headspace of the bottle was withdrawn by syringe and injected into a gas chromatograph for analysis. The following levels of H 2 S were recorded.
______________________________________Total Amount of H.sub.2 SCompound Added (μL) (ppm-V)______________________________________ 0 3212 5 364625 285645 234585 1592______________________________________
The samples were thermostatted at 60° C. for 60 hours to determine if further reaction with the H 2 S would occur. The level of H 2 S had dropped to 47 ppm during this period indicating that further reaction was occurring. An additional 10 microliters of the compound was injected into the fuel which further reduced the H 2 S to 23 ppm.
Having now described our invention, variations, modifications and changes within the scope of our invention will be apparent to those of ordinary skill in the art, as set forth in the following claims. | Sour sulfhydryl group containing oils and gases are treated with an effective amount of a sweetening, hydrogen sulfide quantity reducing aminocarbinol of the formula
R.sub.2 N--CH(--R.sup.1)OH
wherein R 1 is hydrogen or a hydrocarbyl or inertly substituted hydrocarbyl and each R is independently hydrocarbyl or inertly substituted hydrocarbyl or both R groups are collectively a divalent hydrocarbon or ether radical combined with the nitrogen of the aminocarbinol to form a heterocyclic ring represented by the formula
(--R--R--)>N--CH(--R.sup.1)OH.
The aminocarbinols used in this treatment are especially suitable for sour gases and high boiling, heavy residual fuels under low mix conditions. | 2 |
FIELD OF THE INVENTION
[0001] The invention relates to a method for strengthening a yarn which is provided with fibers at least in a sheath zone enclosing the core zone.
DESCRIPTION OF THE PRIOR ART
[0002] The strength of fibers which are provided with a sheath zone made of fibers which enclose the core zone depends, among other things, on the anchoring of the enveloping fibers in the yarn core. If the yarn is obtained by a twisting of a fiber slubbing, the enveloping fibers are usually well incorporated in the fiber structure as a result of the twisting of the stubbing. If a yarn core is wrapped around with fibers, the connection between the enveloping fibers and the yarn core remains limited to the friction between the enveloping fibers and the surface of the yarn core, thus giving rise to the likelihood that in the case of a respective load, the fiber sheath may be displaced against the yarn core in the longitudinal direction of the yarn. This can lead to a dissolution of the yarn structure, especially whenever the enveloping fibers are provided with a relatively loose connection among one another. The yarn strength also suffers by stresses placed on the yarn which are accompanied by an untwisting of the twist of the yarn.
SUMMARY OF THE INVENTION
[0003] The invention is thus based on the object of mechanically strengthening a yarn of the kind mentioned above with the help of a comparably simple method, so that not only higher strength requirements can be met, but also the likelihood of an untwisting of the twist of the yarn can be avoided.
[0004] The invention achieves the above object in such a way that fibers are needled from the sheath zone through the core zone along the yarn.
[0005] Since as a result of this measure the enveloping fibers are anchored additionally in the core zone of the yarn, the mutual connection between the enveloping fibers and the core zone of the yarn is strengthened considerably, which has a direct influence on the yarn strength since the needling of enveloping fibers through the core zone of the yarn produces a fixing of the twist of the yarn. This means that yarns with a predetermined degree of twisting are provided with better strength properties or that a lower twist of the yarn is required for a required yarn strength. This applies to yarns from twisted fiber slubbings, but especially to yarns with a fiber sheath wound about a yarn core, because in this case a mutual connection, which otherwise would not be possible, can be achieved between the enveloping fibers and the yarn core. An additional aspect is that the condensation of the fiber structure which is caused by the needling leads to a certain compensation of thick and thin places, which is disclosed by an even yarn quality.
[0006] In order to perform the needling of yarns, it is possible to assume a conventional apparatus with a drivable needle board reciprocating in the direction of the needle penetration and a stitch base opposite of the needle board. It is merely necessary to ensure that the needles are disposed behind one another in the traveling direction of the yarn and the yarn cannot escape the penetrating needles to the side. For this reason the stitch base is provided with at least one guide groove for the yarn which extends in the direction of yarn passage, with the needles of the needle board penetrating into the guide groove. The side walls of the guide groove, which can be formed by a groove in the stitch base or guide rules provided on the stitch base, prevent a lateral migration of the yarn to be needled, so that the needles need merely be disposed in one row on the needle board in the direction of the guide groove in order to needle the yarn pulled through the guide groove in such a way that the enveloping fibers are pulled through the core zone of the yarn. The enveloping fibers extending through the core zone to the opposite sheath zone substantially prevent any relative movements between the sheath and core zones, so that a yarn needled in this manner is provided not only with favorable strength values, but is also advantageously protected against untwisting.
[0007] Since the desired unity of the fiber structure between the sheath and the core zones of a yarn requires a comparably low stitching density, the passage speed of the yarns to be needled can be kept relatively high in the apparatuses provided for such purposes, which allows a favorable adaptation to the working speed of downstream yarn treatment. In order to enable the simultaneous needling of several yarns, the stitch base can be provided with several parallel guide grooves for one yarn each. The smooth entry and exit of the yarns into and out of the guide grooves can be enforced in a simple way by guide eyes for the yarns.
[0008] In order to obtain a lateral guidance within the guide groove which is advantageous for the needling of a yarn, the clearance of the guide groove can decrease in the direction of needle penetration so that the yarn, depending on its respective thickness, rests on the two side walls of the guide groove when the yarn to be needled is pulled into the guide groove. For this purpose the stitch base can be provided with a convexly arched arrangement at least in the entrance and exit zones, so that in the case of a tensile stress on the yarn to be needled, a force component is obtained which presses the yarn against the stitch base in the guide groove. If the curvature extends over the entire length of the guide groove, this effect is also extended to the needling zone with the advantage that the needle-penetration angle of the needles into the yarn changes along the guide groove, which influences the strength properties accordingly. This effect of the curvature of the stitch base is naturally not dependent on any special arrangement of the cross section of the guide groove which in the case of low requirements placed on the lateral guidance of the yarn can also have a rectangular cross section.
[0009] Although a convex stitch base causes a force component which is perpendicular to the stitch base in the case of a respective tensile load of the yarn which presses the yarn against the stitch base, the provision of a stripper between the stitch base and the needle board is recommended because in this way it is possible to achieve a substantially calmed yarn guidance with a simultaneously lower yarn tension.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The method in accordance with the invention is now explained in closer detail by reference to the enclosed drawing, wherein:
[0011] [0011]FIG. 1 shows an apparatus in accordance with the invention for strengthening a yarn in a simplified, partly sectional side view;
[0012] [0012]FIG. 2 shows a sectional view along line II-II of FIG. 1 on an enlarged scale;
[0013] [0013]FIG. 3 shows an embodiment of an apparatus in accordance with the invention in a representation corresponding to FIG. 1;
[0014] [0014]FIG. 4 shows on an enlarged scale a schematic longitudinal sectional view through a yarn which is strengthened according to FIG. 1, and
[0015] [0015]FIG. 5 shows a schematic longitudinal sectional view through a yarn strengthened according to FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] The apparatus according to FIG. 1 consists substantially of a stitch base 1 and a needle board 2 which is opposite of stitch base 1 and is inserted in a conventional manner in a needle beam 3 . The needle beam 3 is driven reciprocatingly by way of an eccentric drive in the needle-penetration direction of needles 4 . In contrast to conventional stitch bases, the stitch base 1 in accordance with the invention is associated with parallel guide grooves 5 for the yarns 6 to be needled which are held under tensile load between a roller feed 7 and a roller draw-off 8 . Additional guide eyes 9 can be provided for the purpose of improved guidance of the yarns 6 .
[0017] Although the guide grooves 5 are arranged in the form of guide channels in the stitch base 1 , this arrangement is in no way mandatory. The guide grooves 5 could also be formed by guide rules on the stitch base 1 , since the lateral guidance of the yarns 6 is concerned in particular. The channels of the guide grooves 5 are rounded off towards the groove base according to FIG. 2, which leads to an advantageous lateral guidance for the yarns 6 , which are pulled into the guide grooves because the stitch base 1 is provided on the inlet and outlet side with a convex curvature in the direction of passage of yarns 6 , so that force components are obtained as a result of the tensile load of yarns 6 , which force components press against the stitch base 1 . Said force components which occur in the curvature zone are not sufficient, however, in order to allow the omission of a stripper 10 which is disposed between the stitch base 1 and the needle board 2 .
[0018] The embodiment according to FIG. 3 differs from the one according to FIG. 1 merely by the arrangement of the stitch base 1 which is continuously curved in a convex manner from the inlet to the outlet side, so that force components which are perpendicular to the stitch base 1 are obtained over the entire guide length of the guide grooves 5 , which force components press the yarns 6 against the stitch base 1 . A stripper 10 is used nevertheless in order to ensure a calmed yarn guidance which is advantageous for the needling process.
[0019] The embodiments according to FIGS. 1 and 3 differ not only with respect to the forces acting upon the yarns 6 , but particularly by the type of needling as is illustrated by the FIGS. 4 and 5 which each show a yarn 6 with a yarn core 11 and a fiber sheath 12 which can consist of enveloping fibers which are wound about the fiber core 11 .
[0020] The yarn core 11 and the fiber sheath 12 can also be formed by core and sheath zones of a fiber strand twisted into a yarn. Since according to FIG. 1 the needles 4 of the needle board 2 penetrate the yarns 6 perpendicular to the stitch base 1 , enveloping fibers are needled substantially perpendicular to the yarn axis through the yarn core 11 according to FIG. 4, as is illustrated by the indicated fiber bridges 13 . Said fiber bridges 13 connect the fiber sheath 12 with the yarn core 11 and additionally hold the twist of the yarn 6 , which causes the desired yarn strengthening.
[0021] According to FIG. 3, the needles 4 are made to penetrate under different needle-penetration angles the yarns 6 which are guided along the convex stitch base 1 , which leads to fiber bridges 13 which are inclined differently with respect to the longitudinal yarn axis, as is schematically indicated in FIG. 5 in a purely schematic way. The differently inclined fiber bridges 13 lead to a different interfelting between enveloping fibers and yarn core in comparison with FIG. 4, so that an influence on the yarn strengthening can be made through the arrangement of the curvature of the stitch base 1 .
[0022] Although the needles 4 penetrate the yarns 6 substantially in a common axial plane when the needles 4 are not disposed in a mutually slightly offset way, the fiber bridges 13 are usually not disposed in a common axial plane because a twist of the yarn during the passage through the guide grooves cannot be prevented due to the tensile load on the yarns 6 , so that needle penetrations are obtained which are distributed over the circumference of the yarn which is advantageous for an even strengthening of the yarns 6 . | A method and an apparatus for strengthening a yarn ( 6 ) is described which is provided with fibers at least in a sheath zone enclosing a core zone. In order to provide advantageous process conditions it is proposed that fibers are needled from the sheath zone through the core zone along the yarn ( 6 ). | 3 |
BACKGROUND OF THE INVENTION
The present invention relates to a non-contact thermometer for detecting the existence of an object to be examined and/or measuring surface temperatures of the object by means of a pyroelectric infrared sensor that remotely detects infrared rays radiated from the object in a non-contact manner.
A pyroelectric element disposed in a pyroelectric infrared sensor is spontaneously polarized and electrical charges are developed on its surface at all times. These electrical charges are coupled with electrical charges in the air under normal steady state condition, thereby presenting an electrically neutral charge. When infrared rays are incident on the pyroelectric element under this steady state condition, the temperature of the pyroelectric element is changed and the electrically neutral condition is then disturbed, resulting in changes in surface electrical charges. At which time it becomes possible to measure the amount of incident infrared rays by detecting the electrical charges developed on the surface of the pyroelectric element. When this pyroelectric element is used in a thermometer, the amount of infrared rays radiated from the object being examined is then compared with that from the another object, of which the temperature is already known. The temperature of the object to be examined can be determined by the difference in the amount of infrared rays between these two objects. Methods of measuring temperatures of inner walls of a cylindrically-shaped chopping drum having a bottom, can be used to determine the relation between the amount of infrared rays and the temperature levels. These methods (e.g., by means of a thermistor or the like) make it possible to measure the temperature of the object to be measured.
FIG. 11 is an exploded perspective view showing the structures of a conventional non-contact thermometer using a pyroelectric infrared sensor, as described above.
As illustrated in FIG. 11, the prior art non-contact thermometer comprises: a stepping motor 21 (referred to as a motor hereafter) mounted on a unit base 22, which is capable of rotating in clockwise and counterclockwise directions and also capable of controlling a specified incremental rotational angle in steps; a bottomed cylindrical type chopping drum 24, including an arc-shaped cam 24b, which is rotated by the motor 21 and provided with slits 24a, each of which has an opening at one end; a pyroelectric infrared sensor 26 disposed in the chopping drum 24 for detecting infrared rays radiated from an object to be measured, which passes through the slits 24a of the chopping drum 24, a temperature detection means 30 for detecting the temperature of the above chopping drum 24; a swing arm 23 having a cam follower 23e that sustains contact with a cam 24b provided on the cylindrical chopping drum 24; a holder 25 that is attached to the swing arm 23 and maintains the position of the pyroelectric infrared sensor 26 inside the cylinder of the chopping drum 24; a switch 31 for setting a reference position of activation; a protecting shutter 29 that shields the pyroelectric infrared sensor 26 from the surrounding environment when it is not in use; and a shielding case 28 for covering all the elements as described above.
The pyroelectric infrared sensor 26 includes a lead terminal 26a that has a 90° bend. Other electronic components are mounted on a printed circuit board 27a, which are fixed on the sensor holder 25 by screws and are electrically connected to other external circuits through lead wires and connectors.
FIG. 12 shows one of the simplest structures of a pyroelectric type temperature measurement instrument. The problem associated with this structure is that a cylindrical chopper 32a is rotated within an exterior case 30 having a window such that the detection of temperatures of an object can be measured at only a single point.
In order to solve this problem, a method of rotating a sensor and an exterior case by 360° was conceived. However, this presents another problem in that a large driving motor for the sensor 31 is required and this method is not suitable for measuring a specific temperature range of an object to be measured.
When it is desired to detect a specific temperature range of an object to be measured, a conventional method is provided wherein a motor 32b in the foregoing non-contact thermometer is rotated clockwise and counterclockwise, and a swing arm mounted with the sensor 31, is made to swing by a cam provided on the cylindrical chopper 32a.
The foregoing swinging action makes it possible to measure the amount of infrared rays within the swinging angle range. Thus, enabling the detection of temperatures for each respective measurement spot in a non-contact manner. However, this non-contact thermometer is constructed so that the exciting phase of the foregoing motor 32b may serve as a reference position when the motor 32b is brought to a stop upon activating a position detection switch after continuous rotation. The motor 32b continues rotating when the non-contact thermometer is not in use and stops only when the position detection switch is turned on.
Therefore, the measurement of the amount of infrared rays radiated from an object to be measured is likely to be incorrect due to a reduced accuracy of the motor's continual revolving motion. This is caused by variations in the components employed, rotational performance and the like, as well as leakage of light and the like.
SUMMARY OF THE INVENTION
The conventional non-contact thermometer, as described above, suffers from various problems, such as requiring preforming processes and numerous assembly steps because of the design of the pyroelectric infrared sensor 26 in relation to the lead terminal 26a. In particular, the pyroelectric infrared sensor 26 is preformed with a 90° bend and is then inserted into the sensor holder 25. The lead terminal 26a of the pyroelectric infrared sensor 26 is inserted in the printed circuit board 27a, having various electronic components mounted thereto, which are affixed by a soldering means.
Moreover, since a very small input to the foregoing pyroelectric infrared sensor 26 is amplified by about 1000 times before being outputted, even the slightest noise will interfere with the performance of the sensor as such noises will infiltrate into the sensor through the lead terminals 26a and the like. This presents a problem since the accuracy of the sensor's detection is adversely affected.
A first object of the present invention is to solve the foregoing problems associated with the prior art by providing a non-contact thermometer which has fewer number of assembly steps, has lower manufacturing costs and stabilizes performance and detection.
In order to solve these problems, the non-contact thermometer of the present invention is structured as shown in FIG. 1 and comprises: a stepping motor 1 linked with a unit base 2; a chopping drum 4 which is cylindrically-shaped with a bottom, having a plurality of cut-outs formed around its outer walls and linked with the stepping motor 1; a pyroelectric infrared sensor 6 placed inside the chopping drum 4; a flexible printed circuit board 7a, comprising a thermistor 12 mounted thereon that detects the temperatures of the pyroelectric infrared sensor 6 and the interior of the chopping drum 4, and also comprises a comparator mounted thereon that compares the outputs of the thermistor 12 corresponding to the temperature of the pyroelectric infrared sensor 6 and the interior of the chopping drum 4, wherein the output side of which is connected to the unit base 2; a swing arm 3, having an upper part of which is coupled with the sensor holder 5 that holds the pyroelectric infrared sensor 6, and being placed between the unit base 2 and the chopping drum 4 so as to be freely rotatable; and a shield case 8 which is provided with a window and which is mounted on the unit base 2.
Further, a boss 5c is formed on the sensor holder 5 and a hole, having an inner diameter that is smaller than the outer diameter of the boss 5c, is formed on a copper foil pattern of the flexible printed circuit board 7a. Thus, the sensor holder 5 is fixed to the flexible printed circuit board 7a by pressing the boss 5c into the foregoing hole formed in the flexible printed circuit board 7a.
In addition, a feedthrough ceramic capacitor 9 is mounted on the unit base 2, which is made from solder plated steel, by inserting it into a pillar hole 2c and affixing it with solder. One end of the feedthrough ceramic capacitor 9 is connected to the output side of the flexible printed circuit board 7a with the other end thereof connected to external circuits.
According to the structure as described above, all of the electronic components are mounted on the same upper surface of a flexible printed circuit board, of which has excellent bending properties. Therefore, even if there are some components that require to be mounted on the bottom surface of the flexible printed circuit board because of the directional requirements thereof, those components can be mounted on the same upper surface after the flexible printed circuit board has been bent over. In turn, this eliminates a lead preforming process which conventionally has been required, and thereby reduces the number of assembly steps.
In addition, the flexible printed circuit board 7a can be easily and accurately fixed to a sensor holder 5 without the use of any mounting fixtures by way of having a boss 5c formed on the sensor holder whereby the boss is pressed into a pillar hole 8b provided on the shield case 8.
Furthermore, the intrusion of external noises can be prevented by connecting the circuit inside a non-contact thermometer with the external circuit via a feedthrough ceramic capacitor 9a, which is mounted by inserting the capacitor into the unit base 2 and fixing it thereto with solder.
A second object of the present invention is to provide a non-contact thermometer which is suitable for measuring the temperatures of an object that exists within a specified range of angles, and which measures these temperatures in a stable and accurate manner.
In order to achieve this object, the non-contact thermometer of the present invention comprises: a stepping motor 1 which is mounted on a unit base 2, rotatable in the clockwise and counterclockwise directions and controllable in incremental rotational angles; a cylindrical chopping drum 4 rotated by the motor 1 and provided with opening slits 4a; a pyroelectric infrared sensor 6 for detecting infrared rays radiated from an object to be measured, which passes through the slits 4a of the cylindrical chopping drum 4; a temperature detection means, such as a thermistor 12 for detecting temperatures of the cylindrical chopping drum 4; a cam provided on the cylindrical chopping drum 4; a swing arm 3 having a cam follower 3h that comes into contact with the cam; a sensor holder 5 that holds the pyroelectric infrared sensor 6 and which is located inside the cylinder of the cylindrical chopping drum 4; and a shielding case 8, which has a window 8a for receiving infrared rays from the object to be measured, and covers the cylindrical chopping drum 4, swing arm 3, pyroelectric infrared sensor 6 and sensor holder 5.
The present invention enables the motor 1 to give a stepping operation that is needed to measure the temperature. It also establishes a structure so as to set up a performance reference position by activating the number of steps needed for containing the pyroelectric infrared sensor 6 and reaching a specified exciting phase that serves as a reference.
Accordingly, the present invention makes it possible to set up the reference position without relying on a position detection switch and, thus, enhance the detection accuracy by controlling the rotation of the motor which revolves at different speeds.
In addition, the rotational performance of the chopping drum and that of the swing arm can be synchronized with each other. The chopping drum is rotated by the stepping motor 1, which is rotatable in both directions, thus changing the amount of infrared rays incident on the pyroelectric infrared sensor, and at the same time, rotating the foregoing pyroelectric infrared sensor.
Therefore, the temperature of an object to be measured can be detected and measured at a plurality of positions located within a specific area, by measuring the signal from the temperature detection means which detects the temperature of the chopping drum and the temperature differential signal. The temperature differential signal is obtained from the foregoing pyroelectric infrared sensor by determining the temperature differential which exists between the chopping drum and the object to be measured by using a temperature calculation means.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of a non-contact thermometer for the first and second exemplary embodiments of the present invention.
FIG. 2(a) to FIG. 2(c) are top plan sectional views to show operating conditions of a swing arm in the first exemplary embodiment of the present invention.
FIG. 3 is a perspective view to show how to use the non-contact thermometer in the first and second exemplary embodiments of the present invention for measuring temperature.
FIG. 4(a) and FIG. 4(b) are perspective views to show the structures of the flexible printed circuit board in the first exemplary embodiment of the present invention.
FIG. 4(c) is a cross-sectional view to show how the flexible printed circuit board and a sensor holder are put together for the first and second exemplary embodiments of the present invention.
FIG. 5 is a cross-sectional view to show how a feedthrough ceramic capacitor is mounted in the first exemplary embodiment of the present invention.
FIG. 6 is a flow chart to show how the initializing operation of the non-contact thermometer is performed in the second exemplary embodiment of the present invention.
FIG. 7(a) to FIG. 7(c) are top plan sectional views to show operating conditions of the swing arm of the non-contact thermometer in the second exemplary embodiment of the present invention.
FIG. 8(a) to FIG. 8(c) are top plan sectional views to show operating conditions of the swing arm of the non-contact thermometer during the transition to a waiting position in the second exemplary embodiment of the present invention.
FIG. 9(a) and FIG. 9(b) are an exploded perspective view and a plan view, respectively, to show how the aperture of the non-contact thermometer is structured in the second exemplary embodiment of the present invention.
FIG. 10 is a chart to show the operation timing of the stepping motor versus the chopping drum for the non-contact thermometer in the second exemplary embodiment of the present invention.
FIG. 11 is an exploded Perspective view to show how a conventional non-contact thermometer is structured.
FIG. 12 is an exploded perspective view to show how some segments of another conventional non-contact thermometer are structured.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Exemplary Embodiment 1!
Turning now to FIGS. 1-3, FIG. 1 shows how the non-contact thermometer of the first exemplary embodiment of the present invention is structured. As illustrated in FIG. 1, a stepping motor 1 (referred to as "motor" hereafter), which is rotatable in both directions, is linked to a unit base 2 by inserting a motor flange 1a into a slit 2a, which is formed in the unit base 2, and fastening a screw 1d in a threaded hole 2b, which is also formed in the unit base 2, via a threaded hole 1b disposed in the motor flange 1a.
A swing arm 3 is arranged between the unit base 2 and a chopping drum 4, which is fixed to the shaft 1c of the motor 1. The swing arm 3 is supported by inserting a pillar 3a, which is formed on the swing arm 3, into a unit base pillar hole 2c so that the swing arm 3 may rotate around the pillar 3a, thereby serving as the center of rotation.
The chopping drum 4 is cylindrically-shaped with a bottom and has a plurality of slits 4a disposed in the walls 4b, and which are uniformly spaced along the walls 4b of the cylindrical chopping drum 4. In addition, the swing arm 3 is continually subjected to tension forces exhorted by a tension spring 11.
FIG. 9 shows how a sensor holder 5 is structured. As shown in FIG. 9, a sensor holding member 5a is provided on the sensor holder 5 so that it may be located inside the cylinder of the chopping drum 4 and held by a clamping means provided by claws 3b and 3c formed on plates located in the upper section of the swing arm 3, and which extends over the chopping drum 4. Also, claws 3e are formed in an aperture 3d that is situated between a shield case window 8a and a pyroelectric infrared sensor 6.
Referring to FIGS. 1 and 4, an electronic circuit 7 includes mounting pads formed on a flexible printed circuit board 7a, which is connected to lead wires 6a of the pyroelectric infrared sensor 6. Also, connector terminals 7d, which are located in the output section of the flexible printed circuit board 7a, are connected to leads 9a of a feedthrough ceramic capacitor 9 that is fixed on the unit base 2 with solder.
Furthermore, a through hole 7b, which has its inner surfaces plated with copper foils, is disposed on the flexible printed circuit board 7a so that a fixing pillar 5d, which is formed on the sensor holder 5, can be pressed into the through hole 7b.
A shield case 8 has an elongated hole-like window 8a formed on its side surfaces, a guide wall and a pillar hole 8b for receiving a pillar (boss) 5c provided on the sensor holder 5 and a pillar hole 8b disposed on its top side opposite to the flexible printed circuit board 7a.
Projected sections comprising of a claw 8c, which are provided on the opening side of the shield case 8, are fixed in a mounting hole 2d, and the mounting slots 2e of the unit base 2, which are for attaching the shield case 8 to the unit base 2. The projected sections are formed at a plurality of locations and their respective projected sections and claws 8c prevent the shield case 8 from getting disengaged from the unit base 2. Thus, the swing arm 3, chopping drum 4, sensor holder 5, pyroelectric infrared sensor 6, electronic circuit components and the like are contained inside the shield case 8.
Next, an explanation will be made on how the non-contact thermometer of the present exemplary embodiment performs. As shown in FIG. 1, a chopping drum 4 is first rotated by the rotation of a motor 1, a pyroelectric infrared sensor 6 detects the amount of infrared rays that are radiated from an object to be measured, which are transmitted through the alternating slits 4a, and the amount of infrared rays, which are transmitted from the side walls 4b of the chopping drum 4. The difference between the foregoing amounts of infrared rays is then inputted to an electronic circuit 7 as an electrical signal.
A thermistor 12 built in the electronic circuit 7 detects the temperatures inside the chopping drum 4 and these detected temperatures are inputted into the electronic circuit 7 as electrical signals.
Since the swing arm 3 swings in conjunction with the swinging of the chopping drum 4, the pyroelectric infrared sensor 6 also swings accordingly. The swinging of a swing arm in conjunction with the swinging of a chopping drum will be explained below with reference to FIG. 2(a) to FIG. 2(c). As shown in the drawings, when a chopping drum 4 swings, then the swing arm 3 is also made to swing by a cam follower 3h which slides while keeping in contact with a decentered cam 4c formed on the bottom surface of the chopping drum 4.
Thus, as illustrated in FIGS. 1 and 3, a pyroelectric infrared sensor 6 can detect the approximate temperatures of an object 10 to be measured and side walls 4b of the chopping drum 4 by swinging in a fashion which alternates between clockwise and counterclockwise directions. The chopping drum 4 has slits 4a in its side walls, and can detect the amount of infrared rays from the object 10 to be measured at a plurality of points by also swinging the pyroelectric infrared sensor 6. As a result, the present invention provides a non-contact thermometer that makes it possible to accurately measure a temperature distribution of an object 10 to be measured in a non-contact manner.
Next, a flexible printed circuit board 7a comprised of an electronic circuit 7 will be explained with reference to FIG. 4(a) to FIG. 4(c). The flexible printed circuit board 7a is formed by superimposing one copper foil upon another with each respective copper foil sandwiched between thin resin films and characterized by presenting excellent bending properties.
As shown in FIG. 4(a), the pyroelectric infrared sensor 6 is mounted on the flexible printed circuit board 7a, in an area between two slits. The flexible printed circuit board 7a can be readily bent such that the bend extends between the two slits without causing any damage or problems, thus making it possible to readily mount the pyroelectric infrared sensor 6 on a sensor holder 5, as illustrated in FIG. 4(b).
Furthermore, narrow belt-like connection leads 7c are formed on the flexible printed circuit board 7a and fastened to the terminals 7d that are connected to the feedthrough ceramic capacitor 9. The capacitors 9 are fixed on a unit base 2 with solder for the purpose of eliminating external noise.
The narrow belt like connection leads 7c are twisted every time the swing arm 3 swings. However, since the printed circuit board 7a is comprised of very thin copper foil, which is protected by a resin coating, it does not incur damage due to the twisting.
A plurality of holes 7b, each of which having a slightly smaller diameter than the outer diameter of a mounting pillar 5d formed on the sensor holder 5, are provided on the side of the flexible printed circuit board 7a on which electronic components are mounted. The sensor holder 5 and the flexible printed circuit board 7a are securely put together by pressing the pillars 5d into the holes 7b.
As shown in FIG. 4(c), the copper foil in the periphery of the hole 7b is deformed upwards such that it is wedged against the mounting pillar 5d. This wedging prevents the mounting pillar 5d from sliding off the flexible printed circuit board 7a and thereby assures for a solid linkage.
Moreover, a thermistor 12, which is mounted on the flexible printed circuit board 7a, is situated inside a window hole 5f formed on the sensor holder 5, as shown in FIG. 4(b), when the flexible printed circuit board 7a is folded in half. This location of the thermistor 12 makes it possible to detect temperatures in the vicinity of the chopping drum 4 located below the thermistor 12 and to use these detected temperatures instead of using the temperatures of the chopping drum 4.
FIG. 5 illustrates the manner in which the feedthrough ceramic capacitor 9 is fixed on the unit base 2 with solder. The feedthrough ceramic capacitor 9 is mounted by soldering directly onto the unit base 2. The unit base 2 is made from a solder plated steel sheet and has a cylindrically-shaped hole which has been made by a metal stamping process. The connection of the terminals 7d of the flexible printed circuit board 7a to the pyroelectric infrared sensor 6, as well as the electronic circuit 7 mounted on the flexible printed circuit board 7a, which is affixed to an external flexible printed circuit board 131, which is connected to external circuits by way of the feedthrough ceramic capacitor 9, makes it possible to shield off external electrical noises.
Thus, it is demonstrated from the foregoing exemplary embodiment that the present invention makes it possible to simultaneously mount all of the electronic circuit components with solder, including a pyroelectric infrared sensor and a thermistor, on one side of a flexible printed circuit board. The flexible printed circuit board is cut into slit like shapes so as to be bendable and to serve as a circuit substrate, which can connect with the pyroelectric infrared sensor. Thus, the present design eliminates the necessity of preforming the leads of the pyroelectric infrared sensor. This reduces the associated processing steps and related costs.
Furthermore, since the flexible printed circuit board is fixed to a sensor holder by pressing a sensor holder boss into a hole (having a diameter less than the diameter of the boss) disposed on the flexible printed circuit board, the need for inserting a mounting screw is eliminated, thereby simplifying and automating the assembly.
Moreover, the solder plated steel sheet of the unit base makes it easier to solder a feedthrough ceramic capacitor directly onto the unit base. This provides for the feedthrough ceramic capacitor to separate the circuits inside of a non-contact thermometer from the circuits outside of the non-contact thermometer (including the flexible printed circuit board). As a result, associated external electrical noises are prevented from infiltrating to the inside of the non-contact thermometer, thereby enhancing the ability to take accurate measurements.
Exemplary Embodiment 2!
As discussed previously, FIG. 1 shows how the non-contact thermometer of the first or second exemplary embodiment of the present invention is structured. The non-contact thermometer of the second exemplary embodiment has common elements with the first exemplary embodiment and, therefore, an explanation on such elements will be omitted by using the same reference numerals.
Next, an explanation will be made an how the non-contact thermometer of the present exemplary embodiment performs. As shown in FIG. 1, a chopping drum 4 is first rotated by the rotation of the motor 1, the pyroelectric infrared sensor 6 alternately detects the amount of infrared rays received from an object 10 to be measured and the amount of infrared rays from the side walls 4b of the chopping drum 4 through the slits 4a. The difference between the foregoing amounts of infrared rays is inputted to the electronic circuit 7 as an electrical signal. The thermistor 12, serving as a temperature detection means to detect the temperatures of the chopping drum 4, outputs electrical signals corresponding to the temperatures detected to the electronic circuit 7.
As shown in FIGS. 7(a)-(c), a swing arm 3 rotates in conjunction with the rotation of the chopping drum 4 as a result of a cam follower 3h being attached to the swing arm 3. The swing arm is linked with a first cam 4c and a second cam 4d by a pulling spring 11, thereby causing the pyroelectric infrared sensor 6 also to rotate.
Thus, the pyroelectric infrared sensor 6 can detect the approximate temperatures of an object 10 to be measured and the side walls 4b of the chopping drum 4 by rotating the chopping drum 4, which has slits 4a disposed on its side walls. Further, the temperature of the objects 10 can accurately be measured in a non-contact manner at a plurality of points by rotating the pyroelectric infrared sensor 6.
Next, a method for establishing a reference position of rotation for the chopping drum 4, swing arm 3 and the like will be explained with reference to FIGS. 1, 3, 6 and 8.
FIG. 6 is a flow chart which shows how the initializing operation of the non-contact thermometer is performed in the present second exemplary embodiment. When an electric power source is turned on, each respective element, such as the chopping drum 4, swing arm 3 or the like is at an arbitrary stopping position as shown in FIG. 8, thus placing the reference positions in an obscure state. Therefore, in order to give the rotational performance a maximum scope and an operational leeway, the stepping motor 1 is fed with a series of performance input steps, where it is finally brought to a stop at a pre-established reference exciting phase.
The operation thereafter takes place based on the reference exciting phase after the stepping motor has been brought to a stop. Here, the maximum scope in operation means the scope where the swinging action of the swing arm 3 travels to a waiting position. The operational leeway refers to a scope outside the maximum scope in operation which can be observed at a cam 4c of the chopping drum 4.
As illustrated in FIG. 3, the reference position of rotation coincides with the waiting position of the pyroelectric infrared sensor 6, and at this time the opening of an aperture 13 is closed by a shield case 8.
Although a stepping motor is used as a prime motor in the present exemplary embodiment, a DC motor can also be used. In such a case the performance of the control system can be made simpler than that with a stepping motor.
Next, with reference to FIG. 7(a) to FIG. 7(c), a detailed explanation is provided on how the lower part of the chopping drum 4 is structured. A cam 4c formed on and projected from the bottom surface of the chopping drum 4 is pressed onto a cam follower formed of a cam roller 3h that is freely rotating around a pillar 3g located on the end of the swing arm 3 by means of a tensile spring 11. The respective ends of the tensile spring 11 are fastened to spring holders 2f and 3f of the unit base 2 and swing arm 3.
Since the cam roller 3h is pressed onto the cam 4c, the swing arm 3 is made to rotate according to the rotation of the motor 1. Therefore, when the contact point A, between the cam 4c and the cam roller 3h (as shown in FIG. 7(a)) moves to the contact point B (in FIG. 7(c)) due to the clockwise ("CW" hereafter) rotation of the chopping drum 4, the swing arm 3 is rotated around a pillar 3a serving as the center of rotation. At this time, the motor 1 is rotated so as to make the swing arm 3 move in a sequence as shown in FIGS. 7(a)-(c), and is pre-set to reverse its rotation to bring back the swing arm 3 to the position as shown in FIG. 7(a).
Next, as illustrated in FIGS. 8(a)-8(c), the swing arm 3a undergoes a transitional movement until it reaches its waiting position, which takes place prior to measuring the temperatures. An inner cam 4d formed on and protruding from the lower surface of the chopping drum 4 is linked with the cam 4c. When the motor 1 is rotated counterclockwise ("CCW" hereafter) from the position that brings about the state as shown in FIG. 8(a) (the position where a swing movement ends), the cam roller 3h of the swing arm 3 hits the inner cam 4d, as illustrated in FIG. 8(b).
Thereafter, the cam roller 3h moves along the inner cam 4d as the motor 1 rotates. In other words, the swing arm 3 can be moved from the state of FIG. 8(a) to the waiting position, as shown in FIG. 8(c), by feeding a specified pulse input to the motor 1.
By making the last exciting phase of the foregoing specified pulse input coincide with the reference exciting phase established in the beginning, the reference position is set up every time the waiting operation takes place, thus enabling the measurement of temperatures without worrying about variations in position that might have been caused by a long non-operational period, mechanical vibrations and the like.
A cylindrical-shaped aperture 13, which is formed on the tip end of the swing arm 3, in combination with a sensor holder 5 limits the amount of the infrared rays radiant from an object to be measured and incident on the pyroelectric infrared sensor 6.
The aperture 13 moves to a position concealed from the window hole 8a of the shield case 8 at the waiting position. Further, as shown in FIG. 8(c), a shield plate 3i, having an area slightly larger than the area of the foregoing window hole 8a of the shield case 8, is formed by molding one piece with both sides of the tip end of the aperture 13 so as to keep a shape that curves along the periphery of the window hole 8a of the shield case 8 and also to maintain a small gap from the shield case 8. During the waiting state, the foregoing shield plate 3i closes the shield window 8a of the shield case 8, thereby allowing the inside of the non-contact thermometer of the present exemplary embodiment to be shielded from the environment.
The motor 1 moves counterclockwise at the foregoing waiting position (the reference position) when it is fed with the same input pulses as the ones fed to the swing arm 3 for covering the swing end position through the waiting position. As such, the cam roller 3h of the swing arm 3 is guided by the cam 4c of the chopping drum 4 and the swing arm 3 is made to move to the swing start position as shown in FIG. 8(a).
Next, a combination of the swing arm 3 and sensor holder 5 will be explained in detail with reference to FIG. 9(a) and FIG. 9(b). As illustrated in FIG. 9(a), a cylindrical aperture, which serves as a channel for limiting the amount of infrared rays getting to a pyroelectric infrared sensor 6 from an object to be measured, is comprised of a U-shaped slot 3d of the swing arm 3 and an inverted U-shaped slot 5b of the sensor holder 5. The diameter of the foregoing cylindrical aperture is smaller than the effective diameter of a light-gathering lens 6b provided on the tip end of the pyroelectric infrared sensor 6. As a result, this prevents the infrared rays, which are radiated from objects other than the object to be measured, from entering into the pyroelectric infrared sensor 6.
The relative position between the swing arm 3 and the sensor holder 5 is fixed and these components are put together securely by means of fixing claws 3e formed on the U-shaped slot 3d of the swing arm 3 and guide ribs 5e formed on the inverted U-shaped slot 5b of the sensor holder 5.
Furthermore, an interfacing surface is provided on the upper part of the swing arm 3 to accommodate the sensor holder 5 and the fixing claws 3b and 3c are formed on the foregoing interfacing surface to hold the sensor holder 5 securely by clamping.
Next, the operation of the stepping motor 1, pyroelectric infrared sensor 6 and chopping drum 4 will be explained with reference to FIG. 10. In the present exemplary embodiment, a four phase motor is used as the stepping motor 1. The first phase serves as the reference phase and is adjusted so that the center of the foregoing Pyroelectric infrared sensor 6 is positioned with the center of walls 4b or slits 4a, which are located equidistant from one another around the perimeter of the chopping drum 4. This enables the pyroelectric infrared sensor 6 to pass by the center of the walls 4b and slits 4a when the stepping motor 1 is rotated. At this time, when the motor speed is reduced, enough time exists to measure the amount of infrared rays from the object to be measured. The infrared rays pass through the foregoing aperture for comparing the amount of infrared rays from the chopping drum 4.
As is evident from the foregoing explanations of the exemplary embodiments, the non-contact thermometer of the present invention comprising: a pyroelectric infrared sensor; a motor rotatable in either direction and mounted on a unit base; a cylindrically-shaped chopping drum having a bottom; a cam provided on the bottom of the chopping drum; a swing arm having a cam follower that remains in contact with the foregoing cam by sliding thereon; a sensor holder; and a shield case having an opening extending in width to cover the swing range of an aperture provided on the swing arm, makes it possible to quickly measure the temperatures on an object to be measured at a plurality of points located over a certain range or area.
Furthermore, since the foregoing cam includes a first cam that is used to swing the swing arm and a second cam that guides the swing arm to a waiting position, the aperture can be closed inside the window of the shield case, thereby shielding it from the outside and preventing the entry of dirt and the like. Moreover, a shield plate provided on the tip end of the swing arm closes the window of the shield case at the waiting position, thus enhancing the dust prevention effect even further. | A non-contact thermometer uses a pyroelectric infrared sensor which makes it possible to measure temperatures of an object having a large area required to be measured, and at a plurality of points. The thermometer sets up a reference position without using a position detecting switch and also improves the accuracy of measuring the temperature due to its increased amount of incident infrared rays transmitted as a result of reducing the motor speed and extending the time of measurement at the point where infrared rays of the object to be measured is to be detected. The thermometer's stepping motor is fed with its operation step input and brought to a stop at the reference exciting phase of the motor which has been set up in advance. The whole measurement operation thereafter is arranged to proceed, starting from the above exciting phase serving as the reference, at which point the motor was brought to a stop. | 6 |
FIELD OF THE INVENTION
The present invention relates to methods and apparatus for Integrated Circuit (IC) address reconfigurability and, more particularly, to a method and apparatus for providing a single integrated circuit (IC) having external address pins that may be switched internally to provide either a standard pin assignment or a reverse pin assignment.
BACKGROUND OF THE INVENTION
Lead routing between Integrated Circuit's (IC's), for example SDRAM memories on a memory module printed circuit board (PC board) play an important role in both the cost and the performance of the PC board design. The cost of manufacturing a PC board is directly related to the number of layers required to effectively route all of the leads between the IC's. The ability to reduce the number of leads, match the length of leads and the potential for interference between leads enhances the performance of the PC board. As the IC density on PC boards increase and the number of pin assignments and associated leads per IC go up, lead routing becomes increasingly more difficult. In the mid-80's, surface mount technology (SMT) and double sided SMT were introduced as an alternative to standard through-hole PC board technology. Instead of pre-drilling PC boards to accept the pins of IC's, special packaging for IC's was developed which provided for gluing IC's to the PC board. Since the requirement for sticking pins through to the opposite side of the PC board and soldering the IC's in place was eliminated, it became possible to mount IC's on both sides of the PC board.
Even though SMT provides for increased efficiency in lead routing, problems still exist as the total number of IC's on the PC board doubles with two-sided SMT. The number of leads required to interconnect IC's goes up with both the total number of IC's on the PC board, as well as with advances in Very Large Scale Integration (VLSI) design (up to 1,000,000 components may now be integrated into a single IC). A standard 1 megabyte memory chip has 44 pin assignments, a custom memory controller chip may have over 200 pin assignments, and a multichip module (MCM) which approaches 2.5 centimeters square may have over 500 pin assignments.
The layout of a circuit board generally proceeds from the circuit diagram to a geometric layout in which IC's are grouped in their respective isolation regions. Leads coupling IC's are laid out to eliminate potential lead crossovers. Lead routing is a three dimensional problem and becomes very complex with high chip and associated lead densities. Lead crossovers are typically eliminated by adding additional layers to the circuit board such that leads can be re-routed through vias to different levels. Via is the term used to describe a hole partially through the circuit board which enables a lead to travel from one board level to another. Additionally, lead routing is made even more complex as constraints such as maximum length and a consistency between lead lengths must be provided for.
As circuit speeds increase the distributed capacitance and inductance over the length of each lead causes it to act like transmission lines. Reduction of the overall lead length reduces adverse electronic emissions from the circuit board. Crosstalk (an undesirable coupling between an active line and an adjacent passive line) may occur do to mutual inductance or capacitance. Crosstalk can also cause a loss of signal strength in the active line, and interference or false triggering in an adjacent line. Lateral crosstalk may occur when adjacent leads are located on the same plane. Leads located on opposite sides of a dielectric laminate may result in vertical crosstalk. Crosstalk can be minimized by increasing the distance between adjacent leads or reducing the length of parallel lead sections. Vertical crosstalk can be virtually eliminated by orthogonal routing of leads on adjacent layers.
In circuit boards incorporating more than one IC of the same type (for example, a memory module in which a large number of DRAM's or SDRAM's are coupled together), circuit board complexity, problems associated with crossover and crosstalk, can be minimized by utilizing pairs of integrated circuits designed with two identical but reversed pin assignments. As illustrated in FIG. 1, an eight MBIT Flash memory sold by Intel (F28F008SA) is offered in both a standard pin assignment (FIG. 1A) and a reversed pin assignment (FIG. 1B) configuration. By alternating the memory chips in a serpentine layout on one side of a PC board (FIG. 2), a reversed pin assignment on one half of the IC's provides for a greatly simplified board layout as crossovers and the length of the interconnecting leads are minimized. Unfortunately, two different IC's must be manufactured and proper placement on the PC board necessitates subsequent identification during IC insertion.
U.S. Pat. No. 5,502,621 to Schumacher et al. discloses a mirrored pin assignment designed to eliminate the requirement for two different IC's to provide a standard and a reversed pin assignment. One or more IC's having the same set of mirror image pin assignments are mounted on each side of a circuit board by rotating an IC 180 degrees in relationship to the other IC already positioned directly on the opposite side of the circuit board. The inherent mirror image of the pin assignments and the rotation by 180 degrees ensures that the pin assignments of the same type will be directly opposite each other and separated by the circuit board.
Many types of Dynamic Random Access Memories (DRAM's) are offered with a standard and a reversed pin assignment. Nevertheless, many manufacturers will only purchase a single type of DRAM to simplify automated insertion at the expense of added complexity to the PC board routing. Unfortunately, some types of SDRAM's are not offered in a reversed pin assignment such that lead routing is a problem.
A need exists for a single integrated circuit having the potential for both a standard pin assignment and a reverse pin assignment to eliminate the need for providing two different IC's. It would be advantageous to provide for a single integrated circuit in which the pin assignment may be reversed by an external control signal to activate an internal switch, or via firmware in which a command activates and internal switch to reverse the address pin assignments.
It would be desirable and of considerable advantage to provide for increasing the density of SDRAM's on memory modules without using two different types of SDRAM's.
There is accordingly a need for a single integrated circuit having an externally actuated internal switch that provides for both a standard pin assignment and a reverse pin assignment.
SUMMARY OF THE INVENTION
The invention is a method and apparatus for an integrated circuit having a pin assignment that is switchable between a standard and a reverse pin assignment to simplify lead routing when a plurality of such integrated circuits are mounted on either or both sides of a PC board. An internal switch is actuated through either hardware or firmware to control remap-multiplexers to implement the remapping of the pin assignments.
Other aspects and advantages of the present invention will be come apparent from the following detailed description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a plan view of a prior art IC having a standard pin assignment and FIG. 1B is a second IC having a reversed pin assignment.
FIG. 2 is a plan view of a prior art PC board layout incorporating the prior art IC's of FIG. 1 in a symmetrically blocked architecture.
FIG. 3 is a perspective view of a memory module having SDRAM's mounted on both sides of a memory module PC board.
FIG. 4 is a plan view of the top of an SDRAM constructed in accordance with the preferred embodiment of the invention.
FIG. 5A depicts a memory device having left and right address pins, 5B depicts the normal addressing of a remap-multiplexer that is not enabled, and FIG. 5C depicts the remapped addressing of a remap-multiplexer that is enabled in accordance with the preferred embodiment of the invention.
FIG. 6A depicts the exterior ALx and the ARx address pins and the AiLx and AiRx interior address portion of the signal switch 410 illustrated in FIG. 4, FIG. 6B is a gate logic diagram implementation for the portion of the signal switch 410 depicted in FIG. 6A, and FIG. 6C is a CMOS logic implementation of the portion of the signal switch 410 depicted in FIG. 6A.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference now to the drawings wherein like reference numerals designate corresponding parts throughout the several views, FIG. 3 illustrates a perspective view of an SMT memory module board 300 having two identical sides, each containing nine SDRAM's (301-309 and 310-318. Since only one type of SDRAM must be purchased, the cost of purchasing and installation is decreased. During operation, and/or upon system bootup, SDRAM's from one side or "bank" are provided an invert signal and are configured with a reverse pin assignment such that identical address pin assignments will be adjacent to each other on opposite sides of the memory module board and connected by vias (not shown).
A schematic diagram of an integrated circuit memory 400 is shown in FIG.4. The memory 400 includes an address bus 402 having address pins corresponding to both memory row and column addresses (A0-A10 and A11-A20). These addresses are multiplexed together through standard techniques to reduce the total pin count. The address bus 402 is coupled internally to a signal switch 410. A plurality of internal row addresses 416 and internal column addresses 418 couple the signal switch to the memory bank 430 through a row address buffer 440 and a column address buffer 450, respectively. The signal switch 410 further comprises a set of remap-multiplexers 420 coupling the address bus 402 to the internal row addresses 416 and the internal column addresses 418 for remapping the address pins of the address bus 402 to a new set of remap addresses. In particular, the signal switch 410 is responsible for supplying the memory bank 430 with a physical address as received from the address bus 402 or a remap address as remapped by the remap-multiplexers 420 representing a "virtual"0 reverse pin assignment.
A plurality of external control signals leads communicate control signals to a control logic 460. The control logic 460, is employed for processing these external control signals and generating internal control signals that control the timing of row address and column address buffers (440 and 450) to access individual memory bank cells in the memory bank 430. A special external invert control signal 455 is defined for directing the control logic 460 to generate an internal invert control signal 465 for controlling the remap-multiplexers 420 in the signal switch 410.
FIG. 5(a) is a diagram of the signal switch in which the remap-multiplexer 420 in the disenabled state such that the address bus and associated address pins are not remapped. For example, left and right external addresses (ALx) and (ARx) at the input of the signal switch correspond directly with the internal addresses (AiLx) and (AiRx). FIG. 5(b) is a diagram of the remap-multiplexer 420 in the enabled state such that the address bus and associated address pins are oriented with a reverse pin assignment. For example, left and right external addresses (ALx) and (ARx) at the input of the signal switch now correspond to the internal row addresses (AiRx) and (AiLx), respectfully. The remapping is transparent to the memory and results in a "virtual" reverse pin assignment.
In an alternative embodiment of the invention, firmware is employed to define a new command in the IC command set. For example, the functional description of a Samsung KM41654030A CMOS 1MX16BitX4 Bank Synchronous DRAM as published on Apr. 1st, 1996 by Samsung Electronics, employs a function truth table that uses control signals as commands. Most IC's have several combinations of control signals which are left undefined such that they may be defined by a memory module designer. Any of these undefined commands may be employed as a "virtual" address command. For example, in the Samsung 1MX16Bit DRAM, an undefined command has a CS pin as a logic high and the RAS, CAS and WE pins as "don't care". Once the virtual address command is defined, it will only be issued for the appropriate bank or individual SDRAM's where the SDRAM's are wired "virtually". Therefore, the clock enable signal (CKE) should be used to prevent other banks (ie the ones with non virtual addresses) from listening to this virtual addressing mode command) In this manner, the new virtual command is defined in firmware to activate the remap-multiplexers in the signal switch directly. In particular, the user programs a new mode register command after a virtual address command such that the circuit will interpret the mode of operation in accordance to the new virtual address. The signal switch 420 will only be activated if (1) the external INV signal 455 is asserted, or (2) the mode register set has been programmed in firmware to enable the remapping feature.
FIG. 6A depicts the exterior ALx and the ARx address pins and the AiLx and AiRx interior address portion of the signal switch 410 illustrated in FIG. 4. An control signal S is employed for actuating the switch in accordance with the switch function AiLx=ALxS+ARx/S, and AiRx=ARXS+ALx/S. FIG. 6B is a gate logic diagram implementation for the portion of the signal switch 410 depicted in FIG. 6A in which either AND or NAND gates may be employed. FIG. 6C is a CMOS logic implementation of the portion of the signal switch 410 depicted in FIG. 6A which illustrates how the interior address AiLx may be obtained from the exterior address ALx or ARx.
While the invention has been described and illustrated with reference to specific embodiments in the area of SDRAM's, those skilled in the art will recognize that modification and variations may be made such that the invention is equally applicable to other IC's in which both a standard and a reverse pin assignment are desired. For example, where multiple microprocessors are employed, it is convenient to offer a reverse pin assignment on either or both sides of a PC board. | An integrated circuit having an internal switch including remap-multiplexers that are actuated through either hardware or firmware for remapping external addresses such that the IC switches between a standard and a reverse pin assignment to simplify lead routing between a plurality of integrated circuits mounted on a PC board. | 6 |
BACKGROUND OF THE INVENTION
I. Field of the Invention
This invention relates generally to implantable body tissue stimulating apparatus, and more particularly to an improved configuration for a capacitor used therein for periodically dumping a charge from a battery to tissue to be stimulated under control of an electronic switching circuit.
II. Discussion of the Prior Art
Implantable tissue stimulators of various types are known in the art for delivering electrical stimulating pulses to selected tissue structures. For example, cardiac pacemakers and implantable cardiac defibrillators have been developed for maintaining a desired pacing rate or for treating serious arrhythmias. While other tissue stimulating devices are known for treating a variety of conditions, the present invention will be described in relation to cardiac defibrillators, but it is not intended that the invention be limited to that particular application.
In its simplest form, an implantable cardiac defibrillator typically includes a metallic housing that is hermetically sealed and, therefore, impervious to body fluids. Contained within the housing is a battery power supply, electronic circuitry for detecting pathologic and/or non-pathologic arrhythmias and an electronic switching circuit for dumping a charge built up on a capacitor bank to cardiac tissue, via a set of defibrillating leads.
It is widely understood that life-saving implantable defibrillators need to be small. Making small devices that deliver large amounts of energy has typically been an inversely proportional relationship. The capacitors currently used in implantable defibrillators at least over the past ten years are typically cylindrical in shape. This shape and construction tends not to be volume efficient. There are spaces at the ends of each such cylindrical capacitor and along each side thereof that necessarily goes unused, limiting the ability to reduce the size of the housing. These spaces exist because the capacitor geometry transitions sharpely along corners and edges, while biocompatability requirements necessitate more gradual transitions in the housing to prevent it from causing tissue erosion at the implant site. The energy density and shape of the cylindrical capacitors significantly restricts the ability to design physiologically compatible housings that are extremely energy efficient.
Recent efforts have typically been made to fabricate flat, or cubic, capacitors (capacitors with a rectangular cross-section). These capacitors have been aluminum electrolytic in construction or ceramic, thin film or other known technologies. Like the cylindrical shape, the flat rectangular shape has the same inefficient abrupt corners and ends.
The Lin U.S. Pat. No. 5,370,663 discloses a capacitor construction for an implantable defibrillator which is intended to conserve space and allow a thinner profile than can be achieved using cylindrical or cubic capacitors. Here, a capacitor is formed by spirally winding elongated aluminum foil strips separated from one another by an insulating paper layer in an oval shape conforming somewhat to the oval shape of the metal housing of the defibrillator. The center portion of the helix is open and permits specially shaped, relatively flat batteries and circuitry to be inserted therein.
Another approach that purports to reduce the overall thickness dimension of an implantable defibrillator device is described in the Kroll U.S. Pat. No. 5,527,346. Here, relatively thin sheets of a suitable polymer that are first provided with a deposited metallic coating on the opposed surfaces thereof are stacked with separate intermediate thin polymer sheets as insulators to fabricate a capacitor of a desired capacitance value. Because of the fabrication techniques employed, the polymer thin film dielectric layers must have a thickness in the range of between 1 and 10 micrometers so as to be able to withstand the handling during fabrication of the capacitors. Films that are handled multiple times due to the processing steps involved, such as casting, stretching, slitting, metallizing, clearing and winding or stacking requires such layer thickness to withstand the stresses imposed during these operations. Films of lesser thickness are likely to have pinholes or other defects imparted to them due to processing stresses, leading to reduced voltage breakdown strength. Moreover, when attempting to work with films thinner than one micron one is presented with even greater difficulties in terms of processing and handling such thinner films. The Kroll patent attempts to minimize capacitor volume by utilizing a relatively high voltage and lower capacitance than is otherwise typically employed in cardiac defibrillating systems.
The Cichanowski U.S. Pat. No. 4,586,111 describes a capacitor construction with high volumetric efficiency in which a metal substrate has a base coat of a pre-polymer layer applied to it and this layer is then polymerized using electron beam bombardment. The polymerized layer is about 3-6 microns in thickness. Next, a vacuum deposited aluminum electrode of a thickness in the range of from 300 to 500 Angstroms is applied. The patent also suggests that monolithic multi-layer capacitors may be produced by depositing alternating electrode and dielectric layers so as to provide alternate electrode layers with portions projecting from the stack and contacting each other in electrically connected relation. The dielectric coating between each layer is preferably a polymer of polyacrylate which is formed by the vapor deposition of the pre-polymer and subsequent polymerization thereof.
Various techniques are known in the art for vapor depositing polyacrylates and, in this regard, reference is made to the Shaw et al. U.S. Pat. Nos. 5,440,446 and 5,032,461.
It is a principal object of the present invention to provide an improved capacitor arrangement in an implantable cardiac stimulating device that occupies significantly less volume while still permitting the device to deliver ample amounts of energy. An important benefit derived from the improved capacitor arrangement is the ability to design a housing having improved physiologic compatibility.
SUMMARY OF THE INVENTION
The present invention is an implantable tissue stimulating device having a hermetically sealed chamber defined by a metal housing, where the housing has an inner and an outer wall surface of a predetermined contour. Contained within the housing is a battery power supply, a capacitor means for storing a charge from the battery and an electronic switching means coupled to the capacitor means for periodically discharging said capacitor means into a tissue load. A particular feature of the device of the present invention is that the capacitor means comprises a multi-layer configuration preferably deposited in situ and occupying at least a portion of the inner wall surface of the housing. The capacitor's dielectric layers are an acrylate and the metal layers, preferably aluminum, but could be aluminum alloy, zinc or zinc alloy, are applied to the acrylate layers in a deposition process. Depending upon the copolymer used, the intermediate acrylate layers may have a thickness in a range from about 0.5 to 5 microns, and the metal layers may be in the range from about 200 to 500 Angstroms. Hence, a large multiplicity of the deposited acrylate and metallization layers occupy a relatively small volume and conform closely to the contours of the portion of the housing on which the deposited capacitor is adhered.
DESCRIPTION OF THE DRAWINGS
The foregoing features, objects and advantages of the invention will become apparent to those skilled in the art from the following detailed description of a preferred embodiment, especially when considered in conjunction with the accompanying drawings in which:
FIG. 1 is a side elevation of a cardiac stimulating device fabricated in accordance with a first embodiment of the present invention;
FIG. 2 is an edge view of the device of FIG. 1;
FIG. 3 is a cross-sectional view taken along the line 3--3 in FIG. 2 showing a deposited capacitor adhered to an inner wall of the device housing;
FIG. 4 is a greatly enlarged sectioned view taken along the line 4--4 in FIG. 3;
FIG. 5 is a cross-sectional view taken along the line 5--5 in FIG. 1 showing the arrangement of electronic components contained in the housing of the cardiac stimulating device;
FIG. 6 is a side elevation of a cardiac stimulating device fabricated in accordance with the alternative embodiment of the present invention;
FIG. 7 is an edge view of the device of FIG. 6;
FIG. 8 is a cross-sectional view taken along the line 8--8 in FIG. 7 showing a deposited capacitor adhered to an inner wall of the device housing;
FIG. 9 is a greatly enlarged sectioned view taken along the line 9--9 in FIG. 8; and
FIG. 10 is a cross-sectional view taken along the line 10--10 in FIG. 6 showing the arrangement of electronic components contained in the housing of the cardiac stimulating device;
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1, there is illustrated an implantable tissue stimulating device incorporating the present invention. The device is indicated generally by numeral 10 and includes a housing 12 formed from a suitable, body-compatible metal approved for medical use, such as titanium. In FIG. 1, the housing 12 is shown to be generally circular in its configuration, but those skilled in the art can appreciate that the housing will generally be shaped physiologically so as to avoid sharp edges which might lead to tissue necrosis following implantation.
Fitted on to the metal housing 12 and smoothly conforming to the generally circular configuration thereof is a molded plastic connector housing 14 having a plurality of bores as at 16, 18, 20 and 22 (FIG. 2) formed therein for receiving terminal pin connectors of one or more pacing/defibrillating leads (not shown) used to couple the tissue stimulator 10 to the tissue site to be stimulated. As is known in the art, the bores 16-22 contain contacts that mate with connector pins on the leads and the contacts are connected via hermetically sealed feed-throughs (not shown) that extend through a header 24 (FIG. 5) of the metal housing 12.
With reference to FIG. 2, the housing 12 will typically be formed from two can halves 26 and 28 that are welded together along a midline, such as is identified by 3--3 in FIG. 2.
Next, with reference to the cross-sectional view of FIG. 5, it can be seen that there is contained within the housing 12 defined by the housing halves 26 and 28, the components implementing the tissue stimulating device. More particularly, the device 10 will normally include a battery type power supply 30 and one or more printed circuit boards, as at 32, on which is mounted the hybrid electronic components including discrete components and integrated circuitry. This circuitry will typically include a microprocessor based controller, a sense amplifier for processing cardiac signals picked up by the leads and a pulse generator for issuing tissue stimulating pulses under command of the microprocessor-based controller. In addition to the battery 30 and the hybrid-electronic circuitry, the implantable device will also include at least one energy storage capacitor, which in FIG. 5 is identified by numeral 34, and in accordance with the present invention, is preferably formed in situ as a monolithic capacitor on an inner wall surface of the housing half 26. Of course, a similar deposited monolithic capacitor 35 can also be disposed on the inner wall of housing half 28.
Referring next to FIG. 3, there is shown the inside wall surface 36 of the housing half 26 and formed thereon is the monolithic multi-layer energy storage capacitor 34. For a better explanation of the constructional features of the capacitor 34, reference is next made to the cross-sectional view of FIG. 4. Here, the housing half 26 functions as a substrate for the multi-layer deposited acrylate capacitor 34. More particularly, there is first formed on the inside surface 36 of the housing half 26 a base layer 38 of a suitable acrylate polymer or blend of polymers (co-polymer and tripolymers). The base layer may typically be of a thickness in a range between 50 and 100 microns and it is preferably built up by vacuum-depositing multiple coats of the acrylate polymer to thereby avoid pin-hole flaws therethrough. The base layer 38 is also able to withstand implant situations where the device case acts as one of the electrodes. Once the base layer 38 is applied and polymerized, a first electrode 40 is vacuum-deposited thereon. The electrode 40 will preferably comprise an ultra thin aluminum metal layer of a thickness in the range of from 100 to 500 Angstroms thick. Following that, a further layer of acrylate material 42 is deposited over the electrode 40 to a thickness preferably of about 0.5 to 2.5 microns in thickness.
Following formation of the intermediate layer 42 and its polymerization, a next metallic electrode 44 is vacuum-deposited on the intermediate layer 42, with these steps being repeated until a capacitor of desired design parameters is achieved.
It is to be noted from FIG. 4 that the odd electrode layers 40, 44, etc. in the stack are brought out to a first terminal point 46 and the even numbered electrodes in the stack are electrically connected in common to another terminal point 48, thus defining the two terminals of the monolithic capacitor.
Various methods are known in the art for depositing monolithic capacitors on a substrate. In this regard, reference is made to the Yializis U.S. Pat. No. 4,954,371 and the Shaw et al. U.S. Pat. No. 5,125,138. Further information on applicable processes are described in an article entitled "A New High Process for Vapor Depositing Acrylate Thin Films: An Update" by D. G. Shaw et al., published in the 36th Annual Technical Proceedings of the Society of Vacuum Coaters (1993), pp. 348-352, the teachings of which are hereby incorporated by reference as if fully set forth.
Using the approach of this invention, a high energy density capacitor can be incorporated on the inside surface of the case or housing of a tissue stimulating device such as a defibrillator or pacemaker. The multiple layers of acrylate are laid up on the internal surface, be it flat or arcuate, to form a capacitor capable of being charged up to a suitable voltage in the range of from 100 to 900 volts for a defibrillator depending on the type of arrhythmia being addressed. Similarly, the capacitor for a defibrillator may exhibit a capacitance value ranging from 60 microfarads to 140 microfarads or higher. Capacitors of these voltage ratings and capacitance values may be created by laying down about 1500 electrode layers which project inward by a depth dimension of only about 3 mm. An important benefit of the thin film deposited capacitor technology as applied to implantable devices is that the capacitor can be tailored to a given application. For example, if it is desired to have, say, 32 joules delivered to the heart in response to the detection of ventricular fibrillation, the internal dielectric layers would be made thicker to handle the 700 to 900 volts typically required. However, if atrial fibrillation is to be treated with an implantable defibrillator, a defibrillating shock of only three joules may be needed. Here, the capacitor would be designed to handle about 200 volts. Similarly, if the implantable device is to address ventricular fibrillation with a combination of low energy pre-shocks and larger subsequent post-shocks, multiple capacitors connected in parallel or in series/parallel configuration may be incorporated into the device which are tailored for the desired energies and voltages.
As previously indicated, if the capacitor energy requirements dictate, it is possible to form capacitors on both housing halves 26 and 28 as shown in FIG. 5. By forming two such capacitors, one on each housing half, it would be possible to interconnect them either in series or in parallel depending upon device requirements. By always making sure that the outermost layer of the energy storing capacitors is the acrylate material, the circuitry contained on the printed circuit board 32 will be electrically insulated from the inside walls of the two housing halves.
The implantable stimulator depicted in FIGS. 1 through 5 of the drawings represent the general shape configuration of the state-of-the-art implantable devices. FIGS. 6 through 10 depicts a more physiologic shape of the implantable device made possible by the present invention. As can best be seen in the edge view of FIG. 7, by substituting vacuum-deposited monolithic acrylate capacitors for conventional, cylindrical or rectangular capacitors, a generally thinner and more smoothly rounded profile can be used on the housing half 28'. In this embodiment, the header 24' and connector housing 14' extend only across the thickness dimension of a single housing half 26' as best seen in FIGS. 7 and 10. The housing half 28' thus has an increased area for supporting a larger deposited acrylate capacitor 35'. Moreover, the thinner, gently rounded, lighter weight construction tends to be more physiologically compatible with the body for either pectoral or abdominal siting. The constructional features of the monolithic capacitor illustrated in FIG. 9 is generally identical to that shown in FIG. 4 and already described. Hence, further explanation of the constructional features of the monolithic capacitor or capacitors used in the embodiment of FIGS. 6 through 10 is deemed unnecessary.
It is not necessary to limit the placement of the capacitor to the planar portions of the case halves in that when using a vacuum deposition technique for applying both the acrylate insulating material and the aluminum capacitor plates, those materials will conform to the shape characteristics of the housing, thus further improving the packaging efficiency/density of the device, especially when contrasted to prior art implantable stimulating devices incorporating cylindrical or cubic energy storage capacitors.
A further advantage of the formation of the energy storage capacitors on the inner wall of the can or housing resides in the inherent physical properties of tightly cross-linked acrylates. The physical strength of the acrylate, after processing, is sufficient to lend additional rigidity to the housing itself. That is to say, when a sufficient amount of acrylate is deposited on the inside surfaces of the can for high energy storage capacitor purposes, it also increases the strength of the case halves. This permits reduction in the thickness of the walls of the metal housing. For example, existing state-of-the-art pacemakers/defibrillators have a titanium case whose thickness is typically about 0.016 inch so as to provide both a hermetically sealed enclosure impervious to body fluids and physical protection to the electronic circuits contained within it. By adhering the acrylate capacitors to the inner surfaces of the housing, the can material thickness can be reduced to about 0.006 to 0.008 inches. This represents approximately a 2-3 cubic centimeter reduction in volume and a 10-12 gram reduction in the weight from the present day designs.
By way of summary, the present invention provides an improved construction of an implantable tissue stimulating device by the formation of a monolithic vacuum deposited capacitor on the inside walls of the can or housing that provides the hermetic seal for the electronics involved. Inherent in the present invention are the following advantages:
1. The energy storage capacitor(s) are integrated into the device case.
2. The capacitor is tolerant of most any device shape.
3. The capacitor construction maximizes the device's packaging efficiency by taking advantage of unused and difficult to use spaces.
4. The monolithic deposited flat acrylate capacitor(s) allows reduction in device volume and weight due to the structural nature of the capacitor and potential for reduction in the metal thickness of the case or housing.
5. The coating technique employed in formation of the monolithic energy storage capacitor(s) offers electrical protection and isolation between the inside housing surface and all internal components.
6. The fabrication technique involved provides an ability to segregate and customize energy sources for different arrhythmia therapies.
While the present invention has been illustrated and described with particularity in terms of a preferred embodiment, it should be understood that no limitation of the scope of the invention is intended thereby. The scope of the invention is defined only by the claims appended hereto. It should also be understood that variations of the particular embodiment described herein incorporating the principles of the present invention will occur to those of ordinary skill in the art and yet be within the scope of the appended claims. For example, one such variation that comes to mind would involve formation of the acrylate multi-layer capacitor on a reusable mold having the same shape configuration as the inner surfaces of the stimulator's housing followed by removal of the finished capacitor from such mold and the placement thereof into the stimulator's housing at the location conforming to the shape of the mold. | An implantable tissue stimulator includes a polymer film capacitor adhered to an inside wall surface of the stimulator's case or housing in a way that minimizes the size and weight of the stimulator device. The energy storage capacitor for the tissue stimulator comprises a monolithic, multi-layer device and where the polymer is a suitable acrylate of a known formulation, over 1500 parallel plate capacitor electrodes can be built it with the height dimension of the resulting capacitor being less than about 3 mms. Instead of forming the capacitor on the inner surface of the stimulator's case in situ, such a capacitor can be formed on a mold member corresponding in shape to the inner surface of the stimulator's case and inserted into the stimulator's case following removal from the mold. | 0 |
RELATED APPLICATIONS
The herein disclosed subject matter is closely related to that of the inventor's co-pending U.S. patent application Ser. No. 11/509,342 filed Aug. 24, 2006 for a Method Of Merchandising Complementary Medallions which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
Ceiling medallions in the form of decorative disks are used to accent or enhance the appearance of a ceiling fixture, such as a light fixture or ceiling fan. The medallions are decorative and a variety of surface ornamentations are used to provide the desired aesthetic effect. There are a great many variations in room decor and there are many differences in personal preferences concerning interior decoration thus giving rise to a need for a wide variety of ceiling medallions.
BRIEF DESCRIPTION OF THE INVENTION
A relatively large annular base plate or disk includes concentric annular recesses in which interchangeable decorative rings may be releasable mounted. The decorative effect of the medallion can be changed by choosing from several differently decorated rings and inserting the chosen ring in the mating annular recess. A base plate with two concentric annular recesses permits a variety of medallion designs to be produced by choice of inserted ring or rings. The chosen ring is inserted into the recess and rotated to bring mating detent components into registry or engagement in snap lock fashion, which releasably holds the ring in its associated recess.
BRIEF DESCRIPTION OF THE DRAWINGS
The construction of medallion base plates, insertable rings and plate plus ring combination are illustrated in the drawings, in which:
FIG. 1 is a front view of a first medallion base plate;
FIG. 2 is a front view of a second medallion base plate;
FIG. 3 is a front view of a large decorative ring;
FIG. 4 is a front view of a decorative ring that is smaller than the ring of FIG. 3 ;
FIG. 5 is a front view of a decorative ring which can be substituted for the decorative ring of FIG. 4 ;
FIG. 6 shows the ring of FIG. 3 inserted into a large annular recess in the base plate of FIG. 1 ;
FIG. 7 shows the ring of FIG. 4 inserted into an annular recess of the base plate of FIG. 1 which is concentric with but of smaller diameter than the large annular recess;
FIG. 8 shows rings of FIGS. 3 and 4 in the base plate of the medallion;
FIG. 9 is a section taken on line 9 - 9 in FIG. 8 ;
FIG. 10 is a section taken on line 10 - 10 in FIG. 9 ;
FIG. 11 is a partial section showing the rings of FIGS. 3 and 5 installed in the medallion base plate;
FIG. 12 is a partial front view a base plate and a ring showing notches, tabs and knobs which facilitate insertion and retention of the ring in the base plate and
FIG. 13 shows the ring of FIG. 12 rotated counter clockwise 45 degrees bringing the knobs into a snap lock connection with the tabs.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIGS. 1 and 9 , a medallion base plate 21 is provided which has a contoured outer annular ridge 22 at its radially outer edge. A shoulder 23 in the ridge 22 provides a decorative effect. The base plate 21 includes a somewhat smaller diameter annular ridge 26 and a flat bottom annular recess 27 between the ridges 22 , 26 . The base plate 21 also includes an annular ridge 29 near its center 28 , which is somewhat higher than the intermediate ridge 26 , and a smaller diameter flat bottom recess 31 between the ridges 26 , 29 . An opening 32 is provided in the center of the plate 22 .
A base plate 36 shown in FIG. 2 is similar to the base plate of FIG. 1 except radially extending openings 37 , 38 have been formed in the bottoms of the recesses 41 , 42 , respectively, to produce a floral design. This configuration also saves material and produces a more ornamental appearance when the base plate 36 is used singularly as a medallion. FIG. 3 shows a relatively large diameter annular decorative ring 44 which is insertable into the recess 27 of the base plate 21 or into the recess 41 of the base plate 36 . FIG. 4 shows a smaller diameter annular decorative ring 46 which is insertable into the recess 31 of the base plate 21 or into the recess 42 of the base plate 36 . FIG. 5 shows an ornamental ring 47 having a different central configuration which is insertable into the recess 31 of the base plate 21 or into the recess 42 of the base plate 36 . The ring 47 has a central annular opening 48 with a diameter slightly larger than the diameter of the central opening 32 in the base plate 21 . The rings 44 , 46 , 47 , and the plates 21 , 36 , can be used separately as individual medallions and in various combinations. Thus a set of mix and match ceiling medallions is provided which may be advantageously marketed individually or as a package.
FIG. 6 shows a medallion in which the large diameter decorative ring 44 is installed in the recess 27 of base plate 21 and there is no ring installed in the recess 31 . FIG. 7 shows a medallion in which the smaller diameter ring 46 is installed in the annular recess 31 and the recess 27 is empty. FIG. 8 shows a medallion in which the recess 27 is filled with the ring 44 and the recess 31 is fitted with the ring 47 . Using either ring 46 or ring 47 in the base plate 21 produces substantially the same decorative effect; however, when the rings 46 , 47 are used individually as medallions there is a distinct difference in their appearance.
Referring also to FIGS. 9 , 10 , 11 and 12 , the radially inner shoulder of the outer annular ridge 22 has four radially inward projecting, and equally circumferentially spaced, detent elements in the form tabs 52 which are spaced axially from the flat bottom of the recess 27 and the radially outer shoulder of the intermediate ridge 26 has four radially outward projecting tabs or detent elements 52 spaced axially from the flat bottom of the recess 27 . The tabs 51 are aligned radially, respectively, with the tabs 52 . In similar manner, the tabs 56 , 57 are formed on the shoulders of the ridges 26 , 29 , respectively, so as to project into the recess 31 in axially spaced relation to its flat bottom. Each of the tabs 51 , 52 , 56 , 57 has a curved pocket or socket 61 on it's under side facing the associated recess. One such socket 61 is shown in FIG. 10 .
Referring to FIG. 3 , the decorative ring 44 has four radially outwardly open notches 66 at 90 degree intervals in its circumference and has four radially inwardly open notches 67 in its radially inner edge which are in radial alignment; respectively, with the notches 66 . Notches 71 , 72 are formed in a similar manner in the decorative ring 46 as shown in FIG. 4 . The decorative ring 47 shown in FIG. 5 has four equally spaced radially inward extending notches 76 in its outer periphery and no notches in its inner diameter or central opening 32 . The notches 66 , 67 on the ring 44 are sufficiently large to allow passage there through of tabs 51 , 52 , respectively, when the large ring 44 is installed in the recess 27 and the notches 71 , 72 are sufficiently large to allow passage there through of the tabs 56 , 57 , respectively, when the small ring 46 is installed in the recess 31 of the base plate 21 . The notches 76 on the outer periphery or perimeter of the ring 47 are sufficiently large to permit passage of the tabs 56 when the ring 47 is installed in the recess 31 of the base plate 21 . There are no notches on the inner diameter of the ring 47 .
Four detent elements in the form of four rounded or spherically shaped axially projecting knobs 81 are formed at equally spaced internals on the ring 44 near its radially outer edge and four detent elements or spherically shaped axially projecting knobs 82 are formed at 90 degree internals on the ring 44 near its radially inner edge. The knobs 81 are aligned radially with the knobs 82 , respectively. In a similar manner knobs 83 , 84 are formed on the ring 46 . Knobs 86 are formed on the ring 47 at 90 degree intervals near its radially outer edge.
The ring 44 can be installed in the recess 27 of the base plate 21 by aligning the notches 66 , 67 with the tabs 51 , 52 , respectively, and passing the tabs 51 , 52 through the notches 66 , 67 , respectively. The ring 44 is then rotated relative to the base plate 21 , as shown in FIG. 6 , by an angle 91 of 45 degrees about the axis 28 to bring the knobs 81 , 82 into a snap lock registration or detented relationship, respectively with the tabs 51 , 52 . As shown in FIG. 10 the knob 81 is releasably retained or detented in the socket 61 of the tab 51 in a snap lock engagement. The engaging surfaces of the tabs 51 and the knobs could be cylindrical in shape to provide a similar snap lock action when moved into and out of engagement. The tabs are made of a resilient material and flex during engagement with and disengagement from the knobs. The knobs on the ring could be circumferentially offset from the notches on such ring by an angle other than 45 degrees.
The herein described mix and match ceiling medallions are advantageous for a number of reasons. Each medallion based plate and ring can be used independently or various base plate and ring combinations can be used to produce a multitude of decorative medallions. In merchandising, the floor space is minimized and the customer is provided more choices of final design. The medallion base plates and rings can be marketed in a single package. The base plates and rings can also be packaged and sold individually. | A multiple component decorative medallion includes a decorative annular base plate adapted to receive decorative rings which are held in place by releasable detents. The base plate and the rings can be used individually as decorative medallions or selectively combined to produce a variety of ornamental images. | 4 |
FIELD OF THE INVENTION
[0001] This application relates to a tool for removing material from a work piece, such as a metal work piece. More specifically, this application relates to a clamp to hold a cutting insert on a tool holder that is positionable to engage the cutting insert with a work piece to remove chips of material from the work piece.
BACKGROUND
Background of the Related Art
[0002] The present invention relates to a clamp to hold a cutting inserts on a tool holder. Cutting inserts are detachably clamped on a tool holder that is controllably positionable relative to a work piece, generally a rotatable work piece. The work piece may rotate as the tool holder positions the cutting insert to engage the exterior of the work piece and to cut or remove chips of material from the work piece to obtain a desired exterior shape.
[0003] Cutting inserts are often made with a plurality of cutting edges. The provision of two or more cutting edges on an insert makes the cutting insert more economical to use. The cutting insert is generally discarded when it becomes dull or chipped, and the life of a cutting insert is generally shortened by high temperatures at which a cutting insert is used.
[0004] A cutting insert must be securely held in place in a pocket on a tool holder during the cutting operation. When the inserts are of a substantial area, it is possible to fix the insert both accurately and firmly within the pocket of a tool holder by providing the insert with a central hole and the tool holder with a pin-type clamping device. In other cases, such inserts may be held in place by a top clamp. Examples of such holders are found in U.S. Pat. Nos. 3,754,309; 3,399,442, 3,762,005 and 4,834,592 and British Patent No. 1,363,542.
[0005] The main object of metal machining is the shaping of the exterior surface of the work piece. Much attention is paid to the formation of chips during the machining process, even though the chip is a waste product. The work piece is generally rotated using a spindle powered to rotate by a motor. The motor provides the power to keep the work piece turning at a generally uniform rate notwithstanding the drag and friction introduced by engagement of the cutting insert with the exterior surface of the work piece. The consumption of energy and the generation of heat occur mainly in the formation of metal chips.
BRIEF SUMMARY
[0006] One embodiment of the present invention comprises a clamp to secure a cutting insert to a tool holder, the clamp being connectable to a coolant supply conduit that is external to the tool holder and comprising a proximal portion with a toe, a distal portion with a heel, an aperture intermediate the proximal portion and the distal portion to receive a fastener, such as a screw or bolt, through the clamp to engage a hole in the tool holder, and a coolant passage having an inlet to the coolant passage in the distal portion of the clamp to receive a flow of coolant from the coolant supply conduit, an outlet from the coolant passage in a proximal portion of the clamp to direct a stream of coolant to impinge on the work piece adjacent to a cutting interface between a cutting edge of the cutting insert and a work piece engaged thereby, and an intermediate portion of the coolant passage between the inlet and the outlet and passing laterally to the aperture of the clamp, wherein the toe on the proximal portion of the clamp engages a receiving groove on the cutting insert to secure the cutting insert in position on the tool holder and against dislodgment from the forces applied by engagement of the cutting insert with the work piece, wherein the heel on the distal portion of the clamp engages a receiving détente to position the clamp relative to the tool holder, wherein the flow of coolant through the coolant passage of the clamp, at coolant temperatures at or near ambient temperature or below, lubricates the cutting interface to reduce the amount of heat generated at the interface and transferred to the cutting insert held in place on the tool holder using the clamp. A secondary benefit of coolant flow through the coolant passage of the clamp is that heat can be removed from the clamp to the coolant flow stream.
[0007] Another embodiment of the present invention provides a threaded inlet in the distal portion of the clamp to connect the coolant supply conduit that is external to the tool holder. The coolant supply conduit connects to the threaded inlet of the clamp using a threaded end connection, and provides a flow of coolant from the coolant supply conduit, through the threaded end connection on the coolant supply conduit, through the inlet and the coolant passage of the clamp to the outlet.
[0008] Another embodiment of the present invention provides a plurality of inlets in the distal portion of the clamp to enable the connection of the threaded end connection on the coolant supply conduit to a selected inlet on the clamp. This embodiment provides flexibility so that the coolant supply conduit can be connected to the clamp without crossing the coolant supply conduit over the tool holder or without otherwise impairing access to the fastener that secures the clamp to the tool holder. An inlet that is not in use can be isolated using a threaded plug.
[0009] Embodiments of the present invention generally require that the clamp be rigid, made of a material that can be forcibly secured to the tool holder using a fastener and securable on a tool holder without substantial flexure so that the cutting insert is held fast against movement by forces generated in removing chips of material from the work piece. The coolant passage in the clamp can be formed in segments using a drill bit of sufficient hardness. For example, tungsten carbide drill bits are suitable for drilling segment of the coolant passage in the clamp. A drill bit is generally useful for forming only straight channels, and the formation of the coolant passage using drill bits may require the formation in the clamp of a plurality of intersecting channel segments that together form the coolant passage.
[0010] Embodiments of the clamp of the present invention include an outlet from the coolant passage directed to impinge a stream of coolant onto the cutting interface between the cutting edge of the cutting insert and the work piece. The impingement of the stream of coolant lubricates and cools the cutting interface. The lubrication effect reduces the overall amount of heat generated in the cutting insert as a result of the formation and removal of chips of material. The continuous flow of coolant through the coolant passage in the clamp also removes some heat from the clamp and thereby has an additional cooling effect on the cutting insert. The resulting operating temperature of the cutting insert is reduced and the life of the cutting insert is increased. Preferably, the outlet of the coolant passage in the clamp is directed to impinge a stream of coolant on the cutting interface below a chip of material as it is being formed by removal of material from the work piece and above the cutting edge of the cutting insert. Impingement of the stream of coolant below the chip being removed and above the cutting edge of the cutting insert provides the most beneficial lubrication and reduction in heat generated by the machining process.
[0011] Embodiments of the clamp of the present invention may be advantageously used with existing tool holders and with existing inventories of cutting inserts to save substantial costs. In one embodiment, the clamp of the present invention comprises two inlets, each of which is in coolant communication with the coolant passage through the clamp to enable connection to a coolant supply conduit from either side. In this embodiment, an inlet that is not connected to the coolant supply conduit may be closed using a threaded plug.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0012] FIG. 1 is a perspective view of a conventional tool holder having a pocket in which a cutting insert is received and secured using a clamp of the present invention.
[0013] FIG. 2 is a plan view of an embodiment of a clamp of the present invention.
[0014] FIG. 3 is an elevation view of the clamp of FIG. 2 .
[0015] FIG. 4 is the perspective view of FIG. 1 with dotted lines illustrating the position of a portion of a work piece to be engaged by the cutting insert held on the tool holder by an embodiment of the clamp of the present invention.
[0016] FIG. 5 is a plan view of an alternative embodiment of the clamp of the present invention.
[0017] FIG. 6 is a plan view of another alternative embodiment of the clamp of the present invention.
[0018] FIG. 7 is a perspective view of a conventional tool holder having a pocket in which a cutting insert is received and secured using the alternative embodiment of the clamp of FIG. 6 .
DETAILED DESCRIPTION
[0019] FIG. 1 is a perspective view of a conventional tool holder 19 having a pocket 47 therein which a cutting insert 39 is received and secured using a clamp 10 of the present invention. The tool holder 19 is generally connected to and controllably movable using, for example, precision hydraulics (not shown) that provide for smooth and reliable positioning of the cutting insert 39 secured in the pocket 47 for movement with the tool holder 19 relative to the work piece (not shown) from which material chips are removed using the cutting insert 39 . A support member 37 may be received into the pocket 47 and supported on the floor 38 of the pocket 47 prior to receiving the cutting insert 39 to act as a buffer or cushion between the cutting insert 39 and the pocket 47 and to prevent unwanted deformation of the pocket 47 . It will be noted that the pocket 47 has a rear wall 49 at an angle to the floor 38 to better secure the cutting insert 39 in the pocket 47 .
[0020] The tool holder 19 comprises a threaded hole (not shown) to receive a fastener 40 . The clamp 10 of the present invention comprises an aperture 12 (not shown in FIG. 1 ) to receive the fastener 40 to secure the clamp 10 to the tool holder 19 at the threaded hole (not shown). In the embodiment of the clamp 10 of FIG. 1 , the clamp 10 comprises a first inlet (not shown in FIG. 1 ) having threads for being sealably connected to a threaded fitting 32 on an end 31 of the coolant supply conduit 30 . The clamp 10 of FIG. 1 further comprises a second inlet (not shown), generally opposite the first inlet, and having threads (not shown) for being sealably connected to a threaded plug 33 to close the second inlet while not in use. It will be understood that the provision of the first inlet and the second inlet in the clamp 10 enables the convenient connection of the coolant supply conduit 30 on either side of the clamp 10 . It will be further understood that embodiments of the clamp 10 of the present invention may comprise only a single inlet. The clamp 10 of FIG. 1 comprises an outlet 11 directed to impinge a coolant stream provided from the coolant supply conduit 30 , and through a coolant passage (not shown in FIG. 1 ) in the clamp 10 , onto a cutting interface between the cutting edge 17 of the cutting insert 39 and the work piece (not shown).
[0021] FIG. 2 is a plan view of another embodiment of the clamp 10 of the present invention with dotted lines used to reveal internal structures. The clamp 10 of FIG. 2 comprises a first lateral side 20 , a second lateral side 21 , a distal wall 19 along a distal portion 29 of the clamp 10 , a coolant passage 36 fluidically connected, at a first end, to an inlet 13 in the distal portion 29 of the clamp 10 that is adapted to sealably receive a threaded fitting 32 (not shown in FIG. 2 —see FIG. 1 ) on the end 31 of the coolant supply conduit 30 . The coolant passage 36 is fluidically connected at a second end to the outlet 11 in a proximal portion 22 of the clamp 10 . The outlet 11 is directed to impinge a stream of coolant emerging from the coolant passage 36 onto an interface between the cutting edge 17 (not shown in FIG. 2 —see FIG. 1 ) of the cutting insert 39 and the work piece (not shown). The clamp 10 of FIG. 2 further comprises an aperture 12 to receive a fastener 40 (not shown in FIG. 2 —see FIG. 1 ). The aperture 12 is intermediate the proximal portion 22 and the distal portion 29 of the clamp 10 . The inlet 13 comprises a well 16 having threads 15 provided therein for making up a sealed threaded connection with the threaded fitting 32 (not shown in FIG. 2 —see FIG. 1 ) on the end 31 of the coolant supply conduit 30 .
[0022] It will be understood that the position of the outlet 11 of the coolant passage 36 of the clamp 10 relative to the cutting edge 17 of the cutting insert 39 , and the direction of the coolant stream emerging from the outlet 11 of the coolant passage 36 of the clamp 10 , together determine the location on a work piece (not shown) at which the coolant stream impinges upon the work piece. This concept is illustrated in FIG. 4 and discussed further below. The clamp 10 of the present invention is adapted to impinge the coolant stream emerging from the outlet 11 at a location on the work piece below the chip being removed and above the cutting edge 17 of the cutting insert 39 . This strategic placement of the coolant stream provided by embodiments of the present invention prevents unwanted shielding of the cutting edge 17 of the cutting insert 39 by the chip of material being removed from the work piece which acts as an umbrella to impede a stream introduced from a position above the clamp 10 .
[0023] The position of the outlet 11 and the direction of the coolant stream emerging therefrom is determined by the physical configuration of the clamp 10 . The coolant passage 36 includes an intermediate channel 23 and an outlet channel 24 terminating at the outlet 11 . It will be understood that the inlet 13 , the intermediate channel 23 and the outlet channel 24 that together make up the coolant passage 36 in the clamp of FIG. 2 may be formed using a conventional drill bit (not shown), and that a drill bit generally includes a conical or beveled tip that provides better penetration and chip removal during the drilling process. A conventional drill bit will, therefore, bore generally straight channels terminating at conical or beveled portions 34 and 26 . It will be understood that, in FIG. 2 , intermediate channel 23 can be drilled from and through well 16 of the inlet 13 , and that intersecting outlet channel 24 can be drilled by initially creating the outlet 11 and then extending the outlet 11 to form outlet channel 24 to intersect with intermediate channel 23 at intersection 35 . Intermediate channel 23 and the well 16 of the inlet 13 intersect at intersection 25 .
[0024] FIG. 3 is an elevation view of the clamp 10 of FIG. 2 as seen from the first lateral side 20 (as shown in FIG. 2 ) and illustrating the internal structures. The inlet 13 in the distal portion 29 includes the well 16 and the threads 15 therein, and the proximal portion 22 includes the outlet channel 24 . The intermediate channel 23 fluidically connects to the inlet 13 at intersection 25 and to the outlet channel 24 at intersection 35 . The intermediate channel 23 passes from the distal portion 29 to the proximal portion 22 laterally to the aperture 12 (see plan view in FIG. 2 ). The aperture 12 that receives the fastener 40 (see FIG. 2 ) is not shown in FIG. 3 but is behind the intermediate channel 23 revealed in FIG. 3 . The strategic placement and sizing of the inlet 13 , the intermediate channel 23 and the outlet channel 24 within the clamp 10 of FIG. 3 will maximize the capacity of the clamp 10 to sustain a load applied downwardly on the clamp 10 by the fastener 40 (see FIG. 1 ) and transferred through the clamp 10 to bear on the heel 28 and to the toe 27 to secure the cutting insert 39 (not shown in FIG. 3 —see FIG. 1 ) to the tool holder 19 .
[0025] FIG. 4 is the perspective view of FIG. 1 with a portion of a work piece 50 in dotted lines to illustrate the position of a work piece 50 engaged by the cutting insert 39 secured on the tool holder 19 by the clamp 10 . The work piece 50 is supported on a spindle (not shown) that rotates the work piece 50 to move an exterior surface 53 of work piece 50 in the direction of arrow 55 as the cutting edge 17 of the cutting insert 39 engages the exterior surface 53 of the work piece 50 to remove material therefrom by the formation of chips (not shown). The coolant stream 52 emerging from the outlet 11 of the clamp 10 is directed to impinge on the cutting interface between the cutting edge 17 and the exterior surface 53 of the work piece 50 . The clamp 10 of FIG. 4 includes a plug 33 sealably received in a second inlet (not shown) to accommodate connection of the threaded fitting 32 at the end 31 of the coolant supply conduit 30 on either side of the clamp 10 .
[0026] FIG. 5 is a plan view of an alternative clamp 10 of the present invention in which an alternate location of the inlet 14 to the coolant passage 36 is illustrated. The clamp 10 of FIG. 5 includes a proximal portion 22 and a distal portion 29 , a first side 20 and a second side 21 , and an aperture 12 therebetween to receive a fastener (not shown). The inlet 14 remains in the distal portion 29 of the clamp 10 , but does not open into the distal wall 19 of the clamp 10 . In the embodiment of FIG. 5 , the coolant passage 36 comprises the inlet 14 , which includes a well 18 and threads 17 therein, an initial channel 56 drilled into the distal portion of the clamp 10 from the inlet 14 to establish coolant communication between with the intermediate channel 23 at intersection 57 . Intermediate channel 23 is bored from the distal wall 19 of the clamp 10 through a drilling access bore 60 having a well 62 with threads 61 therein to receive a threaded plug 69 to close the drilling access bore 60 and to isolate the coolant passage 36 to communicate only with the inlet 14 and the outlet 11 connected thereto. The intermediate channel 23 is connected to the outlet channel 24 at intersection 34 .
[0027] FIG. 6 is another alternate embodiment of the clamp 10 of the present invention including an inlet 13 disposed at an angle to the second side 21 and also to the distal wall 19 of the distal portion 29 of the clamp 10 to accommodate a different angle and configuration for the connection of the coolant supply conduit 30 (not shown) and the threaded fitting 32 at the end 31 of the coolant supply conduit 30 (not shown). The embodiment of the clamp 10 of FIG. 6 comprises an aperture 12 to receive a fastener (now shown) and a coolant passage 36 extending from the inlet 13 to the outlet 11 , and passing laterally to the aperture 12 . The coolant passage 36 comprises the inlet 13 , having a well 16 and threads 15 , an intermediate channel 23 passing between a first side 20 and the aperture 12 and laterally to the aperture 12 , an outlet channel 24 and the outlet 11 . The intermediate channel 23 is connected at an intersection 25 to the inlet 13 and at an intersection 35 to the outlet channel 24 . The clamp 10 of FIG. 6 further comprises a drilling access bore 60 having a well 62 with threads 61 to receive and mate with a threaded plug 69 to close the drilling access bore 60 and to isolate the coolant passage 36 to communicate only with the inlet 13 and the outlet 11 connected thereto. It will be understood that the drilling access bore 60 is provided to enable the drilling of the intermediate channel 23 of the coolant passage 36 . The embodiment of the clamp 10 of FIG. 6 further comprises a shelf 65 to align and position a threaded fitting 32 (see FIG. 1 ) for being threadably connected to the adjacent inlet 13 .
[0028] FIG. 7 is a perspective view of another embodiment of the clamp 10 of the present invention secured in a pocket 47 of a conventional tool holder 19 using a fastener 40 received through the aperture 12 (not shown in FIG. 7 ) of the clamp 10 . The clamp 10 of FIG. 7 has an angled inlet (not shown in FIG. 7 ), like the embodiment of the clamp 10 of FIG. 6 , but includes a second inlet (not shown) closed using a plug 33 . It will be understood that the angled inlet 13 (not shown in FIG. 7 ) allows the threaded fitting 32 on the end 31 of the coolant supply conduit 30 to be connected to the clamp 10 without unwanted bends in the coolant supply conduit 30 .
[0029] It will be understood that the clamp of the present invention may comprise a conductive material suitable for optimizing heat transfer from the cutting insert to the clamp and/or to optimize heat transfer from the clamp to the coolant stream flowing from the inlet in the distal portion of the clamp, through the coolant passage, and exiting the clamp at the outlet in the proximal portion of the clamp. In one embodiment, heat transfer structures may be provided within the coolant passage to promote heat transfer from the clamp to the coolant stream. For example, but not by way of limitation, a portion of the coolant passage in the clamp of the present invention may be threaded or otherwise machined to provide fins or other protruding structures within the coolant passage to increase the effective heat transfer area within the coolant passage across which heat is transferred from the clamp to the coolant stream while in use. It will be understood that such structures, if provided, should not compromise the capacity of the clamp to transfer force applied to the clamp by the fastener received through the aperture to the cutting insert engaged by the toe of the clamp of the present invention.
[0030] It will be understood that the coolant provided from the source of pressurized coolant, through the coolant source conduit to the coolant passage may be selected to maximize lubrication and heat prevention in the cutting insert. The coolant may also be selected for its heat carrying capacity, but the primary benefit is to minimize the amount of heat generated at the interface of the cutting edge of the cutting insert and the work piece. In one embodiment, the coolant comprises a water-based coolant including a lubricating substance or additive. Also, while embodiments of the clamp of the present invention illustrated in the appended drawings have a single outlet, it will be understood that other embodiments may include additional outlets from the coolant passage.
[0031] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, components and/or groups, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The terms “preferably,” “preferred,” “prefer,” “optionally,” “may,” and similar terms are used to indicate that an item, condition or step being referred to is an optional (not required) feature of the invention.
[0032] The corresponding structures, materials, acts, and equivalents of all means or steps plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but it is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated. | A clamp for holding a cutting insert on a tool holder and having a coolant passage therethrough to receive a coolant from a coolant supply conduit external to the tool holder and into an inlet of the clamp, and to impinge a coolant stream emerging from an outlet of the coolant passage onto a cutting interface between the cutting insert and a work piece. The flow of coolant through the coolant passage extends the life of the cutting insert by reducing heat generation at the cutting interface between the cutting edge of the cutting insert and the work piece. The coolant passage can be formed using conventional drilling tools. The clamp enables the extension of the service life of a cutting insert and can be used with conventional tool holders. | 8 |
FIELD OF THE INVENTION
[0001] The present invention relates to handling devices used in the transfer of molten metals such as aluminum and more specifically to heated such devices designed to maintain the temperature of the molten metal during handling.
BACKGROUND OF THE INVENTION
[0002] U.S. Pat. No. 6,973,955 B2 issued Dec. 13, 2005 describes a heated trough for the transfer of molten metal. This patent broadly describes a trough comprising an outer shell defined by a bottom wall and two side walls, an insulating layer filling the outer shell and a conductive U-shaped refractory trough body for carrying molten metal, the trough body being embedded in the insulating layer. The device of this patent further includes at least one heating element positioned in the insulating layer, adjacent to but spaced apart from the trough body, to provide an air gap between the heating element and the trough body. The trough is described as being fabricated from a material that is generally highly conductive and resistant to corrosion from molten metal. The only examples of suitable such materials provided in this patent are dense refractories such as silicon carbide and graphite. No definition of the terminology “highly conductive” is presented in this patent. Presumably this term as used in this patent is meant to refer to thermal conductivity since the structure described is utilized to impart heat to molten metal being transferred in the trough. From the literature, it is known that silicon carbide has a thermal conductivity on the order of about 100-300 W/m-K°, and graphite is reported to have a thermal conductivity on the order of above 100 W/m-K° (see www.matweb.com that provides materials properties data of this type). Thus, to the skilled artisan, these materials would be recognized as “highly thermal conductive”.
[0003] While the foregoing device provides a useful tool for the maintenance of molten metals temperature during transfer in a trough, it possesses several inherent commercial and technical weaknesses. Most notably, silicon carbide is a very expensive material that, while providing excellent thermal conductivity as noted hereinabove, and very high resistance to erosion and attack by, for example, molten aluminum, it is very difficult to form into shapes such as troughs. As a general observation, a trough fabricated from such a material would be very expensive to produce, and would in all probability not be commercially viable. As to a graphite trough, again while the thermal conductivity of such a device would be very desirable form the point of view of heat transfer, graphite is generally considered much too prone to oxidation and is furthermore generally quite friable (not particularly wear resistant), thus not providing a trough material of suitable commercial value.
[0004] Accordingly there exists a continuing need for a device such as that described in U.S. Pat. No. 6,973,955 B2 that is equally useful, but significantly less expensive to produce while providing heat transfer and wear characteristics adequate for use in most metal transfer applications.
OBJECT OF THE INVENTION
[0005] It is therefore an object of the present invention to provide a commercially viable heated molten metal handling device that provides both adequate wear properties and heat transfer characteristics at a commercially acceptable cost.
SUMMARY OF THE INVENTION
[0006] According to the present invention there is provided a molten metal handling device comprising an outer shell defined by a bottom and two side walls, an insulating layer partially filling the outer shell and a conductive refractory body comprising a trough or metal containing body for carrying molten metal, the refractory body being within the boundaries of the insulating layer. The device further includes at least one heating element positioned within the insulating layer, in contact with the refractory body. The refractory body is fabricated from a castable alumina or silicon carbide refractory as described hereinafter. Quite unexpectedly, the use of castable refractories as substitutes for the much higher thermal conductivity more conventional silicon carbide and graphite materials described in the prior art in these applications has proven highly successful.
DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a cross-sectional view of a heated trough in accordance with one preferred embodiment of the present invention.
[0008] FIG. 2 is a cross-sectional view of an alternative embodiment of the heated trough of the present invention incorporating a metallic fence external to the castable trough lining.
[0009] FIG. 3 is a cross-sectional view of another alternative embodiment of the heated trough of the present invention incorporating a metallic fence internal to the castable trough lining.
[0010] FIG. 4 is yet a perspective view of another alternative embodiment of the heated trough of the present invention wherein the external surface of the castable portion of the trough liner that contacts the heaters has is rippled or defines a wavy pattern.
[0011] FIG. 5 is a top plan view of the trough liner of FIG. 4 .
DETAILED DESCRIPTION
[0012] Referring now to FIG. 1 which shows a cross-sectional view of a heated trough that represents one preferred embodiment of the present invention, trough 10 comprises an outer shell 12 having a bottom 14 and side walls 16 , an insulating layer 18 , a calcined castable refractory trough body 20 within the insulating layer and a heating element(s) 22 positioned between outer shell 12 and calcined castable refractory trough body 20 and in contact with thermally conductive refractory trough body 20 . One or more heating elements 22 may be used and these may be positioned as shown in FIG. 1 , i.e. between sides 16 and refractory trough body 20 . Element 24 in the area of bottom 14 may comprise suitable thermal insulation or, alternatively, an additional heater 22 for imparting heat to calcined castable refractory trough body 20 . According to the preferred embodiment shown in FIG. 1 , heaters 22 are maintained in position below and along side refractory trough 20 through the use of insulating material supports 18 that comprise an insulating material such as Wollite. Heaters 22 drive heat into refractory trough 20 as shown by the arrows in FIG. 1 .
[0013] As used herein, the term “castable refractory” is readily understood by those skilled in the refractory shape forming arts and is meant to refer to a composition that can be shaped or molded in the “green state” and then subsequently fired or calcined at a suitable elevated temperature to produce a hard, tough ceramic-like structure having the shape of the shaped or molded “green state” product.
[0014] According to the present invention, preferred, but not limiting, castable refractories include: low moisture alumina based refractories such as ArmorKast 65AL commercially available from ANH Refractories Co., Cherrington Corporate Center, 400 Fairway Drive, Moon Township, Pa. 15108 and Pyrocast SC-2600 a high purity silicon carbide based refractory commercially available from Pyrotek, Inc., E. 9503 Montgomery Ave., Spokane, Wash. 99206. The preferred alumina based refractory comprises from about 60 to about 65 weight percent alumina and from about 25 to about 35 weight percent silica in the calcined state. The preferred silicon carbide based refractory comprises from about 80 to about 85 weight percent silicon carbide and from about 10 to about 15 weight percent alumina in the calcined state. While these specific materials are preferred in the successful practice of the present invention, it will be readily understood by the skilled artisan and that many other similar castable refractories demonstrating thermal conductivities similar to these materials may be substituted therefor.
[0015] The thermal conductivities of the preferred castable refractory materials in the calcined state are: for the alumina based refractory from about 1.5 to about 1.9 W/m-K°; and for the silicon carbide based refractory from about 9 to about 11 W/m-K°. These thermal conductivities while significantly below those of silicon carbide and graphite as discussed above (and certainly not considered “highly conductive” in the thermal arts) have surprisingly proven highly useful and successful in application to the structure described above while being much more cost effective due to the availability of common commercial production processes and the relatively lower cost of the starting materials when compared to, for example, silicon carbide. Additionally they are significantly “tougher’ and more resistant to erosion, abuse and attack by molten metal such as aluminum than graphite.
[0016] Referring now to FIGS. 2 and 3 that depict alternative preferred embodiments of the present invention that incorporate a fence 30 either about the periphery of refractory trough 20 ( FIG. 2 ) or cast internally to refractory trough 20 ( FIG. 3 ). The purpose of fence 30 is to provide protection for heater(s) in the case of a perforation of refractory trough 20 through cracking or otherwise. The presence of fence 30 prevents the infiltration of molten metal contained in refractory trough 20 from contacting and destroying heater(s) 22 / 24 .
[0017] Fence 30 may is typically between about 1 and 5 mm in thickness, preferably from about 1.5 and about 2.5 mm in thickness and may comprise any number of materials including, but not limited to, a non-oxidizing metallic sheet, a composite ceramic or a glass fabric whose pores have been sealed with a ceramic slurry.
[0018] Depicted in FIGS. 4 and 5 is yet another additional alternative preferred embodiment of the heated trough of the present invention. According to this embodiment, external surfaces 32 of refractory trough 20 are cast in a waved or rippled pattern comprising waves 34 . Such a pattern maximizes the surface area exposed to heater(s) 22 thus increasing the effectiveness of heat transfer from heaters 22 to refractory trough 20 all while not weakening sides 36 of refractory trough 20 and also providing a stable surface for heater panels 22 to bear against without being damaged. It is important to note that flat surfaces 38 are provided between waves 34 and flat surfaces 40 are provided to supply support for heater panels 22 without inducing compressive damage.
[0019] A further preferred embodiment of the heated trough 10 of the present invention includes a coating 42 (see FIG. 1 ) of a high emissivity material on outer surface 44 of refractory trough 20 . Such a coating can be sprayed or brushed on to surface 44 at a thickness of typically less than about 1 mm and may comprise materials having the ability to absorb and radiate thermal energy. Typical such materials are zirconium and chromium. While as depicted in the accompanying Figures, such a coating is shown specifically in connection with the embodiment of the invention depicted in FIG. 1 , it will be readily understood that such a coating could be equally well applied in the various alternative preferred embodiments depicted in FIGS. 2-5 .
[0020] While the invention has been described largely in connection with its use as a metal transfer trough, it will be readily understood by the skilled artisan that the principles of design and the physical configuration of the device is readily applicable to other molten metal handling devices such as holders, crucibles, and filters.
[0021] As the invention has been described, it will be apparent to those skilled in the art that the same may be varied in many ways without departing from the spirit and scope of the invention. Any and all such modifications are intended to be included within the scope of the appended claims. | A molten metal handling device comprising an outer shell defined by a bottom and two side walls, an insulating layer partially filling the outer shell and a thermally conductive castable refractory body for carrying molten metal, the refractory body being within the insulating layer. The device further includes at least one heating element positioned in the insulating layer, adjacent to the refractory body,. The refractory body is preferably fabricated from a castable alumina or castable silicon carbide material. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
BACKGROUND OF THE INVENTION
[0003] The present invention relates to mirrors used for inspection and examination. More specifically, the invention relates to a dental optical mirror element to be used in combination with a handle and a light source.
[0004] Hand held dental mirrors have long been used in the field of dentistry and are well known to those skilled in the art. Dental mirrors are used to view areas of the mouth which are not easily viewable by direct line of sight.
[0005] Dental mirrors have been combined with a light source. Combining a dental mirror with a light source greatly increases the ability to view relatively dark areas of the mouth which are not visible by direct line of sight. Examples of such mirrors are disclosed in U.S. Pat. Nos. 1,747,009 to Jordan; 2,428,975 to Lamb; 3,638,013 to Keller; 5,139,421 to Verderber; 5,457,611 to Verderber; 6,443,729 to Watson; 6,702,577 to Wong and 7,066,734 to Cooper.
[0006] The illuminated dental mirror disclosed in U.S. Pat. No. 5,139,421 to Verderber is known to be the most successful illuminated mirror marketed to dentists. The Verderber mirror was long produced and marketed by Welch-Allyn, Inc., of Skaneateles, N.Y. and is currently produced and marketed by Integra LifeSciences Holdings Corporation's Miltex Dental business of York, Pa.
[0007] In U.S. Pat. No. 5,139,421 Verderber discloses a mirror element including a light transmitting shank. While the Verderber mirror has demonstrated commercial success, it is problematic; being relatively expensive to manufacture and relatively inefficient in terms of light transmission.
[0008] The shank of the Verderber mirror must be relatively thick in order to admit adequate light and transmit adequate light. As for example, the Verderber mirror is manufactured with a shank diameter of 0.25 inches. It has been discovered that a shank of this diameter is prone to gas bubble inclusions: after molten plastic is injected into a mold, the surface of the cylindrical shank hardens first. As the still molten plastic material within the shank cools, it shrinks, creating gas bubble inclusions. Gas bubble inclusions within the shank are a major fault as they interfere with light transmission and significantly reduce the efficiency of the instrument. To reduce the incidence of gas bubble inclusions within the shank of the Verderber mirror element, high mold pressure must be maintained and the shank must be cooled slowly. Operating an injection mold at high pressure reduces the life of the mold. Cooling the mold slowly increases the molding cycle time. Relatively short mold life and relatively slow molding cycles contribute significantly to the cost of manufacturing the Verderber mirror. It would be ideal to provide an optical mirror element having high quality light distribution, but which could be molded using low mold pressure and fast molding cycles.
[0009] The volume of plastic material comprising the shank of the Verderber mirror element accounts for about two thirds of the plastic material in the mirror element and is significant in terms of materials cost. Reducing the volume of plastic material comprising the shank of the Verderber mirror element would result in a considerable reduction in part cost. It would be ideal to provide a mirror element using a relatively small volume of plastic material, thereby significantly reducing the cost to produce said mirror element.
[0010] Some volume of light traveling through the shank of the Verderber mirror is lost as a result of interference with micro-bubbles and inclusions. As discussed in greater detail above, the Verderber shank is prone to gas bubble inclusions. Although high mold pressure and relatively slow molding cycles reduce the incidence of major gas bubbles, micro-bubbles are inevitably present within said shank. Further, inclusions of dust, oils and other unknown materials are inevitably present within said shank. A portion of the light transmitted through the shank strikes these inclusions and is thereby scattered, reducing the efficiency of the instrument. It would be ideal to provide a mirror element in which the distance light is transmitted through molded optical plastic is minimized.
BRIEF SUMMARY OF THE INVENTION
[0011] The present invention consists of an optical mirror element to be used in combination with a handle and a light source. The shank of the optical mirror element is a hollow cylinder or tube designed to accept and contain a light source. The invention can be used in combination with any suitable light source including, but not limited to a fiber optic light pipe, conventional lamp or a light emitting diode.
[0012] Light from a light source contained within the optical mirror element shank is directed toward a prism formed between the mirror head and the shank. Some light entering the prism is internally reflected and exits the face of the prism to provide illumination in front of the mirror head. Some light entering the prism exits the heel of the prism to provide illumination behind the mirror head. In this way, for example, the invention can be used in dentistry both for illuminated, indirect vision and as an illuminated cheek or tongue retractor.
[0013] In general, the object of the present invention is to provide a disposable optical mirror element having the high quality illumination characteristics of the mirror element disclosed in U.S. Pat. No. 5,139,421 to Verderber, but which is more efficient in terms of light transmission and which can be manufactured at lower cost.
[0014] An advantage of the present invention is that the optical mirror element described herein requires a relatively small volume of plastic material, thereby reducing the cost to manufacture the part.
[0015] A further advantage of the present invention is that it requires relatively thin wall sections, thereby allowing the optical mirror element to be molded using relatively fast molding cycles, further reducing the cost to manufacture the part.
[0016] A further advantage of the present invention is that it reduces light transmission through molded plastic material, thereby increasing the optical efficiency of the part.
[0017] These and other objects, features and advantages will become readily apparent from the following Detailed Description, which should be read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0018] While the specification concludes with claims particularly pointing out and distinctly claiming the present invention, it is believed the same will be better understood from the following description taken in conjunction with the accompanying drawings in which:
[0019] FIG. 1 is a frontal view of the optical mirror element.
[0020] FIG. 2 is an elevation side view of the mirror element in combination with a mirror handle.
[0021] FIG. 3 is a cross-sectional side view of the optical mirror element specifically depicting the mirror head, prism, and shank.
[0022] FIG. 4 is a partial view of the optical mirror element shown in FIG. 3 , specifically showing a light source contained within the shank and illustrating the optical effect the prism formed within the heel of the shank.
[0023] FIG. 5 is an elevation view of a dental mirror handle including a light emitting diode.
[0024] FIG. 6 is an elevation view of a dental mirror handle including a fiber optic light pipe.
DETAILED DESCRIPTION OF THE INVENTION
[0025] For the purpose of promoting an understanding of the principles of the present invention, reference will now be made to the embodiments illustrated in the drawing (where like numerals indicate like elements of the invention) and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.
[0026] An optical mirror element 10 is shown in FIGS. 1 , 2 and 3 . In FIG. 2 optical mirror element 10 comprises the distal portion of a dental mouth mirror. Optical mirror element 10 comprises three major segments, including, a head 14 , a prism 16 and a shank 18 .
[0027] Head 14 , prism 16 and shank 18 are manufactured as a single unit from a light conductive material such as a plastic acrylic. Head 14 is generally disc-shaped and is inclined at a predetermined angle to shank 18 . Within the front surface of mirror head 14 , a recess is provided into which a conventional round mirror 20 may be inset or cemented as illustrated in FIG. 3 . Alternately, a reflective material may be applied directly to the mirror head 14 such that said mirror head 14 can be used for indirect viewing.
[0028] Prism 16 is generally triangular in cross section as shown in FIGS. 3 and 4 . Prism 16 forms the junction between the head 14 and the shank 18 and comprises three major segments, including a base 22 , a heel 24 and a face 26 . Referring now to FIGS. 3 and 4 , face 26 is a flattened or planar surface at the junction of mirror head 14 and shank 18 , and is generally parallel to the longitudinal axis of the shank 18 . Heel 24 is a flattened planar surface at the junction of mirror head 14 and shank 18 . Heel 24 is generally the same angle at which head 14 is inclined in relation to the longitudinal axis of shank 18 . Base 22 is a flattened planar surface adjacent to said face 26 and said heel 24 . Base 22 is generally perpendicular to face 26 and is inclined in relation to heel 18 .
[0029] Shank 18 is a hollow cylinder or tube having a proximal end and distal end. The proximal end of shank 18 terminates in the base 22 of prism 16 . The distal end of hollow tubular shank 18 is open such that shank 18 can be removably inserted onto male receptacle 28 of handle 30 with the longitudinal axis of shank 18 parallel to the longitudinal axis of handle 30 as shown in FIG. 2 . Optical mirror element 10 can be used with any suitable handle 30 having a light source. Said light source may be a conventional lamp 32 as shown in FIG. 4 , light emitting diode 34 as shown in FIG. 5 ., or a fiber optic light rod 36 as shown in FIG. 6 . Because the optical mirror element 10 described herein is separable from handle 30 , said optical mirror element 10 can be easily and effectively sterilized, disinfected or replaced. When shank 18 is in place on handle 30 , the base 22 of prism 16 is in close proximity to light source 32 , 34 , 36 comprising the distal end of male receptacle 28 .
[0030] When the present invention is in use, light from said light source 32 , 34 , 36 is generally directed through the base 22 of prism 16 . As for example, FIG. 4 shows a conventional lamp 32 contained within shank 18 where light is directed through the base 22 of prism 16 schematically illustrated by arrows representing light beams designated A and B. Light is transmitted through prism 16 with some volume of the light designated as A in FIG. 4 being emitted from heel 24 and some volume of light designated as B in FIG. 4 being internally reflected and emitted from face 26 . The relative volume of light which is emitted from heel 24 , or which is internally reflected and emitted from face 26 , is a function of the critical angle of the material used for prism 16 and the angle of heel 24 in relation to the longitudinal axis of shank 18 .
[0031] Varying the angle of heel 24 in relation to the longitudinal axis of shank 18 will cause more or less light to be directed in front of or behind mirror head 14 , depending on the critical angle of the light conductive material utilized. Moreover, by varying the angle of heel 24 in relation to the longitudinal axis of shank 18 , more or less light may be provided in front of mirror head 14 and a suitable mirror element 10 can be designed for specific needs.
[0032] Alternately, base 22 may be molded having a concave surface such that base 22 can be intimately mated with the curved surface of light source 32 , 34 , 36 . Any or all surfaces of the prism including base 22 , heel 24 and face 26 may be provided with a roughened or frosted surface thereby causing light applied to said prism to scatter creating a more uniform illumination pattern and eliminating halos.
[0033] Triangular supports 40 are provided between mirror head 14 and face 26 as shown in FIGS. 1 and 2 to increase the structural strength of the mirror element.
[0034] The hollow cylindrical shank 18 , disclosed herein and shown in cross section in FIG. 3 , reduces the volume of plastic material required to manufacture the mirror element 10 as compared with a mirror element having a solid shank. As for example, it is contemplated that the present invention will require fifty percent less plastic material as compared with the mirror element disclosed in U.S. Pat. No. 5,139,421 to Verderber. Reducing the volume of plastic required to manufacture optical mirror element 10 significantly reduces the cost of production.
[0035] Further, the hollow cylindrical shank 18 disclosed herein results in a mirror element 10 having relatively thin wall sections throughout. As for example the mirror element disclosed in U.S. Pat. No. 5,139,421 to Verderber has been manufactured having a solid cylindrical shank with an outside diameter of 0.25 inches. The present invention contemplates a hollow cylindrical shank 18 , as shown in FIG. 3 , having a 0.25 inch outside diameter with a wall thickness of 0.05 inches or less. The present invention, having relatively thin wall sections throughout, can be molded with faster molding cycles than the mirror element disclosed in U.S. Pat. No. 5,139,421 to Verderber, without resulting gas bubble inclusions, thereby significantly reducing the manufacturing cost.
[0036] Still further, the hollow cylindrical mirror element 10 shank 18 disclosed herein, wherein light source 32 , 34 , 36 is contained in close proximity to the mirror head 14 , eliminates light transmission losses through said shank 18 , thereby increasing the efficiency of the instrument. Micro-bubbles and other inclusions are inevitably present within an injection molded part, and as these inclusions decrease the efficiency of light transmission by means of scatter, the optical efficiency of an injection molded optical mirror element is directly related to the distance light must travel through the plastic material. As for example, the mirror element disclosed in U.S. Pat. No. 5,457,611 to Verderber has been manufactured having a shank length of about 1.75 inches, where light is transmitted through its entire length. The present invention contemplates a mirror element 10 where light would be transmitted through prism 16 having a maximum dimension of about 0.25 inches. The present invention therefore contemplates light transmission efficiency losses related to plastic inclusions to be about 0.25 inches divided by 1.75 inches or about one seventh that of the mirror element disclosed in U.S. Pat. No. 5,457,611 to Verderber. | The present invention consists of an optical mirror element to be used in combination with a light source. Light from a light source contained within the mirror element shank provides illumination in front of and behind the mirror head. In this way, for example, the invention can be used in dentistry both for illuminated, indirect vision in the mouth and as an illuminated cheek or tongue retractor. The invention can be used in combination with any suitable light source including, but not limited to, a conventional lamp, a light emitting diode, or a light pipe. | 8 |
This disclosure is based upon French Application No. 99/06729, filed on May 27, 1999 and International Application No. PCT/FR00/01272, filed May 11, 2000, which was published on Dec. 7, 2000 in a language other than English, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention concerns an adaptor for a portable electronic device, of the smart card type, with a format smaller than the current standard format and more particularly smaller than the current standard minicard format.
The invention also relates to the method of manufacturing the adaptor according to the present invention.
There exist principally two standard formats of smart card on the market. Firstly the smart cards complying with the ISO standard, essentially intended for communication, identification or electronic cash operations for example, and on the other hand smart cards complying with the so-called mini SIM card standard, essentially intended to be inserted in a mobile telephone to the GSM (Global System for Mobile communications) standard for example.
The present invention concerns more particularly the field of minicards for a mobile telephony application.
A minicard to the current standard format is illustrated schematically, seen from above, in FIG. 1 .
Such a minicard constitutes a smart card with contact having a support 100 , produced by plastic moulding or injection, and a microcircuit 10 ′ attached to the said support 100 with metallisation areas 11 ′ flush with the surface of the support 100 so as to allow an electrical connection of the chip of the microcircuit 10 ′ with an operating circuit, for example the electronic circuit of the mobile telephone.
These current minicards comply with an established international standard which fixes their dimensions in order to allow their use with any mobile telephone complying with the same standard. In particular, the minicards have a rectangular-shaped card body 100 , 15 mm by 25 mm, with a thickness of 760 μm, and has a locating cut 105 , 3 mm by 3 mm, on the bottom right hand corner of the card support 100 .
The microcircuit 10 ′ is situated at a precise location on the support 100 of the minicard to allow standard electrical connection with the connectors of the telephones to the standard.
Preferentially, the microcircuit 10 ′ has been placed in a cavity previously provided in the minicard support 100 . The cavity can be produced by machining or at the time of plastic injection in the card mould, for example, or by any other well-known technique.
Likewise, the insetting, or attaching, of the microcircuit 10 ′ in this cavity is produced by hot pressing or by gluing for example, or by any other means, according to techniques also well known to experts.
Thus the microcircuit 10 ′ is situated at a precise location on the support 100 defined by the mini SIM standard, which fixes this location on the corner opposite to the locating cut, that is to say the top left-hand corner, at 1.5 mm from the top edge and 4 mm from the left-hand edge.
SUMMARY OF THE INVENTION
The present invention relates to an adaptor for adapting a portable electronic device, of the smart card, to a new format, to a card to a standard format, ISO or mini SIM, the format of this device being smaller than the standard mini SIM format.
This is because, in the context of a standardisation of third-generation mobile telephones to the GSM standard, a new minicard format is proposed. These new minicards to a new format are referred to hereinafter as PLUG 3G.
Nevertheless it is advantageous to enable the old mobile telephones still on the market to function with cards from the new generation.
Thus the present invention proposes an adaptor which allows the use of a PLUG 3G card with an appliance whose reader is intended to receive an ISO or mini SIM card from the previous generation.
To this end, the present invention proposes to produce a support to the standard format of a mini SIM card provided with a cavity able to receive the device to the smaller format.
According to a preferential embodiment, the present invention proposes to produce a universal adaptor by producing a support to the standard format of an ISO card having a precut which delimits a portion of the support to the standard format of a minicard, this portion being provided with the cavity able to receive the device to the smaller format.
The present invention relates more particularly to an adaptor for a portable integrated-circuit electronic device, of the smart card type, to a smaller format compared with the standard format of a minicard, the device to the smaller format comprising a body on which a microcircuit is disposed, defining contact areas, characterised in that it comprises a support to the standard format of a minicard, provided with a cavity to the dimensions of the device to the smaller format, and means for the removable fixing of the said device in the cavity, and in that the cavity is situated in the support so that the location of the contact areas of the microcircuit of the device to the smaller format coincides with the standard location of the contact areas of a microcircuit of a minicard to the standard format.
According to an essential characteristic of the invention, the support to the standard format of a minicard defines an internal portion of a support to the standard format of an ISO card, the said internal portion being delimited in the ISO support by a precut.
According to one embodiment, the cavity has a bottom.
According to a variant, the cavity has at least one concave wall.
According to another variant, the support has semi-perforated cuts produced on each side of the cavity.
According to another embodiment, the body of the device to the smaller format has an asymmetric shape, the cavity being pierced throughout the thickness of the support, and having an asymmetric shape complementary to the shape of the body of the device to the smaller format.
The present invention also concerns a method of manufacturing an adaptor for a portable integrated-circuit electronic device, of the smart card type, to a smaller format compared with the standard format of a minicard, the device to the smaller format comprising a body on which there is disposed a microcircuit defining contact areas, the said device being intended to be inserted in a mobile telephone, characterised in that it comprises the following steps:
producing a support to the standard format of a smart card; producing a cavity to the dimensions of the card to the smaller format, the said cavity being situated in the support so that the location of the contact areas of the microcircuit of the device to the smaller format coincides with the standard location of the contact areas of a microcircuit of a card to the standard format; fixing the device to the smaller format in the cavity of the support.
According to a first embodiment, the support is produced to the standard format of a minicard.
According to a second embodiment, the support is produced to the standard format of an ISO card.
According to one characteristic of this second embodiment, a precut is effected in the support to the standard format of an ISO card, the precut delimiting an internal portion to the standard format of a minicard.
According to a preferential embodiment, the support is obtained by moulding, the precut being effected at the time of moulding.
According to one characteristic, the precut is effected in the form of a discontinuous slot interrupted by tabs.
According to a first embodiment, the fixing of the device to the smaller format in the cavity of the support is effected by gluing, the cavity having a bottom on which the said device is glued.
According to a second embodiment, the cavity of the support has a bottom and at least one concave wall so as to provide the fixing of the device to the smaller format by gripping between the bottom and the concave wall of the cavity.
According to a third embodiment, the device to the smaller format has an asymmetric shape, the cavity having an asymmetric shape complementary to that of the device, the latter being fixed in the cavity by gripping of the complementary asymmetric shapes.
According to a fourth embodiment, the support has semi-perforated cuts in wave form on each side of the cavity each exerting a pressure force on the walls of the cavity directed towards the inside of the latter, the device to the smaller format being held in the cavity by gripping between the walls and the bottom of the cavity.
The present invention makes it possible to obtain, with a simple method, a universal adaptor allowing the direct use of a PLUG 3G card on appliances intended to receive current mini SIM or ISO cards.
Thus the change in the standard will not close the market of new cards to old appliances, such as mobile telephones for example.
BRIEF DESCRIPTION OF THE DRAWINGS
Other particularities and advantages of the invention will emerge from a reading of the following description given by way of illustrative and non-limitative example made with reference to the accompanying figures, for which:
FIG. 1 , already described, is a schematic plan view of a mini SIM card to the current standard format of minicards;
FIG. 2 is a schematic plan view of a portable electronic device to a smaller format compared with the standard format;
FIG. 3 is a plan view of the adaptor according to the invention to the format of a minicard;
FIG. 4 is a view of FIG. 3 with fitting of the device to the smaller format;
FIG. 5 is a plan view of the principle of the universal adaptor according to the present invention;
FIG. 6 is a plan view of the principle of the universal adaptor with fitting of the device to the smaller format;
FIG. 7 is a view in section of a second embodiment of the adaptor according to the present invention;
FIG. 8 is a view in section of a first variant of a third embodiment of the adaptor according to the invention;
FIG. 9 is a view in section of a second variant of the third embodiment of the adaptor according to the invention;
FIG. 10 is a plan view of a fourth embodiment of the adaptor according to the invention.
DESCRIPTION OF THE INVENTION
Referring to FIG. 2 , the device to the smaller format compared with the standard format of a minicard has a rectangular-shaped card body 60 whose dimensions are smaller than the dimensions of the known formats. This device is referred to below as PLUG 3G.
For example, the card body 60 has a length of 15 mm and a width of 10 mm with a thickness less than or equal to 760 μm and has a locating cut 65 of 1 mm by 1 mm on the bottom right-hand corner of the card.
As on the minicards to the standard mini SIM format, a microcircuit 10 is integrated into a cavity provided in the body 60 of the PLUG 3G card, this microcircuit 10 covering almost all the surface of the PLUG 3G card. More precisely, it is situated at approximately 0.5 mm from the edge of each side of the card.
The microcircuit 10 also has metallisation areas 11 which define the contact areas of the chip of the microcircuit 10 . These contact areas 11 are intended to establish electrical contact between the chip of the microcircuit 10 and an operating circuit.
The operating circuit, integrated into the mobile telephone for example, is designed to read the data carried by the card and to use them. It is provided with a connector in which the user inserts the card. This connector comprises a series of contact blades intended to come into abutment on the contact areas 11 of the microcircuit 10 of the card when the latter is correctly inserted in the connector. It is consequently essential, so that the electrical connection is properly established, for the standard to precisely define the position of the microcircuit 10 , and of its contact areas 11 , with respect to the edges of the card support.
In order to allow the use of this PLUG 3G minicard to the new format with a telephone whose connector is designed to read a card to the current standard format, mini SIM or ISO, it is necessary to place this PLUG 3G minicard on an adaptor which will make it possible to effect a match between the contact areas 11 of the microcircuit 10 and the contact blades of the connector.
A first variant of such an adaptor is illustrated schematically, seen from above, on FIGS. 3 and 4 , FIG. 3 presenting the adaptor and FIG. 4 the fitting of the PLUG 3G minicard in the adaptor.
The adaptor according to the invention comprises a support 100 to the dimensions of a card body to the standard format of a minicard, that is to say a support 100 of 25 mm by 15 mm, with a locating cut 105 of 3 mm by 3 mm on the bottom right-hand corner. This support 100 can be produced according to conventional techniques, by moulding for example.
A cavity 110 is then provided in the support 100 , this cavity 110 having dimensions corresponding to those of the electronic device to be adapted, that is to say to the dimensions of the PLUG 3G minicard, that is to say 15 mm by 10 mm, with a locating cut 115 of 1 mm by 1 mm on the bottom right-hand corner.
The cavity 100 can be produced by moulding or by injection during the production of the support 200 , or by machining. These techniques are well known to the manufacturers of smart cards.
The PLUG 3G minicard can then be transferred into this cavity 110 and held by fixing means such as gluing, or gripping for example. The different means of fixing the PLUG 3G minicard in the cavity 110 will be described subsequently with reference to the different embodiments.
Preferentially, the means of fixing the PLUG 3G minicard are removable to allow the direct use of the device to the smaller format without an adaptor.
The cavity 110 accepting the PLUG 3G minicard is situated in the support 100 so as to comply with the constraint, disclosed above, of the positioning of the contact areas 11 of the microcircuit 10 of the minicard vis-à-vis the contact blades of the connector, so that electrical contact can be established between the microcircuit 10 of the PLUG 3G minicard and the operating circuit of an appliance such as a telephone for example.
A second variant of the present invention consists of producing a universal adaptor which makes it possible to use the device to the smaller format on a support to the format of an ISO card, and/or on a card to the mini SIM format.
Such a universal adaptor is illustrated, seen from above in FIGS. 5 and 6 .
The universal adaptor according to the invention comprises a support 200 to the dimensions of a card body to the standard format of an ISO card, that is to say a support measuring 85 mm by 54 mm. This support 200 can be produced according to conventional techniques, by moulding for example.
A precut 20 is effected around a portion 100 internal to the support 200 . This internal portion 100 has the dimensions of a card body to the standard format of a minicard, that is to say a portion 100 measuring 25 mm by 15 mm, with a locating cut 105 of 3 mm by 3 mm on the bottom right-hand corner.
This precut 20 is provided so as to allow easy separation of the internal portion 100 from the support 200 in order to obtain a support to the mini SIM format. It can advantageously be effected by moulding at the same time as the support 200 .
According to a preferential embodiment, the precut is in the form of a discontinuous slot 20 interrupted so as to create tabs 22 , 24 , 26 which enable the internal portion 100 to remain integral with the support 200 . A support to the mini SIM format can thus be obtained by causing the breakage of the said tabs simply by pressing on the internal portion 100 .
In this embodiment, the cavity 110 is provided in the internal portion 100 of the support 200 according to the conventional techniques mentioned above.
The PLUG 3G minicard can then be transferred into this cavity 110 and held by fixing means.
The cavity 110 accepting the PLUG 3G minicard is situated in the support 200 so as to comply with the constraint, disclosed previously, of the positioning of the contact areas 11 of the microcircuit 10 of the minicard vis-à-vis the contact blades of the connector.
In this way a universal adaptor is obtained which allows the use of the PLUG 3G card either directly in a reader able to receive a card to the ISO format or indirectly in a reader able to receive a card to the mini SIM format after breakage of the tabs 22 , 24 , 26 retaining the support portion 100 .
FIGS. 7 to 10 illustrate several embodiments of the adaptor according to the invention, and more particularly several embodiments of the cavity and of the fixing of the device to the smaller format in this cavity.
A first embodiment, not illustrated, consists of producing a cavity 110 by moulding or machining, with a bottom, and then fitting the PLUG 3G minicard in the cavity 110 in the support 100 by gluing with a glue or any cold adhesive which is disposed in the bottom of the cavity 110 .
Referring to FIG. 7 , a second embodiment is illustrated in section. According to this embodiment, the cavity 110 is pierced throughout the thickness of the support 100 without a bottom. Such a cavity 110 can be machined and/or injected according to known techniques.
The cavity 110 has a given asymmetric shape which is complementary to the shape given to the body 60 of the PLUG 3G minicard. In the example illustrated in FIG. 5 , the asymmetric shape consists of a concave wall 130 opposite a wall in the form of an asymmetric point 140 .
Such complementary asymmetry in the shapes of the minicard body 60 and the cavity 110 of the support 100 make it possible to obtain the holding of the minicard in the cavity 110 in the support 100 by gripping the card body 60 between the walls of the cavity 110 .
The asymmetric shapes are obtained by injection and/or cutting, for example, or by any other suitable technique.
FIGS. 8 and 9 illustrate, with views in section, two variants of a third embodiment.
According to this embodiment, the cavity 110 of the support 100 has a bottom 120 , and at least one wall of the cavity 110 is concave. This concave wall 130 enables the minicard to be held in the cavity 110 of the support 100 by gripping the card body 60 between the bottom 120 and the concave wall 130 .
According to the variant embodiments, the cavity 110 is obtained by moulding and has a single concave wall 130 , as illustrated in FIG. 5 ; or by machining, and can have at least two concave walls 130 , as illustrated in FIG. 6 .
FIG. 10 illustrates a fourth embodiment of the adaptor according to the invention.
According to this embodiment, a cavity 110 , provided with a bottom 120 , is produced by any means, and semi-perforated cuts 150 are produced, in the support 100 , on each side of the cavity 110 .
These cuts 150 advantageously have wave shapes so as to introduce a clearance in the material of the support 100 and to constitute dampers.
These cuts 150 are designed each to exert a force F towards the inside of the cavity 110 and thus to enable the minicard to be held in the cavity 110 in the support 100 by pressing the card between the bottom 120 of the cavity 110 and the walls subjected to the pressure forces F. | An adapter for a portable integrated circuit device of the chip card variety has a reduced format in comparison with the standard mini-card format. The device with a reduced format includes a body on which a microcircuit defining contact pads is disposed. A support which has a standard mini-card format is provided with a cavity having the dimensions of the device with a reduced format. The device is detachably fixed in the cavity. The cavity is located in the support in such a way that the location of the contact pads of the microcircuit of the device with a reduced format coincides with the standardization location of the contact pads of a microcircuit having a standard format mini-card. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to providing computerized simulations of real-world views. In particular, the present invention is directed towards a sensor and display-independent quantitative per-pixel stimulation system.
2. Description of the Related Art
Pilots of aircrafts or other pilot-controlled vehicles sometimes guide their aircraft over a given terrain with the assistance of vision-augmenting equipment known as sensors, including, for example, Night Vision Goggles (NVG's) and Low Level Light Television Cameras (LLLTV's). Sensors typically are used to convert hard-to-see imagery in one or more of the visible and/or invisible spectral bands into imagery that is more clearly visible to the human eye. Sensors often display imagery that is different from the one a pilot may be accustomed to seeing naturally with his or her own eyes (also known as an out-the-window view). Therefore, it is desirable to train pilots ahead of time so that they can correctly interpret what they see with sensors during actual flights.
Flight simulators are commonly used to simulate flight training environments. Flight simulators typically include one or more video display screens onto which video images are projected by one or more projectors. Two known approaches are used in pilot training: simulation systems and stimulation systems.
Simulation systems display images as they would appear to a pilot using a given sensor. For example, if NVGs are being simulated, the display shows an image on a head-mounted display as it might appear to a pilot wearing NVGs. Since the displayed image already incorporates the wavelength translations performed by the sensor—i.e. the system displays simulated images—these types of systems do not allow the pilot to use actual vision-augmenting equipment during training. This is considered a drawback of simulated systems, because a pilot's experience using the simulator will differ from that during actual flight-for example, wearing NVGs, a pilot may see a sensor-based image occupying most of his field of vision, but may see a regular out-the-window image using his peripheral vision. Since in a simulated system only a sensor-adjusted image is displayed, and is based on head tracking, the experience differs from that of the real world. The disparity between the simulator and the real world experience is further augmented by the pilot not being able to wear the sensor equipment.
Stimulated systems, on the other hand, provide a pilot with a stimulated image that can be viewed using an appropriate sensor, e.g., one that can be worn by the pilot. Again using the example of NVGs, with a stimulated system the images displayed will match the spectral wavelengths to which the NVGs are sensitive, allowing the pilot to use a real pair of NVGs and thus provide a more realistic experience. However, because display systems vary widely in their display characteristics, the spectra emitted by one system might appear drastically different than those emitted by a second system, and the real world image different still. Accordingly, stimulated systems are generally of lower fidelity than simulated systems, providing only a qualitative experience versus the more quantitative experience of simulated systems.
Accordingly, what is needed is a system and method for providing high-quality stimulated imaging.
SUMMARY OF THE INVENTION
The present invention enables a sensor-independent per-pixel stimulating spectral method and apparatus that is configurable across different display systems and which combines quantitative simulated sensor rendering with a stimulated system.
Initially, a display system to be used with a system of the present invention is characterized according to the particulars of its emissions. An image generator (IG) generates a test pattern that is then displayed by the display system to be characterized. A spectroradiometer measures radiant power emanating from the display and stores the data. The process is repeated for various combinations of test pattern images—for example, for a color-independent RGB display, each value of red, each value of green, and each value of blue is measured.
Once the display has been characterized (also known as calibrated), the present invention creates color lookup tables that map simulated luminance to stimulating color values. This mapping is specific to the display that has been characterized and to the sensor that will be used with the display.
Once the display has been characterized and the color lookup tables created, the present invention is ready to be used for flight (or other) simulation. A simulated image stream is received by the present invention, and using the color lookup tables, for each luminance value provided in the stream, a set of RGB values (or other input values, depending on the display technology involved) is determined that will produce the equivalent stimulated image on the display system. Those color values are then provided to the display system by the IG, and displayed for use with the appropriate sensor.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a method for performing sensor and display-independent sensor stimulation in accordance with an embodiment of the present invention.
FIG. 2 illustrates a system for providing stimulated images in accordance with an embodiment of the present invention.
FIG. 3 is a block diagram illustrating a display characterization function in accordance with an embodiment of the present invention.
FIG. 4 illustrates a method for automatic display calibration in accordance with an embodiment of the present invention.
FIG. 5 illustrates an example spectral radiance graph in accordance with an embodiment of the present invention.
The figures depict preferred embodiments of the present invention for purposes of illustration only. One skilled in the art will readily recognize from the following discussion that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the invention described herein.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates three steps of a method for performing sensor and display-independent sensor stimulation. First, the display system that will be used in conjunction with the sensor is characterized 102 according to the particulars of its emissions. Next, sensor-dependent color lookup tables that map simulated luminance to stimulating color values are created 104 . This mapping is specific to the display that has been characterized and to the sensor that will be used with the display. Finally, a simulated image stream is received by the present invention, and using the color lookup tables, for each luminance value provided in the stream, a set of RGB values (or other input values, depending on the display technology involved) is determined 106 that will produce the equivalent stimulated image on the display system. Those color values are then provided to the display system for use with the appropriate sensor. Each of these steps is described further below.
System Architecture
FIG. 2 illustrates a system 200 for providing stimulated images in accordance with an embodiment of the present invention. System 200 includes an image generator (IG) 202 and its calibration engine 206 , a simulator engine 204 , and color lookup tables 208 . Each of these components is further described below. FIG. 2 also includes a simulated data stream 210 , a display system 212 , a sensor 214 , and a pilot 216 , meant to represent a user of system 200 .
Calibration
Because each display system has its own particular characteristics, the exact spectral emissions from the display system will vary between systems receiving the same input. Indeed, even a single display system may develop different characteristics over time, for example as the projector ages. Consequently, it is preferable to first calibrate system 200 for use with a particular display system 212 .
FIG. 3 illustrates a way in which display characterization is preferably performed. Image generator 202 creates or displays a color video image assigned to a given color or video level. For display calibration, image generator 202 preferably includes a test pattern generator. IG 202 sends images for display to display system 212 . Display system 212 is a monitor, screen, video projector, rear projector, dome, or any other device adapted to display an image. During display calibration, display system 212 receives images from IG 202 and displays the images. The display is then measured by a spectroradiometer 330 . That is, the radiant power or energy per wavelength emanating from display system 212 is measured by the spectroradiometer 330 . In one embodiment, spectroradiometer 330 is the PR-715 spectroradiometer, by Photo Research Inc. of Chatsworth, Calif.; in an alternative embodiment, spectroradiometer 330 is the Minolta R-1000 by Konica Minolta of Japan. Spectroradiometer 330 returns the results of its measurements to IG 202 , which stores the data sets, e.g., in database 304 .
The result of the display calibration is a series of power spectral tables or datasets for each measured color video level, or for each of the display input levels.
FIG. 4 is a trace diagram of a method for automatic display calibration performed by system 200 in accordance with one embodiment of the present invention. Initially, at step 400 , calibration engine 206 sets intensity values for red, green and blue to a minimum value, e.g., 0 intensity. IG 202 generates 410 an image such as a test pattern and sends it to display system 212 , which then displays 490 the image. A test pattern in a preferred embodiment corresponds to specified red, green and blue values. The example of FIG. 4 illustrates the case in which initially only red values are displayed, and then green and then blue data values are added in as described below. Calibration engine 206 next activates 412 spectroradiometer 330 to perform spectral measurements. Spectroradiometer 330 measures 492 emissions from display system 412 and sends 420 the measurements back to calibration engine 206 . Assuming for purposes of the illustrated example that there are 256 possible values of red intensity, calibration engine 206 increments 430 the value (intensity) of the image being displayed by a delta amount. If 440 the new red-value does not exceed a maximum red value, the process returns to step 410 and the image with the new red value is then measured by spectroradiometer 330 . Once all of the red intensity values have been measured, the red intensity value is reset 450 to its original value, and values are then measured for each green intensity value (i.e. for each intensity value of green, 256 values of red intensity are measured). Once 460 the value of green intensity reaches its maximum, blue values are then measured 470 for each intensity value of red and green. At the conclusion of all steps, emissions for intensity values for each combination of red, green and blue have been measured and stored by calibration engine 206 . In this example, 256×256×256=16,777,216 measurements.
In an alternative embodiment using display systems that feature true color independence, such as on CRT RGB video projectors, the number of measurements taken can be reduced. Because of their color independence, there is no need to measure all color parameter combinations—only the independent values of each color. In the case of RGB color parametric space, if 256 levels are used, only 256+256+256=768 measurements will be required, compared the 16,777,216 measurements required when a display system lacks color independence.
FIG. 5 illustrates an example spectral radiance graph 500 for a measurement taken with a red value of 255, and blue and green values of 0 each.
Color Lookup Table Determination
System 200 uses color lookup tables 208 to map simulated luminance to stimulating color values. That is, color lookup tables 208 indicate for a particular simulated luminance that is part of simulated data stream 210 what corresponding color values of a stimulated image would produce that simulated luminance given a particular sensor and a particular display device. Once the stimulated color values are known they can be sent by image generator 202 to display system 212 and viewed by pilot 216 using sensor 214 .
As is known by those of skill in the art, a sensor 214 such as NVGs enables increased perception of the environment by amplifying and translating the wavelengths captured by the sensor. A particular sensor has a spectral response that is characteristic of that sensor and can be determined experimentally using methods known to those of skill in the art, or obtained from the manufacturer of the sensor. The spectral response of the sensor is the response of the sensor to a power at a given wavelength (or range of wavelengths).
Thus, simulator engine 204 constructs a color lookup table by iterating through the various color value combinations, e.g., RGB values from 0 to 255. For each color value, simulator engine 204 determines the actual image that would be displayed by the particular display system 212 , and the stimulated luminance value that would be produced by the sensor from the displayed image values. Performing this step for each color value and then sorting by resulting luminance provides a color lookup table 208 that system 200 then can use to map from a luminance value to a color value set that can be used with the specified sensor on the calibrated display system.
In an alternative embodiment, luminance values that result in deviant colors—i.e. those colors that vary substantially from grayscale values—are excluded from the lookup table. This has the effect of producing images that while still stimulating the sensor create less distracting colors for an observer not wearing a sensor such as NVGs, as well as being less distracting through peripheral vision of an observer who is wearing a sensor like NVGs, which only covers a subset of the field of view. This takes advantage of the fact that unaided human vision at night or at low light levels is not very perceptive of small color deviations from gray scale.
Run-Time Operation
System 200 uses color lookup table 208 to render pixels or texels appropriate to the display system 212 and sensor 214 in use in the simulator. Simulator engine 204 takes as input a simulated data stream 210 provided by conventional real-time sensor simulation software or hardware, determines a corresponding stimulating color value set by referring to color lookup table 208 , and generates an image using IG 202 that is then displayed by display system 212 . Because the color lookup table 208 is specific to the display system 212 in use as well as to the sensor in use, the stimulated image generated by IG 202 will look to a pilot 216 using sensor 214 and display system 212 essentially identical to the simulated image originally provided by the simulated stream 210 . However, because the image is stimulated instead of simulated, the pilot has the advantage of being able to participate in a much more real-world simulation, e.g., by wearing NVGs that correctly account for peripheral vision effects, head motion, and the like—and because the stimulated image is accurate for the display system and the sensor in use, the lack of fidelity that previously plagued stimulated image systems is not present when using system 200 .
The present invention has been described in particular detail with respect to a limited number of embodiments. Those of skill in the art will appreciate that the invention may additionally be practiced in other embodiments. First, the particular naming of the components, capitalization of terms, the attributes, data structures, or any other programming or structural aspect is not mandatory or significant, and the mechanisms that implement the invention or its features may have different names, formats, or protocols. Further, the system may be implemented via a combination of hardware and software, as described, or entirely in hardware elements. Also, the particular division of functionality between the various system components described herein is merely exemplary, and not mandatory; functions performed by a single system component may instead be performed by multiple components, and functions performed by multiple components may instead performed by a single component. For example, the particular functions of the image generator and so forth may be provided in many or one module.
Some portions of the above description present the feature of the present invention in terms of algorithms and symbolic representations of operations on information. These algorithmic descriptions and representations are the means used by those skilled in the art of sensor simulation to most effectively convey the substance of their work to others skilled in the art. These operations, while described functionally or logically, are understood to be implemented by computer programs. Furthermore, it has also proven convenient at times, to refer to these arrangements of operations as modules or code devices, without loss of generality.
It should be borne in mind, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. Unless specifically stated otherwise as apparent from the present discussion, it is appreciated that throughout the description, discussions utilizing terms such as “processing” or “computing” or “calculating” or “determining” or “displaying” or the like, refer to the action and processes of a computer system, or similar electronic computing device, that manipulates and transforms data represented as physical (electronic) quantities within the computer system memories or registers or other such information storage, transmission or display devices.
Certain aspects of the present invention include process steps and instructions described herein in the form of an algorithm. It should be noted that the process steps and instructions of the present invention could be embodied in software, firmware or hardware, and when embodied in software, could be downloaded to reside on and be operated from different platforms used by real time network operating systems.
The present invention also relates to an apparatus for performing the operations herein. This apparatus may be specially constructed for the required purposes, or it may comprise a general-purpose computer selectively activated or reconfigured by a computer program stored in the computer. Such a computer program may be stored in a computer readable storage medium, such as, but is not limited to, any type of disk including floppy disks, optical disks, CD-ROMs, magnetic-optical disks, read-only memories (ROMs), random access memories (RAMs), EPROMs, EEPROMs, magnetic or optical cards, application specific integrated circuits (ASICs), or any type of media suitable for storing electronic instructions, and each coupled to a computer system bus. Furthermore, the computers referred to in the specification may include a single processor or may be architectures employing multiple processor designs for increased computing capability.
The algorithms and displays presented herein are not inherently related to any particular computer or other apparatus. Various general-purpose systems may also be used with programs in accordance with the teachings herein, or it may prove convenient to construct more specialized apparatus to perform the required method steps. The required structure for a variety of these systems will appear from the description above. In addition, the present invention is not described with reference to any particular programming language. It is appreciated that a variety of programming languages may be used to implement the teachings of the present invention as described herein, and any references to specific languages are provided for disclosure of enablement and best mode of the present invention.
Finally, it should be noted that the language used in the specification has been principally selected for readability and instructional purposes, and may not have been selected to delineate or circumscribe the inventive subject matter. Accordingly, the disclosure of the present invention is intended to be illustrative, but not limiting, of the scope of the invention. | Sensor independent display characterization system spectrally characterizes a display system to measure radiant power emitted by the display system that displays a video image to a trainee pilot during sensor stimulation. A sensor spectral response for each wavelength produced by the stimulated sensor is determined. A stimulated luminance for each color level of the displayed image or for a range of color levels is computed. A color look up table that maps computed stimulated luminance to a set of stimulating color values is generated. When a trainee pilot looks at the displayed image using a sensor having a sensor response that was used in computing the stimulated luminance, the pilot will see an image that was created by simulated spectral rendering. The displayed image is an accurate, display and sensor independent image that the pilot can see during the real flight. | 6 |
FIELD OF THE INVENTION
The present invention pertains to light emitting diode arrays and more specifically to light emitting diode arrays utilizing less surface area.
BACKGROUND OF THE INVENTION
Light emitting diodes (LEDs) are useful in various displays and especially in a new compact virtual display which utilizes an array of LEDs as an image source. The image source consists of a high pixel count (240 columns by 144 rows for a total of 34,560 pixels) 2-dimensional array of LEDs. The array of LEDs is used to form complete images containing pictorial (graphic) and/or alphanumeric characters. The complete images are then magnified to produce virtual images which appear to an operator to be at least the size of a standard sheet of paper.
One important factor in the quality of an image viewed on a given display, whether real or virtual, is the fill factor of the pixels within the emitting area. A high fill factor is desirable to obtain high quality images. For CRTs, the emission profiles of adjacent pixels actually overlap giving effective fill factors greater than unity, and producing a very smooth (not grainy) image. With matrix LED displays, however, it is not possible to achieve unity fill factors since there needs to be isolation between pixels. In addition, since conventional row/column matrix addressing schemes use metal row and column interconnects, there needs to be room for the column and row interconnect busses to pass through the pixel and to make contact to each electrode of the diode making up the pixel. For the columns, this interconnect component turns out to be the major component in the space required between pixels because of the minimum line width and alignment tolerances associated with this interconnect bus/contact processing.
In a copending application entitled "Electro-optic Integrated Circuit and Method of Fabrication", filed May. 9, 1994, Ser. No. 08/239,626, and assigned to the same assignee, a method of fabricating LED arrays is disclosed utilizing mesa etched processing technology. As can be seen in the figures of this copending application, one minimum dimension is needed for isolation, another for the column bus/cathode contact, and two alignment tolerances for placement of the metal. Generally, utilizing the present semiconductor fabrication techniques, 2 micron minimum line widths, spaces and alignment tolerances together with a 10 micron emission square for each diode give a minimum linear fill factor of 0.5 or an area fill factor of (0.5) 2 =0.25. The images produced by this display are somewhat grainy as a result of this relatively low fill factor.
Another problem faced in productizing the etched mesa LED arrays of the above describe copending application, at the present time, is the nonplanarity of the resulting structures. Efficient opto-electronic light emitters require relatively thick layers of epitaxial material grown on a substrate. Because of the relatively thick layers of epitaxially grown material, the mesa etching produces nonplanarities which tend to be on the order of 1 micron or greater. Such large nonplanarities can lead to problems with resolute photolithography, uniform dielectric coverage, metal step coverage, or metal column and row connectors.
Accordingly, it is highly desirable to provide methods of fabricating LED arrays which overcome these problems.
It is a purpose of the present invention to provide a new and improved method of fabricating LED arrays.
It is a further purpose of the present invention to provide a new and improved LED array with a substantially improved fill factor.
It is still a further purpose of the present invention to provide a new and improved method of fabricating LED arrays which is simpler and more efficient than prior methods and which is easily adaptable to high production levels.
It is another purpose of the present invention to provide a new and improved method of fabricating LED arrays which provides substantially planar semiconductor chips.
SUMMARY OF THE INVENTION
The above problems and others are at least partially solved and the above purposes and others are realized in a high density light emitting diode array with semiconductor interconnects including a plurality of layers of material formed on a substrate including at least a conductive layer of material supported by a major surface of the substrate, a first carrier confinement layer on the conductive layer, an active layer on the first carrier confinement layer, and a second carrier confinement layer on the active layer. The plurality of layers of material are separated into a plurality of isolated light emitting diodes positioned in a matrix of rows and columns with the conductive layer connecting a first electrode of each diode in a column to a first electrode of each other diode in the column. A plurality of row conductors, one for each row, connect a second electrode of each diode in a row to a second electrode of each other diode in the row and a plurality of column conductors, one for each column, are connected, one each, to the conductive layer adjacent an end of each column.
The above problems and others are at least partially solved and the above purposes and others are further realized in a method of fabricating a high density light emitting diode array with semiconductor interconnects including the step of providing a substrate of non-conductive material with a major surface, a conductive layer of material on the major surface of the substrate, a first carrier confinement layer on the conductive layer, an active layer on the first carrier confinement layer and a second carrier confinement layer on the active layer. The method further includes the step of separating portions of the second carrier confinement layer, the active layer and the first carrier confinement layer into a plurality of light emitting diodes positioned in rows and columns and separating the conductive layer into a plurality of columns connecting a first contact of each light emitting diode in a column to a first contact of each other light emitting diode in the column. Finally, the steps of forming column contacts connected to the conductive layer at an end of each column and forming a row contact on the cap layer of each light emitting diode and connecting row contacts for all light emitting diodes in a row are performed.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring to the drawings:
FIGS. 1 and 2 are simplified sectional views illustrating various steps in a fabrication process of an array of light emitting diodes, portions thereof broken away;
FIG. 3 is a simplified sectional view as seen generally along a column of an array of light emitting diodes embodying the present invention, portions thereof broken away;
FIG. 4 is a simplified sectional view as seen generally along a row of the array of light emitting diodes of FIG. 3, portions thereof broken away;
FIG. 5 is a simplified sectional view of another embodiment of an array of light emitting diodes embodying the present invention; and
FIG. 6 is a view in top plan of a portion of the array of FIGS. 3 or 5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring specifically to FIG. 1, a first structure in a fabrication process of an array of light emitting diodes is illustrated in a simplified sectional view, portions thereof broken away. The structure includes a substrate 15 having an upper surface on which is positioned, in the following order, a conductive layer 16, a first carrier confinement layer 17, an active layer 18, a second carrier confinement layer 19 and a conductive cap layer 20.
In a specific embodiment of the fabrication process, substrate 15 is formed of undoped gallium arsenide (GaAs) so that substrate 15 is a semi-insulating semiconductor. Conductive layer 16 is a layer of GaAs epitaxially grown on the surface of substrate 15 and is heavily doped (10 18 or greater) with a dopant such as selenium, silicon, etc. to make it a relatively good N+-type conductor. In this specific example, conductive layer 16 is grown to a thickness in the range of approximately 1000-10,000 angstroms. First carrier confinement layer 17 is a layer of indium-gallium-aluminum phosphide epitaxially grown on the surface of conductive layer 16 and doped (10 17 - 10 18 ) with silicon for N-type semiconductivity. In this specific embodiment, carrier confinement layer 17 is grown to a thickness in the range of approximately 1000-8000 angstroms. Active layer 18 is an undoped layer of indium-gallium-aluminum phosphide epitaxially grown on the surface of carrier confinement layer 17 to a thickness in the range of approximately 100-1000 angstroms. Second carrier confinement layer 19 is a layer of indium-gallium-aluminum phosphide epitaxially grown on the surface of active layer 18 and doped (10 16 -10 18 ) with zinc for P-type semiconductivity. In this specific embodiment, carrier confinement layer 19 is grown to a thickness in the range of approximately 1000-8000 angstroms. Conductive cap layer 20 is epitaxially grown on the surface of carrier confinement layer 19 to a thickness in the range of approximately 200-1000 angstroms and is heavily doped (10 19 ) with zinc to make it a good P+-type conductor. The molecular fraction of aluminum in carrier confinement layers 17 and 19 is in the range of approximately 0.7-1.0 and in active layer 18 is approximately 0.0 to 0.24. For simplicity of fabrication in the specific example disclosed, layers 16 through 20 are epitaxially grown as blanket layers over the entire substrate 15 but it will be understood that other methods, including masking and selective growth or selective etching, can be utilized to provide the area necessary for the following steps.
Referring specifically to FIG. 2, a second structure is illustrated in which portions of cap layer 20, carrier confinement layer 19, active layer 18 and carrier confinement layer 17 have been etched to form, or separate, mesas organized into a two dimensional array or matrix of rows and columns (only one mesa illustrated for convenience). FIG. 3 illustrates a sectional view taken generally along a row of the array and FIG. 4 illustrates a sectional view taken generally along a column of the array. The upper surface of each mesa in the array defines a light emitting area for a light emitting diode.
A column isolation step (see FIG. 2) is performed by etching trenches 27 through cap layer 20, carrier confinement layer 19, active layer 18, carrier confinement layer 17, conductive layer 16 and partially into substrate 15. Trenches 27 extend the entire length of each column so that conductive layer 16 is separated into a plurality of columns, each column of conductive layer 16 being associated with only one column of mesas and each column of mesas being electrically separated from each other column of mesas by a trench 27.
In a similar fashion, the mesas are defined by etching a trench 26 through cap layer 20, carrier confinement layer 19, active layer 18 and partially into carrier confinement layer 17 between each row in the array, as illustrated in FIG. 4. Each trench 26 extends the length of a row and prevents cross-talk between adjacent light emitting diodes in a column while allowing the lower terminal of each light emitting diode in a column to be connected to the lower terminal of each other light emitting diode in the same column.
A layer 28 of dielectric material, which in this specific example is Si 3 N 4 , is then deposited over the wafer to provide passivation of the etched surfaces and isolation between metal layers, as illustrated in FIGS. 3 and 4. The wafer surface is replanarized with a layer 29 of polyimide. Vias are then etched in layer 29 and layer 28 on the top of each of the mesas to provide access to conductive cap layer 20. P-contact metal 35 is applied to the exposed surface of conductive cap layer 20 using standard lift-off techniques to ohmic contacts with the upper terminal of each light emitting diode in a row and to form row current buses therebetween, as illustrated in FIG. 6.
Referring to FIG. 5, a second structure or embodiment of an array of light emitting diodes is illustrated in a simplified sectional view, portions thereof broken away. The second structure includes a substrate 15' having an upper surface on which is positioned, in the following order, a conductive layer 16', a first carrier confinement layer 17' an active layer 18', a second carrier confinement layer 19' and a conductive cap layer 20'. Separation of the various layers into a plurality of light emitting diodes is achieved by implanting impurity material to form an isolating resistive volume, or moat 25', around each of a plurality of defined light emitting areas 21'. Resistive moat 25' laterally confines current flow across the P-N junction (carrier confinement layer 19', active layer 18' and carrier confinement layer 17') of each of the light emitting diodes and, therefore, defines the emitting region of each of the light emitting diodes.
It should be understood that cap layer 20' is generally removed, or selectively deposited, to form exposed areas 22'. In the present embodiment, the exposed row areas and exposed column areas define a matrix of diode light emitting areas 21'. Also, in the described embodiment carrier confinement layer 17' and conductive layer 16' are common to each light emitting diode. This allows the lower terminals (carrier confinement layer 17') of each of the light emitting diodes in each column to be conveniently connected in common. However, in this embodiment it is necessary to isolate the columns of light emitting diodes from each other to prevent crosstalk therebetween.
The column isolation is provided by an isolation implant 30' extending downwardly through carrier confinement layer 19' active layer 18' carrier confinement layer 17' and conductive layer 16' to electrically isolate adjacent columns from each other. In the specific embodiment illustrated, isolation implant 30' need only isolate the N-type layers (carrier confinement layer 17' and conductive layer 16'), since resistive moat 25' isolates the P-type layers (carrier confinement layer 19' and active layer 18').
The remainder of the fabrication process includes patterning interconnect metallization. The lower terminal of each light emitting diode, which in this embodiment is the cathode, in each column is connected to the lower terminal of each other light emitting diode in the column through conductive layer 16'. An external contact 34 (see FIG. 6) is connected to conductive layer 16' adjacent an end thereof. Similarly, the upper terminal of each diode (light emitting area 21' of cap layer 20') in each row is connected by a connection 35' which also serves as a row bus (see FIG. 6). Thus, the upper terminal of each light emitting diode in a row is connected to the upper terminal of each other light emitting diode in the row.
A more complete description of an array similar to that illustrated in FIG. 5 and process for fabrication of the array is disclosed in a copending Patent Application entitled "Implanted LED Array and Method of Fabrication", filed May. 9, 1994, Ser. No. 08/240,055, assigned to the same assignee and included herein by reference.
Thus, a new array and pixel design is disclosed which uses only highly doped buried layer 16 or 16' beneath the light emitting diode double heterostructure as the common column interconnect and cathode contact for each pixel in a column. This connection eliminates the need for column bus metallization and the associated minimum dimension and alignment tolerances required for its formation. As can be seen in FIG. 6, the space between pixels drops from 2 minimum line widths plus 2 alignment tolerances to a single minimum line width retained for isolation. With the 2 micron design rules and emission dimensions cited above, the linear fill factor increases to 10/12 =0.833 and the area fill factor comes up to (0.833) 2 =0.694. This is nearly a factor of 3 increase in the area fill factor and significantly increases the quality of displayed images.
In addition, narrow, high aspect ratio trenches 26 and 27 between pixels replanarize much more readily than the topology resulting from the metallized interconnect utilized in the copending application entitled "Electro-optic Integrated Circuit and Method of Fabrication" first cited above. This simpler replanarizing makes the fabrication process less complicated, more repeatable and more reliable.
Generally, semiconductor layers have a significantly lower conductivity than metal interconnects and, consequently, increased column resistance is expected with this design. Buried semiconductor layer 16 or 16' should be designed for maximum conductivity by making it as thick and as heavily doped as possible, or practical, using, for example, n-type GaAs to achieve the highest carrier mobility. Still, the conductivity will generally be lower than that of a metal interconnect. However, because in the standard scanned array the column interconnects carry current for only a single light emitting diode (˜50 microamps), the resulting voltage drop along the column interconnect is small compared to the forward voltage of the light emitting diode (˜2.0 volts). For layer 16 or 16' which is 10 micrometers wide, 1.0 micrometer thick, doped n-type to 10 18 cm 3 with electron mobility of 3000 cm 2/ volt-sec, the resistance is 20.8K ohms/cm (compared to only 244 ohms/cm for a 2 micrometer by 0.5 micrometer Au strip). However, for a display having 144 rows of light emitting diodes with a pixel pitch of 12 micrometers and a pixel current drive of 50 microamperes, the voltage drop along the semiconductor column interconnect (layer 16 or 16') is only 0.18 volts, which is less than 10% of the forward voltage of the light emitting diode. Therefore, the increased resistance of the column interconnects in not a problem.
Throughout this description references to rows and columns are made for simplicity of the disclosure but it will be understood by those skilled in the art that these terms are completely interchangeable since rows and columns of a matrix generally depend upon a physical orientation and are changed, for example, by simply rotating the device 90o. Further, while specific sequences of steps have been disclosed and claimed, it will be understood by those skilled in the art that many of the steps are interchangeable, and the exact sequence utilized depends upon the specific methods applied, including chemicals, temperatures, etc. Further, it should be understood that neither the sequence disclosed nor claimed is intended to in any way limit the present invention to a specific sequence of steps.
While we have shown and described specific embodiments of the present invention, further modifications and improvements will occur to those skilled in the art. We desire it to be understood, therefore, that this invention is not limited to the particular forms shown and we intend in the appended claims to cover all modifications that do not depart from the spirit and scope of this invention. | A high density LED array with semiconductor interconnects includes a plurality of layers of material stacked on a substrate including a conductive layer, a first carrier confinement layer, an active layer, and a second carrier confinement layer. The layers are separated into isolated LEDs in a matrix of rows and columns with the conductive layer connecting a first electrode of each LED in a column to a first electrode of each other LED in the column. Row conductors connect a second electrode of each LED in a row to a second electrode of each other LED in the row and column conductors are connected to the conductive layer of each column. | 7 |
This is a continuation-in-part application of U.S. patent application Ser. No. 08/664,809 filed Jun. 27, 1996 now abandoned, which is a continuation of U.S. patent application Ser. No. 08/265,437 filed Jun. 24, 1994 now abandoned.
BACKGROUND OF THE INVENTION
Inflatable air cells have been used in a variety of configurations to provide adjustments to the contour of a seat and in this manner enhance the comfort of the individual using the seat. This is especially important in automobiles where long periods of driving can cause pain and distraction or in other seating applications where individuals are sedentary for long periods of time.
The seating system described in U.S. Pat. No. 4,915,124 involves a simple system of multiple air cells in which each cell is connected through a valve to a source of pressurized air in a manner which allows for simultaneous inflation or deflation of the cells in response to a manually operated switch.
Another air cell inflation system is shown in U.S. Pat. No. 5,263,765. This device inflates the air cells according to two predetermined modes, through tubes individually controlled by valves which are in turn controlled by a microcomputer. The microcomputer is responsive to the fatigue of the driver as represented by seat belt displacement.
The air cells of U.S. Pat. No. 4,722,550 are adjusted in response to engine speed or steering angle and allows for selective inflation between two zones of air cells, one at the sides and one for the bottom and back of the seat. One valve controls each of the zones and is actuated by a microcomputer which receives sensed signals relative to the operating parameters of the automobile.
A manually operated power control system for a lumbar cushion is described in U.S. Pat. No. 4,707,027. A complex seating mechanism is devised to allow the operator to inflate and deflate the cushion while sensing pressure in the cushion to limit actuation of the system to prevent damage.
U.S. Pat. No. 4,833,614 shows a system by which an air cell can be inflated to a selected pressure by sensing the actual pressure, comparing it to the pressure selected and then adjusting the air supply to inflate or deflate the air cell to the selected pressure. In this case the microcomputer converts the pressure signal it receives to a time based signal relative to the period necessary to run the pump to obtain the selected pressure. The pressure is sensed directly from sensors within the air support.
The above systems are limited either to narrow preset operational boundaries or rely on the operator to provide a manual interactive response. Although each attempts to improve the comfort of the user and adjust in some manner to the variety of shapes and sizes of the user, each falls short because of the inherent limitations in the particular system.
Inflatable air cells have been used as a means to actuate adjustment mechanisms for altering the contour of a seat for many years. This adjustment is desirable to customize the seat contour to a particular user. In applications such as automobile seating where fatigue may become a factor, it is of particular interest to provide adjustment from user to user and during use by an individual. Air cells have also been used to adjust the tactile support for such critical regions as the lumbar portion of the back which is particularly susceptible to fatigue. In this instance the air cell provides direct support and not just an adjustment mechanism.
An air cell adjustment mechanism of the prior art is shown in U.S. Pat. No. 5,137,329. This patent describes a support structure consisting of front and back plates between which are sandwiched two air cells. The air cells may be selectively inflated and deflated to provide pivoting adjustment motion to the front plate which provides the support contour for the seat.
Tactile adjustment is provided by the air cell of U.S. Pat. No. 4,807,931 which is also mounted in a seat to provide the support contour for directly engaging the lumbar region of the user's back.
U.S. Pat. No. 4,655,505, assigned to NHK Spring Co. Ltd., discloses a pneumatically controlled seat for a vehicle that has a mechanism which can sense the pressure in each air cell remotely in a manifold using one sensor. However, the prior art does not show multiple low power, low fluid resistant valves nor provide automatic adjustment responsive to the user's comfort. The system of this invention accomplishes all of the objects of the prior art while providing many combinations of modes of operation from fully automatic to manual.
SUMMARY OF THE INVENTION
A system of inflatable air cells is constructed and installed in a seat at locations which are strategic to the comfort of the user. The air cells are connected to a pump through a manifold which simultaneously or sequentially, as desired, connects each cell to the pump. The manifold controls the flow of fluid in the air cell distribution system by means of a system of valves and senses the pressure in each cell by means of one or more transducers. A microcomputer's non-volatile memory is programmed with data representing a desired comfort level for each of the air cells. By sequentially activating individual manifold valves, a pressure signal from the transducer can be generated for each cell. The pressure signals are received by the microcomputer and are compared with the predetermined comfort data to generate a control signal which activates the pump or opens the exhaust valve. In a preferred embodiment, proportional control is used to regulate pressure in any air zone. The cells can be individually inflated or deflated to the desired pressure level. By varying the number and location of the cells the system becomes responsive to the localized pressures exerted on the body for a great variety of uses.
One purpose of this invention is to provide a pneumatically controlled seat surface for a vehicle having an array of air cells, each connected to a source of pressurized fluid (air), and arranged in a manner to operate both as an adjustment mechanism for the lumbar support of a seat contour and as an adjustable tactile support contour as well. A fluid distribution system is associated with the array of air cells to provide a simple method of adjusting the lumbar region of a seat to the satisfaction of the user without complex mechanics and while allowing multiple adjustment motions.
Another purpose of this invention is to provide a pneumatically controlled seat for a vehicle having a multiple air cell inflation system which can adjust the pressure in each of the cells simultaneously or sequentially, as desired, in accordance with sensed parameters which can be compared to a predetermined comfort level and operatively to individually inflate or deflate the cells to a desired or computed pressure level. This is accomplished in a manner which minimizes weight, cost, and complexity while maximizing flexibility, reliability, and above all seating comfort.
One feature of the present invention is to provide the system of the preceding object wherein a microcomputer control is provided for user inflation or deflation of the pressure in one or more of the cells to adjust lumbar firmness and thereafter sensing the pressure by a transducer and storing the adjusted pressure condition in the microcomputer to provide a new pressure target that up-dates the comfort data by changing a target pressure for one or more of the cells.
Another feature of the present invention is to provide a control system for such pneumatically controlled seats having a single pressure sensor and a microcomputer that is programmed to automatically exhaust or fill an air cell to correct for pressure changes produced by occupant movement or to compensate for small leaks in order to maintain a desired target pressure within one or more of the air cells even as environmental factors change (e.g., temperature).
Still another feature of the present invention is to provide a single pressure sensor and microcomputer for such pneumatically controlled seats that detect a signature of occupant movement produced by wiggling movements of an occupant and to adjust the system in response to such signature to recycle the system to assure that initial target pressures are present therein.
Yet another feature of the present invention is to provide a sensor and microcomputer as set forth above that is operative in response to multiple input signals including one or more of an occupant detection condition; a temperature condition; system power-up; on-off switch and a system override switch.
Still another feature of the present invention is to provide a microcomputer in the aforesaid systems in which the controller is programmed to operate multiple valves and a pump to conduct an initial inflate of the system cells to a gross pressure level with all of the valves initially open followed by continuous pressure reads and a sequential closure of each pressure zone formed by one or more cells as the pressure therein is compared by operation of the microcomputer to a desired target pressure.
A further object of the present invention is to provide a microcomputer control of the preceding object wherein the sequential control of each cell is either by a pressure pump inflation or by an exhaust valve deflation.
A still further object of the present invention is to provide for such a pressure inflation or exhaust deflation by establishing a pressure ε (or error range) range for the target pressure and to conduct only a select number of trial adjustments before terminating a correction sequence for establishing a desired target pressure condition within an air cell.
Still another feature of the present invention is to provide a microcomputer in the aforesaid systems that conditions the system to open all the cells to atmosphere when a seat is not occupied.
Another feature of the present invention is to provide a microcomputer in the aforesaid systems in which the microcomputer is programmed to produce a pulse width modulation of the drive motor for a pressurization pump and wherein the duty cycle of the drive motor energization is regulated in accordance with the number of open control valves, thereby controlling the inflation pressure and flow.
Still another feature of the present invention is to provide a microcomputer in the aforesaid systems in which an initial occupant assessment is made and inputted to the microcomputer and utilized to establish the target pressures in a look-up table for use in the comfort control operation of the system.
Still another feature of the present invention is to provide a microcomputer in the aforesaid systems in which an initial occupant assessment is made and inputted to the microcomputer and utilized to establish the position of motor driven vehicle mirrors; motor driven operating pedals; motor driven seat frames and motor driven steering wheels.
Yet another feature of the present invention is to provide a system having pressure controlled cells on a seat pan having fore and aft adjustment and to control the seat pan position in accordance with pressures produced in the cells during initial occupant assessment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram of the air cell arrangement of this invention;
FIG. 2 is a schematic diagram of the fluid distribution system of this invention;
FIG. 3 is a schematic diagram of the manifold of this invention;
FIG. 4 is a chart depicting the flow of information amongst the components of the system of this invention; and
FIG. 5 is a flow chart illustrating the steps of the method of this invention.
FIG. 6 is a perspective view of an automotive seat showing a second embodiment of the invention for adjusting the position of air cells therein;
FIG. 6A is a view like FIG. 6 showing a thigh support air cell in an extended position;
FIG. 6B is an enlarged fragmentary sectional view taken along the line 6B--6B of FIG. 6 looking in the direction of the arrows;
FIG. 6C is an enlarged fragmentary sectional view taken along the line 6C--6C of FIG. 6 looking in the direction of the arrows;
FIG. 7 is a view of a pressure supply system for the embodiment of FIG. 6;
FIG. 8 is a view of another embodiment of a pressure supply system for the embodiment of FIG. 6; and
FIG. 9 is a flow chart for controlling the fluid distribution systems of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The Seat
A series of air cells or bladders 1 are placed at strategic locations about the contour of an automotive seat 2 as shown in FIG. 1. The air cell placement is selected to coincide with key pressure points on the body to enhance the ability to respond to the comfort needs of the user. In particular, a pair of cells 3 are positioned in the thoracic region while three cells 4 are combined in the lumbar region. To further facilitate the adjustability of the seat, pairs of cells 5, 6, 7 and 8 are positioned at either side of the back and seat as well as the front and back of the thighs respectively. Each of these cells is in direct contact with the body to provide the control system with information which may be related to the comfort of the user. The cells are connected to a source of pressurized fluid 9 through a manifold 10 as shown in FIG. 2. The manifold 10 and pump 9 are controlled by a microcomputer 21 in response to information stored in the microcomputer which is compared to data provided by a sensor 12.
Each individual cell is constructed of a suitable flexible material such as rubber, polyurethane coated fabric or any other material provided with a fluid tight connection to the manifold to provide a path for conducting fluid into and out of the cell. The cells may be connected individually to the manifold or jointly with other cells. While three cells 4 are shown at the lumbar region and multiple cells are shown on the seat, the invention also contemplates use of a pressurizable mat in place thereof.
The Manifold
The manifold 10 consists of a housing 13 enclosing a chamber 14 constructed with multiple outlet ports 15 for connecting the chamber 14 to the inlet/outlet tubes of each individual cell or regional group of cells. Each outlet port 15 is provided with an outlet valve 16 for controlling the flow of fluid to and from the air cells. In this embodiment, the sensor is a pressure sensing transducer 17 that is operatively connected in the manifold to sense the pressure in the manifold chamber 14 and generate a signal indicative thereof. Chamber 14 is also constructed with a single inlet port 18 which is connected to a feed tube 19 to receive pressurized fluid, in this case air, from pump 9. A supply valve 20 is provided in feed tube 19 to control the flow of pressurized fluid to the manifold. The manifold can be molded of a high strength plastic material or other suitable material. The plastic material arrangement can have many of its components integrally molded therein. It is preferred that it be as compact and light weight as possible. However, the invention can be configured with other than light weight components and other than with integral components. A common bleed or exhaust valve 22 is provided to selectively release pressure from the manifold chamber 14 through venting port 30. The pressure in chamber 14 can therefore be adjusted by either actuating pump 9 or bleed valve 22.
Valves 16 are actuatable by an electrical signal and are designed for low power, low fluid resistant operation. More specifically valve 16 is an adaptation of highly efficient valves used in medical applications and comprises a two stage piezoelectric actuated valve in which a pilot valve acts to expose the main valve to its operable pressure. The bodies and valve seats of this design are easily moldable and can be integral with the manifold or within a valve module. Individual valve bodies can be designed for stacking assembly to form the manifold of this invention. In addition to a piezoelectric actuated valve 16 other low energy actuatable valves are contemplated by the present invention including but not limited to electrically pulsed reed valves; valves having an actuator configured of nickel titanium alloy such as Nitinol; magnetic inductive type valves or fluidic control valves so long as low energy consumption will operate the valve in on-off positions in which the flow from an inlet to outlet will satisfy the flow requirements of the pressure adjusted air cells in a given electropneumatic system for controlling a seating surface such as a seat, chair or bed to provide contouring, movement, support and/or comfort at a user interface. The importance of the use of such a valve arrangement in the present invention is that, in the past, pressure adjusted systems have utilized solenoid actuated valves to open and close an air cell to a pressure source for inflating the air cell or to a relief path for deflating the air cell. In such applications, power consumption is a problem since the major power consumers in the system combine power flow for operation of a motor driven pump and the power flow for operating the solenoids connected to the mechanical valving components. In one working embodiment, nine (9) valves are required to control flow to the eight air zones shown in the embodiment of FIG. 6 and to one exhaust. Depending on the type of pump, power consumption can be as little as 6 watts or as much as 72 watts during normal operation. Added to this power consumption, in the case of solenoid controlled valves, is an additional power draw on the order of 1 watt for each solenoid. During a deflate function, when all the valves are open the power draw for the valves would be approximately 10 watts. The total power consumption of the system could thus vary between 16 watts and 82 watts, depending upon the type of pump used to inflate the cells. Thus, the invention contemplates one order of magnitude power consumption variance. Thus, the invention, in one aspect, has a power consumption variance of one order of magnitude.
In vehicular applications such power consumption can overload existing wiring harness configurations and thus require larger capacity electrical systems and can generate excessive electrical noise and thus require additional components to reduce. Larger capacity electrical systems and noise reduction components add additional cost and weight to the vehicle.
The low power valves in the present invention draw microwatts of power for each operational valve when energized and, in a typical active surface during the maximum power draw for all valves in an exhaust mode, a total less than 1 milliwatt. Such power draw or less occurs during the valve control states established by the various programmable modes of the microcomputer, to be described following in greater detail. The low energy consumption valves in the present invention allow the initial inflate process in which the pump and all valves (but the exhaust valve) are energized to allow pressure flow to the various air cells of the system at very low power requirement levels.
The importance of this aspect of the active surface control system of the present invention is best understood in battery powered applications where power consumption is a rigid design constraint. The orders of magnitude decrease in valve power consumption provided by the present invention becomes a significant, and heretofore unrecognized advantage since a smaller power source can be used for lower cost and reduced weight; fewer modifications to wiring harness designs in vehicular operations are required and less heat is generated in systems where heat build up can be disadvantageous as for example in space shuttle and other vehicular operations where the system is used in a controlled environment.
The fact that the valves further have a high flow rate capability is important in applications where the air cell volume is relatively large, e.g., in hospital bed applications or in which the operation of the system is required to be non-subtle, e.g., pressure adjustments in the cell are made rapidly. In such applications the large flow rate is especially advantageous. However, in all applications, the flow rate will directly impact system energy dissipation. The activation time (time required for the system to reach a desired programmed target) will depend upon the flow rate of the valves, pump flow rate capacity, and volume of the target air cell(s). If the flow rate of an individual valve is low, more time will be required to achieve the target, a pump will be required to run for a longer period of time in which its power consumption over greater time will produce greater energy dissipation. Another disadvantage of such prior art lower flow rate valves is that they are pneumatically lossy since pressure drop across the valves will be higher and usable pressure at the outlet of the valve will be less.
The manifold 10 is shown in FIG. 3 as a stack of integrally molded valve bodies 21 enclosing a common interior chamber 14 which communicates with a plurality of output ports 15 through output valves 16. Although only two ports 15 are shown, it should be clear that this number is only limited by the size of the space allocated for each particular application.
The Control
The active parts of the system of this invention namely: the outlet valves 16, the transducer 17, pump 9, as well as bleed valve 22 and supply valve 20 are interconnected electrically to a microcomputer unit 21 which controls the operation of the system. The MPU 21 can be a commercially available microcomputer such as the 68HCO5 variant manufactured by Motorola. A microcomputer as used herein includes all subsystems and peripheral components as is well known to those skilled in the art.
The MPU 21 has access to non-volatile memory which has been programmed to provide a predetermined comfort standard such as the algorithm described in U.S. Pat. No. 5,283,735. These data can be compiled and coded for use with individual air cells or regions of air cells. Data sensed by transducer 17 is compared to the comfort standard and an actuation signal is generated which actuates the system to compensate for any differential between the programmed comfort level and the sensor generated data.
In order to operate each cell or group of cells independently to provide an extensively adjustable system, the MPU 21 must also be programmed to actuate the output valves 16 to isolate a selected air cell or group of air cells in communication with the manifold. The actuation is controlled in closed loop fashion to allow the pressure in the chamber 14 to equalize with the pressure in the air cell or cells with which it is communicating. On an instantaneous basis there is a closed system among the connected air cell(s), the feed tube, the chamber 14, and the fluid supply thereby allowing the sensor to provide data from the closed system and to provide adjustment of the pressure in the isolated air cell(s) by the MPU 21 to the desired comfort or pressure level.
Operation
The operation of the invention will be understood to have application to either the embodiment of FIG. 2 or the embodiments shown in FIG. 6 and in FIG. 7 with it being understood that the operation of the target pressure control variants to be described herein apply equally well to systems in which the air cells can be independently positioned or remain in a predetermined position on a support surface of a vehicle seat or the like.
In operation, the MPU 21 will open a valve 16 interconnecting a selected air cell or air cell group, such as the lumbar region cells 4, with the manifold chamber 14 and allow the pressure in the selected system to settle out. The time to let pressure equalize is "pressure settling time". After the settling time, the pressure is sensed and a signal is sent to the MPU 21 for comparison with the preprogrammed comfort data. The MPU 21 then generates a signal relative to the difference in the comfort level sensed to the programmed comfort level and initiates a flow of fluid to or from the selected cell system to reduce the difference to zero. This sequence of operations is then repeated "n" times until each of the air cell systems are sensed and adjusted.
Alternative Embodiments
The device and method of this invention may be simplified by using a preset pressure as the programmed comfort level and allowing the system to poll each air cell system and adjust the pressure in each air cell to the preset pressure. In addition the operator could be allowed to adjust the pressure level in accordance with his or her own perceived comfort. Also the instantaneous data may be sensed by an array of force sensors as described in U.S. Pat. No. 5,283,735 in the place of the transducer 17. In the latter instance the sequencing would remain the same, but it would be coordinated with a polling of the sensor array. It is observed that by varying the comparative comfort data and the number and location of the air cells, the system of this invention allows for a wide variety of comfort styles and an almost infinite flexibility of adjustment in a package that is simple, light weight, low cost and efficient.
In the embodiment of the invention shown in FIG. 6, a vehicle seat 58 suitable for use in a motor vehicle application is illustrated that includes ten (10) air cells and eight (8) air zones. In this embodiment a first air zone 60 includes a moveable seat pan 62 with thigh air cells 64, 66. The seat pan 62 is extendible and retractable on a suitable track system 65 that can include laterally spaced side rails 65a, 65b or single center track 65c with side guide surfaces on each side of the seat pan 62. The seat pan 62 is driven on the track system by suitable actuators such as a motor driven ball screw actuator 68 that can be substituted by a pneumatic cylinder or other electrical, mechanical or pneumatic actuator that will connect to a seat pan support member 66a for positioning it fore and aft with respect to the side rail or support systems.
A second air zone 70 is defined by an ischial air cell 72 on a fixed seat portion 74. The ischial air cell 72 has a generally butterfly shaped configuration with a center region 74a and four wing regions 76, 77, 78, 79. The air zone 70 is controlled such that the pressure acting on the posterior of a user will be in a range that will not unduly restrict capillary blood flow.
A third air zone 80 is defined by a right pan bolster air cell 82 located laterally outboard and above the air zone 70. A fourth air zone 84 is the left counterpart of the air cell 82 and is defined by a left pan bolster air cell 85 located laterally outboard and above the air zone 70 opposite to the air cell 82 such that the occupant is provided good lateral pressure support as desired.
Fifth and sixth air zones 86, 87 are defined by a pair of seat back bolster air cells 88, 89 located in side arm regions of the vehicle seat 58.
A seventh air zone 90 is defined by a top lumbar air cell 92; an eighth air zone 94 is defined by a middle lumbar air cell 96 and a ninth air zone 98 is defined by a bottom lumbar air cell 99. The design and placement of air zones and air cell or cells within the air zones is determined by the particular application to which the occupant support pertains. In the illustrated arrangement, both pairs of the bolsters provide support, and depending on the seat or chair design, can produce a holding action on the occupant within the confines of the seat. The ischial cell 72 is designed so as to distribute pressure in a manner to reduce pressure points that can unduly restrict capillary blood flow. The lumbar cells 92, 96, 99 provide support at the spinal regions of the occupant and depending upon the level of inflation in each of the lumbar cells can be configured to ensure that lumbar lordosis is preserved.
In FIG. 7 a fluid distribution system is shown for controlling the zones described in the seat 58 illustrated in FIG. 6. In this arrangement, a fluid control system 100 is provided having a microcomputer 102 operatively connected to a pump drive 104 for driving a pump 106 having its discharge connected through a check valve 108 to a manifold 110 comprised of a plurality of stacked low energy consumption, low flow resistance, e.g., high volume flow type valves 110a-110h, each having an inlet connected to the manifold 110 and each having an outlet connected to one of the air zones in the fluid distribution system. The manifold 110 is also connected to a single exhaust valve 112. In this embodiment a valve drive control 114 is connected to an output from the microcomputer 102 to selectively condition one or more of the valves 110a-110h to be connected to the manifold 110 in accordance with a programmed control sequence to be discussed. Additionally, each of the air zones has the pressure condition therein independently processed by an MUX or analog multiplexer 116 that directs a pressure signal selectively from a separate pressure sensor 116a-116h located between each of the valves 110a-110h and a respective one of the air zones shown in the seat 58 of FIG. 6. Since the pressure signals are processed by the MUX 116 only a single analog to digital port 116a on the microcomputer 102 is required for pressure sensing.
Additionally, the fluid distribution system in FIG. 7 includes an independently operable user switch 118 for overriding automatic programmed control sequences. The automatic programmed control sequences are modified not only by the pressure signals inputted by the MUX 116 to the microcomputer 102 but they are also controlled in response to additional signals from a temperature sensor 120, an occupant sensor 122, and other sensors that will be discussed.
Another embodiment of the invention is shown in FIG. 8 as a fluid distribution system 124 controlled by a control system 126 having a microcomputer 128 similar to that previously discussed. In this embodiment, air zones are provided similar to those in the seat 58 shown in FIG. 6 and they are connected to a manifold 130 through low energy consumption, low flow resistance, e.g., high volume flow valves 130a-130h like those discussed in the previous embodiments. In this embodiment, the manifold 130 is connected to a suitable pressure fluid source comprised of a pump drive 132 such as a power transistor (not shown) controlled by the microcomputer 128. Drive 132 receives an operating signal from the microcomputer 128 so as to enable an electric motor 133 to be energized by a pulse width modulated power supply from the drive 132 that will control the flow rate from a fluid pump 134 for reasons to be discussed. The control system 126 further includes a valve drive 136 that opens and closes the high volume flow valves 130a-130h to the manifold 130 pressure when the pump 134 is operating or, alternatively, will connect the respective valves 130a-130h and the air cells within the respective air zones to exhaust through a single exhaust valve 138 when the pump 134 is turned off such that the individual air cells within the respective air zones can be decremented (deflated) or incremented (inflated) in pressure if desired to meet a desired preprogrammed or user override surface condition that will actively control the surface to provide a desired contouring, movement support and or comfort as desired so as to selectively control the surfaces of the air cells in each of the respective zones. A single pressure transducer or sensor 139 connects to the manifold 130 upstream of exhaust valve 138 for determining the pressure in the respective air zones when the exhaust valve 138 is closed and the flow valves 130a-130h are open in accordance with the program of microcomputer 128. In this embodiment of the invention, the microcomputer 128 is also associated with a plurality of sense cells 140a-140i, one of which is embedded in each of the air cells in the seat 58 of FIG. 6. The sense cells can be variable resistance sensors, capacitive sensors or the like that will produce an appropriate output signal to be processed by the microcomputer 128 when flexed or compressed. The sense cells are embedded in the surface of each of the cells as shown in FIG. 6B where a fragmentary sectional view is shown including a seat cover portion 143 covering an air cell 145 and wherein a force sensing array of the type sold by Vistamed is adhered to the air cell 145 or alternatively embedded in the seat cover portion 143 or alternatively is disposed within the interior of the air cell at a point where it will detect changes in the shape of the air cell produced by user movements thereacross so as to automatically adjust the pressure within the cell in accordance with a programmable sequence to be described. The sense cells 140a-140i are connected to an analog multiplexer 142 for directing sense cells signals to a single port 144 on microcomputer 128. Switches common to those in FIG. 8 are designated with the same numeral primed.
In one aspect of the invention, the pressure transducers can be used for monitoring pressure in selected cells for changes in pressure related to occupant movement and the microcomputer can compare such readings against programmed comfort values to establish a rate of change and the microcomputer can be programmed to produce output signals for compensating for such occupant wiggling movements by controlling the valves to adjust the system in response to such signature to recycle the system to assure that initial target pressures are present therein.
The flow chart shown in FIG. 9 is a high level flow chart of one suitable program sequence for control of the embodiments previously described at FIGS. 1-8. At step S1 initialization determines if a vehicle ignition switch sensor 146 is on; if no the program ends; if yes, the program proceeds to step S2 where various switch selection modes are determined; if no the program repeats. If yes, (at step S2') meaning that one of a plurality of switch operations is initiated, the program proceeds to either of the steps S3, S4 or S5.
Switch selection indicated at the control steps S3, S4 or S5 includes the operator selecting an on-off switch 118, 118' or a lumbar deflate or inflate switch 148, 148'. The step S5 is an automatic step that occurs if a temperature limit switch sensor 120, 1201 and an occupant switch sensor 122, 122' are properly set and one of the switches 118, 118' (on) is selected.
If the power off switch 118, 118' is operated or if an occupant seat switch sensor 122, 1221 detects that there is no occupant or if a temperature sensor switch 122, 122' detects an elevated temperature that can cause the various air cells to be overpressured, the program proceeds to step S3 "deflate all". At step S3 the microcomputer outputs a deflate signal to the low energy high flow valves between the air cells and the manifold causing them to open; a deflate signal to the exhaust valve causing it to open and a deflate signal to the pump drive turning it and the pump motor off. This causes all of the air cells to simultaneously deflate to atmospheric pressure. Thus the microcomputer under all or some of such conditions produces a "deflate trigger"; in the case of the occupant sensor the deflate trigger occurs, for example, when a desired sensor signature indicating the presence of an occupant or a seat pattern such as produced by packages and the like, and if the signal pattern differs from an acceptable signature, the microcomputer will produce an occupant "deflate trigger" output; in the case of the temperature sensor signal, the microcomputer will compare the actual temperature signal to a preprogrammed temperature value and if such comparison indicates that the cell or cells can be overpressurized a temperature induced deflate trigger occurs thus producing a third "deflate trigger". Such deflate triggers from the microcomputer cause the valve drive to condition all of the individual supply valves to open simultaneously while at the same time opening the single exhaust valve from the manifold. Thus, the program will produce a simultaneous deflation of all of the air cells by opening the valves 16 in the FIG. 3 embodiment; or by opening the valves 110a-110d in the FIG. 8 embodiment or by opening the valves 130a-130h in the embodiment of FIG. 9 as well as their associated exhaust valves.
Following the deflation of each of the air cells in the respective seating systems, the bolster air cells will be reduced in size allowing for easier egress from the vehicle. Following the deflate all at step S3, the control sequence is returned to the switch selected step S2.
The flow chart shown in FIG. 9 also includes a lumbar adjustment mode at step S4 in which the lumbar switch 148, 148' is positioned to inflate or deflate. In this mode, inflation or deflation is performed in a continuous manner as opposed to an incremental one. When the lumbar switch 148, 148' is positioned to inflate, the microcomputer reads this signal, opens the appropriate valve(s) and turns the pump on. Pressure is read continuously. When either the switch is released or the maximum preset lumbar pressure is reached, the microcomputer turns off the pump, waits for pressure to settle, reads the new lumbar pressure and closes the valves. When the lumbar switch 148, 148' is positioned to deflate, the microcomputer reads this signal, opens the appropriate valve(s) and the exhaust valves. The system remains in this state until the switch is released. Once the switch is released, the microcomputer closes the exhaust valve, waits for the pressure to settle and reads the new lumbar pressure. In both cases, the new lumbar pressure is stored in the target pressure look-up table and remains until the lumbar function is reactivated or power is removed.
Thus, the new desired lumbar pressures can be established in accordance with whether a user selected deflation or inflation of the original lumbar pressure for comfort or as established by user juries or other standards for comfort. In either case, the comparison pressures for lumbar comfort are programmed in accordance with the desires of a user and remain in place until the control system is turned off, at which time the originally selected base line pressures for user comfort are used as a standard for carrying out a sequential control to be discussed.
At control step S5, an automatic pressure control sequence is established that proceeds to step S7 if the previous state is "deflate all"; at step S7 an initial inflate step occurs wherein the microcomputer transmits valve signals to open all valves except the exhaust valve; the pump is actuated until all the air cells are pressurized during which the pressure is sensed in common while air is flowing and the valves are closed as a target pressure plus over target pressure ε is reached for each zone.
At control step S8, the microcomputer provides a sequential adjust that is initiated by an interval timer 150. The sequential adjust is operated following initial inflate mode of operation or at any autocycling not following a deflate all or system power up. In the sequential adjust mode, the pressures in each of the cells (or zones) are read and adjusted one zone at a time.
In the sequential adjust, the microcomputer is programmed such that it will initiate a control sequence in which a "pressure read" is initiated by first determining if the exhaust valve is open or if the pump is operating. These conditions will be detected and if present the controller will initiate a sequence to close the exhaust valve and to shut off the pump motor.
A pressure read consists of closing the exhaust valve or bleed if it is open or turning the pump off if it is on, opening the valve to the target zone, waiting for the pressure to settle then reading the pressure in the common. The pressure read sequence applies to the single sensor embodiment shown in FIG. 8. In the multiple sensor embodiment shown in FIG. 7, the valves do not change state for a pressure read since the pressure sensing is done at the output or air cell side of the valves.
The pump on-time, in the case of inflate, or the bleed valve open-time, in the case of deflate, are modulated proportional to the difference between the read pressure and the target pressure. Inflate/deflate factors are used to compensate for pressure read errors while air is flowing. Using an electrical analog, pressure is viewed as voltage, flow as current and pneumatic impedance as electrical impedance. The effective IR drop between the pressure transducer(s) and the air cell is determined empirically and is the compensation factor used during inflates. In the case of deflation, the compensation factor is the effective IR drop between the pressure transducer(s) and atmosphere. Continuing the electrical analogy, IR corresponds to flow times impedance which is pressure. When the read pressure approaches the target pressure, the bleed valve open time is determined by the minimum valve open time.
A delay period is initiated to stabilize the pressure in the manifold (only in the single sensor embodiment of FIG. 8).
The sequential adjust for each cell or cell zone is as follows:
1. Enter sequential mode.
2. Read pressure in selected cell.
3. Compare read pressure to target pressure.
4. If read pressure too low initiate inflate; if too high initiate deflate.
If inflate:
A. Open valve.
B. Turn pump on for time calculated in accordance with the difference in pressure between the target pressure and the read pressure.
C. Close valve and allow pressure to settle.
D. Read pressure.
E. Compare read pressure to target pressure minus pressure ε.
F. Repeat steps B through E until target pressure minus pressure ε is achieved.
If deflate:
A. Open valve.
B. Open bleed valve for calculated time.
C. Read pressure.
D. Compare read pressure to target pressure plus pressure ε.
E. Prepare steps B through D until target pressure plus pressure ε is achieved.
5. Repeat 2 through 4 until all zones are at target pressure.
6. Repeat 1 through 5 until all zones are at target without adjustment or following a predetermined number of cycles of steps 1-5 to avoid hunting.
FURTHER CONSIDERATIONS
While switch initiation of the control is discussed at S1, S2, S3, S4 or S5, system activation can be preprogrammed if desired and system activation could range from a microcomputer with no peripheral switches to more than four switches, as desired. For example, the microcomputer could be programmed so that the use of a keypad ;or keyfob entry system with a seat memory 1 or seat memory 2 could initiate a preprogrammed sequence to control the cell pressures to meet the desires of two different users. In such case, the peripheral switches 118, 118' described in the embodiments of FIGS. 8 and 9 are not required.
Further, at S3, as currently implemented, temperature sensing is used to protect temperature sensitive system components (valves, pump). If the sensed temperature is out of range (too hot or too cold), the microcomputer opens all of the valves (deflate all) and goes to a safe state. In the safe state, the microcomputer monitors temperature and prevents system operation until temperature returns to the active region.
With the temperature sense capability, the microcomputer could be programmed to compensate for temperature dependent pressure changes in the air cells of the apparatus for adjusting the contour of a seat.
Still further, at S3, or at another control point, an occupant movement monitoring algorithm can be employed to prevent the system from adjusting during movement. A possible sequence is as follows. The system is monitored for occupant movement. If movement is detected, the system waits until the movement (wiggling) stops then initiates an adjustment. If movement is not detected, the system continues to monitor but does not trigger an adjustment.
Still further, at step S4, alternatively, the lumbar adjust mode can operate the lumbar switches 148, 148' to inflate or deflate. Either switch operation can direct an incremental step signal that is processed by the microprocessor as for example by selecting a value of an originally inputted target pressure and adding a desired incremental value to each of the target pressures and outputting a modified target value into a second look-up table or register in the microcomputer that will be utilized at control step S4 during subsequent control operations to be described. These modified lumbar values remain in place until the microcomputer control ends, at which time the originally selected target pressures will be reestablished as the desired predetermined pressure condition in each pressure zone for obtaining the predetermined comfort level for seating.
In another configuration, a reversible pump can be connected to the common manifold through a blocking valve. The dedicated exhaust or bleed valve is eliminated. Inflates occur as in the other embodiments except that the blocking valve must be opened when the pump is on. Deflates are now active rather than passive. In this case, the pump is energized in the reverse direction so that it pulls air from the air cells through the commanded open (by the microcomputer) blocking valve. In this mode, the cells deflate more rapidly and can be completely deflated without external pressure being applied to them. The advantages of this mode are faster and more complete deflation.
While the best modes for carrying out the invention have been described herein in detail, those familiar with the art to which this invention pertains will recognize various alternative designs and embodiments for practicing the invention are possible within the scope of the following claims. | A system of inflatable air cells is constructed and installed in a seat at locations that are strategic to the comfort of the user. The air cells are connected to a pump through a manifold which sequentially connects each cell independently to the pump. The manifold controls the flow of fluid in the air cell distribution system by means of a system of valves and senses the pressure in each cell by means of a transducer. A microcomputer is programmed with data representing a desired comfort level for each of the air cells. By sequentially activating individual manifold valves, a pressure signal from the transducer can be generated for each cell. The pressure signals are received by the microcomputer and are correlated with the predetermined comfort data to generate a control signal which activates the pump. In this manner each of the cells can be individually inflated or deflated to the desired pressure level. By varying the number and location of the cells the system becomes responsive to the localized pressures exerted on the body for a great variety of users. | 1 |
FIELD OF THE INVENTION
[0001] This invention proposes a decision support system and method to visualize the relationship among the polytopes in order to help with decision support. In specific, the visualization system includes a relational algebra visualize used to provide various methodical points of assistance to users making decisions.
DISCUSSION OF PRIOR ART
[0002] US2002107819A proposes a Strategic Planning and Optimization System that uses historical sales data to predict optimal prices and similar factors for meeting a number of business goals. Unlike previous systems that allow a user to model prices and other factors based on physical constraints, the present invention allows the optimization to occur against the background of one or more strategic objectives. Such objectives, such a price image, are not set by physical constraints but instead are imposed by the user with the notion that they will provide a strategic and ultimately an economic advantage. The system allows the analysis of the costs and benefits of such management imposed strategic objectives.
[0003] Two major techniques for handling uncertainty in algorithms are Stochastic Programming [BGN*04] [SAG*03] and Robust Programming [BT06] [BN98]. The word “uncertainty” is taken to mean insufficient knowledge—all parameters cannot be specified completely. Stochastic Programming uses a probabilistic formulation of the world and single/dual stage optimization (with recourse) can be used to optimize expected values of the size, capacity, cost etc. The probability distribution that is assumed affects the outcome of the result and the distribution is difficult to estimate in practice. Robust programming assumes a set of scenarios (a scenario is a set of values for all the parameters), and optimizes the worst-case value of the metric over the set of scenarios. The limitation of Robust Programming is the generation of set of scenarios. Prior work in this field has extended and applied the robust programming formulations in the context of supply chains, credit risk, and finance and so on. This prior work mitigates the scenario specification difficulty, by specifying sets of scenarios as a hierarchical set of ensembles, each ensemble being specified by linear or in general convex constraints, these constraints having domain specific meaning. These ensembles provide a framework for decision support—determination of relationships between ensembles provides a framework for analyzing the relationships between different sets of assumptions about uncertainty. The proposed invention finds the relationships between these ensembles (that drive the robust optimization) and also, presents a visualization technique, which is useful in decision support.
[0004] Robust programming in the simplest form adds uncertainty to an optimization problem specified as a linear program (this formulation encompasses many optimizations, including path optimizations, flow optimizations, topological optimizations, etc):
[0000] MinC t X
[0000] Ax<=b
[0000] The uncertainty can be in the elements of matrix A, right hand side b, or cost coefficients C. These uncertainties represent limited knowledge about system parameters (e.g. future demand), and the optimization has to be the best taking all these possibilities into account. It is easy to show that all these uncertainties can be represented by constraints on A only, keeping C and b fixed [BT06]. Different assumptions about the uncertainties on the matrix elements A ij lead to different classes of problems, ranging from linear programming itself to quadratic/Second Order Cone Programming (SOCP)/Semi-Definite Programming (SDP) formulations (in cases of quadratic constraints) [BT06].
[0005] In a large class of applications, the constraints on the matrix elements, cost coefficients, right hand sides, etc. are linear (or quadratic) constraints. For example, in supply chains, the R.H.S b represents demands, which have to be often forecasted. Aggregates of these demands, differences between related demands/sets of demands etc can be forecasted better than each individual element, leading to linear constraints [PA03]. In such cases, the robust programming problem is to optimize the metric under linear (or quadratic) constraints on the matrix elements). In general this results in upper/lower bounds on the metric as the parameters vary satisfying the constraints. These bounds can be determined using techniques of convex optimization developed in the last decade by [BT06] [BN98] [BN99] [BN00].
[0006] Clearly, the bounds produced by robust optimization techniques are valid for only the particular constraint set assumed—the specific ensemble of scenarios is illustrated in FIG. 1 of the accompanying drawings (better and more illustrative diagram, with multiple polytopes and associated bounds—maybe show the contour lines of C T x, also show a simple example right here with 2 goods). Different ensembles (sets of constraints) will result in general in different answers. Comparison amongst different answers requires both qualitative and quantitative comparison amongst the ensembles, which is handled using polytope geometric algorithms. Qualitative comparisons are set-theoretic—subset, intersections and disjointness, reflecting more specific assumptions, overlapping assumptions, and totally separate assumptions about the future respectively. Quantitative comparisons are handled using information theoretic concepts.
SUMMARY OF THE INVENTION
[0007] The present invention has several advantages, including the ability to handle ensembles composed of an infinite number of scenarios, representing an infinite set of assumptions about the future. Additionally, the use of polytope (in general convex body) geometric algorithms enables one to compare different sets of assumptions both qualitatively (using subset, intersection, and disjointness relations between two polytopes) and quantitatively (polytope volume) facilitating decision support. The main challenge is dimensionality of the polytopes (or in general convex bodies)—large problems can have millions of dimensions, challenging the fastest polytope geometry algorithms known to date. This invention illustrates the applicability of existing computational geometry algorithms, for the comparison and visualization of different polytopes corresponding to different sets of future assumptions, for medium scale problems with 1000's of variables. Described herein are key elements of a software package based on the above, for decision analysis and optimization. These techniques will become more useful as more powerful computational geometry algorithms are developed.
[0008] Visualization of sets of N-dimensional Convex Polytopes is extremely challenging. In classical set theory, the relation between polytopes treated as sets (subset, disjointness, intersection) is shown using Venn diagrams. This cannot be meaningfully applied for representing the relationship among high-dimensional polytopes, due to complex relationships encountered between polytopes, and associated clutter in the Venn Diagram. There is a parallel coordinate technique [ID90] [C195], which represents an N-dimensional object in 2-dimensional space, but this is not intuitive to the decision maker, and looses information. Moreover, the problem that has been dealt here has polytopes specified by linear constraints, the vertices of which are unknown. Computing the vertices [AD00] is itself an exponential process, and does not scale to thousands to millions of dimensions. There is a visualization scheme that is presented in [CI01] to find the solution of a 3-D linear programming problem, but that is meant to understand the solution process and not the relations among polytopes. Work at Cornell University [CU] on supply chains, deals with non-linear relationships among thousands of parts at hundreds of location using animations and not with the representation of relationships among convex polytopes representing uncertainty. The contribution herein, is applying relational algebraic concepts to find relations between polytopes and also a visualization technique for these relations. This contribution enables different sets of assumptions about the future to be compared in a global manner, without comparing only sample points belonging to different sets (local comparison). As such it offers a powerful tool for decision analysis and optimization under uncertainty, a topic of current interest.
BRIEF DESCRIPTION OF DRAWINGS
[0009] FIG. 1 illustrates a Convex Polytope in which each of the point inside the polytope forms a scenario;
[0010] FIG. 2 illustrates a subset;
[0011] FIG. 3 illustrates an intersection;
[0012] FIG. 4 illustrates disjoint sets;
[0013] FIG. 5 illustrates the volume of information content;
[0014] FIG. 6 illustrates the supply chain;
[0015] FIG. 7 illustrates a graphical visualization for algorithm for subset;
[0016] FIG. 8 illustrates a graphical visualization for algorithm for intersection;
[0017] FIG. 9 illustrates the runtime for intersection relation between constraint sets;
[0018] FIG. 10 illustrates the runtime for subset relations between sets;
[0019] FIG. 11 illustrates runtime for K-way intersection relations between sets;
[0020] FIG. 12 illustrates the input analysis phase; and
[0021] FIG. 13 illustrates the Time Series of Relations, together with inter-polytope max distances.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Qualitative and Quantitative Set Comparisons
[0022] Qualitative Set theoretic Relationships:
[0023] Qualitative set theoretic relationship between polytopes is illustrated below. FIGS. 2 , 3 and 4 show polytopes in 2-Dimensions, usually the constraint sets specified for large applications consists of tens of thousands or even million variables forming an N-dimensional polytope. While the present work is specified in terms of linear constraints and associated polytopes, the results are valid for general convex constraints and associated N-dimensional convex bodies, provided more sophisticated algorithms based on convex optimization (REF) are used.
[0024] Subset: This is the case when one of the polytope forms a subset of other (FIG. 2 )—the larger polytope includes all the possibilities about the future corresponding to the smaller, and may have some more also. In this case, the volume of information content (explained in section 3.2) in the larger polytope is more than the smaller one, which implies that larger polytope is more uncertain. By adding more constraints to the larger polytope, more information is added and hence uncertainty decreases.
[0025] Intersection: In this case, the polytopes intersect each other (FIG. 3 )—there are some commonalities that exist between the assumptions about the future represented by the polytopes. These commonalities refer to those sets of parameters that satisfy both the constraint sets.
[0026] Disjoint: The polytopes do not intersect; they are disjoint sets ( FIG. 4 ). In other word s, there is no commonality amongst assumptions represented by these polytopes.
Quantitative Information Estimates:
[0027] FIG. 5 shows two scenario ensembles,—A and B, B being a subset of A. Bounds on the metric of interest as the parameters varying inside B clearly are tighter than the bounds that vary inside the larger polytope A. The amount of information represented by the polytopes A and B, can be quantified as follows. Assume that in the lack of information, all scenarios in large region R are equally probable. R is taken to be of finite volume (for simplicity initially) V max . Then the constraints specifying any convex polytope CP (e.g. A) specify a subset of Region R, of Volume V CP . The amount of information provided by the constraints specifying the convex polytope can be equated to the Shannon [Sha48] surprisal of scenarios falling within CP given by
[0000]
I
=
log
2
(
V
max
V
Cp
)
bits
(
1
)
[0028] Relative comparison of the information content among different polytopes (Say for A and B in FIG. 5 ) can be done by comparing their relative volume as follows
[0000]
I
1
-
I
2
=
log
2
(
V
CP
2
V
CP
1
)
(
2
)
[0029] An algorithm to compute the volume of convex bodies is given in [LV03]. This algorithm is of the Order O(n 4 ), which does not scale to the problem addressed herein, since problems with 1000's of dimensions are commonplace. However, most meaningful and easily interpreted ensembles are composed of simple linear constraints, with sums of parameters, differences, etc, and special techniques for such structured polytopes can be used to scale to the large number of dimensions encountered in this application. Due to the large number of dimensions, it is also evident that the volume cannot be represented using a reasonable number of digits; rather its logarithm is used.
An Example—Supply Chain Management
[0030] The concepts explained above are applied by taking Supply chain as an example. A typical supply chain consisting of supplier, factory and market is as shown in FIG. 6 . It may consist of other intermediate nodes like warehouse, dealers etc. A supply chain necessarily involves decision about future operations like demands, supplies etc. However, forecasting for large number of commodities is difficult, especially for new products. Techniques of robust optimization are applied, by specifying the ensembles using linear constraints (which are the aggregates or the differences) on demand variables, supply variables, production variables, warehouse capacity variables etc. The number of linear constraints is typically smaller than the number of variables. By specifying the linear constraints on demand, it is possible to find the optimum supplies needed through the techniques of robust optimization [BT06] [BN98] [BN99] [BN00]. As shown in FIG. 6 , d 1 , d 2 and d 3 are the demands that are uncertain. For ease of explanation, Let us consider only demands d 1 and d 2 . For specificity, assume that d 1 is one brand of soap and d 2 is its competitor. Now, these demands can be expressed in the form of linear constraints as follows
[0031] 1. Limits per demand, e.g. for demand 1
[0000] Min 1<=d1<=Max1. This specifies only a priori knowledge about the limits on demand 1 (for toothpaste and/or its competitor).
[0033] 2. Substitutive demands
[0000] Min2 <=d 1 +d 2<=Max2 As the demand for soap one increases, the demand for the other has to decrease so as to maintain the constraints with the specified limits, reflecting total industry size constraints.
[0035] 3. Complementary demands
[0000] Min3 <=d 1 −d 2<=Max3 As the demand for one brand of soap increases, the demand for other brand also has to increase for the difference to be within the specified limits such a constraint reflects a competitive response of the second brand to the first brands increase.
[0037] These linear constraints form a polytope. There may be several different polytopes corresponding to different constraint sets. For example, consider the following three constraint sets:
Case 1: Constraint Set—CP 1
[0038] 200 <=d 1 +d 2<=400
[0000] 0 <=d 1 −d 2<=200
[0000] 0 <=d 2 −d 1<=200
Case 2: Constraint Set—CP 2
[0039] 250 <=d 1 +d 2<=350
[0000] 0 <=d 1 −d 2<=100
[0000] 0 <=d 2 −d 1<=100
Case 3: Constraint Set—CP 3
[0040] 250 <=d 1 +d 2<=350
[0000] 0 <=d 1 −d 2<=100
[0000] 0 <=d 2 −d 1<=300
[0041] Now, it is evident that CP 2 is a subset of CP 1 and also CP 2 is subset of CP 3 , where as CP 3 intersects with CP 1 . The notion of subset says that one is more specific than the other, implying one is less uncertain than the other and the intersection says that there are a set of commonalities among the two sets. Now, these set theoretic relationships among these polytopes are found by applying methods described in section 5 and represented graphically as mentioned in section 6. This two dimensional example can be solved by most LP solvers, but in large applications like supply chains, millions of variables exist, necessitating solvers like CPLEX.
[0042] Quantification of the relative information content between the sets CP 1 and CP 2 , CP 2 and CP 3 , and between CP 3 and CP 1 is done using algorithms for polytope volume (Equation 2) and the results are given below (volume here is the area of the polytope in 2 dimensions).
Volume of CP 1 −V CP1 =38500 square units. Volume of CP 2 −V CP2 =10125 square units. Volume of CP 3 −V CP3 =20625 square units. Information in CP 2 relative to CP 1 :
[0000] I 1 −I 1 =log 2 V CP1 /V CP2 =1.92 bits Information in CP 2 relative to CP 3 :
[0000] I 2 −I 3 =log 2 V CP3 /V CP2 =1.02 bits Information in CP 1 relative to CP 3 :
[0000] I 3 −I 1 =log 2 V CP1 /V CP3 =0.9 bits
[0049] This quantifies the relative uncertainty in different polytopes.
Qualitative Decision Support—Relational Algebra of Convex Polytopes
[0050] A set theoretic relational algebra for polytopes (which generalizes to convex bodies) can be developed as follows. This relational algebra can be used in a query language for decision support as shown below.
[0051] Query Language: Let A 1 , A 2 , A 3 . . . denote polytopes (or convex bodies) corresponding to different sets of assumptions about the future. A query can be written in sum-of-products form as
[0000] Q=ΣΠA i1 A i2 A i3 . . .
[0000] Where the product operation is intersection of polytopes and the sum the union (this results in non-convex bodies, and has to be handled carefully by enumeration for small number of terms). The subset and disjointness operations can also be specified using intersection as shown below in Algorithm No. 1. For example, the query—Is there at least one future possibility in Ensemble A, or is there one in the intersection of B and C and D is answered by the satisfiability of Q
[0000]
Q=A+BCD
[0052] Decision support involves answering the satisfiability of Q for at least one point in the polytopes, corresponding to one possible realization of the future as per the assumptions outlined by Q.
[0053] Executing this query requires fast techniques for fundamental set-theoretic operations of polytopes—pair wise intersection, subset, and disjoint ness, and their generalizations to multiple polytopes, which is shown as follows (Pair wise). Note that all three operations are reduced to finding the intersection below:
[0054] First, suppose P and Q(P c and Q c are the complement of the sets P and Q) are two sets then
1 If P∩Q=φ, then P and Q are disjoint 2 If P∩Q c =φ and Q∩P c ≠φ then P is a proper subset of Q 3 If QΩP c =φ and P∩Q c ≠φ then Q is a proper subset of P
[0058] Based on the above Algorithm No. 1 results,
Algorithm No. 1: Subset, Intersection and Disjointness Among Convex Polytopes
[0000]
1. Take two constraint sets 1 at a time (say P and Q). 2
2. Combine the linear inequalities from both P and Q to form a new set R. Check for feasibility using an LP Solver 3 1 The terms Constraint sets and Convex Polytopes are used interchangeably 2 Each constraint set consists of linear inequalities and both the constraint sets are not the same, if it is same then it can be checked before the executing the algorithm. 3 QSOPT, and the industry standard CPLEX were both used in the present work.
3. If R is Infeasible then P and Q are disjoint sets, stop. Else, Continue.
4. Take each inequality from set P, reverse the inequality sign and add it to set Q, to form a set Q′.
5. Check for the feasibility of set Q′ at step 4.
6. If Q′ is infeasible for every inequality added from P to Q with inequality sign reversed then Q is subset of P.
7. If Q′ is feasible for at least one inequality added from P to Q, then Take each inequality from set Q, reverse the inequality sign and add it to set P, to form a set P′.
8. Check for the feasibility of set P′ at step 7.
9. If P′ is infeasible for every inequality added from Q to P with inequality sign reversed, then P is subset of Q
10. Again, if feasibility exists for at least one inequality, then P and Q intersect each other.
[0069] The proof of Algorithm No. 1 is simple and omitted for brevity. The Order of the algorithm is O(m+n) calls to a linear programming (LP) Solver, with m and n being the number of linear inequalities in the two constraint sets P and Q respectively. If there are p constraint sets, then the Order of the algorithm will be O((m+n)p 2 ) to check the relationship between all pairs. The algorithm can of course be speeded up by using special structure in the constraints, etc.
[0070] In passing, it may be noted that the large number of computational geometry algorithms that find the intersection of polytopes predominantly use vertices and/or points to compute the intersection [MP78], (which can also be used to find the subset). However, the number of vertices is exponential in the number of constraints, which makes these methods inapplicable in the present application domain. One is unaware of similar work connecting the fields of computational geometry and decision support, at least in these applications.
Algorithm No. 2: Multi-way Disjointness, Intersection, and Subset
[0071] Algorithm No. 1 yields a yes-no answer, but does not yield a representation of the intersection of two polytopes (if non-null). This representation is required for a cascaded query (A∩B∩C). Algorithm No. 3 explicitly constructs this representation, allowing a multiple way intersection to be determined. The algorithm basically determines which of the constraints defines the intersection, and which do not.
Algorithm No. 3: (Intersection Representation) Finding the Minimum Number of Linear Equations Forming the Intersection
[0000]
1. Take two constraint sets at a time (say P and Q). *
2. Take each inequality from set P, reverse the inequality sign and add it to set Q to form set Q′.
3. Check for the feasibility of set Q′ at step 2.
4. If set Q′ is feasible, store the inequality (This inequality is forming intersection with the other polytope that is added from P to Q).
5. Repeat steps 2-4 by adding each inequality from set Q to set P, which forms set P′.
* Each constraint set consists of linear inequalities and both the constraint sets are not same.
[0077] The algorithm is of the Order O(m+n) call to the LP Solver where m and n is the number of constraints in P and Q respectively. The estimation of polytope volume to yield quantitative information content estimates is the topic of forth coming publications—sampling methods through domain specific methods can be used.
Graphical Visualization of Relations
[0078] Once the relationships between all pairs of polytopes is determined, using the algorithm No. 1, these relationships among the constraint sets are graphically represented using the following conventions (see FIG. 7 ).
1. Each constraint set is represented as a square box. They are arranged in a circular layout. 2. A directed arrow is used to represent that one constraint set is the subset of the other. For example, as shown in FIG. 7 constraint set 3 is subset of constraint set 2. 3. A double directed arrow is used to represent that one constraint set is intersecting with the other. For example, constraint set 1 intersects constraint set 2 in FIG. 7 4. If the constraint sets are equal then a straight line from one set to another is used to represent the relation of equality. Constraint set 3 and constraint set 0 are equal as shown in FIG. 7 . 5. Disjoint constraint sets are not connected by any lines.
[0084] The graph obtained from algorithm No. 1 might be non-planar (usually for more than 5 constraint sets), but this is inevitable when representing topological properties of high-dimensional spaces in spaces of lower dimension. Multi-way intersection results in cliques of double arrows—this is shown in FIG. 8 for a 3-way intersection. Determination of multiway intersections is done under user control, since the number of possible combinations is exponential in the number of sets of constraints N and the order of intersection M—the number of combinations of M constraint sets out of N total constraint sets.
Experimental Results:
[0085] A Java implementation of algorithm No. 1 was developed, and tested using polytopes resulting from a supply chain optimization. Linear constraint sets (considering demand as variables) are generated randomly by varying the number of variables and number of constraints. The algorithm was profiled on IBM Machine with Intel 1.4 GHz, 512 MB RAM, and a disk speed of 4200 rpm. The readings have been taken by varying the number of—constraint sets, variables and inequalities. FIG. 9 and FIG. 10 shows the runtime considering two, three and four constraint sets (ensembles). Note that four ensembles correspond to four sets of assumptions about the future, each of which involves thousands to millions of variables, and many tens of constraints amongst them. FIG. 9 shows the time to determine all pair-wise intersections between the polytopes, if present, FIG. 10 , likewise determines which ensemble is a subset of another, if such a relation exists. It can be seen that the time taken by the algorithm for four intersecting sets with 1000 variables and 62 constraints each is around 20 seconds and the time taken for 4 sets which are subset of each other is around 9.3 seconds (with 1000 variables in each set and 62,52,42,32 constraints in four sets respectively). Other metrics can be evaluated from the figures and Table 1. FIG. 11 shows runtime for the algorithm No. 2, it can be seen that for a single 4 way intersection the time taken for 1000 variables is around 5.5 minutes and for a single 3 way intersection the time taken is around 80 seconds. Larger problems with millions of variables can potentially be handled using high speed large-scale multiprocessors.
[0000]
TABLE 1
Time Taken for Different sets.
Standard
Deviation
Re-
Mean Time for
Deviation
from
sult
Algorithm
from Mean
mean as
No
Forms
(seconds)
(seconds)
% age
1
Two
1.145 (1.57)
0.097 (0.166)
8.5% (10.6%)
Intersecting
sets 1a
2
Two Subset
0.854 (1.28)
0.153 (1.155)
17.92% (18.2%)
sets 2a
3
Four
20.47 (21.98)
0.88 (1.14)
4.56% (5.61%)
Intersecting
Sets 1b
4
Four Subset
9.38 (9.7)
1.38 (1.388)
14.17% (14.24%)
sets 3##
Figures in bracket indicate the overall time or % age for the algorithm including Visualization
1 62 in each set
2 62 and 52 in each set
3 62, 52, 42, 32 in each set
a No. of Variables - 100
b No. of variables - 1000
Embodiment in a Supply Chain Network Analytics Package
[0086] Based on the above description, an embodiment in a supply chain network analytics package, possibly operating in real time, is described herein. We shall refer to this as the SCMA package. A critical problem in the practice of supply chain analysis/optimization is that different assumptions result in different answers, and one is at a loss how to compare them together. SCMA enables us to thoroughly analyze this dilemma, both at the assumption (input) stage, and at the output stage.
[0087] The basic operation of SCMA is as follows. (Refer FIG. 12 ).
[0088] First, a set of constraints is created, based on either
User Input 106 , creating constraints in constraint specification/generation module 103 . Prediction 107 from historical time series data, plus a-priori information about the constraints. In other language, the input analysis engine 119 looks at the database 104 and creates an model of its contents—these are the constraints derived from the point data. In this embodiment, the invention is a database-modeling engine, which transforms point data into constraints. Transformation 102 from me-existing constraints, preserving information content (or increasing/decreasing it).
[0092] Each set of constraints in polytope module 100 (forming a polytope if all constraints are linear) is an assumption about the supply chains operating conditions, exemplarily in the future. Multiple sets of constraints can be created (CP 1 , CP 2 , CP 3 , in polytope module 100 ), referring to different assumptions about the future.
[0093] Then, SCMA's analysis, done in the input analyzer 119 is performed using the following steps (not necessarily in this order)—
1. Analysis of each assumption (polytope) by itself for information content—this is the information estimator 108 as described in our earlier PCT application published under No. WO/2007/007351. 2. Analysis of different assumptions (polytopes) in extended relational algebra module 109 to determine if
Are two assumptions totally different—disjoint sets? Do they have something in common—intersecting? Is one a superset of the other, which is more general?
This is done in SCMA, which shows a graphical representation of answers to these questions (as in FIGS. 7 and 8 ) for a variety of polytopes representing different assumptions about the supply chain's operation. 3. Analysis of Sequences of constraints:
In the case of constraints sets (polytopes) evolving with time, or other index variables, SCMA's extended relational algebra module 109 , plots the evolution of the relations between the polytopes. While this can be solved by repeatedly calling the basic algorithms outlined above, these can be considerably speeded up by using methods of incremental linear programming, wherein small changes in constraints sets do not necessarily change the basis globally. FIG. 13 indicates three polytopes evolving with time and the relations change as a, b, c are intersecting in the first two time steps, but a is disjoint and b and c are intersecting in the third step (the convention of FIGS. 7 and 8 is not used for clarity, and the relationships are stated in textual form in FIG. 13 ). The distance min/max/between analytic, centers is depicted by lines between a, b, and c, and continuously shown increasing and can be determined by methods of convex optimization as described earlier. The sequence depicted need not be with respect to time, but can be with respect to product id, node id, etc.
4. Metric-based Analysis: In addition to set theoretic properties, metric-based properties (distance, volume) can also be evaluated, to obtain further information. We refer to this facility as the extended relational algebra engine.
a. In the case of polytopes A and B, it is of interest to determine how far apart they are. This can be solved by the linear program given below. C A /B A is the constraint set/right hand side for A, C B /B B for B, and X is a point in A and Y in B.
[0000] A={X:C A X<=B A }
[0000] B={Y:C B Y<=B B }
[0000] Min∥X−Y∥
[0000] C A X<=B A
[0000] C B Y<=B B Maximizing instead of minimizing finds the points in the two polytopes farthest from each other, and this can be used to normalize the minimum distance. Instead of the min of absolute value another norm like the L 2 norm can be used also, using convex optimization. Note that this can be used even if the polytopes are intersecting (min is always zero, and max can be determined) In addition to the min/max distance between polytopes, the distances between two random points inside each, distance between analytic centers (using convex optimization), distances between each polytope and any or all the constraints of the other, etc can all be found using techniques well-known in the state-of-art (having runtimes polynomial in the problem size). b. In the case of A being a subset of B, we need to know how smaller (relatively) A is compared to B. This can be estimated from volume estimation methods, comparing the volume of A to B by sampling algorithms c. In the case of A and B being neither disjoint nor subsets, we would like to know what percentage of A and B are in the intersection, which can be analyzed using volume estimation methods, using either A or B as a normalizing volume.
[0108] In addition to the distances and volumes, projections of the polytope along the axes or random directions can be used to determine their geometric relations.
[0109] The relational algebra relations (subset, disjoint, intersecting), together with associated min/max distances between polytopes, and their volume, form the basis for input analysis. FIG. 13 also has the distances marked.
[0110] In a real time supply chain, inputs are read from the SCM database 104 in FIG. 12 , which is updated in real time. The answers from input analysis can be used to trigger responses 111 in FIG. 12 , where exemplarily orders are triggered if stock levels are too low, or demand levels are high.
SCMA Database
[0111] SCMA operates on sets of constraints derived from exemplarily historical data in a database 104 in FIG. 12 . The constraints are arbitrary linear or convex constraints, in demand, supply, inventory, or other variables, each variable exemplarily corresponding to a product, a node and a time instant. The number of variables in the different constraints (constraint dimensionality) need not be the same. Zero dimensional constraints (points) specify all parameters exactly. One-dimensional constraints restrict the parameters to lie on a straight line, 2-D ones on a plane, etc.
[0112] These constraint sets are the atomic constituents of an ensemble of polytopes, which are made using combinations of them, as shown in the examples below:
P 1 =C 1 AND C 2 P 2 =C 1 AND C 3 P 3 =P 1 AND P 2
[0116] Note that the third polytope is succinctly written as the intersection of P 1 and P 2 . The set of all the polytopes (of various dimensions), together with the constraints forms a database of constraints, part of which is attached to polytope module 100 (but not shown to avoid cluttering the diagram), and part of which is in query database 110 . This database of constraints drives the complete decision support system. These constraints and polytopes can be time dependent also. The constraint database is stored in a compressed form, by using one or more of:
1. Standard Compression Techniques like Lempel-Ziv. 2. Optimizing Polytope Representation in terms of other polytopes, i.e. using the most succinct representation, determined using algebraic simplification.
[0119] Then these polytopes are analyzed to determine their qualitative and quantitative relations with each other, as outlined in the description above.
Database Optimizations.
[0120] In addition to one-shot analyses of relationship between polytopes, decision support systems have to support repeated analyses of different relations made up of the same constraint sets. Let A, B, C, D, and X be constraint sets (polytopes). Then in a decision support system, we would like to verify the truth of
[0000] A≠φ
[0000] B≠φ
[0000] C≠φ
[0000] A⊂B
[0000] A⊂C
[0000] B⊂C
[0000]
X=B×C
[0000]
D=A×X∪B
[0000] B ×( A×X )=φ
[0000] A ×( B×C )− D=B
[0121] One method is to explicitly compute these expressions ab-initio from the relational algebra methods presented in the thesis. However, the existence of common subexpressions between the X=B×C, and A×(B×C)−D enables us to pre-compute the relation X=B×C (this is an intersection of two constraint sets, which can be obtained by methods like those described in Algorithm 5.3), and use it directly in the relation A×(B×C)−D. Common sub-expression elimination methods (well known in compiler technology) can be used to profitably identify good common subexpressions. These methods require the costs of the atomic operations to determine a good breakup of a large expression into smaller expression, and these costs are the costs of atomic polytope operations (disjoint, subset, and intersection) as outlined in the description above. These costs depend of course on the sizes of the constraint sets—the number of variables, and constraints, etc.
[0122] These precomputed relations are stored in a query database 110 in FIG. 12 , and read off when required. The database is indexed by a combination of the expression's operators and operands, which is equivalent to converting the literal expression string into a numeric index, using possibly hashing. Caching strategies are used to quickly retrieve portions of this database, which are frequently used. Since the atomic operations on polytopes are time consuming, pre-computation has the potential of considerably increasing analysis speed. This pre-computation can be done off-line, before the actual analysis is performed.
[0123] We note that the relational algebra operators—subset, disjoint, intersection can be used at the conditions in a relational database generalized join. If X and Y are tables containing constraint sets (polytopes), the generalized join X Y, is defined as all those tuples (x,y), such that x (a constraint set in X) is a subet of, disjoint from, or intersecting y (a constraint set in Y) respectively. This extends the relational databases to handle the richer relational algebra of polytopes (or general convex bodies if nonlinear convex constraints are allowed).
Exemplary Application of SCMA
[0124] Below we give an example of the utility of the SCMA embodiment of this invention. Consider the task of optimizing a supply chain for unknown future demand. Depending on the future prediction model, the teams involved in the prediction, etc, very different answers can be obtained. For example, for expansion of a retail chain, some future assumptions are possibly:
The total sales of the company will increase by at least Rs 1000 crores to no more than Rs 2000 crores, AND The product mix will be no more than 5% different from what it is. AND The industry revenue will experience a minimum of 3% and a maximum of 10% growth.
OR
[0000]
The product mix will migrate by at least 10% to higher paying products, AND
The total disposable income available to spend on goods by the customers will not change by more than 10% AND
The industry profit will experience a minimum of 4% and a maximum of 20% growth.
The first set of assumptions is over variables (Company Sales, Product Mix, Industry Revenue. The second set is over variables (Product Mix, Consumer Disposable Income, Industry Profit). The only variable common is the Product Mix. Clearly optimization under these two sets of assumptions is likely to yield very different answers. Which is correct? The relational algebra engine helps us resolve this dilemma by examining first, if these two sets of assumptions have anything in common (intersecting), or are totally different (disjoint). Then the common set can be separated, and the differences examined for further analysis as outlined in the description.
REFERENCES
[0000]
1. [BGN*04] Benisch M., Greenwald A., Naroditskiy V., Tschantz M C., A Stochastic Programming Approach to Scheduling in TAC SCM , Proceedings of the 5 th ACM conference on Electronic Commerce, 2004.
2. [SAG*03] Santaso T, Ahmed S, Goetschalckx M, Shapiro A, A Stochastic Programming Approach for Supply Chain Network Design Under Uncertainty , Technical Report, School of Industrial & Systems Engineering, Georgia Institute of Technology, 2003
3. [BT06] Bertsimas Thiele. Robust and Data - Driven Optimization: Modern Decision - Making under Uncertainty . Tutorials in Operations Research, INFORMS, 2006.
4. [BN98] Ben-Tal, A., and Nemirovski, A., A Robust Convex Optimization. Mathematics of Operations Research, 1998.
5. [BN99] Ben-Tal, A., and Nemirovski, A., Robust Solutions to Uncertain Linear Programs , Operations Research Letters, Volume 25, August 1999.
6. [BN00] Ben-Tal, A., and Nemirovski, A., Robust Solutions of Linear Programming Problems contaminated with uncertain data , Mathematical Programming, 2000
7. [MP78] David E. Muller and Franco P. Preparata., Finding Intersection of Two Convex Polyhedra . Theoretical Computer Science, Vol. 7, 1978.
8. [CI01] Jean Pierre Charalambos and Ebroul Izquierdo, Linear Programming Concept Visualization , Proceedings of the Fifth International Conference on Information Visualisation, 2001.
9. [AD00] David Avis and Luc Devroye, Estimating the Number of Vertices of a Polyhedron , Information Processing Letters, February 2000.
10. [LV03] Lovász L., and Vempala S., Simulated Annealing in Convex Bodies and an O* ( n 4 ) Volume Algorithm , Proceedings of the 44th Annual IEEE Symposium on Foundations of Computer Science, 2003.
11. [ID90] Inselberg A., and Dimsdale B., Parallel Coordinates: A Tool for Visualizing Multi - Dimensional Geometry , IEEE Visualization Conf., 1990, 361-378.
12. [CI95] Chatterjee A., and Inselberg A., Visualizing multi-dimensional polytopes and topologies for tolerances, Doctoral Thesis, ACM, 1995
13. [Sha48] Shannon C. E., A Mathematical Theory of Communication , The Bell System Technical Journal, Vol. 27, 1948.
14. [PA03]. Prasanna G. N. S., and A Vishwanath, Traffic Constraints Instead of Traffic Matrices: Capabilities of a New Approach to Traffic Characterization, ITC, 2003.
15. [CU] Cornell University website for dynamic modeling of supply chain http://www.orie.cornell.edu/orie/research/casestudy/profile.cfm?id=6983. | Modern decision support methods handle uncertainty or hypothesis about operating conditions, using one of two techniques viz. probabilistic formulation and constraints based method, which is the subject of the present invention. A large number of applications use linear constraints to specify uncertainty. These linear constraints are the set of linear inequalities, which are used to define the demand/supply in the area of supply chains. The set of linear inequalities forms a polytope, the volume of which represents the information content. The present invention deals with the application of computational geometrical methods to find the set theoretic relationship—subset, intersection and disjointness among the polytopes and then present a visualization technique to represent these relationships among polytopes. This invention proposes a decision support system and method to visualize the relationship among the polytopes to help with decision support. A specific embodiment is a Decision Support System for Supply Chain Management. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a strand coating device, and more particularly to a head assembly for pressurized coating of optical fibers.
2. Description of the Prior Art
The coating of elongated strands of fiber material, such as glass fibers used in fiber optics, has been accomplished by a method referred to generally as the "open cup" method, which is illustrated and described in U.S. Pat. No. 4,419,958, issued Dec. 13, 1983 to Giacomo Roba. Utilizing such method, fibers of silica glass are passed in a downward direction through a mass of liquid resin contained in a reservoir which terminates in a converging outlet duct. The reservoir and outlet duct are referred to by Roba as the "nozzle". After the fiber emerges from the duct, its resin coating is allowed to set by drying or curing. To facilitate the insertion of the fiber under traction into the nozzle, the nozzle body of Roba is split into two parts with complementary cavities defining the passage.
In U.S. Pat. No. 4,510,884, issued Apr. 16, 1985 to Nathan B. Rosebrooks, there is shown and described a device for coating an optical fiber in which the coating material is supplied to chamber under pressure and the fiber strand is drawn downwardly through the chamber. Using the pressurized chamber, the Rosebrooks device facilitates the movement of the fiber through the device at a substantially higher rate of speed than is the case with a device of the Roba type.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a split coating head assembly for elongated strands, such as optical fibers, the assembly including first and second complementary mounting blocks, each mounting block having therein upper and lower half-dies, the dies defining therebetween a coating chamber in communication with a pressurized reservoir of coating material. The mounting blocks and upper and lower half-dies are joined together to form a substantially closed system, but are readily separable to permit cleaning, and/or removal of broken fibers.
With the above and other objects in view, as will hereinafter appear, a feature of the present invention is the provision of a coating head assembly for elongated strands, the assembly comprising a first mounting block, half-die means disposed in the first mounting block, a second mounting block, and half-die means disposed in the second mounting block, the mounting blocks being adapted to be joined together to join the half-die means together, the half-die means and the mounting blocks, when joined, forming a coating chamber, the assembly being adapted to have an elongated strand moved continuously therethrough, one of the mounting blocks being adapted to convey a coating material therethrough to the coating chamber to coat the strand during its continuous movement through the assembly.
The above and other features of the invention, including various novel details of construction and combinations of parts, will now be more particularly described with reference to the accompanying drawings and pointed out in the claims. It will be understood that the particular device embodying the invention is shown by way of illustration only and features of this invention may be employed in various and numerous embodiments without departing from the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference is made to the accompanying drawings in which is shown an illustrative embodiment of the invention from which its novel features and advantages will be apparent.
In the drawings
FIG. 1 is a top plan view of the coating head assembly, illustrative of an embodiment of the invention;
FIG. 2 is a side elevational view thereof;
FIG. 3 is a perspective view of the assembly, showing the first and second mounting blocks separated;
FIG. 4 is a perspective view of the assembly, shown disposed on a platen and shown in the closed position with means shown for retaining the assembly in the closed position;
FIG. 5 is a sectional view, taken along line V--V of FIG. 3;
FIG. 6 is a sectional view, taken along line VI--VI of FIG. 3; and
FIG. 7 is a sectional view, similar to FIG. 6, but illustrative of an alternative embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, it will be seen that an illustrative assembly includes a first mounting block 2, preferably of stainless steel, having a first recess 4 therein. Disposed in the first recess 4 is a first upper half-die 6 and, thereunder, a first lower half-die 8. Each of the first half-dies 6, 8 is provided with a tapered outlet 10, and is preferably of tungsten carbide. The first half-dies 6, 8 are machined to fit precisely in the first recess 4 and are permanently fixed therein by brazing material 12.
The first half-dies 6, 8 are spaced from each other in the first recess 4 to provide a first portion 14 of a coating chamber. The first mounting block 2 is provided with a passage 16 extending therethrough to the coating chamber first portion 14. A conduit 18 is fixed to the first mounting block 2 and is in communication with a pressurized source (not shown) of a selected coating material, for example an ultra violet light curable urethane acrylate, a thermally curable silicone and/or epoxy, or the like.
The first mounting block 2 is mounted on a platen 20 having an aperture 22(FIG. 2) therein, and is provided with a pair of protrusions 24 extending from a face portion 26 of the first mounting block.
The assembly further includes a second mounting block 32, preferably of steel, having a second recess 34 (FIG. 6) therein. Disposed in the second recess 34 is a second upper half-die 36 and, thereunder, a second lower half-die 38. Each of the second half-dies is substantially a mirror image of the first half-dies, upper and lower respectively, and the second half-dies are provided with tapered outlets 40 complementary to the tapered outlets 10 of the first half-dies. A brazing material 42 permanently fixes the second half-dies 36, 38 in the second recess 34.
The second upper and lower half-dies 36, 38 are spaced from each other in the second recess 34 to provide second portion 41 (FIG. 6) of the above-mentioned coating chamber.
The second mounting block 32 is provided with a pair of bores 44 disposed in a face portion 46 complementary to the first mounting block face portion 26. The bores 44 are adapted to receive the protrusions 24, to ensure proper alignment of the mounting blocks 2, 32, and thereby the respective half-dies.
The platen 20 is adapted to receive the second mounting block 32 thereon in opposition to the first mounting block 2. Joining of the two mounting blocks 2, 32 is accomplished by placing the mounting block face portions 26, 46 in abutting position (FIG. 4). The first and second upper half-dies 6, 36 are precisely aligned with each other such that they come together to form a complete upper die 6, 36; in like manner, joining of the first and second lower half-dies 8, 38 forms a complete lower die 8, 38, the upper and lower dies having outlets 10, 40 defined by the dies and in alignment with each other and with the platen aperture 22. The dies further form a coating chamber comprising the two chamber portions 14, 41.
The platen 20 preferably is provided with a mechanism for retaining the mounting blocks 2, 32 in tightly abutting relationship; as illustrated, the mechanism may be a screw 50 retained in a block 52 and adapted to impinge upon the moveable mounting block, i.e. the second mounting block 32.
In operation, the first and second mounting blocks 2, 32 are closed together about an optical fiber (not shown) which extends through the upper and lower tapered outlets 10, 40 and through the platen aperture 22. In closing, the protrusions 24 of the first mounting block enter the bores 44 of the second mounting block to accurately align the two half-die sets, and the two mounting block faces 26, 46 abuttingly engage. Turning the screw 50 serves securely to join the two mounting blocks with the optical fiber extending therebetween.
Referring to FIGS. 5 and 6 it will be seen that the lower half-dies 8, 38 are each chamfered to present a bevel surface 60 which effectively enlarges the coating chamber 14, 41, forming an enlarged annular gallery 62. The gallery 62 serves to distribute the coating material more uniformly around and onto the fiber. In some applications it is desirable to enlarge the gallery further, and such may be accomplished by extending the gallery into the mounting blocks, that is, by hollowing out portions 70 of the mounting blocks adjacent the gallery 62, as illustrated in FIG. 7.
By operation of valve means (not shown) connected to the above-referred-to pressurized reservoir of coating material, the material is caused to flow from the reservoir, through the conduit 18, the passage 16, and into the coating chamber 14, 41, and the gallery 62 (as well as the hollowed out portions 70 in the embodiment illustrated in FIG. 7), from whence the material impinges upon and coats the surgace of the optical fiber. The fiber is drawn vertically downwardly through the device, such that the fiber is continuously coated.
In the event of clogging of the device, breakage of the fiber, and the like, the operation is stopped, the screw 50 loosened, and the mounting blocks separated to provide quick and easy access to the coating chamber and tapered outlets. Because of the ease of cleaning and repairing, the "down" time of the device is minimal.
It is to be understood that the present invention is by no means limited to the particular construction herein disclosed and/or shown in the drawings, but also comprises any modifications or equivalents within the scope of the disclosure. | A split coating head assembly for elongated strands, the assembly comprising first and second mounting blocks with first and second die components respectively mounted therein, the die components defining therebetween a coating chamber which is in communication with a pressurized source of coating material, the die components forming upper and lower apertures for drawing of the strand vertically therethrough, and through the coating chamber. | 8 |
This is a Continuation application of application Ser. No. 08/397,486, filed on Mar. 2, 1995 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a substrate processing apparatus in which a plurality of substrates stored in a cassette are taken out of one by one to be transported to a plurality of processing units for being processed in said processing units serially.
2. Description of the Background Art
As a substrate processing apparatus in which a plurality of substrates stored in a cassette are taken out of the cassette one by one, and transported to a plurality of processing units arranged serially in a predetermined order to be processed, an apparatus of a flow type is known. In this type of substrate processing apparatus, a loading section, a processing section including a plurality of processing units, and an unloading section are arranged in a predetermined transport path. Each of substrates stored in the cassette is taken out of the cassette one by one, and put on a transporting mechanism having a plurality of transporting rollers. The substrate put on the transporting mechanism is transported serially through said plurality of processing units to be processed serially in each of said processing units. The substrate transported through all of said processing units is serially stored in a cassette located in the unloading section.
In this type of substrate processing apparatus, each substrate must be transported through each of the processing units in the order determined by the arrangement of the processing units. Hence, it is difficult to skip some processing units or to change the order of the processing units. Further, the substrate processing apparatus of the flow type is too long along the transport path, since the loading section, a plurality of processing units, and the unloading section are arranged along it.
To overcome the disadvantage of the flow type substrate processing apparatus, another type of substrate processing apparatus is proposed in U.S. Pat. No. 4,985,722. In this type of substrate processing apparatus, a loading/unloading section, an interface mechanism for taking out of a substrate stored in a cassette put on the loading/unloading section and for taking a processed substrate into a cassette put thereon, a conveying mechanism for transporting the substrate taken out by the interface mechanism, and a plurality of processing units, are provided. The conveying mechanism can move along a transport path, and the plurality of processing units are arranged both sides of the transport path. Thus, a substrate taken out of the cassette by the interface mechanism is delivered to the conveying mechanism, and inserted to each of the plurality of processing units in a predetermined order by the conveying mechanism. The substrate processed by all of the processing units is transported by the conveying mechanism to the interface mechanism, and supplied to the cassette in the loading/unloading section by the interface mechanism.
The conveying mechanism of the substrate processing apparatus disclosed by U.S. Pat. No. 4,985,722 can directly supply the substrate to all of the processing units and can take the processed substrate out of all of the processing units. Thus, in this apparatus, it is easy to skip some processing units or to change the order of the processing units, if necessary. Additionally, the length of whole apparatus can be reduced, because all of the processing units are arranged both sides of the transport path.
However, all of the substrates taken out of the cassette by the interface mechanism should be delivered one by one to the conveying mechanism, and all of the processed substrates should be delivered one by one from the conveying mechanism to the interface mechanism. It makes the apparatus more complex. Furthermore, the apparatus is large since both the interface mechanism and the conveying mechanism have a respective transport path along which the substrate is transported.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a substrate processing apparatus having a simple construction and a small transport path and which makes it easy to skip some processing units or to change the order of processing units.
The present invention relates to a substrate processing apparatus for transporting a plurality of substrates stored in a cassette serially one by one to a plurality of processing units in each of which a substrate set therein is processed by respective manner, comprising: cassette storing means for storing a plurality of cassettes, each of which is capable of storing a plurality of substrates, said plurality of cassettes being arranged in a predetermine direction; processing means, including a plurality of processing units, for processing the substrate in a predetermined manner, said plurality of processing units being arranged parallel to said predetermined direction; and transporting means, disposed between said cassette storing means and said processing means, for transporting the substrate stored in said cassette in the cassette storing means to one of the processing units in the processing means, and for transporting the substrate processed by said processing means to the cassette.
According to the present invention, a single transport path for transporting a substrate between the cassettes and a plurality of processing units, is arranged between the cassette storing means and the processing means. Hence, it is possible to skip some processing units or to change the order of processing units easily, with simplifying the construction of the apparatus. Furthermore, the single transport path causes to reduce the space for transporting the substrate.
These and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a substrate processing apparatus according to a preferred embodiment of the present invention;
FIG. 2 is a plan view of the apparatus of FIG. 1;
FIG. 3 is a perspective view of a transport part;
FIG. 4 is a plan view showing an operation of the substrate processing apparatus of FIG. 1;
FIG. 5 is a plan view of a substrate processing apparatus according to a modification of the present invention; and
FIG. 6 is a plan view of a substrate processing apparatus according to other modification of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a perspective view of a substrate processing apparatus according to a preferred embodiment of the present invention, and FIG. 2 is a plan view of the apparatus of FIG. 1. The illustrated apparatus is used to clean a substrate, and comprised of a cassette storing system 1, a processing system 2 and a transporting system 3.
The cassette storing system 1 includes three cassette mounting portions 11 which are arranged in a direction X. Each cassette mounting portion 11 is for receiving a cassette 4 which can contain a plurality of substrates (for example, substrate), twenty-five. When an AGV (auto guided vehicle) not shown, moves to the substrate processing apparatus and mounts the cassettes 4 onto the respective cassette mounting portions 11 to arrange three cassettes 4 in the direction X, it is possible to unload or load substrates from or into the cassettes 4 by the transporting mechanism 3. In short, the cassette storing system 1 functions as both the substrate supplying part and the substrate receiving part of the conventional substrate processing apparatus. In FIG. 1, generally noted at 12 are recesses in which each cassette 4 is transferred between the substrate processing apparatus and the AGV.
The processing system 2 includes a brush module 21 for cleaning both surfaces (or only the back surface) of a substrate and a spin part 22 for cleaning the surfaces of the substrate while spinning the substrate. The brush module 21 and the spin part 22 are arranged to face each other at a certain distance from the cassette storing system 1 in a direction Y but to be approximately parallel to the direction X in which the cassettes 4 are arranged. Above the brush module 21, a UV lamp house 23 is disposed which performs ashing of organic substances on the upper surface of the substrate by irradiation of ultraviolet light, i.e., dry cleaning. Thus, a plurality of the processing units (the brush module 21, the spin part 22 and the UV lamp house 23 will be each hereinafter generally referred to simply as "processing unit.") are disposed in the processing system 2. Thus, a substrate is transported to each of the processing units in an appropriate order so as to be cleaned. In this embodiment, on the back side of the processing system 2 with respect to the cassette storing means 1, a transport hand 5 is disposed to transport a substrate from the brush module 21 to the spin part 22 as shown in FIG. 1.
FIG. 3 is a perspective view of the transporting system 3. The transporting system 3 is disposed in a transport space 6 (FIGS. 1 and 2) between the cassette storing system 1 and the processing system 2. In the transport space 6, a guide rail 31 (FIG. 3) is fixed to a bottom portion of the substrate processing apparatus to extend in the direction X. A base 32 engages the guide rail 31 and is capable of moving back and forth in the direction X. An X-direction drive mechanism (not shown) is linked to the base 32. Actuated by an instruction from a control system (not shown) which controls the entire apparatus, the X-direction drive mechanism moves the base 32 in the direction X.
A triaxial transport robot 33 is fixed to the base 32. The X-direction drive mechanism drives the transport robot 33 to move back and forth along the arrangement of the cassettes 4 and along an arrangement of processing units which are disposed in the processing system 2 so that the transport robot 33 is moved between desired ones of the cassettes 4 and desired ones of the processing units.
The transport robot 33 includes a column 35 which may be extended from a robot body part 34 in a vertical direction Z. Linked to a Z-direction drive mechanism (not shown), the column 35 extends and retracts in the vertical direction Z when the Z-direction drive mechanism is driven by an instruction from the control system. One end of a first arm 36 which extends in a horizontal direction is attached to a tip portion of the column 35 so as to be freely rotatable about a rotation axis A1. One end of a second arm 37 is linked to the other end of the first arm 36 for free rotation about a rotation axis A2, while one end of a hand 38 is linked to the other end of the second arm 37 for free rotation about a rotation axis A3. The transport robot 33 includes a motor (not shown) which rotates the first arm 36 about the rotation asix A1. A link mechanism is disposed between the first arm 36 and the second arm 37, and the other link mechanism is also disposed between the second arm 37 and the hand 38. Thus, if the first arm 36 is rotated by the motor, the second arm 37 is also rotated about the rotation axis A2 by the link mechanism in relation to the rotation of the first arm 36, and the hand 38 is further rotated about the rotation axis A3 by the other link mechanism in relation to the rotation of the second arm 37. The other end of the hand 38 includes a plurality of suction holes (not shown). Due to suction force applied through the suction holes, a substrate is held on the hand 38.
The transport robot 33 can move the hand 38 in three-dimensional directions in accordance with an instruction from the control system while holding a substrate on the hand 38 by suction force. The hand 38 with a substrate held thereon stops in front of a selected one of the cassettes 4 or a selected one of the processing units, and then loads or unloads the substrate into or from the selected cassette or unit. For example, when an instruction is supplied to the transport robot 33 which has stopped in front of the nearest cassette to an operation panel 7 of the control system as shown in FIG. 1, the transport robot 33 can remove a substrate from this cassette 4.
Although the X-direction drive mechanism drives the base 32 which is movable back and forth in the direction X along the guide rail 31, and as a result, the triaxial transport robot 33 which is fixed to the base 32 transports a substrate in three-dimensional directions in the transporting system 3 of the embodiment. However, the structure of the transporting system 3 is not limited to this. As far as being able to transport a substrate among the processing units and between the cassettes 4 and the processing units, the transporting system 3 may have other structures.
Now, an operation of the substrate processing apparatus having such a construction above will be described in reference to FIG. 4. Here, it is assumed that the cassette 4A which is nearest to the operation panel 7 is used to store unprocessed substrates and the cassette 4B which is farthest from the operation panel 7 is used to store processed substrates. A description will be given on an order of cleaning processes which are performed on one substrate. It is to be noted that the invention is not limited to the specific order and combination of the processes the described below. In FIG. 4, a substrate transport line for the transporting system 3 is indicated by the dash, one-dot line and a substrate transport line for the transport hand 5 is indicated by the dash, two-dot line.
First, after the transport robot 33 has moved in the direction X and has stopped in front of the cassette 4A, the column 35 of the robot 33 moves upward so that the hand 38 is positioned a little lower than the height of a target substrate to be processed which is stored in the cassette 4A. The motor is then driven, thereby moving the hand 38 to just below the back surface of the substrate. The column 35 is moved further upward, and the substrate is received by the hand 38, held thereon by suction force and lifted up in the cassette 4A. Following this, the hand 38 retracts driven by the motor to remove the substrate from the cassette 4A.
Next, the transport robot 33 moves in a direction (-X) along the guide rail 31 and stops in front of a shutter 23a of the UV lamp house 23 (See FIG. 1). Controlled by the column 35, the hand 38 moves to locate the substrate at the same height as the shutter 23a which will be subsequently opened. The hand 38 moves forward and enters into the UV lamp house 23 (as shown by the arrow F1). Upon setting of the substrate into the UV lamp house 23, the hand 38 withdraws, the shutter 23a closes and dry cleaning starts.
When dry cleaning in the UV lamp house 23 is finished, the transport robot 33 moves back to the UV lamp house 23 and the shutter 23a opens. The hand 38 moves forward to receive the substrate from the UV lamp house 23. The hand 38 then retracts and the shutter 23a is closed. The substrate is unloaded from the UV lamp house 23 in this manner.
As shown by the arrow F2, the substrate unloaded from the UV lamp house 23 is transferred to the brush module 21. In FIG. 4, the substrate is moved in the direction X (arrow F2). However, this is only for convenience of illustration. The substrate is transferred to the brush module 21 in the following manner since a shutter 21a of the brush module 21 is located immediately below the shutter 23a of the UV lamp house. That is, the column 35 moves downward so as to move the substrate which is held on the hand 38 to the same height of the shutter 21a of the brush module 21 without moving the transport robot 33 in the direction X. The shutter 21a then is opened and the hand 38 moves forward. The substrate is thereafter inserted into the brush module 21.
The substrate is cleaned at both of its surfaces (or the back surface only) in the brush module 21. The cleaned substrate is pushed upward in the direction Z from an opening 21b (FIG. 1) by push-up pins (not shown) which are disposed in the brush module 21, and transferred to the transport hand 5 which is located above the opening 21b. Following this, the transport hand 5 holding the substrate is moved by a hand drive mechanism 8 (FIG. 1) in the direction X and stopped above the spin part 22. The substrate is thereafter transferred and set to the spin part 22 (arrow F3).
A series of surface cleaning processes are performed onto the upper surface of the substrate which is set to the spin part 22. First, the substrate is rotated while in contact with a rotation brush 22a (FIG. 1) while cleaning liquid is being supplied. Next, the substrate is further rotated while being supplied cleaning liquid vibrated supersonically, the cleaning liquid being showered on the substrate from a supersonic cleaning nozzle 22b. Finally, the substrate is further rotated for being rinsed with pure water supplied from a pure water nozzle 22c. After that, the substrate is further rotated at a high speed for being dried.
Upon surface cleaning in the spin part 22, the transport robot 33 moves to the spin part 22. The hand 38 enters the spin part 22 to receive the substrate and exits from the spin part 22 with the substrate held thereon by suction force in the same manner as described above. The transport robot 33 then moves to the cassette 4B to load the substrate into the cassette 4B in a reversed manner from that of unloading the substrate from the cassette 4A (arrow F4). The substrate which went through all the cleaning processes by the processing units is transferred to the cassette 4B. Each substrate is cleaned in this manner.
These operations as above are repeated to clean all substrate which are contained in the cassette 4A.
As described above, in the present embodiment, the transporting system 3 can transport a substrate freely among the processing units and between the cassettes 4 and the processing units. In other words, the transporting system 3 accesses the processing units while holding a substrate in any desired order depending on a need. It is therefore possible to change the order of the surface treatments in an easy manner.
The present embodiment is advantageous over the conventional technique disclosed by U.S. Pat. No. 4,985,722. The apparatus of this embodiment is simple since it is possible to transport a substrate between the cassettes 4 and the processing units by the transporting system 3, whereas this conventional technique requires the interface mechanism in the loading/unloading section to load and unload a substrate into and from the cassette 4. The treatment processes are also simple since it is not necessary to transport a substrate between the interface mechanism and the conveying mechanism.
In addition, since the transporting system 3 is disposed between the cassette storing system 1 and the processing system 2 which are arranged in an opposing relation, the transport space 6 is sufficient as a substrate transport space. This contributes to a reduction in the size of the substrate processing apparatus, which in turn increases the freedom of the layout of the substrate processing system including the substrate processing apparatus and makes it easy to change the location of the substrate processing apparatus within the system.
Further, since the processing system 2 includes the spin part 22 which cleans a substrate while spinning the substrate, it is possible to load a substrate which was unloaded from the cassette 4A into the cassette 4B in any desired direction regardless of the orientation of substrates contained within the cassette 4A. That is, by controlling the orientation of the substrate in the spin part when spinning of the substrate is stopped, it is possible to load the substrate into the cassette 4B so that a rim portion of the substrate which used to be located immediately in front of the opening of the cassette 4A is located farthest from the opening in the cassette 4B when the spinning treatment is finished, or if desired immediately in front of the opening in the cassette 4B when the spinning treatment is finished. The orientation of loaded substrates is freely selected substrate by substrate, or cassette by cassette, or rot by rot.
While the embodiment disclosed includes three types of the processing units disposed in the processing system 2 and three cassettes 4 disposed in the cassette storing system 1 the invention is not so limited. Other types and number of the processing units or other numbers of cassettes 4 may be used. For example, six cassettes 4 may be disposed in the cassette storing system 1 and the same types of the processing units as above may be additionally disposed in the processing system 2 along the direction X. However, in such a structure, since effective transportation of a substrate is difficult and a tact time becomes longer in some cases with only one transport robot 33, a plurality of transport robots 33 may be disposed in the transport space 6 depending on the structures of the cassette storing system 1 and the processing system 2.
The embodiment above also requires that the hand 5 transports a substrate from the brush module 21 to the spin part 22 mainly because the hand 38 must not be wet. If the hand 38 receives a substrate which is wet at the back surface due to previous cleaning performed by the brush module 21, this will be a big problem later. To avoid this, the brush module 21 may include a mechanism such as an air knife for drying a substrate which was already cleaned at the both surfaces (or only the back surface). With such a mechanism, a substrate is transported with the back surface dry from the brush module 21 to the spin part 22, which makes it possible to transport the substrate to the spin part 22 by the transport robot 33 and to omit the transport hand 5 and the hand drive mechanism 8.
Additional processing units 24 or other type units may be disposed at the both sides of the transport space 6 as shown in FIG. 5 to utilize the transport robot 33 more efficiently. The additional processing unit 24 or the type unit may be selectively disposed at one end side of the transport space 6. Only one such substrate processing apparatus as hereinabove described may be used, or as shown in FIG. 6, two such substrate processing apparatuses may be serially arranged. Further alternatively, the substrate processing apparatus may be linked to other type of substrate processing apparatus with an interface 9 interposed therebetween for one-way or two-way transportation of substrates between the two substrate processing apparatuses.
The foregoing has described the substrate processing apparatus of the embodiment as an apparatus for cleaning a substrate, the present invention is not limited to this particular use. Rather, the present invention is applicable to any substrate processing apparatuses in general such as a substrate processing apparatus for coating a substrate with a resist or a substrate processing apparatus for developing a substrate.
While the invention has been described in detail, the foregoing description is in all aspects illustrative and not restrictive. It is understood that numerous other modifications and variations can be devised without departing from the scope of the invention. | A single transport path for transporting a substrate between the cassettes and a plurality of processing units, is arranged between the cassette storing means and the processing means. Hence, it is possible to skip some processing units or to change the order of the processing units easily, with simplifying the construction of the apparatus. Furthermore, the single transport path causes to reduce the space for transporting the substrate. | 7 |
FIELD OF THE INVENTION
This invention relates to a method and apparatus for processing industrial tail gases, and more particularly, is concerned with a heater assembly for generating a reducing gas by combustion of a fuel in an oxygen limited atmosphere, and mixing the reducing gas and industrial gas.
BACKGROUND OF THE INVENTION
In U.S. Pat. No. 3,752,877, for example, there is described a process for the reduction of compounds, such as sulfur, nitrogen oxides, and the like, occurring in industrial gases, such as the tail gases from Claus plant, or the like. In the patented process, the tail gases are first heated to an elevated temperature by a conventional burner through a heat exchanger that prevents mixing of the products of combustion with the tail gases. After heating, the tail gases are mixed with a reducing gas containing hydrogen and carbon monoxide. The reducing gas is produced by burning air and fuel in the presence of steam in a sub-stoichiometric combustion reaction. When hydrocarbon is burned stoichiometrically or sub-stoichiometrically, it is difficult to avoid formation of free carbon or soot, which is harmful to subsequent process steps. It is also difficult to insure complete consumption of free oxygen, which of course is not wanted in the reducing gas.
SUMMARY OF THE INVENTION
The present invention is directed to an improved method and apparatus for generating a reducing gas and at the same time using the heat generated by the production of the reducing gas to preheat the industrial gas, and then mixing the industrial gas with the reducing gas. In the past, high operating temperature in the reducing gas generator has presented cooling problems since operating temperatures generally exceed working temperatures of common metals. The present invention provides improved efficiency by utilizing the industrial gas as a cooling agent for the walls of the combustion chamber. In brief, the apparatus of the present invention includes a combustion chamber comprising a refractory lined elongated metal cylinder preferably having a length to a diameter ratio of 2 to 1 surrounded by a concentric outer cylinder forming an annulus through which the industrial gas flows.
The combustion chamber terminates in a radiant end wall having an exit orifice of an area up to about 50% of the end wall. Fuel gas preferably premixed with steam is directed into the combustion chamber through a burner ring with multiple outlet holes. Air or oxygen is admitted into the combustion zone through a wind box positioned rearward of the burning into which a source of oxygen, typically air is introduced tangentially to form a vortex flow within the combustion chamber. Relatively high rotary velocity is imparted by a constricted throat section at the entrance to the combustion chamber. Preferably, the constricted throat doubles the velocity of the gas in the wind box which is in the range of about 50 to 150 ft./sec. The products of combustion are mixed with the industrial gas after the products of combustion pass through a flame exit orifice.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the invention, reference should be made to the accompanying drawings, wherein:
FIG. 1 is a side elevational view of the apparatus of the present invention;
FIG. 2 is an end view of the apparatus;
FIG. 3 is a sectional view taken substantially on the line 3--3 of FIG. 2;
FIG. 4 is a partial sectional view taken on the line 4--4 of FIG. 3; and
FIG. 5 is a fragmentary view showing the burner.
DETAILED DESCRIPTION
Referring to the drawings in detail, the numeral 10 indicates generally the combustion and mixing apparatus which includes an inner metal cylinder 12 having an inner lining 14 of refractory material forming a combustion chamber 16. A metal inner wall 18 having an opening 20 is lined with refractory material 22 surrounding the opening 20 to form a restricted throat at the inlet end of the combustion chamber 16. The other end 24 of the combustion chamber is formed of refractory material having an outlet opening 26 therethrough forming a flame exit orifice.
An annular burner 28 surrounds the outside of the opening 20 in the metal wall 18. As shown in detail in FIG. 5, the burner ring is formed of a hollow pipe having a plurality of equally spaced holes 30 around the inner periphery thereof for directing fuel gas into the combustion chamber. An inlet pipe 32 is connected to the burner 28 and extends through a 90° elbow 34 outwardly through the metal cylinder 12. The pipe 32 connects through a T-connection 36 to a source of a gaseous or liquid fuel which is hydrocarbon, such as natural gas, methane or the like, a fuel gas containing hydrogen, carbon monoxide, or mixtures thereof, normally liquid hydrocarbons and the like. The T-connection 36 also connects to a source of steam, the T-connection mixing the steam and fuel together before the mixture is directed into the combustion chamber through the burner 28.
The inlet end of the metal cylinder 12 is provided with a flange 38 to which is bolted or otherwise secured an end plate 40. The space within the cylinder 12 between the end plate 40 and inner wall 18 provides a wind box 42. Air, oxygen, or other oxygen-containing gas is connected into the wind box through an inlet pipe 44. As best seen in FIG. 2, the inlet pipe 44 is positioned off center, so that the flow of air into the wind box is tangential to the cylindrical wall 12. Thus a rotary motion is imparted to the air within the wind box 42 by the flow of air out of the pipe 44.
The air from the wind box enters the combustion chamber through the opening 20 where it mixes with the fuel and steam from the burner ring 28. The mixture is ignited by suitable means, such as a pilot flame, an electrical spark or the like.
In order to produce high turbulance in the throat zone indicated at 48, formed by the opening through the refractory material 22, air is introduced through the pipe at a velocity in the range of 50 to 150 ft. per second, thus maintaining a high rotary velocity in the wind box and a still higher velocity in the throat 48 preferably in the range of about 100 to about 300 ft. per second or double the velocity in the wind box. The constriction formed by the throat 48 is preferably less than half the diameter of the combustion chamber 16.
To provide cooling for the combustion chamber, and at the same time to provide preheating of the industrial or tail gases, the combustion chamber is provided with a cylindrical shell or jacket 50. The jacket 50 is supported from an end ring 52 which surrounds and is welded to the cylinder 12 in the same plane as the inner wall 18. The jacket 50 is provided with an annular flange 54 which is bolted or otherwise secured to the end ring 52.
The outer jacket 50 extends substantially beyond the orificed refractory end wall 24 of the combustion chamber and terminates in an end wall 56, which is welded or otherwise secured and sealed to the end of the jacket 50. The area of the orifice 26 is up to about one-half the area of the end wall to maximize back radiation without impeding gas flow. The industrial gases are directed into the annular space between the cylinder 12 of the combustion chamber and the jacket 50 through an inlet pipe section 58. As best seen in FIG. 4, the pipe section 58 has its axis off center from the axis of rotation of the cylinder 12 and jacket 50. In addition, a series of baffle plates 60, 62, and 64 are positioned inside the inlet pipe section 58 adjacent the opening into the annular space within the jacket 50 so as to direct the industrial gas in a flow direction which is tangential to the cylinder 12. Thus a rotary component of motion to the flow of industrial gas along the outside of the combustion chamber is provided.
As the industrial gases move longitudinally off the combustion chamber they enter the region between the end of the combustion chamber and the end wall 56 where they mix with the products of combustion from the combustion chamber which pass out through the flame exit orifice 26. This mixture is directed out through an outlet pipe 66. Because the gas from the combustion chamber enters the mixing region at a relatively high temperature, the outlet 66 and the jacket 50 are lined with a layer of refractory material 68 which also serves to radiate heat back to the combustion chamber. The refractory material extends back along the jacket 50 to a point where the temperature of the jacket is maintained at a safe level by the cooling effect of the industrial gases flowing in the annular space between the jacket and the cylindrical wall 12.
In operation, the addition of steam to the fuel gas has been found to provide substantially soot-free combustion. The presence of steam with the hydrocarbon gas has the effect of reducing any thermal reaction or cracking process in which free carbon is released from the hydrocarbon molecules. Even though some cracking of the hydrocarbon molecules may still take place in the combustion chamber, the intimate mixture of water molecules enhances the reaction of the released carbon with oxygen to form carbon monoxide and carbon dioxide. Typically, up to about 5 pounds of steam is mixed with each pound of fuel.
The combination of greater turbulance to provide improved mixing of the fuel gas and air, the high temperature within the combustion chamber, the radiating end wall 24 of refractory material for re-radiating energy into the combustion chamber, and the addition of steam to the fuel gas combine to insure more complete oxidation thereby removing all free oxygen from the reducing gas produced by the combustion operation. The combustion chamber preferably has a length to diameter ratio of about 2 to 1 to provide a volume equivalent to a gas residence time of 0.1 to 1 second. A residence time of about 0.5 second is preferred when the fuel gas containes 10% or more of propane and heavier hydrocarbon molecules. With fuel gases lean in propane or heavier components, very little steam need be premixed with the fuel gas. About one pound of steam for each pound of fuel is preferred. With fuel gases having heavier components or with liquid fuels, the ratio of steam may be increased to as much as five pounds of steam per pounds of fuel. If a liquid fuel is used, a steam atomizing spray nozzle is substituted for the burner ring for injecting the fuel into the combustion chamber.
While the combustion process has been described as generating a reducing gas, the same apparatus may be used where a neutral gas is required. This of course depends only on the amount of oxygen supplied in relation to the fuel gas. | Apparatus for heating and mixing industrial tail gases with a reducing gas by burning a mixture of fuel, air, and steam in a combustion chamber having a small outlet opening at the end of the chamber. A jacket surrounds the combustion chamber. The industrial gases are circulated around the combustion chamber inside the jacket, heat being transferred from the combustion chamber to the industrial gas. It is then mixed with the combustion products from the outlet of the combustion chamber to form a high temperature mixture of an industrial gas and a reducing gas for subsequent processing. | 5 |
FIELD OF THE INVENTION
This invention relates to improvements in noise reduction in FM reception.
INTRODUCTION
A characteristic of FM reception is the so-called ‘threshold effect’, whereby impulsive noise appears in the FM demodulator output when the input signal to noise ratio (SNR) to the FM demodulator is low. In systems using analogue FM modulation to transmit an audio signal, the noise impulses are heard as ‘clicks’ in the demodulated audio signal. The process that leads to the impulsive noise has been studied extensively in [1] S. O. Rice, “Statistical properties of a sine wave plus random noise”, Bell Sys. Tech. J., vol. 27, pp. 109-157, January 1948, and [2] M. J. Malone, “On the threshold effect in FM data systems”, IEEE Transactions on Communication Theory, Vol. COM-14, No. 5, pp. 625-631, October 1966. The process is briefly described below.
An FM-modulated signal can be represented as:
c ( t )=sin(2 π*Fc*t+∫m ( t ) dt ),
where ‘t’ represents time, Fc is the carrier frequency and m(t) is the modulating signal. The FM signal available at a receiver often contains additive noise and can be represented at baseband (for Fc=0) by the mathematical expression
y ( t )= e j∫m(t)dt +n ( t )
Note that m(t) is the instantaneous frequency deviation relative to Fc. In stereo FM broadcasts, m(t) is called ‘stereo multiplex’ and is a frequency multiplex of ‘left+right’ (L+R) and ‘left−right’ (L−R) audio signals, a ‘pilot’ tone of 19 kHz, and optionally other data or audio signals.
When the SNR of the received signal y(t) is below a certain value, the receiver component which estimates the carrier angle of the received signal loses accuracy. This results in fast steps of 2π appearing in the carrier angle estimated by the receiver. For example, in the absence of modulation (m(t)=0), a step of 2π in the estimated carrier angle occurs when noise causes the vector representing y(t) in the ‘complex plane’ to circle around the origin.
The rapid steps of 2π in the phase of the estimated carrier angle create impulses in the instantaneous carrier frequency estimated by the receiver. The estimated instantaneous frequency is equal to the differential of the estimated angle with respect to time and so a rapid change in phase results in a high value in the estimated output signal. These impulses are relatively short and are heard as clicks in the audio signal recovered from the stereo multiplex. With decreasing SNR, these clicks become more and more frequent per unit of time, until eventually they can no longer be heard individually, sounding like white noise to a listener.
From the equation describing y(t) above, an estimate of the modulating signal m(t) can be obtained by first estimating the angle of y(t) and then differentiating this estimated angle. This is a simple and viable method of FM demodulation. By comparison with this simple FM demodulation method, FM demodulation methods that reduce the number of noise impulses present in the demodulated signal per unit of time are known as ‘threshold extension’ methods.
Threshold extension by removing clicks post-demodulation has been previously researched. [3] M. J. Malone, “FM threshold extension without feedback”, Proc. IEEE, pp. 200-201, February 1968, and [4] I. Bar-David, S. Shamai, “On the Rice model of noise in FM receivers”, IEEE Transactions on Information Theory, vol. 34, no. 6, November 1988, show techniques for removing clicks by estimating the position of a click and applying a 2π correction to the demodulated signal at the estimated position.
What is required is an improved method of removing the clicks which takes advantage of modern signal processing technologies and accounts for the characteristics of FM stereo broadcast signals to achieve better performance.
SUMMARY OF THE INVENTION
According to a first aspect of the present invention there is provided apparatus for reducing FM click noise on a demodulated FM signal, the apparatus comprising, filter means configured to produce a click detection signal according to the demodulated FM signal, click detection means configured to receive the click detection signal and produce a click occurrence signal, and click correction means configured to correct FM clicks on the demodulated FM signal according to the click occurrence signal.
According to a second aspect of the present invention there is provided a method of reducing interference in received FM signals, the method comprising: estimating a carrier angle of a received FM signal and demodulating the signal according to the estimated carrier angle, determining that a fast step of 2π has occurred in the estimated carrier angle which results in an instance of click interference, correcting the click interference instance in the demodulated FM signal.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described by way of example with respect to specific embodiments thereof, and reference will be made to the drawings, in which:
FIG. 1 illustrates a click correction system according to the present invention.
FIG. 2 illustrates a detection filter impulse response according to a typical embodiment of the present invention.
FIG. 3 illustrates the frequency response of a detection filter according to a typical embodiment of the present invention.
FIG. 4 illustrates the click detection signal before cancellation and its frequency spectrum, when the FM modulation consists of a stereo multiplex signal including a mono (L=R) 1 kHz audio tone with 75 kHz frequency deviation and a pilot tone with 6.75 kHz frequency deviation.
FIG. 5 illustrates the click detection signal after one pass of the click cancellation algorithm and its frequency spectrum, for the same FM modulating signal as the one corresponding to FIG. 4 .
FIG. 6 illustrates a short section in time of the click detection signal prior to click cancellation and after one, two or three passes (iterations) of the click cancellation algorithm.
FIG. 7 illustrates audio output signal to noise ratio (SNR) vs. Intermediate Frequency SNR, when varying the number of applications of the click cancellation algorithm, and when the click cancellation algorithm includes rejecting the pilot tone or not.
FIG. 8 illustrates an enlarged view of the graph shown in FIG. 7 .
DETAILED DESCRIPTION
The present invention provides an improved method for reducing the number of clicks in a demodulated signal by detecting each instance of this type of interference, and applying a correction to the output signal which removes each click.
In the system illustrated in FIG. 1 , the FM signal is received by antenna 5 and amplified by FM signal amplifier 10 . Amplified signal 15 is then down-converted by down-converter module 11 to produce an intermediate frequency (IF) signal 16 . Signal 16 is sent to carrier angle estimator 20 . Carrier angle estimator 20 produces an uncorrected output signal 25 which is then split and fed into both click corrector 50 and differentiator 60 . Differentiator 60 differentiates the estimated carrier angle and provides differentiated signal 65 to detection filter 30 . Detection filter 30 filters out any unwanted frequencies from signal 65 to produce the click detection signal 35 which is suitable to allow click detector 40 to determine the location of clicks in the signal 25 . The click location signal 45 is then applied to click corrector 50 , which uses signal 45 to apply click corrections to signal 25 . The output of click corrector 50 is the corrected estimated carrier angle signal 55 . Signal 55 is passed to differentiator 70 whose output signal is the estimated FM modulating signal.
In an embodiment of the present invention, the procedure for removing clicks consists of the following steps:
1. Filtering the differential of the demodulated angle, to produce a ‘click detection’ signal. 2. Estimating where clicks occur in the demodulated angle. 3. Cancelling each click by adding a correction at the estimated location of the click.
Each of these steps will now be described in detail.
Filtering
In an embodiment of the invention, a filter 30 is used to filter the differential of the demodulated angle to produce a click detection signal 35 which allows easier identification of click positions. Unlike the filters described in the prior art, the filter of this embodiment is specially designed for reception of FM stereo broadcast signals.
To produce a ‘click detection’ signal, the filter is designed according to the following criteria
a. The filter should reject the wanted signal and preserve or amplify the clicks. Ideally, the click detection signal should be clear of most of the received signal except for the clicks caused by the noise present in the IF signal.
b. The filter should not cause excessive dispersion of the clicks. i.e. when a click is applied to the input of the detection filter, the filter should not be such that the resulting output signal has components of large amplitude (relative to its largest amplitude) occurring over a long period of time. A reduced dispersion of the filtered clicks allows a good estimation of the click positions and reduces the likelihood that the estimated position of the click is far from its true position. This also means that the amplitude of the filter output signal peak (for a click input) is larger for equal energy, resulting in a more reliable detection of clicks on the basis of the filter output signal amplitude
c. The filter should attenuate high frequencies, to reduce ‘non-click’ noise. High frequencies which do not form the clicks are effectively excluded from the click detection signal this way.
A typical detection filter impulse response according to one embodiment of the invention is illustrated in FIG. 2 . FIG. 3 illustrates its frequency response. The detection filter is designed to have a high attenuation around the ‘mono’ and ‘stereo’ sub-carrier frequencies, respectively 0 and 38 kHz in a typical FM broadcast receiver. The filter is designed to preserve other frequencies, in particular relatively low frequencies located between the mono and stereo sub-carriers.
In one embodiment of the present invention, the pilot tone is removed from the click detection signal prior to the step of estimating click positions. The phase and amplitude of the pilot tone are stable and so they are easy to estimate in order to remove the pilot tone from the click detection signal by subtraction. If it is not rejected in this way, the pilot tone interferes with the threshold-based detection of the clicks. For example, if the pilot tone happens to add destructively to a detection filter output corresponding to a click, in conjunction with noise it can reduce the detection filter output below the threshold and so it can cause the detection of that click to fail. Therefore, rejecting the 19 kHz pilot tone from the click detection signal improves the reliability of click detection.
Estimation/Detection
In one embodiment of the invention, a click is detected by click detector 40 when the click detection signal 35 meets either of the following conditions at that time:
1. Its absolute value exceeds a first threshold and is largest within a first time neighbourhood surrounding it; or
2. Its absolute value exceeds a second, higher threshold, and is largest within a second, smaller time neighbourhood surrounding it.
The first type of test is suitable for the detection of isolated clicks, whereas the second type of test resolves some occurrences of multiple adjacent clicks. Therefore, the advantage provided by using the two types of threshold tests is that both isolated clicks and clusters of clicks can be effectively detected from the filtered signal.
The click cancellation performs well when the audio component within the FM modulating signal is of a frequency below 5 kHz, regardless of the signal frequency deviation, for R=L, R=0 and R=−L signals. Audio modulation that is high frequency (above 7 kHz) and also has large frequency deviation may not be sufficiently rejected by the detection filter to allow reliable click detection, resulting in ‘false’ detection of clicks.
Click detection may be unreliable in the presence of high-frequency wanted modulation with large frequency deviation. Therefore, in a preferred embodiment, to prevent degradation of the demodulated signal caused by false click detection, the click detection is disabled when the click detection signal medium-term average power exceeds a threshold. However, on average the signal power in real FM broadcasts is concentrated in low frequencies, and therefore most of the time the click detection is not disabled in this way.
Cancelling
Cancellation of the clicks is performed by click corrector 50 on demodulated signal 25 according to the click location signal 45 . In one embodiment, the click cancellation is performed by adding a correction of magnitude 2π and opposite polarity to the detected click.
An advantage of cancelling the clicks from the demodulated FM signal in this way, compared with alternative methods of threshold extension such as a phase locked loop FM demodulator (PLL FM demodulator) or an FM feedback (FMFB) demodulator, is that high frequency information in the modulating signal, such as the stereo sub-carrier and RDS sub-carrier, is preserved. In comparison, the bandwidth of PLL or FMFB demodulators has to be reduced to improve their sensitivity, for example to select only the ‘mono’ or ‘left+right’ audio component of the stereo multiplex signal, which occupies frequencies below 15 kHz.
FIG. 4 illustrates the click detection signal and its frequency spectrum before click cancellation and FIG. 5 illustrates the click detection signal and its frequency spectrum after one iteration of the click cancellation algorithm, when the FM modulation consists of a stereo multiplex signal including a mono (L=R) 1 kHz audio tone with 75 kHz frequency deviation and a pilot tone with 615 kHz frequency deviation. Clicks are visible as large amplitude impulses present in the click detection signal. FIGS. 4 and 5 demonstrate (a) the effectiveness of the cancellation (there are much fewer clicks left after one iteration of the click cancellation algorithm); (b) removing the clicks reduces the noise especially in low frequencies, suggesting that that is where a lot of the power of clicks is located.
Iterative Application
In one embodiment of the invention, iterative application of the click removal process provides improved click removal success and as a result it improves the quality of the demodulated signal.
FIG. 6 illustrates a short section in time of the click detection signal prior to click cancellation and after one, two or three passes (iterations) of the click cancellation algorithm. FIG. 6 shows that (a) isolated clicks can be resolved in one pass of the click cancellation algorithm, while (b) iterative application of the click cancellation algorithm can resolve multiple clicks that are very close together in time.
FIG. 7 presents the results of Monte-Carlo simulation of the audio output signal to noise ratio (SNR) vs. Intermediate Frequency SNR (IF SNR}, when varying the number of applications of the click cancellation algorithm, and with or without rejecting the 19 kHz pilot tone prior to click cancellation. The simulation assumes a mono (L=R) 1 kHz audio tone modulation with 22.5 kHz audio frequency deviation and including a pilot tone with a 6.75 kHz frequency deviation. The click cancellation improves sensitivity (for 26 dB output SNR) by more than 3 dB. Using two iterations provides a gain of about 0.5 dB compared to using a single iteration. Rejecting the 19 kHz pilot tone from the click detection signal prior to click cancellation provides a further SNR gain of around 0.3 dB.
FIG. 8 is a ‘zoomed-in’ version of FIG. 7 , showing that to achieve 26 dB audio output SNR, with 2 click cancellation iterations and pilot tone rejection, the receiver requires a 2.5 dB IF SNR in 256 kHz bandwidth. For example, this means that with a receiver noise figure of 2 dB, the receiver sensitivity is equal to −119.75+2+2.5=−115.25 dBm (the power of thermal noise fed into a matched receiver at room temperature is −119.75 dBm).
The applicant hereby discloses in isolation each individual feature described herein and any combination of two or more such features, to the extent that such features or combinations are capable of being carried out based on the present specification as a whole in the light of the common general knowledge of a person skilled in the art, irrespective of whether such features or combinations of features solve any problems disclosed herein, and without limitation to the scope of the claims. The applicant indicates that aspects of the present invention may consist of any such individual feature or combination of features. In view of the foregoing description it will be evident to a person skilled in the art that various modifications may be made within the scope of the invention. | Apparatus for reducing FM click noise on a demodulated FM signal, the apparatus comprising, filter means configured to produce a click detection signal according to the demodulated FM signal, click detection means configured to receive the click detection signal and produce a click occurrence signal, and click correction means configured to correct FM clicks on the demodulated FM signal according to the click occurrence signal. | 7 |
RELATED CASES
This application refers to subject matter disclosed in U.S. patent application Ser. No. 009,532, filed Feb. 5, 1979, which is a continuation-in-part of U.S. patent application Ser. No. 003,898, filed Jan. 16, 1979, which is a continuation-in-part of U.S. patent application Ser. No. 902,444, filed May 3, 1978.
BACKGROUND AND SUMMARY OF THE INVENTION
Certain known systems for securing the transmission of data between locations rely upon computer-operated terminals as input and output devices. These terminals commonly include an encoding module which encrypts applied data so that the subsequent transmission thereof to a remote location remains secured against unauthorized reception, alteration or duplication. The encoding module is commonly controlled by an encoding key which is only known to one or two trusted persons, but which nevertheless must be changed periodically to assure continued integrity of the secured data-transmission system.
In the banking industry where secured-data transmission systems of this type have become widely used, it is common practice to allow a bank officer to initially establish the encoding key at each terminal at the start of operations for the day. This encoding key most usually must also be established at a remote end of the transmission system (say, at the central processor of the bank) in order to facilitate the decryption of transmitted and received encrypted data, and to permit the encryption of return messages that can then be decrypted according to the same key at the receiving terminal.
Previous schemes for disseminating the encoding key for use at remote locations have included too many people who thereby obtain sufficient information about the encoding key to seriously degrade the security of the system against unauthorized use of the encoding key by individuals who have access to the system from within the bank or from along the transmission system.
In accordance with a preferred embodiment of the present invention, encryption and decryption keys for controlling the encoding and decoding of secured, transmitted data are generated and distributed over the secured transmission system without the involvement of additional individuals than the person who initializes the system, and who may not even learn about the operating encoding key for himself. This is accomplished by relying on a secret code number or word or phrase which is selected by and known only to an authorized individual, which code (called a Personalized Individual Number or Code or Phrase) is combined in logical manner with an identification number for the terminal and a sequence number (or date, or random number, etc.) to produce a pair of codes, one of which remains stored in the terminal as an initialization key and the other of which (TRAC) can then be sent to the central processor at a remote location for proper analysis.
At the central processor, the PIN (or PIC or PIP) for the authorized individual (and for all other authorized individuals) is retained in storage (preferably in encrypted form with its requisite encrypting key) along with the identification number of the terminal (and all other terminals included within the system). Thus, the central processor may regenerate the authorized individual's PIN for use within the processor only by decrypting the stored encrypted PIN using the stored encryption key code. The PIN and the terminal identification number accessed from the processor memory may be combined in the same logical manner as at the identified terminal to yield a pair of codes, namely, a TRAC and an initialization key. The TRAC thus generated, and the TRAC transmitted and received from the remote terminal may then be compared for parity. Upon detection of parity, any set of numbers may be randomly selected for encoding to provide the session key, and this session key may be encoded with the initialization key to produce an encrypted session key for transmission back to the identified terminal. Since the session key actually determines the encryption/decryption for the day (or other session period), it is only necessary to decrypt the encrypted session key as received back at the terminal using the initialization key stored therein to produce the requisite session key. Thereafter, the initialization key can be discarded. In accordance with this embodiment of the invention, the users of a terminal cannot know the session key, and other terminals cannot be used to intercept a message selected for transmission to one terminal. In addition, terminals cannot simply be connected unauthorizedly into the system because of the need for proper initial conditioning.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a simplified block schematic diagram of one embodiment of the present invention; and
FIG. 2 is a chart showing the steps by which a secured data transmission system is initialized in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the block diagram of FIG. 1 and to the chart of FIG. 2, there is shown an input device 9 such as a keyboard as part of a data terminal. The keyboard enables an operator to enter data, a Personal Identification Number (PIN), and the like. In addition, the input device 9 may be capable of supplying a predetermined machine identification number (I.D. x ), for example, by accessing a register by a single keystroke to produce the machine number I.D. x .
Also, as part of a data terminal, there is provided an encryption module 11 of the type, for example, referred to as a data encryption standard utilizing the National Bureau of Standards circuit chip (available from various semiconductor component suppliers). A pair of input signals to the encryption module 11 may be provided using the illustrated format or any other suitable format which provides two inputs from at least the PIN from the authorized individual, the machine identification number, and a sequence number which may be a random number, one of a sequence of numbers, a date, time, etc. The sequence number assures that the encrypted output number will be different for each initialization operation performed. In addition, the data terminal may also include a storage register 13 for storing key codes during the operation thereof.
In operation, the data terminal must be initialized in the first operating cycle A to establish an operating key code that, ideally, is different for each business day or other operating session. The key code for the terminal will be used to encrypt data for secured transmission, say, to a central processor at a remote location. An authorized individual enters his personal identification number PIN A via the input device 9, and this number is combined with the identification number of the machine and a sequence number in a conventional manner to produce a pair of input signals for the encryption module 11 having a signal format as illustrated. The encryption module 11 of the type described encodes one input number as a function of the other input number (each 56 to 64 bits long) to produce an output signal which may be considered as including an initializing-key code number, Key i , in the least significant bits, say, 56 bits, and a TRansmission Authentication Code in the remaining most significant output bits. The initializing-key code number, Key i , is stored in storage register 13, and the TRAC signal is transmitted over any suitable data transmission link 17 to the central processor at a remote location.
The central processor 19 includes a memory file which contains all the identification numbers for all data terminals that are properly connected within the system. This memory file also contains all of the personal identification numbers (ideally, in encrypted form with associated encryption key) for all individuals who are authorized to initialize a terminal. Thus, an encryption module 21 (of the NBS-type previously described) at the remote location may operate with the central processor 19 to regenerate the PIN A (for internal use only) from information in the storage file. A pair of input signals may then be provided in the same format as used with module 11, using the regenerated PIN A , the received sequence number, and the machine identification number I.D. x for the terminal being initialized. This module also generates an initializing-key code number (Key i ) which can be stored in a register 23, and a TRAC signal which can be compared in comparator 25 with the TRAC signal that was produced and transmitted by the terminal being initialized. These TRAC signals should compare favorably, if the machine-identifying numbers are the same and the proper PIN A for an authorized individual was entered and the transmitted TRAC signal and sequence number were received unaltered.
Upon favorable comparison of the two TRAC signals in comparator 25, a pair of code numbers (e.g., random numbers) from generator 27 may then be gated into encryption module 21' of the NBS-type previously described using the requisite input-signal format also previously described. Of course, modules 21, 21', 21" and 21'" may all be the same module operating under control of the central processor during different portions of the operating cycle to perform the encoding or decoding described herein. The entire encrypted output from module 21' may be regarded as the encryption key for the session (Key s ), and this may be encrypted in module 21" with the initializing key (Key i ) from the storage register 23. The resulting encrypted session key (Key' s ) may then be transmitted back to the data terminal over the data link 17, and the initializing key (Key i ) previously stored in register 23 may now be discarded and replaced with the session key (Key s ).
At the data terminal, the encrypted session key (Key' s ) is received from the central processor via the data transmission link 17, and is applied to a reversible encryption module 11' of the NBS-type previously described, along with the initializing key (Key i ) from storage register 13. Of course, the modules 11 and 11' may be the same module operated in sequential states of the data terminal to perform the encoding or decoding functions described herein. The resulting decoded output from module 11' is the session key (Key s ) which can be stored in register 13. The initializing key (Key i ) may be discarded and replaced with the session key (Key s ) to complete the initialization of the data terminal.
After the initialization of the data terminal, as just described, input data may be encrypted during the second operating cycle B by inserting the data via input device 9 as one input to the encryption module 11 and by applying the session key (Key s ) from register 13 as the other input of the encryption module. The resulting encrypted data may be transmitted via data link 17 to the central processor. There, it is applied as one input to module 21'", and the session key (Key s ) from register 23 is supplied as the other input to module 21'". This module, operating as a decoder, thus regenerates the data that was previously received in encrypted form.
Therefore, the present invention provides the method and means for establishing an encrypting key which need not be known even to authorized individuals once it is properly established by such an individual. Also, since the encryption key is established using data which must be on file about a terminal, it is conveniently possible to exclude the unauthorized connection of additional terminals within the system of the present invention. | An improved secured data transmission system relies on the favorable comparison of coded signals derived from information about authorized individuals and particular data terminals that is both prestored and subsequently supplied under manual command in order to generate an operating key which is then used to encode and decode data that is entered after the initialization procedure. | 6 |
PRIORITY
This application claims priority to European Patent Application No. 10191376.2, filed 16 Nov. 2010, and all the benefits accruing therefrom under 35 U.S.C. §119, the contents of which in its entirety are herein incorporated by reference.
BACKGROUND
The present invention relates to a method and a system for managing the energy consumption in a manufacturing process. More specifically, the present invention relates to a method and a system for managing the energy consumption in a manufacturing process comprising a plurality of individual manufacturing entities.
Energy consumption is getting more and more critical within manufacturing environments and can no longer be buried within the facility cost. With further increasing energy cost there must be a new way to introduce this significant factor into the manufacturing and total cost of ownership (TCO) calculations. Energy, therefore, is becoming more and more of a product cost factor which has to be considered. The problem is to monitor energy consumption down to highest granularity.
In the actual production approach, production is calculated as a function of the variables forecast, demand, capacity, WIP, facility, yield, lead time, supply, maintenance, priorities, etc. However, energy consumption is not considered in the manufacturing planning, at least not in the high granularity down to the single equipment level. To make manufacturing planning more feasible with respect to the total costs, energy consumption of the manufacturing process has to be considered down to each individual manufacturing entity.
Published patent application US20100168897 discloses a control component and method for an energy management unit (EM) in an industrial automation arrangement which is configured to control one of a process, a subprocess and a system part of the industrial automation arrangement. Here, the control component is configured to detect the energy consumption of at least one part of the industrial automation arrangement, and the control component is configured to relate the detected energy consumption to at least one stored specification. The control component is also configured to generate a request for at least one automation component as the result of the relating operation. The control component is configured to transmit a message containing the request to the automation component and to receive an acknowledgement message from this automation component, where the request is directed to changing an operational state of one of the process, subprocess and system part that is controlled by the automation component.
Published patent application US20040225413 discloses an energy evaluation support system and the like which can more efficiently and precisely compute electric power consumption for each of predetermined processing units such as production steps and the like. The energy evaluation support system includes a receiving section which receives a factory design request including a production condition instruction indicating a production condition from the user, a storage section which stores a production device database containing data relating to production devices and a requisite-power supply device database containing data relating to requisite-power supply devices, a processing section which computes energy consumption for each of the production devices and the requisite-power supply devices and for each requisite power type, based on the production device database and requisite-power supply device database according to the factory design request from the user, and an output section which presents the energy consumption computed by the processing section to the user in a predetermined form.
U.S. Pat. No. 5,148,370 discloses a method employed by an expert system for batch scheduling the multiple-pass manufacture of a plurality of parts by at least one parts process, where the parts have a plurality of delivery dates and the parts and parts processor have a plurality of production constraints variable during manufacture, which includes creating a knowledge base of select characteristics of the parts processor and parameters of the parts, and generating a plurality of rules expressing a scheduling and planning strategy that substantially satisfies parts delivery dates, substantially maximizes use of the parts processor, substantially maximizes part throughput, substantially minimizes energy utilization of the parts processor and meets the production constraints. Parts suitable for simultaneous processing by the parts processor are combined into all possible preferred combinations by applying a first plurality of the rules to the knowledge base. Preferred combinations are scheduled for manufacture in batches by applying a second plurality of the rules to the knowledge base.
Published patent application US20090177505 discloses the modeling of a carbon footprint of a supply and distribution chain as a carbon dioxide (CO 2 ) cost that can be considered alongside monetary or dollar costs in supply, manufacturing, and distribution operations. Databases on products and services, supply chain policies, and targets, costs, and/or greenhouse gas (GHG) emissions are used by a GHG calculator to output carbon footprint data and/or by a supply chain optimizer to output supply chain planning and policy data. Client computers obtain carbon footprint and/or supply chain planning and policy data by querying a server with access to a database storing calculated carbon footprint data. Input data to the GHG calculator is updated based on choices made by users of the system.
Published patent application US20090281677 discloses systems and methods for assessing and optimizing energy use and environmental impact can be designed to receive energy consumption and emission data from one or more energy consumption sources of a facility over a network. The data can be transformed into a database format that can be processed and analyzed. The data can be validated according to predefined validation rules. The data can be aggregated according to predefined time intervals and stored in memory. The data can be used to generate a report to a user, for example, via a user interface.
SUMMARY
In one embodiment, a method for optimizing energy efficiency in a manufacturing process includes monitoring power consumption of each of a plurality of manufacturing entities of the manufacturing process using a power metering device assigned thereto; collecting, from the power metering devices, a first data stream that includes information about the power consumption; collecting a second data stream that includes information about the manufacturing entity and process; determining an optimized product routing of products to be manufactured by the manufacturing process from one manufacturing entity to another manufacturing entity, based on the collected first and second data streams, by simulating different product routings and determining the optimal product routing with respect to the overall energy consumption of the manufacturing process; and adjusting, via a manufacturing control system, the manufacturing process based on the optimized product routing.
In another embodiment, a system for optimizing the energy efficiency in a manufacturing process includes a power metering device assigned to each of a plurality of manufacturing entities of the manufacturing process; means for collecting data streams including information about the power consumption from the power metering devices and information about the manufacturing entity and process; communication means for transmitting the data streams to a calculation means, the calculation means configured to calculate an optimized product routing of products to be manufactured by the manufacturing process from one manufacturing entity to another manufacturing entity, based on the collected data streams with respect to the overall energy consumption of the manufacturing process; and communication means for transmitting information about the optimized product routing calculated by the calculation means to a manufacturing control system that controls the manufacturing entities.
In another embodiment, a computer program product includes a non-transitory, computer usable medium, having computer readable instructions stored thereon that, when executed by a computer, perform a method for optimizing energy efficiency in a manufacturing process. The method includes monitoring power consumption of each of a plurality of manufacturing entities of the manufacturing process using a power metering device assigned thereto; collecting, from the power metering devices, a first data stream that includes information about the power consumption; collecting a second data stream that includes information about the manufacturing entity and process; determining an optimized product routing of products to be manufactured by the manufacturing process from one manufacturing entity to another manufacturing entity, based on the collected first and second data streams, by simulating different product routings and determining the optimal product routing with respect to the overall energy consumption of the manufacturing process; and adjusting, via a manufacturing control system, the manufacturing process based on the optimized product routing.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
Embodiments of the invention are illustrated in the accompanied figures. These embodiments are merely exemplary, i.e. they are not intended to limit the content and scope of the appended claims.
FIG. 1 schematically shows the setup of an inventive system for managing the energy consumption in a manufacturing process;
FIG. 2 schematically shows an inventive system with a calculation which is connected to the manufacturing facility via a public network;
FIG. 3 shows an algorithm flow to determine an optimized energy consumption.
DETAILED DESCRIPTION
The state of the art lacks methods and systems for optimization the energy consumption of an overall manufacturing process down to each individual manufacturing entity.
Referring now to FIG. 1 , a plurality of manufacturing entities 200 , 201 , 202 is shown. Each of these entities 200 , 201 , 202 may depict a process station in a manufacturing process of a product. The manufacturing entities 200 , 201 , 202 are connected to individual power metering devices 400 , 401 , 402 , which measure the power consumption of the manufacturing entities 200 , 201 , 202 . The power metering devices 400 , 401 , 402 are connected to a calculation means 600 by communication means 500 , 501 , 502 for sending a data stream comprising information about power consumption of the individual manufacturing entities 200 , 201 , 202 to the calculation means 600 . The calculation means is adapted for calculating an optimized product routing of the products to be manufactured by the manufacturing process from one individual manufacturing entity 200 , 201 , 202 to another individual manufacturing entity 200 , 201 , 202 based on the collected data streams with respect to the overall energy consumption of the manufacturing process. For example, in entity 200 a base product is pretreated, while entity 201 makes a recess into the product surface and entity 202 drills a hole into the product. While the pretreatment in entity 200 has to be performed as a first manufacturing step, the order of the manufacturing steps of making the recess and drilling the hole may be interchangeable. If the hole has to be drilled in the area were entity 201 has made the recess, making the recess first may be favorable in terms of energy consumption since less material has to be bored out in the drilling step performed by entity 202 . However, depending on the product it may be favorable to drill the hole first and to make the recess subsequent since a plurality of drilled intermediate products can be aligned in a row and the entity 201 for making the recess, like, e.g., a rotary cutter, has to be started only. This may be favorable since the energy consumed by the starting current of the rotary cutter is reduced. The best order of product steps can be calculated by the calculation means 600 based on the information received from the power metering devices. The calculation means 600 is connected to a manufacturing control system 300 via a communication means 700 . The manufacturing control system 300 controls the individual manufacturing entities 200 , 201 , 202 and is capable to influence the order of the manufacturing steps. The calculation means 600 sends information about the best order of manufacturing steps in terms of energy consumption to the manufacturing control system 300 , which amends the overall manufacturing process according to information received by the calculation means 600 .
Referring now to FIG. 2 , in a manufacturing facility 1000 , a plurality of individual manufacturing entities 200 , 201 , 202 are provided. Each of the individual manufacturing entities 200 , 201 , 202 is connected to a power metering device 400 , 401 , 402 . Via a communication means 500 , the power metering devices 400 , 401 , 402 send information about the power consumption of the manufacturing entities 200 , 201 , 202 to a database 800 located onside the manufacturing facility. Via a packet-switched data network 900 , like the Internet, the database 800 sends a data stream comprising information about the power consumption of the manufacturing entities 200 , 201 , 202 to the calculation means 600 . Via communication means 700 , the calculation means 600 is connected to a manufacturing control system 300 . The manufacturing control system 300 controls the individual manufacturing entities 200 , 201 , 202 . Based on the information received from the calculation means 600 , the manufacturing control system 300 amends the overall manufacturing process to minimize the energy consumption, for example, by interchanging the order of the manufacturing steps performed by manufacturing entities 200 , 201 , 202 . The data calculated by the calculating means 600 can be stored together with the data about the power consumption in a storage databank system 1100 .
In FIG. 3 , an example of an algorithm flow to determine the best energy consumption in a manufacturing facility is shown. Beneath information 60 about the energy consumption, information 10 about the demand or forecast of the production, information 20 about the equipment availability, information 30 about the facility constrains, information 40 about the dependency of the individual manufacturing entities, and information 50 about the volume planning of the production is taken into consideration for optimization 70 of the product routing. Based on the product routing 70 , the related costs 80 are estimated. In a decision step 90 it is considered whether the chosen product routing is the optimal one or not. If not, product routing is amended iteratively until the optimized product routing is achieved. Based on the calculated optimized routing the process parameters 95 are amended to perform the manufacturing according to the optimized product routing.
The flowchart and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods and computer program products according to various embodiments of the present invention. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts, or combinations of special purpose hardware and computer instructions.
An individual manufacturing entity in that concern should be understood as a process station, a single machine or also a part of a machine in the manufacturing process.
With the invention a method is provided which enables the optimization of the energy consumption within a manufacturing process with a high granularity down to the individual manufacturing entities. This gives the opportunity to optimize the overall manufacturing process with respect to the energy consumption without the need to make major constructional amendments to the manufacturing facility. The method enables an optimization also within a running manufacturing process, thereby offering the opportunity to address recent changes, like, e.g., changes in the base product or a change of a manufacturing tool. Also downtimes of an individual manufacturing entity due to maintenance can be considered and the product routing within the manufacturing process can be changed to minimize the influence of this downtime on the overall energy consumption of the manufacturing process.
In an embodiment of the invention, the simulation and optimization of the product routing is performed by a business intelligence system (BI). Such BI systems are commonly used in the art of manufacturing process controlling. To enable such BI systems to perform the simulation and optimization adequate subroutines can be added or implemented. So, the costs for integrating the inventive method to a manufacturing facility can be kept low.
In another embodiment of the invention, additionally a data stream comprising information about at least one of the product demand and the product forecast is collected and taken into consideration for creating an optimized product routing. The consideration of such additional data enables to optimize the process routing also with a predictive horizon.
Yet in another embodiment of the invention, the information about the power consumption of the individual manufacturing entities is collected in database system onside the manufacturing facility. This allows to collect the data retrieved from the power metering devices centrally and to send them as a data package to a BI system.
According to an embodiment of the invention, the information about the power consumption of the individual manufacturing entities is transmitted from the power metering device to the database system onside the manufacturing facility by one of wireless communication and a local area network (LAN).
According to another embodiment of the invention, the collected information about the power consumption of the individual manufacturing entities is transmitted to a BI system via a packet-switched data network. Here, especially public TCP/IP based data network like the internet can be used for transferring the data from the power metering devices to the BI system, either directly or via a database system onside the manufacturing facility, as described above.
As will be appreciated by one skilled in the art, aspects of the present invention may be embodied as a system, method or computer program product. Accordingly, aspects of the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, aspects of the present invention may take the form of a computer program product embodied in one or more computer readable medium(s) having computer readable program code embodied thereon.
Any combination of one or more computer readable medium(s) may be utilized. The computer readable medium may be a computer readable signal medium or a computer readable storage medium. A computer readable storage medium may be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing. More specific examples (a non-exhaustive list) of the computer readable storage medium would include the following: an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing. In the context of this document, a computer readable storage medium may be any tangible medium that can contain, or store a program for use by or in connection with an instruction execution system, apparatus, or device.
A computer readable signal medium may include a propagated data signal with computer readable program code embodied therein, for example, in baseband or as part of a carrier wave. Such a propagated signal may take any of a variety of forms, including, but not limited to, electro-magnetic, optical, or any suitable combination thereof. A computer readable signal medium may be any computer readable medium that is not a computer readable storage medium and that can communicate, propagate, or transport a program for use by or in connection with an instruction execution system, apparatus, or device.
Program code embodied on a computer readable medium may be transmitted using any appropriate medium, including but not limited to wireless, wireline, optical fiber cable, RF, etc., or any suitable combination of the foregoing.
Computer program code for carrying out operations for aspects of the present invention may be written in any combination of one or more programming languages, including an object oriented programming language such as Java, Smalltalk, C++ or the like and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The program code may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).
Aspects of the present invention have been described above with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
These computer program instructions may also be stored in a computer readable medium that can direct a computer, other programmable data processing apparatus, or other devices to function in a particular manner, such that the instructions stored in the computer readable medium produce an article of manufacture including instructions which implement the function/act specified in the flowchart and/or block diagram block or blocks.
The computer program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other devices to cause a series of operational steps to be performed on the computer, other programmable apparatus or other devices to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide processes for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
While the invention has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive; the invention is not limited to the disclosed embodiments. Other variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word “comprising” does not exclude other elements or steps, and the indefinite article “a” or “an” does not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measured cannot be used to advantage. Any reference signs in the claims should not be construed as limiting the scope. | A method for optimizing energy efficiency in a manufacturing process includes monitoring power consumption of each of a plurality of manufacturing entities of the manufacturing process using a power metering device assigned thereto; collecting, from the power metering devices, a first data stream that includes information about the power consumption; collecting a second data stream that includes information about the manufacturing entity and process; determining an optimized product routing of products to be manufactured by the manufacturing process from one manufacturing entity to another manufacturing entity, based on the collected first and second data streams, by simulating different product routings and determining the optimal product routing with respect to the overall energy consumption of the manufacturing process; and adjusting, via a manufacturing control system, the manufacturing process based on the optimized product routing. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention regards a rotation unit for a torque tong for making and/or breaking threaded connections between pipes and/or spinning pipes during screwing and/or unscrewing of pipes, primarily pipes used in petroleum production.
2. Description of Background Art
A prior art torque tong is described in NO 163973, which concerns a torque tong arranged both to break and make a threaded connection between two pipes, and also spin one of the pipes relative to the other in order to uncouple the pipes from each other or tighten the connection.
In older solutions, a special device was used to make and break the connection, while another special device was used to spin the pipes apart or together. The solution of NO 163973 allowed both making/breaking and spinning to be carried out in the same apparatus.
The solution of NO 163973 also entailed the advantage of being able to handle pipes within a wide range of diameters.
In order to achieve this, NO 163973 proposes the use of one or more master cylinders which upon rotation of the rotary part of the tong, and as a result of the placement of the cylinders, are pressed together, applying pressure to a number of slave cylinders. The slave cylinders will in turn displace jaws to engage one of the pipes involved, ensuring that these maintain a sufficiently powerful grip on the pipe to break or make the connection to a prescribed torque without the jaws slipping relative to the pipe.
A solution similar to that of NO 163973 has been described in NO 306572. Here the jaws are also equipped with respective slave cylinders. These are pressurized by a master cylinder mounted on the rotary part, which master cylinder is then influenced by a piston mounted outside the rotary part. The jaws are brought into engagement with the pipe by increasing the pressure from the master cylinder Valves ensure that the pressure in the slave cylinders is maintained independently of the master cylinder.
A considerable disadvantage of the latter of the above solutions is that the jaw travel is restricted by the displacement of the master cylinder. In a subsequent patent application (WO 00/45027) from the same applicant as NO 306572, it is stated that in the solution of the latter patent, the piston must push the master cylinder repeatedly in order to provide a sufficient volume of hydraulic fluid to push the jaws into engagement and also achieve sufficient retaining power. This causes a significant delay in the operation. In WO 00/45027, this problem is apparently solved by means of pressure accumulators.
SUMMARY OF THE INVENTION
However, the present invention provides a far simpler solution to this problem. This solution is obtained through a fixed part and a rotary part designed to grip a pipe to be rotated, which rotary part comprises at least one movable gripping jaw arranged to be moved into engagement with the pipe wherein the fixed part comprises at least one gripping cylinder arranged to move the gripping jaw into engagement with the pipe, when the gripping jaw is operatively engaged with the gripping cylinder.
By the rotary part comprising at least one holding cylinder arranged to maintain the gripping jaw in engagement with the pipe after having been moved to engage the pipe, the gripping jaw will be certain to maintain engagement with the pipe during rotation of the rotary part.
Connecting the holding cylinder to a valve arranged to selectively prevent hydraulic fluid from flowing out of the holding cylinder and allow hydraulic fluid to flow out of the holding cylinder, allows selective retaining and releasing of the pipe.
Controlling the valve by means of an actuator disposed on the fixed part and designed to control the valve independently of the position of the rotary part, ensures that the pipe may be released independently of the position of the rotary part.
The holding cylinder being hydraulically connected to at least one slave cylinder on the rotary part, and a master cylinder on the fixed part being arranged to actuate the slave cylinder upon operative engagement between the master cylinder and the slave cylinder, facilitates expedient pressurizing of the holding cylinder.
Connecting the holding cylinder to an accumulator, which is arranged to provide hydraulic pressure for disengaging the holding cylinder from the pipe, ensures expedient retraction of the gripping jaw.
By equipping the holding cylinder with a return spring designed to disengage the holding cylinder from the pipe, it is possible to achieve expedient retraction of the gripping jaw.
Connecting the holding cylinder to a closed hydraulic system on the rotary part allows a simple hydraulic system to be achieved, which requires little maintenance and is not subjected to any significant external influences.
The hydraulic system comprises an accumulator designed to provide pressure in order to return the slave cylinder so as to allow hydraulic fluid to flow from the holding cylinder to the slave cylinder, thus achieving expedient retraction of the gripping jaw.
The gripping cylinder acts on a protrusion on the gripping jaw, achieving expedient cooperation between the gripping cylinder and the holding cylinder.
The holding cylinder is disposed inside the gripping jaw or a support for this, possibly integrated into this, thus achieving a compact solution.
The rotation unit is equipped with from one to six gripping jaws, preferably-three gripping jaws, thus achieving a good grip on the pipe, also in the event of varying dimensions.
The gripping cylinder acts on an arm, which in turn is connected to a tappet that is arranged to exert a force against the holding cylinder when the tappet is rotated from a first to a second position, thus achieving an alternative embodiment, in which the hydraulic system on the rotary part is not dependent on any other pressurizing than that provided by the gripping cylinder.
It is practical for the rotary part to be driven by chain drive. A chain drive ensures a more robust design and smoother running. Smoother running reduces the risk of “bite marks” from the jaws on the pipe. The chain will engage the rotary part across a significantly longer area than a cogwheel. This will reduce the loading on each tooth on the rotary part, and compared with direct engagement between a cogwheel and the rotary part, the loading on the chain will be more even. Moreover, the chain will be able to engage the rotary part over a section large enough to ensure that even if the rotary part does not have teeth around its entire periphery (e.g. due to an opening for introduction of pipes), the chain will be in engagement with the rotary part at all times. This would not be the case in the event of a direct engagement with cogwheels, where the cogwheels would engage and disengage the rotary part at every rotation. This increases the strain and the risk of damage to both cogwheels and teeth on the rotary part.
In the case of direct engagement with a cogwheel, the component most exposed to wear will be precisely the cogwheel. In the case of chain drive, it will be the chain. It is easier to replace a worn or damaged chain than a cogwheel, as a cogwheel inevitably of necessity would have to be securely fixed to the shaft, while the chain is arranged more or less loosely around the cogwheels. In addition, the teeth on the rotary part may be arranged so as to be replaceable, allowing easy replacement of worn or damaged teeth. The tong will be usable even with missing teeth, as the chain will be in engagement with other teeth. Drive systems incorporating a chain will not be as sensitive to dirt as drive systems based on e.g. direct gearing. The noise generated by the system will also be less.
Furthermore, the costs of producing such a system could also be lower.
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 invention will now be described in greater detail by means of an example of an embodiment shown in the accompanying drawings, in which:
FIG. 1 shows a rotary torque tong according to the present invention;
FIG. 2 shows the rotation unit of the torque tong according to the invention;
FIG. 3 mainly shows the rotary part of the rotation unit;
FIG. 4 is a sectional view of the rotation unit;
FIG. 5 shows a hydraulic connection diagram of the most important components that bring about the gripping of the pipe;
FIG. 6 shows an alternative hydraulic connection;
FIG. 7 shows alternative gripping and holding means, with
FIG. 7 a showing a jaw fully retracted from the pipe; FIG. 7 b showing the jaw about to be pushed into engagement with the pipe; and FIG. 7 c showing the jaw fully engaged with the pipe; and
FIG. 8 illustrates a principle for distribution of teeth on the rotary part.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows the rotary torque tong according to the present invention. The tong has a frame 60 generally consisting of a horizontal part 61 and a vertical part 62 . The frame 60 may be mounted on a guide rail (not shown) to allow it to be displaced horizontally on a drill floor for the tong to engage or disengage a pipe 70 (shown in FIG. 4 ).
On the vertical part 62 of the frame 60 there is disposed, as the lowermost component, a holding unit (back-up) 63 . This comprises gripping jaws 64 arranged to grip a pipe below a pipe joint (not shown) in order to hold this. The construction of the holding unit is, in principle, conventional and will be understood by a person skilled in the art. Thus this will not be explained in any detail herein.
Above the holding unit 63 there is a rotation unit 65 arranged to grip a pipe above a pipe joint. The rotation unit 65 will be explained in detail in the following. Above the rotation unit 65 there is disposed a spin unit 66 . This unit is arranged to spin the pipe above the pipe joint out of threaded engagement with a pipe below the pipe joint, or spin the pipe into threaded engagement with the pipe below the pipe joint. The spin unit has a lighter construction than the rotation unit 65 and operates at a significantly lower torque than the rotation unit. Thus it is not capable of breaking or making a pipe joint. The spin unit 65 may however rotate pipes at a considerably higher speed than the rotation unit 65 .
FIG. 2 shows the rotation unit 65 of the tong according to the invention. It comprises a rotary part 40 and a fixed part 41 . The rotary part 40 is mounted on a plate 42 attached to the fixed part via bolts 54 and brackets 55 . The plate 42 has an opening 49 . The rotary part is generally disk-shaped with a central cavity 44 and an opening 45 extending from the cavity 44 to the periphery of the disk 40 . Toothing 43 is provided around the periphery of the rotary part 40 . This toothing may consist of single teeth fixed, e.g. screwed, to the disk 40 . The toothing 43 engages two chains 46 , 47 , each of which extends across two cogwheels 48 , 50 . One of the cogwheels 50 is power-coupled to a motor 51 , preferably a hydraulic motor. Alternatively, one chain may be used, which extends across a sector of a circle greater than either of the chains 46 , 47 . When one chain 46 , 47 passes over the opening 45 , it is important for the chain to land on the first tooth after the opening as accurately as possible, to avoid wear on the tooth and chain to the greatest possible extent, and to avoid jerky movements. Consequently, the distance over which the chain extends between the teeth on either side of the opening 45 is matched so as to be equivalent to a whole number of teeth. It has been found that this may be achieved by satisfying the following two equations:
t 2 · 1 sin ( 2 · π - α 2 · N 2 ) = 0 ( 1 ) 2 · α sin ( N 1 · t 2 · r ) - α = 0 ( 2 )
in which:
t is the chain pitch, in mm, N 1 is the number of teeth that will fit over the opening 45 , between the two teeth nearest the opening, N 2 is the number of teeth along the curved section of the rotary part 40 , α is the angle (in radians) between the teeth nearest the opening, and r is the radius of the rotary part 40 at the chain, i.e. the distance from the centre of the rotary part 40 to the centre of the chain rollers.
In FIG. 8 , the relationship defined above through equations (1) and (2) has been illustrated by an example of an embodiment. The figure shows a schematic plan view of the rotary part 40 . Also shown is one chain 46 extending across the two cogwheels 48 , 50 . A number of teeth 43 are shown around the periphery of the rotary part 40 . In the example shown, it has been decided that there should be room for 67 teeth along the curved section of the rotary part 40 . However, there is no requirement for such a high density of teeth, and so only every third tooth has been installed, except on either side of the opening 45 , where two teeth have been placed close to each other in order to provide greater strength at this location, and diametrically opposite of the opening, where three teeth in a row are missing, in order to achieve symmetry. Using a smaller number of teeth than the maximum possible allows a reduction in costs and makes it easier to mount the teeth.
The rectilinear distance L r between the two teeth 43 a and 43 b closest to the opening 45 on either side of this, is shorter than the curved distance L b , that follows the curve of the rotary part 40 . If the chain had followed the curved distance L b the positioning of the teeth would be given unequivocally by the total number of teeth and the radius r of the rotary part at the chain. The chain will however follow the rectilinear distance L r . Consequently, this distance L r must provide room for a whole number of teeth. In the example shown, it has been decided that there should be room for 8 teeth along the rectilinear distance L r between the two teeth 43 a and 43 b.
Also, the chain has been chosen to have a pitch, i.e. a distance t between the centres of each of the chain's 46 rollers, of 76.2 mm.
Inserting these figures into the equations (1) and (2) will make it possible to calculate the angle α and the radius r. This gives the radius as 911.7119 mm and the angle α as 0.68176 rad, which is equivalent to 39.06°. If the stretching of the chain 46 between the teeth 43 a and 43 b had not been taken into account, the chain would have missed the tooth by 12 mm. This would have resulted in a great strain on this tooth and jerky movements.
The above way of spacing the teeth on a rotary part, and the condition of equations (1) and (2), may also be used in other contexts than that which has been described, where for various reasons, one may wish to have access to an area inside the toothing of the rotary part.
The fixed part 41 comprises a frame 52 that supports the plate 42 , the cogwheels 48 , 50 and the motors 51 . The frame 52 is mounted so as to float in a joint 53 . Through this mounting, the rotation unit 65 can automatically orient itself relative to the pipe to be gripped.
The fixed part 41 has gripping cylinders 4 , 5 , 6 mounted on it. These use their piston rod to push against a protrusion 1 c , 2 c , 3 c on each of three gripping jaws 1 , 2 , 3 . However, the piston rod is not attached to the protrusion. The holding cylinders 1 a , 2 a , 3 a are located inside the gripping jaws 1 , 2 , 3 and so are not visible in FIG. 2 , but one of them may be seen in FIG. 4 . Three displaceable gripping jaws may be used, as shown, but it is also possible to use more or fewer gripping jaws. When using fewer gripping jaws, one or more fixed gripping jaws may also be used, which are rigidly mounted to the rotary part. This will depend on how much of the pipe dimension the tong is to be used on.
When the rotary part is to be rotated, the motors 51 are actuated, causing the chains 46 , 47 to move in the same direction. Thus the chains 46 , 47 rotate the rotary part 40 , which slides on slide bearings (not shown) on the plate 42 .
In FIG. 3 the fixed part of the rotation unit has been removed. Thus in this figure, two slave cylinders 18 and two master cylinders 19 become visible. Preferably, these are positioned so as to act against each other and synchronously, so that the master cylinder 19 does not contribute to the rotation of the rotary part 40 .
The rotation unit 65 is equipped with sensors (not shown) to detect the position of the rotary part 40 , to allow the rotary part to be carefully positioned with the opening 45 in line with the opening 49 , so that the tong may be pushed onto pipes to be screwed by guiding the openings 45 , 49 onto the pipe. The jaws 1 and 3 closest to the opening 45 have been retracted to make room for the pipe to pass. Therefore these jaws 1 and 3 must be moved over a greater distance than jaw 2 before engaging the pipe.
Description will now be given of a relief mechanism for the holding cylinders. This comprises two plates 57 and 58 which, apart from an opening 45 a and 45 b , are annular. The lower plate 58 lies on the rotary part 40 and is operationally connected to three relief valves 10 b , 11 b , 12 b (see FIG. 5 ). The upper plate 57 is connected to the fixed part 41 via actuators 56 . The valves 10 b , 11 b , 12 , which relieve the pressure from the holding cylinders 1 a , 2 a , 3 a (see FIG. 5 ), are operated by actuating the actuators 56 . The upper plate 57 is forced down against the lower plate 58 , which in turn displaces the valves 10 b , 11 b , 12 b from a first position to a second position. The upper plate 57 will be able to force the lower plate down regardless of the position of the rotary part 40 relative to the fixed part 41 .
FIG. 4 is a sectional view of part of the rotation unit showing, among other things, one of the motors 51 , one of the chains 46 , the rotary part 40 , the plate 42 , one of the gripping cylinders 5 , which pushes against the protrusion 2 c with its piston rod, and one of the gripping jaws 2 . One of the holding cylinders 1 a may be seen inside the gripping jaw 2 . Also illustrated is a pipe 70 , which has just been gripped by the gripping jaw 2 after the gripping cylinder 5 has advanced this towards the pipe 70 .
FIG. 5 shows a possible example of an embodiment of the hydraulic connection for the gripping function of the rotation unit, and also shows a connection for the rotational function. In the figure, components located on the rotary part 40 of the rotation unit 65 are drawn within a line 30 . Components outside this are located on the fixed part 41 .
On the rotary part 40 are jaws 1 , 2 , 3 , which are designed to grip and hold a pipe 70 , as described above.
The jaws 1 , 2 , 3 are connected to the respective holding cylinder 1 a , 2 a , 3 a . The piston sides of the cylinders 1 a , 2 a , 3 a are connected to respective valve assemblies 10 , 11 , 12 via respective connecting lines 1 b , 2 b , 3 b . The valve assemblies 10 , 11 , 12 comprise a check valve 10 a , 11 a , 12 a , that opens for hydraulic communication with the respective holding cylinder 1 a , 2 a , 3 a when the hydraulic fluid is at a certain pressure and stops communication in the opposite direction, and the two-way relief valve 10 b , 11 b , 12 b , which is mentioned in connection with FIG. 3 , and which in a first position provides communication with the piston side of the respective holding cylinder 1 a , 2 a , 3 a and stops communication in the opposite direction, and in a second position opens for communication both ways.
The respective check valve 10 a , 11 a , 12 a communicates with the piston side of a slave cylinder 18 via a respective line 10 c , 11 c , 12 c . Preferably, three mechanically connected slave cylinders 18 are provided, but only one is shown in FIG. 5 . The respective two-way valve 10 b , 11 b , 12 b also communicates with the piston side of the slave cylinder 18 , via a respective line 10 d , 11 d , 12 d and a common check valve 20 , which opens for hydraulic communication with the slave cylinder 18 at a certain hydraulic pressure and stops communication in the opposite direction. The lines 10 d , 11 d , 12 d also communicate with a common hydraulic reservoir 16 .
The two-way valves 10 b , 11 b , 12 b are operated by a relief actuator 56 that acts on the valves 10 b , 11 b , 12 b via a first plate 57 on the fixed part and a second plate 58 on the rotary part. As shown in FIG. 3 , there are preferably at least three relief actuators 56 .
The rod side of the slave cylinder 18 communicates with the piston side of the same cylinder 18 via a valve 21 . The valve 21 comprises a check valve 21 a , which opens for communication from the piston side to the rod side and stops communication in the opposite direction, and a choke 21 b that allows limited hydraulic communication from the rod side to the piston side. The slave cylinder is equipped with a return spring 18 a that acts to push the piston 18 b towards the rod side.
The rod sides of the holding cylinders 1 a , 2 a , 3 a communicate with respective valves 13 , 14 , 15 . Each valve 13 , 14 , 15 comprises a check valve 13 a , 14 a , 15 a that opens for communication from the piston side of the respective holding cylinder 1 a , 2 a , 3 a and stops communication in the opposite direction, and a choke 13 b , 14 b , 15 b that allows limited hydraulic communication with the rod side. The valves 13 , 14 , 15 further communicate with a common accumulator 17 .
On the fixed part 41 is a hydraulic cylinder 19 , which in the following is denoted a master cylinder 19 . The master cylinder will, upon actuation and when the slave cylinder 18 is in the correct position for this, use its piston rod 19 a to push against the piston rod 18 c of the slave cylinder 18 .
When the rotary part 40 is located in such a position as to leave the master cylinder 19 and the slave cylinder 18 facing each other operationally, a respective gripping cylinder 4 , 5 , 6 will also be located operationally straight opposite the protrusion 1 c , 2 c , 3 c (not shown in FIG. 5 ) on a respective jaw 1 , 2 , 3 . The three gripping cylinders 4 , 5 , 6 will, upon actuation in this position, move the jaws 1 , 2 , 3 to engage the pipe.
On the piston side, the gripping cylinders 4 , 5 , 6 are hydraulically connected to a respective slave cylinder 31 , 32 , 33 . The pipe 70 is closer to the gripping jaw 6 . The slave cylinders 31 , 32 , 33 are actuated via a synchronizing element 36 of a synchronizing cylinder 34 , which is connected to a pump (not shown) via a load holding valve assembly 35 . The cylinder 32 is shorter than cylinders 31 and 33 , as the gripping cylinder 5 will displace its gripping jaw 2 over a shorter distance to engage the pipe, as explained in connection with FIG. 3 .
The piston sides of the gripping cylinders are connected to the pump (not shown) via a respective load holding valve assembly 7 , 8 , 9 .
The hydraulic motors 51 are connected to a pump (not shown) capable of driving the motors 51 in one direction or the other. Each motor 51 is connected to a respective cogwheel 50 via a gear 37 . Also shown is a mechanical brake 38 operable via valve assemblies 39 a , 39 b.
The principle of operation of the hydraulic connection in FIG. 5 will now be explained in greater detail.
In order to activate the three gripping jaws 1 , 2 , 3 , which form part of the rotary part of the tong, use is made of the three gripping cylinder 4 , 5 , 6 , which are activated and positioned synchronously via synchronizing cylinder 34 and slave cylinders 31 , 32 , 33 . Preferably, the synchronizing cylinder receives hydraulic power from the ring main or a stand-alone hydraulic motor-driven pump, which may be disposed on the tong or near this. The gripping cylinders are controlled by means of the hydraulic load holding valve assemblies 7 , 8 , 9 and synchronized by the synchronizing cylinder 34 being driven towards the three slave cylinders 31 , 32 , 33 , which are mechanically interconnected via the synchronizing element 36 . The slave cylinders 31 , 32 , 33 are connected to the gripping cylinders 4 , 5 , 6 , so that when the synchronizing cylinder 34 is driven towards the slave cylinders 31 , 32 , 33 , a hydraulic volume flow from the respective slave cylinders 31 , 32 , 33 will be transferred to the respective gripping cylinders 4 , 5 , 6 , achieving a synchronized movement of the gripping cylinders.
Movement and positioning of the gripping jaws is performed by running the respective gripping cylinders towards the protrusion 1 c , 2 c , 3 , c on the jaws 1 , 2 , 3 , the jaws thus being pulled out towards the centre of the cavity 44 until they meet the pipe 70 . The gripping cylinders will keep the jaws at a standstill, pressing against the pipe 70 .
When the jaws are pulled towards the pipe, they also pull three holding cylinders 1 a , 2 a , 3 a with them, sucking hydraulic oil from the open reservoir 16 through the valve assembly 10 , 11 , 12 and into the piston side of the holding cylinders 1 a , 2 a , 3 a . The valves 10 b , 11 b , 12 b are then in the position shown in FIG. 1 , in which oil is permitted to flow past in the direction of the holding cylinders 1 a , 2 a , 3 a , but is not allowed to flow away from these. The hydraulic oil on the rod side of the holding cylinders 1 a , 2 a , 3 a is evacuated through the valves 13 , 14 , 15 to the accumulator 17 .
In order to increase the clamping force between the gripping jaws and the pipe a volume of oil is delivered to the piston side of the holding cylinders 1 a , 2 a , 3 a . Since the added volume of oil does not generate any movement of the gripping jaws, this added volume of oil will cause the pressure, and consequently the clamping force, to increase. The delivery of this volume of oil is achieved by the master cylinder 19 , which is disposed on the fixed part of the tong, pressing against the slave cylinder 18 , which is disposed on the rotary part of the tong. This volume of oil flows to the holding cylinders 1 a , 2 a , 3 a via the valves 10 a , 11 a , 12 a . The pressure in the master cylinder 19 is regulated by means of a pressure transmitter in a closed loop with a proportional directional valve (not shown). Since the gear ratio between the master cylinder 19 and the slave cylinder 18 is constant, the pressure in the holding cylinders 1 a , 2 a , 3 a can easily be controlled. Upon reaching the desired pressure, the master cylinder 19 returns to the initial position. When the cylinder 19 returns, the cylinder 18 will follow, due to the return spring 18 a , and oil will flow from the rod side of the cylinder 18 to the piston side via the valve assembly 21 . At the same time, the cylinder 18 will also be refilled from the reservoir 16 via the check valve 20 . As the valve assemblies 10 , 11 and 12 stop oil flowing away from the holding cylinders 1 a , 2 a , 3 a , these will maintain their clamping force against the pipe.
When the gripping cylinders 4 , 5 , 6 are also brought back to their initial positions, the tong may rotate freely with the pipe until the desired torque has been obtained. The tong can be rotated as shown by means of hydraulic motors, impellers and chains. The torque is regulated by a closed control loop with torque feed-back from the fixture for the fixed part of the tong and a proportional valve (not shown) connected to the hydraulic motors 51 .
The pipe is disengaged from the gripping jaws 1 , 2 , 3 by operating the relief actuator 56 , which via plates 57 and 58 displaces the valve 10 b , 11 b , 12 b in the valve assembly 10 , 11 , 12 to the position that allows communication in both directions. Thus the pressure will be relieved from the piston side of the holding cylinders 1 a , 2 a , 3 a , relieving the pressure of the gripping jaws. The accumulator 17 , which is connected to the rod side of the holding cylinders 1 a , 2 a , 3 a , delivers pressure to the rod side of the holding cylinders 1 a , 2 a , 3 a through choke 13 b , 14 b , 15 b . This pressure ensures that the holding cylinders are returned to their initial position. The chokes 13 b , 14 b , 15 b will control the speed of this return stroke.
FIG. 6 is a simplified view of an alternative hydraulic connection. Here the reservoir 16 has been removed. The accumulator 17 may be a bladder accumulator filled with nitrogen, as shown, or a piston accumulator. Instead of a return spring in the slave cylinder 18 , each holding cylinder 1 a , 2 a , 3 a is equipped with a return spring 1 c , 2 c , 3 c . When the two-way valves 10 b , 11 b , 12 b are open, these return springs will push the pistons of the holding cylinders back, thereby forcing the hydraulic fluid back to the slave cylinder 18 and returning this. The accumulator 17 will also contribute to this. Thus there will be no requirement for a return spring in the holding cylinder.
An alternative solution for increasing the clamping force between the pipe and the gripping jaws after the gripping cylinders have moved these to engage the pipe, is shown in FIG. 7 . Instead of using the hydraulic arrangement shown to supply hydraulic power to the holding cylinder, use is here made of the gripping cylinders 4 , 5 , 6 ( FIGS. 7 a, b, c show only one 4 of the cylinders) to push against an arm 80 connected to a tappet 81 on the gripping jaw 1 . In FIG. 7 a the jaw 1 is fully retracted, and the gripping cylinder 4 is ready to push on the arm 80 . In a first phase (see FIG. 7 b ) the gripping cylinder pushes against the arm 80 but without rotating this about the tappet 81 . This will move the jaw 1 towards the pipe 70 to engage this. At the same time, the holding cylinder 1 a is pulled along. The holding cylinder sucks hydraulic fluid from a reservoir (not shown). After the jaw 1 has engaged the pipe 70 and no further displacement of the jaw 1 is possible, the gripping cylinder will start to rotate the arm 80 about the tappet 81 . This will cause the tappet 81 to attempt to lengthen the gripping jaw 1 . However, this is not possible in the direction of the pipe 70 , and so the piston rod and piston of the holding cylinder 1 a will be forced into the actual cylinder while the centre line 82 of the holding cylinder and the piston rod is rotated over the centre of rotation 83 of the tappet. This will reduce the available volume for the limited quantity of oil in the holding cylinder 1 a , thus increasing the pressure. The force required by the gripping cylinder 4 to rotate the arm with the tappet 81 and the position of the arm 80 will be related to the pressure in the holding cylinder 1 a , allowing the clamping force between the pipe 70 and the gripping jaws to be determined and controlled. When the force from the gripping cylinders stops acting on the arm 80 , the net force from the pressure against the piston of the holding cylinder 1 a will attempt to displace the piston forward in the actual cylinder, but as the holding cylinder has rotated about its fixture in the actual cylinder, over the centre of rotation, it will be mechanically locked. The holding cylinder will therefore act as a hydraulic spring.
For the embodiment of FIG. 7 , a simplified hydraulic arrangement may be used, which includes no master and slave cylinders, but which will include valves for relieving hydraulic pressure from the holding cylinders, in accordance with the principles illustrated in FIGS. 5 and 6 .
Return of the jaws can be achieved e.g. by opening a valve (equivalent to valves 10 b , 11 b , 12 b ) that relieves the pressure from the holding cylinders. The jaws will be retracted, either by means of a return spring or by hydraulic pressure. The arm 80 with the tappet 81 may be equipped with a return spring (not shown) to bring it back to its initial position. Alternatively, the return of the arm 80 can be brought about through gravity alone.
An alternative embodiment for synchronization of the gripping cylinders would be to have position measurement for each gripping cylinder with separate proportional valves, to allow the gripping cylinders to be individually positioned and thereby synchronized.
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. | A rotation unit for a torque tong for making and/or breaking threaded connections between pipes and/or spinning pipes during screwing and/or unscrewing of pipes, primarily pipes used in petroleum production. The unit includes a fixed part and a rotary part arranged to grip a pipe to be rotated. The rotary part includes at least one movable gripping jaw arranged to be moved into engagement with the pipe. The fixed part includes at least one gripping cylinder arranged to move the gripping jaw to engage the pipe when the gripping jaw is operatively engaged with the gripping cylinder. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to an instruction handling sequence control system for use in a vector computer to issue and execute instructions without following the sequence of instruction executions designated by a program.
A system to increase the speed of instruction handling by dynamically determining the sequence of instruction handling and issuing instructions to the arithmetic unit and the main storage processing unit without following a program-designated sequence is used in computers for scalar processing. For details of this system, reference may be made to D. W. Anderson et al., "The IBM System/360 Model 91: Machine Philosophy and Instruction-Handling", IBM Journal of Research & Development, vol. 11, No. 1, IBM, January 1967, pp. 8-24, and S. Weiss et al., "Instruction Issue Logic for Pipelined Supercomputers", 11th Annual International Symposium on Computer, IEEE, 1984, pp. 110-118.
The computers controlling the sequence of instruction handling have means to detect collisions of the input/output operands and memory addresses of instructions, judge how the arithmetic unit and the main storage handling unit are used, and decide on the issue of instructions to the arithmetic unit and the main storage handling unit without following a programmed sequence. This instruction issuing system can be as well applied to vector computers as to scalar computers. In a vector computer, however, it is difficult to judge whether a plurality of memory referencing vector instructions can be supplied to the main storage handling unit in a sequence reverse to what is designated by a program. Thus, the store starting point address of a vector store instruction designated for programmed execution being represented by base1; the distance between the elements of the vector to be stored under the vector store instruction, by dist1; the length of the vector to be stored thereunder, by len1 (len1≧1); the load starting point address of a vector load instruction designated for programmed execution after the vector store instruction being represented by base2; the distance between the elements of the vector to be loaded under said vector load instruction, by dist2; and the length of the vector to be loaded thereunder, by len2 (len2≧ 1), it is judged that the vector load instruction may reference the main store earlier than said vector store instruction only when the set of intersections between {base1, base1+dist1×1, base1+dist1×2, . . . , base1+dist1×(len1-1)}, which is the set of addresses to be stored under the vector store instruction, and {base2, base2+dist2×1, base2+dist2×2, . . . , base2+dist2×(len2-1)}, which is the set of addresses to be loaded under the vector load instruction, is void. It is difficult, however, to pass judgement in a short period of time on an arbitrary combination of bas1, dist1, len1 (len1≧1), base2, dist2, len2 (len2≧1).
In this connection, there is proposed, as applicable to cases permitting simple judgment, a method to determine the overlapping of address ranges by which referencing the main store by a vector load instruction ahead of a vector store instruction can be allowed if the set of intersections between {add1:base1≦add1≦(base1×dist1×(len1-1))} whose address set elements range from a store starting point address base1, designated by a preceding vector store instruction, to base1×dist1×(len1-1), the final store address of the same vector store instruction, and {add2:base2≦add2≦(base2×dist2×(len2-1))} whose address set elements range from a load starting point address base2, designated by a following vector load instruction, to base2+(len2-1)×dist2, the final load address of the same vector load instruction, is void. While this method permits the needed judgment with comparative ease, the combinations of base1, dist1, len1 (len1≧1), base2, dist2 and len2 (len2≧1) allowing correct judgment of passability are limited. Thus the method to determine the overlapping of address ranges has the disadvantage that, out of the 24 possible sequential relationship among base1, last1, base2 and last2, at most the following eight:
(base1≦last1≦base2≦last2)
(base1≦last1≦last2≦base2)
(last1≦base1≦base2≦last2)
(last1≦base1≦last2≦base2)
(base2≦last2≦base1≦last1)
(last2≦base2≦base1≦last1)
(base2≦last2≦last1≦base1)
(last2≦base2≦last1≦base1)
permit correct judgment, where base1 is the store starting point address of a vector store instruction designated for programmed execution; dist1, the inter-elemental distance of the vector to be stored under the vector store instruction; len1 (len1≧1), the vector length to be stored thereunder; last1, the address of the final vector element to be stored thereunder; base2, the load starting point address of a vector load instruction designated for programmed execution after the vector store instruction; dist2, the inter-elemental distance of the vector to be loaded under the vector load instruction; len2 (len2≧1), the vector length to be loaded thereunder; and last2, the address of the final vector element to be loaded thereunder.
SUMMARY OF THE INVENTION
An object of the present invention, therefore, is to provide an instruction handling sequence control system which is cleared of the aforementioned disadvantage and capable of passing judgment in a short period of time on a greater variety of combinations of base1, dist1, len1, base2, dist2 and len2 as to the reversibility of the sequence of instructions with respect to referencing the main storage.
According to one aspect of the present invention, there is provided an instruction handling sequence control system comprising first means for holding a group of instructions to be issued to a vector operating unit and a main storage handling unit; second means for holding the states of the vector register, operating unit and main storage unit used under an instruction being executed; third means for determining, out of the group of instructions held by the first means and on the basis of the states of the resources held by the second means, an instruction to be issued to the vector operating unit and the main storage handling unit without conforming to the programmed sequence of instruction issues; and another means for issuing, with respect to a vector store instruction in the group of instructions held by the first means and a vector load instruction in the group of instructions held by the first means, programmed to be issued after the vector store instruction, the vector load instruction before the vector store instruction to the vector operating unit and the main storage handling unit when the distance between vector elements designated by the vector store instruction is equal to that designated by the vector load instruction, the store starting point address designed by the vector store instruction is unequal to the load starting point address designated by the vector load instruction, and the difference between the store starting point address designated by the vector store instruction and the load starting point designated by the vector load instruction is smaller than the distance between vector elements designated by the vector load instruction.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects, features and advantages of the present invention will become more apparent from the detailed description hereunder when taken in conjunction with the accompanying drawings, in which:
FIG. 1 illustrates a preferred embodiment of the invention;
FIGS. 2 and 3 illustrate examples of the main memory referencing logic contention checking section 9 of FIG. 1;
FIG. 4 illustrates an example of program for explaining the operation of the invention;
FIGS. 5A and 5B illustrate how vector load/store instructions reference the main storage;
FIGS. 6A to 6B illustrate how instructions are stored in the instruction storage section 2 of FIG. 1;
FIG. 7 illustrates the detailed configuration of the register referencing logic contention checking section 8;
FIG. 8 illustrates the detailed configuration of part of the instruction issue deciding section 7;
FIG. 9 illustrates how instructions are executed and how different busy signals vary with the execution of the instructions; and
FIG. 10 illustrates how instructions are executed.
In the figures, the same reference numerals denote respectively the same constituent elements.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a preferred embodiment of the present invention comprises a program holding section 1 for storing a program; an instruction storage section 2 for storing a plurality of Instructions "1" and "2" from the program holding section 1, standing by to be issued; a vector operating section 5 consisting of a plurality of vector registers and one or more arithmetic units; a main memory referencing handling section 6 for controlling access to a main storage unit; a state holding section 3 for holding the states of the vector registers, arithmetic unit(s) and main storage unit used under an instruction being executed; and an instruction handling sequence determining section 4 for determining instructions to be issued to the vector operating section 5 and main memory referencing handling section 6 on the basis of instructions from the instruction storage section 2 and information on the states of the resources from the state holding section 3 without conforming to the programmed sequence of instruction issues.
The instruction storage section 2, every time a vacancy arises therein, stores a succeeding instruction in accordance with a programmed sequence. This section 2 holds, for instance, two instructions including Instruction "1" and Instruction "2" in such a manner that what precedes in the programmed sequence is kept as Instruction "1" and what succeeds, as Instruction "2".
The instruction handling sequence determining section 4 comprises a main memory referencing logic contention checking section 9, register referencing logic contention checking section 8 and instruction issue deciding section 7.
Referring now to FIG. 2, the main memory referencing logic contention checking section 9 further consists of a register 21 for storing the vector access starting point address (base1) of Instruction "1"; a register 22 for storing the vector access starting point address (base2) of Instruction "2"; a register 23 for storing the interelemental distance (dist1) to be vector-accessed under Instruction "1"; a register 24 for storing the interelemental distance (dist2) to be vector-accessed under Instruction "2"; a subtractor circuit 25; absolute value circuits 26, 27 and 28; a comparator 29 for judging whether or not a relationship of inequality holds; another comparator 30 for judging whether or not a relationship of one value being greater than the other holds; still another comparator for judging whether or not a relationship of equality holds; and a three-input AND circuit 32.
Referring to FIG. 7, the register referencing logic contention checking section 8 comprises a comparator circuit 77 for comparing the write register number 71 of the preceding Instruction "1" and the write register number 74 of the succeeding Instruction "2", and outputting a signal when the two numbers are not identical; a comparator circuit 78 for comparing the write register number 71 of the preceding Instruction "1" and a second read register number 76 of the succeeding Instruction "2", and outputting a signal when the two numbers are not identical; a comparator circuit 79 for comparing the write register number 71 of the preceding Instruction "1" and a first read register number 75 of the succeeding Instruction "2", and outputting a signal when the two numbers are not identical; a comparator circuit 80 for comparing a first read register number 72 of the preceding Instruction "1" and the write register number 74 of the succeeding Instruction "2"; a comparator circuit 81 for comparing a second read register number 73 of the preceding Instruction "1" and the write register number 74 of the succeeding Instruction "2"; and an AND gate 82 for obtaining the logical product of the outputs of the comparator circuits 77 through 81.
"Passability of an instruction" basically requires satisfaction of all of the three following conditions.
First, no succeeding instruction should read out the contents of a register in which the results of the execution of a preceding instruction are stored.
Second, no succeeding instruction should write into a register from which a preceding instruction is to read out.
Third, the write register of a preceding instruction and that of a succeeding instruction should not be the same register.
The register referencing logic contention checking section 8 illustrated in FIG. 7 is an example of circuit presenting such requirements; if the output of its AND gate 82 is logical "0", passing is prohibited or, if it is logical "1", passing is allowed.
The second requirement can be eliminated by so composing this checking section 8 that the content of the read register for the preceding instruction is copied in advance. Thus, before the execution of passing by the succeeding instruction, the content of the register read out by the preceding instruction is buffered. In this case, even if the succeeding instruction writes into a register from which the preceding instruction is to read out, the preceding instruction can be properly executed by using the prebuffered value as the value of the read register for the preceding instruction.
Next, the instruction issue deciding section 7 will be described in detail. Referring to FIG. 8, an instruction issue permit/forbid signal generating circuit, one of the main constituents of the instruction issue deciding section 7, is provided for each of the preceding and succeeding instructions. Each such circuit comprises a decoder 83 for decoding the instruction code; a decoder 84 for decoding the write register number; a decoder 85 for decoding the first read register number; a decoder 86 for decoding the second read register number; a group of AND gates 87 through 101 for obtaining logical products between the decoding results of these decoders 83 through 86 and state signals each indicating a busy or an unbusy state, fed from the state holding section 3 of FIG. 1 via a line 14; and an OR gate 102 for obtaining the logical sum of the outputs of the AND gates 87 through 101.
This instruction issue permit/forbid signal generating circuit judges whether or not a given instruction can be issued (executed). The signals indicating a busy or an unbusy state, fed from the state hold section 3 via the line 14, refer only to a main memory access bus, an adder, a multiplier and registers (VR0 to VR3). The types of such signals, however, are not limited to these, but there can be more, depending on the configurations of the vector operating section 5 and the main memory referencing handling section 6. Here are shown, for the sake of describing convenience, only the minimum required check signals.
The decoder 83 generates output signals listed in Table 1 below correspondingly to the value of the instruction code.
TABLE 1______________________________________Instruction Output Output OutputCode signal 0 signal 1 signal 2______________________________________VLOAD 1 0 0VSTORE 1 0 0VMULT 0 0 1VADD 0 1 0______________________________________
The decoders 84 through 86 generate output signals listed in Table 2 below correspondingly to the value of the register number.
TABLE 2______________________________________Register Output Output Output OutputNumber signal 0 signal 1 signal 2 signal 3______________________________________VR0 1 0 0 0VR1 0 1 0 0VR2 0 0 1 0VR3 0 0 0 1______________________________________
Next will be described the operation by way of a typical program shown in FIG. 4.
Referring to FIG. 4, VLOAD denotes the instruction code of vector load; VADD, that of vector addition; VSTORE, that of vector store; and VMULT, that of vector multiplication. Each of VR0 through VR3 denotes the vector register of an instruction operand, and each vector register is supposed to be able to store 256 vector elements. An instruction operand represented by a set of three, (a, b, c) denotes the main storage operand of a vector load/store instruction, with a corresponding to the starting point of vector access, b, to the distance between vector elements and c, to the vector length. The first instruction, "VLOAD VR0←(base, 5, 256)", for instance, requires loading of such vector elements as the memory starting point address of "base", the distance between vector elements of "5" and the vector length of "256" into the vector register VR0.
Now will be described with reference to FIG. 5 the sequence of referencing the main storage under the program shown in FIG. 4. FIG. 5A shows the memory address referenced by the first instruction of FIG. 4 and the main storage access instruction, second in the same figure. As both of these first two are vector load instructions and there is no contention for a vector register between them, they are executed in the programmed sequence. Next, after the execution of the first two instructions is started, the third instruction, a vector add instruction, is put to execution in synchronism with the loading of operands into the vector register VR0 and VR1, but the fourth instruction, a vector store instruction, to write the result of the execution of said add instruction into the main storage cannot be executed before the result of the addition is written into the VR0. Meanwhile the fifth instruction, a vector load instruction, is not for loading the result of storing under the fourth vector store instruction, and accordingly can be executed ahead of the fourth instruction.
The essence of the present invention consists in the judgment that this fourth vector store instruction can be passed by the fifth vector load instruction with respect to referencing the main storage. According to the invention, the passability can be determined because the fourth vector store instruction and the fifth vector load instruction are equal to each other in the distance between vector elements (|5| in both), the former's store starting point address (base) is unequal to the latter's load starting point address (base+2), and the difference between the former's store starting point address and the latter's load starting point address (|base+2-base|=2) is smaller than the inter-elemental distance of the fourth vector store instruction (|5|=5).
The instruction issue deciding section 7 will now be described in detail below on this basis with reference to actual instructions.
-VLOAD VR0←(base, dist, len)
As the instruction code is VLOAD, this instruction cannot be issued if the main storage access memory is busy at the moment. As the write register number is VR0, this instruction cannot be issued if VR0 is busy reading at the moment.
-VSTORE VR1→(base, dist, len)
As the instruction code is VSTORE, this instruction cannot be issued if the main storage access memory is busy at the moment. As the read register number is VR1, this instruction cannot be issued if VR1 is busy writing at the moment.
-VMULT VR2←VR0, VR1
As the instruction code is VMULT, this instruction cannot be issued if the multiplier is busy at the moment. As the write register number is VR2, this instruction cannot be issued if VR2 is busy reading at the moment. Further, as the read registers are VR0 and VR1, this instruction cannot be issued if either of these registers is busy writing at the moment.
The generating circuits of FIG. 8 are intended to check, with respect to these three examples, if the hardware resources to be used under the instruction now to be issued are used under an instruction already issued and now being executed.
Referring again to FIG. 1, the final judgment by the instruction issue deciding section 7 is given on the combined basis of the result of judgment by the main memory referencing logic contention checking section 9 provided via a line 16, and by the register referencing logic contention checking section 8 provided via a line 152 and those of the generating circuits of FIG. 8 provided corresponding to the preceding and succeeding instructions.
The relationships among them are shown in Table 3.
TABLE 3__________________________________________________________________________ Judgment result by instructionJudgment result Judgment result issue deciding sectionof main storage register Judgment on Judgment onreferencing referencing preceding succeeding Final action oflogic contention logic contention instruction instruction instruction issuechecking section checking section (Instruction "1") (Instruction "2") deciding section__________________________________________________________________________Any Any Issue permitted Any Instruction "1" issuedAny Any Issue prohibited Issue prohibited No actionPassing Passing Issue prohibited Issue permitted No actionprohibited prohibitedPassing Passing Issue prohibited Issue permitted No actionprohibited permittedPassing Passing Issue prohibited Issue permitted No actionpermitted prohibitedPassing Passing Issue prohibited Issue permitted Instruction "2"permitted permitted issued__________________________________________________________________________
Now, before describing the operation of the preferred stop embodiment of the present invention, the relationships between the states of execution of instruction and different busy signals will be described in detail with reference to FIGS. 9 and 10.
First will be described the states of execution of the instructions.
Referring to FIG. 9, the states of execution of the instruction including VLOAD, VADD, VMULT and VSTORE are represented by parallelograms. The meaning of the parallelogram will be explained with reference to FIG. 10. In a vector operation, the processing of main storage referencing, arithmetic operation and so forth is achieved in a pipeline system. Therefore, first, second, third vector elements and so on are simultaneously processed in a pipeline manner. Each oblique side of the parallelogram represents the progress of processing of one of these elements over time. Each horizontal side of same denotes the progress of successive processing of new vector elements.
The steps of vector element processing in vector loading, for example, are address generation, main storage accessing and storing of read data into vector registers.
Those in vector operations (VADD and VMULT), for instance, are reading out of vector registers, arithmetic operation and storing of the results of operation into vector registers.
Next will be described changes in the states of busy signals.
Referring to FIG. 9, solid lines indicate that the busy signals they represent are ON. Numerals over the busy signals indicate what instructions in execution make the respective units busy.
The first instruction (VLOAD VR0←(base, 5, 256)) will be taken up as an example. As this instruction is taken out of a queue standying by for execution and its actual execution started, the main storage access bus and VR0 are made busy to be written into. The release timing of the busy state differs between the main storage access bus busy and the VR0 write busy. For the main storage access bus, the busy state continues until immediately before the main storage access bus becomes available for use by the succeeding VLOAD/VSTORE instructions, while the VR0 register remains busy to be written into until immediately before the succeeding instruction to read out of the VR0 is actually allowed to read.
Whereas the type of busy signal and the setting of its release timing vary with the configurations of the vector operating section and of the main storage handling section, reading out of each vector register in this particular embodiment is supposed to permit simultaneous handling in response to read demands by a plurality of instructions.
Next, the operation of the preferred embodiment of the present invention will be described in detail by way of the typical program of FIG. 4 with reference to FIGS. 1, 2, 6 and 9.
Referring to FIGS. 1, 2, 6 and 9, first in the state of an execution awaiting queue 2 in the initial state (at point of time t 0 in FIG. 9), the vector load instruction, the first in the program, is set as Instruction "1", and the vector load instruction, the second in same, as Instruction "2" (the state of FIG. 6(a)). The register referencing logic contention checking section 8 notifies the instruction issue deciding section 7 of the passability because the register into which Instruction "1", given the precedence by the program, is to write is not referenced by Instruction "2", succeeding according to the program, for reading and because the register to be referenced by Instruction "2" for writing is not referenced by Instruction "1" for reading. The main storage referencing logic contention checking section 9, having the circuitry illustrated in FIG. 2, notifies the instruction issue deciding section 7 of the passability because the main storage reference starting point address base1 of Instruction "1" is unequal to the main storage reference starting point address base2 of Instruction "2", the vector reference inter-elemental distance of Instruction "1" is unequal to the main storage reference interelemental distance of Instruction "2", and the difference between the main storage reference starting point address base1 of Instruction "1" and the main storage reference starting point address base2 of Instruction "2" is smaller than the vector reference inter-elemental distance of Instruction "1". The instruction issue deciding section 7 determines, according to a signal from the state holding section 3 that neither Instruction "1" nor Instruction "2" contends for the registers, arithmetic unit and main storage handling section used by the instruction currently under execution. It is therefore judged that either Instruction "1" or "2" can be issued and there is no logical sequential relationship between Instructions "1" and "2", so that the vector load instruction, the first for Instruction "1", is issued (at point of time t 1 in FIG. 9).
In the next state of the execution awaiting queue 2, there are set the vector load instruction, and second in the program, as Instruction "1", and the vector add instruction, the third in same, as Instruction "2" (the state of FIG. 6(b)). The register referencing logic contention checking section 8 notifies the instruction issue deciding section 7 of the non-passability because the register into which Instruction "1", given the precedence by the program, is to write is referenced by Instruction "2", succeeding according to the program, for reading. The main storage referencing logic contention checking section 9 passes no judgment because Instruction "1" does not reference the main storage. The instruction issue deciding section 7 issues the vector load instruction, the second for Instruction "1", at such a timing that the main memory referencing handling section 6 can handle the next instruction in accordance with a signal from the state holding section 3 because a signal from the register referencing logic contention checking section 8 indicates non-passability between Instructions "1" and "2" (at point of time t 2 in FIG. 9).
In the following state of the execution awaiting queue 2, there are set the vector add instruction, the third in the program, as Instruction "1", and the vector store instruction, the fourth in same, as Instruction "2" (the state of FIG. 6(c)). The register referencing logic contention checking section 8 notifies the instruction issue deciding section 7 of the non-passability because the register into which Instruction "1", given the precedence by the program, is to write is referenced by Instruction "2", succeeding according to the program, for reading. The main storage referencing logic contention checking section 9 passes no judgment because Instruction "1" does not reference the main storage. The instruction issue deciding section 7 issues the vector and instruction, the third for Instruction "1", at such a timing that the vector registers VR0 and VR1 permit reading in accordance with a signal from the state holding section 3 because a signal from the register referencing logic contention checking section 8 indicates non-passability between Instructions "1" and "2" (at point of time t 3 in FIG. 9).
In the next state of the execution awaiting queue 2, there are set the vector store instruction, the fourth in the program, as Instruction "1", and the vector load instruction, the fifth in same, as Instruction "2" (the state of FIG. 6(d)). The register referencing logic contention checking section 8 notifies the instruction issue deciding section 7 of the passability because the register into which Instruction "1", given the precedence by the program, is to write is not referenced by Instruction "2", succeeding according to the program, for reading and because the register to be referenced by Instruction "2" for writing is not referenced by Instruction "1" for reading. The main storage referencing logic contention checking section 9, having the circuitry illustrated in FIG. 2, notifies the instruction issue deciding section 7 of the passability because the main storage reference starting point address base1 of Instruction "1" is unequal to the main storage reference starting point address base2 of Instruction "2", the vector reference inter-elemental distance of Instruction "1" is equal to the main storage reference inter-elemental distance of Instruction "2", and the difference between the main storage reference starting point address base1 of Instruction "1" and the main storage reference starting point address base2 of Instruction "2" is smaller than the vector reference inter-elemental distance of Instruction "1". The instruction issue deciding section 7 issues the vector load instruction, the fifth for Instruction "2", because, according to a signal from the state holding section 3 the vector store instruction for Instruction "1" cannot be issued before the result of processing of the third vector add instruction, issued in the previous state, begins to be written into the vector register VR0 and Instruction "2" can pass Instruction "1" (at point of time t 4 in FIG. 9).
In the ensuing state of the execution awaiting queue 2, there are set the vector store instruction, the fourth in the program, as Instruction "1", and the vector load instruction, the sixth in same, as Instruction "2" (the state of FIG. 6(e)). It is supposed that the result of the processing of the third vector add instruction, earlier issued for execution, has begun to be written into the vector register VR0 by this point of time. The register referencing logic contention checking section 8 notifies the instruction issue deciding section 7 of the passability because the register into which Instruction "1", given the precedence by the program, is to write is not referenced by Instruction "2", succeeding according to the program, for reading and because the register to be referenced by Instruction "2" for writing is not referenced by Instruction "1" for reading. The main storage referencing logic contention checking section 9, having the circuitry illustrated in FIG. 2, notifies the instruction issue deciding section 7 of the passability because the main storage reference starting point address base1 of Instruction "1" is unequal to the main storage reference starting point address base2 of Instruction "2", the vector reference inter-elemental distance of Instruction "1" is equal to the main storage reference inter-elemental distance of Instruction "2", and the difference between the main storage reference starting point address base1 of Instruction "1" and the main storage reference starting point address base2 of Instruction "2" is smaller than the vector reference inter-elemental distance of Instruction "1". The instruction issue deciding section 7 determines, according to a signal from the state holding section 3 that neither Instruction "1" nor Instruction "2" contends for the registers, arithmetic unit and main storage handling section used by the instruction currently under execution. It is therefore judged that either Instruction "1" or "2" can be issued and there is no logical sequential relationship between Instructions "1" and "2", so that the vector store instruction, the fourth for Instruction "1", is issued (at point of time t 5 in FIG. 9).
Thereafter, the state of the execution awaiting queue 2 changes to those of FIG. 6(f) and FIG. 6(g) by the same procedure.
Whereas this preferred embodiment of the invention, as described above, judges the logical passability between two vector/main storage referencing instructions in an oblique relationship to each other, the execution awaiting queue 2 can be enlarged to permit three or more entries. While this embodiment concerns passing of a vector store instruction by a vector load instruction, the invention can as well be applied to passing of one vector store instruction by another, of one vector load instruction by another or of a vector load instruction by a vector store instruction.
It is also made possible to pass judgment on both oblique and overlapping relationships of addresses by adding a circuit which determines passability with respect to main storage referencing if the main storage referencing logic contention checking section 9 judges that the set of intersections between {add1:base1≦add1≦(base1×dist1×(len1-1))}, whose address set elements range from a store starting point address base1, designated by a preceding vector store instruction, to base1×dist1×(len1-1), the final store address of the same vector store instruction, and {add2:base2≦add2≦(base2×dist2 (len2-1))} whose address set elements range from a load starting point address base2, designated by a following vector load instruction, to base2+(len2-1)×dist2, the final store address of the same vector load instruction, is void.
Another example of the main storage referencing logic contention checking section 9 for judging an overlapping relationship between addresses will now be described in detail with reference to FIG. 3.
Referring to FIG. 3, the other example of the main storage referencing logic contention checking section 9 comprises a register 33 for storing the starting point address of vector accessing under Instruction "1" (base1); a register 34 for storing the vector length of vector accessing thereunder (len1); a register 35 for storing the inter-elemental distance of vector accessing thereunder (dist1); a register 36 for storing the starting point address of vector accessing under Instruction "2" (base2); a register 37 for storing the vector length of vector accessing thereunder (len2); a register 38 for storing the inter-elemental distance of vector accessing thereunder (dist2); an adder 39; a multiplier 40, an adder 41; an adder 42; a multiplier 43; an adder 44, a 2×2 switching circuit 45; registers 46 to 49; a comparator 50 for judging whether or not a relationship of one value being greater than the other holds; a comparator 51 for judging whether or not a relationship of one value being smaller than the other holds; a comparator 52 for judging whether or not a relationship of one value being greater than the other holds; a comparator 53 for judging whether or not a relationship of one value being smaller than the other holds; an OR circuit 54; an AND circuit 55; an OR circuit 56; an oblique relationship judging circuit 57; and an OR circuit 58.
The oblique relationship judging circuit 57 is the same as the corresponding one in FIG. 2. The 2×2 switching circuit 45 achieves a cross connection when the code section of the register 35 storing the inter-elemental distance of vector accessing under Instruction "1" (dist1) indicates a negative number and a non-intersecting connection when the code section of the register 35 storing the inter-elemental distance of vector accessing under Instruction "1" (dist1) indicates a positive number.
The present invention provides the advantage that, if the address on the main storage to be referenced by a vector store instruction and that to be referenced by a vector load instruction, programmed to follow the vector store instruction and equal in distance between vector elements to the vector store instruction, are in an oblique relationship to each other and the starting point address to be accessed by the vector store instruction and that to be accessed by the vector load instruction are not more distant from each other than the distance between vector elements of said vector store, passability with respect to main storage referencing can be correctly judged. | An computer program instruction sequence control system to allow parallel or simultaneous execution of instructions. The system begins by loading two instructions for sequence determination. The system then checks if either instruction reads from or writes into the other instruction, if both instructions reference the same address, or if either instruction will contend with a currently executing instruction for the registers, arithmetic unit, or main memory. If no interference occurs, both instructions will be issued in parallel or simultaneously. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates generally to air bags of the type utilized in vehicle occupant restraint systems. More particularly, the present invention relates to a vehicle air bag constructed substantially entirely of an uncoated fabric, as well as methods of producing such an air bag.
Virtually all motor vehicles in service today are equipped with seatbelts to restrain vehicle occupants during a collision. Recently, however, many vehicles have also been equipped with air bag systems to supplement the protection provided by seatbelts. These air bag systems utilize at least one folded air bag in fluid communication with a source of inflation gas. A sensor is provided to detect a collision between the vehicle and another object. When such a collision is detected, the sensor actuates the source of inflation gas. As a result, the air bag is rapidly expanded to absorb at least a portion of the impact force which would otherwise have been imparted to the vehicle occupant.
Typically, thee air bag is designed to inflate in a period which generally corresponds to the "crash pulse" of the vehicle in which it is installed. For example, a vehicle having relatively "stiff" frame may have a crash pulse of approximately 30 milliseconds. In other words, a period of 30 milliseconds will elapse between the time in which a collision occurs at the front end of the vehicle and the time in which the force of such a collision is transmitted back to the vehicle occupant and the cushion is fully inflated.
In contrast, a vehicle having a relatively "soft" frame may have a crash pulse of approximately 50 milliseconds or more. Thus, an air bag installed in an exemplary vehicle having a relatively "stiff" frame may be required to inflate 20 milliseconds or more faster than an air bag installed in an exemplary vehicle have a relatively "soft" frame. To effect this faster inflation, a larger and more powerful source of inflation gas will typically be required.
Air bags have generally been divided into two types, i.e. driver side and passenger side. Driver side air bags have often been fitted into the vehicle steering column. These air bags, which typically have a circular configuration when fully inflated, have tended to be smaller because of the relatively small space between the driver and the steering wheel.
Passenger side air bags, on the other hand, have generally been fitted into the vehicle dash ahead of the front seat passenger. Due to the relatively large space between the front seat passenger and the dash, these air bags have tended to be larger than driver side air bags. When fully inflated, a passenger side air bag will generally have a box-like configuration.
Due to various considerations, driver side air bags and passenger side air bags have often been constructed of different materials. Specifically, driver side air bags have frequently been constructed of a base fabric of either nylon or polyester which has been coated with chloroprene (neoprene), silicone or other appropriate elastomeric resin to reduce permeability. Passenger side air bags have generally been constructed of uncoated fabric.
It is important to design an air bag such that a specific rate of deflation is achieved. In other words, the air bag should quickly deflate in a controlled manner as it is impacted by the vehicle occupant. Adequate support will thereby be provided to the vehicle occupant without excessive rebounding.
To achieve the desired rate of the deflation, driver side air bags have generally been constructed having relatively large vent holes through which the inflation gas is expelled. It should be appreciated that an air bag intended to be used in a vehicle having a stiff frame will generally be required to deflate faster than an air bag for use in a soft frame vehicle. Thus, the specific size of these vent holes will generally be related to the crash pulse of the vehicle.
Because the inflation gas is generally very hot, the vent holes have typically been defined in the rear panel of the air bag opposite the front panel which is impacted by the driver. While face burns are largely avoided by placing the vent holes in this location, finger and hand burns have often occurred. Additionally, relatively large vent holes often allow sodium azide particulate in the inflation gas to escape into the vehicle's passenger compartment.
Due to these problems, the air bag industry has developed various alternative designs which do not have large vent holes. One such design is referred to as a "hybrid" air bag. The hybrid air bag is a driver side air bag utilizing a coated front panel which is generally impermeable to air, while having a back panel constructed of an uncoated fabric. This uncoated fabric, like the uncoated fabric utilized to produce many passenger side air bags, provides a degree of air permeability by venting air through the fabric's natural interstices.
Prior art uncoated fabrics utilized in vehicle air bags rely heavily on processing parameters to control air permeability. For example, different air permeability values have often been achieved by adjusting such factors as yarn preparation, weaving, scouring or heat setting. A problem with attempting to achieve a specific air permeability in this manner is that such processing parameters are often difficult to control on a consistent basis. As a result, relatively large variations in air permeability are often seen between respective lots of uncoated fabric which have ostensibly been prepared to the same permeability specification. In fact, variations of ±three (3) cubic feet per minute (CFM) at 1/2 inch of water pressure are not uncommon. These wide variations in permeability may undesirably result in large variations in the deflation rates of respective air bags produced for a particular vehicle model.
SUMMARY OF THE INVENTION
The present invention recognizes and addresses the foregoing disadvantages, and others of prior art constructions and methods.
Accordingly, it is an object of the present invention to provide an improved air bag for use in a motor vehicle.
It is a more particular object of the present invention to provide an improved vehicle air bag which is constructed substantially entirely of an uncoated fabric.
It is a further object of the present invention to provide an improved vehicle air bag constructed substantially of an uncoated fabric which has multiple panels of various permeabilities.
It is also an object of the present invention to provide an improved fabric material for use in an air bag.
It is an additional object of the present invention to provide improved methods of producing a vehicle air bag.
Some of these objects are achieved by a vehicle air bag for use with an on-board inflator mechanism. When constructed as a driver side air bag, it may include a front panel of substantially uncoated fabric having a permeability of less than approximately two (2) CFM. A back panel of uncoated fabric is also provided having a permeability of greater than approximately two (2) CFM. In presently preferred embodiments, the back panel will have a permeability falling within a range of approximately four (4) CFM to six (6) CFM. (Unless otherwise indicated, permeability values given herein are expressed with reference to a pressure drop of 1/2 inch of water.) With the exception of a hole defined therein for providing fluid communication with the on-board inflator mechanism, the back panel is substantially continuous throughout its extent.
The air bag may also be constructed as a passenger side air bag further having a body panel and a pair of side panels. In this case, the body panel will preferably have a permeability of less than approximately two (2) CFM, whereas the side panels will preferably each have a permeability of greater than approximately five (5) CFM. Preferably, the permeability of the side panels will fall within a range of approximately five (5) CFM to seven (7) CFM.
Controlled permeability in the various panels may be achieved according to the invention by a multiplicity of needle punctures having a larger diameter at a first side of the fabric than at a second side of the fabric. In this case, the fabric of the front or body panels may be arranged such that the first side defines a portion of an exterior of the air bag. Conversely, the fabric of the back and side panels may be arranged such that the first side defines a portion of an interior of the air bag.
Some objects of the present invention are also achieved by a method of producing a vehicle air bag constructed substantially entirely of an uncoated fabric. Preferably, a first step in such a method is to provide an uncoated fabric of appropriate synthetic yarn. A first portion of the uncoated fabric may then be selectively processed to achieve a first preselected permeability. Next, a second portion of the uncoated fabric may also be selectively processed to achieve a second preselected permeability which is higher than the first preselected permeability. The vehicle air bag may then be constructed utilizing the first portion and second portion of the uncoated fabric for various panels thereof.
In a presently preferred methodology, the first and second portions of the uncoated fabric are selectively processed by being calendered under selected temperature and pressure conditions to achieve a low reference permeability. The portions are then further processed to increase a porosity thereof such that a selected permeability is achieved on a consistent basis. In the case of a front panel of a driver side air bag or a body panel of a passenger side air bag, this controlled permeability would generally be less than two (2) CFM. For a back panel of a driver side air bag this controlled permeability would generally be greater than approximately two (2) CFM, whereas a controlled permeability of greater than five (5) CFM would generally be selected for side panels of a passenger side air bag.
This further processing may be accomplished by moving the uncoated fabric at a selected speed past a plurality of needles reciprocating at a selected rate into and out of engagement therewith. In this case, a plurality of barbless needles are preferably utilized if the preselected permeability is less than a threshold permeability. If the preselected permeability is greater than the threshold permeability, a plurality of barbed needles are preferably utilized for this purpose. The threshold permeability may generally fall within a range of 3.0 CFM to 4.0 CFM, With a value of approximately 3.5 CFM being typical.
Alternatively, the uncoated fabric may be moved past a plurality of fluid jets, preferably water jets, which impact the uncoated fabric under selected operating conditions. Pores created by the fluid jets may be set in the uncoated fabric by heat. As a result, the fabric will maintain the desired permeability level during use.
Other object, features and aspects of the present invention are discussed in greater detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
A full and enabling disclosure of the present invention, including the best mode thereof, to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, including reference to the accompanying figures, in which:
FIG. 1 is a back elevation of a typical prior art driver side air bag;
FIG. 2 is a side elevation of a driver side air bag constructed in accordance with the present invention;
FIG. 3 is a perspective view of a passenger side air bag constructed in accordance with the present invention;
FIG. 4 diagrammatically illustrates calendering of an uncoated fabric to selectively reduce the permeability thereof;
FIG. 5 diagrammatically illustrates needling of a calendered uncoated fabric to selectively increase the porosity thereof;
FIG. 6A and 6B respectively illustrate a barbless needle and a barbed needle such as may be used in the needling apparatus of FIG. 5;
FIG. 7 diagrammatically illustrates a cross section of a calendered uncoated fabric which has been needled to show the configuration of the respective punctures; and
FIG. 8 diagrammatically illustrates a water jet apparatus which may alternatively be used to increase the porosity of the uncoated fabric.
Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present invention, which broader aspects are embodied in the exemplary construction.
Referring now to FIG. 1, a typical driver side air bag of the prior art is indicated generally at 10. Air bag 10 includes a front panel (not shown) which is attached to a back panel 12 via stitching or other appropriate means of such attachment. Back panel 12 defines an inflator hole 14 to provide fluid communication with a source of inflation gas. As discussed above, the front panel and back panel 12 are each typically constructed of fabric which has been coated with an elastomeric resin to be practically impermeable to the passage of air. Accordingly, vent holes, such as vent holes 16 and 18, are defined in back panel 12 to,expel the inflation gas so that air bag 10 will quickly deflate as desired.
As described above, the use of vent holes has often produced a number of undesirable consequences, such as finger or hand burns and excessive gas particulate. Additionally, air bags constructed of coated material tend to be more bulky than air bags constructed of uncoated material. Coated material is also generally more expensive to produce than uncoated material. As used herein, it is to be understood that the term "coated", refers to the coating of a fabric with some type of elastomer or the like to reduce its air permeability Thus, the term "uncoated" is not intended to preclude coating of the fabric with some other type of material having a relatively small weight in comparison with the base fabric for purposes other than reducing air permeability.
FIG. 2 illustrates a driver side air bag 20 of the present invention which is constructed substantially entirely of uncoated fabric. Air bag 20 has a back panel 22 and a front panel 24 attached about their respective circumferences by stitching or other appropriate means of such attachment. Back panel 22 defines therein an inflator hole 26, but preferably is otherwise continuous throughout its extent. In other words, back panel 22 may be generally devoid of large vent holes, such as vent holes 16 and 18 of air bag 10.
Instead of relying upon the natural interstices of the fabric to provide venting, the uncoated fabric of back panel 22 and front panel 24 has been processed according to the invention to provide a controlled permeability. AS indicated by the relative occurrence of stippling in FIG. 2, back panel 22 will preferably have a greater permeability than front panel 24. In presently preferred embodiments, the permeability of back panel 22 is greater than approximately two (2) CFM, often falling within a range of approximately four (4) CFM to six (6) CFM. In an exemplary construction, the permeability of back panel 22 may fall within a range of five (5) CFM to six (6) CFM. Front panel 24 will generally have a permeability of less than two (2) CFM.
FIG. 3 illustrates a passenger side air bag 28 of the present invention. Air bag 28 is also constructed substantially entirely of uncoated fabric, which has not been uncommon in passenger side air bags of the prior art. Air bag 28 differs from the prior art, however, in that respective panels thereof are produced according to the invention to have a controlled permeability. As a result, greater consistency in deflation may be achieved.
A body panel 30 forms a top, front and bottom portion of air bag 28. Preferably, body panel 30 has a permeability of less than two (2) CFM. A left side panel 32 and a similar right side panel (not shown) are stitched or otherwise attached to body panel 30. The controlled permeability of such side panels is preferably greater than five (5) CFM, and may generally fall within a range of approximately five (5) CFM to seven (7) CFM. Air bag 28 further includes a snout assembly 34 to provide fluid communication with the source of inflation gas.
Presently preferred methods by which controlled permeability maybe achieved in the fabric utilized in air bags 20 and 28 may be best understood with reference to FIGS. 4 through 8. According to at least one exemplary technique, an important step in providing this controlled permeability is to stabilize the permeability of the fabric at a low reference permeability. Once this low reference permeability is achieved, further processing may be utilized to selectively increase fabric porosity. The amount and character of such further processing will then determine the final permeability of the fabric.
The low reference permeability is preferably achieved by calendering, as illustrated in FIG. 4. In this regard, a supply roll 38 provides uncoated fabric 40 of the type which is appropriate for use in an air bag. A number of specifications for air bag fabric are well known, including weight, thickness and strength. Preferably, the fabric of supply roll 38 will be either woven or warp knitted fabric constructed substantially entirely of synthetic fibers. Because nylon is somewhat hygroscopic, i.e. water absorbing, presently preferred embodiments may frequently utilize polyester yarn. Such yarn may have a size of 600 denier or other yarn size appropriate for the exigencies of a particular application.
Fabric 40 is delivered from supply roll 38 into a calender device 42, which includes a relatively large center roller 44 and a pair of smaller rollers 46 and 48. As shown, fabric 40 extends between rollers 44 and 46 and then around roller 48. After leaving calender device 42, fabric 40 is delivered to take up roll 50 as illustrated.
Rollers 46 and 48 apply heat and pressure onto contiguous portions of center roller 44. As a result, fabric 40 is calendered on one side at two nip locations 52 and 54. It has been found that calendering fabric 40 at a temperature of 300 degrees Fahrenheit and a pressure of 3000 lbs. per square inch produces a reference permeability of less than one (1) CFM, as is generally desired according to presently preferred methodology.
After the reference permeability is achieved, further processing is utilized to raise the overall permeability of the fabric to a desired level. FIG. 5 illustrates one presently preferred method which may be utilized for this purpose. As shown, fabric 40 is moving in the direction of arrow A under the influence of an appropriate conveyor mechanism 56. A needle carrier 58 having thereon a plurality of needles (referenced generally as 60) is shown reciprocating into and out of engagement with fabric 40, as indicated by arrow B. Preferably, needles 60, which may generally have a size of 18 gauge to 40 gauge, will engage the calendered side of fabric 40.
The density of needles 60 (in number of needles per unit area), along with the speed of fabric 40 and the rate of reciprocation of carrier 58 (as measured in strokes per minute (SPM)) gives a characteristic number of punctures per square inch (PPSI). It has been found that, for a particular needle size operating under defined conditions, a PPSI value may be selected to achieve a desired permeability with greater consistency than has generally been achieved by relying only upon processing parameters as has been the case in the past. In fact, it has been found that a particular air permeability may be achieved according to the invention with a variation of less than approximately ±1.0 CFM, as opposed to the ±3.0 CFM as was common in the prior art.
When relatively low levels of permeability are desired, needles 60 are preferably barbless needles, such as needle 60A of FIG. 6A. As shown, needle 60A includes a conical tip portion 62 integrally extending into a tapered shaft portion 64. Because of the shape of tapered shaft portion 64, greater permeability may often be produced at a given PPSI level by increasing the depth of needle penetration.
With barbless needles, it has been found that upon achieving a certain threshold permeability, further needling becomes largely ineffective to provide additional increases in permeability. Generally, this threshold permeability will fall within a range of 3.0 CFM to 4.0 CFM, with a value of approximately 3.5 CFM being typical.
If it is desired that the permeability of fabric 40 be greater than this threshold permeability, a barbed needle, such as needle 60B of FIG. 6B, may be utilized. Like needle 60A, needle 60B includes a generally conical tip portion 66 integrally extending into a tapered shaft portion 68. However, needle 60B further includes at least one barbed portion 70 which functions to enlarge the size of the puncture created when fabric 40 iS engaged. It should be appreciated that, while a barbed needle could be utilized to produce permeabilities below the threshold permeability, such is often not desired. This is because the use Of a barbed needle creates a rougher fabric surface, Which may not be desirable in panels (such as front panel 24 of air bag 20 and body panel 30 of air bag 28) which may come into contact with the face of a vehicle occupant.
FIG. 7 diagrammatically illustrates a plurality of punctures 72 which may be produced in fabric 40 by needling as described. As shown, the conical configuration of needles 60 produces punctures 72 which have a greater diameter at a first side 74 of fabric 40 than at a second side 76 of fabric 40. This generally produces a more laminar flow as gas moves through punctures 72 from side 74 to side 76 than vice versa. As a result, the permeability of fabric 40 is generally greater when side 74 is situated on an interior of the air bag. Thus, to provide a lower permeability in front of the occupant's face, front panel 24 of air bag 20 and body panel 30 of air bag 28 are configured having first side 74 on the exterior. Further smoothness is provided to the occupant's face by the fact that side 74 is also preferably the side which has been calendered. Other areas of air bags 20 and 28 are preferably constructed having first side 74 on the interior to enhance permeability.
An alternative methodology of producing a controlled permeability in fabric 40 is illustrated in FIG. 8. In this case, fabric 40 is shown moving beneath a plurality of fluid jet headers 78 under the influence of an appropriate conveyor mechanism 80. Each of headers 78 emits a plurality of fluid jets, which strike fabric 40 with predetermined operating characteristics. As a result, pores are created to allow the fluid to flow therethrough.
Several factors will affect the permeability of fabric 40 produced in a fluid jet system, such as that illustrated. In addition to total fluid energy delivered, such factors include the number of orifices in each of headers 78, as well as the spacing and size of these orifices. Generally, conveyor 80 will include a wire mesh substrate which fabric 40 will have a tendency to mimic as it is impacted by the fluid jets. Thus, the type of substrate will also affect the permeability, as well as whether the fluid jet system is flat as illustrated or a rotary type system. In order to permit lower jet energies to form these pores, fabric 40 is preferably uncalendered when this method is utilized.
Preferably, the fluid jets emitted by header 78 are water jets. This water is shown being collected in respective collection basins 82 from which it is carried away. It can be seen that the system of FIG. 8 is similar to a "hydroentanglement" system of the type utilized to produce nonwoven materials. Some of the principals of a hydroentanglement apparatus are described in U.S. Pat. No. 3,494,821, issued Feb. 10, 1972 to Evans, which is incorporated herein by reference.
Generally, nonwoven material produced in a hydrogentanglement apparatus is subjected to a relatively strong vacuum to remove absorbed water. However, when used with a woven fabric, such as fabric 40, a vacuum treatment of this type will generally tend to make fabric 40 have a relatively stiff "hand." To retain a relatively "soft" hand, fabric 40 is preferably dried in a tenter oven 84. Oven drying in this manner may also serve to heat set the pores formed by the fluid jets. As a result, such pores will remain in fabric 40 to give the desired air permeability level. In this regard it is desirable that, once dry, that fabric 40 remain heated to a temperature of approximately 350 degrees Fahrenheit to 380 degrees Fahrenheit for a period exceeding approximately 20 to 30 seconds.
It can thus be seen that the invention provides an improved technology for constructing an air bag substantially entirely of uncoated material while achieving a more consistent permeability than was generally achievable with the prior art. While presently preferred embodiments of the invention and presently preferred methods of practicing the same have been shown and described, it should be understood that various modifications and variations may be made thereto by those of ordinary skill in the art. In addition, it should be understood that aspects of the various embodiments may be interchanged both in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only and it is not intended to be limitative of the spirit and scope of the invention so further set forth in the following claims. | An air bag of the type utilized in a vehicle occupant restraint system is constructed of a plurality of panels of uncoated fabric. Respective of the panels have been processed to achieve a selected air permeability with greater accuracy on a lot-to-lot basis than had generally been achieved with uncoated fabrics of the prior art. In one presently preferred methodology, the panels are first calendered under selected temperature and pressure conditions such that a low reference permeability is achieved. Next, respective of the panels may be needled such that the permeability is raised from the low reference permeability to a selected permeability level. Alternatively, a plurality of fluid jets, preferably water jets, may be utilized to impact panels of the uncoated fabric under selected operating conditions. Pores created by the fluid jets may be heat set to achieve a selected permeability. | 3 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a divisional under Rule 1.53(b) of application Ser. No. 08/708,428, now U.S. Pat. No. 5,939,763, filed Sep. 5, 1996. Application Ser. No. 08/708,428 is hereby incorporated by reference in its entirety into the subject application.
FIELD OF THE INVENTION
This invention relates to processes for the formation of ultra-thin dielectric layers for use as gate or tunnel oxides employed in integrated circuits.
BACKGROUND OF THE INVENTION
The trend in integrated circuits is toward higher performance, higher speed, and lower cost. Correspondingly, device dimensions and feature sizes are shrinking for all types of integrated circuit technology. This trend necessitates the use of ultra-thin dielectrics in the fabrication of such devices as Metal-Oxide-Semiconductor (MOS) transistors and floating gate memory elements.
MOS transistors are comprised of highly doped source and drain regions in a silicon substrate, and a conducting gate electrode is situated between the source and drain but separated from the substrate by a thin gate dielectric layer. When an appropriate voltage is applied to the gate electrode, a conducting channel is created between the source and drain. Shorter channels, shallower source and drain junctions, and thinner gate dielectrics are critical to achieving smaller and faster MOS devices.
Certain Electrically Erasable Programmable Read-Only Memory (EEPROM) elements utilize a two layer polysilicon structure comprising an electrically disconnected polysilicon gate electrode, referred to as “floating gate”, and a second control transistor gate above the floating gate and more removed from the substrate. The floating gate, which retains electrical charge for a long time period unless altered by an external energy source, is charged or discharged by quantum mechanical tunneling of electrons through very thin dielectrics known as “tunnel oxides”. The threshold voltage of the control transistor differs for the charged and uncharged states of the floating gate.
Presently, ultra thin dielectrics less than 100 Angstroms thick, usually of high quality SiO 2 , are utilized as MOS gate dielectrics (commonly called gate oxides), and as tunnel oxides in floating gate EEPROM memory elements. Reliability and reproducibility of these ultra-thin oxides can be adversely affected by many factors including lack of thickness control, poor interface structure, high defect density, and impurity diffusion through the oxides. These factors can seriously degrade device performance.
Diffusion of impurities, particularly boron, through thin oxides is a major problem in processing technology. In Complementary MOS (CMOS) technology, many front end processing steps such as polysilicon gate deposition can be performed simultaneously for the NMOS and PMOS devices of CMOS circuits; however, the dopant implantation steps are performed separately, since different dopants are required. Arsenic and phosphorous, donor-type materials which provide free electrons as charge carriers, are most often used to dope the gate and source/drain regions of the NMOS devices. Boron, an acceptor-type material which provides free holes as charge carriers, is the most often used dopant for PMOS devices. Boron from the doped polysilicon gate has a much higher diffusion rate through the gate oxide layer than do arsenic or phosphorus, and can cause severe degradation of PMOS device characteristics. A concentration of charged boron ions within the gate oxide degrades the insulating characteristics of the oxide, causing gate oxide rupture at sufficiently high concentration. Additionally, boron charge within the gate oxide results in a shift of the transistor threshold voltage V T . The magnitude of this shift is a function of the concentration of diffused boron ions times the depth of their penetration into the oxide. For ultra-thin gate oxides, boron can diffuse completely through the gate oxide into the underlying substrate, causing even more severe threshold shift problems. Similar problems with boron diffusion are evidenced for the very thin tunnel oxides used in floating gate memory elements of EEPROMS. The resulting degradation in oxide breakdown characteristics lowers the number of possible program erase cycles.
Poor interface structure between a Si substrate and an SiO 2 layer results largely from strain caused by lattice mismatch between Si and SiO 2 . One consequence of this is the formation of interface states during high electric field stress or during exposure to high energy radiation such as x-rays. These interface states cause degradation of transistor turn-on characteristics.
Incorporation of nitrogen into the thin oxide layer has been shown to inhibit boron diffusion and to improve the Si—SiO 2 interfacial structure. Specifically, a nitrogen concentration profile having a double peaked structure with a peak of nitrogen at the Si—SiO 2 interface and a peak at the SiO 2 surface adjacent the polysilicon gate in MOSFET's, and having a low nitrogen concentration therebetween, has been shown to effectively impede boron diffusion from the doped polysilicon gate and to maintain oxide integrity. Additionally, incorporation of nitrogen at the Si—SiO 2 interface has been shown to relax the interfacial strain and improve the immunity of the oxides to interface state generation under high field stress.
Several methods for forming a nitrided oxide layer have been used. The first of these is referred to as the Nitrided Oxide (NO) method, which is described by M. Moslehi et al in J Electrochem Soc: Solid State Science and Technology, Vol 132, No. 9, September 1985, pp 2189-2197, which is hereby incorporated by reference. This method comprises growing a thin thermal oxide on the Si substrate which is then annealed in an ammonia (NH 3 ) atmosphere to incorporate nitrogen into the oxide. Furnace anneal was initially utilized, but most recently, Rapid Thermal Anneal (RTA) has been used as an alternative. Using the NO method, peaks in nitrogen concentration are seen at the Si—SiO 2 interface, hereafter referred to as the “interface”, and at the SiO 2 surface adjacent the polysilicon gate in MOSFET's, hereafter referred to as the “oxide surface”. The nitrogen concentration within the oxide film increases monotonically with nitridation time. Thin oxides fabricated using the NO method exhibit improved resistance to boron penetration, as well as improved Si—SiO 2 interfacial characteristics and low defect densities. However, decomposition of NH 3 during the nitridation process also results in incorporation of hydrogen into the SiO 2 layer. Si—H bonds and Si—OH bonds form, causing a large increase in electron and hole trapping and a high density of fixed charges, which result in threshold voltage instability for MOSFET's and degradation of breakdown endurance for MOSFET's and EEPROMs.
A second method, known as the reOxidized Nitrided Oxide (ONO) method, is described by T. Hori et al in IEEE Transactions on Electron Devices, Vol. 36, No. 2 February 1989, pp 340-350, also hereby incorporated by reference. The ONO method adds an additional high-temperature (800-1200° C.) oxidation step after the ammonia nitidation of the NO method. The hydrogen incorporated into the oxide layer during the ammonia nitridation is reduced by the oxygen present during the subsequent oxidation step, and diffuses out at the high oxidation temperature. As reoxidation proceeds, the hydrogen concentration in the film is found to decrease monotonically, with the rate of decrease depending on the reoxidation temperature and on the nitrogen peak concentration. The hydrogen concentration approaches a minimum value approximately equal to the hydrogen levels found in thermally grown oxide. A more heavily nitrided surface layer is thought to act as a higher barrier for oxygen diffusion, making the reoxidation process slower. The reduction in hydrogen concentration is shown to proportionately reduce the electron charge trapping evidenced in the nitrided oxides.
A disadvantage of the ONO method is the relatively narrow process window for achievement of optimum oxide quality. Over-reoxidation has been shown to actually degrade oxide electrical qualities. A further disadvantage of the NO and ONO processes is the high level of nitrogen in the bulk of the oxide. The bulk nitrogen concentration, which can be as high as 5-10×10 20 atoms/cc, weakens the dielectric and degrades its breakdown characteristics.
Another method of formation of an oxynitride layer utilizes an anneal in N 2 O ambients. Two variations of this method have been used:
1. Formation on a Si substrate of a thermal SiO 2 layer in oxygen ambient, followed by anneal in N 2 O, which is described by A. Uchiyama et al in IEDM Technical Digest, IEEE, 1990, pp 425-428, hereby incorporated by reference, and
2. Growing of a thin silicon oxynitride layer directly on the Si substrate by high temperature exposure of the Si substrate to a pure N 2 O ambient, described by H. Hwang et al in Appl Phys Lett 57 (10), Sep. 3, 1990, pp 1010-1011, which is hereby incorporated by reference.
Dielectric layers formed by both of these variations exhibit a nitrogen peak at the Si—SiO 2 interface, and relatively small amounts of nitrogen incorporated into the oxide bulk. By way of example, a nitrogen peak concentration of 2-3×10 21 /cc and a nitrogen concentration in the oxide bulk of approximately 10 18 /cc have been measured for a thermal oxide annealed at 1100 degrees Centigrade in N 2 O. Compared with control thermal oxides, these oxynitrides show significant reduction in interface state generation under high field stress, and lowered electron trapping. They are also shown to act as a barrier for inhibiting boron penetration into the Si substrate. The relatively low nitrogen levels in the oxide bulk yield favorable oxide breakdown characteristics.
For ultra-thin silicon oxynitride dielectric layer growth, the oxidation of Si directly in an N 2 O ambient (the second variation of the above cited N 2 O method), has the added advantage of a suppressed growth rate. The growth rate of silicon oxynitride in pure N 2 O ambient at 1100° C. using an RTP has been measured as 1.2 Å/second. By comparison, the growth rate of oxide in an O 2 ambient for the same processing conditions is 10 Å/second. Simultaneous nitrogen incorporation with oxide growth results in gradual formation of an interfacial silicon oxynitride (SiO x N y ) layer which acts as an oxidant diffusion barrier. The suppressed oxidation rate provides good thickness control even in the ultra-thin range (<60 A).
A major problem with ultrathin oxides formed with N 2 O ambients is the absence of any nitrogen-rich layer at the oxide surface, as reported by H. Hwang et al, in IEDM Technical Digest, IEEE, 1990, pg. 424. Accordingly, no barrier exists to prevent boron from penetrating into the oxide, even if the nitrogen peak at the Si surface is effective in preventing boron penetration into the substrate. Furthermore, studies have shown that boron has diffused into the substrate for N 2 O-based oxynitrides, indicating that their Si—SiO 2 interface nitrogen peak concentration is below the optimal level for blocking boron diffusion.
Another prior method of nitridation of a thermally grown SiO 2 layer, by either furnace or rapid thermal exposure directly to a nitric oxide (NO) ambient, has been reported very recently. The rapid thermal method is described by M. Bhat et al, in IEDM Technical Digest, IEEE, 1994, pp 329-332, which is hereby incorporated by reference. The depth profile, as measured by Secondary Ion Mass Spectrometry (SIMS), of nitrogen incorporated into the oxide is similar in shape to that of a thermal SiO 2 annealed in N 2 O, and has an interface peak nitrogen concentration as high as 10 22 /cc for anneal at 1000 degrees Centigrade. This peak value is nearly 2 orders of magnitude higher than that seen by the authors for an N 2 O annealed oxide under similar processing conditions. The enhanced interfacial nitrogen peak also provides a highly self-limiting oxynitride growth due to the barrier properties of incorporated nitrogen to diffusion of oxidants. The thickness of the nitrogen-rich interface oxynitride layer saturates at a value of approximately 3 Å. The oxynitrides produced by exposure of thermal SiO 2 to NO, while having higher interface nitrogen peak levels than those produced in N 2 O, share the problem of lacking a surface nitrogen barrier to prevent boron diffusion into the oxide layer itself.
It has been concluded from kinetic studies described by P. Tobin et al in VLSI Tech. Sympos., 1993, pp 51-52, which is hereby incorporated by reference, that NO is the critical species producing interfacial nitrogen pileup during oxynitridation of thermal oxide in N 2 O. Heating of the N 2 O causes its decomposition by the reactions:
N 2 O→N 2 +O, where the atomic O recombines into O 2 , and
N 2 O+O→2NO
It has been estimated that at 950° C., the N 2 O is fully decomposed before the N 2 O reaches the wafer, and the composition of the oxynitridation ambient is 64.3%N 2 , 31.0%O 2 , and 4.7%NO. Thus, the formation of a nitrogen interfacial peak by N 2 O anneal depends on the indirect, thermodynamically unfavorable dissociation reaction of N 2 O to NO. In contrast, the favorable, direct reaction of NO with Si is thought to produce the enhancement of interface nitrogen peak levels for NO-annealed oxides.
Still another method of incorporating nitrogen into a thin oxide layer is by ion implantation of nitrogen, described by Haddad et al in IEEE Electron Device Letters, Vol. EDL-8, No. 2, February 1987, pp 58-60, which has been utilized to provide a two-peaked nitrogen structure. Whereas this method can be effective for inhibiting boron diffusion and improving interface state generation and charge-to-breakdown values, it has numerous drawbacks. Ion implantation is expensive, and incorporating it into the process during oxide growth involves major redesign of the standard CMOS manufacturing process. Additionally, the process windows for optimal implant dose and energy are narrow, to avoid damage to the dielectric structure while still improving breakdown characteristics.
SUMMARY OF THE INVENTION
We have provided an improved process for forming an ultra thin silicon oxynitride dielectric layer on a Si substrate with improved thickness control, electrical characteristics, and resistance to boron penetration into the oxide as well as into the Si substrate. In this process a thin nitrogen-rich silicon oxynitride layer is grown on the substrate, then further processing provides an oxynitride layer with a nitrogen peak at the silicon-dielectric interface, and a peak at the dielectric surface.
An object of this invention is to provide an improved process for forming an ultra thin dielectric layer on Si, and an improved ultra thin dielectric layer formed by this process.
Another object of this invention is to provide a process for forming an ultra thin silicon oxynitride layer on Si which is resistant to boron penetration, and a silicon oxynitride layer formed by this process.
Another object of this invention is to provide a process for forming an ultra thin silicon oxynitride layer on Si which has a low density of electron traps, and a silicon oxynitride layer formed by this process.
A further object of this invention is to provide a process for forming an ultra thin silicon oxynitride layer on Si with favorable oxide breakdown characteristics, and a silicon oxynitride layer formed by this process.
A further object of this invention is to provide a process for forming an ultra thin silicon oxynitride layer on Si with a peak in nitrogen concentration at the oxide-silicon interface and a peak in nitrogen concentration at the oxide surface, and a silicon oxynitride layer formed by this process.
A further object is to provide a process for forming an ultra thin silicon oxynitride layer on Si which has precise thickness control, and a silicon oxynitride layer formed by this process.
A further object is to provide a process for forming an ultra thin silicon oxynitride layer on Si which includes forming a self-limiting nitrogen-rich layer and thereafter forming an oxide beneath the nitrogen-rich layer with a second nitrogen-rich layer forming at the Si interface.
A further object is to provide a process for forming an ultra thin oxynitride layer on Si which does not utilize hydrogen-bearing species, and an oxynitride layer formed by this process.
A further object is to provide a process for forming an improved ultra thin oxynitride layer on Si which is compatible with existing semiconductor manufacturing process flow.
A further object is to provide a process for forming an improved ultra thin oxynitride layer on Si which does not substantially add to manufacturing costs.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a process flow diagram for a preferred embodiment of the invention.
FIG. 2 a is a cross sectional view of the preferred oxynitride layer structure.
FIG. 2 b is a schematic representation of the nitrogen concentration profile in the oxynitride layer of FIG. 2 a.
FIG. 2 c is a cross sectional view of the preferred oxynitride layer structure utilized in a MOS transistor structure.
FIG. 2 d is a schematic representation of the nitrogen concentration profile in the oxynitride layer of FIG. 2 c.
FIG. 2 e is a schematic representation of the concentration profile of dopant species in the MOS transistor structure of FIG. 2 c.
FIG. 3 is a SIMS profile of nitrogen concentration vs. depth below oxide surface, for a first sample processed according to this invention.
FIG. 4 is a SIMS profile of nitrogen concentration vs. depth below oxide surface, for a second sample processed according to this invention.
FIG. 5 is a prior art SIMS profile of nitrogen concentration vs. depth below oxide surface, for sample with thermal oxide annealed in N 2 O.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIG. 1, a preferred process flow embodiment of our invention is shown. The entire process sequence has been performed in a Reactive Thermal Processing (RTP) system, such as the Rapid Thermal Reactor manufactured by PAPRO. In step 1 , a silicon wafer is provided with a clean silicon surface on which to grow the dielectric layer. In step 2 , the wafer is immersed in a one atmosphere pressure of nitric oxide (NO) gas at elevated temperatures in the range of 800° C. to 1150° C. for a time period in the range of 10 to 3000 seconds. In step 4 , the NO flow is turned off, the NO is pumped out, and one atmosphere pressure of N 2 O is introduced. The wafer is annealed in the N 2 O at temperatures in the range of 800° C. to 1150° C. for a time period in the range of 10 to 3000 seconds. Other embodiments of the invention may utilize other oxidizing ambients in place of N 2 O, oxygen or steam by way of example. In step 6 , the N 2 O is pumped out, and an NO ambient is again introduced when additional nitrogen incorporation at the oxide/silicon interface is desired. In that case, the wafer is again annealed in NO at temperatures in the range of 800° to 1150° C. for a time period in the range of 10 to 3000 seconds.
With reference to FIG. 2 a, the preferred structure for the oxynitride layer on the Si substrate is shown. Substrate 8 is annealed in NO and N 2 O gases as described in the process flow, forming dielectric oxynitride layer 10 on surface 11 . Upper surface 12 of oxynitride layer 10 would be adjacent to any subsequently formed conducting gate for a MOS transistor. Surface region 14 , and interface region 16 of dielectric 10 have elevated nitrogen concentrations, as represented by nitrogen concentration profile 20 in FIG. 2 b. Nitrogen concentration surface peak 22 and nitrogen concentration interface peak 24 provide barriers to impurity diffusion through dielectric 10 , as well as improving structure of the Si-dielectric interface at surface 11 . In FIG. 2 c, the preferred structure for oxynitride layer 10 on Si substrate 8 is shown, with a conducting gate 13 such as heavily doped polysilicon above the oxynitride layer 10 . Nitrogen surface peak 22 in region 14 provides a barrier to impurity diffusion of impurities 23 from polysilicon gate 13 into oxynitride 10 . FIG. 2 e schematically illustrates the abrupt concentration profile of a dopant species of a transistor according to this invention in which the oxynitride layer of this invention is seen to preclude the diffusion of the high concentration dopant from the conductive polysilicon gate 13 into or across the oxynitride layer 10 , as well as serving as a barrier for diffusion of dopant species from or into the underlying Si 8 .
TABLE I
Effect of N 2 O cycle parameters on oxide thickness
Sample Description (N 2 O cycle)
Oxide Thickness (Å)
I. 100 sec. @ 1050° C. (RTA)
45
II. 200 sec. @ 1100° C. (RTA)
110
Table I summarizes N 2 O anneal conditions and thickness data for oxide grown on Si substrates processed according to the process flow of FIG. 1 . The data is obtained from SIMS analysis, with a low energy, low fluence Cs + ion beam used to collect depth profiles of CsO + , CsN + , and CsSi + molecular clusters. The position of the oxide/Si interface is defined as the depth at which the CsO signal drops by one decade. In all calculations and depth profiles the first few data points are excluded to eliminate the SIMS blast-through artifact. Unfortunately, this artifact prevents obtaining accurate data points at the surface of the oxide layer. SIMS analysis is described in Semiconductor Material and Device Characterization, D. K Schroder, John Wiley and Sons, 1990, Ch. 10.
For the experiments of Table I, substrate samples I and II have both been first rapidly thermally annealed in 1 atmosphere NO for 50 seconds, at a temperature of 1000° C. Then sample I is provided 100 seconds rapid thermal anneal in 1 atmosphere N 2 O at 1050° C. Measured oxide thickness on sample I is 45 Å, corresponding to a growth rate of 0.45 Å/sec. Sample II is provided 200 seconds rapid thermal anneal in 1 atmosphere N 2 O at 1100° C. Measured oxide thickness on sample II is 110 Å, corresponding to a growth rate of 0.55 Å/sec. These growth rates are approximately a factor of two lower than those observed in the prior art for oxidation in an N 2 O ambient without initial NO anneal.
For each of the samples, there is considerable oxide growth during the N 2 O anneal. This growth indicates that, during the N 2 O anneal, oxidizing species penetrate through the nitrogen-rich interface layer 16 formed during the initial NO anneal, since basic oxidation kinetic theory states that the oxidation reactions occur directly at the Si surface. Thus, the oxidation mechanism must involve the diffusion of atomic or molecular oxygen, which are products of the dissociation reaction of N 2 O, through the nitrogen-rich interface region. Although the oxide growth occurs, it is quite slow, and therefore the inventive process provides precise control of the oxide thickness.
With reference to FIG. 3, a SIMS depth profile through the oxide layer and the Si—SiO 2 interface is shown for Sample I, but the data very near (i.e., within the first 10 Angstroms beneath) the oxide surface is excluded because of the blast through artifact. A peak nitrogen concentration of approximately 7×10 20 atoms/cc is seen near the Si—SiO 2 interface, at a depth of approximately 30 Å. This peak concentration corresponds to approximately 1 atomic% nitrogen.
With reference to FIG. 4, a SIMS depth profile through the oxide layer and the Si—SiO 2 interface is shown for Sample II, again with the surface data excluded. A peak nitrogen concentration of approximately 6×10 20 atoms/cc is seen near the Si—SiO 2 interface, at a depth of approximately 90 Å. This peak concentration corresponds to approximately 0.9 atomic% nitrogen. For the samples of Table I, the hydrogen atom concentration in said silicon oxynitride layer is less than 10 18 atoms/cc. Also, the bulk nitrogen concentration in said layer is less than 10 18 atoms/cc.
FIG. 5 shows a SIMS depth profile from the reference by Bhat et al, cited above, for a thermally grown SiO 2 layer of 104 Å thickness rapidly thermally annealed in N 2 O at 1000° C. for 100 seconds. The surface data is excluded, as in FIGS. 3 and 4. It is seen that the position and magnitude of the nitrogen peak concentration closely match with those for substrate II after 200 seconds rapid thermal anneal in N 2 O at 1100° C., as seen from FIG. 4 . The nitrogen incorporation in the bulk of the oxide and at the SiO 2 —Si interface for the inventive process of an NO anneal followed by N 2 O anneal is quite similar to that for the prior art thermal SiO 2 annealed in N 2 O. However, in the inventive process, since the oxygen species from the N 2 O dissociation reaction must penetrate the nitrogen-rich layer formed during NO anneal to grow the oxide layer at the Si surface, it is believed that the nitrogen-rich layer must be pushed up and remain at the surface of the oxide layer, even though it cannot be resolved by SIMS due to the SIMS blast-through artifact. The resultant structure will provide the desired double-peaked nitrogen profile for blocking of boron penetration into the oxide and substrate, and for yielding improved Si-oxide interface characteristics. The low nitrogen concentration in the oxide bulk will avoid degradation of oxide breakdown characteristics.
When higher interface nitrogen concentration is required, tailoring of the interface peak nitrogen concentration is accomplished by further anneal in NO ambient following the N 2 O anneal.
Our invention, in addition to providing the preferred nitrogen profile in the ultra thin oxide layers, involves process modifications which are easily incorporated into existing semiconductor manufacturing processes, and they add insubstantially to the cost of the process. Our invention provides precise oxide thickness control without narrowing the process window due to the extremely slow oxide growth rate. Also, the preferred embodiment of the inventive process is performed without introduction of any hydrogen species, and avoids hydrogen-induced charge trapping.
Although our preferred process utilizes rapid thermal processing in the temperature range 800° C. to 1150° C., and ambient atmospheric pressures of NO and N 2 O, it is not essential that this exact method and parameters be used. Other embodiments may utilize furnace anneals for all the processes, and other oxidizing ambients such as O 2 or steam may be used in place of N 2 O.
It is not our intention to limit our invention to the preferred embodiment, but rather the scope of our invention should be construed in view of our claims. With this in mind, | A process for growing an ultra-thin dielelctric layer for use as a MOSFET gate or a tunnel oxide for EEPROM's is described. A silicon oxynitride layer, with peaks in nitrogen concentration at the wafer-oxynitride interface and at the oxynitride surface and with low nitrogen concentration in the oxynitride bulk, is formed by a series of anneals in nitric oxide and nitrous oxide gas. This process provides precise thickness control, improved interface structure, low density electron traps, and impedes dopant impurity diffusion from/to the dielelctric and substrate. The process is easily integrated into existing manufacturing processes, and adds little increased costs. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to a device which assists in the mounting of a plow on a vehicle and more specifically to a dolly designed to support and render a snow plow blade easily movable.
In the northern parts of the United States, snow fall can be quite heavy. With the heavy snow fall, comes the opportunity to provide services by removing snow from roads, driveways and other arteries; and profit by providing the services. For this purpose, it is quite common for a person to purchase a four wheel drive vehicle and have a snow plow blade installed on the vehicle. This combination of equipment renders it possible for many people to keep their own arteries clear and possibly make a living plowing arteries of others.
There are however, several problems with this endeavor. For example, the smaller plows used in these businesses weigh in excess of 500 pounds. Thus, it becomes clearly a problem to move--let alone mount--the particular plows on the vehicles. It clearly requires the efforts of at least two persons to mount the plow on the vehicle. It is also difficult to remove the plow from the vehicle.
It thus becomes common to leave the snow plow on the vehicle during the period of time when snow is extremely likely to fall. In fact, most people install the plow at the beginning of the winter and remove it at the end. This long period of installation creates a substantial number of problems, while supposedly solving the problem of storage of the blade.
There are many disadvantages to this extended installation. The great weight of the plow, which is required for the snow plow to be effective, causes an extra burden on the front end of the vehicle. For example, the front tires and bearings of the vehicle, together will all of the other component parts of the frontend, wear out much more quickly than similar parts of a vehicle not carrying a plow blade.
Therefore, it is clearly desirable to provide a device, which will permit a snow plow blade to be installed and removed more easily. Design of such a device is very difficult. Different brands of plows are available. Different vehicles have different heights and require flexibility for installation. The differences in the vehicles and the plows compound the problems of making a device to assist in the mounting and removal of a blade. Thus, the required flexibility in the device causes substantial problems--the solution of one problem adding to the other problem.
Thus, it may be seen that it is extremely desirable to prepare a blade mounting device for use with a multiplicity of vehicles while at the same time making the device capable of permitting easier installation and removal of the blades.
SUMMARY OF THE INVENTION
Therefore, it is an object of this invention to provide for a device which will simplify the installation of a snow plow blade on a vehicle.
A further object of the invention is to provide a device which simplifies removal of the snow plow blade from a vehicle.
A still further object of the invention is to provide a device which permits the snow plow blade to be moved easily.
Yet a further object of the invention is to provide a device which permits the snow plow blade to be stored easily.
Also an object of this invention is to provide a device which is adjustable to compensate for different types of vehicles.
Another object of this invention is to provide a device which accommodates different styles of blades.
Still another object of this invention is to provide a device which minimizes wear on the front tires of the vehicle.
Yet another object of this invention is to provide a device which minimizes wear on the front bearings of the vehicle.
A further object of the invention is to provide a device which minimizes wear on the component parts of a vehicle front end.
These and other objects of the invention are met by providing a dolly for a snow plow blade in a generally T-shaped configuration wherein the base of the T is easily dismounted for storage of the dolly. The T-shaped dolly has a wheel secured to each end of the cross piece and the base of the leg.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. I depicts a perspective view of T-shaped snow plow dolly 10 of this invention.
FIG. II depicts a top view of FIG. I.
FIG. III depicts a side view of FIG. I showing a side view of base piece 20.
FIG. IV depicts an end view of FIG. I showing a side view of cross piece 20.
Throughout the Figures of the Drawings, where the same part appears in more than one Figure, the same number is given thereto.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A T-shaped dolly having a castor at the base of the T and a wheel at each end of the cross of the T provides for a device capable of receiving snow plow blade to be held in position for easy mounting and removal from a vehicle.
Referring now to FIG. I which is a perspective view of the dolly 10 of the invention, it becomes clear that dolly 10 of the invention is generally T-shaped and includes a cross piece 20 and a base piece 40 substantially centrally secured to cross piece 20. Adjacent each end of the cross piece 20, are wheels 22 secured to the cross piece 20. The wheels 22 may be castors and rotated about a vertical axis 24 and a horizontal axis 26 to achieve desired swivel characteristics. However, wheels rotating only about a horizontal axis are preferred for ease of steering the dolly 10.
Dolly 10 may be made from metal stock having a hollow square or hollow rectangular cross-section; or any other suitable cross-section. Other suitable cross-sections may be circular or elliptical. Wheels 22 are, of course, on the bottom 28 of cross piece 20. Assuming a rectangular cross-section, cross piece 20 includes an outer vertical side 30 oppositely disposed from base piece 40, and inner vertical side 32 adjacent base piece 40. On outer vertical side 30 and secured thereto are plow rests 34. Each of plow rests 34 is adjacent the location of a wheel 22. Plow rests 34 provide a place for resting the blade (not shown) on dolly 10.
Centrally secured to cross piece 20 on inner vertical side 32 is base receiver 36. Base receiver 36 has a structure similar cross piece 20, and includes cross apertures 38 in the vertical sides thereof so that base piece 40 may be secured to cross piece 20 by bolting or similar means.
The mounting arm of the blade rests on base piece 40. At a cross end 42 (adjacent cross piece 20) of base piece 40, base piece 40 fits into base receiver 36 in a preferred fashion. Base piece 40 can be secured to cross piece 20 in any suitable fashion. Base piece 40 is slidably mounted within base receiver 36 and includes base apertures 56, so that base piece 40 may be secured therein by bolts 80.
Oppositely disposed from cross piece 20 on base piece 40 is base castor 44 on the same side as wheels 22. Base castor 44 is secured to castor end 46 of base piece 40. Castor end 46 is oppositely disposed from cross end 42 of base piece 40. Adjacent base castor 44 is mounting support 50. Mounting support 50 is secured to base piece 40 in an adjustable fashion by a plurality of mounting apertures 52 in mounting support 50. Mounting apertures 52 line-up with base apertures 56 to secure mounting support 50 to base piece 40.
The top view of dolly 10 in FIG. II more clearly emphasizes the relative positions of cross piece 20, base piece 40, mounting support 50, plow rest 34, and base receiver 36.
The side view of dolly 10 in FIG. III more clearly emphasizes the relative positions of wheel 22, base castor 44, and mounting support 50.
Mounting support 50 is shown in FIG. IV to have a blade mount receiver 58 at a right angle connecting arm 60. Connecting arm 60 includes the plurality of height adjusting mounting apertures 52 (shown in FIG. III) of mounting support 50. Blade mount receiver 58 is thus adaptable for the various vehicles and the height of the respective mounting apparatus.
In this fashion, mounting support 50 can be adjusted in height to compensate for the vehicle on which the blade is to be installed. The use of the castors in the various mounting procedures permits the blade to be handled and mounted by one man in much less time than two men can do it.
The following examples are offered for the purpose of illustrating the disclosed and claimed invention. The specification and claims are to be taken as a whole, without drawing undue limitations thereon from the instant examples.
EXAMPLE ONE
Two men using a Jeep Cherokee with a standard western plow mount already secured to the Jeep attempt to secure the plow blade to the plow mount. These men, being experienced in the field, take one half hour to complete mounting of the plow blade and render the Jeep thus ready to begin plowing the snow.
EXAMPLE TWO
The plow blade from the Jeep of Example One is mounted on the dolly 10 of the invention. The blade rests against plow rests 34 while the mounting supports for blade rest against support rest 54. One of the men of example one steps aside and the other is permitted to mount the blade by himself. The dolly 10 with the blade thereon is wheeled into position and mounted on the Jeep in standard fashion in ten minutes.
Because of this disclosure and solely because of this disclosure, various modifications to snow plow dolly 10 will become clear to those having ordinary skill in the art. Such modifications are clearly covered hereby. | A dolly for a snow plow blade is in a generally T-shaped configuration wherein the base of the T is easily dismounted for storage of the dolly. The T-shaped dolly has a wheel secured to each end of the cross piece and the base piece. | 4 |
TECHNICAL FIELD
[0001] The present invention relates to a thin film transistor (TFT) used for display devices such as a liquid crystal display (LCD) or an organic light emitting diode (OLED). More particularly, it relates to a thin film transistor including a polycrystalline silicon (i.e., polysilicon) active layer providing the source, drain and channel regions of the TFT, and to a method for making a TFT including the polycrystalline silicon active layer.
BACKGROUND OF THE INVENTION
[0002] Thin film transistor (TFTs) used for display devices such as liquid crystal display (LCD) and organic light emitting diode (OLED) is formed by depositing a silicon layer on a transparent substrate such as a glass or quartz, forming a gate and a gate electrode on the silicon layer, implanting dopant in the source and the drain regions of the silicon layer, annealing the silicon layer to activate the dopant, and finally forming an insulation layer thereon. An active layer constituting the source, drain, and channel regions of a TFT is formed by depositing a silicon layer on a transparent substrate such as glass by chemical vapor deposition (CVD) technique. The silicon layer directly deposited on the substrate by the CVD technique is an amorphous silicon layer, which has low electron mobility. As a display device using thin film transistors requires a rapid operation speed and a miniaturized structure, the integration degree of its driving IC becomes higher and the aperture ratio of the pixel region becomes lower. Therefore, it is required to enhance the electron mobility of the silicon layer so that the driving circuit can be formed together with the pixel TFT of the display devices and that the pixel aperture ratio is increased. For this purpose, technologies for forming a polycrystalline silicon layer having high electron mobility by crystallizing an amorphous silicon layer with thermal treatment have been in use as described below.
[0003] Solid phase crystallization (SPC) method is used to anneal an amorphous silicon layer at a temperature of 600° C. or below for a few hours or tens of hours. 600° C. is the temperature causing deformation of the glass constituting the substrate. However, the SPC method has the following disadvantages. Since the SPC method requires a thermal treatment for a long time, the SPC method has low productivity. In addition, when annealing a large-sized substrate, the SPC method may cause deformation of the substrate during the extended thermal treatment even at a temperature of 600° C. or below.
[0004] Excimer laser crystallization (ELC) method locally generates a high temperature on the silicon layer for a very short time by scanning an excimer laser beam to instantaneously crystallize the silicon layer. However, the ELC method has the following disadvantages. The ELC method has difficulties in accurately controlling the scanning of the laser beam. In addition, since the ELC method processes only one substrate at a time, the ELC method has relatively low productivity as compared to a method wherein a plurality of substrates are processed in a furnace at one time.
[0005] To overcome the aforementioned disadvantages of the conventional silicon crystallization methods, a method of inducing crystallization of an amorphous silicon layer at a low temperature about 200° C. by contacting or implanting metals such as nickel, gold, and aluminum has been proposed. This phenomenon that low-temperature crystallization of amorphous silicon is induced with metal is conventionally called as metal induced crystallization (MIC). However, this metal induced crystallization (MIC) method also has following disadvantages. If a TFT is manufactured by the MIC method, the metal component used to induce the crystallization of silicon remains in the crystallized silicon providing the active layer of the TFT. The metal component remaining in the active layer causes current leakage in the channel region of the TFT.
[0006] Recently, a method of crystallizing a silicon layer by inducing crystallization of amorphous silicon in the lateral direction using a metal, which is conventionally refereed to as “metal induced lateral crystallization” (MILC), was proposed. (See S. W. Lee and S. K. Joo, IEEE Electron Device Letter, 17(4), p. 160, 1996) In the metal induced lateral crystallization (MILC) phenomenon, metal does not directly cause the crystallization of the silicon, but the silicide generated by a chemical reaction between metal and silicon induces the crystallization of the silicon. As the crystallization proceeds, the silicide propagates in the lateral direction of the silicon inducing the sequential crystallization of the adjacent silicon region. As the metal causing this MILC, nickel and palladium or the like are known to those skilled in the art. Crystallizing a silicon layer by the MILC, a silicide containing crystallization inducing metal moves along the lateral direction as the crystallization of the silicon layer proceeds. Accordingly, little metal component is left in the silicon layer crystallized by the MILC. Therefore, the crystallized silicon layer does not adversely affect the current leakage or other characteristics of the TFT including the silicon layer. In addition, using the MILC, crystallization of silicon may be induced at a relatively low temperature of 300° C.˜500° C. Thus, a plurality of substrates can be crystallized in a furnace at one time without causing any damages to the substrates.
[0007] [0007]FIG. 1A to FIG. 1D are cross-sectional views illustrating a conventional method for crystallizing a silicon active layer of TFT using the MIC and the MILC methods. Referring to FIG. 1A, an amorphous silicon layer 11 is formed on an insulation substrate 10 having a buffer layer (not shown) thereon. The amorphous silicon layer 11 is patterned by photolithography so as to form an active layer. A gate insulation layer 12 and a gate electrode 13 are formed on the active layer 11 by using conventional methods. As shown in FIG. 1B, the substrate is doped with impurity using the gate electrode 13 as a mask. Thus, a source region 11 S, a channel region 11 C and a drain region 11 D are formed in the active layer. As shown in FIG. 1C, photoresist 14 is formed to cover the gate electrode 13 , the source region 11 S and the drain region 11 D in the vicinity of the gate electrode 13 , and a metal layer 15 is deposited over the substrate 10 and the photoresist 14 . As shown in FIG. ID, after removing the photoresist 14 , the entire substrate is annealed at a temperature of 300-500° C. As a result, the source and drain regions 16 covered with the residual metal layer 14 are crystallized by the MIC caused by the metal layer 14 , and the metal-offset source and drain regions 15 not covered with the metal layer and a channel region 17 under the gate electrode 13 are respectively crystallized by the MILC propagating from the source and drain regions 16 covered with the metal layer 14 .
[0008] The photoresist 14 is formed to cover source and drain regions adjacent to the gate electrode 13 in order to prevent the current leakage in the channel region and the degradation of the operation characteristics of the same. If the metal layer 15 is formed to cover the entire source and drain regions, the current leakage and the degradation of the operation characteristics occur because the metal component used to cause the MIC remains in the channel region 11 C and the boundaries between the channel region and the source and the drain regions. Since the operation of the source and drain regions excluding the channel region are not substantially affected by the residual metal component, the source and drain regions apart from the channel region by a distance over 0.01˜5 μm is crystallized by the MIC caused by the MIC metal. Meanwhile, the channel region and the source and the drain regions adjacent to the channel region are crystallized by MILC induced by and propagating from the MIC metal. Crystallizing only the channel region and its vicinity by MILC, the time required to crystallize the entire active layer may be significantly reduced. However, when using the process shown in FIGS. 1A to 1 D, a step of forming a photoresist layer, a step of patterning and removing the photoresist should be included in the conventional TFT fabrication process.
[0009] [0009]FIG. 2A is a TEM photograph of a nickel-silicide line formed in the channel region when crystallizing the silicon layer by the MILC as illustrated in FIGS. 1 A˜ 1 D using Ni as the crystallization source metal. FIG. 2B illustrates the layout of a TFT, the active layer of which is crystallized by the method of FIGS. 1 A˜ 1 D. The arrow in FIG. 2B indicates the crystallization direction by the MILC. As show in FIGS. 2 A˜ 2 B, the nickel-silicide which induces the MILC of the active layer from the portions of the source and drain regions covered with the MIC metal moves toward the channel region as the MILC is progressed on both sides of the channel region. As a result, the nickel-silicide propagating from both sides of the channel region meets around the center of the channel region and forms a boundary in the channel region. A metal component contained in the nickel-silicide deteriorates the electrical characteristics of the channel region such as the field effect mobility and the threshold voltage, and thus adversely affect the performance of the TFT comprising such active layer.
[0010] To overcome the aforementioned disadvantages, a technique shown in FIGS. 3A to 3 B has been proposed. Referring to FIG. 3A, an active layer 31 , a gate insulation layer 32 , and a gate electrode 33 are sequentially formed on a substrate 30 . A photoresist pattern 34 is formed on the gate electrode 33 and the active layer 31 , and a metal layer 35 is deposited to cover the substrate 30 and the photoresist pattern 34 . As shown in FIG. 3A, the photoresist pattern 34 is formed to cover the gate electrode 33 and portions of the source and drain regions adjacent to the gate electrode 33 . The photoresist is located at a position biased toward either the source region or the drain region. As shown in FIG. 3B, when the photoresist pattern 34 is removed by lift-off or other methods, metal offset areas 37 are formed in the portions of the source and drain regions adjacent to the channel region, and the metal layer 35 resides on the other areas of the source and drain regions. Annealing the substrate 30 in this state, the source and drain regions on which the metal layer 35 is formed are crystallized by the MIC cause by the MIC metal, and the metal-offset areas in the source and drain regions and the channel regions are respectively crystallized by the MILC phenomenon propagated from the MIC regions. As shown in FIG. 3C, since the metal offset area in either the source region or the drain region is broader than the other, the MILC boundary 36 between the crystallized regions may be located outside of the channel region 31 C. By doing so, the degradation of the electrical characteristic of the channel area 31 C caused by the MILC boundary may be prevented. However, in order to use the process shown in FIGS. 3A to 3 C, steps of forming, patterning and removing a photoresist layer also should be included in the conventional TFT fabrication process.
SUMMARY OF THE INVENTION
[0011] It is an object of the present invention to provide a thin film transistor including a crystallized active layer and a method for making the same, which overcomes aforementioned problems. The method of the present invention can simultaneously perform the crystallization of a plurality of substrates using MIC and MILC at a lower temperature than those used by the SPC and the ELC methods. Thus, it becomes possible to manufacture poly-silicon TFT's at a low cost without damaging the substrate.
[0012] It is another object of the present invention to provide a poly-silicon TFT and a method for making the same, which does not have the MIC metal component and the MILC boundary in the a channel region, without requiring the processes of forming, patterning and removing a photoresist mask.
[0013] In order to achieve these objects, the present invention provides a method for fabricating a TFT comprising the steps of a) providing a substrate; (b) depositing an amorphous silicon layer on the substrate to provide an active layer of the TFT including a source, drain and channel regions; (c) forming a gate insulation layer and a gate electrode on the substrate and the active layer; (d) doping impurity in the source and drain regions of the active layer; (e) forming a contact insulation layer on the substrate, the active layer and the gate electrode and forming contact holes in the contact insulation layer to expose portions of the source and drain regions; (f) applying MILC source metal on the portions of the source and drain regions exposed by the contact holes; (g) conducting thermal treatment of the substrate and the active layer to crystallize the active layer formed of amorphous silicon; and (h) forming contact electrodes electrically connected to the source and the drain regions through the contact holes.
[0014] In other aspect of the invention, the present invention provides a thin film transistor comprising a substrate; a polysilicon active layer formed on said transparent substrate and including a source, drain and channel regions of the TFT; a gate insulation layer and a gate electrode formed on the substrate and the active layer; a contact insulation layer covering the substrate, the active layer and the gate electrode and including contact holes formed to expose portions of the source and the drain regions; and contact electrodes electrically connected to the source and the drain regions through said contact holes, wherein the active layer of the TFT is formed by crystallizing an amorphous silicon layer formed on the substrate by conducting a thermal treatment of the amorphous silicon layer, and the thermal treatment causes a MILC propagating from the portions of the source and drain regions exposed by the contact holes and having MILC source metal formed thereon.
[0015] Additional features and advantages of the present invention will be set forth or will be apparent from below detailed description of the invention. The objectives and other advantages of the invention will be realized and attained by the scheme particularly pointed out in the written description and claims hereof as well as the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The embodiments of the present invention will be explained with reference to the accompanying drawings, in which:
[0017] [0017]FIG. 1A to FIG. 1D are cross-sectional views illustrating a conventional method for fabricating a poly-silicon TFT using MILC;
[0018] [0018]FIG. 2A and FIG. 2B illustrate the crystallization state of the active layer of the TFT fabricated according to the conventional method as illustrated in FIGS. 1A to 1 D;
[0019] [0019]FIG. 3A to FIG. 3C are cross-sectional views illustrating another conventional method for fabricating a poly-silicon TFT using MILC;
[0020] [0020]FIG. 4A to FIG. 4G are cross-sectional views illustrating a method for fabricating a poly-silicon TFT according to a preferred embodiment of the present invention;
[0021] [0021]FIG. 5A and FIG. 5B are cross-sectional views illustrating the structure of a TFT fabricated according to another preferred embodiment of the present invention;
[0022] [0022]FIG. 6A and FIG. 6B are graphs respectively showing the I-V characteristic of asymmetric Ni offset TFT according to the present invention and that of a symmetric Ni offset TFT; and
[0023] [0023]FIG. 7 is a cross-sectional view illustrating a TFT structure according to a still another preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0024] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
[0025] [0025]FIG. 4A to FIG. 4G are cross-sectional views illustrating the sequence of the process for fabricating a poly-silicon TFT using the MILC according to one embodiment of the present invention. Referring to FIG. 4A, an amorphous silicon layer 41 constituting the active layer of the TFT is formed and patterned on an insulation substrate 40 . The substrate 40 is preferably made of transparent insulator such as non-alkaline glass, quartz or silicon oxide. According to needs, an optional buffer layer (not shown) may be formed on the substrate in order to prevent the diffusion of contaminants from the substrate 40 . The buffer layer is formed by depositing SiO 2 , SiNx, SiOxNy or a combination thereof with a thickness of 300 Å to 10,000 Å, preferably with a thickness in the range of 500 Å to 3,000 Å, at a temperature below 600° C. The buffer layer is formed by various deposition methods such as PECVD (plasma-enhanced chemical vapor deposition), LPCVD (low-pressure chemical vapor deposition), APCVD (atmosphere pressure chemical vapor deposition), ECR CVD (electron cyclotron resonance CVD), and sputtering. The active layer 41 is formed by depositing amorphous silicon with a thickness in the range of 100 Å to 3,000 Å, preferably with a thickness in the range of 500 Å to 1000 Å, by using PECVD, LPCVD or sputtering method. The active layer 41 includes source, drain and channel regions and may also include areas reserved for other devices and electrodes. The active layer 41 is patterned to fit the size of the TFT to be fabricated. The active layer 41 is patterned by dry etching using a mask made by photolithography.
[0026] [0026]FIG. 4B illustrates a cross-section of the structure in which a gate insulation layer 42 and a gate electrode 43 are formed on the substrate 40 and the patterned active layer 41 . As shown in FIG. 4B, the gate insulation layer 42 is formed by depositing SiO 2 , SiNx, SiOxNy or a combination thereof with a thickness in the range of 300 Å to 3,000 Å, preferably with a thickness in the range of 500 Å to 1,000 Å using various deposition methods such as PECVD, LPCVD, APCVD and ECR CVD. Then, the gate electrode layer consisting of conductive material such as metal and doped poly-silicon is formed on the gate insulation layer 42 by sputtering, heating evaporation, PECVD, LPCVD, APCVD, or ECR CVD, and it is patterned to form the gate electrode 43 . The gate electrode layer is formed with a thickness in the range of 1,000 Å to 8,000 Å, preferably with a thickness in the range of 2,000 Å to 4,000 Å. The gate electrode 43 is patterned by a wet etching or dry etching method according to a pattern made by photolithography.
[0027] [0027]FIG. 4C is a cross-sectional view illustrating the process of doping the source region 41 S and the drain region 41 D of the active layer 41 using the gate electrode 43 as a mask. For fabricating a NMOS (N-channel metal oxide semiconductor) TFT, the active layer is doped with a dopant such as PH 3 , P and As with a dose of 1E11˜1E22/cm 3 (preferably 1E15˜1E21/cm 3 ) at the energy level of 10˜200 KeV (preferably 30˜100 KeV) using ion shower doping method or ion implantation method, etc. For fabricating a PMOS (P-channel metal oxide semiconductor) TFT, the active layer is doped with a dopant such as B 2 H 6 , B and BH 3 with a dose of 1E11˜1E22/cm 3 (preferably 1E14˜1E21/cm 3 ) at the energy level of 20˜70 KeV. In order to form a lightly doped region or an offset junction region in the drain region, or to fabricate a CMOS, the doping process may be conducted in multiple stages employing additional masks.
[0028] [0028]FIG. 4D is a cross-sectional view illustrating a structure in which a contact insulation layer 44 is formed on the gate insulation layer 42 and the gate electrode 43 and contact holes 45 are formed in the gate insulation layer 44 . The contact insulation layer 44 is formed by depositing SiO 2 , SiNx, SiOxNy, or a combination thereof with a thickness in the range of 1,000 Å to 15,000 Å, preferably with a thickness in the range of 3,000 Å to 7,000 Å by using various deposition methods such as PECVD, LPCVD, APCVD, ECR CVD and sputtering. The contact insulation layer 44 is patterned by wet etching or dry etching according to a photolithography pattern in order to form the contact holes 45 therein. The contact hole 45 provides a path though which a contact electrode is electrically connected to the source/drain regions of the active layer.
[0029] [0029]FIG. 4E is a cross-sectional view illustrating that a metal layer 46 for inducing the MILC of the amorphous silicon active layer is formed on the portions of the source region 41 S and the drain region 41 D which are exposed though the contact hole 45 . Although, Ni or Pd is preferably used as the source metal for inducing the MILC in the amorphous silicon, other metals such as Ti, Ag, Au, Al, Sn, Sb, Cu, Co, Cr, Mo, Tr, Ru, Rh, Cd and Pt or their combination may also be used as the MILC source metal 46 . Although the MILC source metal such as Ni and Pd may be formed on active layer by sputtering, heating evaporation, PECVD, or ion implantation, sputtering method is preferably used to form the MILC source metal 46 . The thickness of the metal layer 46 can be freely selected within a range that is adequate to induce the MILC of the active layer. The metal layer 46 is formed with a thickness in the range of 1 Å to 10,000 Å, preferably with a thickness in the range of 10 Å to 200 Å.
[0030] The MILC source metal can be deposited on the active layer without removing the mask such as photoresist, which was formed on the contact insulation layer 44 to form the contact holes 45 . Alternatively, the MILC source metal can be deposited on the active layer after removing the mask. If the MILC source metal 46 is deposited prior to removing the mask, a MILC source metal formed outside of the contact hole 45 is automatically removed when removing the mask from the contact insulation layer 44 . In the case, the process for removing the MILC source metal deposited outside of the contact hole may be eliminated. In the present invention, since the MILC source metal is formed on the portions of the source and drain regions exposed through the contact hole 45 , the MILC source metal can be formed on predetermined positions of the source and drain regions 41 S and 41 D without requiring additional mask. Thus, the MILC source metal 46 can be offset from the channel region 41 C of the active layer.
[0031] [0031]FIG. 4F illustrates a process of crystallizing the active layer by conducting a thermal treatment after forming the MILC source metal 46 in the contact holes 45 , and activating the dopant implanted in the source and drain regions of the active layer. For the thermal treatment, RTA (rapid thermal annealing) or ELC (excimer laser crystallization) method can be used. The RTA method heats the substrate at a temperature range of 700° C.˜800° C. for a few seconds or a few minutes using a heating lamp such as tungsten-halogen lamp or a xenon arc lamp. The ELC method heats the substrate at a very high temperature for a very short time using excimer laser. In the present invention, the active layer is preferably crystallized using the MILC, which can crystallize amorphous silicon into poly-silicon at a relatively low temperature in the range of 300° C.˜600° C. Preferably, the crystallization thermal treatment is performed in a furnace at a temperature of 400° C.˜600° C. for 0.1˜50 hours, more preferably for 0.5˜20 hours. During the thermal treatment in a furnace, the source and drain regions 47 on which the MILC source metal is formed are crystallized by MIC caused by the MILC source metal. The remaining portions of the source and drain regions and the channel region which are not covered with the MILC source metal 46 are crystallized by MILC propagating from the regions crystallized by the MIC. In FIGS. 4F and 4G, the arrow indicates the direction in which the MILC propagates. The MILC propagating from the portions of the source and drain regions on which the MILC source metal is applied gradually crystallizes the entire area of the active layer, and eventually forms a MILC boundary 49 at a center between the two contact holes. The technical problems associated with the MILC boundary 49 will be described with reference to another preferred embodiment of the present invention.
[0032] Since this present invention crystallizes the active layer at a relatively low temperature using a furnace, deformation or damage of the substrate can be prevented. In addition, this present invention may conduct the thermal treatment of a plurality of substrates in a furnace at a time, so that the productivity of the process can be enhanced. Besides, since the conditions for crystallizing the active layer by MILC are substantially similar to those of the annealing process for activating the dopant implanted in the active layer, it is possible to simultaneously conduct the crystallization and activation of the active layer in a single process.
[0033] [0033]FIG. 4G is a cross-sectional view illustrating the state in which the active layer is crystallized by the thermal treatment and contact electrodes 50 are formed to connect the source and drain regions of the active layer to the external circuit through the contact holes. In order to form the contact electrodes 50 , conductive material such as metal or doped poly-silicon is deposited on the contact insulation layer by sputtering, heating evaporation or CVD with a thickness in the range of 500 Å to 10,000 Å, more preferably with a thickness in the range of 2,000 Å to 6,000 Å. Then, the layer of the conductive material is patterned into a desired shape by wet etching or dry etching.
[0034] The contact electrode 50 may be made of the same material as the MILC source metal 46 as long as it satisfies the required electrical and the mechanical characteristics. If the MILC source metal 46 and the contact electrode 50 are made of the same material, the process of forming the MILC source metal 46 and the process of forming the contact electrode 50 may be combined into a single process. Then, the MILC source metal 46 and the contact electrode 50 can be formed as a single structure after forming the contact hole in the contact insulation layer 44 , and the thermal treatment is conducted after forming the contact electrode 50 . Forming the MILC source metal 46 and the contact electrode 50 as a single structure in a single deposition process, the process for fabricating the TFT can be further simplified.
[0035] The aforementioned description referring to FIGS. 4 A˜ 4 G has been directed to a symmetric TFT structure where the MILC source metal 46 is formed at the locations which are symmetric with respect to the channel region. In the embodiment illustrated in FIGS. 4 A˜ 4 G, the channel region may be crystallized faster because the channel region is crystallize by MILC propagating from both sides of the channel region. However, in the symmetric TFT, a MILC boundary 49 is formed in the channel area to deteriorate the characteristics of the leakage current and the field effect mobility of the channel area. Thus, it eventually deteriorates the performance of the TFT. Hereinafter, another preferred embodiment of the present invention for overcoming this disadvantage will be described.
[0036] [0036]FIG. 5A and FIG. 5B are cross-sectional views illustrating a TFT structure according to another embodiment of the present invention. The TFT shown in FIG. 5A has contact holes 53 and MILC source metal 54 formed at asymmetric locations with respect to the channel region 52 C. Except the location of the contact holes and the MILC source metal, the TFT shown in FIGS. 5A and 5B has the same structure as the TFT shown in FIGS. 4A to 4 F. If the active layer of the TFT in FIG. 5A is crystallized by the MILC under the same condition as described above referring to FIG. 4F, the MILC boundary 55 is formed outside of the channel area 52 C as shown in FIG. 5B. Thus, the problem that the MILC boundary adversely affects the characteristics of the channel region may be avoided. In the embodiment illustrated in FIGS. 5A and 5B, the position of the contact holes 53 may be freely selected so that the MILC boundary 55 is formed at a location which is separated from the channel region by at least 0.1 μm.
[0037] Table 1 below compares the field effect mobility of a TFT having a symmetric structure to that of a TFT having an asymmetric structure in which a MILC boundary in not formed in the channel area. Both TFT's have a Ni offset region formed in the source and drain regions.
TABLE 1 N-channel P-channel Asymmetric Symmetric Asymmetric Symmetric Variable Ni offset Ni offset Ni offset Ni offset Field effect 82 60 38 32 mobility (cm 2 /Vs)
[0038] As shown in Table 1, the Ni offset TFT having an asymmetric structure has superior field effect mobility compared to that of a TFT having a symmetric structure.
[0039] [0039]FIG. 6A and FIG. 6B are graphs respectively showing the I-V characteristic of a TFT having an asymmetric Ni offset structure and that of a TFT having a symmetrical Ni offset structure, where the channel width/length (W/L) ratio =20/8 and Vd=5, with respect to N-channel and P-channel TFT's. As shown in FIG. 6A and 6B, the TFT having an asymmetric offset structure has a lower leakage current as compared to the TFT having a symmetric offset structure. In the light of the foregoing, it can be seen that the Ni offset TFT having an asymmetric structure has improved electrical characteristics such as the field effect mobility and the leakage current as compared to the Ni offset TFT having a symmetric structure. It is because that the electrical characteristics of the TFT channel region having a symmetric Ni offset structure is adversely affected by the MILC boundary, where the nickel-silicide which caused the MILC resides.
[0040] [0040]FIG. 7 is a cross-sectional view illustrating a TFT structure according to a still another embodiment of the present invention, in which the MILC boundary is not formed in the TFT channel region. FIG. 7 shows a dual gate TFT which comprises two gate electrodes 71 . The dual gate TFT may be fabricated using the same method as described referring to FIGS. 4A to 4 G. The MILC source metal 73 is formed at a location symmetric with respect to a pair of gate electrodes 71 . When the active layer with the MILC source metal 73 is crystallized by the thermal treatment as described referring to FIG. 4F, the MILC boundary 74 is formed between the two channel regions 72 . As such, fabricating a dual gate TFT according to the method of the present invention, the problems caused by the MILC boundary formed in the channel region may be effectively prevented.
[0041] As described above, the method for fabricating a TFT according to the present invention may simultaneously crystallize a plurality of amorphous silicon layers in a furnace using the MILC at a relatively low temperature compared to those used by the RTA and the ELC method. Thus, the inventive method may enhance the productivity of crystalline TFT. In particular, the method of the present invention crystallizes the TFT active layer at a temperature range of 400° C.˜600° C., which is lower than the deformation temperature of glass around of 600° C. Thus, the method of present invention can effectively prevent the deformation or damage of the substrate during the fabrication of the TFT. In addition, the present invention may simultaneously performs the crystallization and the activation process of the active layer, thereby simplifying and expediting the TFT fabrication process.
[0042] As compared to prior art for forming a metal offset area using a photoresist pattern formed on the source/drain regions of the active layer, the present invention forms the MILC source metal on selected locations in the active layer through the contact holes using the contact insulation layer as a mask. Thus, the present invention has an advantage that the MILC source metal can be offset from the channel region without requiring additional masking process. In addition, if the contact electrode is formed with the same material as the MILC source metal, the processes of forming the contact electrode and the MILC source metal can be integrated into a single process. In addition, the present invention does not form the MILC boundary in the channel region of the TFT by using dual gate electrodes or forming the MILC source metal at the asymmetric locations with respect to the channel region. Thus, the method of the present invention has an advantage of providing a TFT having improved electrical characteristics.
[0043] Although, the present invention has been described with respect to specific embodiments thereof, various changes and modifications and be carried out by those skilled in the art without departing from the scope of the invention. It is intended, therefore, that the present invention encompass such changes and modifications as fall within the scope of the appended claims. | A thin film transistor (TFT) including a polycrystalline active layer and a method for making the same are disclosed. An amorphous silicon layer is deposited on a substrate and is crystallized by using MILC (metal induced lateral crystallization) to provide a poly-silicon active layer of the TFT. Specifically, the amorphous silicon layer is poly-crystallized during a thermal treatment of the active layer. The thermal treatment causes the MILC of the active layer propagating from portions of the source and the drain regions on which MILC source metal is formed through the contact holes of the TFT. The TFT fabricated according to the present invention has improved electrical characteristics such as electron mobility and leakage current. The present invention further improves the performance of the TFT by making the MILC boundary is formed outside of the channel region so that the MILC boundary may not adversely affect the operation of the TFT. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to high performance multiconductor flat cable and more particularly to controlled impedance low loss low attenuation cable employing a plurality of conductor pairs which can be used in undercarpet installations.
2. Description of the Prior Art
Conventional multiconductor cable for transmitting high frequency digital signals includes both shielded twisted pair cable and coaxial cable. Shielded twisted pair cable utilizes a conventional twisted pair configuration and employs a shield around the twisted pair to reduce EMI radiation and to minimize cross talk. Coaxial cables similarly use an EMI shield to reduce radiation and cross talk.
Considerable effort has been extended to develop a flat multiconductor coaxial cable which would yield the same performance as conventional coaxial cable but would also enable the use of conventional mass termination techniques to attach connectors to the cable. For example, U.S. Pat. No. 4,488,125 discloses a flat cable assembly in which a signal conductor and at least one drain conductor are embedded in a first insulating matrix and surrounded by a shield which is in turn surrounded by an outer insulating layer. The drain wires are positioned in contact with the outer layer to enable both the signal and drain wires to be connected by a mass termination process. Other flat coaxial cables are disclosed in U.S. Pat. Nos. 4,487,992 and 3,775,552. One application for flat data cable is the use of this cable in under the carpet wiring situations in which a flat low profile cable is extended beneath a carpet for connection to digital equipment.
Conventional twisted pair cable does not have a profile suited for use in undercarpet applications. The invention disclosed herein comprises a relatively low profile flat cable having the performance characteristics of shielded twisted pair cable but yet having a low profile suited for undercarpet installations. The flat cable disclosed herein also has the mass termination capabilities of flat cable with conductors spaced on repeatable precise center lines, unlike conventional shielded pair cable.
SUMMARY OF THE INVENTION
The preferred embodiments of this invention comprise a controlled impedance, low attenuation, balanced flat cable having the performance characteristics of shielded twisted pair cable and comprising a multilayer extruded cable having an annealed copper shield encapsulating associated pairs of conductors. Each conductor is surrounded by a first insulating material having a lower dielectric constant than a second dielectric material which surrounds each of the two conductors forming an associated pair. The second layer of insulation gives dimensional stability to the conductors comprising the pair and precisely positions the foil shield relative to the conductors. An outer layer of insulating material is extruded over the shields of adjacent conductor pairs and holds the shield in place to prevent radiation. In the preferred embodiment of this invention, the second insulating material is extruded into a generally oval configuration having one planar surface. The metal foil shield is disposed around the second insulating material and the overlapping ends of the metal foils are positioned along the planar end which extends generally perpendicular to the plane of the conductors. Integral wings or ramps are provided on the sides of the central body of the cable to provide a smooth transition with the surface on which the cable is positioned. Weakened sections can be provided between the outer wings and the main body of the cable and weakened sections can also be provided in the second insulating material to permit easy separation of the conductors from the cable to facilitate termination to connectors positioned on the ends of the cable.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a two-pair flat cable especially adapted for use in under-the-carpet installations.
FIG. 2 is a cross-sectional view of a single pair cable embedded in an insulating core surrounding both conductors of an associated pair.
FIG. 3 is a cross-sectional view similar to FIG. 2 demonstrating the positioning of an EMI shield during fabrication of a shielded conductor pair.
FIG. 4 is a view similar to FIG. 3 demonstrating the final position of the EMI shield encircling both conductors of the conductor pair.
FIG. 5 is a cross-sectional view showing the single conductor pair surrounded by a EMI shield encapsulated within an outer insulating body.
FIG. 6 is a plan view of a cable in accordance with the preferred embodiment of this invention showing the removal of respective layers of insulation from the four conductors comprising two conductor pairs.
FIG. 7 is an elevational view of the cable as shown in FIG. 6 in which successive layers of the composite structure are shown adjacent one end of the cable.
FIG. 8 is a view similar to FIG. 1 showing an alternate embodiment of a flat cable in accordance with this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The multilayer shielded pair cable comprising the preferred embodiment of this invention provides a controlled high impedance, low cross talk, low attenuation multiconductor flat cable suitable for use in transmitting digital or other high frequency data. The preferred embodiment of this invention will be described in terms of a flat cable having two separate pairs of associated conductors, four conductors in all. It should be understood however that some applications may require cable having more than two pairs of conductors. This invention is consistent with the use of any number of pairs of conductors and can be employed with a single pair of conductors or with a large number of pairs. Indeed this invention is intended for use in applications requiring three pairs of conductors in a manner similar to the use of the two-pair cable which comprises the preferred embodiment of this invention. The principal embodiment of this invention depicted herein is intended for use in installations in which the flat cable is to be installed along the floor of an office building and under the carpet to enable connections to be made with portions of a network arbitrarily distributed in an office building. It should be understood however that this high performance cable, having conductors located within the same plane, is not limited to use in undercarpet installations. Indeed, the constant orientation of the conductors in the same plane renders this cable quite suitable to applications in which it is desirable that the conductors be simultaneously mass terminated to the connector position at the end of the cable. Indeed this cable is quite suitable for use as a predeterminated cable assembly in which connectors may be assembled at each end of precise lengths of cable in a factory environment.
The cross-sectional configuration shown in FIG. 1 demonstrates the relative positioning of four conductors 11, 12, 21 and 22 in a flat cable assembly 2. Each of the conductors 11, 12, 21 and 22 employed in the preferred embodiment of this invention comprises a conventional round wire conductor. Conductors 11 and 12 comprise one associated pair of conductors while conductors 21 and 22 comprise a similar pair of associated conductors. Each of the conductors 11, 12, 21 and 22 are positioned in the same plane, thus facilitating a low profile necessary for use in undercarpet installations. Each conductor pair nevertheless retains the capability for balanced signal transmission. Both of the conductor pairs are embedded in an outer insulating body 4 which comprises the central longitudinally extending portion of the cable 2. Similar wings or ramps 6 and 8 are bonded longitudinally along the opposite sides of the central body 4. Each of the wings 6 and 8 comprises an inclined surface to provide a smooth transition laterally of the axis of the cable, thus eliminating any sharp bump when the cable is positioned beneath a carpet. In the preferred embodiment of this invention, the insulating ramps 6 and 8 are formed from the same material as the insulating material forming insulating body 4. Wings 6 and 8 are joined to body 4 along weakened longitudinally extending sections 30 and 32. In the preferred embodiment of this invention, the insulating material forming the body 4 and the insulating material forming wings 6 and 8 comprises an extruded insulating material having generally the same composition. Conventional polyvinyl chloride insulation comprises one material suitable for use in the jacket or body 4 in the wings 6 and 8.
Each shielded cable pair is separately embedded within the insulating body 4. As shown in FIG. 2, the conductors 21 and 22 forming one pair 20 of associated conductors is encapsulated within a separate insulating core 25 which is in turn embedded within the body 4 of the cable 2. Each conductor 21 and 22 is however encircled by a first insulation 23 and 24 respectively which comprises a foam-type insulation having a relatively low dielectric constant. Foam-type insulation such as polypropylene or polyethylene, each of which contain the large percentage of air trapped within the material comprise a suitable dielectric material for use around the conductors in areas of relatively high dielectric field. These foam covered conductors can then be embedded within an insulating material 25 which completely surrounds the foam insulation 23 and 24 in the immediate vicinity of the conductors. The insulating material 25 need not have as low a dielectric constant as the foam insulation 23 and 24, since the insulating material 25 is located in areas of relatively lower electric fields. The insulating material 25 thus has less effect on the cable impedance than the foam insulation 23 and 24. The insulating material 25 must however be suitable for imparting dimensional stability to conductors 21 and 22. In fact in this invention the dielectric material 25 holds the conductors 21 and 22 in a parallel configuration along precisely spaced center lines. The insulating material forming the core 25 also comprises a material having greater strength when subjected to compressive forces than the foam type insulation 23 and 24 surrounding conductors 21 and 22. A material suitable for forming core 25 is a conventional polyvinyl chloride which can be extruded around the foam insulation 23 and 24 surrounding conductors 21 and 22. It is desirable that the foam type insulation 23 and 24 not adhere to the extruded insulating material forming the core 25 since the conductors must be removed from the core 25 for conventional termination into a connector. In the preferred embodiment of this invention, longitudinally extending notches 26 and 27 are defined along the upper and lower surfaces of the core 25. These notches, which can be conveniently formed as part of the extrusion process are located in areas of relatively low dielectric field and define a weakened section of insulating core 25 to permit separation of conductors 21 and 22 for termination purposes.
The cross talk and noise performance of each pair of conductors is greatly enhanced by the use of EMI shields 18 and 28 encircling the cores 15 and 25 of the conductors within each conductor pair 10 and 20. As shown in FIG. 3, an EMI shield 28 can be positioned in partially encircling relationship to conductors 21 and 22 within insulating core 25. The ends 28A and 28B of EMI shield extend beyond the lateral edge of core 25 during fabrication of the cable. FIG. 4 shows that these ends 28A and 28B can then be folded into overlapping relationship along one end or edge of the core 25. In the preferred embodiment of this invention, the one edge of core 25 comprises a planar edge extending transversely, and preferably perpendicular to the plane in which the conductors 21 and 22 are positioned. This planar edge facilitates assembly of the shield 28 in overlapping relationship along the edge of core 25. Furthermore by providing sharp corners at the upper and lower extent of this planar surface, good contact is maintained between the overlapped portions 28A and 28B of the cable at these two points. Thus gaps, which can act as an antenna in the shielding are prevented. As shown in FIG. 5, the overlapped ends 28A and 28B of the EMI shield 28 are secured in a tightly held configuration by the insulating material extruded around the EMI shield and comprising the insulating body 4. Thus the ends 28A and 28B would not be subject to movement upon flexure of the cable to create a gap or radiating antenna. In the preferred embodiment of this invention, an annealed metallic foil is employed as the EMI shields 18 and 28. For example, an annealed copper foil having a 2 mil thickness is suitable for use as an EMI shield in the preferred embodiment of this invention.
FIG. 8 shows an alternate embodiment of this invention in which planar ends of the insulating cores, at which the EMI shield is overlapped are positioned on the exterior of the conductor pairs. FIG. 1 shows the two ends of the separate EMI shields positioned adjacent to each other within the body 4. Since the invention is suitable for use with more than two pairs of conductors, it is apparent that the relative positioning of the flat overlapping ends of the cable is a matter of choice. For example if three pairs are employed, the flat ends of all three shields cannot be adjacent if all conductors are positioned within the same plane.
Not only is this cable suitable for use in applications in which high electrical performance is required, this cable is also easily adaptable to termination of the separate conductors to an electrical connector at the end of the cable. FIGS. 6 and 7 illustrate the ease in which the conductors may be presented for termination. Initially the wings 6 and 8 can be removed adjacent the ends. Weakened sections 30 and 32 facilitate the preparation of the ends of the cable since the wings can be removed by simply tearing along the weakened sections 30 and 32. The insulating material comprising the insulated body 4 can then be removed from the shielded cable pairs. The use of annealed copper foil, to which the insulating material forming the body 4 does not adhere permits the simple removal of this insulating material from the two conductor pairs. The shields 18 and 28 can then be cut and bent away from the extruded insulating core 15 and 25. The extruded insulating material forming core 25 can in turn be simply removed from the foam insulation surrounding conductors 21 and 22, since the foam insulation 23 and 24 does readily adhere to the extruded insulating material forming core 25. At this point the conductors 21 and 22 within foam insulation 23 and 24 are suitable for solderless mass termination by conventional insulation displacement techniques. Both FIGS. 6 and 7 however show the conductors 21 and 22 extending beyond the foam insulation 23 and 24. It should be appreciated that conductors 21 and 22 are shown primarily for illustrative purposes since it will normally not be necessary to remove insulation 23 and 24 from the bare conductors 21 and 22. However it may be desirable in certain installations to remove the insulation 23 and 24 before terminating conductors 21 and 22 and this invention is suitable for use in this matter.
Although the invention has been described in terms of two embodiments and additional extensions of this invention have been discussed, it will be appreciated that the invention is not limited to the precise embodiments disclosed or discussed since other embodiments will be readily apparent to those skilled in the art. | A high performance controlled impedance low loss low attenuation cable having the characteristics of a shielded twisted pair cable is disclosed. The cable contains a plurality of pairs of associated conductors located in a single plane to give a low profile flat cable suitable for use in undercarpet wiring installations. The cable comprises a plurality of layers of extruded insulating material with a metal foil shield surrounding only associated pairs of conductors. Insulating material having different dielectric constants is employed in conjunction with the encircling foil shield to give the cable the characteristics of a conventional shielded twisted pair cable. | 7 |
This invention is an installation for protecting windows during inclement weather, such as storms and hurricanes.
BACKGROUND OF THE INVENTION
The provision of storm shutters and the like for protecting a glass window during inclement weather is well known. The standard technique is to simply nail plywood over the exposed window. This has many disadvantages.
As might be expected, there are a number of sophisticated commercially available approaches to protect windows, glass doors and the like during storms, such as roll up shutters and the like. Some of these devices are priced so high as to be uneconomic in all but the most expensive homes.
U.S. Pat. No. 3,745,704 discloses aluminum extrusions shaped to receive and support a single removable plywood panel. The extrusions are attached above and below the window to be protected and define a pair of facing channels to receive the plywood panel. Although this approach is effective to a substantial degree, the resultant structure does not meet many newer codes, such as in South Florida.
Other disclosures of interest are found in U.S. Pat. Nos. 2,622,285; 5,335,452; 5,347,775; 5,477,646 and 5,509,239.
The Dade County, Florida code for window protective devices includes a test where a standard 8' stud (nominal 2"×4"×8' weighing 9.4 pounds) is shot from a device spaced 12' from the glass opening at a speed of 50 feet/second. The window protective covering must be at least 2" from the window glass and be sufficiently strong that it does not touch the window glass or glass frame in the above impact test. In addition, the window protective covering must be sufficiently strong to pass a wind-load test of 140 miles per hour. To pass these code tests requires a window covering of formidable strength.
SUMMARY OF THE INVENTION
In this invention, two or more window protective panels are received in parallel channels provided by supports near the upper and lower edges of the window to be protected. The protective panels are typically plywood but may be a tough transparent plastic such as LEXAN to provide visibility and light to overcome the feeling of claustrophobia experienced by many. The supports are conveniently aluminum extrusions and are connected to the building in one of a variety of techniques depending on the configuration of the building adjacent the window. The supports are installed with conventional tools available to knowledgeable workmen.
Angle members are fixed to the building adjacent the sides of the window protective panels and provide two important functions. First, they restrict air flow paths to the rear of the window protective panels thereby reducing the likelihood that high velocity wind gets behind the panels. Second, they provide vertical supports for one or more, and preferably two, removable horizontal bars restraining movement of the window protective panels toward and/or away from the window glass. The horizonal bars deter deflection of the panels toward the window glass and thus act as supports against rearward movement of the panel thereby effectively halving its maximum unsupported length.
After the supports and side rails have been installed, assembly of the window protective system of this invention requires no tools and can be done in a few minutes. The home-owner needs only to insert the first horizontal bar in its support slots and then position the window protective panels in their respective channels. The second horizontal bar is then inserted in its support slots. One or more thumb screws are then used to clamp the panels and the horizontal bars together. The result is a window protective covering of formidable strength.
It is an object of this invention to provide an improved window protective system.
A further object of this invention is to provide a window protective system providing two or more parallel protective panels removable received in channels in a permanent support.
Another object of this invention is to provide a window protective system providing side rails restricting air flow behind a window protective panel and to support and retain one or more removable horizontal bars deterring deflection of the panels toward the window.
These and other objects and advantages of this description will become more apparent as this description proceeds, reference being made to the accompanying drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view of the window protective system of this invention installed over a conventional window;
FIG. 2 is an enlarged broken side elevational view of the window protective system of FIG. 1;
FIG. 3 is a broken exploded isometric view illustrating the window protective system of FIGS. 1 and 2;
FIG. 4 is an enlarged isometric view of the panel receiving supports;
FIG. 5 is a front elevational view of another embodiment of the window protective system of this invention installed over a conventional window;
FIG. 6 is an enlarged broken side elevational view of the window protective system of FIG. 5;
FIG. 7 is an enlarged exploded isometric view of the window protective system of FIGS. 5 and 6; and
FIG. 8 is a cross-sectional view of the support bar of FIGS. 5-7.
DETAILED DESCRIPTION
Referring to FIGS. 1-4, a window protective system or installation 10 of this invention is positioned in front of a conventional opening, such as a door or window, in a building wall 12. Typically, the installation 10 protects a window 14 including a glass pane or panel 16. The installation 10 includes, as major components, upper and lower channel supports 18, 20 and a pair of structural panels 22, 24.
The upper and lower supports 18, 20 are quite similar but are not identical. The supports 18, 20 are conveniently aluminum extrusions providing a base 26, 28 from which extend a multiplicity of vertical walls 30-40 providing channels 42, 44, 46, 48 for receiving and supporting the structural panels 22, 24. As shown best in FIG. 2, the channels 42, 46 define a plane for receiving the front or outer panel 22 and the channels 44, 48 define a plane for receiving the rear or inner panel 24.
The supports 18, 20 also provide mounting flanges 50-56 for attaching the aluminum extrusions to the building wall 12. The flanges 50-56 lie in a common plane 58 and abut the building wall 12 to receive suitable fasteners 60 connecting the supports 18, 20 to the building wall. The supports 18, 20 provide weakened sections or break off points 62 for separating the mounting flanges 50-56 from the supports 18, 20 so the supports 18, 20 can be modified to fit the configuration of the building wall 12 around the window 14. Those skilled in the art will recognize that the flange 50, for example, can be broken off the support 18 by grasping the flange 50 with a pair of pliers and bending the flange in a counterclockwise direction. This breaks the flange 50 off the support at the break off point 62. In this manner, the supports 18, 20 can be modified to suit the configuration of the window 14 and the building adjacent thereto.
The supports 18, 20 also provide a series of score lines 64 for aligning the center of the leg to promote precise drilling of holes to receive threaded fasteners.
The ends of the walls 30, 32, 36, 38 bend or taper away from the plane 58 to facilitate placement of the structural panels 22, 24 in their respective channels 42, 46 and 44, 48 as will be more fully apparent hereinafter. This is seen best in FIG. 2 where the ends 66, 68 of the forward walls 30, 36 diverge away from the panel 22 and the intermediate walls 32, 38 provide a tapered sections 70, 72 diverging away from the panel 24. It will accordingly be seen that the intermediate walls 32, 38 of the upper and lower supports 18, 20 include a first inner section adjoining the base 28, 26 and generally parallel to the plane 58 and a second outer section 70, 72 adjoining the inner section and defining an acute angle with the plane 58. It will be seen that these features enlarge the mouth of the channels 42, 44, 46, 48 and allow the panels 22, 24 to move more easily into the channels.
The rear wall 34 of the upper channel 18 differs significantly from the rear wall 40 of the lower channel 20 and is at an angle more nearly parallel to the tapered section 70 than to the vertical. In other words, the angle of the inside surface of the rear wall 34 is between the angle of the tapered section and the angle of the rear surface of the intermediate wall 32.
It will be seen that the upper channels 42, 44 are deeper than the lower channels 46, 48. The upper channels 42, 44 must be of sufficient depth to receive the upper end of the panels 22, 24 during installation so the panels 22, 24 can clear the lower support 20 and still retain the panels 22, 24 when the panels 24 are lowered into the operating position shown in FIG. 2.
The panels 22, 24 may be of any suitable material. The least expensive practical material is plywood. A more expensive but very desirable material is a transparent or translucent polymer plastic material such as LEXAN. A transparent plastic material allows light inside the building and allows people to see outside. This minimizes the feeling of claustrophobia that affects some people.
Installation and operation of the window protective system of this invention should now be apparent. Trained workmen attach the supports 18, 20 above and below the window 14 to be protected. The panels 22, 24 are cut to size. To install the inner or rearward panel 24, it is raised and tilted until the upper end thereof passes into the upper channel 44 between the rear wall 34 and the tapered section 70 of the intermediate wall 32. The panel 24 is raised until the bottom end thereof clears the bottom support 20. The panel 24 is then pivoted until the bottom end thereof is aligned with the channel 48. The panel 24 is then lowered until it is supported by the lower support 20. The outer or forward panel 22 is installed in essentially the same manner, i.e. it is inserted into the upper channel 42 until the lower end thereof clears the lower support 20 and the panel 22 is then pivoted until it is aligned with the lower channel 46. The panel 22 is then lowered into the channel 46 and is thereby supported by the lower support.
Referring to FIGS. 5-7, there is illustrated an improved embodiment of a window protective system or installation 74 of this invention comprising, as major components, upper and lower supports 76, 78, a pair of structural panels 80, 82 and a pair of removable support bars 84, 85. The installation 74 protects a conventional window 86 having a glass pane or panel 88.
The upper and lower supports 76, 78 are substantially the same as the supports 18, 20 except for the provision of fastener receiving openings 90, 92 provided by the intermediate and rear walls 94, 96.
The support bars 84, 85 are attached to the building wall 98 by a pair of side rails 100 each of which comprise an angle having a first leg 102 parallel and quite close to a plane 104 defined by the mounting flanges 106 and a second leg 108. Suitable threaded fasteners 110 extend through the second leg 108 into the fastener openings 90, 92 to attach the side rails 100 to the upper and lower supports 76, 78 thereby affixing the side rails 100 to the building wall 98.
The side rails 100 provide two pairs of aligned slots 112 and two pairs of aligned openings 113 immediately below the slots 112. As will be more fully apparent hereinafter, the ends of the support bars 84, 85 are supported and retained in the slots 112 and openings 113. To this end, the support bars 84, 85 each comprise lug shaped ends 114, 115 adjacent rectangular slots 116, 117 opening through the bottom of the bars 84, 85 to provide tangs 118, 119. The ends 114, 115 are sized to pass through the slots 112, the slots 116, 117 are sized and shaped so the edge of the leg 108, adjacent the slots 112, fits into the slots 116, 117 and the tangs 118, 119 are sized and shaped to fit in the openings 113. It will be seen that the slots 116, 117 include an enlarged portion opening through the bottom edge of the bar. It will accordingly be seen that the slots 112, are of sufficient vertical extent to receive the ends of the bars 84, 85 so the slots 112, 116, 117 can mesh and the tangs 118, 119 fit in the openings 113.
As best shown in FIG. 6, one pair of the slots 112 are parallel to the plane 104 and located between the plane 104 and the inner panel 82. Thus, any deflection of the panel 82 toward the window glass 88 is resisted by the support bar 84. To this end, the support bar 84 is desirably configured to resist deflection in the direction shown by the arrow 121. Thus, as shown in FIG. 8, the bar 84 includes a rib 120 extending along the back of the bar 84 for part of the length thereof. As will be apparent to those skilled in the art, the rib 120 stops well short of the ends 114 of the bar 84 and does not interfere with the connection between the bar 84 and the side rails 100.
The second pair of slots 112 are also parallel to the plane 104 and are located outboard of the outer protective panel 80. This has two effects. First, the leg 108 extends outwardly past the outer protective panel 80 so the gap between the inner panel 82 and the window glass 88 is substantially restricted against movement of high velocity winds. Second, the bars 84, 85 are positioned so the panels 80, 82 may be clamped together in the center thereof. The ends of the panels 80, 82 will accordingly be clamped against the intermediate walls 94 to provide a rugged barrier against debris propelled toward the window 86.
It will be seen that the side rails 100 have two functions. First, the side rails 100 support the bars 84, 85 in a position where the bars 84, 85 resist deflection of the panels 80, 82 and specifically resists deflection of the inner panel 82 in the direction shown by the arrow 118. Thus, the bars 84, 85 reduce the unsupported length of the structural panels 80, 82. By placing the bars 84, 85 in a common horizontal plane approximately midway along the height of the panels 80, 82, the unsupported length of the panels 80, 82 is halved. Second, the legs 108 of the side rails 100 substantially decrease the extent to which high velocity wind can get between the panels 80, 82 and the window 86. In this regard, it will seen that the legs 108 of the side rails 100 extend away from the building at least as far, and preferably further, than the outer panel 80. This also minimizes damage under many circumstances. Those skilled in the art will recognize that the system of FIGS. 5-8 is substantially stronger than the system of FIGS. 1-4.
Installation and operation of the window protective system of FIGS. 5-8 should now be apparent. Trained workmen attach the supports 76, 78 above and below the window 86 to be protected, using threaded fasteners extending through those of the flanges 106 that suit the building configuration and by using threaded fasteners extending through the base of the channels. The side rails 100 are attached to the supports 76, 78 with the fasteners 110. The inner bar 84 is installed in the inner set of slots 112 by inserting the bar ends 114 through the slots 112 until the openings to the slots 116 align with the legs 108. The bar 84 is then moved downward until the tangs 118 align with the openings 113 and the bar 84 is then moved to the right in FIG. 7. The panels 80, 82 are cut to size. The panels 80, 82 are installed as in the embodiment of FIGS. 1-4. The outer bar 85 is then installed in the outer set of slots 112 and the bars 84, 85 and panels 80, 82 clamped together, as by the provision of threaded fasteners 122, such as thumb screws or the like, received in nuts 124. Clamping the bars 84, 85 and the panels 80, 82 together in the middle also causes the panel ends to grip the intermediate walls 94 of the supports 76, 78 so the panels 80, 82 are essentially immobile. Clamping the panels 80, 82 together also makes the connection between the bars 84, 85 and the side rails 100 secure. Even without the tangs 118, 119, or even without the sophisticated slot configurations, if the panels 80, 82 are clamped together with the bars 84, 85 in place, the bars 84, 85 cannot move out of engagement with the side rails.
Although this invention has been disclosed and described in its preferred forms with a certain degree of particularity, it is understood that the present disclosure of the preferred forms is only by way of example and that numerous changes in the details of operation and in the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention as hereinafter claimed. | A storm shutter installation includes a pair of supports attached above and below a window to be protected. The supports include a pair of parallel channels to receive a pair of plywood panels. One or more removable brace are provided to support the plywood panels. The braces typically run parallel to the short dimension of the panels thereby reducing the unsupported long dimension of the panels. The braces are clamped together, thereby clamping the panels together and clamping the panels to the supports. The resulting storm shutter installation is substantially stronger, perhaps as much as an order of magnitude, than single plywood panel installations. | 8 |
FIELD OF THE INVENTION
[0001] The present invention relates to liquid dispensers and more specifically relates to a precompression system for a liquid dispenser whereby liquid in a container is not discharged from the dispenser until a predetermined pressure level is reached. The invention also relates to a method of assembling such a recompression system in a liquid dispenser.
BACKGROUND OF THE INVENTION
[0002] Containers having liquid dispenser assemblies secured thereto are well known. U.S. Pat. No. 5,730,335 discloses a liquid dispenser including a precompression system. This liquid dispenser is a trigger sprayer having a sprayer housing that may be fixed onto the neck of a container. The sprayer housing contains a manually operated pump. An operating element in the shape of a trigger is pivotally connected to the housing for operating the pump. A dip tube may extend from the pump and into the container so that the liquid in the container may be drawn through the dip tube and into the pump during operation thereof. The trigger sprayer also includes an outlet in fluid communication with the pump for discharging the fluid. The trigger sprayer further includes a spring located in the pump for biasing the piston of the pump to return to a charged position at the end of a discharging pump stroke.
[0003] The precompression system of this prior art trigger sprayer serves to prevent liquid from leaving the outlet at too low a pressure, which would result in insufficient atomization of the liquid with large drops of fluid or liquid being formed in the spray pattern. The precompression system includes a precompression valve moveable between a position that closes off communication between the pump and the outlet and an open position in which it is spaced from a valve seat for opening communication between the pump and the outlet. The recompression valve is a shallow dome made of a spring material, such as stainless spring steel or a stiff but resilient plastic material. It is biased toward a closed position, in which its convex side engages the valve seat, by its inherent spring characteristics. The precompression valve is flexed to its open position only when a predetermined pressure is attained within the pump.
[0004] Among the problems associated with this prior art liquid dispenser and its precompression system are the large number of separate parts, which moreover are made from different materials, and the sometimes irregular dispensing pressures achieved by the precompression system.
[0005] The high number of parts results in a product that is both difficult to manufacture and assemble. As a result, both the manufacturing and the assembly of the dispenser parts are expensive and time consuming. In addition, the different materials pose problems in handling and recycling the trigger sprayer and the container when the items are ready to be discarded. For example, the metal spring used for returning the piston and the stainless steel spring valve must both be removed from the trigger sprayer before the plastic portion of the item may be recycled.
[0006] The variations in the pressure that is built up in the prior art precompression system is due to the fact that the convex side of the dome shaped spring valve is moved away from the valve seat by flexing the valve such that it assumes a somewhat “wavy” shape in cross section. This is an unstable situation, which may lead to the same amount of pump pressure resulting in varying deformation and consequently varying degrees of opening of the spring valve. Moreover, there is a risk that the spring valve may abruptly snap to an inverted position, thus leaving an open connection between the pump and the outlet.
[0007] In response to the above problems, commonly assigned U.S. Pat. No. 6,378,739 discloses another liquid dispenser which includes a precompression system. In this prior art liquid dispenser, which has generally the same functionality and structure as the dispenser of the '335 patent discussed above, both the number of separate parts and the use of different materials is reduced in comparison to the liquid dispenser of the '335 patent. To this end the springs for returning the piston at the end of a pump stroke are made from a plastics material and are integrally molded with the neck of the container. Moreover, the precompression system of this prior art liquid dispenser includes a precompression valve that is made of a plastics material as well and that is integrally molded with a sleeve which mounts the valve in a valve chamber. This extensive use of integrally molded plastic structures limits the number of separate parts, resulting in a liquid dispenser that is easy to manufacture and assemble. Moreover, handling and recycling of the liquid dispenser when it is discarded after use is facilitated.
[0008] The precompression valve of the liquid dispenser disclosed in the '739 patent includes a dome shaped elastic diaphragm that engages the recompression valve seat with its convex side. Therefore, this elastic diaphragm is still crone to inversion when subjected to pump pressure. In order to limit the amount of deflection of the diaphragm and prevent it from being moved to an inverted position, a stop member protrudes from the concave side of the diaphragm towards a fixed cart of the dispenser housing. Nevertheless, the degree to which the diaphragm deflects when the pressure in the pump increases and consequently also the valve opening may vary.
SUMMARY OF THE INVENTION
[0009] The present invention relates to various types of precompression systems for liquid dispensers and assembly methods for making such precompression systems that overcome the problems described above.
[0010] In accordance with a first aspect of the present invention, a precompression system for a liquid dispensing device that has an inlet and an outlet comprises a pump chamber and a valve chamber. The pump chamber includes a piston that is movable in the pump chamber for drawing liquid through the inlet and discharging the liquid through the outlet. The valve chamber includes a valve member that is disposed between the pump chamber and the outlet and that is operable to allow liquid in the pump chamber to reach the outlet only after a predetermined pressure is established in said pump chamber and to stop liquid from reaching the outlet when the pressure in the pump chamber falls below said predetermined pressure. The valve chamber has an inlet end in fluid communication with said pump chamber, an outlet end in fluid communication with the outlet and a valve seat that is arranged between the inlet end and the outlet end and that has an opening extending therethrough. The valve member comprises an elastic diaphragm that normally closes the valve seat opening and that includes a concave surface facing the valve seat opening and in fluid communication with the pump chamber and a convex surface in fluid communication with atmospheric pressure. By arranging the elastic diaphragm such that its concave surface faces and engages the valve seat, the pressure at which the precompression valve opens may be controlled more accurately. This is due to the fact that the valve is opened by stretching of the elastic diaphragm, rather than flexing. Moreover, this configuration of the valve member avoids any risk of inversion of the diaphragm.
[0011] In a preferred embodiment, the elastic diaphragm is stretched around the valve seat. By stretching the diaphragm it is prestressed, which results in improved sealing and better control of the opening pressure.
[0012] In a further preferred embodiment the elastic diaphragm has an outer periphery and the valve member includes a sleeve surrounding and holding the outer periphery of the diaphragm and extending substantially perpendicular to the plane of the diaphragm, the sleeve being sealingly arranged in the valve chamber. In this way the elastic diaphragm may be easily mounted in the valve chamber.
[0013] In order to reduce the number of separate carts and to facilitate manufacture and assembly of the precompression system, it is preferred that the elastic diaphragm and the sleeve be integrally molded from a plastics material. Since the diaphragm is arranged with its concave side against the valve seat and the valve is operated by stretching, rather than by deflection of the diaphragm, the plastics material may be more flexible than in the case of a convex valve as described in the prior art. Suitable plastic materials are e.g. polypropylene or polyethylene.
[0014] The elastic diaphragm may advantageously be molded in an unstretched shape that is substantially less concave than its shape when stretched over the valve seat. In this manner a suitable degree of prestress may be obtained. Preferably, the elastic diaphragm is molded in a convex shape and is stretched to a concave shape when the sleeve is arranged in the valve chamber.
[0015] In order to ensure that deformation of the valve member will be limited to the elastic diaphragm only, the sleeve preferably includes a plurality of ribs extending along an inner wall thereof substantially perpendicular to the plane of the diaphragm. In this way movement of the diaphragm is well defined, while the sleeve will continue to seal the valve chamber.
[0016] In a further preferred embodiment of the precompression system of the invention, the sleeve has a lengthwise dimension substantially perpendicular to the plane of the diaphragm and a diametral dimension substantially parallel to the plane of the diaphragm, wherein the lengthwise dimension is greater than a corresponding dimension of the valve chamber. This ensures that the sleeve is clamped tightly in the valve chamber when the precompression system is assembled.
[0017] Where the sleeve has a lengthwise dimension substantially perpendicular to the plane of the diaphragm and a diametral dimension substantially parallel to the plane of the diaphragm, this diametral dimension may further advantageously be greater than the lengthwise dimension. This results in a relatively short and sturdy sleeve, which is less prone to deformation when the valve member is subjected to the pressure generated by the pump.
[0018] A precompression system which is relatively easy to assemble is obtained when the dispensing device comprises a shroud including an end wall, and the end wall of the shroud is in alignment with the valve chamber and in contact with the sleeve for securing the valve member within the valve chamber.
[0019] The invention further provides a liquid dispensing device having an inlet and an outlet and a precompression system arranged between the inlet and outlet, wherein the recompression system comprises a pump chamber including a movable piston, and a valve chamber including a valve member disposed between the pump chamber and the outlet. The valve chamber has an inlet end, an outlet end and a valve seat arranged between the inlet end and the outlet end, with an opening extending through the valve seat. The valve member comprises an elastic diaphragm normally closing the valve seat opening and including a concave and a convex surface. The concave surface of the elastic diaphragm faces the valve seat opening and is in fluid communication with the pump chamber, while its convex surface is in fluid communication with atmospheric pressure.
[0020] In accordance with vet another aspect of the invention a method is provided for assembling a precompression system for a liquid dispensing device having an inlet and an outlet. This inventive method comprises providing a pump chamber including a piston movable therein and providing a valve chamber disposed between the pump chamber and the outlet. This valve chamber has an inlet end in fluid communication with said pump chamber, an outlet end in fluid communication with the outlet and a valve seat arranged between the inlet end and the outlet end and having an opening extending therethrough. The method further includes arranging a valve member in the valve chamber such that it normally closes the valve seat opening. In this method the valve member comprises an elastic diaphragm including a concave surface facing the valve seat opening and in fluid communication with the pump chamber and a convex surface in fluid communication with atmospheric pressure.
[0021] In another embodiment the invention provides a precompression system for a liquid dispensing device having an inlet and an outlet. This precompression system comprises a pump chamber including a piston movable in the pump chamber for drawing liquid through the inlet and discharging the liquid through the outlet; and a valve chamber including a valve member disposed between the pump chamber and the outlet and being operable to allow liquid in the pump chamber to reach the outlet only after a predetermined pressure is established in said pump chamber and to stop liquid from reaching the outlet when the pressure in the pump chamber falls below said predetermined pressure. The valve chamber has an inlet end in fluid communication with the pump chamber, an outlet end in fluid communication with the outlet and a valve seat arranged between the inlet end and the outlet end and having an opening that extends through the valve seat. The valve member comprises an elastic diaphragm that is stretched around the valve seat and that normally closes the valve seat opening.
[0022] In accordance with vet another aspect of the invention a method of assembling such a precompression system is provided. The inventive method comprising the steps of providing a pump chamber, providing a valve chamber and arranging a valve member in the valve chamber. The pump chamber that is provided includes a movable piston, while the valve chamber is disposed between the pump chamber and the outlet. The valve chamber that the method provides has an inlet end in fluid communication with the pump chamber, an outlet end in fluid communication with the outlet and a valve seat arranged between the inlet end and the outlet end and having an opening extending therethrough. The valve member that is arranged in the valve chamber comprises an elastic diaphragm and is arranged such that the elastic diaphragm is stretched around the valve seat and normally closes the valve seat opening.
[0023] Finally, the invention provides a valve member for use in a valve chamber of a precompression system for a liquid dispensing device. The valve member of the invention comprises an elastic diaphragm engaging a valve seat in the valve chamber. This elastic diaphragm includes a concave surface engaging the valve seal and a convex surface facing away from the valve seat.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 shows a longitudinal sectional view of a liquid dispenser subassembly having a housing, a piston, a trigger, an outlet nozzle and a precompression system in accordance with a first embodiment of the present invention.
[0025] FIG. 2 shows a longitudinal sectional view of the precompression valve used in the liquid dispenser of FIG. 1 .
[0026] FIG. 3 shows a bottom perspective view of the precompression valve of FIG. 2 .
[0027] FIG. 4 shows a first step for assembling the precompression system of the liquid dispenser in accordance with the first embodiment of the present invention.
[0028] FIG. 5 shows the dispenser subassembly with the precompression valve loosely arranged in a valve chamber.
[0029] FIG. 6 shows a fragmentary longitudinal sectional view of the liquid dispenser after a shroud of the housing has been mounted so as to secure and prestress the precompression valve.
[0030] FIG. 7 shows a longitudinal sectional view of the liquid dispenser of FIG. 1 during a pump stroke, when the precompression valve is opened.
[0031] FIG. 8 is a view corresponding with FIG. 7 and showing the liquid dispenser at the end of the pump stroke, when the precompression valve is closed again.
[0032] FIG. 9 is a view corresponding with FIG. 2 and showing a precompression valve used in a second embodiment of the present invention.
[0033] FIG. 10 is a view corresponding with FIG. 5 and showing the second embodiment of the precompression valve loosely arranged in a valve chamber.
[0034] FIG. 11 is a view corresponding with FIG. 1 and showing the second embodiment of the liquid dispenser after assembly.
[0035] FIG. 12 is an exploded view of a liquid dispenser including a housing, a pushbutton type operating element, a precompression valve, a dip tube, a locking element and a container, in accordance with a third embodiment of the present invention.
[0036] FIG. 13 shows a fragmentary cross-sectional view of the liquid dispenser of FIG. 23 after final assembly thereof.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0037] FIG. 1 shows a fragmentary longitudinal sectional view of a liquid dispenser 1 in accordance with a first embodiment of the present invention. The liquid dispenser 1 comprises a housing 2 , a pump 3 , an operating mechanism 4 , an inlet 5 , an outlet 6 and a precompression system 7 . A discharge nozzle 49 is arranged on the outlet 6 for atomizing the liquid that is dispensed. The liquid dispenser 1 is connected to a container 9 having an opening 10 bordered by a neck 11 . In the illustrated embodiment this connection is a snap connection, which is effected by snapping lugs 12 arranged on an inner surface of the housing 2 into recesses 13 formed in the outer surface of the neck 11 . A dip tube 14 extends from the inlet 5 of the liquid dispenser 1 into the container 9 for drawing liquid from the container 9 into the liquid dispenser 1 .
[0038] The pump 3 includes a pump chamber 15 and a piston 16 that is arranged in the pump chamber 15 for reciprocating movement. Pump chamber 15 has an inlet opening 17 communicating with the liquid dispenser inlet 5 and an outlet opening 18 communicating with a discharge conduit 19 that leads to the liquid dispenser outlet 6 . Pump chamber 15 further has an aerating opening 20 communicating with the interior of the container 9 . This aerating opening 20 is selectively opened and closed by two peripheral flaps 21 , 22 arranged on the piston 16 .
[0039] The operating mechanism 4 includes a trigger 23 , the top of which is pivotally connected to the housing 2 by means of a hinge (not shown here). Trigger 23 is also pivotally connected to piston 16 by means of a pin 24 received in an opening 25 . The trigger 23 is biased to its extended position as shown in FIG. 1 by a pair of flexion springs (not shown here), which are arranged in the housing 2 outside the pump chamber 15 .
[0040] The precompression system 7 is arranged between the pump chamber 15 and the outlet 6 . It includes a valve chamber 26 in which a precompression valve member 27 is arranged. The valve chamber 26 has an inlet end 28 communicating with the pump chamber outlet opening 18 and an outlet end 29 communicating with the discharge conduit 19 and hence the liquid dispenser outlet 6 . Arranged between the inlet and outlet ends 28 , 29 is an annular valve seat 31 , which surrounds a valve opening 30 that constitutes the outlet end 29 of the valve chamber. Precompression valve member 27 includes an elastic diaphragm 32 which normally closes the valve opening 30 . This elastic diaphragm 32 is dome shaped and includes a concave surface 32 A facing the valve seat 31 and its opening 30 , as well as a convex surface 32 B facing away from the valve seat opening 30 towards the interior of valve chamber 26 . A stabilizing member 45 is attached to the center of the convex surface 32 B.
[0041] Precompression valve member 27 further includes a sleeve 33 surrounding and holding an outer periphery 34 of the elastic diaphragm 32 . This sleeve 33 is arranged in the valve chamber 26 and seals against an inner wall 35 thereof by means of a peripheral flap 36 and an annular ridge 37 arranged on an outer surface 38 of the sleeve 33 . Sleeve 33 further includes a second peripheral flap 39 which serves as a flap valve between liquid dispenser inlet 5 and inlet opening 17 of pump chamber 15 . Finally, as shown more clearly in FIGS. 2 and 3 , sleeve 33 includes a plurality of ribs 40 evenly distributed in peripheral direction and extending along an inner surface 41 of the sleeve 33 . In the illustrated embodiment there are four ribs 40 each spaced 90 degrees from the adjacent ribs 40 .
[0042] Sleeve 33 has a stepped contour which corresponds with the stepped configuration of the inner wall 35 of the valve chamber 26 . Sleeve 33 extends beyond the plane of the elastic diaphragm and has an inner ridge 42 —when considered in the direction of valve chamber 26 —which engages a bottom surface 46 of the valve chamber 26 . The inner ridge 42 includes a plurality of openings 43 allowing liquid to flow from the pump chamber 15 towards the discharge conduit 19 . The length of the sleeve 33 measured from the inner ridge 42 to an outer ridge 44 is slightly greater than the corresponding depth of the valve chamber 26 . This ensures that the valve member 27 is tightly clamped in the valve chamber 26 when the liquid dispenser 1 is assembled. The force required for pressing the valve member 27 tightly into the valve chamber 26 is provided by an end wall 47 that forms part of a shroud 48 of the dispenser housing 2 .
[0043] Valve member 27 including the sleeve 33 and elastic diaphragm 32 is integrally molded from a plastics material, like e.g. polypropylene. When molded, the elastic diaphragm 32 has a shape which is substantially less concave—considered in the direction facing the valve seat 31 —than it has when the valve member 27 is arranged in the valve chamber 26 . In the illustrated embodiment the elastic diaphragm 32 is actually molded in a convex shape, which is inverted when the valve member 27 is pressed into the valve chamber 26 by the end wall 47 . In this way the elastic diaphragm 32 is prestressed against or stretched over the valve seat 31 , which is an important feature with a view to obtaining excellent sealing until the liquid in the pump chamber 15 reaches the predetermined pressure at which the precompression valve should open.
[0044] Referring to FIG. 4 , the precompression system 7 is assembled by first inserting the valve member 27 in the valve chamber 26 , which is integrally formed as part of the housing 2 of the liquid dispenser 1 . The valve member 27 is first pressed into the valve chamber 26 until the elastic diaphragm 32 engages the valve seat 31 . In this position, which is shown in FIG. 5 , the inner ridge 42 does not yet engage the bottom 46 of valve chamber 26 . Since the distance between the elastic diaphragm 32 —when unstressed—and the outer ridge 44 of sleeve 33 is greater than the distance between the valve seat 31 and the end of valve chamber 26 , sleeve 33 of valve member 27 still protrudes somewhat from valve chamber 26 .
[0045] In a final assembly step the shroud 48 is connected to the rest of the housing 2 . During this step the end wall 47 engages the protruding outer ridge 44 of sleeve 33 and presses valve member 27 tightly into valve chamber 26 until the inner ridge 42 abuts the valve chamber bottom 46 . Since the valve seat 31 protrudes further from the valve chamber bottom 46 than the distance between the sleeve inner ridge 42 and the elastic diaphragm 32 , the latter is stretched over the valve seal 31 and the face 32 A of the diaphragm 32 assumes its concave shape, as shown in FIG. 6 . The liquid dispenser 1 is now ready for operation.
[0046] When the trigger 23 is first operated, the piston 16 will move inwards, reducing the volume of the pump chamber 15 and thereby compressing the air inside—assuming the pump 3 has not been primed. The resulting air pressure is not enough to force the precompression valve away from the valve seat 31 . When the trigger 23 is released, it will be returned to its original position by the springs. During this return or suction stroke, the pressure in the pump chamber 16 will be lowered, thus drawing liquid from the container 9 through the dip tube 14 and the dispenser inlet 5 , past the flap valve 39 , through the inlet opening 17 into the pump chamber 16 .
[0047] When the trigger 23 is operated again, movement of the piston 16 will result in a sharp increase in the pressure within the pump chamber 16 , since the liquid is not compressible. This pressure acts on all parts of the pump chamber 16 and is also present in the outlet opening 18 , which is closed by the elastic diaphragm 32 of the precompression valve 27 . Once the pressure exceeds a predetermined value, for instance in the order of three bar, the elastic diaphragm 32 will stretch and be lifted from the valve seat 31 , as shown in FIG. 7 . This pressure is determined by the elasticity of the diaphragm 32 and the ambient pressure, which acts on the convex surface 32 B of the diaphragm 32 . Once the diaphragm 32 is lifted from the valve seat 32 pressurized liquid from the pump chamber 16 may flow through the outlet opening 18 , between the valve seat 31 and the elastic diaphragm 32 , into the valve opening 30 . From there the liquid will flow through the discharge conduit 19 to the outlet 6 of the liquid dispenser 1 . Since the liquid is dispensed only after reaching the predetermined pressure, it will be properly atomized upon leaving the outlet 6 and the spraying pattern will be evenly distributed, without any large drops being dispensed.
[0048] Referring now to FIG. 8 , when the pressure in the pump chamber 16 drops below the predetermined level at the end of the pump stroke, the elasticity of the diaphragm 32 will overcome the liquid pressure. Consequently the diaphragm 32 will contract again until it comes to rest against the valve seat 31 . This closes the valve opening 30 and instantly interrupts the flow of liquid from the pump 3 to to the outlet 6 . In this way the liquid dispenser 1 will not “drip” at the end of the pump stroke.
[0049] FIG. 9 shows a valve member 127 for use in a second embodiment of the precompression system 107 . This valve member 127 has a square, rather than elongated shape, since its length—the distance between the inner and outer edges 142 and 144 , resoectively—is no larger than its diameter. This configuration results in a sturdy sleeve 133 , which has even less tendency to deform when pressure is applied to the diaphragm 132 . Although the length of this alternative valve member 127 is smaller than that of the valve member 27 of the first embodiment, it is still longer than the depth of the valve chamber 126 . Consequently, the outer ridge 144 still protrudes from the valve chamber 126 when the valve member 127 has been inserted up to the point where the diaphragm 132 contacts the valve seat 131 , as shown in FIG. 10 . Therefore, also in this embodiment the elastic diaphragm 132 is stretched and prestressed when the valve member 127 is finally clamped tight in the valve chamber 126 by connecting the shroud 148 including the end wall 147 to the rest of the liquid dispenser 101 , as illustrated in FIG. 11 .
[0050] FIG. 12 shows a liquid dispenser 201 in accordance with a third embodiment of the present invention. Like the first and second embodiments, this liquid dispenser 201 comprises a housing 202 , a pump 203 , an operating mechanism 204 , an inlet 205 , an outlet 206 and a precompression system 207 . The liquid dispenser 201 is again connected to a container 209 having an opening 210 bordered by a neck 211 . A dip tube 214 again extends from the inlet 205 of the liquid dispenser 201 into the container 209 for drawing liquid from the container 209 into the liquid dispenser 201 .
[0051] This liquid dispenser 201 is not a trigger sprayer, but is intended for dispensing more viscous liquids like e.g. hand soap. Consequently, the discharge nozzle 249 at the outlet 206 is not arranged for atomizing the liquid, but merely for deflecting the flow of liquid downward. The dispenser further has a different mechanism for operating the pump 203 , using a pushbutton 223 that is slidable within the housing 202 , rather than a hinged trigger. The pushbutton 223 is biased to a position of rest by two substantially S-shaped combined torsion/flexion springs 250 , only one of which is shown. In this embodiment of the liquid dispenser 201 the piston 216 is integrated in the pushbutton 223 . This embodiment of the liquid dispenser 201 further includes a vent chamber 251 arranged next to the pump chamber 215 . The pushbutton 223 also includes a second piston (not shown here) that is arranged for reciprocating movement in the vent chamber 251 .
[0052] The valve member 227 of this third embodiment is somewhat different from that of the first two embodiments in that the elastic diaphragm 232 is arranged substantially halfway the sleeve 233 , rather than near its inner ridge 242 . Like in the first two embodiments, the diaphragm 232 is stretched over the valve seat 231 , as shown in FIG. 13 . Its concave side 232 A again faces both the valve opening 230 and the outlet opening 218 of the pump chamber 215 and is exposed to the pressure generated by the pump 203 . The convex side 232 B of the elastic diaphragm 232 faces the rear of the valve chamber 226 and is exposed to atmospheric pressure.
[0053] Again, the elastic diaphragm 232 is originally molded in a shape that is substantially less concave than the shape it has to assume by being stretched over the valve seat 231 when valve member 227 is inserted into valve chamber 226 . This deformation of the elastic diaphragm 232 leads to a certain degree of prestress that results in an excellent seal between the diaphragm 232 and the valve seat 231 . Depending on the degree of prestress that is required to obtain the required sealing action and a specific precompression of the liquid, the elastic diaphragm 232 may also be molded in a straight or even a convex shape.
[0054] The sleeve 233 includes an opening 243 in its side wall 235 for allowing liquid to pass from the outlet opening 218 of the pump chamber 215 to the valve opening 230 . Since in this embodiment the pump 203 and the inlet 205 are arranged on opposite sides of the valve chamber 226 , the sleeve 233 further includes a groove 252 allowing liquid to pass along the outside of the sleeve 233 . In this embodiment, the outer ridge 244 of the sleeve 233 has a somewhat greater diameter than the outer end of the valve chamber 226 so that it is held thereby. The valve member 227 is locked in position by a plurality of ribs 253 protruding from end wall 247 of shroud 248 .
[0055] Reciprocating movement of the pushbutton 223 between its two positions also reciprocates the pump piston 216 and the vent piston in the pump chamber 215 and vent chamber 251 , respectively. During a suction stroke, the pump piston 216 moves in an upward direction to create a vacuum in the pump chamber 215 , thereby drawing liquid from the container 209 through dip tube 214 and inlet 205 , past the sleeve 233 and into the pump chamber 215 . During a discharge stroke, the pump piston 216 moves in a downward direction to reduce the volume of the pump chamber 215 . Once the pressure within the pump chamber 215 is greater than the combined elastic force of the diaphragm 232 and the ambient pressure on the convex face 232 B of the diaphragm, the diaphragm 232 stretches and moves away from the valve seat 231 and the liquid is free to pass through the valve opening 230 and into the discharge conduit 219 towards the outlet 206 .
[0056] Although the invention has been illustrated by means of a number of examples, it should be apparent that it is not limited thereto. For example, the precompression system might be used in other types of liquid dispensers. Moreover, the flexible diaphragm and sleeve of the valve member could be formed separately. In addition, both the configuration of the elastic diaphragm and sleeve and the choice of materials might be varied as well. Accordingly, the scope of the invention is defined solely by the appended claims. | The invention relates to a precompression system for a liquid dispensing device, which prevents liquid from being discharged until a predetermined pressure has been built up. The precompression system comprises a pump for drawing liquid through an inlet and discharging it through an outlet and a precompression valve disposed between the pump and the outlet. The precompression valve allows liquid in the pump to reach the outlet only after the predetermined pressure is established and stops liquid from reaching the outlet when the pressure falls below the predetermined level. The precompression valve comprises an elastic diaphragm normally closing the valve opening and including a concave surface facing the valve opening and in fluid communication with the pump and a convex surface in fluid communication with atmospheric pressure. The elastic diaphragm may be stretched around a valve seat.
The invention further relates to a method of assembling such a precompression system in a liquid dispensing device. | 8 |
FIELD OF THE INVENTION
This invention relates to a method for hydrodesulfurizing naphtha. More particularly, a Co/Mo metal hydrogenation component is loaded on a silica or modified silica support in the presence of an organic additive and then sulfided to produce a catalyst which is then used for hydrodesulfurizing naphtha. The silica support has a defined pore size distribution which minimizes olefin saturation.
BACKGROUND OF THE INVENTION
Environmental regulations mandate the lowering of sulfur levels in motor gasoline (mogas). For example, it is expected that regulations will require mogas sulfur levels of 30 ppm or less by 2006. In many cases, these sulfur levels will be achieved by hydrotreating naphtha produced from Fluid Catalytic Cracking (FCC cat naphtha), which is the largest contributor to sulfur in the mogas pool. Since sulfur in mogas can also lead to decreased performance of catalytic converters, a 30 ppm sulfur target is desirable even in cases where regulations would permit a higher level. As a result, techniques are required that reduce the sulfur in cat naphthas while at the same time minimizing the reduction of beneficial properties such as octane number.
Conventional fixed bed hydrotreating can reduce the sulfur level of cracked naphthas to very low levels. However, such hydrotreating also results in significant octane number loss due to extensive reduction of the olefin content in the naphtha as well as excessive consumption of hydrogen during the hydrotreating process. Selective hydrotreating processes have recently been developed to avoid such olefin saturation and octane number loss. Unfortunately, in such processes, the liberated H 2 S reacts with retained olefins forming mercaptan sulfur by reversion. Unfortunately, the H 2 S liberated in the process reacts with retained olefins forming mercaptan sulfur by reversion. Such processes can be conducted at severities which produce product within sulfur regulations. However, significant octane number loss also occurs.
One proposed approach for preserving octane number during sulfur removal is to modify the olefin content of the feed using an olefin-modification catalyst followed by contact with an HDS catalyst (U.S. Pat. No. 6,602,405). The olefin modification catalyst oligomerizes the olefins.
One recently developed method of HDS is SCANfining which is a process developed by Exxon Mobil Corporation. SCANfining is described in National Petroleum Refiners Association paper #AM-99-31 titled “Selective Cat Naphtha Hydrofining with Minimal Octane Loss” and U.S. Pat. Nos. 5,985,136 and 6,013,598. Typical SCANfining conditions include one and two-stage processes for hydrodesulfurizing a naphtha feedstock. The feedstock is contacted with a hydrodesulfurization catalyst comprised of about 1 wt. % to about 10 wt. % MoO 3 ; and about 0.1 wt. % to about 5 wt. % CoO; and a Co/Mo atomic ratio of about 0.1 to about 1.0; and a median pore diameter of about 60 {acute over (Å)} to about 200 {acute over (Å)}.
Even though SCANfining controls the degree of olefin saturation while achieving a high degree of HDS, there is still a need to improve the selectivity of the catalyst system to further reduce the degree of olefin saturation thereby further minimizing octane number loss.
SUMMARY OF THE INVENTION
This invention relates to a method for making a catalyst and a method for the hydrodesulfurization (HDS) of naphtha. One embodiment relates to a method for making a catalyst suitable for the HDS of naphtha comprising: (i) impregnating a silica support that has a silica content of at least about 85 wt. %, based on silica and has a pore volume between about 0.6 cc/g and about 2.0 cc/g and median pore sizes in the range of about 150 Å to about 2000 Å with an aqueous solution of (a) a cobalt salt, (b) a molybdenum salt, and (c) at least one organic additive to form a catalyst precursor; (ii) drying the catalyst precursor at temperatures less than about 200° C. to form a dried catalyst precursor; and (iii) sulfiding the dried catalyst precursor to form the catalyst, provided that the dried catalyst precursor or catalyst is not calcined prior to sulfiding or use for HDS.
Another embodiment relates to a method for the HDS of naphtha having an olefin content of at least about 5 wt. %, based on the weight of the naphtha comprising: (i) contacting the naphtha with a selective HDS catalyst under hydrodesulfurization conditions, wherein the selective HDS catalyst is prepared by impregnating a silica support that has a silica content of at least about 85 wt. %, based on the weight of the silica, and has a pore volume between about 0.6 cc/g and about 2.0 cc/g, and median pore sizes in the range of about 150 Å to about 2000 Å with an aqueous solution of (a) a cobalt salt, (b) a molybdenum salt, and (c) at least one organic additive to form a catalyst precursor; (ii) drying the catalyst precursor at temperatures less than about 200° C. to form a dried catalyst precursor; and (iii) sulfiding the dried catalyst precursor to form the catalyst, provided that the dried catalyst precursor or catalyst is not calcined prior to sulfiding or use for HDS.
The silica supported catalyst, when used for the HDS of a naphtha, shows improved selectivity towards olefin saturation while maintaining a high level of HDS of the naphtha feed.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 a is a plot of olefin saturation at 90% HDS vs. median pore diameter (MPD) measured by mercury intrusion.
FIG. 1 b is a plot of olefin saturation at 90% HDS vs. the reciprocal of median pore diameter.
FIG. 1 c is a plot of olefin saturation at 90% HDS vs. the percentage of surface area in pores with pore diameter >150 Å.
FIG. 2 is a graph showing pore size distribution (PSD) of a silica support as measured by mercury porosimetry.
FIG. 3 is a plot of olefin selectivity vs. HDS activity for four different CoMo/SiO 2 catalysts.
FIG. 4 is a plot of olefin selectivity vs. HDS activity for CoMo/SiO 2 catalysts having different organic ligands on a selected silica support and the reference CoMo/Al 2 O 3 catalyst.
FIG. 5 is a plot of olefin selectivity vs. HDS activity for CoMo/SiO 2 catalysts prepared with different organic ligands and the reference CoMo/Al 2 O 3 catalyst.
FIG. 6 is a plot of olefin selectivity vs. HDS activity of high temperature aged CoMo/SiO 2 and CoMo/Al 2 O 3 catalysts.
FIG. 7 is a plot of olefin selectivity vs. HDS activity for CoMo/SiO 2 catalysts vs. the reference CoMo/Al 2 O 3 catalyst.
FIG. 8 is a plot of olefin selectivity vs. HDS activity for CoMo-CA/SiO 2 catalysts dried at three different conditions vs. the reference CoMo/Al 2 O 3 catalyst.
FIG. 9 is a plot of olefin selectivity vs. HDS activity for two small pore CoMo/SiO 2 catalysts vs. the reference CoMo/Al 2 O 3 catalyst.
FIG. 10 is a graph showing pore size distribution (PSD) of a silica support (SC-595) as measured by N 2 adsorption.
DETAILED DESCRIPTION OF THE INVENTION
The term “naphtha” refers to the middle boiling range hydrocarbon fraction or fractions that are major components of gasoline, while the term “FCC naphtha” refers to a preferred naphtha that has been produced by the well known process of fluid catalytic cracking. Naphthas having a middle boiling range are those have boiling points from about 10° C. (i.e., from about C 5 ) to about 232° C. (50 to 450° F.) at atmospheric pressure, preferably from about 21° C. to about 221° C. (70 to 430° F.). Producing naphtha in an FCC process without added hydrogen results in a naphtha that is relatively high in olefins and aromatics. Other naphthas such as steam cracked naphthas and coker naphthas may also contain relatively high concentrations of olefins. Typical olefinic naphthas have olefin contents of at least about 5 wt. % up to about 60 wt. %, based on the weight of the naphtha, preferably about 5 wt. % to about 40 wt. %; sulfur contents from about 300 ppmw to about 7000 ppmw, based on the weight of the naphtha; and nitrogen contents from about 5 ppmw to about 500 ppmw, based on the weight of the naphtha. Olefins include open chain olefins, cyclic olefins, dienes and cyclic hydrocarbons with olefinic side chains. Because olefins and aromatics are high octane number components, olefinic naphtha generally exhibits higher research and motor octane values than does hydrocracked naphtha. While olefinic naphthas are typically high in olefin content, they may also contain other compounds, especially sulfur-containing and nitrogen-containing compounds.
Selective Catalyst
In one embodiment, the catalyst for the selective removal of sulfur with minimal olefin saturation from an olefinic naphtha is a silica supported catalyst that has been impregnated with (a) a cobalt salt, (b) a molybdenum salt, and (c) at least one organic additive. Organic additives are organic ligands. The silica support contains at least about 85 wt. % silica, based on silica support, preferably at least about 90 wt. % silica, especially at least about 95 wt. % silica. Examples of silica supports include silica, MCM-41, silica-bonded MCM-41, fumed silica, metal oxide modified siliceous supports and diatomaceous earth.
The cobalt and molybdenum salts used to impregnate the silica support may be any water-soluble salts. Preferred salts include carbonates, nitrates, heptamolybdate and the like. The amount of salt is such that the silica support will contain from about 2 wt. % to about 8 wt. % cobalt oxide, based on catalyst, preferably from about 3 wt. % to about 6 wt. %, and from about 8 wt. % to about 30 wt. % molybdenum oxide, preferably about 10 wt. % to about 25 wt. %, based on support.
The silica supports have large pore volumes as measured by mercury porosimetry using ASTM method no. D4284 and large pore sizes. The pore volumes are in the range from about 0.6 cc/g to about 2.0 cc/g, preferably about 1.0 to about 1.5. The median pore sizes as measured by mercury are in the range from about 150 Å to about 2000 Å, preferably about 150 Å to about 1000 Å, more preferably 200 Å to about 500 Å. Silica supports having the desired median pore sizes are commercially available.
While not wishing to be bound to any particular theory, it is postulated that the present silica supports with large pore sizes and large pore diameters when combined with organic additives, i.e., organic ligands such as arginine, citric acid and urea, lead to an HDS catalyst having the desired selectivity towards olefin saturation while maintaining the activity of the HDS catalyst for desulfurizing the naphtha feed. The organic ligands may cause metals to be distributed throughout the silica support which in turn is a factor in the increased selectivity exhibited by the present catalysts. During the HDS reaction, the catalysts have minimum diffusion constraints. The large pores of these silica supports allow free, transport of gas phase naphtha range hydrocarbons to and away from the HDS catalysts active sites. This helps to fully utilize the intrinsic characteristics of low olefin saturation of the present catalysts.
The silica support may also be doped with metals from Groups 2-4 of the Periodic Table based on the IUPAC format having Groups 1-18, preferably from Groups 2 and 4. Examples of such metals include Zr, Mg, Ti. See, e.g., The Merck Index, Twelfth Edition, Merck & Co., Inc., 1996.
As noted above, organic ligands are organic additives that are hypothesized to aid in distributing the Co and Mo components on the silica support. The organic ligands contain oxygen and/or nitrogen atoms and include mono-dentate, bi-dentate and poly-dentate ligands. The organic ligands may also be chelating agents. Organic ligands include at least one of carboxylic acids, polyols, amino acids, amines, amino alcohols, ketones, esters and the like. Examples of organic ligands include phenanthroline, quinolinol, salicylic acid, acetic acid, ethylenediaminetetraacetic acid (EDTA), cyclohexanediaminetetraacetic acid (CYDTA), alanine, arginine, triethanolamine (TEA), glycerol, histidine, acetylacetonate, guanidine, and nitrilotriacetic acid (NTA), citric acid and urea.
While not wishing to be bound to any particular theory, it is postulated that the organic ligands form complexes with at least one of Co and Mo. These Co- and/or Mo-organic ligand complexes interact with the silica surface to disperse the metals more evenly across the silica surface.
Catalyst Preparation and Use
Silica supports were impregnated with aqueous solutions of Co and Mo salts using conventional techniques. The organic ligand may be added to the aqueous solution of salts prior to contact with the silica support. One embodiment for impregnating the silica support with metal salt is by the incipient wetness method. In this method, an aqueous solution containing metal salts and organic additive is mixed with the support up to the point of incipient wetness using conventional techniques, i.e., techniques that are well known in the art of hydroprocessing catalyst preparation, manufacture, and use.
The manner of impregnation of the silica support by metal salt may be by impregnating the silica support with a mixture of a cobalt salt and organic ligand using incipient wetness, drying the impregnated support and then impregnating the dried support with a molybdenum salt solution or molybdenum salt solution containing organic ligand up to the point of incipient wetness. In another embodiment, the order of impregnation by cobalt salt followed by molybdenum salt may be reversed. In yet another embodiment, the support may be co-impregnated with a mixture of cobalt salt and molybdenum salt plus organic ligand to incipient wetness. The co-impregnated support may be dried and the co-impregnation process repeated. In yet another embodiment, an extruded silica support may be impregnated with a mixture of cobalt salt, molybdenum salt and organic ligand and the impregnated support dried. This treatment may be repeated if desired. In all the above embodiments, the organic ligand may be a single ligand or may be a mixture of ligands. The impregnated silica support isolated from the reaction mixture is heated and dried at temperatures in the range from about 50° C. to about 200° C. to form a catalyst precursor. The drying may be under vacuum, or in air, or inert gas such as nitrogen.
The dried catalyst precursor is treated with hydrogen sulfide at concentrations of from about 0.1 vol. % to about 10 vol. % based on total volume of gases present, for a period of time and at a temperature sufficient to convert metal oxide, metal salt or metal complex to the corresponding sulfide in order to form the HDS catalyst. The hydrogen sulfide may be generated by a sulfiding agent incorporated in or on the catalyst precursor. In an embodiment, the sulfiding agent is combined with a diluent. For example, dimethyl disulfide can be combined with a naphtha diluent. Lesser amounts of hydrogen sulfide may be used, but this may extend the time required for activation. An inert carrier may be present and activation may take place in either the liquid or gas phase. Examples of inert carriers include nitrogen and light hydrocarbons such as methane. When present, the inert gases are included as part of the total gas volume. Temperatures are in the range from about 150° C. to about 700° C., preferably about 160° C. to about 343° C. The temperature may be held constant or may be ramped up by starting at a lower temperature and increasing the temperature during activation. Total pressure is in the range up to about 5000 psig (34576 kPa), preferably about 0 psig to about 5000 psig (101 to 34576 kPa), more preferably about 50 psig to about 2500 psig (446 to 17338 kPa). If a liquid carrier is present, the liquid hourly space velocity (LHSV) is from about 0.1 hr −1 to about 12 hr −1 , preferably about 0.1 hr −1 to about 5 hr −1 . The LHSV pertains to continuous mode. However, activation may also be done in batch mode. Total gas rates may be from about 89 m 3 /m 3 to about 890 m 3 /m 3 (500 to 5000 scf/B).
Catalyst sulfiding may occur either in situ or ex situ. Sulfiding may occur by contacting the catalyst with a sulfiding agent, and can take place with either a liquid or gas phase sulfiding agent. Alternatively, the catalyst may be presulfurized such that H 2 S may be generated during sulfiding. In a liquid phase sulfiding agent, the catalyst to be sulfided is contacted with a carrier liquid containing sulfiding agent. The sulfiding agent may be added to the carrier liquid or the carrier liquid itself may be sulfiding agent. The carrier liquid is preferably a virgin hydrocarbon stream and may be the feedstock to be contacted with the hydroprocessing catalyst but may be any hydrocarbon stream such as a distillate derived from mineral (petroleum) or synthetic sources. If a sulfiding agent is added to the carrier liquid, the sulfiding agent itself may be a gas or liquid capable of generating hydrogen sulfide under activation conditions. Examples include hydrogen sulfide, carbonyl sulfide, carbon disulfide, sulfides such as dimethyl sulfide, disulfides such as dimethyl disulfide, and polysulfides such as di-t-nonylpolysulfide. The sulfides present in certain feeds, e.g., petroleum feeds, may act as sulfiding agent and include a wide variety of sulfur-containing species capable of generating hydrogen sulfide, including aliphatic, aromatic and heterocyclic compounds.
The dried catalyst is not calcined prior to either sulfiding or use for HDS. Not calcining means that the dried catalyst is not heated to temperatures above about 300° C., preferably about 200° C. By not calcining the catalyst, from about 60% to about 100% of the dispersing aid remains on the catalyst prior to sulfiding or use for HDS.
Following sulfiding, the catalyst may be contacted with naphtha under hydrodesulfurizing conditions. Hydrodesulfurizing conditions include temperatures of from about 150° C. to about 400° C., pressures of from about 445 kPa to about 13890 kPa (50 to 2000 psig), liquid hourly space velocities of from about 0.1 to about 12 and treat gas rates of from about 89 m 3 /m 3 to about 890 m 3 /m 3 (500 to 5000 scf/B). After hydrodesulfurization, the desulfurized naphtha can be conducted away for storage or further processing, such as stripping to remove hydrogen sulfide. The desulfurized naphtha is useful for blending with other naphtha boiling-range hydrocarbons to make mogas.
Selected embodiments, including preferred embodiments, are illustrated in the following examples.
Example 1
This example demonstrates an important feature of the subject CoMo supported on SiO 2 catalysts which is to maximize the mass transport rate for the HDS reaction; that is, to minimize diffusion limitations for this reaction. For catalyst spheres and extrudates with cross-section diameters of about 1.3 to about 2.4 mm, median pore sizes of about 200 Å to about 2000 Å allows for effective access of naphtha range sulfur containing molecules in and out of the catalyst particles. Reducing the pore sizes of the silica supports leads to diffusion limitations on the HDS reaction, and to more olefin saturation at a given HDS level, as shown in FIG. 1 . In FIG. 1 a , the Y-axis is the olefin saturation tendency expressed as a percentage of C 5 olefin saturation at 90% HDS conversion (both measured on a weight basis), and the X-axis is the median pore diameter in Angstroms, measured by mercury porosimetry, of silica supports of extrudates or spheres with nominal cross-section diameter in the range of about 1.3 mm to about 2.4 mm. As a reference, a commercial catalyst (RT-225) manufactured by Albemarle (CoMo/Al 2 O 3 , 1/16″ cylinder extrudate) tested under the identical conditions shows 14 wt. % C 5 olefin saturation at 90% HDS conversion, based on the weight of the sulfur and olefin in the naphtha. Compared to the reference catalyst, all catalysts on silica supports shown in FIG. 1 a have lower olefin saturation. In particular, when the pore sizes of the silica supports are larger than 200 Å, the olefin saturation is reduced to 8% or below, much lower than the reference catalyst. As the median pore diameter increases above 200 Å, selectivity continues to improve. When the median pore diameter is between about 500 Å to 2000 {acute over (Å)}, olefin saturation is nearly flat/constant, indicating that diffusion is no longer affecting HDS reactions under the testing conditions employed, and pore size is no longer limiting selectivity. As shown in FIG. 1 b , which is a plot of olefin saturation vs. the reciprocal of median pore diameter, olefin saturation shows a linear relationship to the reciprocal of median pore diameters of the silica supports. As shown in FIG. 1 c , there is also correlation of olefin saturation with the percentage of surface area in pores with pore diameter over about 150 Å.
Table 1 lists various silica supports together with their median pore diameters (by Hg porosimetry) and surface areas (by nitrogen BET measurement) as well as percentages of olefin saturation at 90% HDS conversion, based on the weight of the sulfur in the naphtha. This table shows examples of silica supports and their porosities and olefin selectivity when used as HDS catalyst carriers.
TABLE 1
Silica Supports Used as HDS Catalyst Carriers
Median Pore
Size by Hg
PV by Hg,
Total Hg
Hg Area for
Hg Area for
% SA for
Support ID
Silica Support Description
Volume, Å
cc/g
Pore Area
MPD >150 Å
MPD <150 Å
MPD >150 A
SC-509
1.4-2.4 mm spheres (PQ)
131
1.10
316.7
36.2
280.6
11%
SC-509-5S
1.4-2.4 mm spheres
455
1.12
97.0
97.0
0.0
100%
SC-592
1/16″ cylinder (Criterion)
162
1.12
313.0
126.3
186.8
40%
SC-593
1/16″ cylinder (Criterion)
454
1.04
89.9
89.7
0.2
100%
SC-741
1/20″ quadrilobe
336
1.19
156.9
132.5
24.4
84%
SC-742
1/16″ cylinder
208
0.98
199.8
123.5
76.3
62%
SC-743
1/20″ quadrilobe
212
0.99
196.4
124.8
71.6
64%
SC-745
1/20″ quadrilobe
187
0.89
198.2
112.4
85.7
57%
SC-747
1/16″ cylinder
211
0.93
203.0
123.8
79.1
61%
SC-748
1/20″ quadrilobe
211
0.94
205.1
128.8
76.3
63%
SC-795
1/16″ cylinder (Criterion)
410
1.07
107.8
107.0
0.8
99%
SC-826
1.7-2.0 mm spheres (PQ)
113
1.06
345.5
35.3
310.2
10%
SC-924
1.7-2.0 mm spheres (PQ)
105
1.21
414.5
32.8
381.8
8%
SC-926
1/20″ quadrilobe
219
0.71
149.9
104.7
45.3
70%
SC-927
1/20″ quadrilobe
230
0.70
138.4
104.0
34.4
75%
SC-928
1/20″ quadrilobe
381
0.67
73.2
70.8
2.4
97%
SC-1063
1/16″ cylinder
999
0.66
26.7
26.7
0.0
100%
SC-1236
Ultrasil (80:20 w/
196
0.777
184.3
113.0
71.3
61%
Nyacol) steam 1200 F./1 h
SC-1237
Ultrasil (80:20 w/
224
0.73
146.7
114.2
32.6
78%
Nyacol) steam 1400 F./1 h
SC-1238
Ultrasil (80:20 w/
298
0.686
98.5
92.2
6.3
94%
Nyacol) steam 1500 F./1 h
SC-1239
Stm ultrasil/Nyacol/
1769
0.762
20.1
20.1
0.0
100%
PVA 1/20″ Q 1500 F./45 m
SC-1240
Steamed Ultrasil/
1147
0.88
37.9
37.3
0.6
98%
Nyacol/PVA 1/20″ Q 1400 F./1 h
SC-1241
Steam Ultrasil/
294
0.90
153.2
111.3
41.9
73%
Nyacol/PVA 1/20″ Q 1200 F./1 hr
SC-1242
Stm/air ultrasil/Nyacol/
404
0.876
98.1
85.6
12.6
87%
PVA 1/20″ Q 1300 F./45 m
% C 5 =
1/(Pore
% SA for
Hg SA for
Hg SA for
N2 BET
Saturation
Diamter),
Support ID
Silica Support Description
MPD <150 A
MPD >100 Å
MPD <100 Å
SA, m 2 /g
at 90% HDS
Å −1
SC-509
1.4-2.4 mm spheres (PQ)
89%
287.2
29.6
218
9.4
0.0076
SC-509-5S
1.4-2.4 mm spheres
0%
97.0
0.0
55
7.3
0.0022
SC-592
1/16″ cylinder (Criterion)
60%
220.4
92.6
234
9.5
0.0062
SC-593
1/16″ cylinder (Criterion)
0%
89.7
0.2
56
7.7
0.0022
SC-741
1/20″ quadrilobe
16%
146.6
10.3
194
7.6
0.0030
SC-742
1/16″ cylinder
38%
157.3
42.5
184
9.3
0.0048
SC-743
1/20″ quadrilobe
36%
157.3
39.0
176
8.7
0.0047
SC-745
1/20″ quadrilobe
43%
152.3
45.9
186
8.9
0.0053
SC-747
1/16″ cylinder
39%
158.0
45.0
203
8
0.0047
SC-748
1/20″ quadrilobe
37%
163.1
41.9
205
7.9
0.0047
SC-795
1/16″ cylinder (Criterion)
1%
107.8
0.0
72
7.7
0.0024
SC-826
1.7-2.0 mm spheres (PQ)
90%
276.0
69.5
283
9.7
0.0088
SC-924
1.7-2.0 mm spheres (PQ)
92%
295.4
119.2
274
9.7
0.0095
SC-926
1/20″ quadrilobe
30%
132.3
17.7
190
8.5
0.0046
SC-927
1/20″ quadrilobe
25%
124.3
14.1
112
8
0.0043
SC-928
1/20″ quadrilobe
3%
72.8
0.3
51
7.6
0.0026
SC-1063
1/16″ cylinder
0%
26.7
0.0
14
7.3
0.0010
SC-1236
Ultrasil (80:20 w/
39%
146.7
37.6
151
8.3
0.0051
Nyacol) steam 1200 F./1 h
SC-1237
Ultrasil (80:20 w/
22%
131.7
15.1
108
8
0.0045
Nyacol) steam 1400 F./1 h
SC-1238
Ultrasil (80:20 w/
6%
96.1
2.4
68
7.2
0.0034
Nyacol) steam 1500 F./1 h
SC-1239
Stm ultrasil/Nyacol/
0%
20.1
0.0
13
6.3
0.0006
PVA 1/20″ Q 1500 F./45 m
SC-1240
Steamed Ultrasil/
2%
37.9
0.0
26
6.3
0.0009
Nyacol/PVA 1/20″ Q 1400 F./1 h
SC-1241
Steam Ultrasil/
27%
130.2
23.0
122
6.7
0.0034
Nyacol/PVA 1/20″Q 1200 F./1 hr
SC-1242
Stm/air ultrasil/Nyacol/
13%
92.2
5.9
75
7.1
0.0025
PVA 1/20″ Q 1300 F./45 m
As can be seen from the data in Table 1, silica catalysts having larger median pore diameters have lower olefin saturation (OSAT) at 90% HDS. In general, supports having similar surface areas but larger pore volumes will have larger pore sizes while carriers having similar pore volumes but larger surface areas will have smaller pore sizes.
FIG. 2 is a graph showing pore size distribution (PSD) of silica support SC-593 as measured by mercury porosimetry. As shown in FIG. 2 , the silica support exhibits a uni-modal pore size distribution.
Example 2
The CoMo/silica catalysts were prepared by the incipient wetness technique. A molybdenum urea solution was prepared by dissolving ammonium heptamolybdate tetrahydrate and urea in distilled water and was impregnated on the silica support SC-593 so that the MoO 3 concentration on the final catalyst was 21.3 wt. %, based on the weight of the catalyst. The impregnated solid was dried under vacuum at 60° C. Four separate cobalt-organic ligand aqueous solutions were prepared by reacting cobalt carbonate hydrate with citric acid (CoCA), EDTA (CoEDTA), nitrilotriacetic acid (CoNTA), or ethylenediamine (CoEDA). Each cobalt-organic ligand solution was impregnated on the MoUrea/SC-593 so that the CoO concentration on the final catalyst was 5.3 wt. %, based on the weight of the catalyst. The catalysts were dried under vacuum at 60° C.
The silica supported CoMo catalysts and a commercially available reference CoMo/Al 2 O 3 (SC-154) catalyst were sulfided using 3% H 2 S in H 2 and virgin naphtha under sulfiding conditions. Feed for the catalyst evaluation was a C 5 -177° C. (350° F.) FCC naphtha feed containing 1408 ppm S and 46.3 wt. % olefins, based on the weight of the feed. Catalysts were evaluated in an MCFB-48 unit (Multi Channel Fixed Bed-48 Reactor) at 274° C. (525° F.) at 220 psig using H 2 . Feed flow rate was adjusted to obtain a range of 2-methylthiophene desulfurization from 65 wt. % to 95 wt. %, based on the weight of the feed. Product streams were analyzed using on-line GCs and SCDs. C 5 Olefin content in the product was compared with C 5 olefin content in the feed on a weight basis to calculate the percentage of olefin saturation (% OSAT). Results of % HDS and % OSAT were stable after about 30 hours of catalyst on stream, and were used to evaluate the olefin saturation (% OSAT) at various HDS conversions (% HDS). FIG. 3 plots the olefin selectivity vs. HDS activity for these four CoMo/SiO 2 (SC-593) catalysts and the industrial reference CoMo/Al 2 O 3 catalyst. At 90% HDS conversion, there was about 7.7 wt. % olefin saturation for the CoMo/SiO 2 catalysts prepared using support SC-593, much less than the olefin saturation of 14 wt. % on the reference CoMo/Al 2 O 3 catalyst.
Example 3
Three impregnation solutions were prepared by dissolving ammonium heptamolybdate tetrahydrate and cobalt carbonate hydrate with three organic ligands: citric acid (CA), nitrilotriacetic acid (NTA), and arginine (Arg). The cobalt-to-molybdenum atomic ratio was 0.48 in all three solutions. The CoMo-CA solution was impregnated on silica support SC-741 using the incipient wetness impregnation technique in a single step in an amount so that the dried solid would contain 5.85 wt, % CoO and 23.4 wt. % MoO 3 , based on the weight of the catalyst. The impregnated solid was dried under vacuum at 60° C. The CoMo-NTA solution was also impregnated in a single step and dried under vacuum at 60° C. For the CoMo-Arg solution, the solubility was low and a double impregnation (with a vacuum drying at 60° C. after the first impregnation) was required in order to impregnate a similar amount of CoO (5.83 wt. %) and MoO 3 (23.4 wt. %) on the catalyst.
The catalyst evaluations of the CoMo/SiO 2 catalysts on SC-741 were done similar to the evaluation of CoMo/SiO 2 catalysts on support SC-593, as described above. FIG. 4 plots the olefin selectivity vs. HDS activity for these three CoMo/SiO 2 (SC-741) catalysts and the industrial reference CoMo/Al 2 O 3 catalyst. At 90 wt. % HDS conversion, there was about 7.6 wt. % olefin saturation for the CoMo/SiO 2 catalysts prepared using support SC-741, much less than the olefin saturation of 14 wt. % on the reference CoMo/Al 2 O 3 catalyst.
Example 4
Two impregnation solutions were prepared by dissolving ammonium heptamolybdate tetrahydrate and cobalt carbonate hydrate with two organic chelating agents as ligands: citric acid (CA) and arginine (Arg). The cobalt to molybdenum atomic ratio was 0.48 in both solutions. The CoMo-CA solution was impregnated to silica support SC-743 using the incipient wetness impregnation technique in a single step in an amount so that the dried solid would contain 5.2 wt. % CoO and 20.9 wt. % MoO 3 , based on the weight of the catalyst. The impregnated solid was dried under vacuum at 60° C. For the CoMo-Arg solution, the solubility was low and a double impregnation (with a vacuum drying at 60° C. after the first impregnation) was required in order to impregnate the same amount of CoO and MoO 3 on the SC-743 support.
The evaluation was done similar to the evaluation of CoMo/SiO 2 catalysts on support SC-593, as described above in Example 2. FIG. 5 plots the olefin selectivity vs. HDS activity for these two CoMo/SiO 2 (SC-743) catalysts and the industrial reference CoMo/Al 2 O 3 catalyst. At 90% HDS conversion, there was about 8.7 wt. % olefin saturation for the CoMo/SiO 2 catalysts prepared using support SC-743, much less than the olefin saturation of 14 wt. % on the reference CoMo/Al 2 O 3 catalyst.
Example 5
This example is directed to high temperature aging and stability of CoMo/SiO 2 catalysts. CoMo/SiO 2 catalysts prepared above were subject to a stability evaluation against the industrial reference CoMo/Al 2 O 3 catalyst as follows. After about one week of MCFB-48 unit testing with FCC naphtha feed at 274° C. (525° F.), the reactor bed temperature was raised to 299° C. (570° F.) and aged at 570° F. for about 3 days. The temperature was then lowered to 274° C. (525° F.) and catalyst performance (olefin saturation and HDS activity) was evaluated. The reactor bed temperature was then raised again to 316° C. (600° F.) and aged at 316° C. for another 2 days. The temperature was then lowered to 274° C. (525° F.) again and catalyst performance (olefin saturation and HDS activity) was evaluated.
Evaluation results are plotted for CoMo/SiO 2 Catalysts on silica supports SC-593, SC-741, and SC-509-5S, and are compared to the reference CoMo/Al 2 O 3 catalyst in FIG. 6 . It is apparent from FIG. 6 that the CoMo catalysts on silica supports were at least as stable as the reference CoMo/Al 2 O 3 catalyst.
Example 6
An impregnation solution was prepared by dissolving ammonium heptamolybdate tetrahydrate and cobalt carbonate hydrate in aqueous citric acid. The cobalt to molybdenum atomic ratio was 0.48. The CoMo-CA solution was impregnated on the silica supports SC-745, 746, 747 and 748 using the incipient wetness impregnation technique in a single step in an amount so that the dried solid would contain 5.2 wt. % CoO and 20.9 wt. % MoO 3 , based on the weight of the catalyst. The impregnated solid was dried under vacuum at 60° C.
The evaluation was done similar to the evaluation of CoMo/SiO 2 catalysts on support SC-593, as described above. FIG. 7 plots the olefin selectivity vs. HDS activity for these four CoMo/SiO 2 catalysts (SC-745, 746, 747, 748) catalysts and the industrial reference CoMo/Al 2 O 3 catalyst. At 90% HDS conversion (on a weight basis), CoMo/SiO 2 on SC-747 and SC-748 showed about 8% olefin saturation while the other two catalysts showed from 9 wt. % to 9.3 wt. % olefin saturation, which were much less than the olefin saturation of 14 wt. % on the reference CoMo/Al 2 O 3 catalyst.
Example 7
This example is directed to air drying vs. vacuum drying of the impregnated silica support. An impregnation solution was prepared by dissolving ammonium heptamolybdate tetrahydrate and cobalt carbonate hydrate in aqueous citric acid (CA). The cobalt to molybdenum atomic ratio was 0.48 in these solutions. The CoMo-CA solution was impregnated on silica support SC-593 using the incipient wetness impregnation technique in a single step in an amount so that the dried solid would contain 5.3 wt. % CoO and 21.4 wt. % MoO 3 , on a weight basis. The impregnated solid was dried under vacuum at 60° C. In another preparation using the same CoMo-CA solution and silica support SC-593, the impregnated solid was dried in air at 110° C. In a third preparation, the impregnated solid was dried in air at 180° C.
The evaluations were done similar to the evaluation of CoMo/SiO 2 catalysts on support SC-593, as described above. FIG. 8 plots the olefin selectivity vs. HDS activity for the CoMo-CA/SiO 2 catalysts dried at three different conditions, and compared to the industrial reference CoMo/Al 2 O 3 catalyst. At 90% HDS conversion (on a weight basis), these CoMo/SiO 2 catalysts showed similar selectivities (7.7 wt. % olefin saturation), which were much less than the olefin saturation of 14 wt. % on the reference CoMo/Al 2 O 3 catalyst. These experiments demonstrate that CoMo/SiO 2 catalysts dried in air at 110° C. to 180° C. have similar selectivity in gasoline HDS as CoMo/SiO 2 catalysts dried under vacuum at 60° C.
Example 8
The effect of smaller pore sizes is demonstrated in this example. An impregnation solution was prepared by dissolving ammonium heptamolybdate tetrahydrate and cobalt carbonate hydrate in aqueous citric acid. The cobalt to molybdenum atomic ratio was 0.48. The CoMo-CA solution was impregnated on silica support SC-592 using the incipient wetness impregnation technique in a single step in an amount so that the dried solid would contain 5.6 wt. % CoO and 22.4 wt. % MoO 3 , based on the weight of the catalyst. For silica support SC-595, less impregnation solution was used so that the final dried solid would contain 3.8 wt. % CoO and 15.3 wt. % MoO 3 , based on the weight of the catalyst. Both impregnated solids were dried under vacuum at 60° C.
The evaluation was done similar to the evaluation of CoMo/SiO 2 catalysts on support SC-593, as described above. FIG. 9 plots the olefin selectivity vs. HDS activity for these two CoMo/SiO 2 catalysts (SC-592, 595) catalysts and the industrial reference CoMo/Al 2 O 3 catalyst. At 90% HDS conversion, CoMo/SiO 2 on SC-592 showed about 9.5% olefin saturation while CoMo/SiO 2 on SC-595 showed about 10.3% olefin saturation. SC-595 is a 1/16″ cylinder and has a bi-modal pore size distribution with the pores centered around 35 Å and slightly over 100 Å. FIG. 10 is a pore size distribution plot of SC-595 obtained by N 2 adsorption analysis. The N 2 adsorption was used over Hg intrusion due to the small pores of SC-595. These results demonstrate that directionally, supports having smaller pores may result in greater olefin saturation than supports having larger pores. Thus the smaller pores of SC-592 and 595 resulted in poorer selectivity relative to the larger pore silica supported catalysts as shown in the previous example. However, the small pore silica of this example still exhibits better selectivity than the reference catalyst, RT-225. | A method for hydrodesulfurizing FCC naphtha is described. More particularly, a Co/Mo metal hydrogenation component is loaded on a silica or modified silica support in the presence of organic ligand and sulfided to produce a catalyst which is then used for hydrodesulfurizing FCC naphtha. The silica support has a defined pore size distribution which minimizes olefin saturation. | 2 |
This invention relates to gates provided on railway cars and other vehicles for the discharge of particulate materials from the vehicle.
BACKGROUND OF THE INVENTION
It is well known in the art to provide, at the bottom of railway cars which carry particulate materials, pairs of sloping surfaces which face each other and which are spaced apart at their lower ends for the discharge of the material between such ends. The space between the ends is blocked or unblocked by one or more manually operable valves which are opened for the discharge of the material.
It is also known in the art to provide a trough below the valves for receiving the material from which trough the material is removed through a hose or pipe connected to a vacuum system.
One successful prior art gate structure is disclosed in U.S. Pat. No. 4,500,230 and comprises a pair of downwardly converging walls separated at their lower ends. The space between the ends, in one embodiment, is occupied by two end-to-end, independently rotatable valves which have an arcuate outer surface and an inner surface which is differently shaped so that each valve increases in cross-sectional dimension from one circumferential side to a maximum intermediate cross-sectional dimension and then decreases to a smaller cross sectional dimension at the circumferentially opposite side. There is a trough below the valves for receiving the particulate material discharged past an open valve, and there is a capped discharge tube at each end of the trough to which a vacuum hose can be connected after it is uncapped, for removing the material from the trough.
Each of the valves shown in said U.S. Pat. No. 4,500,230 can be operated from only one side of the car, and the discharge tube cap is held in place by a bail. The bail retainer has been found to be unsatisfactory, and it has been found to be desirable to independently operate both valves from one side of a car. In addition, the trough structure and the attachment of the trough to the slope sheets are relatively complicated.
Said U.S. Pat. No. 4,500,230 also mentions the problem of bridging of the gap between the lower ends of the slope sheets by material being discharged or unloaded. While the gate structure of such patent has been found to be satisfactory for discharging relatively free-flowing, larger particles, bridging of the material and blocking of the discharge flow has been encountered with smaller particles such as particles of corn starch or flour. When such bridging occurs, the bridging material must be dislodged manually causing extra expense and delay in unloading a car.
BRIEF SUMMARY OF THE INVENTION
It is an object of the invention to eliminate the bridging problems encountered with materials having a very small particle size and to do so even when the valves are provided with controls which permit either valve to be operated from either side of a car.
It is a further object of the invention to provide an improved mechanism for retaining and removing the cap which is applied over the trough discharge tube.
It is a further object of the invention to provide a simplified trough construction which is simple to assemble with the slope sheets.
In accordance with the preferred embodiment of the invention, air discharging devices are mounted on the walls forming part of the gate unit so as to agitate the material as it is being discharged and in advance of the point where it enters the gap between the lower edges of the walls. The valves have controls which permit both valves to be individually operated from one side of the car, and the air discharging devices and the controls are mounted so that one does not interfere with the other.
In addition, in the preferred embodiment, the cap which covers the trough discharge tube when the car is in transit, is held in place by a lever which is pivotable in a horizontal plane and which aids in removing the cap when it is desired to discharge material from the car.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view, with some parts, partly broken away, of the preferred embodiment of the invention in association with the hopper of a railway car;
FIGS. 2 and 3 are, respectively, elevation and end views of the embodiment shown in FIG. 1;
FIG. 4 is similar to FIG. 3 but is partly in section;
FIG. 5 is an enlarged, fragmentary, plan view partly in section of the end portion of the apparatus shown in FIG. 3; and
FIG. 6 is an enlarged, partial cross-section of the preferred embodiment and is taken along the line 6--6 shown in FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
While the principles of the invention have application to other gate structures, the gate structure described and illustrated in said U.S. Pat. No. 4,500,230 has advantages over the prior art, and the invention will be described with respect to the modifications thereof required to provide the gate structure of the invention.
With reference to FIGS. 1 and 2, the reference numerals 1-4 designate the slope sheets of the discharge hopper of a conventional railway car so equipped. The hopper discharge structure 5 of the invention has flanges 6-9 by which it is secured by means of bolts 10 to angle irons 11-14 secured to the hopper slope plates 1-4, such as by welding. Preferably, a gasket 15 (see FIG. 2) is between the flanges 6-9 and the angle irons 11-14.
The hopper discharge structure 5 has a pair of vertical end walls 16 and 17 and a pair of inclined or sloping side walls, or slope sheets, 18 and 19, the confronting lower edges of which, 20 and 21 (see FIG. 6), are spaced apart to provide a discharge opening therebetween.
A rotatable valve, having two independently rotatable sections 22 and 23 and of the type described in said U.S. Pat. No. 4,500,230 are disposed between the lower edges 20 and 21 of the side walls 18 and 19. Both of the sections 22 and 23 have an axis of rotation extending along a line parallel to the discharge opening between the edges 20 and 21, and each of the sections 22 and 23 has a peripheral extent such that in one rotational position thereof, the discharge opening adjacent thereto is closed and in another rotational position thereof, the discharge opening adjacent thereto is open to permit particulate material to pass therethrough. As described hereinafter, each of said sections 22 and 23 is rotatable from either side of the railway car.
Particulate material passing through the discharge opening is received in a trough 24 (see FIGS. 2 and 6) underlying the valve sections 22 and 23, and the particulate material is removable from said trough 24 through either or both of the discharge ports 25 and 26 (see FIGS. 2 and 5) disposed at opposite ends of the trough 24, such as by means of a vacuum system connected to a port by a hose.
Each port 25 and 26 is covered by a cap 27 and 28 when the particulate material is not being removed from the trough 24, e.g. when the railway car is being loaded with the particulate material and when the car is in transit. Each cap 27 and 28 is pivotally secured at 29 and 30 to a locking arm 31 and 32 pivotally secured at one end, 33 and 34, to one end of a pivot arm, 35 and 36, which is pivotally connected at 37 and 38 (see FIG. 5) to a bracket, such as the bracket 39, mounted on an extension of the trough 24.
A forked side link, 40 and'41, has its forked end pivotally connected at 42 and 43 to a bracket, such as the bracket 44, mounted on the extension of the trough 24. The locking arms 31 and 32 have slots through which the opposite ends of the side links 40 and 41 extend, and such opposite ends have holes therethrough for receiving detent ring pins 45 and 46 for preventing removal of the respective caps 27 and 28. To prevent loss of the pins 45 and 46, they are secured by chains 47 and 48 to brackets 49 and 50 on the caps 27 and 28.
To remove a cap, 27 or 28, the pin 45 or 46 associated therewith is removed and then, the locking arm 31 or 32, is moved away from the trough 24 causing the cap associated therewith to be removed from the associated port 25 or 26.
Either valve section, 22 or 23, may be opened or closed from either side of a car by means of operating levers 50-53 (see FIGS. 1-4). Operating lever 51 is secured to a pivotable shaft 54 so as to pivot therewith. As seen in FIG. 1, the shaft 54 extends from the lever 51 to the lever 50 which is also secured to the shaft 54 so that by movement of the lever 50 the shaft 54 is rotated. The operating levers 52 and 53 are similarly connected to a shaft 55.
The linkages connecting the operating levers 50-53 to the valve sections 22 and 23 are the same at both ends of the trough 24, and therefore, the linkages at only one end of the trough 24 will be described in connection with FIG. 4. As shown in FIG. 4, an arm 56 is secured to the shaft 57 which rotates the valve section 23 so that when the arm 56 pivots, the shaft 57 rotates. The arm 56 is pivotally connected at 58 to a link 59 which is pivotally connected at 60 to the operating lever 51. Thus, when either the operating lever 51 at one side of the car is pivoted or the operating lever 50 at the opposite side of the car is pivoted, the valve section 23 is rotated, in an obvious manner, from opened to closed and vice versa.
Similarly, when either the operating lever 52 at one side of the car is pivoted or the operating lever 53 at the opposite side the car is pivoted, the valve section 22 is rotated, in an obvious manner, from opened to closed and vice versa.
As mentioned hereinbefore, the hopper discharge structure described hereinbefore has been found to be satisfactory for discharging relatively free-flowing, larger particles. However, with particulate material of smaller particle size, such as corn starch or flour, difficulties have been encountered in that bridging or caking occurs at the discharge opening between the edges 20 and 21 of the slope sheets 18 and 19 which interrupts or reduces the flow of the particulate material through the discharge opening and which has required manual dislodging of the bridges or cakes.
It has been found that by agitating the particulate material adjacent to the discharge opening with air at a pressure above atmospheric pressure during the discharge of the particulate material through the discharge opening, such bridging and caking of the material can be avoided. While the air can be directed toward the particulate material by various means, it has been found that it is preferable to direct the air into the underside of the material through openings in the slope sheets 18 and 19 of the hopper discharge structure adjacent to the discharge opening. However, there are space limitations with the hopper discharge structure described hereinbefore because of the locations of the shafts 54 and 55, the port caps 27 and 28 and the operating levers 50-53, which cause problems in devising means for supplying such air to the openings in the slope sheets 18 and 19.
It has been found that a device on the market which is sold as a Solimar Clear View Air-Aider has a relatively small size and agitates material both by means of flowing air and by mechanical means. Preferably, there are two such devices for each valve section 22 and 23 disposed on opposite sides of the axis thereof.
One of said agitating devices is shown in cross-section in FIG. 6 and comprises a manifold 61, which may be made of a clear plastic or of another material, held against a gasket 62 bearing against the exterior surface of the slope sheet 19 and extending around an opening 63 through the slope sheets 19. A flexible pad 64, e.g. a concave disc of rubber, bears against the interior surface of the slope sheet 19 and is held in place by a stem 65 which has an enlarged head 66 and which passes through the pad 64. At its opposite end, the stem 65 is internally threaded and receives a rotatable threaded bolt 67. The head 68 of the bolt 67 bears against a spring washer 69 which bears against the manifold 61. The manifold 61 has an air inlet extension 70 to which air under a pressure above atmospheric pressure, e.g. 15-20 psig is supplied through a hose 71.
The bolt 67 is adjusted so that the pad 64 presses against the inner surface of the shope sheet 19 with sufficient pressure to prevent particles from flowing through the opening 63 and to hold the manifold 61 against the gasket 62 and the gasket 62 against the exterior surface of the slope sheet 19 when no air under pressure is supplied to the manifold 61 but with a pressure low enough so that when air under pressure is supplied to the manifold 61, the outer edge portion of the pad 64 will lift, permitting air to flow into the lading on top of the pad 64 and causing the outer edge portion to flutter as indicated by the arrows 72. Thus, the lading is agitated both by the air passing between the edge portion of the pad 64 and the interior surface of the slope sheet 19 and by the mechanical movement of the edge portion.
Preferably, there are four such agitating devices, the manifolds 61, 73 and 74 being shown in FIGS. 2 and 6 and the pads 64 of the four devices being shown in FIG. 1. The centerline of each device is spaced from the axis of the associated valve section, 22 or 23, by an amount sufficient to permit the manifolds thereof to clear the shafts 54 and 55, e.g. depending on the locations of the shafts 54 and 55, on the order of nine inches, and is on a line perpendicular to the axis of the associated valve section which is about mid-way between the ends of the valve section.
The four agitating devices are supplied with air under pressure through supply manifolds 75 and 76 (see particularly FIGS. 3 and 4) which are interconnected near their ends by pipes or hoses 77 and 78. So that air may be supplied to the manifolds 75 and 76 at either side of the car from any conventional source thereof, each manifold is provided at one end with a removable cap, 79 and 80, which, after removal, is retained by chains 81 and 82.
The trough 24 usually is an extrusion, e.g. of aluminum, and the troughs of said U.S. Pat. No. 4,500,230 are either relatively large or require relatively complicated extrusion dies. In the preferred embodiment of the invention, the trough 24 is relatively simple and does not require complicated extrusion dies. With reference to FIG. 6, the cross-section of the trough 24 does not have any recesses or indentations for receiving gaskets, which have been found to be unnecessary, and does not have any extensions for securing it to the slope sheets 18 and 19. Instead, the ends of the trough 24 are secured to the slope sheets 18 and 19, such as by welding at 83 and 84, and to increase the capacity of the trough 24, it is wider at its lower portion 24a than the spacing between the upper walls 24b which are secured to the slope sheets 18 and 19.
Although preferred embodiments of the present invention have been described and illustrated, it will be apparent to those skilled in the art that various modifications may be made without departing from the principles of the invention. | A gate for attachment to the hopper of a railway car or other vehicle which carries particulate material. The gate has a pair of sloping walls with facing surfaces, and the lower ends of the walls are spaced apart to permit the particulate material to be discharged into a trough below the spaced ends from which the particulate material is removed by a vacuum hose. A pair of separately operable, rotatable valves of arcuate cross-section are disposed at the space between the ends of the walls to block or permit particulate material flow into the trough. Pneumatically operable agitators are mounted on the walls to prevent bridging of the space between the wall ends of the material during removal thereof. | 1 |
RELATED APPLICATIONS
[0001] This application is a divisional of co-pending application Ser. No. 11/199,715, filed Aug. 9, 2005, which is a divisional of application Ser. No. 10/747,547, filed 29 Dec. 2003, now U.S. Pat. No. 6,981,981, which is a divisional of application Ser. No. 10/411,573, filed Apr. 10, 2003, now abandoned, which is a divisional of application Ser. No. 10/200,674, filed Jul. 22, 2002, now U.S. Pat. No. 6,663,647, which is a divisional of Ser. No. 09/059,796, filed Apr. 13, 1998, now U.S. Pat. No. 6,423,083, which is a divisional of application Ser. No. 08/788,786, filed Jan. 23, 1997, now U.S. Pat. No. 6,235,043, which is a continuation of application Ser. No. 08/188,224, filed on Jan. 26, 1994 (now abandoned).
FIELD OF THE INVENTION
[0002] This invention relates to improvements in the surgical treatment of bone conditions of the human and other animal bone systems and, more particularly, to an inflatable balloon-like device for use in treating such bone conditions. Osteoporosis, avascular necrosis and bone cancer are diseases of bone that predispose the bone to fracture or collapse. There are 2 million fractures each year in the United States, of which about 1.3 million are caused by osteoporosis. Avascular necrosis and bone cancers are more rare but can cause bone problems that are currently poorly addressed.
BACKGROUND OF THE INVENTION
[0003] In U.S. Pat. Nos. 4,969,888 and 5,108,404, an apparatus and method are disclosed for the fixation of fractures or other conditions of human and other animal bone systems, both osteoporotic and non-osteoporotic: The apparatus and method are especially suitable for use in the fixation of, but not limited to, vertebral body compression fractures, Colles fractures and fractures of the proximal humerus.
[0004] The method disclosed in these two patents includes a series of steps which a surgeon or health care provider can perform to form a cavity in pathological bone (including but not limited to osteoporotic bone, osteoporotic fractured metaphyseal and epiphyseal bone, osteoporotic vertebral bodies, fractured osteoporotic vertebral bodies, fractures of vertebral bodies due to tumors especially round cell tumors, avascular necrosis of the epiphyses of long bones, especially avascular necrosis of the proximal femur, distal femur and proximal humerus and defects arising from endocrine conditions).
[0005] The method further includes an incision in the skin (usually one incision, but a second small incision may also be required if a suction egress is used) followed by the placement of a guide pin which is passed through the soft tissue down to and into the bone.
[0006] The method further includes drilling the bone to be treated to form a cavity or passage in the bone, following which an inflatable balloon-like device is inserted into the cavity or passage and inflated. The inflation of the inflatable device causes a compacting of the cancellous bone and bone marrow against the inner surface of the cortical wall of the bone to further enlarge the cavity or passage. The inflatable device is then deflated and then is completely removed from the bone. A smaller inflatable device (a starter balloon) can be used initially, if needed, to initiate the compacting of the bone marrow and to commence the formation of the cavity or passage in the cancellous bone and marrow. After this has occurred, a larger, inflatable device is inserted into the cavity or passage to further compact the bone marrow in all directions.
[0007] A flowable biocompatible filling material, such as methylmethacrylate cement or a synthetic bone substitute, is then directed into the cavity or passage and allowed to set to a hardened condition to provide structural support for the bone. Following this latter step, the insertion instruments are removed from the body and the incision in the skin is covered with a bandage.
[0008] While the apparatus and method of the above patents provide an adequate protocol for the fixation of bone, it has been found that the compacting of the bone marrow and/or the trabecular bone and/or cancellous bone against the inner surface of the cortical wall of the bone to be treated can be significantly improved with the use of inflatable devices that incorporate additional engineering features not heretofore described and not properly controlled with prior inflatable devices in such patents. A need has therefore arisen for improvements in the shape, construction and size of inflatable devices for use with the foregoing apparatus and method, and the present invention satisfies such need.
Prior Techniques for the Manufacture of Balloons for in-Patient Use
[0009] A review of the prior art relating to the manufacture of balloons shows that a fair amount of background information has been amassed in the formation of guiding catheters which are introduced into cardiovascular systems of patients through the brachial or femoral arteries. However, there is a scarcity of disclosures relating to inflatable devices used in bone, and none for compacting bone marrow in vertebral bodies and long bones.
[0010] In a dilatation catheter, the catheter is advanced into a patient until a balloon is properly positioned across a lesion to be treated. The balloon is inflated with a radiopaque liquid at pressures above four atmospheres to compress the plaque of the lesion to thereby dilate the lumen of the artery. The balloon can then be deflated, then removed from the artery so that the blood flow can be restored through the dilated artery.
[0011] A discussion of such catheter usage technique is found and clearly disclosed in U.S. Pat. No. 5,163,989. Other details of angioplasty catheter procedures, and details of balloons used in such procedures can be found in U.S. Pat. Nos. 4,323,071, 4,332,254, 4,439,185, 4,168,224, 4,516,672, 4,538,622, 4,554,929, and 4,616,652.
[0012] Extrusions have also been made to form prism shaped balloons using molds which require very accurate machining of the interior surface thereof to form acceptable balloons for angioplastic catheters. However, this technique of extrusion forms parting lines in the balloon product which parting lines are limiting in the sense of providing a weak wall for the balloon itself.
[0013] U.S. Pat. No. 5,163,989 discloses a mold and technique for molding dilatation catheters in which the balloon of the catheter is free of parting lines. The technique involves inflating a plastic member of tubular shape so as to press it against the inner molding surface which is heated. Inflatable devices are molded into the desired size and shape, then cooled and deflated to remove it from the mold. The patent states that, while the balloon of the present invention is especially suitable for forming prism-like balloons, it can also be used for forming balloons of a wide variety of sizes and shapes.
[0014] A particular improvement in the catheter art with respect to this patent, namely U.S. Pat. No. 4,706,670, is the use of a coaxial catheter with inner and outer tubing formed and reinforced by continuous helical filaments. Such filaments cross each other causing the shaft of the balloon to become shorter in length while the moving portion of the shank becomes longer in length. By suitably balancing the lengths and the angle of the weave of the balloon and moving portions of the filaments, changes in length can be made to offset each other. Thus, the position of the inner and outer tubing can be adjusted as needed to keep the balloon in a desired position in the blood vessel.
[0015] Other disclosures relating to the insertion of inflatable devices for treating the skeleton of patients include the following:
[0016] U.S. Pat. No. 4,313,434 relates to the fixation of a long bone by inserting a deflated flexible bladder into a medullary cavity, inflating the balloon bladder, sealing the interior of the long bone until healing has occurred, then removing the bladder and filling the opening through which the bladder emerges from the long bone.
[0017] U.S. Pat. No. 5,102,413 discloses the way in which an inflatable bladder is used to anchor a metal rod for the fixation of a fractured long bone.
[0018] Other references which disclose the use of balloons and cement for anchoring of a prosthesis include U.S. Pat. Nos. 5,147,366, 4,892,550, 4,697,584, 4,562,598, and 4,399,814.
[0019] A Dutch patent, NL 901858, discloses a means for fracture repair with a cement-impregnated bag which is inflated into a preformed cavity and allowed to harden.
[0020] It can be concluded from the foregoing review of the prior art that there is little or no substantive information on inflatable devices used to create cavities in bone. It does not teach the shape of the balloon which creates a cavity that best supports the bone when appropriately filled. It does not teach how to prevent balloons from being spherical when inflated, when this is desired. Current medical balloons can compress bone but are too small and generally have the wrong configuration and are generally not strong enough to accomplish adequate cavity formation in either the vertebral bodies or long bones of the body.
[0021] U.S. Pat. Nos. 4,969,888 and 5,108,404 disclose a checker-shaped balloon for compressing cancellous bone, but does not provide information on how this balloon remains in its shape when inflated.
[0022] Thus, the need continues for an improved inflatable device for use with pathological bones and the treatment thereof.
SUMMARY OF THE INVENTION
[0023] The present invention is directed to a balloon-like inflatable device or balloon for use in carrying out the apparatus and method of the above-mentioned U.S. Pat. Nos. 4,969,888 and 5,108,404. Such inflatable devices, hereinafter sometimes referred to as balloons, have shapes for compressing cancellous bone and marrow (also known as medullary bone or trabecular bone) against the inner cortex of bones whether the bones are fractured or not.
[0024] In particular, the present invention is directed to a balloon for use in treating a bone predisposed to fracture or to collapse. The balloon comprises an inflatable, non-expandable balloon body for insertion into said bone. The body has a predetermined shape and size when substantially inflated sufficient to compress at least a portion of the inner cancellous bone to create a cavity in the cancellous bone and to restore the original position of the outer cortical bone, if fractured or collapsed. The balloon body is restrained to create said predetermined shape and size so that the fully inflated balloon body is prevented from applying substantial pressure to the inner surface of the outer cortical bone if said bone is unfractured or uncollapsed.
[0025] In addition to the shape of the inflatable device itself, another aspect of importance is the construction of the wall or walls of the balloon such that proper inflation the balloon body is achieved to provide for optimum compression of all the bone marrow. The material of the balloon is also desirably chosen so as to be able to fold the balloon so that it can be inserted quickly and easily into a bone using a guide pin and a cannula, yet can also withstand high pressures when inflated. The balloon can also include optional ridges or indentations which are left in the cavity after the balloon has been removed, to enhance the stability of the filler. Also, the inflatable device can be made to have an optional, built-in suction catheter. This is used to remove any fat or fluid extruded from the bone during balloon inflation in the bone. Also, the balloon body can be protected from puncture by the cortical bone or canula by being covered while inside the canula with an optional protective sleeve of suitable material, such as Kevlar or PET or other polymer or substance that can protect the balloon. The main purpose of the inflatable device, therefore, is the forming or enlarging of a cavity or passage in a bone, especially in, but not limited to, vertebral bodies.
[0026] The primary object of the present invention is to provide an improved balloon-like inflatable device for use in carrying out a surgical protocol of cavity formation in bones to enhance the efficiency of the protocol, to minimize the time prior to performing the surgery for which the protocol is designed and to improve the clinical outcome. These balloons approximate the inner shape of the bone they are inside of in order to maximally compress cancellous bone. They have additional design elements to achieve specific clinical goals. Preferably, they are made of inelastic material and kept in their defined configurations when inflated, by various restraints, including (but not limited to) use of inelastic materials in the balloon body, seams in the balloon body created by bonding or fusing separate pieces of material together, or by fusing or bonding together opposing sides of the balloon body, woven material bonded inside or outside the balloon body, strings or bands placed at selected points in the balloon body, and stacking balloons of similar or different sizes or shapes on top of each other by gluing or by heat fusing them together. Optional ridges or indentations created by the foregoing structures, or added on by bonding additional material, increases stability of the filler. Optional suction devices, preferably placed so that if at least one hole is in the lowest point of the cavity being formed, will allow the cavity to be cleaned before filling.
[0027] Among the various embodiments of the present invention are the following:
[0028] 1. A doughnut (or torus) shaped balloon with an optional built-in suction catheter to remove fat and other products extruded during balloon expansion.
[0029] 2. A balloon with a spherical outer shape surrounded by a ring-shaped balloon segment for body cavity formation.
[0030] 3. A balloon which is kidney bean shaped in configuration. Such a balloon can be constructed in a single layer, or several layers stacked on top of each other.
[0031] 4. A spherically shaped balloon approximating the size of the head of the femur (i.e. the proximal femoral epiphysis). Such a balloon can also be a hemisphere.
[0032] 5. A balloon in the shape of a humpbacked banana or a modified pyramid shape approximating the configuration of the distal end of the radius (i.e. the distal radial epiphysis and metaphysis).
[0033] 6. A balloon in the shape of a cylindrical ellipse to approximate the configuration of either the medial half or the lateral half of the proximal tibial epiphysis. Such a balloon can also be constructed to approximate the configuration of both halves of the proximal tibial epiphysis.
[0034] 7. A balloon in the shape of sphere on a base to approximate the shape of the proximal humeral epiphysis and metaphysis with a plug to compress cancellous bone into the diaphysis, sealing it off.
[0035] 8. A balloon device with optional suction device.
[0036] 9. Protective sheaths to act as puncture guard members optionally covering each balloon inside its catheter.
[0037] The present invention, therefore, provides improved, inflatable devices for creating or enlarging a cavity or passage in a bone wherein the devices are inserted into the bone. The configuration of each device is defined by the surrounding cortical bone and adjacent internal structures, and is designed to occupy about 70-90% of the volume of the inside of the bone, although balloons that are as small as about 40% and as large as about 99% are workable for fractures. In certain cases, usually avascular necrosis, the balloon size may be as small as 10% of the cancellous bone volume of the area of bone being treated, due to the localized nature of the fracture or collapse. The fully expanded size and shape of the balloon is limited by additional material in selected portions of the balloon body whose extra thickness creates a restraint as well as by either internal or external restraints formed in the device including, but not limited to, mesh work, a winding or spooling of material laminated to portions of the balloon body, continuous or non-continuous strings across the inside held in place at specific locations by glue inside or by threading them through to the outside and seams in the balloon body created by bonding two pieces of body together or by bonding opposing sides of a body through glue or heat. Spherical portions of balloons may be restrained by using inelastic materials in the construction of the balloon body, or may be additionally restrained as just described. The material of the balloon is preferably a non-elastic material, such as polyethylene tetraphthalate (PET), Kevlar or other patented medical balloon materials. It can also be made of semi-elastic materials, such as silicone or elastic material such as latex, if appropriate restraints are incorporated. The restraints can be made of a flexible, inelastic high tensile strength material including, but not limited, to those described in U.S. Pat. No. 4,706,670. The thickness of the balloon wall is typically in the range of 2/1000ths to 25/1000ths of an inch, or other thicknesses that can withstand pressures of up to 250-400 psi.
[0038] A primary goal of percutaneous vertebral body augmentation of the present invention is to provide a balloon which can create a cavity inside the vertebral body whose configuration is optimal for supporting the bone. Another important goal is to move the top of the vertebral body back into place to retain height where possible, however, both of these objectives must be achieved without fracturing the cortical wall of the vertebral body. This feature could push vertebral bone toward the spinal cord, a condition which is not to be desired.
[0039] The present invention satisfies these goals through the design of inflatable devices to be described. Inflating such a device compresses the calcium-containing soft cancellous bone into a thin shell that lines the inside of the hard cortical bone creating a large cavity.
[0040] At the same time, the biological components (red blood cells, bone progenitor cells) within the soft bone are pressed out and removed by rinsing during the procedure. The body recreates the shape of the inside of an unfractured vertebral body, but optimally stops at approximately 70 to 90% of the inner volume. The balloons of the present invention are inelastic, so maximally inflating them can only recreate the predetermined shape and size. However, conventional balloons become spherical when inflated. Spherical shapes will not allow the hardened bone cement to support the spine adequately, because they make single points of contact on each vertebral body surface (the equivalent of a circle inside a square, or a sphere inside a cylinder). The balloons of the present invention recreate the flat surfaces of the vertebral body by including restraints that keep the balloon in the desired shape. This maximizes the contacts between the vertebral body surfaces and the bone cement, which strengthens the spine. In addition, the volume of bone cement that fills these cavities creates a thick mantle of cement (4 mm or greater), which is required for appropriate compressive strength. Another useful feature, although not required, are ridges in the balloons which leave their imprint in the lining of compressed cancellous bone. The resulting bone cement “fingers” provide enhanced stability.
[0041] The balloons which optimally compress cancellous bone in vertebral bodies are the balloons listed as balloon types 1, 2 and 3 above. These balloons are configured to approximate the shape of the vertebral body. Since the balloon is chosen to occupy 70 to 90% of the inner volume, it will not exert undue pressure on the sides of the vertebral body, thus the vertebral body will not expand beyond its normal size (fractured or unfractured). However, since the balloon has the height of an unfractured vertebral body, it can move the top, which has collapsed, back to its original position.
[0042] One aspect of the invention provides a device for insertion into a vertebral body to apply a force capable of compacting cancellous bone and moving fractured cortical bone. The device includes a catheter extending along an axis and having a distal end sized and configured for insertion through a cannula into the vertebral body. The catheter carries near its distal end an inflatable body having a wall sized and configured for passage within the cannula into the vertebral body when the inflatable body is in a collapsed condition. The wall is further sized and configured to apply the in response to expansion of the inflatable body within the vertebral body. The wall includes, when inflated, opposed side surfaces extending along an elongated longitudinal axis that is substantially aligned with the axis of the catheter. The inflatable body has a height of approximately 0.5 cm to 3.5 cm, an anterior to posterior dimension of approximately 0.5 cm to 3.5 cm, and a side to side dimension of approximately 0.5 cm to 5.0 cm.
[0043] In a representative embodiment, the inflatable body comprises a balloon and the cannula is a percutaneious cannula.
[0044] In another aspect of the invention, the wall includes changes in wall thickness which restrain the opposed sided surfaces from expanding beyond a substantially flat condition.
[0045] According to another aspect of the invention, the wall includes an internal restraint which restrains the opposed side surfaces from expanding beyond a substantially flat condition. The internal restraint may include a mesh material, a string material, a woven material, a seam, or an essentially non-elastic material.
[0046] In yet another aspect of the invention, the wall includes an external restraint which restrains the opposed side surfaces from expanding beyond a substantially flat condition. The internal restraint may include a mesh material, a string material, a woven material, a seam, or an essentially non-elastic material.
[0047] A primary goal of percutaneous proximal humeral augmentation is to create a cavity inside the proximal humerus whose configuration is optimal for supporting the proximal humerus. Another important goal is to help realign the humeral head with the shaft of the humerus when they are separated by a fracture. Both of these goals must be achieved by exerting pressure primarily on the cancellous bone, and not the cortical bone. Undue pressure against the cortical bone could conceivably cause a worsening of a shoulder fracture by causing cortical bone fractures.
[0048] The present invention satisfies these goals through the design of the inflatable devices to be described. Inflating such a device compresses the cancellous bone against the cortical walls of the epiphysis and metaphysis of the proximal humerus thereby creating a cavity. In some cases, depending on the fracture location, the balloon or inflatable device may be used to extend the cavity into the proximal part of the humeral diaphysis.
[0049] Due to the design of the “sphere on a stand” balloon (described as number 7 above), the cavity made by this balloon recreates or approximates the shape of the inside cortical wall of the proximal humerus. The approximate volume of the cavity made by the “spherical on a stand balloon” is 70 to 90% that of the proximal humeral epiphysis and metaphysis, primarily, but not necessarily exclusive of, part of the diaphysis. The shape approximates the shape of the humeral head. The “base” is designed to compress the trabecular bone into a “plug” of bone in the distal metaphysis or proximal diaphysis. This plug of bone will prevent the flow of injectable material into the shaft of the humerus, improving the clinical outcome. The sphere can also be used without a base.
[0050] A primary goal of percutaneous distal radius augmentation is to create a cavity inside the distal radius whose configuration is optimal for supporting the distal radius. Another important goal is to help fine tune fracture realignment after the fracture has been partially realigned by finger traps. Both of these goals must be achieved by exerting pressure primarily on the cancellous bone and not on the cortical bone. Excessive pressure against the cortical bone could conceivably cause cortical bone fractures, thus worsening the condition.
[0051] The present invention satisfies these goals through the design of inflatable devices either already described or to be described.
[0052] The design of the “humpbacked banana”, or modified pyramid design (as described as number 5 above), approximates the shape of the distal radius and therefore, the cavity made by this balloon approximates the shape of the distal radius as well. The approximate volume of the cavity to be made by this humpbacked banana shaped balloon is 70 to 90% that of the distal radial epiphysis and metaphysis primarily of, but not necessarily exclusive of, some part of the distal radial diaphysis. Inflating such a device compresses the cancellous bone against the cortical walls of the epiphysis and metaphysis of the distal radius in order to create a cavity. In some cases, depending on the fracture location, the osseous balloon or inflatable device may be used to extend the cavity into the distal part of the radial diaphysis.
[0053] A primary goal of percutaneous femoral head (or humeral head) augmentation is to create a cavity inside the femoral head (or humeral head) whose configuration is optimal for supporting the femoral head. Another important goal is to help compress avascular (or aseptic) necrotic bone or support avascular necrotic bone is the femoral head. This goal may include the realignment of avascular bone back into the position it previously occupied in the femoral head in order to improve the spherical shape of the femoral head. These goals must be achieved by exerting pressure primarily on the cancellous bone inside the femoral head.
[0054] The present invention satisfied these goals through the design of inflatable devices either already described or to be described.
[0055] The design of the spherical osseous balloon (described as balloon type 4 above) approximates the shape of the femoral head and therefore creates a cavity which approximates the shape of the femoral head as well. (It should be noted that the spherical shape of this inflatable device also approximates the shape of the humeral head and would, in fact, be appropriate for cavity formation in this osseous location as well.) Inflating such a device compresses the cancellous bone of the femoral head against its inner cortical walls in order to create a cavity. In some cases, depending upon the extent of the avascular necrosis, a smaller or larger cavity inside the femoral head will be formed. In some cases, if the area of avascular necrosis is small, a small balloon will be utilized which might create a cavity only 10 to 15% of the total volume of the femoral head. If larger areas of the femoral head are involved with the avascular necrosis, then a larger balloon would be utilized which might create a much larger cavity, approaching 80 to 90% of the volume of the femoral head.
[0056] The hemispherical balloon approximates the shape of the top half of the femoral (and humeral) head, and provides a means for compacting cancellous bone in an area of avascular necrosis or small fracture without disturbing the rest of the head. This makes it easier to do a future total joint replacement if required.
[0057] A primary goal of percutaneous proximal tibial augmentation is to create a cavity inside the proximal tibia whose configuration is optimal for supporting either the medial or lateral tibial plateaus. Another important goal is to help realign the fracture fragments of tibial plateau fractures, particularly those features with fragments depressed below (or inferior to) their usual location. Both of these objectives must be achieved by exerting pressure on primarily the cancellous bone and not the cortical bone. Pressure on the cortical bone could conceivably cause worsening of the tibial plateau fracture.
[0058] The present invention satisfies these goals through the design of the inflatable devices to be described. Inflating such a device compresses the cancellous bone against the cortical walls of the medial or lateral tibial plateau in order to create a cavity.
[0059] Due to the design of the “elliptical cylinder” balloon (described as balloon type 6 above) the cavity made by this balloon recreates or approximates the shape of the cortical walls of either the medial or lateral tibial plateaus. The approximate volume of the cavity to be made by the appropriate elliptical cylindrical balloon is 50 to 90% of the proximal epiphyseal bone of either the medial half or the lateral half of the tibial.
[0060] According to one aspect of the invention, a system for treating a bone having an interior volume occupied, at least in part, by cancellous bone comprises a first tool, a second tool, and a third tool. The bone may be e.g., a vertebral body. The first tool establishes a percutaneous access path to bone. The second tool is sized and configured to be introduced through the percutaneous access path to form a void that occupies less than the interior volume. The third tool places within the void through the percutaneous access path a volume of filling material.
[0061] In one embodiment, the interior volume has a maximum anterior-to-posterior dimension and the void has a dimension, measured in an anterior-to-posterior direction, that is less than the maximum anterior-to-posterior dimension of the interior volume.
[0062] In one embodiment, the interior volume has a maximum side-to-side dimension and the void has a dimension, measured in a side-to-side direction, that is less than the maximum side-to-side dimension of the interior volume.
[0063] Another aspect of the invention provides a method of treating a bone having an interior volume occupied, at least in part, by cancellous bone. The bone may be, e.g., a vertebral body. The method provides establishing a percutaneous access path to bone. A tool is introduced through the percutaneous access path and manipulated to form a void that occupies less than the interior volume. A volume of filling material is then placed within the void through the percutaneous access path.
[0064] In one embodiment, the interior volume has a maximum anterior-to-posterior dimension and the void has a dimension, measured in an anterior-to-posterior direction, that is less than the maximum anterior-to-posterior dimension of the interior volume.
[0065] In one embodiment, the interior volume has a maximum side-to-side dimension and the void has a dimension, measured in a side-to-side direction, that is less than the maximum side-to-side dimension of the interior volume.
[0066] Other objects of the present invention will become apparent as the following specification progresses, reference being had to the accompanying drawings for an illustration of the invention.
DESCRIPTION OF THE DRAWINGS
[0067] FIG. 1 is a perspective view of a first embodiment of the balloon of the present invention, the embodiment being in the shape of a stacked doughnut assembly.
[0068] FIG. 2 is a vertical section through the balloon of FIG. 1 showing the way in which the doughnut portions of the balloon of FIG. 1 , fit into a cavity of a vertebral body.
[0069] FIG. 3 is a schematic view of another embodiment of the balloon of the present invention showing three stacked balloons and string-like restraints for limiting the expansion of the balloon in directions of inflation.
[0070] FIG. 4 is a top plan view of a spherical balloon having a cylindrical ring surrounding the balloon.
[0071] FIG. 5 is a vertical section through the spherical balloon and ring of FIG. 4 .
[0072] FIG. 6 shows an oblong-shaped balloon with a catheter extending into the central portion of the balloon.
[0073] FIG. 6A is a perspective view of the way in which a catheter is arranged relative to the inner tubes for inflating the balloon of FIG. 6 .
[0074] FIG. 7 is a suction tube and a contrast injection tube for carrying out the inflation of the balloon and removal of debris caused by expansion from the balloon itself.
[0075] FIG. 8 is a vertical section through a balloon after it has been deflated and as it is being inserted into the vertebral body of a human.
[0076] FIGS. 9 and 9A are side elevational views of a cannula showing how the protective sleeve or guard member expands when leaving the cannula.
[0077] FIG. 9B is a vertical section through a vertebral bone into which an access hole has been drilled.
[0078] FIG. 10 is a perspective view of another embodiment of the balloon of the present invention formed in the shape of a kidney bean.
[0079] FIG. 11 is a perspective view of the vertebral bone showing the kidney shaped balloon of FIG. 10 inserted in the bone and expanded.
[0080] FIG. 12 is a top view of a kidney shaped balloon formed of several compartments by a heating element or branding tool.
[0081] FIG. 13 is a cross-sectional view taken along line 13 - 13 of FIG. 12 but with two kidney shaped balloons that have been stacked.
[0082] FIG. 14 is a view similar to FIG. 11 but showing the stacked kidney shaped balloon of FIG. 13 in the vertebral bone.
[0083] FIG. 15 is a top view of a kidney balloon showing outer tufts holding inner strings in place interconnecting the top and bottom walls of the balloon.
[0084] FIG. 16 is a cross sectional view taken along lines 16 - 16 of FIG. 15 .
[0085] FIG. 17A is a dorsal view of a humpback banana balloon in a right distal radius.
[0086] FIG. 17B is a cross sectional view of FIG. 17A taken along line 17 B- 17 B of FIG. 17A .
[0087] FIG. 18 is a spherical balloon with a base in a proximal humerus viewed from the front (anterior) of the left proximal humerus.
[0088] FIG. 19A is the front (anterior) view of the proximal tibia with the elliptical cylinder balloon introduced beneath the medial tibial plateau.
[0089] FIG. 19B is a three quarter view of the balloon of FIG. 19A .
[0090] FIG. 19C is a side elevational view of the balloon of FIG. 19A .
[0091] FIG. 19D is a top plan view of the balloon of FIG. 19A .
[0092] FIG. 20 is a spherically shaped balloon for treating avascular necrosis of the head of the femur (or humerus) as seen from the front (anterior) of the left hip.
[0093] FIG. 20A is a side view of a hemispherically shaped balloon for treating avascular necrosis of the head of the femur (or humerus).
DETAILED DESCRIPTION
Balloons for Vertebral Bodies
[0094] A first embodiment of the balloon ( FIG. 1 ) of the present invention is broadly denoted by the numeral 10 and includes a balloon body 11 having a pair of hollow, inflatable, non-expandable parts 12 and 14 of flexible material, such as PET or Kevlar. Parts 12 and 14 have a suction tube 16 therebetween for drawing fats and other debris by suction into tube 16 for transfer to a remote disposal location. Catheter 16 has one or more suction holes so that suction may be applied to the open end of tube 16 from a suction source (not shown).
[0095] The parts 12 and 14 are connected together by an adhesive which can be of any suitable type. Parts 12 and 14 are doughnut-shaped as shown in FIG. 1 and have tubes 18 and 20 which communicate with and extend away from the parts 12 and 14 , respectively, to a source of inflating liquid under pressure (not shown). The liquid can be any sterile biocompatible solution. The liquid inflates the balloon 10 , particularly parts 12 and 14 thereof after the balloon has been inserted in a collapsed condition ( FIG. 8 ) into a bone to be treated, such as a vertebral bone 22 in FIG. 2 . The above-mentioned U.S. Pat. Nos. 4,969,888 and 5,108,404 disclose the use of a guide pin and cannula for inserting the balloon into bone to be treated when the balloon is deflated and has been inserted into a tube and driven by the catheter into the cortical bone where the balloon is inflated.
[0096] FIG. 8 shows a deflated balloon 10 being inserted through a cannula 26 into bone. The balloon in cannula 26 is deflated and is forced through the cannula by exerting manual force on the catheter 21 which extends into a passage 28 extending into the interior of the bone. The catheter is slightly flexible but is sufficiently rigid to allow the balloon to be forced into the interior of the bone where the balloon is then inflated by directing fluid into tube 88 whose outlet ends are coupled to respective parts 12 and 14 .
[0097] In use, balloon 10 is initially deflated and, after the bone to be filled with the balloon has been prepared to receive the balloon with drilling, the deflated balloon is forced into the bone in a collapsed condition through cannula 26 . The bone is shown in FIG. 2 . The balloon is oriented preferably in the bone such that it allows minimum pressure to be exerted on the bone marrow and/or cancellous bone if there is no fracture or collapse of the bone. Such pressure will compress the bone marrow and/or cancellous bone against the inner wall of the cortical bone, thereby compacting the bone marrow of the bone to be treated and to further enlarge the cavity in which the bone marrow is to be replaced by a biocompatible, flowable bone material.
[0098] The balloon is then inflated to compact the bone marrow and/or cancellous bone in the cavity and, after compaction of the bone marrow and/or cancellous bone, the balloon is deflated and removed from the cavity. While inflation of the balloon and compaction occurs, fats and other debris are sucked out of the space between and around parts 12 and 14 by applying a suction force to catheter tube 16 . Following this, and following the compaction of the bone marrow, the balloon is deflated and pulled out of the cavity by applying a manual pulling force to the catheter tube 21 .
[0099] The second embodiment of the inflatable device of the present invention is broadly denoted by the numeral 60 and is shown in FIGS. 4 and 5 . Balloon 60 includes a central spherical part 62 which is hollow and which receives an inflating liquid under pressure through a tube 64 . The spherical part is provided with a spherical outer surface 66 and has an outer periphery which is surrounded substantially by a ring shaped part 68 having tube segments 70 for inflation of part 68 . A pair of passages 69 interconnect parts 62 and 68 . A suction tube segment 72 draws liquid and debris from the bone cavity being formed by the balloon 60 .
[0100] Provision can be made for a balloon sleeve 71 for balloon 60 and for all balloons disclosed herein. A balloon sleeve 71 ( FIG. 9 ) is shiftably mounted in an outer tube 71 a and can be used to insert the balloon 60 when deflated into a cortical bone. The sleeve 71 has resilient fingers 71 b which bear against the interior of the entrance opening 71 c of the vertebral bone 22 ( FIG. 9A ) to prevent tearing of the balloon. Upon removal of the balloon sleeve, liquid under pressure will be directed into tube 64 which will inflate parts 62 and 68 so as to compact the bone marrow within the cortical bone. Following this, balloon 60 is deflated and removed from the bone cavity.
[0101] FIGS. 6 and 6A show several views of a modified doughnut shape balloon 80 of the type shown in FIGS. 1 and 2 , except the doughnut shapes of balloon 80 are not stitched onto one another. In FIG. 6 , balloon 80 has a pear-shaped outer convex surface 82 which is made up of a first hollow part 84 and a second hollow part 85 . A tube 88 is provided for directing liquid into the two parts along branches 90 and 92 to inflate the parts after the parts have been inserted into the medullary cavity of a bone. A catheter tube 16 is inserted into the space 96 between two parts of the balloon 80 . An adhesive bonds the two parts 84 and 85 together at the interface thereof.
[0102] FIG. 6A shows the way in which the catheter tube 16 is inserted into the space or opening 96 between the two parts of the balloon 80 .
[0103] FIG. 7 shows tube 88 of which, after directing inflating liquid into the balloon 80 , can inject contrast material into the balloon 80 so that x-rays can be taken of the balloon with the inflating material therewithin to determine the proper placement of the balloon. Tube 16 is also shown in FIG. 6 , it being attached in some suitable manner to the outer side wall surface of tube 88 .
[0104] Still another embodiment of the invention is shown in FIG. 3 which is similar to FIG. 1 except that it is round and not a doughnut and includes an inflatable device 109 having three balloon units 110 , 112 and 114 which are inflatable and which have string-like restraints 117 which limit the expansion of the balloon units in a direction transverse to the longitudinal axes of the balloon units. The restraints are made of the same or similar material as that of the balloon so that they have some resilience but substantially no expansion capability.
[0105] A tube system 115 is provided to direct liquid under pressure into balloon units 110 , 112 and 114 so that liquid can be used to inflate the balloon units when placed inside the bone in a deflated state. Following the proper inflation and compaction of the bone marrow, the balloon can be removed by deflating it and pulling it outwardly of the bone being treated. The restraints keep the opposed sides 77 and 79 substantially flat and parallel with each other.
[0106] In FIG. 10 , another embodiment of the inflatable balloon is shown. The device is a kidney shaped balloon body 130 having a pair of opposed kidney shaped side walls 132 which are adapted to be collapsed and to cooperate with a continuous end wall 134 so that the balloon 130 can be forced into a bone 136 shown in FIG. 11 . A tube 138 is used to direct inflating liquid into the balloon to inflate the balloon and cause it to assume the dimensions and location shown vertebral body 136 in FIG. 11 . Device 130 will compress the cancellous bone if there is no fracture or collapse of the cancellous bone. The restraints for this action are due to the side and end walls of the balloon.
[0107] FIG. 12 shows a balloon 140 which is also kidney shaped and has a tube 142 for directing an inflatable liquid into the tube for inflating the balloon. The balloon is initially a single chamber bladder but the bladder can be branded along curved lines or strips 141 to form attachment lines 144 which take the shape of side-by-side compartments 146 which are kidney shaped as shown in FIG. 13 . The branding causes a welding of the two sides of the bladder to occur since the material is standard medical balloon material, which is similar to plastic and can be formed by heat.
[0108] FIG. 14 is a perspective view of a vertebral body 147 containing the balloon of FIG. 12 , showing a double stacked balloon 140 when it is inserted in vertebral bone 147 .
[0109] FIG. 15 is a view similar to FIG. 10 except that tufts 155 , which are string-like restraints, extend between and are connected to the side walls 152 of inflatable device 150 and limit the expansion of the side walls with respect to each other, thus rendering the side walls generally parallel with each other. Tube 88 is used to fill the kidney shaped balloon with an inflating liquid in the manner described above.
[0110] The dimensions for the vertebral body balloon will vary across a broad range. The heights (H, FIG. 11 ) of the vertebral body balloon for both lumbar and thoracic vertebral bodies typically range from 0.5 cm to 3.5 cm. The anterior to posterior (A, FIG. 11 ) vertebral body balloon dimensions for both lumbar and thoracic vertebral bodies range from 0.5 cm to 3.5 cm. The side to side (L, FIG. 11 ) vertebral body dimensions for thoracic vertebral bodies will range from 0.5 cm to 3.5 cm. The side to side vertebral body dimensions for lumbar vertebral bodies will range from 0.5 cm to 5.0 cm.
[0111] The eventual selection of the appropriate balloon for, for instance, a given vertebral body is based upon several factors. The anterior-posterior (A-P) balloon dimension for a given vertebral body is selected from the CT scan or plain film x-ray views of the vertebral body. The A-P dimension is measured from the internal cortical wall of the anterior cortex to the internal cortical wall of the posterior cortex of the vertebral body. In general, the appropriate A-P balloon dimension is 5 to 7 millimeters less than this measurement.
[0112] The appropriate side to side balloon dimensions for a given vertebral body is selected from the CT scan or from a plain film x-ray view of the vertebral body to be treated. The side to side distance is measured from the internal cortical walls of the side of the vertebral bone. In general, the appropriate side to side balloon dimension is 5 to 7 millimeters less than this measurement by the addition of the lumbar vertebral body tends to be much wider than side to side dimension then their A-P dimension. In thoracic vertebral bodies, the side to side dimension and their A-P dimensions are almost equal.
[0113] The height dimensions of the appropriate vertebral body balloon for a given vertebral body is chosen by the CT scan or x-ray views of the vertebral bodies above and below the vertebral body to be treated. The height of the vertebral bodies above and below the vertebral body to be treated are measured and averaged. This average is used to determine the appropriate height dimension of the chosen vertebral body balloon.
Balloons for Long Bones
[0114] Long bones which can be treated with the use of balloons of the present invention include distal radius (larger arm bone at the wrist), proximal tibial plateau (leg bone just below the knee), proximal humerus (upper end of the arm at the shoulder), and proximal femoral head (leg bone in the hip).
Distal Radius Balloon
[0115] For the distal radius, a balloon 160 is shown in the distal radius 152 and the balloon has a shape which approximates a pyramid but more closely can be considered the shape of a humpbacked banana in that it substantially fills the interior of the space of the distal radius to force cancellous bone 154 lightly against the inner surface 156 of cortical bone 158 .
[0116] The balloon 160 has a lower, conical portion 159 which extends downwardly into the hollow space of the distal radius 152 , and this conical portion 159 increases in cross section as a central distal portion 161 is approached. The cross section of the balloon 160 is shown at a central location ( FIG. 17B ) and this location is near the widest location of the balloon. The upper end of the balloon, denoted by the numeral 162 , converges to the catheter 88 for directing a liquid into the balloon for inflating the same to force the cancellous bone against the inner surface of the cortical bone. The shape of the balloon 160 is determined and restrained by tufts formed by string restraints 165 . These restraints are optional and provide additional strength to the balloon body 160 , but are not required to achieve the desired configuration. The balloon is placed into and taken out of the distal radius in the same manner as that described above with respect to the vertebral bone.
[0117] The dimensions of the distal radius balloon vary as follows:
[0118] The proximal end of the balloon (i.e. the part nearest the elbow) is cylindrical in shape and will vary from 0.5.times.0.5 cm to 1.8.times.1.8 cm.
[0119] The length of the distal radius balloon will vary from 1.0 cm to 12.0 cm.
[0120] The widest medial to lateral dimension of the distal radius balloon, which occurs at or near the distal radio-ulnar joint, will measure from 1.0 cm to 2.5 cm.
[0121] The distal anterior-posterior dimension of the distal radius balloon will vary from 0.5 to 3.0 cm.
Proximal Humerus Fracture Balloon
[0122] The selection of the appropriate balloon size to treat a given fracture of the distal radius will depend on the radiological size of the distal radius and the location of the fracture.
[0123] In the case of the proximal humerus 169 , a balloon 166 shown in FIG. 18 is spherical and has a base design. It compacts the cancellous bone 168 in a proximal humerus 169 . A mesh 170 , embedded or laminated and/or winding, may be used to form a neck 172 on the balloon 166 , and second mesh 170 a may be used to conform the bottom of the base 172 a to the shape of the inner cortical wall at the start of the shaft. These restraints provide additional strength to the balloon body, but the configuration can be achieved through molding of the balloon body. This is so that the cancellous bone will be as shown in the compacted region surrounding the balloon 166 as shown in FIG. 18 . The cortical bone 173 is relatively wide at the base 174 and is thin-walled at the upper end 175 . The balloon 166 has a feed tube 177 into which liquid under pressure is forced into the balloon to inflate it to lightly compact the cancellous bone in the proximal humerus. The balloon is inserted into and taken out of the proximal humerus in the same manner as that described above with respect to the vertebral bone.
[0124] The dimensions of the proximal humerus fracture balloon vary as follows:
[0125] The spherical end of the balloon will vary from 1.0.times.1.0 cm to 3.0.times.3.0 cm.
[0126] The neck of the proximal humeral fracture balloon will vary from 0.8.times.0.8 cm to 3.0.times.3.0 cm.
[0127] The width of the base portion or distal portion of the proximal numeral fracture balloon will vary from 0.5.times.0.5 cm to 2.5.times.2.5 cm.
[0128] The length of the balloon will vary from 4.0 cm to 14.0 cm.
[0129] The selection of the appropriate balloon to treat a given proximal humeral fracture depends on the radiologic size of the proximal humerus and the location of the fracture.
Proximal Tibial Plateau Fracture Balloon
[0130] The tibial fracture is shown in FIG. 19A in which a balloon 180 is placed in one side 182 of a tibia 183 . The balloon, when inflated, compacts the cancellous bone in the layer 184 surrounding the balloon 180 . A cross section of the balloon is shown in FIG. 19C wherein the balloon has a pair of opposed sides 185 and 187 which are interconnected by restraints 188 which can be in the form of strings or flexible members of any suitable construction. The main purpose of the restraints is to make the sides 185 and 187 substantially parallel with each other and non-spherical. A tube 190 is coupled to the balloon 180 to direct liquid into and out of the balloon. The ends of the restraints are shown in FIGS. 19B and 19D and denoted by the numeral 191 . The balloon is inserted into and taken out of the tibia in the same manner as that described above with respect to the vertebral bone. FIG. 19B shows a substantially circular configuration for the balloon; whereas, FIG. 19D shows a substantially elliptical version of the balloon.
[0131] The dimensions of the proximal tibial plateau fracture balloon vary as follows:
[0132] The thickness or height of the balloon will vary from 0.5 cm to 5.0 cm.
[0133] The anterior/posterior (front to back) dimension will vary from 1.0 cm to 6.0 cm.
[0134] The side to side (medial to lateral) dimension will vary from 1.0 cm to 6.0 cm.
[0135] The selection of the appropriate balloon to treat a given tibial plateau fracture will depend on the radiological size of the proximal tibial and the location of the fracture.
Femoral Head Balloon
[0136] In the case of the femoral head, a balloon 200 is shown as having been inserted inside the cortical bone 202 of the femoral head which is thin at the outer end 204 of the femur and which can increase in thickness at the lower end 206 of the femur. The cortical bone surrounds the cancellous bone 207 and this bone is compacted by the inflation of balloon 200 . The tube for directing liquid for inflation purposes into the balloon is denoted by the numeral 209 . It extends along the femoral neck and is directed into the femoral head which is generally spherical in configuration. FIG. 20A shows that the balloon, denoted by the numeral 200 a , can be hemispherical as well as spherical, as shown in FIG. 20 . The balloon 200 is inserted into and taken out of the femoral head in the same manner as that described with respect to the vertebral bone. The hemispherical shape is maintained in this example by bonding overlapping portions of the bottom, creating pleats 200 b as shown in FIG. 20A .
[0137] The dimensions of the femoral head balloon vary as follows:
[0138] The diameter of the femoral head balloon will vary from 1.0 cm to up to 4.5 cm. The appropriate size of the femoral head balloon to be chosen depends on the radiological or CT scan size of the head of the femur and the location and size of the avascular necrotic bone. The dimensions of the hemispherical balloon are the same as the those of the spherical balloon, except that approximately one half is provided. | A vertebral body is selected for treatment. The vertebral body has a cortical wall enclosing a cancellous bone volume. The vertebral body has at least one cortical plate that is depressed due to fracture. At least one maximum dimension for the cancellous bone volume is ascertained. An expandable device is provided having an expanded configuration and an unexpanded configuration. The expandable device has a predefined dimension when substantially expanded that is less than the maximum dimension. The expandable device is introduced into the vertebral body through a percutaneous access path while in the unexpanded condition. The expandable device is expanded while disposed within the cancellous bone volume from the unexpanded configuration toward the expanded configuration to move the fractured cortical plate toward a desired anatomic position. | 0 |
CROSS REFERENCE TO RELATED PATENT APPLICATION
The present patent application claims the right of priority under 35 U.S.C. 119 (a)-(d) of German Patent Application No. 100 46 774.1, filed Sep. 21, 2000.
FIELD OF THE INVENTION
The present invention relates to compositions containing matrix polymer, graft polymer and unique additive mixtures. The present invention also relates to the production of molded articles, and molded articles prepared from the compositions of the present invention. The additive mixture is also a subject of the present invention.
BACKGROUND OF THE INVENTION
Acrylonitrile-butadiene-styrene graft copolymer (ABS) molding compositions have already been used for many years in large quantities as thermoplastic resins for the production of all types of molded parts. The property spectrum of these resins typically ranges from relatively brittle to extremely tough.
A special area of use of ABS molding compositions is the production of molded parts by injection molding (e.g., housings, toys and vehicle parts), in which it is an important factor that the polymer material have good flowability. Also, the molded parts produced in this way typically must have a good notched-bar impact strength as well as a good resistance to thermal stresses.
The object therefore exists of achieving, for a given rubber content, a given rubber particle size and given matrix resin molecular weight, toughness values that are as high as possible while retaining the good thermoplastic flowability. In this connection the high toughness values should as far as possible be obtained independently of the type of matrix resin that is employed, and especially when using the styrene/acrylonitrile copolymers and α-methylstyrene/acrylonitrile copolymers typical of ABS.
One possible way of improving the toughness of ABS polymers with a given rubber content, given rubber particle size and given matrix molecular weight is to add special silicone oil compounds (see EP-A 6521). However, disadvantages associated with using silicone oil compounds include poor paintability, unsatisfactory printability or impaired yield stress values (danger of stress whitening). The addition of minor amounts of ethylene/propylene/non-conjugated diene (EPDM) rubber (see EP-A 412 370) or AES polymer (see EP-A 412 371) has also been described. Both methods require the use of considerable amounts of relatively expensive additive components however.
The use of large amounts of individual low molecular weight additive components, may in special cases improve the processability, although this is typically offset by a negative effect on other properties, such as toughness, modulus of elasticity and thermal stability.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a thermoplastic molding composition comprising:
A) 5 to 95 wt. % of a thermoplastic polymer selected from at least one of thermoplastic homopolymers, thermoplastic copolymers and thermoplastic terpolymers, said thermoplastic polymer being prepared from at least one monomer selected from styrene, α-methylstyrene, nuclear-substituted styrene, methyl methacrylate, acrylonitrile, methyacrylonitrile, maleic anhydride and N-substituted maleimide;
B) 5 to 95 wt. % of at least one graft polymer prepared from,
B.1) 5 to 90 parts by weight of at least one monomer selected from styrene, α-methylstyrene, nuclear-substituted styrene, methyl methacrylate, acrylonitrile, methyacrylonitrile, maleic anhydride and N-substituted maleimide, and
B.2) 10 to 95 parts by weight of at least one rubber having a glass transition temperature of ≦10° C.; and
C) 0.05 to 10 parts by weight, based on 100 parts of A+B, of a combination of at least three components selected from components (I), (II), (III) and (IV), wherein
component (I) has at least one structural unit represented by the following formula:
M being a metal, and
n being the valency of the metal M, component (II) has at least one structural unit represented by
and at least one structural unit represented by
component (III) has at least one structural unit represented by the following formula,
and
component (IV) is a compound different from those of components (I), (II) and (III), and is selected from at least one of: paraffin oils; hydrocarbon waxes; polystyrene produced by using C 8 -C 18 alkyl mercaptans as molecular weight regulators, and having a mean weight averaged molecular weight between 2000 and 15,000; styrene/acrylonitrile copolymer produced by using C 8 -C 18 alkyl mercaptans as molecular weight regulators, and having a mean weight averaged molecular weight of between 2000 and 15,000; α-methylstyrene/acrylonitrile copolymer produced by using C 8 -C 18 alkyl mercaptans as molecular weight regulators, and having a mean weight averaged molecular weight of between 2000 and 15,000; and poly(methyl methacrylate) produced by using C 8 -C 18 alkyl mercaptans as molecular weight regulators, and having a mean weight averaged molecular weight of between 2000 and 15,000; C 6 -C 32 alkanols; and C 6 -C 32 alkenols.
In accordance with the present invention, there is further provided an additive composition which comprises at least three components selected from compounds (I), (II), (III) and (IV).
Other than in the operating examples, or where otherwise indicated, all numbers expressing quantities of ingredients, reaction conditions, etc. used in the specification and claims are to be under stood as modified in all instance by the term “about.”
DETAILED DESCRIPTION OF THE INVENTION
Preferably each of the components (I) to (IV) contains at least one terminal aliphatic C 6 -C 32 hydrocarbon radical.
According to the invention suitable examples of thermoplastic polymers A) include those prepared from monomers selected from styrene, α-methylstyrene, p-methylstyrene, vinyltoluene, halogenated styrene, methyl acrylate, methyl methacrylate, acrylonitrile, maleic anhydride, N-substituted maleimide and mixtures thereof.
The polymers A) are resin-like, thermoplastic and rubber-free. Particularly preferred thermoplastic polymers A) include those prepared from the polymerization of: styrene; methyl methacrylate; styrene/acrylonitrile mixtures; styrene/acrylonitrile/methyl methacrylate mixtures; styrene/methyl methacrylate mixtures; acrylonitrile/methyl methacrylate mixtures; α-methylstyrene/acrylonitrile mixtures; styrene/α-methylstyrene/acrylonitrile mixtures; α-methylstyrene/methyl methacrylate/acrylonitrile mixtures; styrene/α-methylstyrene/methyl methacrylate mixtures; styrene/α-methylstyrene/methyl methacrylate/acrylonitrile mixtures; styrene/maleic anhydride mixtures; methyl methacrylate/maleic anhydride mixtures; styrene/methyl methacrylate/maleic anhydride mixtures; and styrene/acrylonitrile/N-phenylmaleimide mixtures.
Polymers from which thermoplastic polymer A) may be selected are known and can be produced by free-radical polymerisation, in particular by emulsion, suspension, solution or bulk polymerisation. The polymers preferably have mean weight averaged molecular weights ({overscore (M)} w ) of 20,000 to 200,000 and intrinsic viscosities (η) of 20 to 110 ml/g (measured in dimethylformamide at 25° C.).
Suitable rubbers B.2) (also referred to herein as “graft bases”) for the production of the graft polymers B) include, for example, polybutadiene, butadiene/styrene copolymers, butadiene/acrylonitrile copolymers, polyisoprene or alkyl acrylate rubbers based on C 1 -C 8 alkyl acrylates, in particular ethyl acrylate, butyl acrylate and ethylhexyl acrylate.
The acrylate rubbers, from which rubber B.2) may be selected, may optionally contain up to 30 wt. % (referred to the rubber weight) of monomers such as vinyl acetate, acrylonitrile, styrene, methyl methacrylate and/or vinyl ether incorporated by copolymerisation. The acrylate rubbers may also contain small amounts, preferably up to 5 wt. % (referred to the weight of rubber) of crosslinking, ethylenically unsaturated monomers incorporated by polymerisation. Crosslinking agents include, for example, alkylene diol diacrylates and methacrylates, polyester diacrylates and methacrylates, divinyl benzene, trivinyl benzene, triallyl cyanurate, allyl acrylate and methacrylate, butadiene and isoprene. Graft bases may also include acrylate rubbers having a core/shell structure, with a core of crosslinked diene rubber of one or more conjugated dienes such as polybutadiene, or a copolymer of a conjugated diene with an ethylenically unsaturated monomer such as styrene and/or acrylonitrile.
Further suitable rubbers B.2) include, for example, the so-called EPDM rubbers (polymers of ethylene, propylene and a non-conjugated diene such as for example dicyclopentadiene), EPM rubbers (ethylene/propylene rubbers) and silicone rubbers that may optionally have a core/shell structure.
Preferred rubbers B.2) for the production of the graft polymers B) include diene rubbers and alkyl acrylate rubbers as well as EPDM rubbers.
The rubbers in the graft polymer B) are present in the form of at least partially crosslinked particles having a mean particle diameter (d 50 ) of 0.05 to 20 μm, preferably 0.1 to 2 μm and particularly preferably 0.1 to 0.8 μm. The mean particle diameter d 50 is determined by ultracentrifuge measurements according to W. Scholtan et al., Kolloid-Z. u.Z. Polymere 250 (1972), 782-796, or by evaluating electron microscope images.
The polymers B) may be produced by free-radical graft polymerisation of the monomers B.1) in the presence of the rubbers B.2), to which the monomers are grafted.
Preferred processes for producing the graft polymers B) include art-recognized methods, such as emulsion, solution, bulk or suspension polymerisation and combinations of these processes. Particularly preferred graft polymers B) are ABS polymers.
Most particularly preferred polymers B) are products that have been obtained by free-radical polymerisation of mixtures of styrene and acrylonitrile, preferably in a weight ratio of 10:1 to 1:1, particularly preferably in a weight ratio of 5:1 to 2:1, in the presence of at least one rubber built up predominantly from diene monomers (preferably polybutadiene that may contain up to 30 wt. % of styrene and/or acrylonitrile incorporated as comonomers) and having a mean particle diameter (d 50 ) of 100 to 450 nm. In a preferred embodiment of the present invention, monomers B.1) are polymerized in the presence of two rubbers built up predominantly from diene monomers (preferably polybutadiene that may contain up to 30 wt. % of styrene and/or acrylonitrile incorporated as comonomers). In a further embodiment of the present invention, a mixture of two rubbers a) and b) are used, and have: a) a mean particle diameter (d 50 ) of 150 to 300 nm; and b) a mean particle diameter (d 50 ) of 350 to 450 nm. The rubbers a) and b) are typically used in a weight ratio (a):(b)=10:90 to 90:10, and preferably 30:70 to 60:40.
The rubber content of the polymers B) is preferably 40 to 95 wt. %, particularly preferably 50 to 90 wt. %, and most particularly preferably 55 to 85 wt. %, based on the total weight of graft polymer B).
Examples of compounds from which components (I), (II), (III) and (IV) of additive mixture C) may each be selected are described as follows.
Compounds from which component (I) may be selected include, but are not limited to, magnesium stearate, calcium stearate, zinc stearate, magnesium montanate, calcium montanate, zinc montanate, magnesium behenate, calcium behenate, zinc behenate, magnesium oleate, calcium oleate, zinc oleate and mixtures thereof. Magnesium stearate and/or calcium stearate are preferred, with magnesium stearate being particularly preferred.
Component (II) may be selected from: esters of β-thiodipropionic acid, such as, lauryl, stearyl, myristyl or tridecyl esters of β-thiodipropionic acid; pentaerythritol-tetrakis-(β-dodecylmercapto)-propionate; and compounds represented by the following formula (V),:
in which
R, R 1 and R 2 independently of one another denote C 1 -C 20 alkyl, phenyl radicals that may be substituted by one or two C 1 -C 8 alkyl groups, C 7 -C 12 aralkyl radicals, or C 5 -C 12 cycolalkyl radicals,
R 3 denotes H or C 1 -C 4 alkyl.
Compounds represented by formula (V) can be produced in accordance with the procedure disclosed in EP-A 64 020.
Component (II) is preferably selected from esters of β-thiodipropionic acid. Particularly preferred esters of β-thiodipropionic acid include lauryl esters of β-thiodiopropionic acid, stearyl esters of β-thiodiopropionic acid and mixtures thereof.
Component (III) may be selected from at least one of ethylenediamine bisstearyl amide, erucic acid amide, oleic acid amide, stearic acid amide, behenic acid amide and montanic acid amide. Component (III) is preferably selected from ethylenediamine bisstearyl amide and/or erucic acid amide, of which ethylenediamine bisstearyl amide is particularly preferred.
Component (IV) may be selected from at least one of: paraffin oils; hydrocarbon waxes; low molecular weight polystyrene produced by using C 8 -C 18 alkyl mercaptans as molecular weight regulators with mean weight averaged molecular weights ({overscore (M)} w ) between 2,000 and 15,000, preferably between 2,500 and 12,000 and particularly preferably between 3,000 and 10,000; low molecular weight styrene/acrylonitrile copolymer produced by using C 8 -C 18 alkyl mercaptans as molecular weight regulators with {overscore (M)} w values between 2,000 and 15,000, preferably between 2,500 and 12,000 and particularly preferably between 3,000 and 10,000; low molecular weight α-methylstyrene/acrylonitrile copolymer produced by using C 8 -C 18 alkyl mercaptans as molecular weight regulators with {overscore (M)} w values between 2,000 and 15,000, preferably between 2,500 and 12,000 and particularly preferably between 3,000 and 10,000; low molecular weight poly(methyl methacrylate) produced by using C 8 -C 18 alkyl mercaptans as molecular weight regulators with {overscore (M)} w values between 2,000 and 15,000, preferably between 2,500 and 12,000 and particularly preferably between 3,000 and 10,000; C 6 -C 32 alkanols, e.g. stearyl alcohol; and C 6 -C 32 alkenols, e.g. oleyl alcohol.
Preferred materials from which component (IV) may be selected include: paraffin oils, low molecular weight styrene/acrylonitrile copolymers and α-methylstyrene/acrylonitrile copolymers (of which paraffin oils and/or low molecular weight styrene/acrylonitrile copolymers are particularly preferred).
Preferably all the components (I), (II), (III), and (IV) have a molecular weight above 300, preferably above 400 and particularly preferably above 500.
The quantitative ratios of at least three components selected from the components (I), (II), (III), and (IV) may be varied within wide ranges. The weight ratios are selected so that the following relationship is observed (as represented by the following formulas):
(I) ≦ (IV) ≦ (II) ≦ (III)
particularly preferred
(I) ≦ (IV) ≦ (II) < (III) and
most particularly preferred
(I) < (IV) ≦ (II) < (III).
Alternatively, the weight ratios of components (I), (II), (III), and (IV) may be selected so that the following relationship is observed (as represented by the following formulas):
(I) ≦ (IV) ≦ (III) ≦ (II)
particularly preferred
(I) ≦ (IV) < (III) ≦ (II) and
most particularly preferred
(I) < (IV) < (III) ≦ (II)
In a preferred embodiment of the present invention, the thermoplastic polymer A) is present in the molding composition in an amount of 35 to 85 wt. %. The thermoplastic polymer is preferably a copolymer prepared from: 5 to 40 parts by weight of acrylonitrile; and 95 to 60 parts by weight of styrene, α-methylstyrene, N-phenylmaleimide or mixtures thereof.
The thermoplastic compositions of the present invention, preferably contain graft polymer B) in an amount of 15 to 65 wt. %. Graft polymer B) is preferably prepared from: 25 to 60 parts by weight of styrene, α-methylstyrene, acrylonitrile, N-phenylmaleimide or mixtures thereof; and 75 to 40 parts by weight of polybutadiene.
Component mixture C) is preferably present in the thermoplastic molding composition of the present invention in an amount of 0.5 to 5 parts by weight per 100 parts by weight of A+B. Preferred components (I), (II), (III) and (IV) are described as follows.
component (I)
magnesium stearate;
component (II)
β,β′-thiodipropionic acid dilauryl ester or β,β′-
thiodipropionic acid distearyl ester;
component (III)
ethylenediamine bisstearyl amide; and
component (IV)
paraffin oil or low molecular weight
styrene/acrylonitrile copolymer.
The thermoplastic molding compositings of the present invention containing A), B), C) and optionally conventional additives such as processing aids, stabilisers, pigments, antistatics and fillers are prepared by mixing the respective constituents in an art-recognized manner simultaneously or successively at room temperature or at elevated temperature. The resultant mixtures are subsequently melt-compounded or melt-extruded at temperatures of 150° C. to 300° C. in conventional equipment such as internal mixers, extruders or double-shaft screw extruders.
The molding compositions of the present invention may be used to produce molded articles of all types. Art-recognized production procedures, such as injection molding, are typically used to prepare molded articles from the thermoplastic molding compositions of the present invention.
Sheets or films may be fabricated from the thermoplastic molding compositions of the present invention, and these sheets or films may be further processed by means of thermoforming techniques that are known to the skilled artisan.
The present invention further provides for the production of the compositions according to the invention, as well as molded articles produced therefrom. The invention also covers the additive combination C).
The present invention is more particularly described in the following examples, which are intended to be illustrative only, since numerous modifications and variations therein will be apparent to those skilled in the art. Unless otherwise specified, all parts and percentages are by weight.
EXAMPLES
Thermoplastic Resin A1
A statistical styrene/acrylonitrile (72:28) copolymer with a {overscore (M)} w of ca. 115,000 determined by GPC (gel permeation chromatography).
Thermoplastic Resin A2
A statistical α-methylstyrene/acrylonitrile (72:28) copolymer with a {overscore (M)} w of ca. 75,000 determined by GPC.
Graft Polymer B1
Graft product obtained by emulsion polymerisation of 42 wt. % of a styrene/acrylonitrile mixture (weight ratio 73:27) on 58 wt. % of a 1:1 mixture (weight ratio) of two particulate polybutadienes with a) a mean particle diameter (d 50 ) of 290 nm and b) a mean particle diameter (d 50 ) of 420 nm. The product is worked up by coagulating the latex with magnesium sulfate, washing with water, followed by drying in vacuo. particle diameter (d 50 ) of 290 nm and b) a mean particle diameter (d 50 ) of 420 nm. The product is worked up by coagulating the latex with magnesium sulfate, washing with water, followed by drying in vacuo.
Graft Polymer B2
Graft product obtained by emulsion polymerisation of 50 wt. % of a styrene/acrylonitrile mixture (weight ratio 73:27) on 50 wt. % of particulate polybutadiene with a mean particle diameter (d 50 ) of 130 nm. The product is worked up as under B1.
Additives C(I)-C(IV)
Additive CI1: magnesium stearate (Bärlocher, Munich, Germany)
Additive CI2: calcium stearate (Bärlocher, Munich, Germany)
Additive CII1: β,β′-thiodipropionic acid dilauryl ester (Irganox PS800®, Ciba Speciality, Basle, Switzerland
Additive CII2: β,β′-thiodipropionic acid distearyl ester (Irganox PS802®, Ciba Speciality, Basle, Switzerland
Additive CIII1: ethylenediamine bisstearyl amide (Henkel KG, Düsseldorf, Germany)
Additive CIV1: low molecular weight styrene/acrylonitrile copolymer ({overscore (M)} w ≈4,200, determined by GPC) produced by free-radical emulsion polymerisation of a mixture of 63.9 parts by weight of styrene, 23.6 parts by weight of acrylonitrile and 12.5 parts by weight of tert.-dodecyl mercaptan.
The individual components are compounded in the weight proportions specified in Table 1 in a 1.3 l capacity internal mixer at temperatures of 160° C. to 200° C. The molded articles are produced in an injection molding machine at 240° C.
The notched-bar impact strength is measured at room temperature (a k RT ) and at −30° C. (a k −30° C. ) according to ISO 180/1A (unit:kJ/m 2 ), and the thermoplastic flowability is evaluated by measuring the melt flow index (MVR) according to DIN 53 735 U (unit:cm 3 /10 min). As can also be seen from Table 1, only by using the mixtures according to the invention can a very good combination of high toughness even at low temperatures and good processability be obtained.
TABLE 1
Compositions and Test Data of the Molding Compositions
A1
A2
B1
B2
CI1
CI2
CII1
CII2
CIII1
CIV1
MVR
Example
Parts by
Parts by
Parts by
Parts by
Parts by
Parts by
Parts by
Parts by
Parts by
Parts by
a k RT
a k −30° C.
(cm 3 /10
No.
weight
weight
weight
weight
weight
weight
weight
weight
weight
weight
(kJ/m 2 )
(kJ/m 2 )
min)
1
70
—
30
—
—
—
2
—
1
0.5
19.2
17.0
11.2
2
70
—
30
—
—
—
—
2
1
0.5
19.2
16.8
11.0
3
70
—
30
—
0.5
—
2
—
—
0.5
18.8
16.7
10.7
4
70
—
30
—
—
—
1
—
2
0.5
18.8
16.8
11.4
5 (comp.)
70
—
30
—
—
—
2
—
—
0.5
14.8
8.3
9.2
6 (comp.)
70
—
30
—
—
—
—
2
—
—
14.9
8.5
8.5
7
—
75
12.5
12.5
0.5
—
2
—
1
0.5
16.8
8.8
7.0
8
—
75
12.5
12.5
—
0.5
2
—
1
0.5
16.9
8.4
6.2
9
—
75
12.5
12.5
—
—
—
2
1
0.5
17.9
10.2
5.3
10
—
75
12.5
12.5
0.5
—
—
2
1
0.5
18.0
9.4
5.7
11 (comp.)
—
75
12.5
12.5
—
—
2
—
—
0.5
10.2
7.8
5.6
12 (comp.)
—
75
12.5
12.5
—
—
2
—
—
—
10.6
8.5
5.0
13 (comp.)
—
75
12.5
12.5
—
—
—
—
—
—
10.3
6.8
4.9
14 (comp.)
—
75
12.5
12.5
—
—
—
—
—
0.5
6.7
n.b.
4.9
15 (comp.)
—
75
12.5
12.5
—
—
—
—
1
0.5
12.1
6.7
5.8
16 (comp.)
—
75
12.5
12.5
0.5
—
—
—
—
0.5
10.9
6.3
4.5
17 (comp.)
—
75
12.5
12.5
—
1
—
11.9
7.1
5.3
18 (comp.)
—
75
12.5
12.5
0.5
—
—
—
—
—
11.5
6.9
4.1
n.b. = not measured
Although the invention has been described in detail in the foregoing for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims. | A thermoplastic molding composition comprising A) a thermopolastic polymer, e.g., a copolymer of styrene and acyrlonitrile, B) a graft copolymer, e.g., a graft copolymer of styrene, acrylonitrile and polybutadiene, and C) an additive mixture is described. The additive mixture C) comprises a combination of at least three components selected from components (I), (II), (III) and (IV). Component (I) contains carboxylic acid metal salt groups, e.g., magnesium stearate. Component (II) contains both carboxylic acid ester linkages and thio linkages, e.g., esters of β-thiodipropionic acid with monhydric alcohols. Component (III) contains amide linkages, e.g., ethylenediamine bisstearyl amide. Component (IV) is a compound that is different than components (I)-(III), e.g., a low molecular weight styrene/acrylonitrile copolymer. Also described are molded articles prepared from the thermoplastic molding composition of the present invention. | 2 |
This application is a continuation of application Ser. No. 07/299,137, filed Jan. 23, 1989, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to lightning protection systems for aircraft and, more particularly, is concerned with lightning shields that can be conformed and bonded to the various compound geometric surfaces found on composite material aircraft.
2. Description of the Prior Art
Composite materials, such as carbon fiber/resin products, are increasingly being used in the aircraft industry to take advantage of their relatively high strength/weight ratio. It can be expected that increasing marketplace pressures for larger payloads and greater fuel economy will continue to encourage the use of composites. However, and not unexpectedly, these non-metallic materials also present several design problems that are new to the industry, among which is a vulnerability to lightning damage. The previous all metal skin provided an excellent conductive surface, which is now replaced, in whole or in part, with a resistive material. Composite aircraft exterior surfaces, or skins, perform poorly when exposed to lightning. Thus, composite surfaces must be shielded against the harmful effects of lightning strikes.
Lightning is a violent, discontinuous discharge of electrical current in the air, most often found inside or around cumulonimbus (thunderstorm) clouds. An aircraft flying in the vicinity of thunderstorms is susceptible to "participating" in the path of a lightning discharge. Recent experimental results ("Aircraft Jolts From Lightning Bolts", IEEE Spectrum, July, 1988, pp. 34-38) indicate, however, that aircraft actually initiate lightning more often than they intercept it. In the majority of aircraft strikes, as the airplane flies into a strong electric field, leaders of opposite charge form at the extremities of the aircraft such as at the nose, tail, and/or wing tips.
Air is a very poor conductor of electricity, and these leaders mark the nascent stage of a lightning strike, as the surrounding air begins to electrically "break down," forming the more conductive ionization channels. The leaders continue to develop bi-directionally and three-dimensionally around the airplane. This process continues at a rate determined by such factors as the ambient electric field strength and the particular characteristics of the electrical "circuit" including the capacitances and conductivities of the aircraft and the leader channels. Given a sufficiently strong field, a lightning discharge will occur down a specific leader pathway or channel of ionized air. This lightning channel may persist for more than a second after the airplane surface has become a "part" of the channel, with this conductive pathway remaining relatively stationary while the airplane continues its forward motion. Such relative movement causes the forward attachment point to "sweep back" over the airplane's surface, (the so-called "swept-stroke" phenomenon), resulting in an increased potential vulnerability for additional aircraft surfaces besides the leading edges and other curved surfaces that have a greater initial electric potential. New lightning attachment points can occur at any location on the aircraft surface, and adequate lightning protection requires a continuous protective shielding for composite materials over the entire aircraft surface.
Metallic aircraft encountering lightning will conduct the electric current of a strike across the skin of the aircraft, in most cases suffering little resultant damage. On the other hand, composite materials like graphite epoxy resins, are resistive conductors that inhibit current conductance. By way of comparison, a graphite composite will absorb nearly 2,000 times the energy absorbed by the same mass of aluminum. It has been shown that the intense current density of a lightning strike, frequently approaching 200,000 amperes in one second, with rates of current change observed to 380,000 amperes per microsecond, can vaporize or "puncture" the thin composite laminates that make up the skin of the aircraft. Once such penetration occurs further damage can be done as the lightning pathway "intrudes" on the avionics, power supply circuitry or other critical systems, and actual physical damage may result as this current surge runs amok inside of the aircraft. Electromagnetic energy may also enter the aircraft through other types of apertures. In addition to holes created suddenly by lightning attachment to nonconducting aircraft skins, other apertures include seams where skin panels meet and repaired locations on skin sections that have been previously damaged. Because present techniques for seam filling and body hole patching utilize a nonconductive body putty, an electromagnetic "aperture" remains after such body putty is applied. Other electromagnetic apertures include exposed conductors, such as antennas.
Electromagnetic fields that enter the aircraft can wreak havoc with on board avionics. This problem is further aggravated by the increasing use of digital designs in modern avionics to control critical flight functions besides their traditional navigation and communication tasks. It is well known that digital circuits, as compared to analog circuits, have little tolerance for electrical disturbances. A chief goal of modern aircraft designers must be to ensure that electromagnetic fields are not permitted to breach the aircraft skin, where they may disrupt avionics, damage structural components, and perhaps injure passengers or crew.
In response to these design requirements, a number of different shielding structures have been proposed for use with the new composite materials. These solutions generally require embedding a metallic substance into the composite skin. After the composite surface has been so shielded, conductivity is improved and the high density lightning currents are harmlessly dissipated over the surface of the aircraft. Three principal techniques have been shown to reduce the hazards associated with lightning, and each has met with varying degrees of success, with each presenting its own unique drawback to the aircraft designer.
In the first technique, composite fibers and aluminum or copper wires are interwoven into a fabric-like mesh. These shielding meshes perform well but they add a great deal of excess weight to the aircraft, typically around 0.08 lb./sq.ft. (see Table 1). To place this in the context of a typical commercial airliner, such as a Boeing 767, having a surface area of approximately 15,000 sq. ft., this interwoven mesh will add 1,200 lbs. to the aircraft weight. The additional load resulting from using this type of shielding forces the aircraft designer to incorporate more powerful engines into his design. The larger engines carrying more weight will naturally burn more fuel.
A second technique is to employ a flame spray of metal, usually aluminum, which is applied to the exterior surfaces of the aircraft. Application thickness may vary between four and six mils. Although halving the weight of the first technique, the lack of uniformity in thickness of this technique may create thin spots on the aircraft skin that are prone to damage.
Aluminized fiberglass, the third technique, is a fabric composed of fiberglass yarns, the outside of which is coated with aluminum metal. The fabric is then bonded to the composite skin of an aircraft with adhesives. The interposition of fiberglass between the aluminum and the graphite epoxy prevents galvanic corrosion that would normally otherwise occur upon the joining of these two dissimilar materials. Nearly as heavy as the flame sprayed metallic coating, the thickness of the fabric poses a major drawback. This material is inflexible and is therefore difficult to apply to compound geometries such as fairings, struts, radomes, wing edges and like complex aerodynamic contours.
Consequently, a need exists for improvements in aircraft lightning shields that will be lighter in weight, of uniform thickness, and that will provide sufficient flexibility, such that the material can be easily applied to and around the compound geometries and apertures commonly found on the exterior surfaces of aircraft.
SUMMARY OF THE INVENTION
The present invention provides a conformal lightning shield device, and method for its production, designed to satisfy the aforementioned needs. The shield is one order of magnitude lighter in weight, 0.007 lb./sq.ft. for one mil aluminum foil), than any of the previously described techniques and, in addition, the present shield may be made to easily conform to the most complex of geometric surfaces. Besides acting as an outer conductive shield for lightning strikes, this invention also provides an effective avionics shield against external electromagnetic interference (EMI) and radio frequency interference (RFI). Furthermore, the subject invention provides an added benefit when used in conjunction with an aircraft skin filler. Substituting for bulkier materials such as Delker screen, the shield can be applied between overlapping contoured sheets or it can be used in conjunction with composite panels to repair damaged surface sections.
The conformal lightning shield is a thin metallic foil, such as aluminum, which has uniformly spaced polygonal apertures cut throughout its body. The shield is manufactured by first applying photolithographic techniques to harden the foil in all places except where the apertures are cut, and then etching and stripping the foil in solvent baths. The foil can optionally be electroplated with a material like nickel, which intercedes between two galvanically dissimilar materials, such as aluminum and graphite epoxy. In use, the subject invention is adhesively bonded to composite material aircraft surfaces. When bonded to composite surfaces, the adhesive completely fills the shield apertures, leaving the aircraft surface extremely smooth.
The subject invention may also be fashioned from copper and applied to composite material antenna support structures. Since copper is a better conductor than aluminum it provides improved performance in the reception of electromagnetic frequencies. Copper also has a higher boiling point than aluminum. Thus, an antenna made from copper permits antenna leads to be soldered to it. Use of the copper foil embodiment about the antenna support both protects the support against lightning damage and enhances the antenna performance.
Various other objects, advantages, and features of the present invention will become readily apparent from the ensuing detailed description, and the novel features will be particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view of an aircraft being struck by lightning.
FIG. 2 is a perspective view of a turbine jet engine and fairing assembly.
FIG. 3a is a fragmentary plan view of an elongated hexagonal aperture embodiment of the present invention.
FIG. 3b is a perspective view of the embodiment shown in FIG. 3a.
FIG. 3c is a cross-sectional view of the embodiment shown in FIG. 3a, taken along line 3c--3c.
FIG. 4 is a perspective view of an elongated hexagonal aperture embodiment of the present invention after it has been stretched over a contoured surface.
FIG. 5a is a plan view of an elongated hexagonal aperture embodiment of the present invention showing the change in aperture size and shape associated with varying degrees of deformation as is required by the surface shown in FIG. 2.
FIG. 5b is a cross-sectional view of the embodiment shown in FIG. 5a, taken along line 5b-5b.
FIG. 6 is a perspective view of a strut to wing fairing with an aircraft wing shown in phantom.
FIG. 7a is a cross-section of FIG. 7b taken along line 7a--7a.
FIG. 7b is a perspective view of a sheet of the present invention having wrinkles removed with a roller.
FIG. 8 is a fragmentary plan view of the plastic photographic artwork mask used to image the elongated hexagonal aperture embodiment of the present invention.
FIG. 9 is a cross-sectional view of the plastic photographic artwork mask and dryfilm coated metallic foil as it is laid on the glass surface of a light box.
FIG. 10 is a perspective view with portions broken away showing a light box used to photolithographically apply the uniformly spaced aperture image to the dryfilm coating the surface of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, and more particularly to FIG. 1, a jet powered aircraft 102 is shown while experiencing a lightning strike, (as conventionally depicted). The strike in fact, consists of an entry channel 104, shown forming an initial attachment point 108 on a turbine jet engine 110, and an exit channel 106, shown forming a trailing attachment point 112 on the tip of an empennage 114. Ideally, on aircraft having a continuous metallic surface or skin, the lightning current will be harmlessly dissipated at the points of attachment 108, 112 and conducted therebetween, across the surface of the aircraft. However, if the aircraft 102 is made out of a composite carbon/resin material, the current densities at the attachment points 108, 112 would far exceed the limits of the material, resulting in an explosive destruction and penetration of the aircraft skin (not shown). Thereafter, the precise path of the lightning current between the attachment points can not be predicted, and depends upon the lowest resistive path existing at that precise moment. More than likely, such a path would include power supply and avionics circuitry, causing disastrous results.
The aircraft 102 shown in FIG. 1 presents many contours that are difficult to wrap with metallic coverings. A typical "hard" surface to cover is a contour that exhibits a compound geometry. The present invention will not only cover simple geometric surfaces, but also these other "hard" contours. Examples of such compound geometries can be found in a turbine jet engine and fairing assembly 116 shown in FIG. 2. One exemplary compound geometry is an aft/forward fairing 118 which abuts an upper strut fairing 120. The aft/forward fairing 118 exhibits an approximate conic curvature about an axis tangent to the upper longitudinal surface of the turbine jet engine 110, with the radius of the cone narrowing towards the front of the engine, forming a fairing vertex 122. The surface of the aft/forward fairing 118, has a second degree of curvature, with a radius of curvature that extends perpendicularly from the surface of the aft/forward fairing 118 to the approximate center of the turbine jet engine 110. The geometry of the aft/forward fairing 118 thus consists of the conical and curvilinear geometries and is classified as compound.
In FIG. 3a, a conformal lightning shield 128 in accordance with the present invention is depicted in its sheet form state, prior to any deformation. Formed of a one mil thick (0.03 mm) of a metal foil, such as aluminum or copper, the lightning shield 128 is provided with a plurality of uniformly spaced, elongated apertures 130 formed therein. Although FIG. 3a depicts hexagonal apertures, the present invention is not to be viewed as being so limited. Other polygonal shapes may be selected, as may circles. However, at present, hexagonal apertures are a preferred shape. FIGS. 3b and 3c provide an illustration of the relative dimensions between the apertures 130 and the thickness of the metal foil used in forming the conformal shield 128.
FIG. 4 shows a fragment of the shield 128 that has been deformed to fit over a compound contour, such as the aft/forward fairing 118 shown in FIG. 2. The elongated hexagonal apertures 130 are most elastic if the material is stretched in the direction perpendicular to the axis of elongation for the hexagons. Thus, opposing polygon segments, a first set of perimeter segments 134a and a set of second perimeter segments 134b, stretch away from each other, forming an oblique angle when the shield 128 is made taught. This transformation or linear axis of expansion can best be understood by comparing the pre-deformed shape of the set of first and second perimeter segments 134a, 134b with a third and fourth set of perimeter segments 136a, 136b, which are also shown in FIG. 5a.
For compound geometries, i.e., those surface exhibiting multiple radii of curvature, the shield 128 should be aligned such that the line of greatest elasticity is made parallel to the direction of greatest curvature. For example, in FIG. 2, the greatest curvature of the compound geometry formed by the aft/forward fairing 118 is about the conic axis, extending back from the fairing vertex 122. It is now evident why circular and triangular shapes are less desirable shapes for the apertures 130. Both shapes are equally strong in all directions, making it more difficult to have the shield 128 conform to the shape of compound aircraft surfaces. It is believed that diamond-shaped apertures (not shown) may provide a suitable compromise between hexagons and these other, less elastic shapes, by providing a degree of flexibility in both perpendicular directions.
In FIG. 5a, the shield 128 exhibits further deformation at one end to show the various degrees of stretching required to "fit" a surface having a rapid degree of angular change, such as conic curvature found in the aft/forward fairing 118 (FIG. 2). FIG. 5a clearly shows how the pair of first and second hexagon perimeter segments 134a, 134b deform to allow conformal stretching of the shield 128. Upon deformation, the previously acute angles formed by the various segments open to become more oblique, with the degree of deformation induced in the shield closely matched to the topography of the particular aircraft surface being covered.
As is shown is FIG. 5(b), after being deformed to closely mate with the aircraft surface, the lightning shield 128 is bonded to the surface. Preferably, such bonding occurs using a compatible structural epoxy or adhesive, such as Magna Bond #6371, manufactured by Magnolia Plastics, Inc., of Chamblee, Ga. Upon application to a cured composite surface 141 having a lightning shield 128 conformed thereto, the bonding agent forms a bonding layer 144 that receives the lightning shield and fills the shield apertures 130. To assure an absolutely flat or matching surface between the shield 128 and the composite surface 141, it is preferred that the bonding layer 144 and the shield 128 be vacuum bagged. This process consists of placing the sandwiched structure to be bonded in a properly sealed vacuum bag enclosure. Then the air is evacuated to eliminate all entrapped air bubbles and create a pressure on the bag and sandwich structure, thus promoting complete material bonding.
A second example of a compound geometry, to which the shield 128 can be applied, is the strut-to-wing fairing 148, which mounts the turbine jet engine and fairing assembly 116 to a wing 150, (shown in phantom in FIG. 6). This assembly is designed to complete the aerodynamic attachment of the jet engine to the aircraft wing. A bridge pan 153 is provided with a curved back lip 156, forming a transition between the upper surface of the jet engine and the curved leading edge of the wing 150. The bridge pan 153 is also provided with a pair of lateral sides 159, 160, which curve downwardly to correspond to the downwardly curving jet engine circumference. At the lateral edges of the back lip, the lateral sides 159, 160 and the bridge pan 153 meet to form a compound geometry of these two curves.
To fabricate the preferred embodiment of the conformal lightning shield in accordance with the present invention, a materials assembly framework 200, (FIG. 7), is assembled to smooth the metal foil. First a sheet of metal foil 202 (FIG. 7a), such as aluminum foil having a thickness of 0.001 inches (0.03 mm) is cut into a sheetform sized to fit the framing assembly 200, for example 24 in. by 26 in. (61 cm by 66 cm). The condition of the foil surface is of critical important for the photolithographic processes to follow; hands must be scrubbed and the working area made free of debris, dust, and grease. Wrinkles can be minimized by eliminating air currents from the working area. A thick base slab 204, such as 0.050 inch-thick aluminum sheet, slightly larger than the foil sheet, e.g., 25 inch×30 inch (63 cm by 76 cm), is then prepared and made free of nicks, scratches, and grease.
As a holding agent for the metal foil 202, a first layer of water 206 is sprayed on the most highly finished, i.e., smoothest side of the base slab 204. The metal foil 202 is then applied to the surface of the water coated base slab 204 and a second layer of water 208 is sprayed on top of the metal foil 202. On the top of this layering is placed a mylar sheet 210, preferably of 0.005 inch (0.13 mm) thickness.
As the next step, a soft rubber print roller 212 is used to further smooth the metal foil 202, now received by the materials assembly framework 200, as shown in Figure 7b. A sharp rubber squeegee (not shown), (e.g., grade 70 rubber), may then be drawn across the mylar sheet 210 until a mirror smooth surface is formed on the metal foil 202. The clear mylar sheet 210 is next removed and any excess water from the first and second layers of water 206, 208 is absorbed with paper towels (not shown). At this point, the surface may be sprayed with alcohol to speed up the drying process and to keep the surface clean.
The metal foil 202 is now ready to have a photosensitive dryfilm laminated on its surface. Prior to lamination, all static is eliminated by brushing the surface twice with a neutral brush. A Dynachem Model 300 laminator, for example, (not shown), using air pressure, may be used to laminate the metal foil 202. If this machine is used, the following operating parameters are recommended: 250 degrees Fahrenheit (121 ° C.) temperature, 30 PSI air pressure, 2-3, per minute speed, using G.S.I. or L.D. dryfilm type supplied by Dynachem. After the dryfilm has been laminated on a first side, the laminated surface should be placed in the framework assembly face down, and the original backside (side 2) should now be layered, smoothed, and then laminated, using the same procedures shown in FIGS. 7a and 7b, and as described above.
The dryfilm coated metal foil is now ready for photoprinting. In a conventional manner, a plastic photographic artwork mask 214, a corner fragment of which is shown in FIG. 8, having a transparent portion 216 and a plurality of opaque portions 218, is placed over the metal foil 202. The opaque portions 218 of the plastic mask 214 correspond to the apertures 124 in the lightning shield 128. The plastic mask 214 has more crisply defined vertices than do the somewhat ragged vertices of the finished lightning shield 128. The loss of definition in the finished lightning shield 128 is believed to primarily result from the undercutting of the masked metal foil during the etching process.
The interaction of these various layers is best shown with reference to FIG. 9. The dryfilm coating material is applied to the metal foil 202, forming a first coating layer 222 and a second coating layer 224. Prior to its first exposure, the plastic mask 214 is placed over the first coating layer 222, with the resultant construction comprising a masking assembly 226. The masking assembly 226 is laid on a glass surface 228 of a photo printing light box 230 (FIG. 10). The light box 230 is of a conventional design and has a mirrored bottom surface 232 to reflect the ultraviolet radiation generated by a plurality of tubular electric lamps 234 toward the glass top 228. A black rubber lid 236 is closed, the lamps turned on, and the pattern embodied in the plastic mask 214 is printed on the metal foil 202 by exposing the dryfilm coating to the ultraviolet electric lamps 234. The second layer dryfilm 224 is then exposed without a mask to harden and thus strengthen the metal foil surface. As mentioned, this is a conventional photoprinting process and the Millington Machine, Model VF-LB (FIG. 10) is one example of an appropriate photoprinting machine. A suitable set of operating parameters for this machine are as follows: 29-29.5 In. Hg. vacuum and a 2 minute exposure time.
The exposed aperture images are then photodeveloped. In the preferred method, the images are developed with 1,1,1 Trichloroethene for five minutes. This process is followed by placing the developed metal foil sheets 202 on a conveyer belt that runs through an enclosed chamber with spray nozzles to provide an even spray pattern of etching solution. Variations in material thickness, etch solution strength, and, to a lesser extent, ambient temperature, make is impossible to predict the precise amount of time required to obtain the proper degree of etching. Those skilled in this art select the time variable by first making a sample etching under the actual temperature and concentration conditions that are to be used, and then observing the etch rate over time obtained. For example, when etching 0.0028 inch copper foil using an ammonia based etchant such as Endura Etch, manufactured by Olin Hunt Specialty Products of Los Angeles, Calif., in a Chemcut Model 547 Etching System a conveyer speed control selection of position 3 at 125°-140° F. has proven to be appropriate in the past. For aluminum foil, a ferric choloride based etchant is preferred, and one skilled in the art will be able to perform a sample analysis to determine the proper etch rate, etch solution strength and temperature for a given foil thickness. After the metal sheets 202 have been etched, every aperture is inspected for defects. The exposed dryfilm is then stripped from the etched metal foil sheet 202 by dipping the metal sheet 202 in a commercial solvent, such as a methylene chloride solution. Care must be taken at this point as there is a tendency for the metal foil sheet to shrink in size and/or wrinkle during this step, and placing a weighted structure (i.e., glass plate or wire mesh) on top of the foil during the stripping process to provide a rigid envelope has been found to lessen this tendency. As a final step, the lightning shield 128 may be electroplated with a minimum 0.0001 inch plate of nickel in a conventional manner.
It is thought that the conformal lightning shield and method of manufacture and many of its attendant advantages will be understood from the foregoing description and it will be apparent that various changes may be made in the form, construction, and arrangement of the parts and steps thereof, without departing from the spirit and scope of the invention or sacrificing all of its material advantages, the form hereinbefore described being merely a preferred or exemplary embodiment thereof.
TABLE 1______________________________________Weight Penalties Weight with AdhesiveProtection System (lb/ft.sup.2)______________________________________Aluminum Wire Screen 0.08(200 × 200)Aluminum Flame Spray 0.04(4-6.9 mil)Aluminized Fiberglass 0.05Conformal Lightning Shield 0.007(aluminum, 1 mil, Ni plate)______________________________________ | A device for shielding composite material surfaces of aircraft from the destructive forces associated with lightning strikes and for protecting avionics from electromagnetic interference (EMI) and radio frequency interference (RFI), is provided, consisting of a thin metallic foil having uniformly spaced polygonal apertures formed therein. The polygonal apertures are so shaped as to provide at least one axis along which the shield material can expand or lengthen, permitting the shield material to better fit the irregular or compound curved surfaces found on aircraft. The foil shield can also be used to protect the filler material used between joints and to repair breaks and openings formed in the aircraft surface. When fashioned out of aluminum and applied to a composite material, such as graphite epoxy, the shield may be plated with nickel to prevent galvanic corrosion caused by the contact between dissimilar materials. When manufactured from copper the shield provides a solderable surface. A method for manufacturing such a shield is also provided where photolithographic techniques are used to mask, expose, and etch apertures into metallic sheets. | 1 |
FIELD OF THE INVENTION
[0001] The invention is directed to the use of Fructus Schisandrae and extracts thereof in preventing and reducing toxicity and side effects of antineoplastic agents.
BACKGROUND ARTS
[0002] Tumor is one of the main causes that leads to human death. Chemotherapy is a main approach to treat tumor. However, antineoplastic agent may result in various toxic and side effects, including cardiovascular toxicity, hepatotoxicity, nephrotoxicity, suppression of bone marrow, immunosuppression, and alopecia, etc.
[0003] Fructus Schisandrae is the mature dry fruit of Schisandra chinensis (Turcz.) Baill. or Schisandra sphenanthera Rehd. Et Wits. Fructus Schisandrae was regarded as a top grade Chinese traditional medicine in an ancient book named “Shennong Ben Cao Jing”. Dibenzocyclooctadiene lignans (Dibenzocyclooctane lignan) are the main ingredient of Fructus Schisandrae , which is the mature dry fruit of Schisandra chinensis (Turcz.) Baill. or Schisandra sphenanthera Rehd. Et Wils. It was described in the book that Fructus Schisandrae had the function of astringency, arresting discharge, nourishing qi to generate fluid, and tonifying kidney to relieve mental stress. It is an usual medicine for strengthening by tonification in traditional Chinese medicine. It has various pharmacological actions, but it was not reported that Fructus Schisandrae and dibenzocyclooctadiene lignans could also prevent and reduce the toxic and side effects produced by an antineoplastic agent.
SUMMARY OF THE INVENTION
[0004] An object of the invention is to provide a new use of Fructus Schisandrae and its extracts, i.e., the use in preventing and reducing toxicity and side effects of antineoplastic agent.
[0005] To achieve the objective, the invention provides the following technical solutions:
[0006] Use of Fructus schisandrae in the preparation of a medicament for preventing and reducing the toxicity and side effects of antineoplastic agent.
[0007] The toxicity and side effects of antineoplastic agent include cardiovascular toxicity, or hepatotoxicity, or nephrotoxicity, or suppression of bone marrow, or immunosuppression, or alopecia, etc., caused by antineoplastic agent.
[0008] Use of the extracts of Fructus schisandrae in the preparation of a medicament for preventing and reducing the toxicity and side effects of antineoplastic agent.
[0009] The toxicity and side effects of antineoplastic agent include cardiovascular toxicity, or hepatotoxicity, or nephrotoxicity, or suppression of bone marrow, or immunosuppression, or alopecia, caused by antineoplastic agent.
[0010] The extracts of Fructus schisandrae are those extracted by organic solvents from Fructus schisandrae or those obtained by the supercritical fluid extraction. The extracts extracted by ethanol are preferred.
[0011] The extract of Fructus schisandrae is dibenzocyclooctadiene lignan. Dibenzocyclooctadiene lignan has a core structure represented by formula 1 (J Chang, J Reiner, J. Xie. Chem. Rev. 2005, 105, 4581-4609).
[0000]
[0012] Concretely, the structure of the dibenzocyclooctadiene lignan is represented by formula (I):
[0000]
[0013] Wherein, R 1 , R 2 , R 5 , R 6 is independently hydroxyl or methoxyl, or, R1 and R2, and R5 and R6 independently take together to form an alkoxyl ring, or they independently do not form a ring;
[0014] R 3 is selected from the group consisting of:
[0000]
[0015] R 4 is selected from the group consisting of:
[0000]
[0016] R 7 is selected from the group consisting of:
[0000]
[0017] R 8 , R 9 is independently selected from the group consisting of:
{circle around (1)} —H {circle around (2)} —OH
;
[0020] R 10 is selected from the group consisting of:
[0000]
[0021] or, R 7 and R 10 take together to form an oxygen bridge, wherein R 1 -R 6 , R 9 , and R 9 are defined as above;
[0022] or, R 3 and R 7 take together to form an acyloxy ring, wherein R 1 , R 2 , R 4 -R 6 , R 8 -R 10 are defined as above.
[0023] Preferably, the dibenzocyclooctadiene lignan is selected from the group consisting of:
[0000]
[0000] Preferably, the dibenzocyclooctadiene lignan is schisandrin B.
The antineoplastic agent, the toxicity and side effects of which can be prevented or reduced by Fructus Schisandrae and its extracts as described above, is selected from the group consisting of aclarubicin, amrubicin, carubicin, daunorubicin, detorubicin, doxorubicin, epirubicin, esorubicin, galarubicin, idarubicin, ladirubicin, leurubicin, medorubicin, nemorubicin, pirarubicin, rodorubicin, sabarubicin, valrubicin, zorubicin, Bleomycin A5, Bleomycin, Pirarubicin, Dactinomycin, Aclarubicin, Mitomycin, Etoposide, Teniposide, Homoharringtonine, Hydroxycamptothecin, Topotecan, Paclitaxel, Docetaxel, Vincristine, Catharanthus Alkaloid, Vindesine, Vinorelbine, Lentinan, Tamoxifen, Formestane, Exemestane, Anastrozole, Letrozole, Toremifene, Flutamide, Bicalutamide, 5-fluorouracil, Cytarabine, Tegafur, Furtulon, fluridine, Mercaptopurine, Methotrexate, Gemcitabine, Capecitabine, Cytoxan, Ifosfamide, Busulfan, Melphalan, Chlorambucil, Semustine, Alestramustine, Mesna, Cisplatin, Carboplatin, Oxaliplatin, Dacarbazine, Asparaginase, Clodronate Disodium, Pamidronate disodium, Etidronate disodium, Ibandronate, Herceptin, Iressa, Mitoxantrone, Hydroxycarbamide, Methylcantharidnimide, Norcantharidin, Cinobufacini, Ubenimex, Arsenic Trioxide, AiDi, Amifostine, Matrine, Imatinfb, Sodium glycididazole, Dianhydrogalactitol, Procarbazine.
[0024] Preferably, the antineoplastic agent is an anthracycline antibiotic.
[0025] The medicine, which can prevent and reduce toxicity and side effects of antineoplastic agent, can be one dibenzocyclooctadiene lignan alone, or can be a mixture of two or more dibenzocyclooctadiene lignans.
[0026] Fructus schisandrae and dibenzocyclooctadiene lignan, the extract of Fructus schisandrae , can be used in the preparation of a medicament for improving cardiac function.
[0027] Drug excipients and carriers can be added with the medicine that can prevent and reduce toxicity and side effects of antineoplastic agent to prepare one of the following dosage forms: injection solution, tablet, capsule, granule, and decoction.
[0028] The Fructus Schisandrae and its extracts of the present invention can produce good clinical foreground in preventing and reducing toxicity and side effects of antineoplastic agent. Fructus Schisandrae and its extracts, especially the ethanol extracts and schisandrin B, can effectively reduce the toxicity and side effects caused by antineoplastic agent, especially the side effects such as cardiovascular toxicity, or hepatotoxicity, or nephrotoxicity, or suppression of bone marrow, or immunosuppression, or alopecia etc., caused by antineoplastic agent. The invention also illustrates that Fructus Schisandrae and its extracts have good effect on improving cardiac function.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 shows that the ethanol extracts of Fructus schisandrae can inhibit the increase of mouse serum myocardium enzyme, creatine kinase (CK), induced by Doxorubicin.
[0030] FIG. 2 shows that the ethanol extracts of Fructus schisandrae can inhibit the increase of mouse serum myocardium enzyme, creatine kinase isozyme (CK-MB), induced by Doxorubicin.
[0031] FIG. 3 shows that the ethanol extracts of Fructus schisandrae can inhibit the increase of mouse serum myocardium enzyme, glutamic-oxalocetic transaminase (GOT), induced by Doxorubicin.
[0032] FIG. 4 shows that the ethanol extracts of Fructus schisandrae can inhibit the increase of mouse serum myocardium enzyme, lactic dehydrogenase (LDH), induced by Doxorubicin.
[0033] FIG. 5 shows that the ethanol extracts of Fructus schisandrae can inhibit the increase of mouse left ventricular myocardium matrix metalloproteinase MMP-2 activity induced by Doxorubicin.
[0034] FIG. 6 shows that the ethanol extracts of Fructus schisandrae can inhibit the death of mouse induced by Doxorubicin.
[0035] FIG. 7 shows that the ethanol extracts of Fructus schisandrae can prevent the cardio toxicity of mouse induced by Epirubicin.
[0036] FIG. 8 shows that the ethanol extracts of Fructus schisandrae can prevent the cardio toxicity of mouse induced by Daunorubicin.
[0037] FIG. 9 shows that the ethanol extracts of Fructus schisandrae can prevent the cardio toxicity of mouse induced by Idarubicin.
[0038] FIG. 10 shows that schisandrin B can inhibit the increase of mouse serum myocardium enzyme, creatine kinase (CK), induced by Doxorubicin.
[0039] FIG. 11 shows that schisandrin B can inhibit the increase of mouse serum myocardium enzyme, creatine kinase isozyme (CK-MB), induced by Doxorubicin.
[0040] FIG. 12 shows that schisandrin B can inhibit the increase of mouse serum myocardium enzyme, glutamic-oxalocetic transaminase (GOT), induced by Doxorubicin.
[0041] FIG. 13 shows that schisandrin B can inhibit the increase of mouse serum myocardium enzyme, lactic dehydrogenase (LDH), induced by Doxorubicin.
[0042] FIG. 14 shows that schisandrin B can inhibit the increase of mouse left ventricular myocardium matrix metalloproteinase MMP-2 activity induced by Doxorubicin.
[0043] FIG. 15 shows that schisandrin B can inhibit the death of mouse induced by Doxorubicin.
[0044] FIG. 16 shows that the prevention of cardio toxicity of mice induced by Daunorubicin by six dibenzocyclooctane lignans.
DETAILED DESCRIPTION OF THE INVENTION
[0045] The invention is further illustrated by the following examples. These examples are only intended to illustrate the invention, but not to limit the scope of the invention.
Example 1
Preparation of the Ethanol Extract of Fructus Schisandrae
[0046] Percolation Method: 5000 g of Fructus schisandrae powder was percolated with 85-95% ethanol in an amount of 6 times of the mass of the powder. The percolation velocity is 15 ml/min. The ethanol leachate was recycled. The ethanol was recycled under reduced pressure until there was no ethanol odor. The leachate was concentrated to obtain an extractum with density of 1.15 g/ml, which was ready for use. The ethanol can be replaced by other alcohols, such as methanol, propanol, etc. Other organic solvents, such as ethyl acetate, ether, etc. can also be used to replace ethanol to prepare the extract of Fructus schisandrae.
Example 2
The Ethanol Extract of Fructus schisandrae can Prevent Toxicity and Side Effects Induced by Doxorubicin
[0047] 1. Materials and Methods
[0048] 1.1 Drugs and Agents
[0000] Doxorubicin Hydrochloride Injection was obtained from Italy pharmacia Co. (Product No.: 5E2002-D). Ethanol extract of Fructus schisandrae prepared from Example 1 was dissolved in 0.5% Poloxamer. CK (creatine kinase), CK-MB (creatine kinase isozyme), LDH (lactic dehydrogenase) and GOT (glutamic-oxalocetic transaminase) were detected by automatic biochemistry analyzer. Tissue Protein extraction solution was obtained from American Pierce Co. Male ICR mice with a body weight of 25-30 g were obtained from Shanghai Experimental Animal Center.
[0049] 1.2 Grouping and Administration
[0050] 150 animals were divided randomly into 5 groups.
[0051] Control group: 24 mice were dosed intragastrically with normal saline in an amount of 20 ml/kg each time at the 1 st -3 rd day of the experiment, once a day. At the 3 rd day, the mice were injected with normal saline in an amount of 25 ml/kg into their abdominal cavities within 2 hours after drench.
[0052] Group of the ethanol extract of Fructus schisandrae (the X group): 24 mice were dosed intragastrically with the ethanol extract of Fructus schisandrae in an amount of 400 mg/kg each time at the 1 st -3 rd day of the experiment, once a day.
[0053] Group of Doxorubicin (the Dox group): 42 mice were dosed intragastrically with normal saline in an amount of 20 ml/kg each time at the 1 st -3 rd day of the experiment, once a day. At the 3 rd day, the mice were injected with Doxorubicin of 25 mg/kg into their abdominal cavities.
[0054] Group 1 of Doxorubicin plus the extract of Fructus schisandrae (group 1 of Dox +X): 24 mice were dosed intragastrically with the extract of Fructus schisandrae in an amount of 400 mg/kg each time at the 1 st -3 rd day of the experiment, once a day. At the 3 rd day, the mice were injected with 25 mg/kg of Doxorubicin into their abdominal cavities 0.5 hours after drench.
[0055] Group 2 of Doxorubicin plus the extract of Fructus schisandrae (group 2 of Dox +X): 24 mice were dosed intragastrically with the extract of Fructus schisandrae in an amount of 200 mg/kg each time at the 1 st -3 rd day of the experiment, once a day. At the 3 rd day, the mice were injected with 25 mg/kg of Doxorubicin into their abdominal cavities 0.5 hours after drench.
[0056] 1.3 Detection of Serum Myocardium Enzymes
[0057] At the 5 th day (48 hours after injection of Doxorubicin into abdominal cavity), blood were collected. The serum was separated by regular separation and frozen at −80° C. CK, CK-MB, LDH and GOT were determined by automatic bio-chemistry analyzer.
[0058] 1.4 Detection of Myocardium Matrix Metalloproteinase (MMP-2)
[0059] Sample Preparation
[0060] The mice were put to death by cervical dislocation after obtaining their blood and were dissected quickly to obtain the hearts. The left ventricular was separated, washed clean with normal saline and weighed. The left ventricular myocardium tissues were taken out, triturating under liquid nitrogen. 500 μl pre-cooling extraction buffer (10 mmol/L Tris-HCL, pH7.5, 1 mmol/L MgCl 2 , 1 mmol/L EGTA, 0.1 mmol/L PMSF, 5 mmol/L β-mercaptoethanol, 5 g/L CHAPS, 0.01% Triton X-100) was added. The mixture was put on the ice for 10 min, then centrifuged at 15000 g for 30 min. The supernatant was removed for detecting protein concentration by Bradford detection. 20 μl sample was added with 5× sample buffer (not including mercaptoethanol) 5 μl and were hold for 15 min under 37° C.
[0061] 10% SDS-PAGE gel was prepared as separating gel (including 0.1% glutin), which is covered with 4% concentrating gel. 20 μl sample after treatment was loaded onto the gel to carry out electrophoresis with 40 mA constant current under a temperature of below 4 C. After electrophoresis, the gel was hold in the eluent (2.5% Triton X-100, 50 mmol/L Tri HCL, 5 mmol/L CaCl 2 , 1 μmol/L ZnCl 2 , pH7.6), agitated and eluted for 2 times, 45 min/time. The gel was then put in the rinsing solution (the eluent without Triton X-100) for rinsing for 2 times, 20 min/time. The gel was then put in the incubation solution (50 mmol/L Tri HCl, 5 mmol/L CaCl 2 , 1 μmol/L ZnCl 2 , 0.02% Brij 35 , pH7.6) for incubation for 18 h under 37° C. The gel was stained with the staining solution (0.05% Coomassie brilliant blue, 30% methanol, 10% acetic acid) for 3 h. After the gel was decolorated for 0.5 h, 1 h, and 2 h by using decoloration solution A, B, and C (containing methanol in a concentration of 30%, 20%, 10% respectively and acetic acid in a concentration of 10%, 10%, 5% respectively), respectively, matrix metalloproteinase (MMP) was showed as a transparent brilliant strip against the blue background. The gel was scanned by UVP gel scanner and was kept in the archives. The electrophoretogram was analyzed by GelWorks ID Advanced v4.01 software to determine the density of bands digested by gelatinase.
[0062] 1.5 Survival Rate Observation
[0063] The remainder mice were observed for 7 days from the day of administering Doxorubicin and the change of survival rate was recorded.
[0064] 2. Results
[0065] 2.1 Effect of the Extract of Fructus schisandrae on Serum Myocardium Enzyme Spectrum of Mice with Myocardial Damage Induced by Doxorubicin
[0066] There was no significant differences between the serum myocardium enzyme spectrum indexes, including CK, CK-MB, LDH, GOT, of the control group and those of the X group (P>0.05). The 4 serum myocardium enzyme spectrum indexes of the Dox group were significantly higher than those of the control group and the X group (P<0.05). The serum enzyme indexes of the two dosage groups which were administered in combination with the extract of Fructus schisandrae were decreased to a certain extent as compared with those of the Dox group. Specifically, the 4 serum enzymology indexes of the group using 400 mg/kg of the extract of Fructus schisandrae for 3 times together with Doxorubicin were significantly lower than those of the group using Doxorubicin alone (P<0.05) (see FIGS. 1-4 ). These indicated that the cardio toxicity induced by Doxorubicin could be effectively prevented by the ethanol extract of Fructus schisandrae.
[0067] 2.2 Detection Results of the Activity of Left Ventricular Myocardium Metalloproteinase
[0068] No activity of left ventricular myocardium matrix metalloproteinase (MMP-2) were detected both in the normal control group and in the X group. The activity of left ventricular myocardium MMP-2 of the Dox group was increased significantly. The gelatinase activity of left ventricular myocardium MMP-2 were inhibited obviously in both groups using the extract of Fructus schisandrae together with Doxorubicin, wherein the inhibition effect of the group using 400 mg/kg of the extract of Fructus schisandrae together with Doxorubicin was the best (see FIG. 5 ). The results indicated that the cardio toxicity induced by Doxorubicin could be effectively prevented by the ethanol extracts of Fructus schisandrae.
[0069] 2.3 Effect of the Extract of Fructus schisandrae on Survival Rate of Mice with Acute Toxicity Induced by Doxorubicin
[0070] The death of mice in the Dox group and in the two groups of Dox+X occurred on the 5 th day. On the 7 th day, the survival rate of the Dox group was 3.7%, the survival rate of the group using 400 mg/kg of the extract of Fructus schisandrae for 3 times together with Doxorubicin was 50% (P<0.01), and the survival rate of the group using 200 mg/kg of the extract of Fructus schisandrae for 3 times together with Doxorubicin was 16.7% (P<0.05). See FIG. 6 . These indicated that toxicity and side effects induced by Doxorubicin could be obviously reduced by the extract of Fructus schisandrae.
[0071] 2.4 Effects of the Ethanol Extract of Fructus schisandrae and Doxorubicin on Apparent Condition of Mice
[0072] Mice in the group using Doxorubicin alone were in bad conditions, manifested as asthenia, listlessness, hypotrichosis. However, mice in the group administered with the extract of Fructus schisandrae for 3 times together with Doxorubicin were relatively active and eutrichosis. These indicated that toxicity and side effects induced by Doxorubicin could be reduced by the ethanol extract of Fructus schisandrae.
Example 3
The Ethanol Extract of Fructus schisandrae Reduces the Cardio Toxicity of Induced by Epirubicin
[0073] Experimental methods: The ethanol extract of Fructus schisandrae obtained in Example 1 was prepared with 0.5% poloxamer as 8 g/ml mutterlauge. ICR mice were purchased from Shanghai Experimental Animal Center. The animals were divided into two groups, 15 mice per group. Each mouse in group 1 was dosed intragastrically with 100 μl solvent (0.5% poloxamer), and each mouse in group 2 was dosed intragastrically with 100 μl ethanol extract of Fructus schisandrae , and then mice in each group were injected with 4 mg/kg Epirubicin through tail vein 3 hours after drench of solvent or the ethanol extract. These administrations were carried out once every 7 days for 10 times totally. The mice were put to death one week after the last injection and their hearts were taken out. The heart was fixed with 4% paraform. 48 hours later, the heart was dehydrated with ethanol and fixed with paraffin. The paraffin piece was sliced into sections (with thickness of 2 μm) and the sections were stained with toluidine blue and were observed under microscope. The heart trauma was evaluated by the reported method (Imondi A R, et al. Cancer Research. 1996, 56:4200-4204). The cardio toxicity was evaluated by Severity and Extent. Severity was divided into two grades: Grade 1, which was represented by sarcoplasmic microvacuolation and/or cellular edema and mesenchyme edema; and Grade 2, which was represented by atrophy, necrotic, fibrotic, endocardium trauma and blood clot based on Grade 1. Extent was divided into four grades. Grade 0.5 was represented by less than 10 exceptional myocardium cells within each view of microscope. Grade 1 was represented by more than 10 exceptional myocardium cells within each view of microscope. Grade 2 was represented by dispersal but agminate exceptional myocardium cells. Grade 3 was represented by some agminate exceptional myocardium cells.
[0074] The myocardium trauma was calculated by the following formula:
[0000] mean total score( MTS )=Σ( S×E )/number of mice
[0000] in which S is Severity, E is Extent. Higher the mean total score, the severer heart trauma.
[0075] Results: As indicated in FIG. 7 , cardio toxicity induced by Epirubicin was significantly prevented by the ethanol extract of Fructus schisandrae , i.e., the cardio toxicity induced by Epirubicin could be significantly reduced by the ethanol extract of Fructus schisandrae.
Example 4
The Ethanol Extract of Fructus schisandrae Reduces Cardio Toxicity Induced by Daunorubicin
[0076] Experimental methods: The ethanol extract of Fructus schisandrae obtained in Example 1 was prepared with 0.5% poloxamer as 8 g/ml mutterlauge. ICR mice were purchased from Shanghai Experimental Animal Center. The animals were divided into two groups, 15 mice per group. Each mouse in group 1 was dosed intragastrically with 100 μl solvent (0.5% poloxamer), and each mouse in group 2 was dosed intragastrically with 100 μl ethanol extract of Fructus schisandrae . Then mice were injected with 4 mg/kg Daunorubicin through tail vein 3 hours after drench of solvent or the ethanol extract. These administration were done once every 7 days for 10 times totally. The mice were put to death one week after the last injection and their hearts were taken out. The heart was fixed with 4% paraform. 48 hours later, the heart was dehydrated with ethanol and fixed with paraffin. The paraffin piece was sliced into sections (with thickness of 2 μm) and the sections were stained with toluidine blue and were observed under microscope. The heart trauma was evaluated by the methods as those described in Example 3.
[0077] Results: As indicated in FIG. 8 , the cardio toxicity induced by Daunorubicin could be significantly reduced by the ethanol extract of Fructus schisandrae.
Example 5
The Ethanol Extract of Fructus schisandrae Reduces Cardio Toxicity Induced by Idarubicin
[0078] Experimental methods: The ethanol extract of Fructus schisandrae obtained in Example 1 was prepared with 0.5% poloxamer as 8 g/ml mutterlauge. ICR mice were purchased from Shanghai Experimental Animal Center. The animals were divided into two groups, 15 mice per group. Each mouse in group 1 was dosed intragastrically with 100 μl solvent (0.5% poloxamer), and each mouse in group 2 was dosed intragastrically with 100 μl ethanol extract of Fructus schisandrae . Then mice were injected with 4 mg/kg Daunorubicin through tail vein 3 hours after drench of solvent or ethanol extract. These administrations were done once every 7 days for 10 times totally. The mice were put to death one week after the last injection and their hearts were taken out. The heart was fixed with 4% paraform. 48 hours later, the heart was dehydrated with ethanol and fixed with paraffin. The paraffin piece was sliced into sections (with thickness of 2 μm) and the sections were stained with toluidine blue and were observed under microscope. The heart trauma was evaluated by the methods as those described in Example 3.
[0079] Results: As indicated in FIG. 9 , the cardio toxicity induced by Idarubicin could be significantly reduced by the ethanol extract of Fructus schisandrae.
Example 6
Prevention of Other Toxicity and Side Effects of Antineoplastic Agent by the Ethanol Extract of Fructus schisandrae
[0080] 1. Materials and Methods
[0081] 1.1 Experimental Materials
[0082] Vincristine, Methotrexate, Cisplatin, Cytoxan, 5-fluorouracil and Doxorubicin were obtained from Shanghai Pharmacy Co. ICR mice with body weight of 20-25 g were from Shanghai Experimental Animal Center. The mice were grouped randomly as below, 6 mice per group.
[0083] 1.2 Grouping and Administration
[0084] Control group: mice were injected into their abdominal cavities with normal saline once every two days, consecutively for 7 times.
[0085] Methotrexate group: mice were injected into their abdominal cavities with 2 mg/kg once every two days, consecutively for 7 times.
[0086] Group of Methotrexate plus the ethanol extract of Fructus schisandrae : mice were dosed intragastrically with 400 mg/kg of the ethanol extract of Fructus schisandrae , followed by injection into their abdominal cavities with 2 mg/kg of Methotrexate within 2 hours, once every two days and consecutively for 7 times.
[0087] Cisplatin group: mice were injected their abdominal cavities with 2 mg/kg Cisplatin once every two days and consecutively for 7 times.
[0088] Group of Cisplatin plus the ethanol extract of Fructus schisandrae : mice were dosed intragastrically with 400 mg/kg of the ethanol extract of Fructus schisandrae , followed by injection into their abdominal cavities with 2 mg/kg of Cisplatin within 2 hours, once every two days and consecutively for 7 times.
[0089] 5-fluorouracil group: mice were injected into their abdominal cavities with 30 mg/kg once every two days and consecutively for 7 times.
[0090] Group of 5-fluorouracil plus the ethanol extract of Fructus schisandrae : mice were dosed intragastrically with 400 mg/kg of the ethanol extract of Fructus schisandrae , followed by injection into their abdominal cavities with 30 mg/kg of 5-fluorouracil within 2 hours, once every two days and consecutively for 7 times.
[0091] Cytoxan group: mice were injected into their abdominal cavities with 30 mg/kg Cytoxan once every two days and consecutively for 7 times.
[0092] Group of Cytoxan plus the ethanol extract of Fructus schisandrae : mice were dosed intragastrically with 400 mg/kg of the ethanol extract of Fructus schisandrae , followed by injection into their abdominal cavities with 30 mg/kg of Cytoxan within 2 hours, once every two days and consecutively for 7 times.
[0093] Vincristine group: mice were injected into their abdominal cavities with 0.3 mg/kg once every two days and consecutively for 7 times.
[0094] Group of Vincristine plus the ethanol extract of Fructus schisandrae : mice were dosed intragastrically with 400 mg/kg of the ethanol extract of Fructus schisandrae , followed by injection into their abdominal cavities with 0.3 mg/kg of Vincristine within 2 hours, once every two days and consecutively for 7 times.
[0095] Doxorubicin group: mice were injected into their abdominal cavities with 4 mg/kg once every two days and consecutively for 7 times.
[0096] Group of Doxorubicin plus the ethanol extract of Fructus schisandrae : mice were dosed intragastrically with 400 mg/kg of the ethanol extract of Fructus schisandrae , followed by injection into their abdominal cavities with 0.3 mg/kg of Vincristine within 2 hours, once every two days and consecutively for 7 times.
[0097] 2. Results
[0098] 2.1 Effect of Fructus schisandrae Together with Doxorubicin on Various Organs of Mice (See Tablet 1)
[0099] Mice were put to death and their heart, liver, spleen, kidney and thymus were weighed. It was discovered that the immune organs of antineoplastic agent groups were obviously lighter than those of control group, indicating that antineoplastic agents produce obvious toxicity and side effects on each organ. The immune organs of the groups using the ethanol extract of Fructus schisandrae together were heavier to a certain extent than those of control group, indicating that the ethanol extract of Fructus schisandrae has potential in reducing toxicity and side effects of antineoplastic agent and in improving immune function.
[0000]
TABLE 1
Inhibition of the weight decrease of each organ of mice induced by
antineoplastic agent by the ethanol extract of Fructus schisandrae
Liver(g)
Heart(mg)
Kidney(mg)
Thymus(mg)
Spleen(mg)
Control group(n = 6)
1.93 ± 0.365
162.2 ± 27.2
389.3 ± 58.9
98.2 ± 19.1
158.7 ± 44.2
Methotrexate
1.57 ± 0.192
161.8 ± 19.5
365.6 ± 27.5
53.9 ± 16.2
101.6 ± 36.7
group(n = 6)
Group of Methotrexate
1.96 ± 0.49
161.7 ± 22.3
375.8 ± 41.6
96.1 ± 15.4*
147.1 ± 22.8*
plus the ethanol extract
of Fructus
schisandrae (400 mg/kg;
n = 6)
Cisplatin group(n = 6)
1.78 ± 0.270
157.4 ± 24.9
313.5 ± 74.88
56.3 ± 12.6
98.4 ± 22.8
Group of Cisplatin plus
1.87 ± 0.19
168.3 ± 25.6
386.3 ± 58.9
89.9 ± 11.7*
151.2 ± 33.5*
the ethanol extract of
Fructus
schisandrae (400 mg/kg;
n = 6)
5-fluorouracil group
1.88 ± 0.28
159.6 ± 22.6
378.6 ± 59.3
61.9 ± 10.4
102.4 ± 22.8
Group of 5-fluorouracil
1.88 ± 0.34
162.5 ± 31.7
371.4 ± 35.7
97.3 ± 15.2*
157.1 ± 25.7*
plus the ethanol extract
of Fructus
schisandrae (400 mg/kg;
n = 6)
Cytoxan group(n = 6)
1.88 ± 0.36
162.6 ± 31.4
396.3 ± 54.7
49.8 ± 12.4
113.5 ± 24.7
Group of Cytoxan plus
1.82 ± 0.35
157.2 ± 34.5
381.4 ± 32.5
89.7 ± 20.3*
149.6 ± 31.7*
the ethanol extract of
Fructus
schisandrae (400 mg/kg;
n = 6)
Vincristine group(n = 6)
1.87 ± 0.33
159.5 ± 21.7
385.3 ± 85.7
58.9 ± 13.3
109.5 ± 18.9
Group of Vincristine
1.83 ± 0.46
161.6 ± 33.7
381.2 ± 62.4
89.3 ± 21.1*
152.5 ± 18.9*
plus the ethanol extract
of Fructus
schisandrae (400 mg/kg;
n = 6)
Doxorubicin
1.51 ± 0.215
134.8 ± 19.5
335.6 ± 27.5
55.8 ± 14.2
91.6 ± 35.9
group(n = 10)
Group of Doxorubicin
1.89 ± 0.26*
156.4 ± 22.1
398.3 ± 66.9*
89.1 ± 19.6*
158.7 ± 23.8*
plus the ethanol extract
of Fructus
schisandrae (400 mg/kg;
n = 6)
*indicating that using in combination with ethanol extract of Fructus schisandrae had notable significance as compared with using antineoplastic agent alone
[0100] 2.2 Effects of the Ethanol Extract of Fructus schisandrae and Antineoplastic Agent on Apparent Condition of Mice
[0101] Mice in the group using antineoplastic agent alone were in bad conditions after 7-8 days, manifested as asthenia, listlessness and hypotrichosis. However, mice in the group administering in combination with the extract of Fructus schisandrae were relatively active and eutrichosis. These indicated that toxicity and side effects induced by antineoplastic agent could be reduced by the ethanol extract of Fructus schisandrae.
[0102] Examples 2-5 indicated that the ethanol extract of Fructus schisandrae can reduce and prevent the toxicity produced by antibiotics anti-tumor agents. Example 6 indicated that the ethanol extract of Fructus schisandrae can reduce and prevent the toxicities of anti-tumor drugs originated from plant, antimetabolism agents, alkylating agents and platinum drugs.
Example 7
Study on Prevention of Cardio Toxicity of Doxorubicin by Schisandrin B (SchB)
[0103] 1. Materials and Methods
[0104] 1.1 Drugs and Agents
[0000] Doxorubicin Hydrochloride Injection was obtained from Italy pharmacia Co. (Product No.: 5E2002-D). SchB was obtained from National Institute for the Verification of Pharmaceutical and Biological Products (Product No.: 110765-200407), which was dissolved in 0.5% Poloxamer. CK, CK-MB, LDH and GOT were determined by automatic biochemistry analyzer. Tissue Protein extraction solution was obtained from American Pierce Co. Male ICR mice with a body weight of 25-30 g were obtained from Shanghai Experimental Animal Center.
[0105] 1.2 Grouping and Administration
[0106] 162 animals were grouped randomly into 6 groups.
[0107] Control group: 24 mice were dosed intragastrically with normal saline at the 1 st -3 rd day of the experiment, once a day and each time with 20 ml/kg. At the 3 rd day, the mice were injected into their abdominal cavities with normal saline within 2 hours after drench.
[0108] Group of Schisandrin B (SchB group): 24 mice were dosed intragastrically with SchB at the 1 st -3 rd day of the experiment, once a day and each time with 100 mg/kg.
[0109] Group of Doxorubicin: 42 mice were dosed intragastrically with normal saline at the 1 st -3 rd day of the experiment, once a day and each time with 20 ml/kg. At the 3 rd day, the mice were injected into their abdominal cavities with Doxorubicin of 25 mg/kg.
[0110] Group 1 of Doxorubicin plus Schisandrin B (group 1 of Dox +SchB): 24 mice were dosed intragastrically with SchB at the 1 st -3 rd day of the experiment, once a day and each time with 100 mg/kg. At the 3 rd day, the mice were injected into their abdominal cavities with 25 mg/kg of Doxorubicin 0.5 hours after drench.
[0111] Group 2 of Doxorubicin plus Schisandrin B (group 2 of Dox +SchB): 24 mice were dosed intragastrically with SchB at the 1 st -3 rd day of the experiment, once a day and each time with 50 mg/kg. At the 3 rd day, the mice were injected into their abdominal cavities with 25 mg/kg of Doxorubicin 0.5 hours after drench.
[0112] Group 3 of Doxorubicin plus Schisandrin B (group 3 of Dox +SchB): 24 mice were dosed intragastrically with SchB at the 1 st -3 rd day of the experiment, once a day and each time with 25 mg/kg. At the 3 rd day, the mice were injected into their abdominal cavities with 25 mg/kg of Doxorubicin 0.5 hours after drench.
[0113] 1.3 Detection of Serum Myocardium Enzymes
[0114] At the 5 th day (48 hours after injection of Doxorubicin into abdominal cavity), blood were taken from 6 mice of each group. The serum was separated by regular separation. CK, CK-MB, LDH and GOT were determined by automatic biochemistry analyzer.
[0115] 1.4 Detection of Myocardium MMP
[0116] The experimental method was carried out as those described in Example 2 (1.4).
[0117] 1.5 Survival Rate Observation
[0118] The remainder mice were observed for 7 days from the day of Doxorubicin administration and the change of survival rate was recorded.
[0119] 2. Results
[0120] 2.1 Effect of Schisandrin B on Serum Myocardium Enzyme Spectrum of Mice with Myocardial Damage Induced by Doxorubicin
[0121] There were no significant differences between the serum myocardium enzyme spectrum indexes, such as CK, CK-MB, LDH, GOT, etc., of control group and those of SchB group (P>0.05). The 4 serum enzyme indexes of Doxorubicin group were significantly higher than those of control group and Sch B group (P<0.05). The serum enzyme indexes of the three dosage groups using in combination with Sch B were decreased to a certain extent as compared with those of the group using Doxorubicin alone. In particular, the 4 serum enzyme indexes of the group using 100 mg/kg of Sch B for 3 times in combination with Doxorubicin had no significant difference as compared with those of control group (P>0.05). The 4 serum enzyme indexes of the group using 100 mg/kg of Sch B for 3 times in combination with Doxorubicin, however, had significant difference as compared with the significantly increased serum enzymes produced by the group using Doxorubicin alone (P<0.05). The CK and CK-MB indexes of the group using 50 mg/kg of Sch B for 3 times in combination with Doxorubicin and those of the group using 25 mg/kg of Sch B for 3 times in combination with Doxorubicin had significant difference as compared with the group using Doxorubicin alone (P<0.05). See FIG. 10-13 . These indicated that the cardio toxicity induced by Doxorubicin could be prevented by Sch B.
[0122] 2.2 Detection Results of the Activity of Left Ventricular Myocardium Metalloproteinase
[0123] No left ventricular myocardium matrix metalloproteinase (MMP-2) activity were detected both in the normal control group and in Sch B group. The MMP-2 activity of the Doxorubicin group was increased obviously. The MMP-2 activity in the three dosage groups using Sch B in combination with Doxorubicin were inhibited significantly, wherein the inhibition effect of the group using 100 mg/kg of Sch B together with Doxorubicin was the best. See FIG. 14 . These results indicated that the cardio toxicity induced by Doxorubicin could be prevented by Sch B.
[0124] 2.3 Effect of Sch B on Survival Rate of Mice with Acute Toxicity Induced by Doxorubicin
[0125] The death of mice in the Doxorubicin group occurred on the 4 th day, and the death of mice in the three groups using Sch B together with Doxorubicin occurred on the 5 th day. On the 7 th day, the survival rate of the Doxorubicin group was 0, the survival rate of the group using 100 mg/kg of Sch B for 3 times together with Doxorubicin was 33.3% (P<0.01), the survival rate of the group using 50 mg/kg of Sch B for 3 times together with Doxorubicin was 25% (P<0.01), and the survival rate of the group using 25 mg/kg of Sch B for 3 times together with Doxorubicin was 16.67% (P<0.05). See FIG. 15 . These results indicated that toxicity and side effects induced by Doxorubicin could be obviously reduced by Sch B.
Example 8
Five Dibenzocyclooctadiene Lignans can Prevent Other Toxicity and Side Effects of Doxorubicin
[0126] 1. Materials and Methods
[0127] 1.1 Experimental Materials
[0128] Doxorubicin Hydrochloride Injection was obtained from Italy pharmacia Co. Six Dibenzocyclooctadiene lignans were obtained from National Institute for the Verification of Pharmaceutical and Biological Products (Product No.: 110765-200407), which were dissolved in 0.5% Poloxamer. Female ICR mice with a body weight of 25-30 g were obtained from Shanghai Experimental Animal Center, which were grouped randomly into 4 groups, 10 mice per group.
[0129] 1.2 Animal Grouping and the Ways and Routines of Administration
[0130] Control group: 10 mice were injected into their abdominal cavities with normal saline once every two days and consecutively for 7 times.
[0131] Group of Doxorubicin (Dox group): 10 mice were injected into their abdominal cavities with 2 mg/kg of Doxorubicin once every two days, consecutively for 7 times. Group 1 of Doxorubicin plus Schisandrin B (group 1 of Dox +SchB): 10 mice were dosed intragastrically with 50 mg/kg of Sch B, followed by injection into their abdominal cavities with 2 mg/kg of Doxorubicin within two hours, once every two days and consecutively for 7 times.
[0132] Group 2 of Doxorubicin plus Schisandrin B (group 2 of Dox +SchB): 10 mice were dosed intragastrically with 100 mg/kg of Sch B, followed by injection into their abdominal cavities with 2 mg/kg of Doxorubicin within two hours, once every two days and consecutively for 7 times.
[0133] Group of Doxorubicin plus Schisandrin A: 10 mice were dosed intragastrically with 100 mg/kg of Schisandrin A, followed by injection into their abdominal cavities with 2 mg/kg of Doxorubicin within two hours, once every two days and consecutively for 7 times.
[0134] Group of Doxorubicin plus Schisandrin C: 10 mice were dosed intragastrically with 100 mg/kg of Schisandrin C, followed by injection into their abdominal cavities with 2 mg/kg of Doxorubicin within two hours, once every two days and consecutively for 7 times.
[0135] Group of Doxorubicin plus Schizandrol A: 10 mice were dosed intragastrically with 100 mg/kg of Schizandrol A, followed by injection into their abdominal cavities with 2 mg/kg of Doxorubicin within two hours, once every two days and consecutively for 7 times.
[0136] Group of Doxorubicin plus Schizandrol B: 10 mice were dosed intragastrically with 100 mg/kg of Schizandrol B, followed by injection into their abdominal cavities with 2 mg/kg of Doxorubicin within two hours, once every two days and consecutively for 7 times.
[0137] 2. Results
[0138] 2.1 Effect of 5 Dibenzocyclooctadiene Lignans in Combination with Doxorubicin on Various Organs of Mice (See Tablet 2)
[0139] Mice were put to death and their heart, liver, spleen, kidney and thymus were weighed. It was discovered that each organ of the Dox group were obviously lighter than those of the other groups, indicating that Doxorubicin produced obvious toxicity and side effects on each organ. The organs of groups using dibenzocyclooctadiene lignan together with Doxorubicin were heavier to a certain extent than those of the Dox group, indicating that dibenzocyclooctadiene lignans had the potential in reducing toxicity and side effects of Doxorubicin and in improving immune function.
[0000]
TABLE 2
Inhibition of the weight decrease of each organ of mice induced
by Doxorubicin by 5 dibenzocyclooctadiene lignans
Liver(g)
Heart(mg)
Kidney(mg)
Thymus(mg)
Spleen(mg)
Control group(n = 10)
1.89 ± 0.436
160.2 ± 29.5
394.8 ± 60.99
95.1 ± 17.3
154.7 ± 51.0
Group of
1.51 ± 0.215
134.8 ± 19.5
335.6 ± 27.5
55.8 ± 14.2
91.6 ± 35.9
Doxorubicin(n = 10)
Group 1 of Doxorubicin
1.66 ± 0.249
130.7 ± 20.4
384.8 ± 40.4*
57.1 ± 10.7
108.1 ± 33.7
plus Schisandrin B
(50 mg/kg; n = 10)
Group 2 of Doxorubicin
1.78 ± 0.270*
147.4 ± 24.9
393.5 ± 74.88*
73.8 ± 20.5*
130.4 ± 42.8*
plus Schisandrin B
(100 mg/kg; n = 10)
Group of Doxorubicin
1.71 ± 0.16*
151.4 ± 21.6
389.2 ± 69.8*
69.6 ± 21.7*
144.6 ± 43.5*
plus Schisandrin A
(100 mg/kg; n = 10)
Group of Doxorubicin
1.82 ± 0.21*
158.4 ± 25.5
373.5 ± 68.2*
76.9 ± 19.5*
129.4 ± 32.8*
plus Schisandrin C
(100 mg/kg; n = 10)
Group of Doxorubicin
1.83 ± 0.310*
164.4 ± 34.9
401.3 ± 84.9
83.9 ± 25.3*
137.4 ± 42.6*
plus Schizandrol A
(100 mg/kg; n = 10)
Group of Doxorubicin
1.85 ± 0.38*
161.5 ± 31.6
395.2 ± 84.66*
85.8 ± 22.3*
133.5 ± 38.68*
plus Schizandrol B
(100 mg/kg; n = 10)
*indicating that as compared with the group of Doxorubicin, the difference was significant(P < 0.05)
[0140] 2.2 Effects of Dibenzocyclooctadiene Lignans and Doxorubicin on Apparent Conditions of Mice
[0141] Mice in the group using Doxorubicin alone were in bad conditions after 7-8 days, manifested as asthenia, listlessness and hypotrichosis. However, mice in the group administered with Doxorubicin in combination with dibenzocyclooctadiene lignans were relatively active and eutrichosis. These indicated that toxicity and side effects induced by antineoplastic agent could be reduced by dibenzocyclooctadiene lignans.
[0142] The antineioplastic used in the Example was Doxorubicin. Doxorubicin has not only the common toxicity and side effects of antineioplastics, e.g. immune inhibition, marrow inhibition, etc., but also cardiovascular toxicity of the medicine with an anthracycline core structure. As a result, Doxorubicin can well reflect the toxicity and side effects of antineoplastic agent.
Example 9
Six Dibenzocyclooctane Lignans can Reduce Cardio Toxicity of Induced by Daunorubicin
[0143] Experimental method: ICR mice were purchased from Shanghai Experimental Animal Center. Schisandrin A, Schisandrin B, Schisandrin C, Schisantherin A, Schizandrol A, and Schizandrol B were prepared with 0.5% poloxamer as 1 g/ml mutterlauge respectively. The animals were grouped into 7 groups, 15 mice each group. Each mouse in group 1 was dosed intragastrically with 100 μl solvent (0.5% poloxamer), each mouse in group 2 was dosed intragastrically with 100 μl Schisandrin A, each mouse in group 3 was dosed intragastrically with 100 μl Schisandrin B, each mouse in group 4 was dosed intragastrically with 100 μl Schisandrin C, each mouse in group 5 was dosed intragastrically with 100 μl Schisantherin A, each mouse in group 6 was dosed intragastrically with 100 μl Schizandrol A, and each mouse in group 7 was dosed intragastrically with 100 μl Schizandrol B, and 3 hours after administration of solvent or the above dibenzocyclooctane lignans, mice in each group were injected with 4 mg/kg Daunorubicin through tail vein. The above administrations were carried out once every 7 days for 10 times totally. The mice were put to death one week after the last time of injection and their hearts were taken out. The heart was fixed with 4% paraform. The operation steps were the same as those in Example 3.
[0144] Results: As indicated in FIG. 16 , the cardio toxicity induced by Daunorubicin could be significantly reduced by the 6 dibenzocyclooctane lignans, indicating that the 6 dibenzocyclooctane lignans had significant prevention effects on cardio toxicity induced by Daunorubicin.
Example 10
Dibenzocyclooctane Lignans can Prevent and Reduce Other Toxicity and Side Effects of Antineoplastic Agent
[0145] The above Examples indicated that dibenzocyclooctane lignans can reduce and prevent the toxicity of antibiotics anti-tumor agents. This Example indicateds that dibenzocyclooctane lignans can also reduce and prevent the toxicities of anti-tumor drugs originated from plant, antimetabolism agents, alkylating agents and platinum drugs.
[0146] 1. Materials and Methods
[0147] 1.1 Experimental Materials
[0148] Vincristine, Methotrexate, Cisplatin, Cytoxan, and 5-fluorouracil were from Shanghai Pharmacy Co. 6 dibenzocyclooctadiene lignans were bought from National Institute for the Verification of Pharmaceutical and Biological Products, which were dissolved in 0.5% Poloxamer. ICR mice, body weight 20-25 g, were obtained from Shanghai Experimental Animal Center. The mice were divided randomly as following, 6 mice per group.
[0149] 1.2 Animal Grouping and the Way and Routine of Administration
[0150] Control group: mice were injected into their abdominal cavities with normal saline once every two days, consecutively for 7 times.
[0151] Methotrexate group: mice were injected into their abdominal cavities with 2 mg/kg once every two days, consecutively for 7 times.
[0152] Group of Methotrexate plus Schisandrin B: mice were dosed intragastrically with 100 mg/kg of Schisandrin B, followed by injection into their abdominal cavities with 2 mg/kg of Methotrexate within two hours, once every two days and consecutively for 7 times.
[0153] Cisplatin group: mice were injected into their abdominal cavities with 2 mg/kg once every two days, consecutively for 7 times.
[0154] Group of Cisplatin plus Schisandrin A: mice were dosed intragastrically with 100 mg/kg of Schisandrin A, followed by injection into their abdominal cavities with 2 mg/kg of Cisplatin within two hours, once every two days, consecutively for 7 times.
[0155] 5-fluorouracil group: mice were injected into their abdominal cavities with 30 mg/kg once every two days, consecutively for 7 times.
[0156] Group of 5-fluorouracil plus Schisandrin C: mice were dosed intragastrically with 100 mg/kg of Schisandrin C, followed by injection into their abdominal cavities with 30 mg/kg of 5-fluorouracil within two hours, once every two days, consecutively for 7 times.
[0157] Cytoxan group: mice were injected into their abdominal cavities with 30 mg/kg once every two days, consecutively for 7 times.
[0158] Group of Cytoxan plus Schisantherin A: mice were dosed intragastrically with 100 mg/kg of Schisantherin A, followed by injection into their abdominal cavities with 30 mg/kg of Cytoxan within two hours, once every two days and consecutively for 7 times.
[0159] Vincristine group: mice were injected into their abdominal cavities with 0.3 mg/kg once every two days, consecutively for 7 times.
[0160] Group of Vincristine plus Schizandrol A: mice were dosed intragastrically with 100 mg/kg of Schizandrol A, followed by injection into their abdominal cavities with 0.3 mg/kg of Vincristine within two hours, once every two days, and consecutively for 7 times.
[0161] 2. Results
[0162] 2.1 Effect of 6 Dibenzocyclooctadiene Lignans in Combination with Doxorubicin on Various Organs of Mice (See Tablet 3)
[0163] Mice were put to death and their heart, liver, spleen, kidney and thymus were weighed. It was discovered that the immune organs of antineoplastic agent groups were obviously lighter than those of control group, indicating that antineoplastic agents produce obvious toxicity and side effects on each organ. The immune organs of the groups using dibenzocyclooctadiene lignans together were heavier to a certain extent than those of control group, indicating that dibenzocyclooctadiene lignans have potential in reducing toxicity and side effects of antineoplastic agents and in improving immune function.
[0000]
TABLE 3
Inhibition of weight decrease of each organ of mice induced
by antineoplastic agents by 6 dibenzocyclooctadiene lignans
Liver(g)
Heart(mg)
Kidney(mg)
Thymus(mg)
Spleen(mg)
Control group(n = 6)
1.93 ± 0.365
162.2 ± 27.2
389.3 ± 58.9
98.2 ± 19.1
158.7 ± 44.2
Methotrexate
1.57 ± 0.192
161.8 ± 19.5
365.6 ± 27.5
53.9 ± 16.2
101.6 ± 36.7
group (n = 6)
Group of Methotrexate
1.86 ± 0.249
159.7 ± 21.4
384.4 ± 40.4
86.1 ± 12.6*
138.1 ± 31.7*
plus Schisandrin B
(100 mg/kg; n = 6)
Cisplatin group(n = 6)
1.78 ± 0.270
157.4 ± 24.9
313.5 ± 74.88
56.3 ± 12.6
98.4 ± 22.8
Group of Cisplatin plus
1.89 ± 0.18
158.9 ± 23.4
383.2 ± 67.6
89.7 ± 13.8*
156.6 ± 42.6*
Schisandrin A
(100 mg/kg; n = 6)
5-fluorouracil group
1.88 ± 0.28
159.6 ± 22.6
378.6 ± 59.3
61.9 ± 10.4
102.4 ± 22.8
Group of 5-fluorouracil
1.89 ± 0.32
162.1 ± 33.8
391.4 ± 45.8
89.8 ± 14.2*
147.4 ± 22.6*
plus Schisandrin C
(100 mg/kg; n = 6)
Cytoxan group(n = 6)
1.88 ± 0.36
162.6 ± 31.4
396.3 ± 54.7
49.8 ± 12.4
113.5 ± 24.7
Group of Cytoxan plus
1.89 ± 0.39
169.2 ± 32.8
391.2 ± 35.6
84.7 ± 21.4*
143.5 ± 35.8*
Schisantherin A
(100 mg/kg; n = 6)
Vincristine group(n = 6)
1.87 ± 0.33
159.5 ± 21.7
385.3 ± 85.7
58.9 ± 13.3
109.5 ± 18.9
Group of Vincristine
1.79 ± 0.36
162.3 ± 42.6
386.2 ± 64.9
81.9 ± 12.1*
143.5 ± 19.8*
plus Schizandrol A
(100 mg/kg; n = 6)
*indicating that as compared with using antineoplastic agent alone, using together with dibenzocyclooctane lignan had notable significance
[0164] 2.2 Effects of 5 Dibenzocyclooctadiene Lignans and Antineoplastic Agents on Apparent Conditions of Mice
[0165] Mice in the group using antineoplastic agent alone were in bad conditions after 7-8 days, manifested as asthenia, listlessness and hypotrichosis. However, mice in the group administered in combination with dibenzocyclooctadiene lignans were relatively active and eutrichosis. These indicated that toxicity and side effects induced by antineoplastic agent could be reduced by dibenzocyclooctane lignans. | Use of Fructus schisandrae in preparation of medicaments for preventing and reducing toxicity and side effects of antineoplastic agents. The toxicity and side effects of antineoplastic agents are cardiovascular toxicity, hepatotoxicity, nephrotoxicity, suppression of bone marrow, immunosuppression, or alopecia etc induced by antineoplastic agents. Fructus schisandrae and extracts thereof, especially ethanol extracts, schisandrin B, are effective in reducing antineoplastic agent's toxicity and side effects. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to automobile suspensions.
2. Brief Description of the Prior Art
A prior art suspension of strut type as shown in FIG. 1, has a lower arm 1 having an inner end 2 fulcrumed to the vehicle body and a strut unit 3 having a piston rod upper end 4 also coupled to the vehicle body. The lower end of the strut is rigidly coupled to a wheel carrier 5, which is in turn coupled to the outer end of the lower arm 1. Vertical motion of the strut 3, which is restricted by an arcuate motion of the lower arm 1 ABOUT the the automobile body side coupling points 2 and 4, is coupled to the wheel carrier 5 to cause a fixed vertical motion thereof. In a prior art suspension of double wishbone type as shown in FIG. 2, an upper and a lower arm 6, 7 have their inner ends both coupled to the automobile body and their outer ends both coupled to wheel carrier 8, these arms undergoing arcuate motions about their automobile body side coupling points as support points cause a fixed vertical motion of the wheel carrier 8.
In the prior art suspensions, the geometry in the vertical motion of the wheel carrier is determined by the length, mounting position, mounting angle, etc. of the upper and lower arms having predetermined lengths, with respect to the automobile body side coupling points of these arms as support points.
Thus, in the suspension, usually of the strut type, the wheel carrier 5 undergoes revolution about point O of intersection between a right angle line extending from the strut piston upper end 4 toward the automobile body and the axis of the lower arm 1. However, on the bump side the distance between the center O of revolution noted above and the tire center P in contact with the ground, i.e., 2 the "swing arm length", is increased with bumping. This means that the negative tire camber change is small. In addition, on the rebound side the positive camber change is increased. Further, the tread changes with respect to both the bump and rebound are large. Therefore, the time performance can not be sufficiently utilized, which is undesired for the improvement of the revolution performance. Besides, on unlevel road surfaces the vehicle body rocks to the left and right, thus resulting in unstable straight running.
The double wishbone type suspension is superior to the strut type one in that it permits optimmization of the suspension geometry and provides high freedom of design. However, if sufficient lengths of the upper and lower arms 6 and 7 can not be secured due to insufficient available space, it leads to insufficient vertical stroke of tire, sudden excessive camber and tread changes, unnatural movement in the transversal direction, reduced convergence period and consequent lack of steadiness of motion.
SUMMARY OF THE INVENTION
The invention has been intended in the light of the above circumstances, and its object is, to provide an automobile suspension which can obviate the drawbacks noted above in the prior art with a unique way of mounting various arms coupling the wheel carrier and the automobile body to each other, such as the upper and lower arms 6 and 7 in the strut and double wishbone type suspensions and further trailing arm in a semi-trailing type suspension, on the automobile body.
To attain the above object, according to the invention, there is provided an automobile suspension which comprises arms for coupling a wheel carrier to the automobile body, the arms including a wheel carrier side arm having an outer end coupled to the wheel carrier and an automobile body side arm having an outer end coupled to the automobile body, the automobile body side end of the wheel carrier side arm and the automobile side end of the automobile side arm being pin coupled, and moving means for moving the point of coupling of the arms up and down and also to the left and right (i.e., inward and outward of the automobile body) in an interlocked relation to and in the same direction as tire movement when the tire is moved up and down.
Also, according to the invention, there is provided an automobile suspension, which is of either strut or double wishbone type, and in which with respect to at least the bump in the up-and-down tire movement the moving means, in the case of the strut type, includes a pull rod coupling a position, at which an automobile body side lower arm or a point of coupling between the automobile body side lower arm and a wheel carrier side lower arm can be pulled up, such as a strut unit or an upper portion of the wheel carrier, and the neighborhood of the automobile body side lower arm or the coupling point and, in the case of the double wishbone type, includes a pull rod coupling the afore-said position, such as an upper portion of the wheel carrier or the wheel carrier side upper arm, and the automobile body side lower arm or the coupling point, the moving means further including, in the case of the double wishbone type, a coupling arm and a pull rod for the coupling between automobile body side upper and lower arms or the coupling between the automobile body side upper arm and the neighborhood of a lower coupling point between an automobile body side lower arm and a wheel carrier side lower arm.
Further, according to the invention, there is provided an automobile suspension, which is of either strut or double wishbone type, and in which with respect to at least the bump in the up-and-down tire movement the moving means, in the case of the strut type, includes a push rod coupling an automobile body side lower arm or a point of coupling between the automobile body side lower arm and a wheel carrier side lower arm, that is, coupling between a lower portion of the wheel carrier and the automobile body side lower arm or a coupling point between the automobile body side lower arm and a wheel carrier side lower arm and, in the case of the double wishbone type, includes a push rod coupling a position, at which an automobile body side upper arm or a ponit of coupling of the automobile body side upper arm and a wheel carrier side upper arm, that is, coupling a lower portion of the wheel carrier or the wheel carrier side lower arm and the automobile body side upper arm or a point of coupling between the automobile body side upper arm and the wheel carrier side upper arm, the moving means further including, in the case of the double wishbone type, a coupling arm coupling the automobile body side upper and lower arms or coupling an upper couping point between the automobile body side upper arm and the wheel carrier side upper arm and a lower coupling point between the automobile body side lower arm and the wheel carrier side lower arm.
Further, according to the invention, there is provided an automobile suspension, in which with respect to at least the bump in the up-and-down tire movement the moving means includes a push rod coupling a position, at which a lever having an end fulcrumed on the automobile body can be pulled up, and the lever, the moving means further including, in the case of the strut type, a pull rod coupling the lever and an automobile body side lower arm or a coupling point between the automobile body side lower arm and a wheel carrier side lower arm and, in the case of the double wishbone type, a pull rod coupling an upper or lower portion of such automobile body side arm and either an upper coupling point between an automobile body side upper arm and a wheel carrier side upper arm or a lower coupling point between the automobile body side lower arm and the wheel carrier side lower arm or a pull rod coupling the upper coupling point and the lower coupling point.
Further according to the invention, there is provided an automobile suspension, in which a wheel carrier side upper arm having an outer end coupled to the wheel carrier and the inner end of an automobile body side upper arm having an outer end coupled to the automobile body are pin coupled, and also in which the moving means includes a coupling arm coupling a lower arm having an outer end coupled to the wheel carrier and an inner end directly coupled to the automobile body and a lower portion of the wheel carrier or the lower arm or a point of coupling between the automobile body side upper arm and the wheel carrier side upper arm.
Further, according to the invention, there is provided an automobile suspension, in which a wheel carrier side lower arm having an outer end coupled to the wheel carrier and the inner end of each automobile body side lower arm having an outer end coupled to the automobile body are pin coupled, and also in which the moving means further includes a coupling arm coupling an upper arm having an outer end coupled to the wheel carrier and an inner end coupled to the automobile body and a point of coupling between an upper portion of the wheel carrier or the upper arm and the automobile body side lower arm or a point of coupling between the automobile body side lower arm and the wheel carrier side lower arm.
According to the invention, with adoption of the above problem solving means, the coupling point can be moved by the moving means vertically and transversally (i.e., inward and outward of the automobile body) in an interlocked relation to and in the direction of motion of the tire in vertical motion theeof. Thus, the coupling point noted above, i.e., the practical center of rotation of the inner arm end coupled to the wheel carrier can be moved to a position of optimum the geometry during running of the automobile, such as braking or whirling. This permits design freedom improvement over the prior art in setting the camber, tread and tow characteristics of the tire and setting the wheel stroke and other suspension geometry. Satisfactory straight running performance and high whirling performance of the automobile thus can be ensured to enhance the steering stability and reduce changes n the automobile attitude.
Further, according to the invention, in addition to the above function, the automobile side end of the arm coupled to the wheel carrier, i.e., the substantial center of rotation of the arm coupled to the wheel carrier, is moved to a set position by a simple mechanism comprising the pull or push rod or the push and pull rods coupled together by the lever. It is thus possible to realize the moving means noted above as a simple mechanism.
Further, according to the invention as claimed in claim 5, on the lower arm side of the double wishbone type suspension the wheel carrier upper portion is controlled with the long lower arm adopting the prior art technique, while on the upper arm side the wheel carrier portion is controlled by adopting and with a function of the invention, thus coping with the long lower arm noted above. It is thus possible to improve the camber and tread characteristics and the wheel stroke extent and provide compact upper arm accommodation space.
Further, according to the invention, on the lower arm side of the double wishbone type suspension with the high-mount upper arm the wheel carrier lower portion is controlled by adopting and with a function of the invention. It is thus possible inexpensively to improve the camber and tread characteristics, wheel stroke, etc. and provide compact lower arm accommodation space.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a structural representation of a prior art suspension of strut type;
FIG. 2 is a structural representation of a prior art suspension of double wishbone type;
FIG. 3 is a structural representation, taken in the longitudinal direction of automobile, of an embodiment and modification of the invention applied to a strut type suspension;
FIG. 4 is a structural representation, taken in the longitudinal direction of automobile, of an embodiment and modification thereof of the invention applied to a double wishbone type suspension;
FIG. 5 is a structural representation, taken in the longitudinal direction of automobile, of an embodiment of the invention applied to a strut type suspension;
FIG. 6 is a structural representation, taken in the longitudinal direction of automobile, of an embodiment of the invention applied to a double wishbone type suspension;
FIG. 7 is a structural representation, taken in the longitudinal direction of automobile, of an embodiment of the invention applied to a strut type suspension;
FIG. 8 is a structural representation, taken in the longitudinal direction of automobile, of an embodiment of the invention applied to a double wishbone type suspension;
FIG. 9 is a structural representation, taken in the longitudinal direction of automobile, of an embodiment of the invention applied to a double wishbone type suspension;
FIG. 10 is a view similar to FIG. 9 but showing a different embodiment;
FIG. 11 is a schematic plan view showing an L-shaped lower arm;
FIG. 12 is a structural representation, taken from the front side of automobile, of a semi-trailing type suspension;
FIG. 13 is a structural representation, taken as a plan view, of the suspension shown in FIG. 12; and
FIG. 14 is a schematic representation, taken in the vertical direction of automobile, of the suspension shown in FIG. 13.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of the invention will now be described.
FIG. 3 is a structural representation, taken in the longitudinal direction of thee automobile, of an embodiment of the invention applied to a suspension of the strut type. Referring to the Figure, designated as 9, is a strut unit including a shock absorber and a spring. The unit 9 has an internal piston rod with the upper end 10 thereof coupled to the automobile body (shown shaded) and a lower portion rigidly coupled to a wheel carrier 11.
Designated at 12 is a lower arm having an outer end, with respect to the automobile body, coupled to the wheel carrier, the other inner end and an axis inclined outwardly downward. Designated at 13 is an automobile body side arm (lower arm) with its outer end coupled to the automobile body (shown shaded), the other inner end pin coupled to the inner end of the lower arm 12 coupled to the wheel carrier. The automobile body side arm 13 has its axis shown to be inclined inwardly downward. Designated at 14 is a point of pin coupling of the inner ends of the arms 12 and 13. Designated at 15 is a pull rod having an upper end coupled to the strut unit 9, or to the wheel carrier 11, and a lower end coupled to the automobile body side lower arm 13, or to the coupling point 14a. The pull rod 15 operates in an interlocked relation to the vertical motion of the tire to raise the lower arm 13 or coupling point 14a at the time of bumping and lower these parts at the time of rebounding. Designated at 16 is the tire, at P the tire center in contact with the ground, and at O the center of the wheel carrier revolution.
In this embodiment, the position of the inner end of the lower,arm 12 coupled to the wheel carrier 11, i.e., the position of the center of rotation of the lower arm 12, is controlled by the pull rod 15, which has the upper end coupled to the strut unit 9 to the wheel carrier 11 and the automobile body side lower arm 13 or to the coupling point 14.
FIG. 4 is a structural representation, taken in the longitudinal direction of the automobile body, of an embodiment of the invention applied to a suspension of the double wishbone type.
Referring to the Figure, designated at 17 is a wheel carrier, at 18 an upper arm coupled to the wheel carrier 17, at 19 a lower arm coupled to the wheel carrier 17, at 20 an upper arm coupled to the automobile body, at 21 a lower arm coupled to the automobile body, at 22 a point of coupling of the upper arm 20 to the automobile body, and at 23 a point of coupling of the lower arm 21 to the automobile body. Designated at 24 is a point of coupling between the upper arms 20 and 18 coupled to the automobile body and wheel carrier, respectively, and at 25 is a point of coupling between the lower arms 21 and 19 coupled to the automobile body and wheel carrier, respectively. Both these coupling points are pin coupling points. Designated at 26 is a coupling arm coupling the coupling points 24 and 25 to each other, and at 27 a pull rod having an upper end coupled to an upper portion of the wheel carrier 17 or to the upper arm 18 coupled to the wheel carrier and a lower end coupled to the other end of the lower arm 21 having one end coupled to the automobile body.
In this embodiment, like the embodiment shown in FIG. 3, the positions of the inner ends of the wheel carrier side upper and lower arms 18 and 19, i.e., the practical centers of rotation of the two arms 18 and 19, are controlled with the pull rod 27.
FIGS. 5 and 6 show further embodiments of the invention applied to suspensions of the strut and double wishbone types.
In FIG. 5, designated at 28 is a push rod, at 29 a wheel carrier, at 30 an automobile body side lower arm having an outer end coupled to the automobile body and a lower end coupled to a wheel carrier side arm, at 31 the wheel carrier side arm having an outer end coupled to the wheel carrier 29 and an inner end coupled to the automobile body side lower arm 30, and at 32 a point of pin coupling between the automobile body side and wheel carrier side arms 30 and 31. Designated at 33 is a point of coupling between the wheel carrier side lower arm 31 and the wheel carrier 29.
In FIG. 6, designated at 34 is a push rod coupling a lower arm 35, which is coupled to the wheel carrier or to a wheel-carrier side lower arm 35, and an automobile body side upper arm 36, at 39 a point of coupling between an automobile body side lower arm 40 and the wheel carrier side lower arm 35, at 38 a point of coupling between the automobile body side upper arm 36 and a wheel carrier side upper arm 37, and at 41 an arm coupling the coupling points 38 and 39 to each other.
In the embodiment of FIG. 5, the position of the inner end of the wheel carrier side arm, i.e., the position of the center of rotation of the arm, is controlled by the push rod 28. In the embodiment of FIG. 6, it is controlled by the push rod 34.
FIGS. 7 and 8 show further embodiments of the invention applied to suspensions of the strut and double wishbone types. In these instances, the position of the inner end of a wheel carrier side arm, i.e., the position of the substantial center of rotation of the arm, is controlled by a push and a pull rod, the push rod having an upper end coupled to a lever fulcrumed on the automobile body and a lower end coupled to the wheel carrier or to a wheel carrier side lower or upper arm, the pull rod having an upper end coupled to the lever noted above and a lower end coupled to an automobile body side lower or upper arm or to a coupling point.
Referring to FIG. 7, designated at 42 is the push rod, which has its lower end coupled to a wheel carrier 43 or to a wheel carrier side lower art 44 and its upper end coupled to an automobile side lever 45. Designated at 46 is the pull rod, which couples an automobile side lower arm 47 or a coupling point 48 between the automobile side lower arm and the wheel carrier side lower arm 44 and the lever 45 to each other. Designated at 50 is an automobile body side coupling point at an end of the lever 45, and at 51 a coupling point between the wheel carrier side lower arm 44 and the wheel carrier 43. Designated at O is the center of rotation of the wheel carrier, and at O' a displaced center of rotation of the wheel carrier.
Referring to FIG. 8, designated at 52 is a wheel carrier, and at 53 a push rod, which has its lower end attached to a wheel carrier side upper or lower arm 54 or 55 or to the wheel carrier 52 and its upper end coupled to a lever 56 having an end coupled to the automobile body. Designated at 57 is a pull rod, which has its upper end coupled to the lever 56 and its lower end coupled to an automobile body side upper or lower arm 58 or 59, or to a coupling point 60 between a wheel carrier side and an automobile body side upper arm 54 and 58 or a coupling point 61 between a wheel carrier side and an automobile body side lower arm 55 and 59. The coupling points 60 and 61 are coupled to each Other by a coupling arm 62.
FIG. 9 shows a further embodiment of the invention applied to the upper arm side of the double wishbone type suspension. Designated at 63 is a wheel carrier, at 64 a lower arm having an outer end coupled to the wheel carrier 63 and an inner end coupled to the automobile body (as shown shaded), at 65 a wheel carrier side upper arm, and at 66 an automobile body side upper arm. The inner ends of the arms 65 and 66 are pin coupled at a point 67 to each other. Designated at 68 is a push rod coupling the coupling point 67 and the wheel carrier 63 or the lower arm 64. The push rod 68 may have an outwardly or inwardly curved shape as well.
While the above embodiment of FIG. 9 is concerned with the upper arm side of the suspension, it is conceivable to apply the invention to the lower arm side of a double wishbone type suspension with a high-mount upper arm side.
FIG. 10 shows such an embodiment. In this instance, an upper arm 72, which has its outer end coupled to an upper portion of wheel carrier 69 extending above tire and its inner arm coupled to the automobile body, and a coupling point 73 between an automobile body side lower arm 71 and a wheel carrier side lower arm 70, are coupled to each other by a pull rod 74.
In the above strut type suspension embodiments, the lower arm plan view is of course conceivable variously, such as an L type, L arm plus trailing rod, inverse A arm, two parallel rings, etc. In such cases, it is conceivable to apply the invention to each automobile body side coupling. In this case, the trailing rod may be one according to the invention and may be one not according to the invention. In the latter case, it is possible to provide the tire with toe-in/toe-out by appropriately setting the position of the point of coupling of the trailing rod to the automobile body, the mounting angle of automobile body side arm coupled to lower arm inner end, etc.
FIG. 11 is a schematic plan view showing an instance of adopting an L type lower arm 75. The lower arm 75 has its inner front and rear ends coupled to automobile body side arms 76 and 77 coupled to automobile body 78 (as shown shaded), and its outer front end is coupled directly to the automobile body (not shown). To provide toe-in/to-out when the tire bumps and rebounds, the axis of the automobile side arm coupled to the inner rear end of the lower arm is inclined outwardly downward. With this arrangement, when the tire bumps, the coupling point between the automobile body side arm and lower arm is displaced transversally outward to provide toe-in. When the tire rebounds, on the other hand, the coupling point is displaced transversally inward to provide toe-out.
FIGS. 12 and 13 show instances of application of the invention to semi-trailing type suspensions. Designated at 79 is a trailing arm with a center O' of momentary rotation, a 80 an automobile body side arm, at 82 a push rod coupling a lever fulcrumed on the automobile body and the training arm 79, and at 84 is a pull rod coupling the lever 83 and coupling point 81. At the time of the bumping, the coupling point 81 is displaced upward. At the time of the rebounding, it is displaced downward. Thus, it is possible to bring the center of momentary rotation of the trailing arm 79 to a position further ahead of the coupling point 81.
FIG. 14 is a view taken in vertical direction of automobile, showing an example of relation between the the axis of rotation of the automobile body side coupling point of the automobile body side arm and the axis of rotation of the coupling point between the wheel carrier side and automobile body side arms. As shown, an angle θ is provided between the axis A--A' of rotation of points 85 of coupling of automobile body side arms 86 and 87 to automobile body and the axis B--B' of rotation of points of coupling of wheel carrier side arms 89 and 90, on one hand, which have their outer end coupled to wheel carrier 88, and the automobile body side arms 86 and 87, on the other hand. This arrangement permits a change to toe-in/toe-in at the time of the bumping/rebounding. To provide the angle θ, the length of the automobile body side arm 86 nearer the front of the automobile body (as shown 1 by arrow in FIG. 14) is set to be less than the length of the automobile body side arm 87 nearer the rear of the automobile body. With this arrangements, the transversal displacement of the coupling point 91 between the automobile body side arm 86 nearer the front and the wheel carrier side arm 89 is less than that of the coupling point 92 between the automobile body side arm 87 nearer the rear and the wheel carrier side arm 90. Thus, the change to toe-in/toe-in can be obtained at the time of the bumping/rebounding.
Where the lengths of the automobile body side arms 86 and 87 are set to be equal while providing an inwardly downward inclination of the axis of the automobile body side arm 87 nearer the rear, for obtaining a change toe-in/toe-out at the time of bumping/rebounding, the axis of the automobile body side arm 87 nearer the rear is inclined outwardly downward. In this arrangement, the transversal displacement of the automobile body side arm 87 nearer the rear is greater than that of the arm 86 nearer the front. Thus, it is possible to obtain a change to toe-in/toe-out at the time of the bumping/rebounding, (however, the the axes of the two automobile body side arms are set to be at an equal angle to the horizontal).
In each of the above embodiments, the distances between mounting positions, mounting angles, etc. of mounting portions of individual parts are of course adequately designed in accordance with the status of the automobile and various conditions of application.
Now, functions of the embodiments will be described.
In the embodiment of FIG. 3, when the tire bumps in response to an input from the road surface, the strut unit 9 absorbs and alleviates the input energy while shrinking with respect to the coupling point of the strut unit piston rod 10 to the automobile body.
At the same time, the arm outer end is coupled to the wheel carrier 11. Further, the wheel carrier side arm 12, which has its axis inclined outwardly downward, is rotated upwardly outward about the coupling point 14 to the inner end of the automobile body side arm 13 (although the upper side with respect to the status parallel to the road surface is changed upwardly inward). However, since the inner end of the automobile body side arm, i.e. the coupling point 14 to the wheel carrier side arm, is coupled via the pull rod 15 to the strut unit, with an upward movement of the strut unit the automobile body side arm, which has its axis inclined inwardly downward about the automobile body side coupling point, is pulled upwardly inward. Thus, the position of the inner end of the wheel carrier side arm, i.e., the fulcrumed point of the wheel carrier side arm, is moved in the same direction as the tire bump. Particularly, on the important bump side the camber characteristic is changed to the negative side. Further, regarding the tread Change, with a change to the outer side (i.e., to the plus side) caused by upward rotation of the wheel carrier side arm the automobile body side arm is changed upward and to the inner side (i.e., to the minus side). Thus, the tread change can be held small.
When the tire rebounds, the wheel carrier side arm 12 is downwardly inward about the coupling point 14 to the inner end of the automobile body side arm 13, thus tending to change the tire camber to the positive side and change the tread to the inner side (i.e., to the minus side). However, simultaneously with the rebounding of the tire, the pull rod 15 coupled to the strut unit 9 is moved downward. Thus, the arm outer end is coupled to the automobile body, and thus the automobile body side arm 13 with the axis thereof inclined inwardly downward is rotated downwardly outward about about its coupling point to the automobile body (i.e., to change the camber to the negative side and change the tread to the plus side).
As a result, the inner end position of the wheel carrier side arm 12, i.e., the fulcrumed point of this arm, is moved outward on the same downward side as the rebound side of the tire. This means that, unlike the prior art strut type suspension, there is no possibility of a great change of the camber characteristic to the positive side on the rebound side or a great change of the tread characteristic to the minus side on the bump side. Thus, on the rebound side, the camber characteristic can be changed to the negative side while holding the tread characteristic change to be small, and on the bump side the camber characteristic can be changed to the negative side.
Further, in the instance of FIG. 3, the axes of the wheel carrier side and automobile body side arms are inclined outwardly and inwardly downward, respectively, this arrangement is by no means limitative. That is, it is possible to use various combinations of the arrangements of the wheel carrier side and automobile body side arm axes, such as in outwardly downward inclination, horizontal, inwardly downward inclination, etc. for appropriate setting of the distances between mounting positions, mounting angles, etc. of the wheel carrier side and automobile body side arms, pull rod, etc. to secure optimum camber and tread characteristics of tire matching varying running state of the automobile.
For instance, as for the camber characteristic, great camber change can be obtained by setting the lengths, mounting positions, mounting angles, etc. of the arms and pull rod such that the center O of rotation of the wheel carrier is moved to the wheel carrier side (i.e., to left lower side in FIG. 3), that is, the distance between the center P of tire in contact with ground and the center O of rotation of the wheel carrier, i.e., the "swing arm length", is reduced as bumping proceeds. This means that with wide tires which are finding increasing applications in recent years, the wide tread surface can be urged uniformly against the road surface at all times.
In the embodiments of FIG. 4 and following Figures, the functions are basically the same as those described above. In the embodiment of FIG. 4, like the embodiment of FIG. 3, the inner ends of the double wishbone type suspension wheel carrier upper and lower arms 18 and 19, i.e., the positions of the centers of rotation of the two wheel carrier side arms, are controlled by the pull rod 27. The up-and-down motion of the tire is transmitted from the wheel carrier side upper arm 18, which is coupled to the wheel carrier 17, via the pull rod 27 to the lower coupling point 25a and thence via the upper coupling point 24 to the positions of the inner end of the wheel carrier side lower and upper arms 19 and 18, i.e., the centers of rotation of these arms, thus moving these positions in the same direction as the tire movement.
In this embodiment, it is again possible to obtain optimum suspension geometry of tire matching varying running status of the automobile.
In modifications of the embodiment of FIG. 4, it is possible to further improve the above various effects as noted earlier.
In the embodiments of FIGS. 5 and 6, the positions of the fulcrumed inner ends of the strut or double wishbone type suspension wheel carrier side arms are controlled by a push rod instead of a pull rod which is used in the above embodiments. In the strut type, the automobile body side arm 30 or the coupling point 32 is pulled upland down in the same direction as the tire movement by the push rod 28 interlocked to the up-and-down movement of the tire. In the double wishbone type, the automobile side upper arm 36 or the coupling point 38 is moved likewise with the push rod 34. In this way, the fulcrumed position 32 of the wheel carrier side lower arm 31 or the fulcrumed positions 39 and 38 of the wheel carrier side lower and upper arms 35 and 37 can be controlled.
In the embodiments of FIGS. 7 and 8, the up-and-down movement of the tire is transmitted to the push rod 42 or 53 with the lower end thereof coupled to the wheel carrier 43 or 52 and then via the upper end of the push rod to the lever 45 or 56 fulcrumed on the automobile body and thence via the pull rod 46 or 57, which has its upper end coupled to the lever and to the automobile body side arm 47 or 58 or 59, to which the lower end of the pull rod is coupled, or to the coupling point 48 or 60 or 61 to pull up or down thee arm or the coupling point in the same direction as the tire movement. In this way, the inner end of the wheel carrier side arm 44 or 54 or 55 is position controlled.
In the embodiment of FIG. 9, in response to up-and-down tire movement the coupling point 67 is moved in the same direction as the rife movement by the push rod 68 coupling the intermediate position of the lower arm 64 and the coupling point 67. In this way, the inner end of the wheel carrier side arm 65 is position controlled.
In the embodiments of FIG. 10, in response to up-and-down tire movements the coupling point 73 is moved in the same direction as the time movement by the pull rod 74 coupling the intermediate position of the upper arm 72 and the coupling point 73 for position control of the inner end of the wheel carrier side arm 70.
In the embodiments of FIGS. 12 and 13, the up-and-down movement of tire is transmitted from the upper end of the push rod 82, which is coupled to the lower end of the swing arm 79 interlocked to the up-and-down tire movement, to the lever 83 with an end thereof coupled to the automobile body, and thence via the pull rod 84, which has its upper end coupled to the lever and its lower end coupled to the coupling point 81 to cause movement thereof in the same direction as the tire movement. In this way, the center O' of rotation of the swing arm 79 can be moved further forward than the coupling point 81 of the automobile side arm 80. These embodiments are applicable to a two-wheeled automobile suspension, particularly to the rear wheel thereof. In this case, by arranging the coupling point center line 81--81 perpendicular to the automobile center line and parallel to the rear wheel axis, it is possible to provide a rear suspension having a great wheel stroke.
With the structures as described above according to the invention, the following effects can be obtained.
According to the invention, the position of the coupling point between the inner end of the wheel carrier side arm coupled to the wheel carrier and the automobile body side arm, i.e., the position of the center of the wheel carrier side arm, can be moved up and down and also to the left and right in an interlocked relation to the up-and-down movement of the tire and in the same direction of tire movement. It is thus possible to set the camber, i.e., the inclination of the wheel carrier carrying the wheel mounted thereon with respect to the road surface, the tread, i.e., the distance between tire centers in contact with the ground, the wheel stroke, etc., to obtain the optimum suspension geometry for the automobile. Thus, the steering stability and comfortability can be improved with improved whirling and straight running performance. In addition, even when the invention is applied to the low profile tire which has recently gaining popularity, it is possible to hold the tire vertical to the road surface at all times. This means that the wear of the tire can be uniformalized to extend the tire life. Further, the length of various arms in the suspension can be reduced compared to that in the prior art to increase the mechanical strength of the arms and reduce the weight thereof, as well as increasing the space of the engine room, the trunk, and passenger room.
Further, according to the invention, in addition to the above effects, a pull rod, a push rod or a structure of a push and a pull rod coupled together by a lever having an end coupled to the automobile body may be used as the means for moving the coupling point between the automobile body side and wheel carrier side arms or the automobile body side arm up and down and also to the left and right in an interlocked relation to the tire and in the same direction as the up-and-down movement of the tire. Thus, moving means, which are simple in construction and comprise a reduced number of components, can be realized. When the invention is applied to the strut type suspension, it is thus possible, in addition to be able to make use of the prior art, to permit movement of the center of revolution of the wheel carrier to the side thereof as in the double wishbone type suspension without greatly changing the individual mounting parts or increasing the number of components. This permits improvement of the camber and tread characteristics.
Further, by adopting the double wishbone type suspension, further improvement of the camber and tread characteristics can be obtained which improves whirling performance compared to the prior art and also reduces the tread change, thus improving the straight running stability and hence the steering stability and ensures safe and comfortable running. Further, since the arm length can be reduced, weight reduction can be obtained. Further, by adopting the semi-trailing or trailing suspension the center of rotation of the trailing arm can be moved to a position ahead of the coupling point between the trailing arm and the automobile body side arm. Thus, the swing of the trailing arm with a greater rotation radius than the actual length of the trailing arm can be obtained. When this structure is adopted for a rear suspension, it is thus possible to improve the ride comfortability without reducing rear seat space or the like.
Further, according to the invention, it is possible to provide a suspension which permits the above effects to be obtained without a cost increase, by adopting the prior art structure for the lower arm.
Further, according to the invention, it is possible to provide a suspension which can make use of the merits of the high-mount type upper arm inexpensively by adopting the prior art structure for the upper arm. | An automobile suspension, either of strut or double wishbone type, which can solve the problems in the prior art suspension including trends of vertical tire stroke shortage and limitations imposed on the whirling and straight running performance due to space restrictions, because the geometry in the up-and-down movement of the wheel carrier determined by the length, mounting position, mounting angle, etc. of upper and lower arms in the suspension.
To this end, in the strut type suspension two different positions on an automobile body side lower arm are selected as a coupling point for a wheel carrier side lower arm and a pull rod to improve the degree of freedom of the suspension geometry design. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to a method for driving the shuttles of a wave-shed loom by reed blades which, during operation, in their entirety press against the transport edge of the shuttles and carry out a ripple or undulating movement in a direction advancing over the width of the loom.
In known wave-shed looms, in which the shuttles are driven by means of swingable reed blades, relatively high frictional forces occur between the transport edge of the shuttles and the reed blades. This leads, on the one hand, to the transport edges of the plastic shuttles becoming so greatly worn that they show sawtooth-like scorings after a relatively short period of operation, as a result of which the shuttles become unusable. On the other hand, the high frictional forces can have the result that in those types of machines in which the shuttles are not guided during their insertion movement by a special guide comb but merely by the warp yarns, the shuttles assume an oblique position and emerge upward or downward out of the warp yarns.
SUMMARY OF THE INVENTION
The object of the present invention eliminates these disadvantages and is achieved in the manner that the transport edge of each shuttle is acted on by a lubricant before its entrance into the warp yarns.
Practical tests have shown that the aforementioned disadvantages are completely avoided by the process of the invention and that, with suitable application of the lubricant, the soiling of the warp yarns with lubricant, which may at first blush be feared by the man skilled in the art, does not occur.
The invention furthermore relates to a wave-shed loom for the carrying out of said process having reed blades which extend at the place where the web is formed, between the warp yarns, and which are arranged alongside of each other along an axis of swing over the weaving width of the loom.
The wave-shed loom of the invention is characterized by a lubricating member, arranged in the region alongside the warp threads, connected to a lubricant reservoir and providing lubrication to the transport edge of the shuttles during operation.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be explained in further detail with reference to an illustrative embodiment and the figures of the drawing, in which:
FIG. 1 is a view in perspective showing diagrammatically a portion of a wave-shed loom with shuttles and the reed blades driving them;
FIG. 2 is a view in perspective of a shuttle, seen in the direction of the arrow II in FIG. 1;
FIG. 3 is a corresponding top view of the reed blades in the region of selvage at the outlet side of the shuttle, seen in the direction indicated by the arrow III in FIG. 1; and
FIG. 4 is a view in perspective, seen in the direction of the arrow IV in FIG. 3, represented on a larger scale.
DESCRIPTION OF PREFERRED EMBODIMENT
Referring to FIG. 1, warp yarns 1, which are moved by heddles 2 and extend towards the fell of the cloth, form an open shed at the place of the front part of each shuttle 3. Between every two successive shuttles 3 a change of shed takes place. The sheds propagate themselves in ripple shape in the direction indicated by the arrow A; the shuttles 3 move together with the sheds in the same direction and during their transport insert one filling yarn 5 each. The warp yarns 1, for clarity in the drawing, have been shown less close together than is actually the case. The cloth formed by the insertion of the filling yarns 5 is designated by 6.
The forward movement of the shuttles 3 is effected by reed blades 4 which act as shuttle drive and filling-yarn beating-up members and extend between the warp yarns 1 and are pressed from the rear against the rear beveled edge 10 of the shuttles 3 (as seen in the direction of transport) and thereby move the shuttles in the direction indicated by the arrow A. At the same time, the corresponding filling yarns 5 are beaten-up against the fell of the cloth by those reed blades 4 which are swung furthest forward. The guiding of the shuttles 3 in the corresponding shed is effected by the warp yarns 1.
As shown in FIG. 2, the shuttles 3 are of elongated, flat, U-shape and consist essentially of two side walls connected with each other along the upper edge 7 of the shuttle and the greatest part of the tip 8 of the shuttle. At the lower edge 9 and at the rear beveled edge 10 the two side walls are not connected with each other. As a result of the U-shape of the shuttles 3, only the arm of the U-shaped rear beveled edge 10 of the shuttle 3 which is at the bottom in FIG. 1 and facing the viewer in FIG. 2 is in contact with the reed blades 4 upon the transportation of the shuttle. This part of the rear oblique edge 10 of the shuttles 3 is referred to hereinafter as the transport edge 11 of the shuttles 3.
Within the shuttles 3 there is maintained, in operation, a yarn package consisting of adjacent loops which has a length sufficient for the required weaving width, the holding of the yarn package being effected exclusively by the inner surfaces of the side walls of the shuttles 3 and by elastic inserts mounted on said inner surfaces. Upon the transport of the shuttles 3 through the sheds, the filling yarn 5 (as can be noted from FIG. 1) is pulled continuously obliquely forward out of the shuttle 3 at the rear oblique edge 10.
The shuttles 3 consist of a suitable plastic, for example polyacetal, and are provided at their transport edge 11 with a reinforcing runner 12 in the form of a small thin plate. The reinforcing runner 12 serves to reduce the wearing down of the transport edge 11 by the reed blades 4 (FIG. 1) and consists of a sufficiently hard material of a hardness corresponding approximately to that of spring steel. Of the metallic materials entering into consideration for the reinforcing runner, a heat-treated beryllium bronze alloy of a hardness of 42 Rockwell has proven particularly suitable.
In accordance with FIGS. 3 and 4, within the region of the selvage (indicated by a dot-dash line 13) on the outlet side of the shuttle 3 from the group of warp yarns, there is provided a lubricating member or means 15 which is connected via a small hose 14 to a reservoir B containing liquid lubricant, for instance polyethylene glycol. The lubricant reservoir B is mounted on a member 21 which member is fastened to the machine frame. The lubricating member 15 feeds lubricant from reservoir B and serves to provide the transport edge 11 of the shuttles 3 with lubricant after the emergence of the shuttles from the warp yarns 1 (FIG. 1) and thereby reduce the friction between the transport edge 11 and the reed blades 4 by presenting a film of lubricant over the reinforcement runner 12 so that upon the following insertion of the shuttle, the transport edge 11 will not become worn. The oil is applied as a thin film to the reinforcement runner 12 (FIG. 2) so that it remains in adherence to the latter in an amount sufficient for the desired lubricating action without there resulting any recognizable soiling of the warp yarns. In the case of shuttles 3 which are made of polyacetal, the reinforcing runner 12 has proven particularly advantageous with respect to the lubrication since polyacetal is a material which cannot be wetted, or only wetted with difficulty, and accordingly the application of a suitable film of lubricant would involve at least great difficulties.
The lubricating member 15, as shown in the drawing, is formed by the outermost reed blade 4' at the outlet side of the shuttle. This reed blade 4' whose length is reduced as compared with that of the other reed blades 4 bears a prismatic lubricating part 16 at its front end. The lubricating part 16 is provided in the region of the front surface 17, viewed from the cloth 6 (FIG. 1) in the longitudinal direction of the reed blade 4', with a first borehole 18 in which a lubricating wick 19 is held. The front surface 17 is so beveled up to near its upper and lower ends that the borehole 18 containing the lubricating wick 19 is partially exposed. The length of the shortened reed blade 4', the dimensions of the lubricating part 16, as well as the bevel of the front surface 17 are so designed that the lubricating wick 19 lies in the path of movement of the transport edge 11 and faces the latter. The lubricating part 16 is furthermore provided with a borehole 20 which extends perpendicular to the first borehole 18 and discharges into same, the hole 14 connected to the reservoir discharging into said borehole 20.
It will be appreciated that it is not absolutely necessary for the lubricating member 15 to be arranged on the outlet side of the shuttle; the lubricating member 15 of course may be mounted outside the group of warp yarns on the shuttle entrance side.
It will also be appreciated that various changes and/or modifications may be made within the skill of the art without departing from the spirit and scope of the invention illustrated, described, and claimed herein. | A method of driving shuttles through sheds formed by warp yarns of a wave-type loom in which a transport edge of the shuttles is lubricated before entrance into the warp yarns, and a wave-shed loom for carrying out the method of driving the shuttles. | 3 |
CROSS-REFERENCE
[0001] The present application claims priority to U.S. Provisional Application No. 61/426,811, filed Dec. 23, 2010, the entirety of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to a crankshaft for a two-stroke engine and to a two-stroke engine comprising such crankshaft.
BACKGROUND
[0003] As with other types of internal combustion engines, two-stroke engines comprise a crankshaft disposed in a crankcase for converting the linear movement of the engine's piston, or pistons, into rotating torque. The crankshaft usually comprises a crankshaft body made of a single piece of hard material, such as steel, and the main components of the crankshaft are integrally formed with the crankshaft body. In some instances, the crankshaft body may also be made of parts connected together by various means known in the art. The crankshaft is rotatably connected to the crankcase via a plurality of main bearing assemblies, and rotatably connected to the connecting rods transmitting the energy generated by the pistons via connecting rod bearing assemblies. Since the crankshaft usually rotates at high speed within the crankcase, the various bearing assemblies connected thereto, including the connecting rod bearing assemblies, need to be appropriately lubricated.
[0004] Two-stroke engines do not generally have sophisticated pressurized lubrication systems for lubricating all the various components of the crankshaft and the various components connected thereto such as those generally found in four-stroke engines. This is particularly true regarding vertically oriented two-stroke engines used in marine outboard engines.
[0005] In particular, it is know in the art to lubricate the connecting rod bearing assemblies of vertically oriented two-stroke engines by spraying lubricant within the crankcase in the vicinity of the connecting rod bearing assemblies rotating path using low capacity lubricant pumps. U.S. Pat. No. 5,193,500 and U.S. Pat. No. 5,375,573 provide examples of such connecting rod bearing assemblies lubrication systems.
[0006] However, since lubricant is not discharged directly within or close to the connecting rod bearing assemblies, a significant volume of lubricant is required to appropriately lubricate the connecting rod bearing assemblies. Furthermore, a significant portion of the lubricant sprayed into the crankcase finds its way to the combustion chamber of the cylinders, and incomplete combustion of such lubricant within the combustion chamber increases the engine's pollutant emissions.
[0007] In view of the above, there is a need for a vertically oriented two-stroke engine having a lubrication system for the connecting rod bearings assemblies discharging a limited volume of lubricant in the vicinity of such connecting rod bearing assemblies so that less lubricant need to be used and less lubricant is ultimately burned in the combustion chamber, which entails that less pollutant emissions are release in the atmosphere when the two-stroke engine is used.
SUMMARY
[0008] It is an object of the present invention to ameliorate at least some of the inconveniences present in the prior art by providing a crankshaft having a receiving platform for catching lubricant dropping from a main bearing assembly, the receiving platform having at least one wall disposed thereon, said wall having one point that is the furthest from the rotational axis of the crankshaft, and one channel defined in the platform having an inlet disposed close to the point of the wall that is furthest from the rotational axis of the crankshaft, the channel having an outlet in the vicinity of a connecting rod bearing assembly, so that lubricant dropped on the receiving platform will flow to the connecting rod bearing assembly.
[0009] It is another object of the present invention to provide a crankshaft for a two-stroke engine having a crankshaft body defining a rotational axis. The crankshaft body comprises at least one main bearing journal and at least one crankpin connected thereto, the at least one crankpin being axially spaced from the at least one main bearing journal. The crankshaft body also comprises at least one receiving platform connected thereto, the at least one receiving platform being disposed between the at least one main bearing journal and the at least one crankpin. The at least one receiving platform has a top surface and a bottom surface, the top surface being disposed between the bottom surface and the main bearing journal. The top surface also has an edge and a wall, portions of the wall being non-equidistant from the rotational axis of the crankshaft body and one of the portions of the wall being furthest from the rotational axis, the one of the portions being an outermost portion. At least one channel is defined at least in part within the at least one receiving platform, the at least one channel having a channel inlet and a channel outlet. The channel inlet is disposed between the outermost portion and the rotational axis, in proximity to the outermost portion. The channel outlet is disposed in proximity to the at least one crankpin.
[0010] In one aspect, the at least one main bearing journal, the at least one crankpin and the at least one receiving platform are integrally formed with the crankshaft body.
[0011] In an additional aspect, the channel outlet is further from the rotational axis than the channel inlet.
[0012] In a further aspect, at least a portion of the channel extends away from the rotational axis as the channel extends from the channel inlet to the channel outlet.
[0013] In an additional aspect, the wall defines a closed perimeter disposed between the wall and the rotational axis.
[0014] In a further aspect, the shape of the closed perimeter is one of a circle, an oval and an ellipse.
[0015] In an additional aspect, the shape of the closed perimeter is a circle, a center of the circle being offset from the rotational axis.
[0016] In a further aspect, the crankshaft further comprises a recess formed within the top surface of the at least one receiving platform and the inlet of the at least one channel is disposed within the recess.
[0017] In an additional aspect, tithe at least one crankpin is at least two crankpins, the at least one channel is at least two channels, and the at least two channels has respective channel inlets disposed adjacent to each other. One of the two channels has a channel outlet disposed in proximity to one of the at least two crankpins, and an other of the two channels has a channel outlet disposed in proximity to an other of the at least two crankpins.
[0018] In a further aspect, when the crankshaft is in use in the two-stroke engine, the rotational axis is generally vertical, the at least one main bearing journal is housed within at least one main bearing body, the at least one main bearing journal and the at least one main bearing body forming an at least one main bearing assembly, and the at least one crankpin is housed in at least one connecting rod bearing body, the at least one crankpin and at least one connecting rod bearing forming an at least one connecting rod bearing assembly. Lubricant is supplied to the main bearing assembly and at least a portion of the lubricant drops from the main bearing assembly on the top surface of the receiving platform. A portion of the lubricant on the top surface of the receiving platform is induced by centrifugal force to flow to the outermost portion and lubricant within the outermost portion flows in the channel via the channel inlet. Lubricant flowing in the channel is discharged from the channel outlet, and from the channel outlet the lubricant flows to the at least one connecting rod bearing assembly.
[0019] In an additional aspect, the receiving platform is a sealing plate.
[0020] It is another object of the present invention to provide a crankshaft for a two-stroke engine having a crankshaft body defining a rotational axis. The crankshaft body comprises at least one main bearing journal and at least one crankpin connected thereto, the at least one crankpin being axially spaced from the at least one main bearing journal. The crankshaft body also comprises at least one receiving platform connected thereto, the at least one receiving platform being disposed between the at least one main bearing journal and the at least one crankpin. The at least one receiving platform has a top surface and a bottom surface, the top surface being disposed between the bottom surface and the main bearing journal. The top surface has an edge and at least one wall, portions of the at least one wall being non-equidistant from the rotational axis of the crankshaft body and at least one portion of the at least one wall being more distant from the rotational axis than the other portions of the at least one wall, the at least one of the portions being at least one outer portion. At least one channel is defined at least in part within the at least one receiving platform, the at least one channel having a channel inlet and a channel outlet. The channel inlet is disposed between the at least one outer portion and the rotational axis, in proximity to the at least one outer portion. The channel outlet is disposed in proximity to the at least one crankpin.
[0021] In a further aspect, the at least one main bearing journal, the at least one crankpin and the at least one receiving platform are integrally formed with the crankshaft body.
[0022] In an additional aspect, the channel outlet is further from the rotational axis than the channel inlet.
[0023] In a further aspect, the at least one channel extends away from the rotational axis as the at least one channel extends from the channel inlet to the channel outlet.
[0024] In an additional aspect, the at least one wall is at least two walls, the at least one outer portion is at least two outer portions, and the at least one channel is at least two channels. Each one of the at least two channels has an inlet and an outlet. Each of the at least two outer portions has disposed therein at least one of the channel inlets.
[0025] In a further aspect, the at least one crankpin is at least two crankpins and the channel outlet of at least one of the at least two channels is disposed in proximity to one of the at least two crankpins. The channel outlet of at least one other of the at least one channel is disposed in proximity to at least one other of the at least two crankpins.
[0026] It is another object of the present invention to provide a crankshaft for a two-stroke engine having a crankshaft body defining a rotational axis. The crankshaft body comprises at least one main bearing journal and at least one crankpin connected thereto, the at least one crankpin being axially spaced from the at least one main bearing journal. The crankshaft also comprises at least one receiving platform connected thereto, the at least one receiving platform being disposed between the at least one main bearing journal and the at least one crankpin. The at least one receiving platform has a top surface and a bottom surface, the top surface being disposed between the bottom surface and the main bearing journal. The top surface has an edge and a wall defining a closed perimeter, portions of the closed perimeter being non-equidistant from the rotational axis and at least one portion of the closed perimeter being more distant from the rotational axis than the other portions of the closed perimeter, the at least one of the portions being at least one outer portion. At least one channel is defined at least in part within the at least one receiving platform, the at least one channel having a channel inlet and a channel outlet. The channel inlet is disposed within the closed perimeter in proximity to the at least one outer portion, and the channel outlet is disposed in proximity to the at least one crankpin.
[0027] In an additional aspect, the at least one main bearing journal, the at least one crankpin and the at least one receiving platform are integrally formed with the crankshaft body.
[0028] In a further aspect, the at least one channel is at least two channels, each one of the at least two channels having an inlet and an outlet. The at least one outer portion of the closed perimeter is at least two outer portions, and each of the at least two outer portions have disposed therein at least one of the channel inlets.
[0029] In an additional aspect, the at least one crankpin is at least two crankpins. The channel outlet of at least one of the at least two channels is disposed in proximity to one of the at least two crankpins, and the channel outlet of at least one other of the at least one channel is disposed in proximity with at least one other of the at least two crankpins.
[0030] It is another object of the present invention to provide a two-stroke engine comprising an engine casing, at least one cylinder disposed within the engine casing, and at least one piston movable within the at least one cylinder. The two-stroke engine also comprises a crankshaft having a crankshaft body defining a rotational axis. The crankshaft body comprises at least one main bearing journal, at least one crankpin and at least one receiving platform having a top surface and a bottom surface, the at least one main bearing journal, crankpin and receiving platform being connected to the crankshaft body. The at least one crankpin is axially spaced from the at least one main bearing journal and the at least one receiving platform is disposed so that to top surface is disposed between the bottom surface and at least one main bearing journal. The crankshaft is rotatably mounted within the engine casing via at least one main bearing assembly comprising a main bearing body and one of the at least one main bearing journal, the main bearing body being connected to the engine casing. At least one connecting rod has a first end and a second end, the first end being operatively connected to the at least one piston and the second end being rotatably connected to the crankshaft via a connecting rod bearing assembly comprising a connecting rod body and one of the at least one crankpin, the connecting rod body being connected to the second end of the connecting rod. The top surface of the at least one receiving platform has an edge and a wall, portions of the wall being non-equidistant from the rotational axis and one of the portions of the wall being furthest from the rotational axis, the one of the portions being an outermost portion. At least one channel is defined at least in part within the at least one receiving platform, the at least one channel having a channel inlet and a channel outlet. The channel inlet is disposed between the outermost portion and the rotational axis, in proximity to the outermost portion. The channel outlet is disposed in proximity to the connecting rod bearing assembly of one of the at least one connecting rod.
[0031] In an additional aspect, the at least one main bearing journal, the at least one crankpin and the at least one receiving platform are integrally formed with the crankshaft body.
[0032] In a further aspect, the channel extends away from the rotational axis as the channel extends from the channel inlet to the channel outlet.
[0033] In an additional aspect, the wall defines a closed perimeter.
[0034] For purposes of this application, terms used to locate elements on an engine or their spatial orientation, such as “forwardly”, “rearwardly”, “front”, “back”, “rear”, “left”, “right”, “up”, “down”, “above”, and “below”, are as they would normally be understood by a person operating the engine in its normal operation position.
[0035] Embodiments of the present invention each have at least one of the above-mentioned aspects and/or aspects, but not necessarily have all of them. It should be understood that some aspects of the present invention that have resulted from attempting to attain the above-mentioned objects may not satisfy these objects and/or may satisfy other objects not specifically recited herein.
[0036] Additional and/or alternative features, aspects and advantages of the embodiments of the present invention will become apparent from the following description, the accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] For a better understanding of the present invention as well as other aspects and further features thereof, reference is made to the following description which is to be used in conjunction with the accompanying drawings, where:
[0038] FIG. 1 is a transverse cross-sectional view of a portion of a two-stroke engine;
[0039] FIG. 2 is a perspective view of a crankshaft according to a first embodiment;
[0040] FIG. 3 is a cross-sectional view of a portion of a crankcase and a portion of the crankshaft of FIG. 2 ;
[0041] FIG. 3( a ) is a enlarged portion of FIG. 3 ;
[0042] FIG. 4 is a perspective view of the crankshaft of FIG. 2 with three main bearings and two connecting rods mounted thereto;
[0043] FIG. 5 is a perspective view of an enlarged portion of the crankshaft of FIG. 2 ;
[0044] FIG. 6 is a transverse cross-sectional view of the crankshaft of FIG. 2 taken along line 6 - 6 in FIG. 2 ;
[0045] FIG. 6( a ) is a transverse cross-sectional view of a crankshaft according to another embodiment taken above a sealing plate thereof;
[0046] FIG. 7( a ) is a cross-sectional view of a portion of the crankshaft of FIG. 2 taken along line 7 - 7 in FIG. 6 ;
[0047] FIG. 7( b ) is a cross-sectional view of a portion of the crankshaft of FIG. 2 taken along line 7 - 7 in FIG. 6 ;
[0048] FIG. 8( a ) is another cross-sectional view of a portion of the crankshaft of FIG. 2 taken along line 8 - 8 in FIG. 6 ;
[0049] FIG. 8( b ) is another cross-sectional view of a portion of the crankshaft of FIG. 2 taken along line 8 - 8 in FIG. 6 ;
[0050] FIG. 9 is a cross-sectional view of a portion of a crankshaft according to another embodiment taken along its rotational axis;
[0051] FIG. 10 is a transverse cross-sectional view of a crankshaft according to another embodiment taken above a sealing plate thereof;
[0052] FIG. 11 is a transverse cross-sectional view of a crankshaft according to another embodiment taken above a sealing plate thereof; and
[0053] FIG. 12 is a transverse cross-sectional view of a crankshaft according to another embodiment taken above a sealing plate thereof.
DETAILED DESCRIPTION
[0054] FIG. 1 illustrates a conventional vertically oriented two-stroke engine 10 comprising a crankcase 12 and a cylinder block 14 connected to the crankcase 12 .
[0055] A cylinder 16 is disposed in the cylinder block 14 and has an exhaust port 18 and a transfer port 19 . The cylinder 16 may be formed in the cylinder block 14 in any suitable manner known in the art, such as by disposing a cylinder liner in a cylindrical bore formed in the cylinder block 14 , or by coating the inner surface of the cylindrical bore with a suitable coating such as Nicasil.
[0056] The crankcase 12 has an admission port 20 and an internal chamber 24 . A crankshaft 26 is disposed in the internal chamber 24 of the crankcase 12 .
[0057] A piston 28 is connected to the crankshaft 26 via a connecting rod 30 so as to reciprocate in the cylinder bore 32 . The piston 28 is adapted to open or close the exhaust port 18 and a transfer port 19 .
[0058] The two-stroke engine 10 has more than one cylinder 16 , each having an exhaust port 18 and a transfer port 19 , a corresponding number of piston 28 housed therein and a corresponding number of connecting rod 30 connected to the crankshaft 26 . For each corresponding cylinder 16 , the crankcase 12 has one corresponding admission port 20 and one internal chamber 24 . In this embodiment, the two-stroke engine 10 is a V-6 and has therefore six cylinders 16 disposed in a “V” configuration.
[0059] As shown in FIG. 2 , the crankshaft 26 comprises a crankshaft body 100 defining a rotational axis 102 . The crankshaft body 100 comprises the main bearing journals 104 ( a ), 104 ( b ), 104 ( c ), three groups of two crankpins 106 ( a ), 106 ( b ) and three groups of three sealing plates 108 ( a ), 108 ( b ), 108 ( c ). Each of the main bearing journals 104 , crankpins 106 and sealing plates 108 are integrally formed with the crankshaft body 100 although it is contemplated that in other embodiments, they may consist of distinct parts connected together by any suitable mean known in the art. Each sealing plate 108 has a circumferential groove 109 defined therein for receiving a sealing ring (not shown).
[0060] The crankshaft body 100 also comprises shafts 110 and 112 at each of its extremities. Shaft 110 connects the crankshaft 26 to the flywheel (not shown) of the two-stroke engine 10 , and shaft 112 connects the crankshaft 26 to the drive shaft (not shown) of the two-stroke engine 10 . Counterweights 114 ( a ), 114 ( b ) are disposed on the crankshaft body 100 to balance the crankshaft 26 . It is contemplated that in other embodiments, the crankshaft body may comprises additional bearing journals, including end main bearing journals, as well as other structures for connecting the crankshaft 26 to the two-stroke engine's 10 flywheel and drive shaft. It is also contemplated that in other embodiments, other counterweights may be disposed along the crankshaft body 100 .
[0061] As shown in FIG. 4 , the crankshaft 26 is mounted within the crankcase 12 via main bearing assemblies 200 ( a ), 200 ( b ), 200 ( c ), each of which comprises a main bearing body 202 , one of the main bearing journal 104 housed therein, and a plurality of needle bearings 203 (see FIGS. 3 and 3( a )). The needle bearings 203 are housed in the main bearing body 202 between the main bearing body 202 and the main bearing journal 104 for supporting the main bearing journal 104 within the main bearing body 202 and allowing the main bearing journal 104 to rotate within the main bearing body 202 . Ports 206 are defined within the main bearing body 202 of each main bearing assembly 200 , and a conduit 204 is fluidly connected to each port 206 . Lubricant flows within the main bearing assemblies 200 through conduits 204 and ports 206 .
[0062] As shown in FIG. 4 , the crankshaft 26 is connected to each of the connecting rods 30 via a connecting rod bearing assembly 250 comprising a main bearing body 252 connected to a connecting rod 30 , one of the crankpins 106 housed within the main bearing body 252 , and a plurality of needle bearings (not shown) housed in the main bearing body 252 between the main bearing body 252 and the crankpin 106 for supporting the crankpin 106 within the main bearing body 252 and allowing the crankpin 106 to rotate within the main bearing body 202 .
[0063] As shown in FIGS. 1 to 4 , the sealing plates 108 are disposed between each main bearing journal 104 and crankpins 106 for defining internal chambers 24 within the crankcase 12 . When the crankshaft 26 is standing in a vertical position in the crankcase 12 of the vertically oriented two-stroke engine 10 , the sealing plates 108 ( a ) are disposed adjacent to and below each one of the main bearing journals 104 and therefore, once the crankshaft 26 is mounted in the crankcase 12 , adjacent to and below each main bearing assemblies 250 . The sealing plates 108 ( b ) are disposed between successive crankpins 106 along the crankshaft body 100 and therefore, once the crankshaft 26 is connected to the connecting rods 30 , between two connecting rod bearing assemblies 250 . When the crankshaft 26 is standing in a vertical position, sealing plates 108 ( c ) are disposed adjacent to and above each one of the main bearing journals 104 and therefore, once the crankshaft 26 is mounted in the crankcase 12 , adjacent to and above each main bearing assemblies 250 .
[0064] It is contemplated that in other embodiments where the two-stroke engine 10 does not have independent internal chambers 24 , the crankshaft body 100 would not comprise sealing plates 108 but rather other structures connecting the main bearing journals 104 and crankpins 106 .
[0065] As shown in FIG. 5 each one of the sealing plates 108 ( a ) defines a platform 300 having a top surface 302 , and a bottom surface 304 . It is contemplated that in other embodiments where the crankshaft body 100 does not comprise sealing plates 108 , the platforms 300 are defined by the other structure connecting the main bearing journals 104 and crankpins 106 .
[0066] The top surface 302 has an edge 306 and a wall 308 defining a closed perimeter 310 . In this embodiment, the wall 308 is formed by a ring 312 made of steel and welded to the top surface 302 . It is contemplated that in other embodiments, the ring 312 may be made of any other hard material fastened to the top surface 302 by any other suitable mean. It is also contemplated that in other embodiments, the wall 308 can be integrally formed with the platform 300 . It is also contemplated that the wall 308 could be formed by a recess in the platform 300 .
[0067] As shown in FIG. 6 , the closed perimeter 310 defines a circle having a central point 311 that is offset from the rotational axis 102 . Point 314 is a point along the closed perimeter 310 that is further from the rotational axis 102 than any other point of the closed perimeter 310 . In this embodiment, the point 314 is also closer to the edge 306 than any other point of the closed perimeter 310 . FIG. 6( a ) shows another embodiment in which the circle defined by the closed perimeter 310 has been moved further toward a portion of the edge 306 to more clearly show that the central point 311 is offset from the rotational axis 102 .
[0068] It is contemplated that in other embodiments, the closed perimeter 310 may have any other suitable form or shape, such as an oval, an ellipse, an hexagon, an octagon, or any regular or irregular form or shape, as long as the closed perimeter 310 has a point such as the point 314 that is further from the rotational axis 102 than any other point of the closed perimeter 310 , whether this is due to the particular shape of the closed perimeter 310 and/or to how the perimeter 308 is disposed within the top surface 302 .
[0069] As shown in FIGS. 3 , 3 ( a ) and 7 ( a ), a channel 316 is defined within the platform 300 and the crankpin 106 ( a ) that is adjacent to and below the platform 300 . The channel 316 comprises two portions 316 ( a ) and 316 ( b ) and has an inlet 318 defined within the closed perimeter 310 of the top surface 302 , close to the point 314 . The channel 316 also has an outlet 320 defined within the exterior surface of the crankpin 106 ( a ) and facing the needle bearings (not shown) within the connecting rod bearing assembly 250 .
[0070] As shown in FIG. 8( a ), a second channel 324 is defined within the platform 300 , the crankpin 106 ( a ), the sealing plate 108 ( b ) and the crankpin 106 ( b ) that is adjacent and below the sealing plate 108 ( b ). The channel 324 comprises two portions 324 ( a ) and 324 ( b ) and has an inlet 326 defined within the closed perimeter 310 of the top surface 302 , close to the point 314 . The channel 324 also has an outlet 328 defined within the exterior surface of the crankpin 106 ( b ) and facing the needle bearings (not shown) within the connecting rod bearing assembly 250 .
[0071] As shown in FIGS. 7( b ) and 8 ( b ), axes 315 , 325 passing through and parallel to portions 316 ( a ), 324 ( b ) of the channels 316 , 324 define acute angles with axis 101 , 103 which are parallel to the rotational axis 102 such that the lower portions 332 , 334 of the portions 316 ( a ), 324 ( b ) of the channels 316 , 324 are further from the rotation axis 102 than the inlets 318 , 326 .
[0072] It is contemplated that in another embodiment (not shown), the channels 316 , 324 can be made of only one portion extending from the inlets 318 , 326 to the outlets 320 , 328 , and that the outlets 320 , 328 can be disposed in other locations in proximity with crankpins 106 ( a ), 106 ( b ) or the connecting rod bearing assemblies 250 . It is also contemplated that one of channels 316 , 324 can have other portions such as portions 316 ( a ), 316 ( b ), 324 ( a ), 324 ( b ) and that one of channels 316 , 324 can split into two or more channels (not shown) so that one of inlets 318 , 326 may be fluidly connected to the two outlets 320 , 328 .
[0073] In the embodiment described in FIGS. 1 to 9 , when the crankshaft 26 is in use in the crankcase 12 of the vertically oriented two-stroke engine 10 , lubricant is supplied to each of the main bearing assemblies 200 via conduits 204 and ports 206 . A portion of the lubricant supplied to the main bearing assemblies 200 drops therefrom on the top surfaces 302 of each platforms 300 defined by the sealing plates 108 . A portion of the lubricant received by the platforms 300 falls within the closed perimeter and is induced by centrifugal force to flow toward the wall 308 . The centrifugal force then causes the portion of the lubricant to flow along the wall 308 toward the point 314 and to accumulate in the portion of the closed perimeter 310 which is close to the point 314 against the wall 308 . A portion of the lubricant accumulated in the portion of the closed perimeter 310 which is close to the point 314 flows within the channels 316 , 324 via the inlets 318 , 326 and is discharged from the outlets 320 , 328 in the connecting rod bearing assemblies 250 . Since portions 316 ( a ), 324 ( a ) of the channels 316 , 324 extend downwardly away from the rotation axis 102 , the centrifugal force assists the gravitational force for drawing lubricant into the inlets 318 , 328 and through the channels 316 , 324 .
[0074] It is contemplated that in another embodiment shown in FIG. 9 , a recess 317 is defined in top surface 302 of the platform 300 close to the point 314 , and the inlets 316 , 326 are disposed within the recess 315 . When the crankshaft 26 is in use in the crankcase 12 of the vertically oriented two-stroke engine 10 , lubricant accumulates in the recess 317 .
[0075] In another embodiment shown in FIG. 10 , the closed perimeter 310 defines an ellipse and has two points 314 ( a ), 314 ( b ) that are further from the rotational axis 102 than any other point of the closed perimeter 310 . The inlet 318 is defined within the closed perimeter 310 , close to the point 314 ( a ), while the inlet 326 is defined within the closed perimeter 310 , close to the point 314 ( b ). It is contemplated that in another embodiment, (not shown) recesses such as the recess 317 can be defined in the top surface 302 of the platform 300 close to each of the points 314 ( a ), 314 ( b ) and that the inlets 318 , 326 can be disposed within those recesses. Channels (not shown) such as channels 316 , 324 have a suitable number of portions (not shown) such as portions 316 ( a ), 316 ( b ), 324 ( a ), 324 ( b ) suitably defined within the platform 300 , and have outlets (not shown) such as outlets 320 , 328 disposed in the exterior surface of one of the crankpins 106 ( a ), 106 ( b ), or in proximity with the crankpins 106 ( a ), 106 ( b ) or the connecting rod bearing assemblies 250 .
[0076] It is also contemplated that in other embodiments (not shown) the closed perimeter 310 may define any other shape having two or more points such as point 314 that are further from the rotational axis 102 than any other point of the closed perimeter 310 and a corresponding number of channel inlets such as inlets 318 , 326 connected to two or more channels such as channels 316 , 324 (which may have various suitable portions such as portions 316 ( a ), 316 ( b ), 324 ( a ), 324 ( b ) defined with the platform 300 ) having outlets such as outlets 320 , 328 disposed in the exterior surface of the crankpins 106 ( a ), 106 ( b ), or in proximity with the crankpins 106 ( a ), 106 ( b ) or the connecting rod bearing assemblies 250 .
[0077] In a further embodiment shown in FIG. 11 , the wall 308 does not define a closed perimeter such as the closed perimeter 310 but rather an arc 336 having a center of curvature 311 that is offset from the rotational axis 102 . The point 314 is disposed along the arc 336 and is further from the rotational axis 102 than any other point of the arc 336 . It is contemplated that in other embodiments (not shown), the wall 308 may define any other shape or form permitting to have a point such as point 314 that is further from the rotational axis 102 than any other point of the shape or form defined by the wall 308 . The wall 308 may also be disposed elsewhere on the top surface 302 of the platform 300 as long as the shape defined thereby has a point such as the point 314 that is further from the rotational axis 102 than any other point of that shape. In this embodiment, the inlets 318 , 326 are disposed close to the point 314 and the channels 316 , 324 and channel outlets 320 , 328 are as described with regard to the embodiment shown in FIGS. 1 to 9 .
[0078] In yet another embodiment, shown in FIG. 12 , two walls 308 ( a ), 308 ( b ) define two curved lines 336 ( a ), 336 ( b ). The point 314 ( a ) is disposed along the line 336 ( a ) and is further from the rotational axis 102 than any other point along the line 336 ( a ), and the point 314 ( b ) is disposed along the line 336 ( b ) and is further from the rotational axis 102 than any other point along the line 336 ( b ). In this embodiment, the inlet 318 is disposed close to the point 314 ( a ) and the inlet 326 is disposed close to the point 314 ( b ). Channels (not shown) such as channels 316 , 324 have a suitable number of portions (not shown) such as portions 316 ( a ), 316 ( b ), 324 ( a ), 324 ( b ) suitably defined within the platform 300 , and have outlets (not shown) such as outlets 320 , 328 disposed in the exterior surface of the crankpins 106 ( a ), 106 ( b ), or in proximity with the crankpins 106 ( a ), 106 ( b ) or the connecting rod bearing assemblies 250 .
[0079] It is contemplated that in other embodiments (not shown), the walls 308 ( a ), 308 ( b ) may define any other shapes, forms or lines, and each of those shapes, forms or lines may or may not be similar to each other even if the walls are disposed on a same top surface 302 of a platform 300 (as shown in FIG. 12 ), as long as such shapes, forms or lines permit to have points such as points 314 ( a ), 314 ( b ) that are further from the rotational axis 102 than any other point along the shapes, forms or lines defined by the walls 308 ( a ), 308 ( b ). It is also contemplated that more than two walls can be disposed on a single top surface 302 of a platform 300 , each wall defining a shape or form having a point such as point 314 that is further from the rotational axis 102 than any other point of the shape or form defined by this wall. In such embodiments, inlets such as inlets 318 , 326 are disposed close to each point such as point 314 . Channels such as channels 316 , 324 have a suitable number of portions such as portions 316 ( a ), 316 ( b ), 324 ( a ), 324 ( b ) suitably defined within the platform 300 and have outlets such as outlets 320 , 328 disposed in the exterior surface of the crankpins 106 ( a ), 106 ( b ), or in proximity with the crankpins 106 ( a ), 106 ( b ) or the connecting rod bearing assemblies 250 .
[0080] It is also contemplated that there may be only one inlet such as inlet 318 connected to only one outlet such as outlet 320 for providing lubricant to only one connecting rod bearing assembly 250 , that inlets such as inlets 318 , 324 may be connected to only one such outlet for providing lubricant to only one connecting rod bearing assembly 250 . It is also contemplated that one inlet such as inlet 318 may be connected to two or more outlets such as outlets 320 , 328 for providing lubricant to two or more connecting rod bearing assemblies 250 . Finally, it is contemplated that more than two inlets such as inlets 318 , 326 may be connected to more than two outlets such as outlets 320 , 328 for providing lubricant to more than two connecting rod bearing assemblies 250 .
[0081] Modifications and improvement to the above described embodiments may become apparent to those skilled in the art. The foregoing description is intended to be exemplary rather than limiting. Furthermore, the dimensions of features of various components that may appear on the drawings are not meant to be limiting, and the size of the components therein can vary from the size that may be portrayed in the figures herein. The scope of the present invention is therefore intended to be limited solely by the scope of the appended claims. | A crankshaft has a receiving platform for catching lubricant dropping from a main bearing assembly. The receiving platform has at least one wall disposed thereon. The wall has one point that is the furthest from the rotational axis of the crankshaft. One channel is defined in the platform and has an inlet disposed close to the point of the wall that is furthest from the rotational axis of the crankshaft. The channel has an outlet in the vicinity of a connecting rod bearing assembly, so that lubricant dropped on the receiving platform will flow to the connecting rod bearing assembly. | 5 |
RELATED APPLICATIONS
The present application is a divisional of U.S. patent application Ser. No. 13/662,640 filed Oct. 29, 2012, which is incorporated herein by reference.
BACKGROUND
1. Technical Field
This disclosure is related to image sensors and, in particular, to image sensors in which ghost images caused by reflection of infrared (IR) radiation are substantially reduced or eliminated.
2. Discussion of Related Art
Image sensors with both visible and near infrared (NIR) capability have been used in automotive sensors in such applications as driver assistance applications and safety applications, such as pedestrian, obstruction and sign detection, rear-view or back-up camera applications, etc. Such sensors can operate in a dual mode, which allows them to function both in daylight (in the visible light spectrum application) and night vision (in the IR application). This newly incorporated IR capability is made possible by the development and implementation of a number of process-level enhancements that expand the senors' spectral light sensitivity to about 1050 nm, which is well into the NIR range of 750-1400 nm.
One drawback of this dual-mode capability is that the new sensitivity in the NIR range has resulted in IR ghost images being created. In certain situations, IR radiation can be reflected, such as, for example, by a redistribution layer (RDL) of the image sensor, and then detected by the image sensor. This introduces noise into the image sensor and, therefore, reduces the sensitivity of the image sensor.
SUMMARY
According to a first aspect, an image sensor is provided. The image sensor includes a photosensing element for receiving infrared (IR) radiation and detecting the IR radiation and generating an electrical signal indicative of the IR radiation. A redistribution layer (RDL) is disposed under the photosensing element, the RDL comprising a pattern of conductors for receiving the electrical signal. An IR reflection layer is disposed between the photosensing element and the RDL, said IR reflection layer reflecting a reflected portion of the IR radiation back to the photosensing element such that the reflected portion of the IR radiation does not impinge upon the RDL.
According to another aspect, an image sensor is provided. The image sensor includes a photosensing element for receiving infrared (IR) radiation and detecting the IR radiation and generating an electrical signal indicative of the IR radiation. A redistribution layer (RDL) is disposed under the photosensing element, the RDL comprising a pattern of conductors for receiving the electrical signal. An IR absorption layer is disposed between the photosensing element and the RDL, IR absorption layer absorbing the IR radiation such that a substantial portion of the IR radiation does not impinge upon the RDL.
According to another aspect, an image sensor is provided. The image sensor includes a photosensing element for receiving infrared (IR) radiation and detecting the IR radiation and generating an electrical signal indicative of the IR radiation. A redistribution layer (RDL) is disposed under the photosensing element, the RDL comprising a pattern of conductors for receiving the electrical signal. An isolation layer is disposed between the photosensing element and the RDL, the isolation layer being adapted to absorb the IR radiation such that a substantial portion of the IR radiation does not impinge upon the RDL.
According to another aspect, an image sensor is provided. The image sensor includes a photosensing element for receiving infrared (IR) radiation and detecting the IR radiation and generating an electrical signal indicative of the IR radiation. A redistribution layer (RDL) is disposed under the photosensing element, the RDL comprising a pattern of conductors for receiving the electrical signal. An IR barrier layer is disposed between the photosensing element and the RDL, said IR barrier layer preventing the IR radiation from impinging upon the RDL.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other features and advantages will be apparent from the more particular description of preferred embodiments, as illustrated in the accompanying drawings, in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the preferred embodiments. In the drawings, the sizes and thicknesses of layers, regions and features may be exaggerated for clarity.
FIG. 1 includes a schematic cross-sectional illustration of an image sensor, illustrating reflection of IR radiation, which can result in generation of an undesirable ghost image.
FIG. 2A includes a clear image, i.e., a control image, in which no ghost image has been formed.
FIG. 2B includes an image in which a ghost image is formed.
FIG. 3 includes a schematic cross-sectional illustration of an image sensor which can generate a ghost image of the RDL of the image sensor.
FIG. 4 includes a schematic cross-sectional illustration of another image sensor which can generate a ghost image of the RDL of the image sensor.
FIG. 5 includes a schematic cross-sectional diagram of an image sensor including an IR reflection layer, according to some exemplary embodiments.
FIG. 6 includes a schematic cross-sectional diagram of another image sensor including an IR reflection layer, according to some exemplary embodiments.
FIG. 7 contains a table which provides examples related to the exemplary embodiments described herein in which multiple transparent sub-layers of dielectric materials achieve constructive reflection.
FIG. 8 includes a graph which illustrates a profile of reflection percentage as a function of wavelength for the multi-layer dielectric materials structure defined in the table of FIG. 7 .
FIG. 9 includes a graph which illustrates a profile of reflection percentage as a function of wavelength for a single layer of aluminum having a thickness of 125.96 nm.
FIG. 10 includes a graph which illustrates a profile of reflection percentage as a function of wavelength for a single layer of chromium having a thickness of 64.72 nm.
FIG. 11 includes a schematic cross-sectional diagram of an image sensor device, including an IR absorption layers, according to some exemplary embodiments.
FIG. 12 includes a schematic cross-sectional diagram of another image sensor device, including an IR absorption layers, according to some exemplary embodiments.
FIG. 13 includes a graph which illustrates absorption (%) vs. wavelength for a metal-dielectric-metal sandwich absorption layer having a chromium-SiO 2 -chromium sandwich structure, according to some exemplary embodiments.
FIG. 14 includes a graph which illustrates absorption (%) vs. wavelength for a metal-dielectric-metal sandwich absorption layer having a nickel-SiO 2 -nickel sandwich structure, according to some exemplary embodiments.
FIG. 15 includes a graph which illustrates a profile of absorption percentage as a function of wavelength for a single layer of chromium having a thickness of 16.85 nm.
FIG. 16 includes a graph which illustrates a profile of absorption percentage as a function of wavelength for a single layer of nickel having a thickness of 11.85 nm.
FIG. 17 includes a schematic cross-sectional diagram of an image sensor having a multi-functional isolation layer, which significantly absorbs IR light, according to some exemplary embodiments.
FIGS. 18A-18C are images which illustrate the results of the approaches of the exemplary embodiments used in reducing or eliminating ghost imaging, specifically, ghost imaging of the RDL of an image sensor. Specifically, FIG. 18A is an image produced without any IR barrier layer. FIG. 18B is an image illustrating the effects of adding an IR reflection barrier layer between the RDL and the sensing layer, according to some exemplary embodiments. FIG. 18C is an image illustrating the effects of adding an IR absorption barrier layer between the RDL and the sensing layer, according to some exemplary embodiments.
DETAILED DESCRIPTION
Referring to FIG. 1 , an image sensor 10 can be formed of multiple layers, which can include a photosensitive sensing layer 12 , which can include photodetectors and which detects both visible and IR light and generates electrical signals indicative of attributes, e.g., intensity, of the detected light, and outputs the electrical signals. Light enters the sensing layer 12 through a window 26 , which is defined by a layer of pixel lenses 16 and a layer of color filters 14 , which are formed on the sensing layer 12 . Color filters 14 may include RGB (red, green and blue) filters arranged in various patters, such as the Bayer Patter as known in the art. They may additionally include panchromatic filters, i.e., clear filters.
An isolation layer 18 is formed beneath sensing layer 12 . A redistribution layer (RDL) 20 , which includes a pattern of conductive traces for conducting electrical signals, e.g., the electrical signals generated by sensing layer 12 , as required, is formed under isolation layer 18 . An isolating protective passivation layer 22 can be formed beneath and within RDL 20 to protect the conductive layer traces from the external environment, such that undesirable open or short circuits in RDL 20 , which could be caused by exposure to the external environment and which could render image sensor 10 inoperable, are prevented. A pattern of conductive input/output (I/O) pads 24 , illustrated in FIG. 1 in the form of conductive solder bumps, is formed within passivation layer 22 in electrical contact with RDL 20 as appropriate to make electrical contact between the external environment and the pattern of conductive traces in RDL 20 . RDL 20 is a patterned metal layer of wiring which enables electrical bonding from various locations internal to image sensor 10 out to external I/O pads 24 . RDL 20 is important to the electrical linking of internal components of image sensor 10 to external components.
As illustrated in FIG. 1 , light 28 , which includes IR light, and, specifically, NIR light, enters sensing layer 12 of image sensor 10 through lenses 16 and filters 14 in window 26 , where it is sensed by the photodetectors in sensing layer 12 . Because IR light has relatively long wavelengths, it may travel deeper through sensing layer 12 . As a result, the IR light may reach RDL 20 and be reflected back into sensing layer 12 , as illustrated in FIG. 1 by reflected portion 30 of IR light 28 . Reflected portion 30 of IR light 28 is then detected by sensing layer 12 , which then produces a ghost image of RDL 20 . Additionally, IR light may also enter image sensor 10 through the back side, can penetrate passivation layer 22 , RDL 20 and isolation layer 18 into sensing layer 12 , and, therefore, can contribute further to generation of a ghost image.
FIGS. 2A and 2B include images illustrating the ghost image that can be formed as described above in connection with FIG. 1 . FIG. 2A includes a clear image, i.e., a control image, in which no ghost image has been formed. FIG. 2B includes an image in which a ghost image is formed. As clearly seen in FIG. 2B , an image of RDL 20 , showing its conductive traces and pads, is generated within the clear image of the region being viewed. That is, reflected portion 30 of IR light 28 carries the information regarding the shape of RDL 20 and adds that information to the information used in generating the image of FIG. 2B . As noted above, this result is highly undesirable since it lowers the sensitivity of image sensor 10 and degrades the quality of images generated by image sensor 10 . It is noted that the images in FIGS. 2A and 2B were generated by an image sensor 10 operating at a wavelength range of λ=900˜1200 nm, as an exemplary illustration. It is noted that other wavelength ranges are possible and are within the scope of the present disclosure.
Possible approaches to reducing the ghost image are illustrated in FIGS. 3 and 4 , which are schematic cross-sectional illustrations of image sensors 110 and 120 , respectively. Various elements of image sensors 110 and 120 are the same as corresponding elements of image sensor 10 described above in detail in connection with FIG. 1 . These like elements are identified by like reference numerals. Detailed description of these like elements will not be repeated.
Referring to FIG. 3 , image sensors 110 and 120 include a layer or coating of black photoresist (BPR) 40 and 42 , respectively, applied to their top side and/or bottom side, respectively. Specifically, image sensor 110 of FIG. 3 includes a layer 40 of BPR applied to its top side, and image sensor 120 of FIG. 4 includes a layer 42 of BPR applied to its bottom side. The layers 40 and 42 of BPR are opaque to IR radiation and, therefore, any IR radiation impinging on the BPR does not penetrate. However, referring to FIG. 3 , even though the BPR 40 is applied to the top side of image sensor 110 and stops IR light 31 from penetrating down to reach RDL 20 , the window 26 which exposes the active area of the device must remain unblocked to allow the radiation/light 28 to penetrate to sensing layer 12 to be detected. As a result, IR light cannot be completely prevented from reflecting from the RDL 20 to produce the reflected portion 30 of the radiation/light, which results in generation of the ghost image.
Referring to FIG. 4 , BPR layer 42 is formed on the back or bottom side of image sensor 120 . It should be noted that it is desirable that the BPR 42 not cover the solder balls or pads 24 on the back side of the device, such that electrical connection to the device is not hindered by BPR 42 . As illustrated in FIG. 4 , the same situation regarding the reflected portion 30 of radiation/light exists, that is, portion 30 is reflected from RDL 20 back into sensing layer 12 , such that the ghost image is generated. However, BPR layer 42 on the back side of image sensor 120 prevents IR light 33 from penetrating into the device. As a result, IR light 33 does not contribute to the ghost image.
According to exemplary embodiments, to prevent ghost images caused by reflection of IR light from the RDL, an IR barrier layer is disposed between the sensing layer and the RDL. According to some exemplary embodiments, the IR barrier layer is an IR reflection layer, and in some exemplary embodiments, the IR barrier layer is an IR absorption layer. FIGS. 5 and 6 include schematic cross-sectional diagrams of image sensor devices 200 and 300 , respectively, including IR reflection layers, according to some exemplary embodiments. Referring to FIGS. 5 and 6 , various elements of image sensors 200 and 300 are the same as corresponding elements of image sensors 10 , 110 , and 120 described above in detail in connection with FIGS. 1 , 3 and 4 , respectively. These like elements are identified by like reference numerals. Detailed description of these like elements will not be repeated.
Referring to FIG. 5 , an image sensor 200 includes an additional IR reflection layer 250 over isolation layer 18 . IR reflection layer 250 reflects IR light 28 which penetrates through sensing layer 212 to generate a reflected portion 230 of IR light. Reflected portion 230 of the IR light passes back through sensing layer 212 where it is detected and, as a result, contributes to the image generated by image sensor 200 . However, because the IR light 28 is reflected back by IR reflection layer 250 before it reaches RDL 20 , a ghost image of RDL 20 including conductive traces, pads, etc., as illustrated in FIG. 2B , is not generated and, therefore, does not affect the image generated by image sensor 200 . That is, even though reflected portion 230 of the IR light is added to the image generated by image sensor 200 and, therefore, does introduce some noise in the form of additional IR light detection, a ghost image of RDL 20 is not formed and does not become part of the final image generated by image sensor 200 .
As shown in FIG. 5 , image sensor 200 can also include BPR layer or film 42 applied to its back surface. BPR layer or film 42 blocks, i.e., absorbs, IR light 33 incident on the back side of image sensor 200 , thus preventing IR light 33 from introducing noise and, therefore, degrading the image generated by image sensor 200 .
Referring to FIG. 6 , another image sensor 300 according to exemplary embodiments is illustrated. Image sensor 300 is the same as image sensor 200 described above in connection with FIG. 5 , with the exception that image sensor 300 includes a BPR layer or film 240 applied to the front or top side of image sensor 300 , instead of the back or bottom side. In this embodiment, IR light 31 incident on the top or front surface of image sensor 300 in the non-active region of the device is blocked, i.e., absorbed, such that it does not enter sensing layer 212 and, therefore, does not introduce noise or degrade the image generated by image sensor 300 .
In image sensor 300 of FIG. 6 , BPR layer or film 240 must remain open at window 26 such that IR light 28 can enter sensing layer 212 and be detected. Some of the IR light 28 completely penetrates sensing layer 212 and is reflected back into sensing layer 212 by IR reflection layer 250 , such that it is detected by sensing layer 212 and is, therefore, included in the image generated by image sensor 300 , thus introducing some noise and image degradation. However, once again, because the IR light 28 does not reach RDL 20 , no ghost image of RDL 20 is formed, and, therefore, substantial noise and image degradation is eliminated.
It will be noted that the embodiments of image sensors 200 and 300 illustrated in FIGS. 5 and 6 include BPR layers or films formed on their back/bottom and front/top sides, respectively. It will be understood that, within the scope of this disclosure, either of image sensors 200 and 300 can include a BPR layer or film on either its back/bottom side, its front/top side, both its back/bottom side and its front/top side, or neither its back/bottom nor its front/top side.
According to exemplary embodiments, IR reflection layer 250 can be a single layer or can be formed of multiple layers or sub-layers. These various configurations of IR reflection layer 250 are described below in detail. In FIGS. 5 and 6 , IR reflection layer 250 is illustrated by including dashed horizontal lines to illustrate the optional multi-sub-layer configurations. It will be understood that three layers are illustrated by the dashed lines for the sake of providing a clear and complete description and are exemplary only. Any number of sub-layers can be used within the scope of this disclosure.
As noted above, according to exemplary embodiments, IR reflection layer 250 can take on any of several possible configurations. For example, in some exemplary embodiments, reflection layer 250 uses constructive reflection to achieve almost total reflection using multiple transparent sub-layers. In some exemplary embodiments, a single layer of reflective metal is used for reflection layer 250 . The single reflective metal layer does not generally achieve as high a level of reflection as the configuration having multiple transparent sub-layers; however, the single reflective metal layer is generally thinner than the multiple transparent sub-layers.
In the embodiments having multiple transparent sub-layers of dielectric materials, constructive reflection refers to using multiple layers to achieve a high degree of reflection. There are generally two factors that contribute to an increased level of reflection.
First, at a simple interface between two dielectric materials, the amplitude of reflected light is a function of the ratio of the refractive indices of the two materials, the polarization of the incident light, and the angle of incidence. For example, at normal incidence, i.e., incident light is perpendicular to the interface, the relative amplitude of the reflected light, as a proportion of the incident light, is given by (1−p)/(1+p), where p=n 1 /n 2 , and intensity is the square of this expression, i.e., ((n 2 −n 1 )/(n 2 +n 1 )) 2 , wherein n 1 and n 2 are the refractive indices of the first and second dielectric materials, respectively. Thus, the greater the difference between refractive indices of the materials, the greater the reflection. For example, for an air/glass interface, n 1 =1 (air), and n 2 =1.5 (glass), so the intensity of the reflected light is 4% of the incident light. Multiple sub-layers of dielectric material will introduce multiple interfaces. As a result, the amount of reflection will increase with additional layers.
Second, the thicknesses of the layers may be chosen so as to reinforce reflected light through constructive interference. This is accomplished through use of a type of interference coating that strengthens reflection. Reflection interference is the opposite of the more commonly known anti-reflection interference, where the thicknesses of the layers are chosen so that the reflected light will destructively interfere and cancel each other since they are exactly out of phase. In reflection interference, the thicknesses of the layers are chosen so that the reflected light will constructively interfere and reinforce each other since they are in phase.
FIG. 7 contains a table which provides examples related to the exemplary embodiments described above in which multiple transparent sub-layers of dielectric materials achieve constructive reflection. Referring to the table of FIG. 7 , two sets of parameters are manipulated to maximize IR reflection. For the first factor of utilizing multiple interfaces of dielectric materials with proper refractive indices, SiO 2 (n=1.455) and TiO 2 (n=2.37) are arranged in an alternating fashion to form an IR reflection layer with 19 sub-layers. For the second factor of choosing specific thicknesses to reinforce reflection interference, thicknesses of each layer in nanometers (nm) are included in the table of FIG. 7 . Referring to the specific exemplary embodiment defined in the table of FIG. 7 , as a result of the selections of materials and the quantity and thicknesses of layers, for IR light with a wavelength between 900 and 1200 nm, a total reflection of 98% is achieved with this multi-layered structure. It will be understood that different reflections can be realized by selections of different materials and quantities and thicknesses of layers.
FIG. 8 includes a graph which illustrates a profile of reflection percentage as a function of wavelength for the multi-layer dielectric materials structure defined in the table of FIG. 7 . As shown in the graph of FIG. 8 , the reflection achieved is almost 100% throughout the entire 900-1200 nm spectral range.
As noted above, in other exemplary embodiments, a single layer of reflective metal is used for the IR reflection layer. When a single layer of metal material is used, the IR reflection layer may be made considerably thinner than the multi-layer dielectric materials structure. However, the reflection performance is not as good as that of the multi-layer dielectric materials approach. Furthermore, increasing the thickness of the metal layer will not increase reflection beyond a certain point.
In some particular exemplary embodiments, when a single layer of, for example, aluminum, is used, reflection of IR (wavelength in the range of 900-1200 nm) will be capped at 89% when the thickness of the layer is 126 nm. A thickness of more than 126 nm will not increase reflection further. If the thickness of the layer is less than 126 nm, reflection will decrease. FIG. 9 includes a graph which illustrates a profile of reflection percentage as a function of wavelength for a single layer of aluminum having a thickness of 125.96 nm. Referring to FIG. 9 , it is readily observed that the reflection performance is not as good as that of the multi-layered dielectric materials structure, although the aluminum IR reflection layer is considerably thinner.
As another example, when a single layer of chromium is used, IR reflection will be capped at 60% at a thickness of 65 nm. Thickness of more than 65 nm will not increase reflection. If the thickness is less than 65 nm, the reflection will decrease. FIG. 10 includes a graph which illustrates a profile of reflection percentage as a function of wavelength for a single layer of chromium having a thickness of 64.72 nm. Referring to FIG. 10 , it is readily apparent that reflection performance is not as good as the multi-layered dielectric materials structure or the single layer of aluminum, although the chromium IR reflection layer is the thinnest of these three examples.
Other metals besides aluminum and chromium can be used in the single-metal-layer configuration. For example, other metals that can be used include, but are not limited to gold, silver, copper, etc.
In accordance with exemplary embodiments, a thinner IR reflection layer is generally desirable because it results in a thinner image sensor. This results in a trade-off between achieving a high level of IR reflection and the extent to which the thickness of the image sensor can be reduced.
As described above, according to exemplary embodiments, to prevent ghost images caused by reflection of IR light from the RDL, an IR barrier is disposed between the sensing layer and the RDL. According to some exemplary embodiments described above, the IR barrier layer is an IR reflection layer. In some exemplary embodiments, the IR barrier layer is an IR absorption layer.
FIGS. 11 and 12 include schematic cross-sectional diagrams of image sensor devices 400 and 500 , respectively, including IR absorption layers, according to some exemplary embodiments. Referring to FIGS. 11 and 12 , various elements of image sensors 400 and 500 are the same as corresponding elements of image sensors 10 , 110 , 120 , 200 and 300 described above in detail in connection with FIGS. 1 , 3 , 4 , 5 and 6 , respectively. These like elements are identified by like reference numerals. Detailed description of these like elements will not be repeated.
Referring to FIG. 11 , an image sensor 400 includes an additional IR absorption layer 450 over isolation layer 18 . IR absorption layer 450 absorbs IR light 28 which penetrates through sensing layer 412 , such that no IR light passes back through sensing layer 412 . As a result, no ghost image is produced.
As shown in FIG. 11 , image sensor 400 can also include BPR layer or film 42 applied to its back surface. BPR layer or film 42 blocks, i.e., absorbs, IR light 33 incident on the back side of image sensor 400 , thus preventing IR light 33 from introducing noise and, therefore, degrading the image generated by image sensor 400 .
Referring to FIG. 12 , another image sensor 500 according to exemplary embodiments is illustrated. Image sensor 500 is the same as image sensor 400 described above in connection with FIG. 11 , with the exception that image sensor 500 includes a BPR layer or film 540 applied to the front or top side of image sensor 500 , instead of the back or bottom side. In this embodiment, IR light 31 incident on the top or front surface of image sensor 500 in the non-active region of the device is blocked, i.e., absorbed, such that it does not enter sensing layer 412 and, therefore, does not introduce noise or degrade the image generated by image sensor 500 . In image sensor 500 of FIG. 12 , BPR layer or film 540 must remain open at window 26 such that IR light 28 can enter sensing layer 412 and be detected. However, IR absorption layer 450 absorbs IR light 28 which penetrates through sensing layer 412 , such that no IR light passes back through sensing layer 412 . As a result, no ghost image is produced.
It will be noted that the embodiments of image sensors 400 and 500 illustrated in FIGS. 11 and 12 include BPR layers or films formed on their back/bottom and front/top sides, respectively. It will be understood that, within the scope of this disclosure, either of image sensors 400 and 500 can include a BPR layer or film on either its back/bottom side, its front/top side, both its back/bottom side and its front/top side, or neither its back/bottom nor its front/top side.
According to exemplary embodiments, IR absorption layer 450 can be a single layer or can be formed of multiple layers or sub-layers. These various configurations of IR absorption layer 450 are described below in detail. In FIGS. 11 and 12 , IR absorption layer 450 is illustrated by including dashed horizontal lines to illustrate the optional multi-sub-layer configurations. It will be understood that three layers are illustrated by the dashed lines for the sake of providing a clear and complete description and are exemplary only. Any number of sub-layers can be used within the scope of this disclosure.
As noted above, according to exemplary embodiments, IR absorption layer 450 can take on any of several possible configurations. For example, in some exemplary embodiments, the absorption layer uses resonance to achieve almost total absorption using a metal-dielectric-metal sandwich structure. In other exemplary embodiments, the absorption layer uses a single layer of metal. In these embodiments, the resulting percent of absorption is not as good as that of the metal-dielectric-metal sandwich embodiments, although the single metal absorption layer is thinner.
As noted above, in some exemplary embodiments, the IR absorption layer includes a composite metal-dielectric-metal sandwich type structure. The metal sub-layer facing the incident IR light can be substantially thicker than the other metal layer. IR light that reaches this composite structure resonates back and forth between the two metal layers, resulting in most of its energy being absorbed. Two sets of parameters are selected. The first set of parameters includes the types of metal and dielectric material. The second set of parameters is the thickness of each sub-layer. When proper parameters are chosen, the IR light will form a standing wave between the two metal layers, resulting in significant resonance and energy absorption.
FIG. 13 contains a graph which illustrates absorption (%) vs. wavelength for a metal-dielectric-metal sandwich absorption layer having a chromium-SiO 2 -chromium sandwich structure, according to some exemplary embodiments. FIG. 14 contains a graph which illustrates absorption (%) vs. wavelength for a metal-dielectric-metal sandwich absorption layer having a nickel-SiO 2 -nickel sandwich structure, according to some exemplary embodiments.
Referring to FIG. 13 , the thickness of each sub-layer is shown in the drawing. As illustrated in the drawing, this absorption layer structure may absorb more than 99% of IR light throughout the 900-1200 nm spectral range. Referring to FIG. 14 , the thickness of each sub-layer is shown in the drawing. As illustrated in the drawing, this absorption layer structure may absorb more than 96% of IR light throughout the 900-1200 nm spectral range.
As noted above, in some exemplary embodiments, the IR absorption layer includes a single layer of metal. In these embodiments, the IR absorption layer can be made considerably thinner. However, the IR absorption performance is not as good as the sandwich composite structure approach described in detail above. Also, increasing the thickness of the metal layer will not increase IR absorption beyond a certain point.
In some particular exemplary embodiments, when a single layer of, for example, chromium, is used, absorption of IR (wavelength in the range of 900-1200 nm) will be capped at 40% when the thickness of the layer is 17 nm. A thickness of more than 17 nm will not increase absorption further. In some particular exemplary embodiments, when a single layer of, for example, nickel, is used, absorption of IR (wavelength in the range of 900-1200 nm) will be capped at 36.5-37.5% when the thickness of the layer is 12 nm. A thickness of more than 12 nm will not increase absorption further.
FIG. 15 includes a graph which illustrates a profile of absorption percentage as a function of wavelength for a single layer of chromium having a thickness of 16.85 nm. FIG. 16 includes a graph which illustrates a profile of absorption percentage as a function of wavelength for a single layer of nickel having a thickness of 11.85 nm. Referring to FIGS. 15 and 16 , it is apparent that the absorption profile of chromium is more even throughout the spectral range than that of nickel. Also, it is readily observed that the absorption performances are not as good as that of the sandwich composite structures, although the metal layers are considerably thinner.
In accordance with exemplary embodiments, in addition to the sandwich composite structures and the single-metal-layer structures, the IR absorption layer can also be formed to have other structures. For example, in some exemplary embodiments, some sandwich type composite IR absorption layers do not use metal-dielectric-metal arrangements. Examples of these include SiO 2 —Cr 2 O 3 —SiO 2 , SiO 2 —TaN—SiO 2 , Cr—CrO x —CrO x N y , etc. Also, according to some exemplary embodiments, there are two-sub-layer type composite IR absorption layers, instead of the three-sub-layer type composite IR absorption layers described above. Examples of these two-sub-layer type composite IR absorption layers include Si 3 N 4 —TaN, SiC—SiO 2 , etc. Also, according to some exemplary embodiments, some single-layer non-composite IR absorption layers do not use metals. Examples of these include Cr 2 O 3 , CrSiO, Ni x O y , carbon black, black inorganic materials, etc.
According to the exemplary embodiments described herein thus far, an IR absorption layer or an IR reflection layer is included in the structure of an image sensor. According to other exemplary embodiments, an isolation layer is disposed over the RDL as in the previously described exemplary embodiments. However, in the present exemplary embodiments, the material of which the isolation layer is formed is chosen such that it significantly absorbs IR light. Therefore, the isolation layer is multi-functional, and the need for separate isolation layers and absorption layers is eliminated.
FIG. 17 includes a schematic cross-sectional diagram of an image sensor 600 having a multi-functional isolation layer 650 , which significantly absorbs IR light, according to some exemplary embodiments. Referring to FIG. 17 , various elements of image sensor 600 are the same as corresponding elements of the various image sensors described above in detail. These like elements are identified by like reference numerals. Detailed description of these like elements will not be repeated.
Referring to FIG. 17 , an image sensor 600 includes an isolation layer 650 formed over an RDL 620 , which is formed over a passivation layer 622 . Isolation layer 650 is composed of a material that significantly absorbs IR. As a result, IR light passing through window or opening 26 into sensing layer 612 is detected and used in generating an image. However, any IR light that reaches isolation layer 650 is absorbed by isolation layer 650 , such that no IR light passes back through sensing layer 612 . As a result, no ghost image is produced. As an isolation layer, layer 650 provides an electric charge insulating function. As an IR absorption layer, layer 650 significantly absorbs IR to reduce or prevent ghost imaging of RDL 620 .
In some exemplary embodiments, image sensor 600 also includes a BPR layer or film 640 applied to the front or top side of image sensor 600 . In this embodiment, IR light 31 incident on the top or front surface of image sensor 600 in the non-active region of the device is blocked, i.e., absorbed, such that it does not enter sensing layer 612 and, therefore, does not introduce noise or degrade the image generated by image sensor 600 . In image sensor 600 of FIG. 12 , BPR layer or film 640 must remain open at window 26 such that IR light 28 can enter sensing layer 612 and be detected. It will be understood that, within the scope of this disclosure, image sensor 600 can include a BPR layer or film on either its back/bottom side, its front/top side, both its back/bottom side and its front/top side, or neither its back/bottom nor its front/top side.
In some exemplary embodiments, isolation layer 650 can include an organic material, such as a NIR absorbing organic compound. This isolation layer material is generally organic instead of inorganic. The advantage of a multi-functional isolation layer is that it can have a simple one-layer structure, as contrasted with other embodiments described herein that can comprise at least two layers. Therefore, the overall sensor structure of FIG. 17 can be simpler and is easier to manufacture.
In general, such NIR absorbing organic compounds are chromophores whose π electrons are effectively delocalized along a conjugated chain. Examples include polyene chromophores such as rylene and its derivatives, polymethine chromophores such as merocyanine, cyanie and hemicyanine dyes, and NIR organic compounds containing donor-acceptor (D-A) chromophores such as tetrathiafulvalene-σ-tetracyano-p-quinodimethane, a D-σ-A compound, and its derivatives. Other examples of D-A chromophores include D-π-A-π-D type, D-A-D type systems of compounds, etc. Yet other examples of NIR absorption material are compounds that are disclosed in U.S. Pat. No. 6,775,059, which is incorporated herein in its entirety by reference.
FIGS. 18A-18C are images which illustrate the results of the approaches of the exemplary embodiments used in reducing or eliminating ghost imaging, specifically ghost imaging of the RDL of an image sensor. The approaches include forming an IR reflection barrier layer between the RDL and the sensing layer and forming an IR absorption barrier layer between the RDL and the sensing layer. FIG. 18A is an image produced without any IR barrier layer. As shown in FIG. 18A , a ghost image of the RDL, showing its conductive traces and pads, is formed. FIG. 18B is an image illustrating the effects of adding an IR reflection barrier layer between the RDL and the sensing layer, such as the embodiments illustrated and described above in connection with FIGS. 5 and 6 . As shown in FIG. 18B , the image of the RDL is eliminated. However, this approach may cause the sensing layer to be flooded by the reflected IR. FIG. 18C is an image illustrating the effects of adding an IR absorption barrier layer between the RDL and the sensing layer, such as the embodiments illustrated and described above in connection with FIGS. 11 , 12 and 17 . As shown in FIG. 18C , the image of the RDL is eliminated. Also, by comparison with FIG. 18B , it is noted that the flooding of the sensing layer is eliminated when using an IR absorption barrier layer, as evidenced by the relative darkness of the image of FIG. 18C .
Generally, the IR reflection layer tends to result in more IR reaching the sensing layer than the IR absorption layer. In a relatively strong lighting environment, the IR reflection layer may cause the sensors to be flooded by IR, thus possibly negatively impacting the detection of other wavelengths, such as those in the visible range. However, in an environment that has very little visible light and relies heavily on IR for detection, the IR reflection layer will have better detection sensitivity than the IR absorption layer, because more IR will reach the sensing layer. An example of this may be a night vision product that is intended for use in a pitch black environment.
It should be noted that in an environment where both visible and IR are important for detection, the IR absorption layer may be a better approach, because the sensor will not be flooded by IR as with the IR reflection layer. It should also be noted that, according to exemplary embodiments, both the IR reflection and the IR absorption may be implemented within the same sensor product, to better prevent IR from reaching the RDL.
While the present inventive concept has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present inventive concept as defined by the following claims. | An image sensor includes a photosensing element for receiving infrared (IR) radiation and detecting the IR radiation and generating an electrical signal indicative of the IR radiation. A redistribution layer (RDL) is disposed under the photosensing element, the RDL comprising pattern of conductors for receiving the electrical signal. An IR reflection layer, an IR absorption layer or an isolation layer is disposed between the photosensing element and the RDL. The IR reflection layer, IR absorption layer or isolation layer provides a barrier to IR radiation such that the IR radiation does not impinge upon the RDL. As a result, a ghost image of the RDL is not generated, resulting in reduced noise and improved sensitivity and performance of the image sensor. | 7 |
FIELD OF THE INVENTION
The present invention relates generally to an air pump and in particular to an air pump structure which allows the pump to be fixed to a bicycle frame and driven by the bicycle chain so that the bicycle rider may be able to fix a tire pressure problem in any time and at any place.
BACKGROUND OF THE INVENTION
Bicycles have been widely used in transportation and exercise. The tire pressure of the bicycle is an important factor that affects the comfort of riding bicycle. The tire pressure has to be maintained at a predetermined level in order to get a comfortable riding experience. Furthermore, sometimes, the bicycle tires may be damaged and a flat tire occurs. Thus, an air pump is of importance for a bicycle rider.
Conventional air pumps, such as hand operating air pump indicated at 10 in FIG. 8 of the attached drawings or foot operating air pump indicated at 20 in FIG. 9, are not designed to be carried with the bicycle so that when the tire pressure gets lower than the predetermined level or a flat tire occurs, the bicycle rider is not able to obtain instant and handy means to fix the tire pressure problem.
Thus, it is desirable to provide a bicycle air pump which is mounted on the bicycle and driven by the operation of the bicycle so as to provide a handy way for supply air to the bicycle tire.
SUMMARY OF THE INVENTION
Therefor, an object of the present invention is to provide an air pump which is suitable to be mounted on the bicycle to be carried thereby so as to provide a handy air supply to the bicycle tire.
Another object of the present invention is to provide an air pump which is mounted to the bicycle frame to be carried thereby and which is driven by the operation of the bicycle so as to provide an efficient way of supplying air to the bicycle tire.
To achieve the above objects, in accordance with the present invention, there is provided a bicycle air pump comprising a cylinder adapted to be secured to the bicycle frame, having a cylinder bore within which a piston reciprocates, a crank shaft rotatably supported on the cylinder and drivingly coupled to the piston by means of a connecting rod and means for coupling the crank shaft to the bicycle chain to be driven thereby so that when the bicycle pedals are actuated to drive the bicycle chain, the bicycle chain forces the crank shaft to rotate and thus making the piston reciprocate within the cylinder bore to pump air through an outlet of the cylinder.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be better understood from the following description of a preferred embodiment thereof, with reference to the attached drawings, wherein:
FIG. 1 is a perspective view showing a bicycle air pump constructed in accordance with the present invention;
FIG. 2 is an exploded perspective view of the bicycle air pump in accordance with the present invention
FIG. 3 is a cross-sectional view of the bicycle air pump of the present invention with the chain wheel of the bicycle air pump at the stowed position;
FIG. 4 is a cross-sectional view similar to FIG. 3, but showing the chain wheel of the bicycle air pump at the working position;
FIG. 5 is a schematic side elevational view showing the bicycle air pump of the present invention mounted to the frame of a bicycle;
FIG. 6 is a schematic side elevational view similar to FIG. 5, but showing the chain wheel of the bicycle air pump of the present invention engaged and driven by the bicycle chain of the bicycle;
FIG. 7 is a schematic side elevational view similar to FIG. 6, but showing a flexible tube is used to connect the outlet of the bicycle air pump to a bicycle tire; and
FIGS. 8 and 9 are perspective views of two conventional air pump structures.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to the drawings and in particular to FIGS. 1-3, wherein a bicycle air pump constructed in accordance with the present invention, generally designated with reference numeral 1 , is shown, the bicycle air pump 1 comprises a cylinder 10 having a cylinder bore 11 formed therein within which a piston 2 is movably received. The cylinder 10 is adapted to be fixed to a bicycle frame (see FIGS. 5-7) with any known means, such as bolts. A crank shaft 5 , which has a hollow portion, is coupled to the piston 2 by means of a connecting rod 3 to drive the piston 2 reciprocating inside the cylinder bore 11 . A driving shaft 6 telescopically and axially movably received within the hollow crank shaft 5 and rotatably fixed thereto to be rotatable in unison therewith for driving the crank shaft 5 . The driving shaft 6 has a chain wheel 7 fixed thereto, which chain wheel 7 is adapted to be coupled to and driven by a chain 40 of the bicycle (see FIGS. 5-7) so that when a rider (not shown) actuates pedals 30 of the bicycle to drive the bicycle chain 40 , the piston 2 is forced to reciprocate within the cylinder 10 by means of the mechanical coupling provided by the chain wheel 7 , the driving shaft 6 , the crank shaft 5 and the connecting rod 3 and thus air is pumped and supplied through an outlet 12 of the cylinder 10 .
In accordance with the present invention, the crank shaft 5 comprises an elongated shaft body 50 extending through and rotatably supported within a hole 15 formed on the cylinder 10 . Preferably the cylinder 10 is provided with a side wall plate 16 having an extension beyond a lower end of the cylinder 12 with the hole 15 formed on the lower extension of the side wall plate 16 . The crank shaft 5 also comprises an arm 4 which is fixed to a first end of the shaft body 50 . The arm 4 has a coupling pin 41 fixed thereto and extending therefrom in a direction substantially parallel with the elongated shaft body 50 to be rotatably received within a corresponding hole 30 formed on the connecting rod 3 so as to form a rotatable or pivotal joint therebetween.
In the embodiment illustrated, the first end of the elongated shaft body 50 is provided with a reduced diameter so as to define a shoulder. The arm 4 is provided with a hole 42 corresponding to and fit over the first end of the shaft body 50 and retained thereon by the shoulder of the shaft body 50 . Preferably, the first end of the shaft body 50 is provided with a threading 54 to which a nut 55 is engaged to secure the arm 4 to the elongated shaft body 50 so as to force the coupling pin 41 to rotate about the elongated shaft body 50 when the shaft body 50 rotates.
The elongated shaft body 50 is also provided with a reduced second end which defines a shoulder placed against the hole 15 of the cylinder 10 and an external threading 52 on the second end to which a nut 56 is engaged to secure the elongated shaft body 50 to the side wall plate 16 of the cylinder 10 in such a way to allow the shaft body 50 to be rotatable with respect to the cylinder 10 . In this respect, it may be desired to have bearing means (not shown) arranged between the hole 15 and the shaft body 50 .
The connecting rod 3 , besides the hole 30 , has a second hole 31 through which a pin 22 extends. The pin 22 also extends through holes 23 formed on support plates 21 fixed to the piston 2 so as to form a rotatable or pivotal joint between the piston 2 and the connecting rod 3 . With such an arrangement, when the crank shaft 5 rotates, the piston 2 is driven to reciprocate within the cylinder bore 11 .
The elongated shaft body 50 of the crank shaft 5 has a central axial bore 51 into which the driving shaft 6 is axially slidably received. The driving shaft 6 is provided with an elongated, axially-extending slot 61 , serving as a keyway. The elongated shaft body 50 is provided with a radially extending hole 57 into which a pin 53 is received. The pin 53 extends through the hole 57 and partially received within the slot 61 of the driving shaft 6 to serve as a key so that by means of the key-keyway engagement of the pin 53 and the slot 61 of the driving shaft 6 , the rotation of the driving shaft 6 is transmitted to the crank shaft 5 .
In addition to the driving connection provided by the engagement between pin 53 and the slot 61 of the driving shaft 6 , the slot 61 and the pin 53 also serve to prevent the driving shaft 6 from sliding off the central bore 51 of the elongated shaft body 50 of the crank shaft 5 . This is done by means of the stopping engagement between the pin 53 and axial ends of the driving shaft 6 .
The driving shaft 6 has an axial length so as to have an end thereof extending out of the crank shaft 5 and the chain wheel 7 is secured to the end of the driving shaft 6 . This may be done by forming threading 62 on the end of the driving shaft 6 with a nut 8 engaged thereto to secure the chain wheel 7 to the driving shaft 6 in such a way to have the driving shaft 6 and the chain wheel 7 rotatable in unison with each other.
The elongated slot 61 allows the driving shaft 6 to be axially movable relative to the crank shaft 5 so that the chain wheel 7 that is secured to the driving shaft 6 is moveable relative to the side wall plate 16 of the cylinder 10 between a stowed position (see FIG. 3) and a working position (see FIG. 4 ).
To shield the chain wheel 7 in the stowed position, a cylindrical shielding member 13 is fixed to the side wall plate 16 of the cylinder 10 and is arranged to be substantially co-axial with the hole 15 . The cylindrical member 13 has a size that is sufficient to shield the chain wheel 7 in the stowed position, but allows the chain wheel 7 to be exposed in the working position.
If desired, a pressure gauge 9 may be attached to the cylinder and in fluid communication with the outlet 12 of the cylinder 10 to indicate the pressures of the pumped air supplied by the air pump 1 of the present invention.
A cover member 14 may be provided to cover and protect the crank shaft 5 and the connecting rod 3 .
As shown in FIGS. 5-7, the air pump 1 of the present invention may be fixed to a suitable position on the bicycle frame so as to allow the chain wheel 7 (at the working position) to be engaged by the chain 40 by manually deflecting the chain 40 (FIGS. 6 and 7) and thus when the rider depresses the pedals 30 , the chain 40 is driven to rotate the chain wheel 7 which in turn drives the piston 2 to reciprocate within the cylinder bore 11 to pump air through the outlet 12 . A flexible tube 60 (see FIG. 7) may be used to connect between the outlet 12 of the air pump 1 and for example a tire 50 to supply the pumped air into the tire 50 . Of course, the flexible tube 60 may be used to connect the air pump 1 to any desired destination to supply pressurized air thereto.
Preferably, the cover 14 is made in such a way to provide an interior space therein which space is sufficient to accommodate the flexible tube 60 therein.
Although the a preferred embodiment has been described to illustrate the present invention, it is apparent that changes and modifications in the specifically described embodiment can be carried out without departing from the scope of the invention which is intended to be limited only by the appended claims. | A bicycle air pump includes a cylinder adapted to be secured to the bicycle frame having a cylinder bore within which a piston reciprocates, a crank shaft rotatably supported on the cylinder and drivingly coupled to the piston by means of a connecting rod and a driving mechanism for coupling the crank shaft to the bicycle chain to be driven thereby so that when the bicycle pedals are actuated to drive the bicycle chain, the bicycle chain forces the crank shaft to rotate and thus making the piston reciprocate within the cylinder bore to pump air through an outlet of the cylinder. | 5 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application claims the benefit of priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application No. 61/177,722, filed May 13, 2009, and entitled, “Illuminated Air Supply Tank”, the contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to indicators for self contained breathing devices. In particular, the indicators are secured to the outside of the breathing devices and illuminated. The indicators include indicia which are readily recognized by individuals associated with a particular activity that employs the self contained breathing devices.
BACKGROUND OF THE INVENTION
[0003] Self contained breathing devices provide individuals the ability to explore certain environments that are not conducive to normal human physiology. Self contained underwater breathing apparatus, or SCUBA tanks and systems are widely used by professional and sport underwater divers. In addition, self contained breathing apparatus, SCBA, are used by emergency workers such as fireman, first aid responders, industrial hazard material workers, military personnel and other individuals who enter environments in which the air is not readily breathable. One of the problems associated with humans interacting within these types of environments is a decreased ability to communicate with fellow divers or emergency personnel. Given the extreme dangers associated with the environments, the need to communicate can be vital to effectively and safely perform a task or save the life of another.
[0004] Diving in open waters exposes humans to different environments and creatures. In addition to normal daylight dives, night time dives or cave exploration further exposes divers to a variety of creatures that are not visible during the day or in open waters. As any experienced diver knows, the deeper the dive, the darker the environment. Common equipment for divers intending to experience such environments therefore must include some type of light source. Typical light sources include dive lights, probes, or chemiluminescent sticks. While such equipment is common, use of these lighting options has several disadvantages. The lighting devices used by divers are mostly hand held lights which, if not held/or attached properly to the dive suit, are easily dropped. Given the depth of the ocean, such lighting devices provide limited visibility which makes it difficult to communicate with fellow divers.
[0005] Since night dives tend to be dangerous, it is not uncommon for divers to travel in groups. If several members of the group get separated, it may be impossible for one diver to visualize other divers beyond his/her own light beam. Unless a diver is in the direct beam of a light source, communication between fellow divers is difficult. Moreover, when traveling in groups, divers run the risk of becoming temporarily blinded should he/she accidentally be exposed to the beam of light being carried by a fellow diver. Because divers are unable to utilize verbal communications underwater, it is imperative that divers find other means of communication to ensure the safety of other members of the group. The dark waters generally prohibit the divers from using hand signals as a means of communication. As such, divers have developed other means of communication. For instance, moving a light source up and down signals distress and a need for help. Forming circles with the light source indicates that the diver is safe. These techniques can be useful when the diver is capable of visualizing the light source. However, such visualization is not always clear and the diver either fails to see the signal or is confused as to what is being conveyed, resulting in either delay in rescue because the diver can not interpret the signal, or a waste of precious oxygen when the diver incorrectly interpreted a signal and goes to check it out.
[0006] Firefighters entering burning buildings face similar concerns as divers exploring the deep, dark waters. Firefighters entering smoke filled buildings are faced with severely restricted visibility. Given the extreme environments that emergency personnel face, properly identifying and tracking those who enter such environments are of extreme importance. In this environment, it is also vital that firefighters have some type of contact with fellow firefighters. While communication devices can be used, poor signal in buildings decreases the effectiveness of these devices. Common markings, such as reflective tape or light devices, are often integral aspects of the firefighter's gear. However, reflective tape and lighting devices are limited and are not always visualized by other firefighters in smoke filled environments. The types of messages and information that can be relayed to a third party are also limited.
[0007] Therefore, what is needed is a notification device that attaches to self contained breathing apparatus and which provides clearly visible messages and information about the user to third parties.
SUMMARY OF THE INVENTION
[0008] The instant invention describes a device for use with self-contained breathing devices, such as a SCUBA tank, which allows a user to display different indicia on the tank. The indicia are preferably illuminated by a self contained illumination system also located on the tank. The device allows a user to readily interchange the indicia so that the currently displayed indicia provide a specific message or indicate a specific condition to a third party individual observing the tank and related indicia. The illumination system permits the indicia on the tank to be clearly seen deep underwater where it is dark, and in smoke-filled environments, such as in a fire, where visibility is minimal.
[0009] In a particular embodiment of the invention, the device is constructed and arranged to attach to the surface of a self contained breathing apparatus and illuminate a message that is viewable to a third party. The device comprises a main body having an outer frame. The outer frame is constructed and arranged to receive and hold an inner plate member. The inner plate member contains one or more types of indicia, such as words or symbols. At least one light source is electrically coupled to a power source for illuminating the inner plate member, whereby illumination of the inner plate member displays a message which is visible to a third party.
[0010] The instant invention also describes a system for illuminating the surface of a self contained breathing apparatus in such a manner so as to convey a message to a third party. The system comprises a notification device in the form of a net. The net is constructed and arranged in a matrix arrangement of flexible material including an array of intersecting rows and columns defining a plurality of open spaces. The net attaches to or can be placed around a self contained breathing apparatus. The system also includes at least one electrical lead interlaced within the net and coupled to a power source and at least one light source coupled to the at least one electrical lead.
[0011] In an alternative embodiment, the system for illuminating the surface of a self contained breathing apparatus in such a manner so as to convey a message to a third party comprises a notification device having a first inner housing member attached to a self contained breathing apparatus. The first inner housing member is constructed and arranged to receive an inner sheath member. The system further includes a second outer housing member constructed and arranged to receive an outer sheath member. An inner sheath member is attached to the first inner housing member and an outer sheath member is attached to the second outer housing member. The outer sheath member contains indicia. The system further includes at least one light source electrically coupled to a power source for illuminating the outer sheath member, whereby illumination of the outer sheath member displays a message which is visible to a third party.
[0012] Accordingly, it is an objective of the instant invention to provide a device which includes a frame, the frame being secured to a contained breathing apparatus and having indicia which may contain a message that is sized to fit within the frame and be clearly displayed.
[0013] It is a further objective of the instant invention to provide a device which includes a frame, the frame being secured to a self contained breathing apparatus and which is constructed to enable the quick change of indicia within the frame.
[0014] It is yet another objective of the instant invention to provide a device which includes a frame, the frame being secured to a self contained breathing apparatus and having a device for illuminating the frame and the indicia within the frame.
[0015] It is yet another objective of the instant invention to provide a device which includes a frame, the frame being secured to a self contained breathing apparatus and having a device for providing a reflective border surrounding the frame.
[0016] It is a still further objective of the invention to provide a device which includes a frame, the frame being secured to a self contained breathing apparatus and having a device for illuminating the entire perimeter of the frame and any indicia contained within the frame.
[0017] It is still yet a further objective of the invention to provide a device which includes a frame, the frame being secured to a self contained breathing apparatus and having a device for illuminating the frame and indicia within the frame which is covered by a lens.
[0018] It is yet another objective of the instant invention to provide a system for illuminating a self contained breathing apparatus; the system including a net having a matrix arrangement of flexible material including an array of intersecting rows and columns defining a plurality of open spaces and containing one or more light sources.
[0019] It is yet another objective of the instant invention to provide a system for illuminating a self contained breathing apparatus, the system including a notification device having a first housing member attached to a self contained breathing apparatus and constructed and arranged to receive an inner sheath member, a second housing member constructed and arranged to receive an outer sheath member, an inner sheath member attached to the first inner housing member and an outer sheath member having indicia and attached to the second housing member and at least one light source electrically coupled to a power source for illuminating the outer sheath member whereby Illumination of the outer sheath member displays a message which is visible to a third party.
[0020] Other objects and advantages of this invention will become apparent from the following description taken in conjunction with any accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. Any drawings contained herein constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE FIGURES
[0021] FIG. 1 is a front view of the notification device of the instant invention which is secured to a self contained breathing apparatus;
[0022] FIG. 2A illustrates the indicia in the form of a symbol;
[0023] FIG. 2B illustrates an alternative embodiment of the indicia;
[0024] FIG. 2C illustrates the indicia in the form of words;
[0025] FIG. 2D illustrates the indicia having multiple messages;
[0026] FIG. 3 is a back view of the notification device of the instant invention;
[0027] FIG. 4 is a perspective view of the notification device secured to SCUBA tank;
[0028] FIG. 5 illustrates the notification device of the instant invention secured to a self contained breathing apparatus, SCBA, typically used by firefighters;
[0029] FIG. 6 is a front view of an alternative embodiment of the instant invention secured to a self contained breathing apparatus;
[0030] FIG. 7 is a bottom perspective view of the alternative embodiment illustrated in FIG. 6 ;
[0031] FIG. 8 is an enlarged view of the net arrangement, electrical leads, and light source of the alternative embodiment of the instant invention as described in FIG. 6 ;
[0032] FIG. 9 is an illustration of an alternative embodiment of the notification device of the instant invention having multiple sheath members; and
[0033] FIG. 10 illustrates indicia positioned on the outer sheath member.
DETAILED DESCRIPTION OF THE INVENTION
[0034] While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred, albeit not limiting, embodiment with the understanding that the present disclosure is to be considered an exemplification of the present invention and is not intended to limit the invention to the specific embodiments illustrated.
[0035] With reference to the drawings, and in particular FIGS. 1-3 , a preferred embodiment of the instant invention will now be described. A notification device or display device 10 is shown in FIG. 1 secured to a side of a self contained breathing apparatus 12 , such as a SCUBA tank. The notification device 10 is preferably curved in its longitudinal cross section to conform to the outer curvature of the tank 12 . This curvature permits the device 10 to be readily secured to the tank 12 and remain affixed thereon.
[0036] The notification device 10 includes a main body 14 which is defined by an outer frame 16 . The outer frame 16 is designed to receive and hold an inner plate member 18 . Inner plate member 18 is preferably transparent or translucent. As illustrated in FIGS. 1 and 3 , the outer frame has a top wall 16 a and a parallel bottom wall 16 b . While the two parallel side walls 16 c and 16 d interconnect with the top wall 16 a and bottom wall 16 b to give the outer frame a generally rectangular shape, the notification device 10 need not be limited to such a shape. The inner plate member 18 contains indicia 20 . Indicia 20 includes a plurality of lettering, however, the indicia may also include symbols, one or more words, or combinations thereof. For example, the indicia can be a symbol such as a diagonal stripe illustrated in FIG. 2A , which is the symbol for underwater divers, or a graphic symbol, such as a lobster, see FIG. 2B . FIGS. 2C and 2D illustrate the indicia in the form of a plurality of words. The inner plate member 18 can be designed to slidably engage the frame, such as for example, through slots or grooves within the frame. This provides the user the ability to easily and quickly interchange one or more inner plate members having different indicia. Once within the frame, the indicia are clearly displayed and can be seen by other individuals in sight of the self contained breathing apparatus 12 . Preferably the indicia are translucent so that they can be illuminated by light contained on the tank. The indicia can also be transparent and/or opaque. The main purpose of the indicia is to convey a message to a third party observing the tank 12 from a distance. The message that is conveyed relates to the individual wearing the tank.
[0037] FIG. 3 is a view of the inner side of the notification device 10 . A plurality of lights 22 is located within the frame 16 at one end thereof. The frame is spaced from the surface of the tank so that when one of the indicia 2 A- 2 D is placed within the frame, lights 22 are positioned between the indicia and the surface of the tank. Thus the indicia are illuminated by the lights. The lights 22 are preferably Light Emitting Diodes (LED). The lights 22 can be clear of any other color, or can be different colors. The lights 22 can be illuminated all together or can be controlled such that they flash, blink or are illuminated in any given pattern. In addition to, or in lieu of the lights 22 , the notification device 10 could also contain a flat light 24 . The flat light 24 can be located within the perimeter of the frame or between the indicia and the surface of the tank.
[0038] In order to increase the visibility of the notification device 10 , the outer frame 16 can also be made of a material that is reflective or that can be illuminated under specific lighting conditions, such as ultra-violet lights. The notification device 10 is preferably positioned on tank 12 so that it is clearly visible to one or more individuals. The size of the notification device can be selected so that it can be visible by photographic detectors, such as cameras, and/or visual, infrared, ultraviolet, optical, scanning devices. Attached to the notification device 10 are various communications receiving and/or transmitting elements, 26 and 28 . Elements 26 and 28 can also be transceivers. For example, elements 26 and 28 may provide audio or acoustic signal. The notification device 10 can also be provided with communication capabilities which can send a signal to a remote location, such as a home base, that the individual wearing the notification device needs assistance. Communications receiving and/or transmitting elements 26 or 28 may include a Global Positioning System (GPS) device. The GPS device enables the individual wearing the notification device 10 to be tracked and located whenever desired, such as in case of an emergency. In an emergency situation the notification device 10 can function like an OnStar® device. The notification device 10 is secured to the tank 12 through various attachment straps 30 and 32 , which include hook and loop fasteners, such as VELCRO®, bungee cords, clasps, or other fastening means known to one of skill in the art.
[0039] A source of electrical energy 34 is preferably located at one end of the frame 16 . In a preferred embodiment the source of electrical energy 34 is one or more batteries. The batteries can be single use or rechargeable. In place of the batteries, a solar panel or other devices which generate electricity can be employed to illuminate the lights 22 and 24 .
[0040] FIG. 4 is a prospective view of the notification device 10 secured to a conventional SCUBA tank 36 and harness 37 . Horizontal straps 38 and 40 which secure the harness 37 to the tank 36 are normally spaced a standardized distance apart. The instant invention is preferably positioned between the straps 38 and 40 . The straps can also be used to secure frame 16 to tank 36 . The notification device 10 is preferably positioned on tank 12 so that it is clearly visible to one or more individuals. The size of the notification device 10 can be selected so that it can be visible by photographic detectors, such as cameras; and/or visual, infrared, ultraviolet, optical, scanning devices. The notification device 10 can also include an audio or acoustic signal. The notification device 10 can also be provided with communication capabilities which can send a signal to a remote location, such as a home base, that the individual wearing the notification device needs assistance. The notification device 10 can also be provided with a Global Positioning System (GPS). The GPS device enables the individual wearing the notification device 10 to be tracked and located whenever desired, such as in case of an emergency. In one type of situation, the individual wearing the notification device can indicate to a third party, such as OnStar®, that they will be returning to a specific location at a certain time. If the individual does not return by that time, the third party will notify persons that the individual has requested to be notified in case of an emergency. These persons can then check the location of the individual in distress by accessing the GPS device secured to the individual.
[0041] The notification device 10 used in conjunction with a SCUBA tank also enables the tracking of the individual associated with the notification device by sonar or other devices from the surface of the water or under the surface of the water. This tracking capability allows a third party to determine the location of the individual in the event of an emergency. Although not shown, all or any portion of the notification device 10 as described herein can be enclosed within a waterproof container to protect one or all portions of the device from aquatic environments.
[0042] Although not illustrated, the notification device 10 may also contain a control panel. The control panel could be electrically connected to the one or more light sources or the power source such that various portions of the notification device or colors of light could be illuminated upon activation. For example, the indicia as illustrated in FIG. 2D could be used by firefighters either in an underwater recovery rescue or in a burning building. Once inside the particular environment, the indicia could be illuminated such that ‘NYFD #210” could be illuminated. This provides non-verbal communication to other firefighters as to who is around them. If firefighter #210 gets injured and needs help, the firefighter could activate the control panel. The activation results in illuminating the “HELP” section of the notification device, thereby alerting fellow firefighters, whom may have limited visibility, that #210 needs help. Additionally, the notification device 10 may also flash red colored lights once activated by the control panel. The notification device can further be programmed to contact a third party, such as On Star®, which will contact specific individuals, as stated herein above.
[0043] A conventional SCBA tank 42 and harness 44 , commonly used by firefighters, are illustrated in FIG. 5 . Horizontal strap 46 secures the harness 44 to the tank. The notification device 10 is preferably positioned substantially parallel to and adjacent tank 42 . The notification device 10 is preferably positioned on tank 42 so that it is clearly visible to one or more individuals. The size of the notification device can be selected so that it can be visible by photographic detectors, such as cameras; and/or visual, infrared, ultraviolet, optical, scanning devices. The notification device 10 can also include an audio or acoustic signal. Strap 46 can be employed to help secure frame 16 to the tank 42 .
[0044] The notification device 10 utilized with the SCBA tank 42 can be connected to or in communication with a device 48 , such as a dead man's device, that detects the position and movement of the individual wearing the SCBA apparatus. In the event that the individual became injured or trapped in a non-vertical position, the detection device 48 would activate the notification device 10 by way of communications receiving and/or transmitting elements, 26 and 28 causing the lights to flash, blink, or emit a different color, thus alerting someone nearby. The notification device 10 can also be provided with a Global Positioning System (GPS) device 50 . The GPS device 50 enables the individual wearing the notification device 10 to be tracked and located whenever desired, such as in case of an emergency. Communication and transmitting elements 26 and 28 operate in conjunction with a GPS device 50 which will determine the exact location of the individual wearing the notification device. In the event the detection device 48 determines that the individual wearing the notification device 10 is in danger, the communication devices 26 and 28 can send a signal which will notify a base station or other individual that someone needs assistance. The GPS device 50 will enable the individuals who have been notified by the communications devices 26 and 28 to determine the exact location of the individual who is in danger.
[0045] An alternative embodiment of the notification device 10 is illustrated in FIGS. 6 and 7 . In this embodiment the self contained breathing apparatus 12 is placed into a net or woven matrix of elements. The net or woven matrix of elements can be constructed of flexible material. As shown in FIGS. 6 , 7 and 8 , one or more electrical leads 52 are interlaced within rows 54 or columns 56 of the woven net 58 . The electrical leads 52 may run alongside a row 54 or a column 56 , or the leads 52 may intersect through the open spaces 55 . Each electrical lead 52 is connected in a bundle to a power source 60 on one end and on the opposite end to a light source 62 . Preferably, each electrical lead 52 terminates at the intersection of a row 54 and a column 56 . At the intersection, the electrical lead 52 is coupled to a light source 62 . The light source 62 is preferably any low-wattage light emitting device, such as but not limited to a light emitting diode (LED). The power source 60 for use with the lit notification device 10 is preferably a battery pack which is attached to the net 58 on the outer bottom edge 64 . Additional power sources can be employed. A separate light 66 is secured to the bottom of the power source 60 ( FIG. 7 ). This light enables an individual to see it when the individual is swimming behind an individual wearing the notification device 10 .
[0046] As shown in FIGS. 6-8 , each light source 62 is coupled to an electrical lead 52 and positioned at the intersection of the rows 54 and columns 56 on the matrix arrangement of the woven net 58 . However, it is contemplated that the leads 52 may also extend further from the intersection and into the open space and the light source 62 would be coupled in the open space, not shown. The light sources 62 can be coupled to a control switch 68 which allows the light source 62 to emit a spectrum of colors. Each light source 62 may transition between spectrums of color controlled by the control switch 68 , for instance a multi-color LED; or each independent light source 62 may be of different spectrums to provide various color arrangements on the net 58 . For instance, the light sources 62 may emit a white light for ordinary purposes, but in emergency situations a red light would be emitted to alert others of an emergency. Furthermore, the controller 68 may selectively light different zones within the net 58 to provide a variety of patterns or symbols by selectively lighting certain light sources 62 within a zone.
[0047] The notification device 10 may also include mounting elements 70 for attachment to the surface of the self contained breathing apparatus or for securing one portion of the device to a second portion. Various mounting elements are contemplated for securing the notification device 10 to the surface, such as suction cups, bungee cords, grommets, clasps, standing posts, weights, or hook and loop fasteners, such as VELCRO®.
[0048] FIG. 9 illustrates an alternative embodiment of the notification device 10 which is secured to a self-contained breathing apparatus 12 . The notification device 10 includes one or more sheath members constructed and arranged to provide notification functionality as described in previous embodiments. Attached to the self-contained breathing apparatus 12 is a first inner housing member 72 . The first inner housing member 72 is constructed and arranged to receive an inner sheath member 74 . A second outer housing member 76 is constructed and arranged to receive an outer sheath member 78 . Inner sheath member 74 and outer sheath member 78 may be constructed of a translucent thermoplastic material, such as PLEXIGLAS®, and take the form of parallel, vertical panels extending in an upward direction from the first inner housing member 72 and the second outer housing member 76 , respectively. Additionally, the inner sheath member 74 and/or the outer sheath member 78 may be designed to contour the outer perimeter of the self-contained breathing apparatus 12 . The outer sheath member 78 of notification device 10 contains indicia 80 , see FIG. 10 , which provides identification and information about the user to a third party. As described previously, indicia 80 can be symbols, letters, words or combinations thereof.
[0049] The notification device 10 contains a plurality of lights 82 , which may be positioned at or near the first inner housing member 72 , on the inner sheath member 74 , or combinations thereof. The plurality of lights, therefore, is preferably positioned between the inner sheath member 74 and the outer sheath member 78 . In this arrangement, the plurality of lights 82 illuminates the indicia 80 that is located on the outer sheath member 78 . The lights 82 are preferably Light Emitting Diodes (LED) and can be clear of any other color, or can be different colors. The lights 82 can be illuminated all together or can be controlled such that they flash, blink or are illuminated in any given pattern. The lights 82 are electrically coupled to a source of electrical energy 84 for illuminating the outer sheath member 78 , whereby illumination of the outer sheath member displays a message which is visible to a third party. The source of electrical energy 84 is preferably located on the first housing member 72 but may be positioned on the inner sheath member 74 . In a preferred embodiment, the source of electrical energy 84 is one or more batteries. The batteries can be single use or rechargeable. In place of the batteries, a solar panel or other devices which generate electricity can be employed to illuminate the plurality of lights 82 .
[0050] Although not illustrated in FIG. 9 , the notification device 10 can also be provided with communication capabilities which can send a signal to a remote location, such as a home base, that the individual wearing the notification device needs assistance. The notification device 10 can also be provided with a Global Positioning System (GPS). The GPS device enables the individual wearing the notification device 10 to be tracked and located whenever desired, such as in case of an emergency.
[0051] All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.
[0052] It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and any drawings/figures included herein.
[0053] One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims. | A device for use with a self contained breathing apparatus, such as a SCBA tank, which allows a user to display different indicia on the tank. The indicia are preferably illuminated by a self contained illumination system also located on the tank. The device allows a user to readily interchange the indicia so that the currently displayed indicia provide a specific message or indicate a specific condition to an individual observing the tank and related indicia. The illumination system permits the indicia on the tank to be clearly seen in poorly lighted environments, such as deep underwater, or in environments with poor visibility, such as in smoke-filled rooms associated with fires. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to an improvement in a contacting type surface temperature sensor adapted to be brought into contact with a surface of a solid to measure the temperature thereof, and more particularly, to a surface temperature sensor which is capable of minimizing a measurement error even when the posture of the sensor with respect to the surface, the temperature of which is to be measured, of a solid varies to a diagonal state, i.e., even when the angle between an object surface of the solid and the sensor contacting the same surface varies to an angle smaller than 90°, and which has a superior durability.
A contacting type surface temperature sensor utilizing a thermocouple has a thin-belt-like resilient contact member. When this contact member consists of a spring type thermocouple plate, or a thin plate spring with a thermoelement, such as a thermocouple or a thermistor, supported on the central portion thereof, the contact member is fixed at its both ends to the free end portion of a support member so that the contact member projects semicircularly in side elevation, to thereby form a temperature measuring portion of the sensor.
When this surface temperature sensor is used, the intermediate portion of the semicircular contact member is brought into contact with the surface of a solid the temperature of which is to be measured, and then pressed lightly against the surface to slightly flatten the semicircular portion of the contact member, whereby a part (contact surface) of the contact member is engaged closely with the object surface of the solid. This contact member is formed so as to enable itself to reliably contact an object surface, the quantity of the heat, which is transferred between the contact member and an object surface when the contact member is engaged with the object surface to be minimized, and the temperature drop at the object surface at such a time to be thereby minimized. The construction of this surface temperature sensor is determined with consideration given to, especially, a solid having a small thermal capacity.
A method of making the contact member extremely thin so as to reduce the thermal capacity thereof is employed as means for enabling the contact member to be pressed against the object surface so that the contact member can thermally sufficiently contact the object surface and the occurrence of transfer of heat between the contact member and object surface can be minimized. However, when the thickness of the contact member is reduced to such an extent, the pressing force thereof to be applied to an object surface decreases, so that the contact member is not fitted accurately along the object surface.
In order that the contact member can reliably contact the object surface of a solid, the thickness of the contact member is increased to increase the pressing force thereof. However, if the thickness of the contact member is increased, the thermal capacity thereof increases. Therefore, when the generation of heat is to be measured in an object solid having a small thermal capacity and a low pressure resistance, for example, a semiconductor device, such a contact member is not suitably used. A surface temperature sensor in which a contact member is supported on a metallic auxiliary spring with a view to eliminating these problems is proposed as disclosed in, for example, Japanese patent publication No. 46-25795.
This surface temperature sensor "is provided with a thermocouple element joined to a thin-belt-like resilient thermocouple or a thin thermocouple wire so as to extend to a predetermined shape, and a metallic auxiliary spring means for the thermocouple element, and formed so that, when the temperature of an object surface is measured, the thermocouple element contacting this surface is supported on the metallic spring means in the same temperature region of the thermocouple element and spring means".
The temperature sensor of the above-described construction consists of a thermoelement composed of a thermocouple, and a spring means supporting the thermoelement, and the temperature measuring portion of the sensor has a complicated construction and a comparatively large thermal capacity.
The thermocouple and the spring means supporting it are fixed to a support member. It is necessary that a heat-sensitive portion of the thermoelement be in press-contact with an object surface accurately (closely) in all temperature measuring operations. Therefore, the heat-sensitive portion requires to be engaged with an object surface quietly. This causes the use of the sensor to be restricted. Namely, it is difficult to momentarily measure the temperature of, for example, a moving solid with which the heat-sensitive portion of the sensor cannot be easily engaged.
If the end portions of a contact member are fixed to a support member of the temperature sensor, fatigue of metal occurs at the fixed end portions of the contact member, so that the contact member is bent or broken. Therefore, it can be said that such a temperature sensor has a problem with respect to the mechanical strength as well.
The end portions of the contact member, which are fixed to the support member or the body of the temperature sensor, cause further problems. Namely, since the root portions of the contact member are fixed, the contact member is necessarily deformed to the shape of a cantilever. This causes the degree of freedom of deformation of the spring to decrease, and the contact surface of the contact member cannot accurately and easily engage the surface of an object solid.
Consequently, for example, when the temperature sensor is brought into contact with an object solid in motion to momentarily measure the temperature of the surface thereof, they do not engage with each other excellently, and an error would occur in a detected temperature.
In more detail, when the contact member engages the surface of an object solid, the deformation of the contact surface of the contact member does not progress, for example, from a semicircular shape to an elongated arcuate shape, i.e., the width or area of the contact surface does not gradually increase but, when the deformation of the contact member has progressed to a certain extent, a part of the contact surface thereof floats from the object solid, so that that part of the contact member on which a temperature measuring element which is important for the measurement of the temperature of an object surface is provided, or a hot junction does not accurately contact the object solid.
These problems will be described with reference to illustrations. As shown in FIG. 10(a), both ends 1a and 1b of a contact member 1, which consists of a thin plate of a thermocouple with a hot junction c (or a heat-sensitive portion) provided on the central section of the thin plate, or a thin plate with a heat-sensitive element, such as a thermistor provided on the central portion thereof, or a thin wire type thermocouple, are fixed to a body 2 (or a support member) of a temperature sensor so that the contact member 1 is bent generally to a semicircular shape. The measuring of the temperature of an object solid 3 with this contact member 1 engaged therewith will now be described.
When the central portion of the semicircular contact member 1 fixed at its both ends to the sensor body 2 as shown in FIG. 10(a) is engaged lightly with the object solid 3, the hot junction c and the center of a contact surface 4 shown in FIG. 10(b) agree with each other.
A segment Q on the contact surface 4 represents a stress-concentrated portion occurring when the contact member 1 engages the object solid 3. This means that, when the contact member 1 is deformed slightly, the hot junction c exists on the contact surface 4 with the contact surface area at an insufficiently low level, and that, therefore, an accurate temperature measuring operation cannot be carried out.
When the sensor body 2 is then moved toward the object solid 3 in the direction of an arrow D shown in FIG. 11(a), the width of the contact surface 4 gradually increases as shown in FIG. 11(b). In this stage, the hot junction c is still positioned on the central portion of the contact surface 4, and the contact surface area is sufficiently large, so that the temperature of the object solid can be accurately measured.
The variation (increase) of the area of the contact surface 4 will now be discussed. When the contact member 1 is pressed toward the surface of the object solid 3 in the direction of the arrow D to be engaged therewith, a force shown by an arrow E and directed from the fixed support point 1b to a stress-concentrated portion Qb on the object solid 3 occurs. The force shown by this arrow E is divided into components working in two directions, i.e. a component of the arrow D by which the contact member 1 is pressed toward the object solid 3, and a component of an arrow F by which the contact member 1 is compressed toward the central portion thereof.
A question as to whether the component working in the direction of the arrow F serves to reliably engage the contact member 1 with the surface of the object solid 3 will now be discussed. When the sensor body 2 is brought closer to the object solid 3 so as to deform the contact member 1 as shown in FIG. 12(a), the component of the arrow F works toward the central portion of the contact member 1, so that the central portion floats from the object solid 3 to cause the hot junction c to be separated by a distance δ from the surface of the object solid 3. The details of such a movement of the central portion designated by a circle R in FIG. 12(a) are shown in an enlarged front elevation of the same portion in FIG. 12(c).
When the contact member is in this condition, the contact surface 4 is separated into contact surface portions 4a and 4b as shown in FIG. 12(b). The above-mentioned upward removal of the hot junction c from the surface of the object solid 3 causes an error of a detected temperature, and it is necessary that this phenomenon be prevented.
If the contact member 1 is engaged momentarily with the surface of the object solid 3 as shown in FIG. 12(a), the hot junction c is not heated directly by the object solid 3. Therefore, it is clear that an error of a detected temperature becomes large.
The above is a description of the case where the contact member 1 is engaged in a regular posture (in which the sensor body 2 is applied to the surface of the object solid 3 so that the direction in which a pressing force is applied to the sensor body is at right angles to the surface of the object solid 3) with the surface of the object solid 3. When the sensor body 2 is applied to the surface of the object solid 3 so that the direction of a pressing force applied to the latter is diagonal with respect to the latter, some more problems arise.
FIGS. 13(a), 13(b), 14(a), 14(b), 15(a) and 15(b) illustrate this case. FIGS. 13(a) and 13(b) correspond to FIGS. 11(a) and 11(b), and indicate that the hot junction c (or heat-sensitive portion) is positioned in the central portion of the contact surface 4, and that an error of a detected temperature does not substantially occur.
When the object solid 3 inclines with respect to the body 2 of the temperature sensor, or when the sensor body 2 is engaged incliningly with the object solid 3, as shown in FIG. 14(a), the heat-sensitive portion c gradually leaves a center line S. As a result, the hot junction c moves toward a corner portion of the contact surface 4 as shown in FIG. 14(b). In this case, the hot junction c is about to leave the contact surface 4, and deviation occurs between a temperature-measuring center c' and the hot junction c.
FIGS. 14(a) and 14(b) show an example of the posture of the contact member 1, which often occurs while the temperature of, for example, a moving object is measured with a contacting type temperature sensor. In this case, the temperature-measuring center c' deviates from the hot junction c, so that a temperature lower than an actual temperature is detected. Namely, an error occurs in a temperature measuring operation in this case.
FIGS. 15(a) and 15(b) show the condition of the sensor body 2 extremely inclined with respect to the object solid 3 with the hot junction c removed or about to be removed from the contact surface 4. In this condition, the accurate transmission of the heat of the object solid to the hot junction c can hardly be expected, so that a considerable error occurs in a detected temperature.
When the sensor body 2 inclines extremely with respect to the object solid 3 as shown in FIG. 15(a), one side portion of the contact member 1 is bent as shown by 1m with a comparatively large radius of curvature, while the other side portion thereof is bent as shown by 1n with a small radius of curvature. When the contact member 1 is bent with a small radius of curvature 1n in this manner, the fixed portion 1b is bent extremely, and large stress occurs therein, so that permanent deformation occurs in the contact member 1. This causes an error in a detected temperature to increase, and the contact member 1 to be finally broken. Moreover, since the hot junction c is moved to an end portion of the contact surface 4, it becomes difficult to measure the temperature of the object surface accurately.
SUMMARY OF THE INVENTION
The present invention has been developed with a view to eliminating the problems with the above-described conventional contacting type temperature sensor. A first object of the present invention is to provide a temperature sensor having a contact member the contact surface of which can be accurately engaged with the surface of an object solid.
In a conventional temperature sensor, the contact surface of the contact member thereof leaves an object solid and floats at the central portion of the former from the latter when the sensor body is pressed against the object solid under a certain condition but such an inconvenience can be eliminated by the present invention.
A second object of the present invention is to provide a temperature sensor having a contact member which is not easily broken at the portions thereof which are in the vicinity of the portions of the same fixed to a support member or a sensor body.
In a conventional temperature sensor, an extremely large deforming force is applied to both end portions, which are fixed to the sensor body, of a contact member. Consequently, permanent deformation occurs in these end portions, or these end portions are bent or broken. These inconveniences can also be eliminated by the present invention.
A third object of the present invention is to provide a temperature sensor having an increased degree of freedom of spring deformation of a contact member, capable of being engaged excellently with an object solid, capable of substantially preventing stress from being concentrated locally in the contact member, and having a high durability.
In a conventional temperature sensor, both ends of a contact member are fixed rigidly to the sensor body, so that a measurement error occurs when the contact member assumes a certain posture while it contacts an object solid or when the contact engages the object solid under a certain condition. Such drawbacks can also be eliminated by the present invention.
A fourth object of the present invention is to provide a temperature sensor having a contact member which is not permanently deformed even when an impact load is imparted thereto, and which has a high durability.
The temperature sensor according to the present invention by which these object can be achieved comprises a generally C-shaped or Ω-shaped contact member consisting of a contact surface, first deformable portions continuing from both ends of the contact surface and bent in the shape of the letter "L", second deformable portions continuing from the end portions of the first deformable portions and bent toward positions above the central portion of the contact surface-carrying portion, and contact lugs composed of locking portions and formed at the end portions of the second deformable portions, the locking portions of the contact member being movably engaged with and supported on support members.
The contact member constituting the temperature sensor according to the present invention is characterized in that it has a generally C-shaped or Ω-shaped construction and is supported on the sensor body with pins engaged from the outside at both end support portions of the contact member so that the contact member can be moved pivotally (the contact member is not in a fixed state and can be moved freely).
The contact member is a member adapted to be engaged directly with an object solid, and shaped mainly like a thin plate and, in some cases, like a metal wire, the contact member consisting of a resilient material.
This resilient material has a contact surface, a first deformable portions bent substantially in the shape of the letter "L", "J" or "C" at both ends of the contact surface, second deformable portions extended from the first deformable portions toward the inner side or center of the width of the contact surface, and support portions formed at the end portions of the second deformable portions, and a hot junction or a heat-sensitive portion is formed at the central portion of the contact surface.
This contact member is formed by using a plate of a thermocouple material, a plate of a spring material, a stainless steel plate of an increased hardness or a titanium plate. The heat-sensitive portion or a hot junction formed at the central portion of the contact surface constitutes a plate on which a hot junction of a thermocouple, a thermistor or a film type resistor of platinum is to be mounted.
In the temperature sensor according to the resent invention, it is important that means for supporting the contact member on the sensor body does not consist of a fixed means but consists of a movable means. What makes this contact member movable are pins implanted in the sensor body or locking portions thereof which work similarly to pins implanted in and formed on the sensor body, and which contact support portions formed at both end sections of the contact member, so as to bend the contact member as a whole.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a principal portion of an embodiment of the surface temperature sensor according to the present invention;
FIG. 2(a) is a perspective view of one member of a sensor body, which is joined to a cylinder;
FIG. 2(b) is a perspective view of a contact member set in the sensor body;
FIG. 3(a) is a front elevation showing an operation of the contact member constituting the surface temperature sensor according to the present invention;
FIG. 3(b) illustrates the condition of contact surface of the contact member of FIG. 3(a);
FIGS. 4(a), 4(b), 5(a) and 5(b) are front elevations of the contact member pressed in different manners, and plans showing the condition of the contact surface in these cases, in both of which cases the contact member is pressed against an object solid so that the direction of the pressing force applied to the contact member is perpendicular to the object surface;
FIGS. 6(a), 6(b), 7(a), 7(b), 8(a), and 8(b) are front elevations of the surface temperature sensor according to the present invention pressed against an object solid so that the direction of the pressing force applied to the sensor is diagonal with respect to the object surface, and plans showing the condition of the contact surface in these cases;
FIG. 9(a) is a perspective view of a second embodiment of the surface temperature sensor according to the present invention;
FIG. 9(b) is a front elevation of the embodiment of FIG. 9(a) in a supported state;
FIGS. 10(a), 10(b), 11(a), 11(b), 12(a) 12(b) are front elevations of a conventional both-end-fixed type surface temperature sensor, and plans showing the condition of the contact surface thereof in various object solid-pressing condition;
FIG. 12(c) is an enlarged view of the portion designated by a circle R in FIG. 12(a); and
FIGS. 13(a), 13(b), 14(a), 14(b), 15(a) and 15(b) are views, taken to illustrate conditions in which a conventional end-fixed type surface temperature sensor undergoes deformations as it is applied at angled positions against an objective contact surface for temperature measurement, wherein FIG. 13(a) shows a front view of the sensor applied at a right angle to the objective contact surface, FIG. 13(b) being a view showing the contact surface in the case of the application of the sensor shown in FIG. 13(a), FIG. 14(a) showing a front view of the sensor applied at an inclination against the objective surface, FIG. 14(b) being a view showing the contact surface in the case of the application of the sensor shown in FIG. 14(a), FIG. 15(a) showing a front view of the sensor applied in an extremely inclined position against the objective surface, and FIG. 15(b) being a view, showing the contact surface at the time of application of the sensor shown in FIG. 15(a) and showing that the center of the contact surface is greatly deviated in this case in comparison to the condition shown in FIG. 13(a).
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be described in conjunction with the preferred embodiments, with reference to the drawings.
FIG. 1 is a perspective view of a principal portion of the temperature sensor according to the present invention. A cylinder 21 extends from a front end of a handle 20, and a two-piece sensor body 22 is fixed to the front end of the cylinder 21. An Ω-shaped or C-shaped contact member 24 is supported in a space defined by cross-sectionally semicircular guide portions 23 and 23 formed at the front end section of the sensor body 22.
The sensor body 22 consists of a molded product of a synthetic resin, a metal or a ceramic material. As shown in FIG. 2(a), each sensor body member has a semi-cylindrical shaft portion 25, contact member support portions 26 and 26 extended from both sides of the shaft portion 25 in a forward direction toward the center of the sensor body member, and a position restricting portion 27, a stepped portion 28 being formed so as to extend from space in front of the support portions 26 and 26 to space at the outer sides of the position restricting portion 27, and by the stepped portion 28, the range of movement of the contact member 24 is restricted.
FIG. 2(b) shows the sensor body 22 in which the contact member 24 is held. This contact member 24 consists of a contact surface 24a, first deformable portions 24b, second deformable portions 24c and support portions 24d, and a hot junction, or a heat-sensitive portion consisting of a thermistor is fixed to the central part of the contact surface 24a. Reference numeral 30 denotes compensating conductors or lead wires.
The contact member 24 is formed in the shape of the letter "C" or "Ω" as previously mentioned, and the corner sections of the position restricting portion 27 are positioned on the inner surfaces of the first deformable portions 24b and 24b so as to prevent the contact surface 24a from being laterally displaced. The horn-shaped support portions 26 and 26 contact the outer surfaces of the L-shaped support portions 24d and 24d, so that the contact member 24 is supported by these parts resiliently engaged therewith.
Accordingly, the main parts of the support mechanism for the contact member 24 are the support portions, or pins 26 and 26, and the position restricting portion 27 contacting the inner surfaces of the first deformable portions 24b and 24b serves as an auxiliary part for preventing the contact surface 24a from being laterally displaced. After all, the contact member 24 is supported at four points on the support portions 26 and 26 and the corner sections of the position restricting portion 27.
FIGS. 3(a) and 3(b) illustrate the condition of the contact member 24 in the present invention, in which the contact member 24 is supported on the pin-type support portions 26 and 26 with the contact surface 24a engaged lightly with the object solid 3 (an illustration of the position restricting portion 27 which supports the contact member 24 auxiliarily is omitted). A comparison between this contact member of FIGS. 3(a) and 3(b) and the conventional contact member of FIGS. 10(a) and 10(b) shows that the hot junction c in each thereof is positioned in the central portion of the contact area 4. This means that the conventional temperature sensor and the temperature sensor according to the present invention are capable of detecting a temperature with an equal accuracy.
FIG. 4(a) shows the condition of the sensor body 22 brought closer to the object solid 3. When a pressing force shown by an arrow G is applied to the support portions 24d and 24d via the pin type support portions 26 and 26, a force shown by an arrow H directed to a stress-concentrated portion Qb on the contact surface 4 shown in FIG. 4(b) occurs. The force of this arrow H consists of a force of an arrow I by which the contact member 24 is pressed against the surface of the object solid 3, and two components shown by arrows J and J, directed in the opposite directions and constituting the tensile force directed from the center of the contact member 24 to the outer sides thereof.
These components J and J directed in opposite directions constitute the tensile force applied to the contact surface 24a. Owing to the components J and J the contact surface 24a acts to pull the contact member 24 from the central portion thereof, on which the hot junction c exists, toward both corner portions thereof.
As a result, the components J and J directed toward both corner portions of the contact surface 24a work so as to further flatten the same surface, so that the contact surface 4 including the hot junction c is engaged under a higher pressure with the surface of the object solid 3.
FIGS. 4(a) and 4(b) illustrate the present invention correspondingly to FIGS. 11(a) and 11(b). In the conventional contact member 1, the compressive stress due to the two components of force directed from both ends of the contact surface thereof to the central portion thereof works on the same contact surface, while, in the contact member 24 in the present invention, tensile stress consisting of the two components J and J of force directed in the opposite directions works on the contact surface thereof. It is necessary that special attention should be paid to this great difference.
FIGS. 5(a) and 5(b) show the contact member 24 to which a pressing force is further applied, in which, in spite of the considerable deformation of the contact member 24, the contact surface 24a is wholly engaged with the object solid 3.
A comparison between the condition of deformation of the contact member of FIGS. 5(a) and 5(b) and that of the conventional contact member 1 of FIGS. 12(a) and 12(b) shows the following: In the conventional contact member 1, two components of force work thereon from both sides thereof toward the central portion thereof, so that compressive stress based on these components occurs to float the central portion of the contact surface. Consequently, the contact surface 4 is separated into to parts 4a and 4b. However, in the present invention, the area of the contact surface 4 increases accurately, and the hot junction c is positioned in the central portion of the contact surface.
When the conventional temperature sensor is in the condition shown in FIGS. 12(a) and 12(b), the temperature of an object solid cannot be measured accurately any more. On the other hand, in the temperature sensor according to the present invention, the contact surface area varies accurately in accordance with a variation of the pressing force applied to the contact member, i.e., irrespective of the magnitude of the pressing force, and the separation of the contact surface into two parts, which is encountered in the conventional temperature sensor, does not occur in this contact member. Accordingly, the temperature of an object solid can be accurately detected.
A case where the temperature sensor contacts the object solid with the direction of a pressing force applied to the sensor inclined at a large angle with respect to an object surface will now be described with reference to FIGS. 6(a), 6(b), 7(a), 7(b), 8(a) and 8(b).
FIGS. 6(a) and 6(b) are drawn correspondingly to FIGS. 13(a) and 13(b), FIGS. 7(a) and 7(b) to FIGS. 14(a) and 14(b), and FIGS. 8(a) and 8(b) to FIGS. 15(a) and 15(b). In these drawings, the temperature sensor according to the present invention in which a contact member is movably supported, and a conventional temperature sensor in which a contact member is fixedly supported are shown so that the pressed condition of the sensors, the condition of deformation of the contact members, and the relation between the contact surface areas and the positions of the hot junctions can be understood.
In the conventional temperature sensor, the hot junction c moves gradually from the central portion of the contact surface 4 to a corner portion thereof, while, in the temperature sensor according to the present invention, the hot junction c is positioned on the central portion of the contact surface irrespective of the pressed condition of the contact member.
As shown in FIGS. 7(a) and 8(a), the pin type support members 26 and 26 press the support portions 24d and 24d of the contact member 24 from the outside to support the contact member 24. Accordingly, a rotational force K occurs in these support portions, so that the first deformable portions 24b and 24b and second deformable portions 24c and 24c are not unduly deformed. Namely, these deformable portions are not greatly deformed. This may be understood clearly if FIGS. 7(a) and 8(a) are referred to FIGS. 14(a) and 15(a).
As stated above, in the sensor according to the present invention, the support portions are not fixed but they are supported on the sensor body by pin type support portions. This enables the contact surface to be engaged accurately with the surface of the object solid irrespective of the angle of the object surface-pressing direction of the sensor, i.e., not only when the direction in which the sensor is pressed against the object solid is at right angles to the surface of the object solid but also when the direction in which the sensor is pressed against the object solid is inclined with respect to the surface of the object solid. This has an important meaning. In the conventional sensor, it is necessary that the sensor be brought into contact with an object solid during a temperature-measuring operation with special attention paid to the sensor-pressing direction but, in the sensor according to the present invention, giving such consideration to the sensor-pressing direction is not required.
A second embodiment of the present invention will now be described with reference to FIGS. 9(a) and 9(b).
FIGS. 9(a) and 9(b) show a contact member 30 formed by combining crosswise the contact pieces shaped as shown in FIG. 3(a), and a hot junction c is formed on a crossing portion of these contact pieces. The portions 26a and 26a correspond to the pin type support portions 26 and 26, and the portions 26b and 26b to the position restricting portion 27 shown in FIGS. 2(a) and 2(b). These parts support the cage-like contact member 30, and prevent an unduly large deforming force from being applied thereto.
According to the present invention, the contact member is formed generally in the shape of the letter "C" or "Ω", or has a modified shape of these letters. It has a contact surface, first deformable portions extended from both sides of this contact surface, second deformable portions joined to the first deformable portions, and support portions formed at the end sections of the second deformable portions and movably supported. The parts supporting these support portions are pins. The support portions are supported on the pins so as to allow the contact member to turn therearound. Since the contact member is also supported on a position restricting portion so as to prevent the lateral displacement thereof, the following effects can be obtained.
Both end portions of the contact member are supported pivotably on the pin type support portions, so that large deformation to be caused by pressing the contact member against an object solid poses no problem.
Since the contact member has first and second deformable portions, it can be deformed sufficiently in the vertical and diagonal directions, and no local permanent deformation occurs therein.
Especially, when the temperature sensor is engaged with an object solid so that the direction of a sensor-pressing force is inclined with respect to an object surface, problems would arise. According to the present invention, the contact surface of the contact member is engaged accurately with an object surface, and, moreover, the heat-sensitive point is positioned at the central portion of the actually contacting portion of the contact surface. Accordingly, a measurement delay and measurement errors do not occur.
When the temperature sensor according to the present invention contacts a moving object or with an impact, it is rarely permanently deformed since the deformable portions thereof has a high degree of freedom of movement, though a conventional sensor of this kind is deformed at its contact surface and becomes unusable in such a case. This ensures the high durability of the sensor according to the present invention. | A surface temperature sensor is disclosed, which comprises a contact member and a position restricting portion for guiding the contact member, of which the contact member comprises a contact surface formed of an elastic material and having a generally C-shaped or Ω-shaped section, a first deformable portion connected to and extending from respective ends of the contact surface, a second deformable portion connected to and inwardly extending from respective ends of the first deformable portions along the contact surface, and a support portion formed at respective free ends of the second deformable portions and pivotally supported about pins, and of which the position restricting portion has ends thereof located in the vicinity of points at which respective first deformable portion and the second deformable portion are connected to each other. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 10/775,442, filed Feb. 10, 2004, now U.S. Pat. No. 7,056,412, which is a division of U.S. application Ser. No. 09/990,422, filed Nov. 21, 2001, now U.S. Pat. No. 6,719,784, which are incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates to methods of preparing tubular prostheses, and, more particularly, to techniques for forming multi-layered prostheses.
BACKGROUND OF THE INVENTION
Formation of prostheses from polytetrafluoroethylene (PTFE), particularly expanded polytetrafluoroethylene (ePTFE) is well known in the prior art. ePTFE includes a node and fibril structure, having longitudinally extending fibrils interconnected by transverse nodes. The nodes are not particularly strong in shear, and, thus, ePTFE structures are susceptible to failure in a direction parallel to the fibril orientation. ePTFE structures (tubes, sheets) are typically paste extruded, and, the fibrils are oriented in the extrusion direction.
Vascular grafts formed of ePTFE are well known in the art. Where sutures have been used to fix such grafts, suture hole elongation and propagation of tear lines from suture holes have been noted.
To overcome the deficiencies of the prior art, techniques have been developed which re-orient the node and fibril structure of an ePTFE element to be transverse to the extrusion direction. By orienting the fibrils at an angle relative to the extrusion direction, the tear strength of a respective product may be greatly improved. In one technique set forth in U.S. Pat. Nos. 5,505,887 and 5,874,032, both to Zdrahala et al., an extrusion machine is described having a counter-rotating die and mandrel arrangement. Accordingly, upon being extruded, a single-layer unitary PTFE tube is formed having an outer surface twisted in one helical direction, and an inner surface twisted in an opposite helical direction. Although tubes formed in accordance with the method of U.S. Pat. Nos. 5,505,887 and 5,874,032 are expandable to form an ePTFE structure, the fibrils of the structure are oriented generally parallel to the expansion direction after expanding as shown in the micrograph of FIG. 5 in U.S. Pat. No. 5,874,032. Also, the tube tends to thin out unevenly under expansion, and, suffers from “necking”.
SUMMARY OF THE INVENTION
To overcome the deficiencies of the prior art, a method is provided wherein ePTFE tubes are counter-rotated, coaxially disposed, and fixed one to another to form a composite multi-layer prosthesis. By rotating the tubes, the tubes each becomes helically twisted with its node and fibril configuration being angularly offset throughout from the longitudinal axis of the tube (and, thus, angularly offset from the extrusion direction of the tube). With counter-rotation, the nodes and fibrils of the two tubes are also angularly offset from each other, resulting in a relatively strong composite structure. The composite multi-layer structure is akin to plywood, where alternating layers have differently oriented grain directions.
These and other features will be better understood through a study of the following detailed description and accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is an elevational view of an ePTFE tube;
FIG. 2A is an elevational view of a helically wound tube twisted in a first rotational direction;
FIG. 2B is a schematic of the node and fibril orientation of the first tube in a helically wound state;
FIG. 3A is an elevational view of a helically wound tube twisted in a second rotational direction;
FIG. 3B is a schematic of the node and fibril orientation of the second tube in a helically wound state;
FIG. 4A is an elevational view of a prosthesis formed in accordance with the subject invention;
FIG. 4B is a schematic of the node and fibril orientations of the composite prosthesis; and,
FIG. 5 is an exploded view of a prosthesis having a radially-expandable support member.
DETAILED DESCRIPTION OF THE INVENTION
The invention herein provides a multi-layer prosthesis which may be used as a graft to replace a portion of a bodily passageway (e.g., vascular graft), or within a bodily passageway to maintain patency thereof, such as an endovascular stent-graft. In addition, the prosthesis can be used in other bodily applications, such as the esophagus, trachea, colon, biliary tract, urinary tract, prostate, and the brain.
The prosthesis is composed of multiple layers, including coaxially disposed ePTFE tubes. To illustrate the invention, reference will be made to the use of two ePTFE tubes, although any number may be utilized consistent with the principles disclosed herein. With reference to FIG. 1 , an ePTFE tube 10 is shown which extends along a longitudinal axis 12 . The ePTFE tube 10 is preferably formed by extrusion, thus having its fibrils generally parallel to the extrusion direction of the tube, which coincides with the longitudinal axis 12 . The ePTFE tube 10 includes a wall 14 (which is seamless if extruded), that extends about a lumen 16 . The wall 14 includes an inner luminal surface 18 facing the lumen 16 , and an outer, abluminal surface 20 . The ePTFE tube may be formed of any length and of various dimensions, although it is preferred that the dimensions be generally constant throughout the length thereof. In describing first and second tubes of the invention, like reference numerals will be used to describe like elements, but with the extensions “A” and “B” for differentiation. Elements associated with a first tube will have the extension “A”, while elements associated with a second tube will have the extension “B”.
Referring to FIG. 2A , a first ePTFE tube 10 A is shown disposed along a longitudinal axis 12 A. The first tube 10 A is twisted about its longitudinal axis 12 A in a first rotational direction, such as clockwise, as shown in FIG. 2A . The tube 10 A may be twisted over any given range of degrees, although it is preferred that the tube be twisted at least 10 degrees. Accordingly, as represented by the hypothetical reference axis 22 A, the first tube 10 A is helically wound in the first rotational direction. As a result and as shown in FIG. 2B , fibrils 24 A are generally parallel to the reference axis 22 A, with the fibrils 24 A being angularly offset an angle α from the longitudinal axis 12 A, and, thus, being also angularly offset the angle α from the original extrusion direction of the first tube 10 A. Nodes 26 A are generally perpendicular to the fibrils 24 A. With the fibrils 24 A, and the nodes 26 A, being obliquely disposed relative to the longitudinal axis 12 A, failure along the longitudinal axis 12 A may be reduced.
Referring to FIGS. 3A and 3B , a second ePTFE tube 10 B is shown being twisted in a second rotational direction different than the first rotational direction of the first tube 10 A. As shown in FIG. 3A , the second ePTFE tube is twisted in a counterclockwise direction. The particular rotational direction of twisting may be switched for the first and second tubes 10 A and 10 B. As with the first tube 10 A, the amount of twisting of the second tube 10 B may be varied, although it is preferred that at least a 10 degree displacement be provided. The helically wound distortion of the second tube 10 B is represented by the hypothetical reference axis 22 B. As shown in FIG. 3B , fibrils 24 B are generally parallel to the reference axis 22 B and are angularly offset an angle β from the longitudinal axis 12 B (and, thus, the extrusion direction). Nodes 26 B are generally perpendicular to the fibrils 26 A. The oblique disposition of the fibrils 24 B and the nodes 26 B resists failure along the longitudinal axis 12 B.
FIG. 4A shows a prosthesis 100 including the first tube 10 A, in its twisted helical state being coaxially disposed within, and fixed to, the second tube 10 B, in its twisted helical state. It is preferred that the tubes 10 A and 10 B be generally coextensive, although the ends of the tubes need not be coterminous. Because of the different rotational orientations of the node and fibril structures of the tubes 10 A and 10 B, the node and fibril structures are angularly offset from each other. In particular, as shown schematically in FIG. 4B , because of the coaxial arrangement of the tubes 10 A, 10 B, the longitudinal axes 12 A and 12 B are generally colinear. Also, the fibrils 24 A of the first tube 10 A are angularly offset from the fibrils 24 B of the second tube 10 B by an angle γ. The angular offset of the fibrils 24 A and 24 B provides the prosthesis 100 with resistance against failure not provided by either tube 10 A, 10 B alone. In a preferred embodiment, with the angles α and β being each at least 10 degrees, the angle γ will be at least 20 degrees. Preferably, the node and fibrils of each of the tubes 10 A, 10 B are generally-equally angularly offset throughout the respective tube 10 A, 10 B.
Because the first tube 10 A is disposed within the second tube 10 B, the second tube 10 B is formed dimensionally slightly larger to accommodate the first tube 10 A within its lumen 16 B.
As an alternative, only one of the tubes 10 A, 10 B may be twisted. The node and fibrils of the two tubes 10 A, 10 B would, nevertheless, be angularly offset.
In a preferred manner of preparing the prosthesis 100 , the first tube 10 A is provided and mounted onto a mandrel where it is twisted into its desired helical configuration. The twisted configuration of the first tube 10 A is maintained. The second tube 10 B is provided and twisted as desired, and in its twisted state telescoped over the first tube 10 A. The first and second tubes 10 A and 10 B are fixed together using any technique known to those skilled in the art, preferably sintering. Adhesive may also be used to bond the tubes, such as a thermoplastic fluoropolymer adhesive (e.g., FEP). Once fixed, the prosthesis 100 is prepared.
Although reference has been made herein to extruded ePTFE tubes, tubes formed by other techniques may also be used, such as with rolling a sheet, or wrapping a tape. Generally, with these non-extrusion techniques, the fibrils of the ePTFE will not initially be oriented parallel to the longitudinal axis of the tube, but rather transverse thereto. These non-extruded tubes may replace one or more of the tubes 10 A, 10 B in a non-twisted state or in a twisted state.
As shown in FIG. 5 , the prosthesis 100 may also include a radially expandable support member 28 , which may be disposed interiorly of the first tube 10 A, exteriorly of the second tube 10 B, or interposed between the two tubes 10 A, 10 B. Additionally, multiple support members located at the aforementioned locations may be provided. The radially expandable support member 28 may be fixed to the tubes 10 A, 10 B using any technique known to those skilled in the art, such as bonding. Additionally, with the radially expandable support member 28 being interposed between the tubes 10 A, 10 B, the tubes 10 A, 10 B may be fixed together through any interstices formed in the radially expandable support member 28 .
The radially expandable support member 28 may be of any construction known in the prior art which can maintain patency of the prosthesis 100 . For example, as shown in FIG. 5 , the radially-expandable support member 28 may be a stent. The particular stent 28 shown in FIG. 5 is fully described in commonly assigned U.S. Pat. No. 5,693,085 to Buirge et al., and the disclosure of U.S. Pat. No. 5,693,085 is incorporated by reference herein. The stent may be an intraluminally implantable stent formed of a metal such as stainless steel or tantalum, a temperature-sensitive material such as Nitinol, or alternatively formed of a superelastic alloy or suitable polymer. Although a particular stent construction is shown with reference to the present invention, various stent types and stent constructions may be employed for the use anticipated herein. Among the various useful radially-expandable support members 28 include, without limitation, self-expanding stents and balloon expandable stents. The stents may be capable of radially contracting as well. Self-expanding stents include those that have a spring-like action which causes the stent to radially expand or stents which expand due to the memory properties of the stent material for a particular configuration at a certain temperature. Other materials are of course contemplated, such as stainless steel, platinum, gold, titanium, tantalum, niobium, and other biocompatible materials, as well as polymeric stents. The configuration of the radially-expandable support member 28 may also be chosen from a host of geometries. For example, wire stents can be fastened in a continuous helical pattern, with or without wave-like forms or zig-zags in the wire, to form a radially deformable stent. Individual rings or circular members can be linked together such as by struts, sutures, or interlacing or locking of the rings to form a tubular stent.
Furthermore, the prosthesis 100 may be used with additional layers which may be formed of polymeric material and/or fabric. Furthermore, any layer or portion of the prosthesis 100 , including the tubes 10 A, 10 B, may be impregnated with one or more therapeutic and pharmacological substances prior to implantation of the prosthesis 100 for controlled release over an extended duration. It is anticipated that the prosthesis 100 can be partially or wholly coated with hydrophilic or drug delivery-type coatings which facilitate long-term healing of diseased vessels. Such a coating is preferably bioabsorbable, and is preferably a therapeutic agent or drug, including, but not limited to, anti-thrombogenic agents (such as heparin, heparin derivatives, urokinase, and PPack (dextrophenylalanine proline arginine chloromethylketone); anti-proliferative agents (such as enoxaprin, angiopeptin, or monoclonal antibodies capable of blocking smooth muscle cell proliferation, hirudin, and acetylsalicylic acid); anti-inflammatory agents (such as dexamethasone, prednisolone, corticosterone, budesonide, estrogen, sulfasalazine, and mesalamine); antineoplastic/antiproliferative/anti-miotic agents (such as paclitaxel, 5-fluorouracil, cisplatin, vinblastine, vincristine, epothilones, endostatin, angiostatin and thymidine kinase inhibitors); anesthetic agents (such as lidocaine, bupivacaine, and ropivacaine); anti-coagulants (such as D-Phe-Pro-Arg chloromethyl keton, an RGD peptide-containing compound, heparin, antithrombin compounds, platelet receptor antagonists, anti-thrombin antibodies, anti-platelet receptor antibodies, aspirin, prostaglandin inhibitors, platelet inhibitors and tick antiplatelet peptides); vascular cell growth promotors (such as growth factor inhibitors, growth factor receptor antagonists, transcriptional activators, and translational promotors); vascular cell growth inhibitors (such as growth factor inhibitors, growth factor receptor antagonists, transcriptional repressors, translational repressors, replication inhibitors, inhibitory antibodies, antibodies directed against growth factors, bifunctional molecules consisting of a growth factor and a cytotoxin, bifunctional molecules consisting of an antibody and a cytotoxin); cholesterol-lowering agents; vasodilating agents; and agents which interfere with endogenous vascoactive mechanisms.
Various changes and modifications can be made in the present invention. It is intended that all such changes and modifications come within the scope of the invention as set forth in the following claims. | A prosthesis, and method for forming same, are provided which includes expanded polytetrafluoroethylene (ePTFE) tubes having angularly offset node and fibril configurations. Also, the node and fibril configurations are angularly offset from the longitudinal axes of the respective tubes, providing resistance against failure in the longitudinal direction. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method and apparatus for producing communication articles such as postcards, envelopes or the like. Particularly, the present invention relates to a method and apparatus for producing communication articles such as postcards, envelopes or the like in which display surfaces for information or the like are separably bonded by heating them through a synthetic resin film or the like in order to conceal information such as correspondence or a print display medium, and then mail it.
2. Description of the Related Art
An example of prior art related to a method and apparatus for producing such communication articles is the invention disclosed in Japanese Patent Laid-Open No. 2-106556.
In the invention disclosed in this publication, information is printed on a predetermined portion of both upper and lower sheets, and an intermediate sheet having portions at both sides thereof which permit both sheets to be separably bonded is then interposed between both sheets during the process of putting the sheets one on top the other so that both sheets are separably bonded with the adhesive intermediate sheet therebetween to form one product.
A continuous sheet is used for both the upper and lower sheets and is cut to each sheet's predetermined size after the upper and lower sheets are bonded with the intermediate sheet therebetween to produce a communication article such as postcards or the like.
However, in the above invention, since the work of cutting the continuous sheets with the film therebetween to each sheet's predetermined size is carried out by employing the tensile force produced by a difference between the transfer velocities of two rolls, the upper and lower sheets can each be cut, but the intermediate sheet made of a synthetic resin film cannot be smoothly cut even if perforations are provided therein. Since the intermediate sheet made of a synthetic film cannot be smoothly cut, therefore, there is the possibility of an error in the operation occurring. Even if no error occurs, there is the problem that an unnecessary portion of the film will be protrude from the upper and lower sheets due to the distortion produced at the edge of the cut intermediate sheet.
Further, in the above-mentioned apparatus, one continuous sheet is cut by a cutter into sheet portions which are used as the upper and lower sheets, and the intermediate sheet is then interposed between the upper and lower sheets. Thus the position of the intermediate sheet interposed between the two sheets is easily deviated. This results in the danger of producing defective products.
SUMMARY OF THE INVENTION
The present invention has been achieved to solve the above problems, and it is an object of the present invention to provide a method and apparatus for producing communication articles such as postcards, envelopes or the like which are capable of easily and smoothly cutting sheets with a film therebetween and accurately interposing the film between the sheets.
To this end, the present invention provides a method of producing communication articles such as postcards, envelopes or the like in which a sheet for forming a communication article such as a postcard, envelope or the like is formed so that it can be folded at least once, and a synthetic resin film is interposed between sheet portions into which the sheet for forming a communication article is folded so that the two sheet portions are separably bonded with the film therebetween, the method comprising folding at least double a continuous sheet having a plurality of sheets for forming communication articles which are connected in series while conveying the continuous sheet, interposing a continuous film between the sheet portions into which the sheet is folded to form a film-containing continuous sheet, heating the film-containing continuous sheet, pressing the film-containing continuous sheet so as to bond the sheet portions of the continuous sheet with the film therebetween, and then hitting the portions between the respective sheets for forming communication articles of the continuous sheet while pulling the film-containing continuous sheet so as to separate the continuous sheet into the sheets for forming communication articles.
The present invention also provides an apparatus for producing communication articles such as postcards, envelopes or the like in which a sheet for forming communication articles such as postcards, envelopes or the like is formed so that it can be folded into at least two, and a synthetic resin film is interposed between the sheet portions into which the sheet for forming communication articles is folded so that the two sheet portions are separably bonded with the film therebetween, the apparatus comprising a folding device for folding a continuous sheet having a plurality of communication article-forming sheets which are connected in series into at least two while conveying the continuous sheet, a film inserting device for inserting a continuous film between the sheet portions into which the continuous sheet is folded by the folding device to form a film-containing continuous sheet, a heating device for heating the film-containing continuous sheet having the film inserted therebetween by the film inserting device, a press device for pressing the film-containing continuous sheet which is heated by the heating device so as to bond the sheet portions of the continuous sheet with the film therebetween, and a separating device for separating the continuous sheet into the communication article-forming sheets by hitting the portions between the respective communication article-forming sheets while pulling the film-containing continuous sheet.
In the present invention configured as described above, the continuous sheet is first folded into at least two portions, the film is inserted between the portions to form a film-containing sheet which is then heated and pressed so that the sheet portions with the film therebetween are bonded, and the film-containing sheet is then separated into the respective communication article-forming sheets by hitting the portions between the respective communication article-forming sheets while pulling the film-containing continuous sheet to continuously and automatically produce communication articles.
As described above, since the continuous sheet is folded into at least two sheet portions, and the film is interposed between the two sheet portions, the film can be accurately interposed between the sheet portions into which the continuous sheet is folded, without producing any positional deviation.
In addition, since the film-containing continuous sheet having the sheet portions which are heated and bonded with the film therebetween is separated into the communication article-forming sheets by hitting the portions between the respective communication article-forming sheets while pulling the film-containing continuous sheet, the sheet is easily and accurately separated.
Further, the method of separating the film-containing continuous sheet into the communication article-forming sheets by hitting the sheet produces no distortion at the edge of the film cut.
These and other objects, features and advantages of the present invention will become clear when reference is made to the following description of the preferred embodiments of the present invention, together with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic front view of the whole of an apparatus for producing postcards;
FIG. 2(a) is a schematic front view of a folding device, and FIG. 2(b) is a schematic side view of the same;
FIG. 3(a) is a perspective view of a principal portion of a film inserting device, and FIG. 3(b) is a schematic plan view showing the direction of transfer of a film when the film is inserted into the sheet portions into which a continuous sheet is folded;
FIG. 4(a) is a schematic front view of an edge cutting device, FIG. 4(b) is an enlarged sectional view taken along the line A--A in FIG. 4(a), and FIG. 4(c) is a schematic perspective view of the same;
FIG. 5 is a schematic side view of a heating device;
FIG. 6 is a schematic front view of press rolls;
FIG. 7(a) is a schematic front view of a separating device, FIG. 7(b) is a schematic plan view of the same showing the state where upper rollers are disposed, FIG. 7(c) is a schematic plan view of the same showing the state where lower rollers are disposed, FIG. 7(d) is a partially sectional schematic side view showing a linkage mechanism comprising shock blocks, a vibration rod, a connecting plate and so on, FIG. 7(e) is a schematic plan view showing a linkage mechanism comprising a vibration rod and a connecting plate, and FIG. 7(f) is a front view of the shock blocks;
FIG. 8 is a schematic plan view of a continuous sheet before being folded;
FIG. 9 is a schematic explanatory view showing the state where a continuous sheet is folded into two by a folding device;
FIG. 10 is a schematic explanatory view showing the state where a continuous sheet is folded into three by a folding device;
FIG. 11 is a schematic explanatory view showing the state where a film is inserted into two portions of a continuous sheet by a film inserting device;
FIG. 12 is a schematic explanatory view showing the state where films are inserted into three portions of a continuous sheet by a film inserting device;
FIG. 13 is a schematic plan view showing the state where a continuous sheet is separated;
FIGS. 14(a) and 14(b) are a schematic front view and a schematic side view, respectively, showing the state where a continuous sheet is hit;
FIG. 15(a) is a front view of a postcard product, and FIG. 15(b) is an enlarged sectional view taken along the line B--B in FIG. 15(a);
FIG. 16 is a schematic side view showing a separating device in an open state; and
FIG. 17 is a schematic front view showing a separating device, press rollers, a heating device and an edge cutting device in an open state.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
A postcard producing apparatus in an embodiment of the present invention is described below with reference to the drawings.
FIG. 1 is a schematic front view of the whole postcard producing apparatus. The arrangement of the whole apparatus is outlined below.
In FIG. 1, reference numeral 1 denotes a folding device for folding, in three, a continuous sheet 2 used for producing postcards, and reference numeral 3 denotes a film inserting device for inserting synthetic resin films 6, 7 into the folded continuous sheet 2. The film inserting device 3 is provided with two guide means 4, 5 for guiding the films to the portions between the sheet portions of the folded continuous sheet 2. Reference numeral 8 denotes an edge cutting device for cutting the edges 37 of the continuous sheet 2. Reference numeral 9 denotes a heating device for heating a film-containing continuous sheet 2d having the films 6, 7 which are inserted therein, reference numeral 10 denotes press rollers for pressing the film-containing continuous sheet 2d which is heated by the heating device 9 so as to bond the films to the continuous sheet 2. Reference numeral 11 denotes a separating device for separating the film-containing continuous sheet 2d. The separating device 11 comprises first rollers 12a, 12b, second rollers 13a, 13b both of which are rotated at the same speed as that of the first rollers 12a, 12b, third rollers 14a, 14b both of which are rotated at a speed higher than that of the first and second rollers 12a, 12b, 13a, 13b, and shock blocks 15c for hitting the film-containing continuous sheet 2d so as to separate the sheet 2d. Reference numeral 16 denotes a discharge conveyor for forwardly conveying the produced postcards which are piled.
A description is now made of the arrangement of each of the devices of the postcard producing apparatus. The arrangement of the folding device 1 is first described below with reference to FIG. 2.
In FIG. 2, reference numeral 26 denotes the base of the folding device, a frame 17 being erectly provided on the base 26, and a support plate 18 being provided on the upper portion of the frame
Reference numeral 19 denotes a conveying roll for conveying the folded continuous sheet 2; reference numeral 20 is a bottom roll for upwardly transferring the continuous sheet 2 which is downwardly conveyed by the conveying roll 19; and reference numeral 21 denotes folding starting rods which are provided slightly above the bottom roll 20. Reference numeral 22 denotes a double folding rod for folding the continuous sheet 2 in two after folding has been started by the folding starting rods 21, and reference numeral 23 denotes an upper roll which is provided slightly above the double folding rod 22, the upper roll 23 and the double folding rod 22 being rotatably supported by the support plate 18. Reference numeral 22 denotes treble folding rods for folding, in three, the continuous sheet 2 which is transferred by the upper roll 23, a direction changing roll 25 being provided below the treble folding rods 22. The treble folding rods 22 and the direction changing rod 25 are rotatably supported by the L-shaped plate 27 provided on a side of the support plate 18.
In FIG. 2, although each of the rods and rolls other than the double folding rod 22, the upper roll 23, the treble folding rods 24 and the direction changing roll 25 is also rotatably supported, the detailed structure of the rods and rolls is not shown in the drawing.
The arrangement of the film inserting device 3 is described below with reference to FIG. 3.
In FIG. 3(a), reference numeral 28 denotes a roll on which one film 6 to be inserted is wound, and reference numeral 29 denotes a roll on which the other film 7 is wound.
Reference numerals 4, 5 denote guide means for guiding the films supplied from the rolls 28, 29, respectively, into the continuous sheet 2.
Reference numeral 30 denotes a guide roller for conveying the continuous sheet supplied from the folding device 1 to the side of the guide means 4, 5.
The arrangement of the edge cutting device 8 is described below with reference to FIG. 4.
In FIG. 2, reference numeral 31 denotes a first roller, and reference numeral 32 denotes second rollers which are provided at a distance from the first roller 31 on the same plane as the first roller 31. Reference numeral 33 denotes a third roller which is provided below the first roller 31 for holding the continuous sheet 2 between the first and third rollers 31, 33, and reference numeral 32 denotes edge cutting rollers provided at a position below the first and second rollers 31, 32 between them for cutting the edges of the continuous sheet 2. A round belt 35 is wound around the first roller 31, each of the second rollers 32 and each of the edge cutting rollers 32.
Each of the edge cutting rollers 32 has a groove 36 formed therein so that the round belt 35 is inserted into the groove 36.
The arrangement of the heating device 9 is described below with reference to FIG. 5.
In FIG. 5, reference numeral 38 denotes an upper heater, and reference numeral 39 denotes a lower heater. The upper heater 38 is provided on a base 20 through an air cylinder 41 and a rod 41a so that it can be moved upward and downward. The lower heater 39 is provided on the base 40 through an air cylinder 42 and a rod 42a so that it can be moved upward and downward.
The arrangement of the press rollers is described below with reference to FIG. 6.
In FIG. 6, reference numeral 10 denotes upper and lower press rolls provided for bonding the continuous sheet 2 heated by the heating device to the films 6, 7 by heating them, in which each roll are placed above and below the continuous sheet 2, being respectively provided in pairs.
The arrangement of the separating device 11 is described below with reference to FIG. 7.
In FIG. 7, reference numerals 12a, 12b denote upper and lower first rollers; reference numerals 13a, 13b, upper and lower second rollers; and reference numeral 14a, 14b, upper and lower third rollers, the three types of rollers being respectively provided in pairs. The three upper rollers 12a, 13a, 14a are supported by right and left support plates 43, and the three lower rollers 12b, 13b, 14b are supported by right and left support plates 44. The support plates 43 for supporting the upper rollers 12a, 13a, 14a are rotated with respect to the support plates 44 for supporting the lower rollers 12b, 13b, 14b so that the upper rollers 12a, 13a, 14a being in contact with the lower rollers 12b, 13b, respectively, in a normal state can be rotated around a shaft 56 with respect to the lower rollers 12b, 13b, 14b. Each of the upper and lower third rollers 14a, 14b has a plurality of slits formed thereon.
Reference numeral 15 denotes a vibration rod which is provided with two shock blocks 15c at both sides thereof for hitting the film-containing continuous sheet 2d and which has both ends 15a, 15b, and the one end 15b is moved upward and downward around the other end 15a serving as a center.
Reference numeral 45 denotes a retainer provided above the center of the shock blocks 15c and the vibration rod 15 opposite to these members so as to hold the upper side of the film-containing continuous sheet 2d when the sheet 2d is hit by the shock blocks 15c.
As shown in FIGS. 7(d) and 7(f), the shock blocks 15c are eccentrically provided on a shaft 15d.
Reference numeral 46 denotes a belt wound around the lower third roller 14b and a motor for driving the third roller 14b.
Reference numeral 48 denotes a belt wound around a pulley 48b and a pulley 48a which is coaxially provided on a motor 49 for driving the vibration rod 15. Reference numeral 50 denotes a connecting plate provided at one end 50a on the vibration rod 15, the other end 50b being eccentrically rotatably provided on the pulley 48b.
An embodiment of the method of producing postcards by using the above-mentioned postcard producing apparatus is described below.
The continuous sheet 2 comprising a plurality of postcard-forming sheets 53 each of which has sheet portions 52a, 52b, 52c and which are connected in series, as shown in FIG. 8, is folded into three by the folding device 1 shown in FIG. 2.
This process is described in detail below. After the folding of the continuous sheet 2 which is passed through the conveying roll 19 and the bottom roll 20 has been started by the folding starting rods 21, the continuous sheet 2 is folded into two by the double folding rod 22 so that the width of one leaf 2e of the continuous sheet 2 is about twice the width of the other leaf 2a, as shown in FIG. 9. The continuous sheet 2 folded in two is then conveyed to the treble folding rods 24 through the upper roll 23 and folded by the treble folding rods 24 to form three sheet portions 2a, 2b, 2c, as shown in FIG. 10.
The continuous sheet 2 folded in three is then transferred to the next process through the direction changing roll 25.
As described above, since the continuous sheet 2 is folded while being conveyed and guided by a plurality of rods and rolls, the continuous sheet 2 is not subjected to concentrated tension. It is also an important point that during the folding operation, since the continuous sheet 2 is first folded in two by the double folding rod 22 so that the width of one sheet leaf 2e of the continuous sheet 2 is about twice the width of the other sheet leaf 2a, and the other sheet leaf 2c of the continuous sheet 2 is folded in the reverse direction to form the sheet 2 folded in three, no stress along a curved surface occurs, but only stress along the sheet surface mainly occurs during double folding and treble folding. It is therefore possible to effectively relieve the tension applied to the continuous sheet 2, without carelessly separating the continuous sheet 2 at a position of perforations.
The continuous sheet 2 folded in three as described above is then sent to the process of inserting the two films 6, 7 by using the film inserting device 3.
This process is described in detail below. The continuous sheet 2 transferred from the folding device 1 is moved straight by the guide roller 30. The film 6 conveyed from one roll 28 is first inserted between the first and second sheet portions 2a and 2b of the continuous sheet 2 through the guide means 4, as shown in FIG. 11. The other film 7 conveyed from the other roll 29 is then inserted between the second and third sheet portions 2b and 2c of the continuous sheet 2 through the guide means 5, as shown in FIG. 2. Each of the films 6, 7 is changed in its moving direction at about 90° by a triangular guide plate (not shown) when being inserted between the respective sheet portions of the continuous sheet 2, as shown in FIG. 3(b).
After the films have been inserted as described above, the edge cutting work is performed by the edge cutting device 8.
This process is described in detail below. The third rollers 33 are first driven by driving a motor (not shown). When the third rollers 33 are driven, the third rollers 33 are rotated, accompanied by the rotation of the first roller 31. The rotation of the first roller 31 causes the rotation of the second roller 32 and the edge cutting rollers 34, on both of which the belt 35 is wound.
When all the rollers are rotated, the edge cutting device 8 is operated.
In the state where the edge cutting device 8 is operated, the edges 37 of the film-containing continuous sheet 2d which is conveyed after the films are inserted therein by the film inserting device 3 are respectively downwardly pressed while being held by the first roller 31, the third rollers 33, the round belts 35 and the edge cutting rollers 34, whereby the edges 37 are cut.
In this case, since the round belts 35 are respectively inserted into the grooves 36 of the edge cutting rollers 34, the round belts 35 are not deviated from the edge cutting rollers 34 regardless of the pressure of the edges 37 acting on the round belts 35.
After the edges 37 have been cut, heating is performed by the heating device 9.
This process is described in detail below. When the film-containing continuous sheet 2d is passed between the upper heater 38 and the lower heater 39 in the heating device 9, the sheet 2d is heated by the heat generated from the upper and lower heaters 38, 39.
When a wrong operation or overheating occurs, the upper heater 38 is separated from the lower heater 39 so that the heating work is stopped. Namely, if the air cylinders 41, 42 are operated, the upper heater 38 is upwardly moved through the rod 41a in the direction of arrow A in FIG. 5, and the lower heater 39 is downwardly moved through the rod 42a in the direction of arrow B so that the upper and lower heaters 38, 39 are separated from the film-containing continuous sheet 2d. This can rapidly prevent the characters or the like printed on the continuous sheet from being burnt.
After the film-containing continuous sheet 2d has been heated, the continuous sheet 2d is bonded to the films 6, 7 by the press rollers 10.
Namely, as shown in FIG. 6, when the film-containing continuous sheet 2d is passed between the press rollers 10, the continuous sheet 2 is securely bonded to the films 6, 7 by virtue of the pressure of the press rollers 10 and the remaining heat generated by the heating device 9.
The film-containing continuous sheet 2d which is heated and bonded as described above is then separated in each predetermined size of postcard.
This process is described in detail below. When the film-containing continuous sheet 2d is passed between the first rollers 12a, 12b, the second rollers 13a, 13b and the third rollers 14a, 14b, as shown in FIG. 14, the both edges of the sheet 2d are hit by the shock blocks 15c provided on the vibration rod 15, while the sheet 2d being horizontally held by the retainer 45.
In this case, the film-containing continuous sheet 2d is easily smoothly separated at each position of perforations 51 by virtue of the tensile force generated among the first rollers 12a, 12b, the second rollers 13a, 13b and the third rollers 14a, 14b corresponding to the transfer speeds thereof, as shown in FIG. 13, to produce postcards 52 each having a standard size.
A detailed description will now be given of the mechanism for hitting the continuous sheet 2d by the shock blocks 15c while holding it by the retainer 45 with reference to FIG. 7(a). When the belt 48 is rotated by driving the motor 49 through the rotation of the pulley 48a, the pulley 48b is rotated. The rotation of the pulley 48b vertically moves the connecting plate 50 having an end 50b eccentrically connected to the pulley 48b. The vertical movement of the connecting plate 50 vertically moves the vibration rod 15 so that both edges of the film-containing sheet 2d are hit by the shock block 15c provided at both sides of the vibration rod 15 while being held by the retainer
This hitting action is described in detail below. The film-containing continuous sheet 2d is hit by the shock blocks provided on the vibration rod 15, while being held within a predetermined central region thereof by the upper retainer 45, as shown in FIG. 14(b). The film-containing continuous sheet 2d is thus torn at the portion of perforations 51 from the both ends thereof to the center so that the film-containing sheet 2d can be smoothly separated.
In this case, the interference amount of the vertical movement of the shock blocks 15c can be adjusted by adjusting the distance between the retainer 45 and the shock blocks 15c. In addition, since each of the shock blocks 15c is eccentrically provided on the shaft 15d, as shown in FIG. 7(f), the interference amount can also be adjusted by replacing the shock blocks 15c provided on the shaft 15d by other blocks. The terms "interference amount" represents the distance between the lower end of the retainer 45 and the upper end of each of the shock blocks 15c when the lower end of the retainer 45 is placed below the upper end of each of the shock blocks 15c. The interference amount is preferably adjusted so that the holding function of the retainer 45 and the hitting function of the shock blocks 15c are made effective.
In addition, since the third roll 14b has a plurality of slits 14c formed thereon, the stress applied to the film-containing continuous sheet 2d can be concentrated in the lengthwise direction thereof.
There is also the advantage that the tensile force is concentrated in the portions at both sides of the film-containing continuous sheet 2d by the second rolls 13a, 13b so that the shock effect of the shock blocks 15c can be further improved.
There is a further advantage that the number of contacts between the film-containing continuous sheet 2d and the shock blocks 15c can be changed by changing the speed of the motor 47 in correspondence with the transfer velocity of the film-containing continuous sheet 2d, the difficulty in tearing the film material or the like, whereby the hitting force can be adjusted.
A description will now be made of an opening mechanism operated when a wrong operation occurs in the above-mentioned postcard producing apparatus.
When a trouble in the separating device 11, rolling-in of the continuous sheet or the like occurs, the support plates 43 for supporting the upper rollers 12a, 13a, 14a is rotated, by using a lever 57, around the shaft 56 with respect to the support plates 44 for supporting the lower rollers 12b, 13b, 14b to create the open state shown in the drawings. In this state, the upper rollers 12a, 13a, 14a are separated from the lower rollers 12b, 13b, 14b, and the state where the film-containing continuous sheet 2d is held by the rollers is thus released. It is thus possible to discharge the film-containing continuous sheet 2d without damaging the sheet 2d and reproduce this portion. In addition, the film-containing continuous sheet 2d can be extracted with good workability, and the operation after the reproduction can be smoothly performed.
As shown in FIG. 17, the upper press roller 10 is rotated relative to the lower press roller 10 by using a lever 58 to produce an open state in the same way as in the separating device 11 in which each of the upper rollers is put into an open state. Similarly, the upper heater 38 in the heating device 9 is rotated with respect to the lower heater 39 by using a lever 59 to create an open state, and the first roller 31, the second rollers 32, and the edge cutting rollers 32 are rotated with respect to the third roller 33 by using a lever 60 to produce an open state.
In this way, the upper portion is put into an open state with respect the lower portion in each of the separating device 11, the press roller 10, the heating device 9 and the edge cutting device 8 so that the film-containing continuous sheet 2d can be smoothly easily discharged even if a trouble occurs in any place.
When such a trouble occurs, the transfer of the film-containing continuous sheet 2d is automatically stopped.
After the continuous sheet 2 has been separated into the postcards 52 each having a standard size, as described above, the postcards 52 produced are successively piled on the discharge conveyor 16 and then forwardly slowly moved. In this case, the conveying velocity of the discharge conveyor 16 can be freely adjusted, whereby the piling amount can be adjusted.
The postcards each of which is folded in three and has the films 6, 7 inserted therein are continuously automatically produced by the above-described method.
Although the above embodiment concerns the case in which postcards folded in three are produced, the postcards produced need not to be folded in three, for example, the postcards may be folded in two. In a word, the postcards may be folded in at least two.
The folding device 1 for postcards is also not limited to the structure above described in the embodiment, and the folding device may have any structure suitable for folding in two.
The structure of the film inserting device 3 is not limited to the structure provided with the guide means 4, 5 in the above embodiment, and the design can be changed arbitrarily.
In the above embodiment, since the edge cutting device 8 comprises the round belts 35 and the edge cutting rollers 34 so that the edges 37 can be cut by the pressure of both members, the embodiment has the preferable effect of easily cutting the edges 37. However, the structure of the edge cutting device 8 is not limited to that in the embodiment.
Although the above embodiment uses the selvaged continuous sheet 2 which is generally used in computers, a continuous sheet 2 without edges can be used. Thus the edge cutting device 8 is dispensable in the invention.
The structure of the heating device 9 is not limited to that in the embodiment, and the structure in which the upper heater 38 and the lower heater 39 can be separated by the function of the air cylinders 49, 42, as in the above embodiment, is also dispensable in the invention.
Further, although the press rollers 10 are independently provided in the embodiment, for example, the first roller 12 of the separating device 11 may also be used as the press rollers 10. The press device is not limited to the rollers in the embodiment, and any device can be employed so far as it is capable of pressing the film-containing continuous sheet 2d after heating.
The structure of the separating device is not limited to that in the above embodiment, and any device having a structure which allows the sheet to be separated by the tensile force of at least two rollers which transfer the sheet at different speeds and a hitting mechanism can be used.
Further, although the above embodiment has the preferable effect that the hitting force can be changed by changing the rotational speed of the motor 49 because the hitting mechanism is a link mechanism comprising the connecting plate 50, the vibration rod 15 and so on, such a link mechanism is a dispensable condition in the invention, and any hitting mechanism can be employed.
In the above embodiment, since each of the shock blocks 15c has a substantially square form, as shown in FIG. 7(b), the embodiment has the preferable effect that the separating effect can be further improved by attaching each of the shock blocks 15c in such a manner that the corner portion thereof contacts with the film-containing continuous sheet 2d. However, the shape of the each of the shock blocks 15c is not limited to the substantially square form, and, for example, the shock blocks may be formed into a roll.
Further, although the films 6, 7 are inserted after the continuous film 2 has been folded in the production method according to the embodiment, these operations may be simultaneously performed, regardless of the procedures thereof.
In addition, although the embodiment concerns the case where postcards are produced, the present invention can be applied to the postcards as well as envelopes. The present invention can be applied to any communicatin articles such as postcards, envelopes and the like.
As described above, in the present invention, since communication articles such as postcards, envelopes or the like are produced through a series of processes of folding, inserting films, heating, bonding by press and separating, the whole process of producing communicatin articles with films can be continuously automatically performed, and an attepmt can be made to perform the mass production of communication articles with films.
In addition, the continuous sheet is not separated by simply employing only the tensile force caused by the speed difference between two rolls, as conventional apparatus, but the continuous sheet is separated by employing the tensile force and hitting the perforations at the bondaries between respective communication article-forming portions. The invention thus has the effect of easily, smoothly, securely separating the sheet into respective communicatin article-foring portions regardless of the interposition of the films in the continuous sheet.
Further, since the film-containing continuous sheet is easily and securely separated into respective communication article-forming portions by hitting, no distortion occurs at the edges of the films separated, as in conventional apparatuses. The invention thus has the effect of preventing the films from extruding from the edges of the communication articles produced and thus preferably preventing the occurence of defective products.
In addition, since a film is not inserted between separate two sheets, as in conventional apparatuses, but a film is inserted between the sheet portions produced by folding the continuous sheet in at least two, the film can securely inserted between the sheet portions of the continuous sheet folded, without producing any positional deviation. The invention thus has no danger of producing a postional deviation between the continuous sheet and the films and the advantage of more preferably preventing the occurrence of defective products.
Many different embodiments of the present invention may be constructed without departing from the spirit and scope of the present invention. It should be understood that the present invention is not limited to the specific embodiments described in this specification, and is only limited in the appended claims. | The present invention relates to a method and apparatus for producing communication articles such as postcards, envelopes or the like in each of which display surfaces for information or the like are separably bonded with a synthetic resin therebetween by heating for concealing information such as correspondence or a printed display medium and then mailing it. It is an object of the invention to enable easy and smooth separating of a film-containing sheet and accurate insertion of a film in a sheet.
In order to achieve the object, a continuous sheet having a plurality of communication article-forming sheets which are connected in series is folded in at least two, a continuous film is inserted between the sheet portions into which the continuous sheet is folded to form a film-containing continuous sheet which is then heated and pressed to that the sheet portions of the continuous sheet are bonded with the film therebetween, and the film-containing continuous sheet is then separated into the respective communication article-forming sheets by hitting the positions between the respective communication article-forming sheets of the continuous sheet while pulling the film-containing continuous sheet to produce communication articles. | 8 |
FIELD OF THE INVENTION
[0001] The present invention relates to new and improved processes for the preparation of Indacaterol and pharmaceutically acceptable salts thereof as well as intermediates for the preparation of Indacaterol.
BACKGROUND OF THE INVENTION
[0002] The compound 5-[(R)-2-(5,6-diethyl-indan-2-ylamino)-1-hydroxyethyl]-8-hydroxy-(1H)-quinolin-2-one, which is known as Indacaterol (INN), and its corresponding salts are beta-selective adrenoceptor agonists with a potent bronchodilating activity. Indacaterol is especially useful for the treatment of asthma and chronic obstructive pulmonary disease (COPD) and is sold commercially as the maleate salt.
[0003] WO 00/75114 and WO 2004/076422 describe the preparation of Indacaterol for the first time through the process:
[0000]
[0004] The condensation between the indanolamine and the quinolone epoxide leads to the desired product but always with the presence of a significant amount of impurities, the most significant being the dimer impurity, which is the consequence of a second addition of the product initially obtained with another quinolone epoxide, as well as the formation of another isomer which is the result of the addition of the indanolamine to the secondary carbon of the epoxide.
[0005] In addition, the reaction conditions to achieve the opening of the epoxide require high energies (ex. 21 of WO 00/75114) with temperatures of 110° C. or more for several hours, which favours the appearance of impurities.
[0006] WO 2004/076422 discloses the purification of the reaction mixture by the initial formation of a salt with an acid, such as tartaric acid or benzoic acid, hydrogenation and final formation of the maleate salt. However, the yield achieved by the end of the process is only 49% overall.
[0007] It has been found that impurities of tartrate and benzoate salts can exist in the final product as a result of displacing the tartrate or benzoate with maleate without prior neutralization to Indacaterol base. In addition, WO 2004/076422 discloses that proceeding via the free base of Indacaterol is not viable due to its instability in organic solvents. WO 00/75114 does disclose a method proceeding via the Indacaterol free base, but it is not isolated in solid form.
[0008] WO 2004/076422 furthermore discloses the method for obtaining the quinolone epoxide from the corresponding α-haloacetyl compound by reduction in the presence of a chiral catalyst, such as an oxazaborolidine compound, by proceeding via the α-halohydroxy compound.
[0009] Documents WO 2007/124898 and WO 2004/013578 disclose 8-(benzyloxy)-5-[(1R)-2-bromo-1-{[tert-butyl(dimethyl)silyl]oxy}ethyl]quinolin-2(1H)-one and 8-(benzyloxy)-5-[(1R)-2-bromo-1-{tetrahydro-2H-pyran-2-yl-oxy}ethyl]quinolin-2(1H)-one, respectively. Said documents are however not concerned with the preparation of Indacaterol.
[0010] There exists, therefore, the need to develop an improved process for obtaining Indacaterol and salts thereof, which overcomes some or all of the problems associated with known methods from the state of the art. More particularly, there exists the need for a process for obtaining Indacaterol and pharmaceutically acceptable salts thereof, which results in a higher yield and/or having fewer impurities in the form of the dimer and regioisomers impurities and/or salts other than the desired pharmaceutically acceptable salt.
SUMMARY OF THE INVENTION
[0011] In one aspect of the invention, it concerns a process for preparing Indacaterol or a pharmaceutically acceptable salt thereof comprising reacting the compound of formula I with 2-amino-5,6-diethylindan of formula II, preferably in the presence of a base, to the compound of formula III and then converting the compound of formula III to Indacaterol or a pharmaceutically acceptable salt thereof:
[0000]
[0000] wherein R 1 is a protecting group, R 2 is a protecting group, which is stable under mildly alkaline conditions, and X is a halogen selected from the group consisting of chloro, bromo, and iodo.
[0012] This process avoids the formation of the dimers and regiostereoisomers associated with the processes known in the art, e.g. in WO 2004/076422, since it avoids the use of the epoxy compound used in the prior art processes. This facilitates the purification of the compound of formula III, possible subsequent intermediates in the process, as well as the final product. The process of the invention furthermore has gentler reaction conditions than the processes known in the art and results in a yield of more than 70% and in some cases more than 80%.
[0013] R 1 is a protecting group commonly known in the art for protecting phenol groups. R 2 is a protecting group, which is stable under mildly alkaline conditions.
[0014] A further aspect of the invention concerns a process for the preparation of the compound of formula III or a salt thereof by reacting the compound of formula I with 2-amino-5,6-diethylindan of formula II to the compound of formula III. Optionally, the compound of formula III is converted to a salt thereof by addition of an acid.
[0015] In another aspect of the invention, it concerns a process for the preparation of a pharmaceutically acceptable salt of Indacaterol by obtaining Indacaterol, isolating it in solid form, and reacting it with a suitable acid, such as maleic acid.
[0016] Still another aspect of the invention concerns the compounds of formula I. Yet another aspect of the invention concerns the compounds of formula III. A further aspect of the invention concerns Indacaterol free base in solid form.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
[0017] In the context of the present invention, the term “C 6-20 aryl” is intended to mean an optionally substituted fully or partially aromatic carbocyclic ring or ring system with 6 to 20 carbon atoms, such as phenyl, naphthyl, 1,2,3,4-tetrahydronaphthyl, anthracyl, phenanthracyl, pyrenyl, benzopyrenyl, fluorenyl and xanthenyl, among which phenyl is a preferred example.
[0018] In the context of the present invention, the term “C 1-6 alkyl” is intended to mean a linear or branched saturated hydrocarbon group having from one to six carbon atoms, such as methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, sec-butyl, tert-butyl, n-pentyl, isopentyl, neopentyl and n-hexyl.
[0019] In the context of the present invention, the term “C 1-6 -alkoxy” is intended to mean C 1-6 -alkyl-oxy, such as methoxy, ethoxy, n-propoxy, iso-propoxy, n-butoxy, iso-butoxy, sec-butoxy, tert-butoxy, n-pentoxy, iso-pentoxy, neo-pentoxy and n-hexoxy.
[0020] In the context of the present invention, the term “C 2-6 alkenyl” is intended to cover linear or branched hydrocarbon groups having 2 to 6 carbon atoms and comprising one unsaturated bond. Examples of alkenyl groups are vinyl, allyl, butenyl, pentenyl and hexenyl.
[0021] In the context of the present invention, the term “C 3-6 cycloalkyl” is intended to mean a cyclic hydrocarbon group having 3 to 6 carbon atoms, such as cyclopropyl, cyclobutyl, cyclopentyl and cyclohexyl.
[0022] In the context of the present invention, the term “heteroaryl” is intended to mean a fully or partially aromatic carbocyclic ring or ring system where one or more of the carbon atoms have been replaced with heteroatoms, e.g. nitrogen (═N— or —NH—), sulphur, and/or oxygen atoms. Examples of such heteroaryl groups are oxazolyl, isoxazolyl, thiazolyl, isothiazolyl, pyrrolyl, imidazolyl, pyrazolyl, pyridinyl, pyrimidinyl, pyrazinyl, pyridazinyl, triazinyl, coumaryl, furyl, thienyl, quinolyl, benzothiazolyl, benzotriazolyl, benzodiazolyl, benzooxozolyl, phthalazinyl, phthalanyl, triazolyl, tetrazolyl, isoquinolyl, acridinyl, carbazolyl, dibenzazepinyl, indolyl, benzopyrazolyl, phenoxazonyl, phenyl pyrrolyl and N-phenyl pyrrolyl.
[0023] In the present context, the term “optionally substituted” is intended to mean that the group in question may be substituted one or several times, preferably 1-3 times, with group(s) selected from hydroxy (which when bound to an unsaturated carbon atom may be present in the tautomeric keto form), C 1-6 -alkoxy, C 2-6 -alkenyloxy, carboxy, oxo (forming a keto or aldehyde functionality), C 1-6 -alkoxycarbonyl, C 1-6 -alkylcarbonyl, formyl, aryl, aryloxycarbonyl, aryloxy, arylamino, arylcarbonyl, heteroaryl, heteroarylamino, heteroaryloxycarbonyl, heteroaryloxy, heteroarylcarbonyl, amino, mono- and di(C 1-6 -alkyl)amino, carbamoyl, mono- and di(C 1-6 -alkyl)aminocarbonyl, amino-C 1-6 -alkyl-aminocarbonyl, mono- and di(C 1-6 -alkyl)amino-C 1-6 -alkyl-aminocarbonyl, C 1-6 -alkylcarbonylamino, cyano, guanidino, carbamido, C 1-6 -alkyl-sulphonyl-amino, aryl-sulphonyl-amino, heteroaryl-sulphonyl-amino, C 1-6 -alkanoyloxy, C 1-6 -alkyl-sulphonyl, C 1-6 -alkyl-sulphinyl, C 1-6 -alkylsulphonyloxy, nitro, C 1-6 -alkylthio and halogen.
[0024] In the present context, the term “mildly alkaline conditions” refers to conditions created when adding the compound of formula II, which is a base, to the compound of formula I, preferably in the presence of a further base, such as triethylamine, diisopropylethylamine (DIPEA), pyridine, 1,4-diazabicyclo[2.2.2]octane (DABCO), 4-dimethylaminopyridine (DMAP), sodium carbonate, potassium carbonate, sodium hydrogencarbonate, potassium hydrogencarbonate, sodium hydroxide, or potassium hydroxide.
Processes
[0025] In one aspect of the invention, it concerns a process for preparing Indacaterol or a pharmaceutically acceptable salt thereof comprising reacting the compound of formula I with 2-amino-5,6-diethylindan of formula II, preferably in the presence of a base, to the compound of formula III and then converting the compound of formula III to Indacaterol or a pharmaceutically acceptable salt thereof:
[0000]
[0000] wherein R 1 is a protecting group, R 2 is a protecting group, which is stable under mildly alkaline conditions, and X is a halogen selected from the group consisting of chloro, bromo, and iodo.
[0026] In one embodiment, the compound of formula III is converted to Indacaterol by first converting it to a compound of formula IV by first removing the protecting group R 2 by addition of an acid, preferably an aqueous acid, and finally isolating/purifying the compound (IV) as a salt by adding the acid HA:
[0000]
[0000] and then converting the compound of formula IV to Indacaterol or a pharmaceutically acceptable salt thereof. Processes for converting the compound of formula IV to Indacaterol or a pharmaceutically acceptable salt thereof are disclosed inter alia in WO 2004/076422.
[0027] In another aspect of the invention, it concerns a process for the preparation of Indacaterol or a pharmaceutically acceptable salt thereof, comprising precipitating a protected Indacaterol acid salt of formula IV in the presence of water and a water-miscible organic solvent and then converting the precipitated protected Indacaterol acid salt of formula IV to Indacaterol or a pharmaceutically acceptable salt thereof:
[0000]
[0000] wherein R 1 is a protecting group as defined herein and A − is the counterion of an acid, HA, as defined herein.
[0028] In one embodiment, the protected Indacaterol acid salt is formed in situ by reacting the protected Indacaterol of formula I with the acid, HA:
[0000]
[0029] In a further embodiment, the compound of formula IV is converted to Indacaterol or a pharmaceutically acceptable salt thereof by:
a) neutralizing the compound of formula IV, removing the protecting group R 1 to obtain Indacaterol free base in solution or suspension, optionally isolating Indacaterol free base in solid form, and, optionally, obtaining a pharmaceutically acceptable salt of Indacaterol by addition of a suitable acid, such as maleic acid, to the free base; b) removing the protecting group R 1 to obtain a compound of formula V:
[0000]
neutralizing the compound of formula V to obtain the free Indacaterol base in solution or suspension, optionally isolating Indacaterol free base in solid form, and, optionally, obtaining a pharmaceutically acceptable salt of Indacaterol by addition of a suitable acid, such as maleic acid, to the free base; or
c) removing the protecting group R 1 to obtain a compound of formula V, reacting the compound of formula V directly with a suitable acid, such as maleic acid, to obtain a pharmaceutically acceptable salt of Indacaterol.
The Compound of Formula III
[0034] The compound of formula III may be isolated as the free base or through the formation of an acid addition salt without removing the protecting group R 2 or used directly without isolating it in the further preparation of Indacaterol or a pharmaceutically acceptable salt thereof, such as proceeding via the compound of formula IV.
R 1 Protecting Groups
[0035] R 1 is a protecting group commonly known in the art for protecting phenol groups. The skilled person will be aware of suitable protecting groups for hydroxy groups in the 8-position of quinolone derivatives such as the compound of formula I. Such suitable protecting groups may be found in WO 00/75114 and WO 2004/076422.
[0036] More particularly, in one embodiment, R 1 is selected from the group consisting of a C 1-6 alkyl, C 6-20 aryl, C 1-6 -alkoxy, C 2-6 alkenyl, C 3-6 cycloalkyl, benzocycloalkyl, C 3-6 cycloalkyl-C 1-6 alkyl, C 6-20 aryl-C 1-6 alkyl, heteroaryl, heteroaryl-C 1-6 alkyl, halo-C 1-6 alkyl, and an optionally substituted silyl group. In another embodiment, R 1 is benzyl or t-butyldimethylsilyl. In yet another embodiment, R 1 is benzyl.
R 2 Protecting Groups
[0037] R 2 is a protecting group, which is stable under mildly alkaline conditions and which can be cleaved off selectively under conditions where R 1 is not cleaved off. A number of protecting groups fulfil these criteria, including, but not limited to, protecting groups forming an acetal together with the adjacent oxygen atom, protecting groups forming an ether together with the adjacent oxygen, protecting groups forming a silyl ether group with the adjacent oxygen, and protecting groups forming an ester together with the adjacent oxygen. Hence, in one embodiment, R 2 forms an acetal, an ether, a silyl ether, or an ester together with the adjacent oxygen. In another embodiment, R 2 forms an acetal, an ether, or a silyl ether together with the adjacent oxygen. In yet another embodiment, R 2 forms an acetal or an ether together with the adjacent oxygen. In a further embodiment, R 2 forms an acetal together with the adjacent oxygen.
[0038] Examples of suitable acetal protecting groups are 1-(n-butoxy)-ethyl acetal and tetrahydro-pyran-2-yl acetal. Thus, in one embodiment, R 2 is 1-(n-butoxy)-ethyl or tetrahydro-pyran-2-yl, such as 1-(n-butoxy)-ethyl. Examples of suitable ether protecting groups are benzyl ether, methoxymethyl (MOM) ether, methylthiomethyl (MTM) ether, and benzyloxymethyl ether. Thus, in another embodiment, R 2 is benzyl, methoxymethyl, methylthiomethyl, or benzyloxymethyl, such as benzyl. Examples of suitable silyl ether protecting groups are trimethylsilyl ether and tert-butyldimethylsilyl ether. Thus, in still another embodiment, R 2 is trimethylsilyl or tert-butyldimethylsilyl. Examples of suitable ester protecting groups are pivaloyl ester and acetate ester. Thus, in yet another embodiment, R 2 is pivaloyl or acetate.
[0039] In a further embodiment, R 2 is selected from the group consisting of 1-(n-butoxy)-ethyl, methoxymethyl, benzyl, and tetrahydro-pyran-2-yl, such as from the group consisting of 1-(n-butoxy)-ethyl, methoxymethyl, and tetrahydro-pyran-2-yl. In yet a further embodiment, R 2 is 1-(n-butoxy)-ethyl and R 1 is benzyl.
Methods for Removing the Protecting Group R 2
[0040] The protecting group R 2 may be removed from the compound of formula III by methods known in the art for the various R 2 protecting groups defined herein. In the case of R 2 forming an acetal together with the adjacent oxygen atom, R 2 may be removed by reacting with an intermediate to strong acid, preferably in the presence of water. Examples of suitable acids are hydrochloric acid, hydrobromic acid, sulfuric acid, nitric acid, phosphoric acid, camphorsulfonic acid, methanesulfonic acid, trifluoromethanesulfonic acid, and combinations thereof.
[0041] In the case of R 2 forming an ether, silyl ether, or ester together with the adjacent oxygen atom, the acids mentioned for the acetal protecting groups are also suitable for removing R 2 . Other suitable agents for removing R 2 in the case of R 2 forming an ether, silyl ether, or ester together with the adjacent oxygen atom are aqueous bases, lewis acids, hydrogen over palladium or platinum catalyst (in the case of benzyl ether), resins such as Dowex, thiols such as thiophenol, and combinations thereof.
Bases Useful in the Reaction of Compounds I and II
[0042] Any organic or inorganic base may be employed in the reaction between compounds I and II in the formation of the compound of formula III, with the exception of primary and secondary amines. Examples of useful organic bases in this reaction are triethylamine, diisopropylethylamine (DIPEA), pyridine, 1,4-diazabicyclo[2.2.2]octane (DABCO), and 4-dimethylaminopyridine (DMAP). Examples of useful inorganic bases in this reaction are sodium carbonate, potassium carbonate, sodium hydrogencarbonate, potassium hydrogencarbonate, sodium hydroxide, and potassium hydroxide. When carrying out the reaction between the compounds of formula I and II in the presence of a base, the 2-amino-5,6-diethylindan of formula II may be added to the reaction mixture in the form of an acid addition salt thereof, such as the hydrochloride salt thereof.
The Acid HA
[0043] Reacting the product obtained by removing the protecting group R 2 from the compound of formula III with the acid HA serves to purify the compound by obtaining the salt of formula IV. Examples of suitable HA acids are benzoic acid, maleic acid, fumaric acid, succinic acid, tartaric acid, hydrochloric acid, hydrobromic acid, dibenzoyl-tartaric acid, mandelic acid, and camphorsulfonic acid.
[0044] In one embodiment, the acid HA is selected from the group consisting of tartaric acid, dibenzoyl-tartaric acid, mandelic acid, succinic acid, and benzoic acid. In another embodiment, the acid HA is selected from the group consisting of tartaric acid, succinic acid, and benzoic acid.
[0045] In another embodiment, the acid HA is selected from the group consisting of L-tartaric acid and dibenzoyl-L-tartaric acid.
The Mixture of Water and Water-Miscible Organic Solvent
[0046] It has been found that a mixture of water and a water-miscible organic solvent rather than the water-miscible organic solvent alone provides a high enantiomeric purity of the final product. In one embodiment, the water-miscible organic solvent is selected from the group consisting of methanol, ethanol, isopropyl alcohol, acetone, acetonitrile, and mixtures thereof. In a further embodiment, the water-miscible organic solvent is selected from the group consisting of acetone, ethanol, and mixtures thereof.
The Halogen X
[0047] Halogens generally constitute good leaving groups in an S N 2-type reaction, such as the reaction between the compounds of formula I and II. In one embodiment, X is selected from the group consisting of chloro, bromo, and iodo. In another embodiment, X is bromo or iodo. In yet another embodiment, X is bromo.
[0048] In a further embodiment, X is bromo or chloro and the reaction between compounds I and II takes place in the presence of an iodine salt, such sodium iodide or potassium iodide, which generates the iodo group in situ.
The Starting Compound of Formula I
[0049] The compound of formula I may be obtained from the corresponding hydroxy-unprotected compound of formula VI:
[0000]
[0000] by reacting with the reagents known in the art to form the acetal, ether, silyl ether, or ester protecting groups defined herein when reacted with an alcohol. In the case of e.g. acetal protecting groups, in the case where R 2 is 1-(n-butoxy)-ethyl or tetrahydro-pyran-2-yl, the compound of formula VI may be reacted with butyl-vinyl ether or dihydro-pyran-2-yl, respectively.
[0050] The compound of formula VI may be prepared by reducing the corresponding haloacetyl compound using a chiral catalyst. Suitable chiral catalysts for this method are disclosed in WO 2004/076422 and WO 2005/123684, the contents of which are incorporated in their entirety herein.
Pharmaceutically Acceptable Salts
[0051] Pharmaceutically acceptable acid addition salts of Indacaterol are easily identified by the skilled person. A useful list of pharmaceutically acceptable acid addition salts may be found in Berge et al: “Pharmaceutical Salts”, Journal of Pharmaceutical Sciences, vol. 66, no. 1, 1 Jan. 1977, pages 1-19. A particularly interesting pharmaceutically acceptable acid addition salt is the maleate salt.
Proceeding Via Indacaterol Base
[0052] As discussed above, Indacaterol free base is known in the art to be unstable in organic solvents. Hence, preparing pharmaceutically acceptable salts of Indacaterol by proceeding via the free Indacaterol base is not considered viable on an industrial scale. It has, however, been found that by isolating the free base in solid form, pharmaceutically acceptable salts of Indacaterol may indeed be prepared on an industrial scale by proceeding via the free Indacaterol base. Furthermore, this avoids the impurities associated with the methods known in the art for converting one salt of 8-protected Indacaterol directly to a pharmaceutically acceptable salt of Indacaterol. Example 2 of WO 2004/076422 was reproduced, hydrogenating the benzoate salt of formula IV using acetic acid as the solvent, and then exchanging the anion of the salt to maleate by addition of maleic acid. The obtained solid was filtered, washed, and dried in vacuum to give the Indacaterol maleate with impurities of Indacaterol acetate as measured by NMR (Comparative example 9).
[0053] Thus, in another aspect of the invention, it concerns a process for the preparation of a pharmaceutically acceptable salt of Indacaterol by obtaining Indacaterol, isolating it in solid form, and reacting it with a suitable acid, such as maleic acid. Indacaterol free base may be obtained as disclosed herein or as known in the art.
Useful Reaction Conditions
Formation of the Compound of Formula III
[0054] The reaction may take place in a number of different organic solvents. Useful examples are acetonitrile, butanone, and dimethylformamide (DMF), in particular acetonitrile and butanone. It has been found advantageous to use small volumes of solvent in the reaction between the compounds of formula I and II. The reaction is advantageously carried out at a temperature in the range of 70 to 110° C., such as at 85° C., with a duration of between 2 and 10 hours, such as 4 to hours. Furthermore, when adding the 2-amino-5,6-diethylindan of formula II as an acid addition salt thereof, a carbonate salt, such as potassium carbonate, is advantageously added to the reaction mixture.
Removing the Protecting Group R 2
[0055] When using an aqueous acid for removing the protecting group R 2 , e.g. 1-(n-butoxy)-ethyl, from the compound of formula III said acid, such as hydrochloric acid, is advantageously added in excess, such as 2 to 6 equivalents, at a temperature between room temperature and reflux until complete removal of the protecting group, e.g. 1 to 3 hours for removing the 1-(n-butoxy)-ethyl protecting group.
Formation of the Compound of Formula IV
[0056] Once the protecting group R 2 has been removed, more water may advantageously be added together with a suitable solvent, such as dichloromethane. The deprotected compound may be neutralized at a pH of 9 to 11 and the resulting phases then separated. After separation, the solvent may be changed to a solvent suitable for precipitation of the compound of formula IV. Useful solvents are ethyl acetate, isopropanol, ethanol, acetone, tetrahydrofuran, and acetonitrile, ethyl acetate, isopropanol, and ethanol currently being more preferred. After changing the solvent, the acid HA may be added to form the compound of formula IV by precipitation. Ethyl acetate is a particularly useful solvent for precipitating the benzoate, succinate, and tartrate salts. The salt of formula IV may be obtained with a yield of 65 to 80% and a purity of greater than 93%% in the case of tartrate precipitated in ethyl acetate, and a yield of 60 to 75% and a purity of greater than 99% in the case of succinate and tartrate precipitated in isopropanol or ethanol. The absence of dimer and regioisomer impurities as known in the art facilitates a more quantitative precipitation using ethyl acetate since there is no competition for the base molecules.
Formation of Indacaterol Base
[0057] The compound of formula IV may be neutralized before deprotection of R 1 . The neutralization may suitably be achieved by addition of dichloromethane, water and soda. When R 1 is removed by hydrogenation, it may suitably be achieved using an overpressure of hydrogen at ambient temperature. Furthermore, a mixture of methanol and dichloromethane as the solvent is suitably employed in the process. Upon completion of the hydrogenation, the catalyst is removed and dichloromethane is distilled off to leave methanol as the only solvent, which causes Indacaterol to precipitate upon cooling. Alternatively, the methanol/dichloromethane mixture is exchanged with isopropanol solvent, which is cooled to achieve precipitation of Indacaterol base with a purity of >99%.
[0058] Precipitated Indacaterol base is a white solid, which may be stored at ambient temperature for extended periods of time. Upon dissolution it may be used to prepare a pharmaceutically acceptable salt, such as the maleate salt. A suitable solvent for the addition of maleic acid is isopropanol. Alternatively, Indacaterol base obtained from the reaction and dissolved in a mixture of methanol and dichloromethane can be used directly, the solvent exchanged for isopropanol, and then precipitated as the maleate salt by adding maleic acid.
Intermediate Compounds
[0059] The process of the invention involves novel intermediates, which have not previously been used in the preparation of Indacaterol. Hence, a further aspect of the invention concerns the compounds of formula I, with the proviso that when R 1 is benzyl and X is Br, then R 2 is not tert-butyl(dimethyl)silyl or tetrahydro-2H-pyran-2-yl.
[0060] Yet another aspect of the invention concerns the compounds of formula III, or salts thereof.
[0061] A further aspect of the invention concerns Indacaterol free base in solid form. In one embodiment, said Indacaterol free base is in crystalline form. In another embodiment, said Indacaterol free base is in amorphous form.
EXAMPLES
Example 1
Protecting the α-halohydroxy Compound of Formula VI
[0062]
[0063] A flask is charged with 5 ml of tetrahydrofuran (THF) and 5 ml of toluene. p-toluene sulfonic acid (0.15 mmol) and molecular sieves are added with stirring for 30 minutes. 6 mmol of butyl-vinylether and 3 mmol of 8-(phenylmethoxy)-5-((R)-2-bromo-1-hydroxy-ethyl)-(1H)-quinolin-2-one are added. The mixture is agitated at 20/25° C. until completion of the reaction, followed by filtration and distillation of the filtrate to remove the solvent. The product is obtained in quantitative yield as an oil consisting of 50% of each of the diastereomers.
[0064] 1 H-NMR (DMSO-d6, δ), mixture 50/50 of diastereomers: 0.61 and 0.82 (3H, t, J=7.2 Hz, CH 3 —Pr—O), 1.12 and 1.22 (3H, d, J=5.6 Hz, acetalic CH 3 ), 0.90-1.40 (4H, m, CH 2 +CH 2 ), 3.20-3.80 (4H, m, CH 2 —OAr+CH 2 —Br), 4.51 and 4.82 (1H, q, J=5.6 Hz, acetalic CH), 5.18 and 5.24 (1H, dd, J=4.0, 8.0 Hz, CH—O-acetal), 6.56 and 6.58 (1H, d, J=10.0 Hz, H4), 7.00-7.57 (7H, m), 8.17 and 8.23 (1H, d, J=10.0 Hz, H3), 10.71 (1H, s, NH)
[0065] 13 C-NMR (DMSO-d6, δ), mixture 50/50 of diastereoisomers: 13.5 and 13.7 CH 3 ), 18.5 and 18.8 (CH 2 ), 19.9 and 20.0 (acetalic CH 3 ), 30.9 and 31.4 (CH 2 ), 36.8 and 37.3 (CH 2 ), 63.7 and 64.2 (CH 2 —Br), 69.8 and 69.9 (CH 2 —OAr), 73.8 and 75.1 (CH—O), 97.5 and 100.4 (acetalic CH), 111.8 (CH), 116.9 and 117.2 (C), 121.2 and 122.4 (CH), 122.3 and 122.6 (CH), 127.7 and 127.8 (C), 127.8 and 127.9 (CH), 128.2 and 128.3 (CH), 128.8 and 129.1 (C), 129.4 and 129.6 (C), 136.1 and 136.5 (CH), 136.5 and 136.6 (C), 144.0 and 144.2 (C), 160.7 and 160.8 (C═O).
Example 2
Protecting the α-halohydroxy Compound of Formula VI
[0066]
[0067] Pivaloyl chloride (0.72 g) is added to a stirred mixture of 8-(phenylmethoxy)-5-((R)-2-chloro-1-hydroxy-ethyl)-(1H)-quinolin-2-one (0.74 g), dichloromethane (15 ml) and 4-dimethylaminopyridine (0.89 g) at 20/25° C., and the reaction is stirred until all the starting material disappeared. Water (22 ml) is added and the phases are separated.
[0068] The organic phase is washed with 1 M HCl (22 ml) and then with water (22 ml). The solvent is removed and the residue is crystallized from acetone to obtain 0.82 g of the product.
[0069] 1 H-NMR (DMSO-d6, δ): 1.13 (9H, s, CH 3 ), 3.92 (1H, dd, J=4.0, 12.0 Hz, CH 2 —Br), 4.00 (1H, dd, J=8.4, 12.0 Hz, CH 2 —Cl), 5.28 (2H, s, Ph-CH 2 —O), 6.25 (1H, dd, J=4.0, 8.4 Hz, CH—OPiv), 6.59 (1H, d, J=10.0 Hz, H4), 7.15 (1H, d, J=8.4 Hz, H6), 7.20 (1H, d, J=8.4 Hz, H7), 7.27-7.30 (1H, m, Ph), 7.33-7.37 (2H, m, Ph), 7.54-7.56 (2H, m, Ph), 8.18 (1H, d, J=10.0 Hz, H3), 10.77 (1H, s, NH).
[0070] 13 C-NMR (DMSO-d6, δ): 26.7 (3×CH 3 ), 38.3 (C), 46.4 (CH 2 —Cl), 69.8 (CH 2 —Ph), 71.3 (CH—OPiv), 111.9 (CH), 116.8 (C), 120.5 (CH), 122.9 (CH), 126.0 (C), 127.8 (2×CH), 127.9 (CH), 128.3 (2×CH), 129.5 (C), 136.0 (C), 136.5 (CH), 144.5 (C), 160.7 (CON), 176.2 (COO).
Example 3
Preparation of the Compound of Formula IV
[0071]
[0072] A flask is charged with 2.5 ml of THF and 2.5 ml of toluene. p-toluene sulfonic acid (5 mg) and molecular sieves (0.2 g) are added with stirring for 30 minutes. 1.5 ml of butyl-vinylether and 2 g of 8-(phenylmethoxy)-5-((R)-2-bromo-1-hydroxy-ethyl)-(1H)-quinolin-2-one are added. The mixture is agitated at 20/25° C. until completion of the reaction. 0.015 ml of diisopropylethyl amine is added, the mixture is filtered, and the solvent is distilled off.
[0073] The residue is dissolved in 6 ml of dimethylformamide (DMF), 1.9 ml of diisoproypylethyl amine, 1.2 g sodium iodide, and 1.5 g of 2-amino-5,6-diethylindane are added and the mixture is heated to 100° C. After completion of the reaction the mixture is cooled to 20/25° C., 0.4 ml of concentrated hydrochloric acid and 0.4 ml of water are added, and the mixture is stirred for 30 minutes.
[0074] HPLC analysis shows the expected product with a purity of 75% and being free from the dimer and regioisomer impurities.
[0075] 20 ml of water, 20 ml of methylene chloride, and 3 ml of 6N NaOH are added with stirring. The organic phase is separated and washed with 20 ml of water. The organic phase is distilled and the solvent is changed to ethyl acetate with a final volume of 100 ml. The mixture is heated to 70° C., 0.8 g of L-tartaric acid is added, and stirring continues for 30 minutes at 70° C. The mixture is cooled slowly to 20/25° C., filtered, and washed with 8 ml of ethyl acetate to obtain 8-(phenylmethoxy)-5-[(R)-2-(5,6-diethyl-indan-2-ylamino)-1-hydroxy-ethyl]-(1H)-quinolin-2-one tartrate in 68% yield. The purity of the product is >95% by HPLC analysis.
Example 4
Preparation of the Compound of Formula IV
[0076]
[0077] A flask is charged with 19 ml of THF and 19 ml of toluene. p-toluene sulfonic acid (75 mg) and molecular sieves (1.5 g) are added and the mixture is stirred for 30 minutes. 11.2 ml of butyl-vinylether and 15 g of 8-(phenylmethoxy)-5-((R)-2-bromo-1-hydroxy-ethyl)-(1H)-quinolin-2-one are added. The mixture is agitated at 20/25° C. until completion of the reaction. 0.1 ml of diisopropylethyl amine are added, the mixture is filtered, and the solvent is distilled off.
[0078] The residue is dissolved in 40 ml of butanone, 14.5 ml of diisoproypylethyl amine, 9 g sodium iodide, and 11.3 g of 2-amino-5,6-diethylindane are added and the mixture is heated to 90-100° C. After completion of the reaction the mixture is cooled to 20/25° C., 3 ml of concentrated hydrochloric acid and 3 ml of water are added, and the mixture is stirred for 30 minutes.
[0079] HPLC analysis shows the expected product with a purity of 84% and being free from the dimer and regioisomer impurities.
[0080] 150 ml of water, 150 ml of methylene chloride, and 22.5 ml of 6N NaOH are added with stirring. The organic phase is separated and washed with 10 ml of water. The organic phase is distilled and the solvent is changed to isopropyl alcohol with a final volume of 300 ml. The mixture is heated to 70° C., 4.9 g of benzoic acid is added, and stirring continues for 30 minutes at 70° C. The mixture is cooled slowly to 20/25° C., filtered, and washed with 30 ml of isopropanol to obtain 8-(phenylmethoxy)-5-[(R)-2-(5,6-diethyl-indan-2-ylamino)-1-hydroxy-ethyl]-(1H)-quinolin-2-one benzoate in 59% yield. The purity of the product is >99% by HPLC analysis.
Example 5
Preparation of the Compound of Formula IV
[0081]
[0082] A flask is charged with 7.5 ml of THF and 7.5 ml of toluene. p-toluene sulfonic acid (30 mg) and molecular sieves (0.6 g) are added and the mixture is stirred for 30 minutes. 4.5 ml of butyl-vinylether and 6 g of 8-(phenylmethoxy)-5-((R)-2-bromo-1-hydroxy-ethyl)-(1H)-quinolin-2-one are added. The mixture is agitated at 20/25° C. until completion of the reaction. 0.040 ml of diisopropylethyl amine are added, the mixture is filtered, and the solvent is distilled off.
[0083] The residue is dissolved in 18 ml of acetonitrile (ACN), 5.8 ml of diisoproypylethyl amine, 3.6 g sodium iodide, and 4.5 g of 2-amino-5,6-diethylindane are added and the mixture is heated to 80-90° C. After completion of the reaction the mixture is cooled to 20/25° C., 1.2 ml of concentrated hydrochloric acid and 1.2 ml of water are added, and the mixture is stirred for 30 minutes. HPLC analysis shows the expected product with a purity of 89% and being free from the dimer and regioisomer impurities.
[0084] 60 ml of water, 60 ml of methylene chloride, and 9 ml of 6N NaOH are added with stirring. The organic phase is separated and washed with 60 ml of water. The organic phase is distilled and the solvent is changed to isopropyl alcohol with a final volume of 120 ml. The mixture is heated to 70° C., 1.9 g of succinic acid is added, and stirring continues for 30 minutes at 70° C. The mixture is cooled slowly to 20/25° C., filtered, and washed with 12 ml of isopropanol to obtain 8-(phenylmethoxy)-5-[(R)-2-(5,6-diethyl-indan-2-ylamino)-1-hydroxy-ethyl]-(1H)-quinolin-2-one succinate in 56% yield. The purity of the product is >99% by HPLC analysis.
Example 6
Purification with EtOH/Water
[0085]
[0086] To 2.0 g of 8-(phenylmethoxy)-5-[(R)-2-(5,6-diethyl-indan-2-ylamino)-1-hydroxy-ethyl]-(1H)-quinolin-2-one, a mixture of 35 ml/g of EtOH and 5 ml/g of water are added and heated to reflux. Once this temperature is reached, benzoic acid is added (1.2 eq.) as a solution in 5 ml/g of the mixture of EtOH/water. The temperature is maintained for 30 minutes. The mixture is then cooled slowly overnight to 20-25° C. The resulting suspension is filtered and a white solid is obtained and dried in vacuum. The white solid is analyzed by HPLC to determine the chromatographic purity and by chiral HPLC to determine the enantiomeric purity, obtaining a white solid product with a proportion of enantiomeric impurity below 0.05%. No other impurities are detected.
Example 7
Purification with Acetone/Water
[0087]
[0088] To 2.0 g of 8-(phenylmethoxy)-5-[(R)-2-(5,6-diethyl-indan-2-ylamino)-1-hydroxy-ethyl]-(1H)-quinolin-2-one, a mixture of 35 ml/g of Acetone and 1 ml/g of water are added and heated to reflux. Once this temperature is reached, Dibenzoyl-L-tartaric monohydrate acid is added (1.2 eq.) as a solution in 5 ml/g of the mixture of Acetone/water. The temperature is maintained for 30 minutes. The mixture is then cooled slowly overnight to 20-25° C. The resulting suspension is filtered and a white solid is obtained and dried in vacuum. The white solid is analyzed by HPLC to determine the chromatographic purity and by chiral HPLC to determine the enantiomeric purity, obtaining a white solid product with a proportion of enantiomeric impurity below 0.05%. No other impurities are detected.
Example 8
Purification with EtOH/Water
[0089]
[0090] To 2.0 g of 8-(phenylmethoxy)-5-[(R)-2-(5,6-diethyl-indan-2-ylamino)-1-hydroxy-ethyl]-(1H)-quinolin-2-one, a mixture of 35 ml/g of EtOH and 5 ml/g of water are added and heated to reflux. Once this temperature is reached, L Tartaric acid is added (1.2 eq.) as a solution in 5 ml/g of the mixture of EtOH/water. The temperature is maintained for 30 minutes. The mixture is then cooled slowly overnight to 20-25° C. The resulting suspension is filtered and a white solid is obtained and dried in vacuum. The white solid is analyzed by HPLC to determine the chromatographic purity and by chiral HPLC to determine the enantiomeric purity, obtaining a white solid product with a proportion of enantiomeric impurity below 0.06%. No other impurities are detected.
Example 9
Synthesis of Protected Benzyl Indacaterol
[0091]
[0092] A solution of sodium carbonate (0.57 kg/kg, 2 equivalents) in water (13 l/kg) is prepared in another reactor. This carbonate solution is added to the product solution from example 1, diethyl indanolamine.HCl (0.72 kg/kg, 1.2 equivalents) is added and the mixture is heated and distilled at atmospheric pressure until a volume of 13 l/kg. Water (3 l/kg) is added and the mixture is distilled at atmospheric pressure until a volume of 13 l/kg. The system is placed in reflux position and reflux is maintained for 20 hours.
[0093] When the reaction is complete, the mixture is cooled to 20-25° C. and methylene chloride (15 l/kg) is added. The mixture is agitated, decanted, and the aqueous phase is extracted with methylene chloride (5 l/kg). The organic phases are washed with water (5 l/kg).
Example 10
Preparation of Indacaterol Maleate
[0094]
[0095] 28 g of 8-(phenylmethoxy)-5-[(R)-2-(5,6-diethyl-indan-2-ylamino)-1-hydroxy-ethyl]-(1H)-quinolin-2-one tartrate is dissolved in a mixture of 560 ml of dichloromethane, 560 ml of water, and 30 ml of an aqueous solution of 6N sodium hydroxide under stirring. The phases are separated and the organic phase is washed with 280 ml of water.
[0096] The organic phase is distilled to a final volume of 140 ml and 420 ml of methanol and 4.2 g of Pd/C (5%-50% water) are added. The system is purged with nitrogen and subsequently with hydrogen at an overpressure of 0.3 bar and stirring until completion of the reaction.
[0097] The catalyst is filtered off and the solvent is changed to isopropanol adjusting the final volume to 950 ml. The solution is heated to 70/80° C. and a solution of 5.4 g maleic acid in 140 ml of isopropanol is added, maintaining the temperature between 70 and 80° C. The mixture is stirred at 70/80° C. for 30 minutes and then slowly cooled to 20/25° C. The resulting suspension is filtered, the solid residue is washed with 90 ml of isopropanol and dried to obtain 18 g of Indacaterol maleate (Yield: 79%). The product shows 99.6% purity by HPLC analysis.
Example 11
Isolation of Indacaterol Free Base in Solid Form
[0098]
[0099] 1 g of 8-(phenylmethoxy)-5-[(R)-2-(5,6-diethyl-indan-2-ylamino)-1-hydroxy-ethyl]-(1H)-quinolin-2-one tartrate is dissolved in a mixture of 20 ml of dichloromethane, 20 ml of water, and 1 ml of an aqueous solution of 6N sodium hydroxide under stirring. The phases are separated and the organic phase is washed with 10 ml of water.
[0100] The organic phase is distilled to a final volume of 5 ml and 15 ml of methanol and 0.15 g of Pd/C (5%-50% water) are added. The system is purged with nitrogen and subsequently with hydrogen at an overpressure of 0.3 bar and stirring until completion of the reaction.
[0101] The catalyst is filtered off and the solvent is changed to isopropanol adjusting the final volume to 8 ml. The resulting suspension is cooled to 0-5° C., filtered and the solid residue is washed with isopropanol and dried to obtain 0.47 g of Indacaterol free base (77%) showing 99.6% purity by HPLC analysis.
[0102] A sample of Indacaterol free base stored at 20-25° C. is analysed one month later without showing any loss of purity.
Example 12
Obtaining the Maleate Salt from Indacaterol Free Base
[0103]
[0104] 0.47 g of solid Indacaterol are suspended in 20 ml of isopropanol, heated to 70/80° C., and a solution of 0.15 g of maleic acid in 5 ml of isopropanol are added, maintaining the temperature between 70 and 80° C. The mixture is cooled to 0/5° C. and filtration of the resulting solid affords 0.52 g of Indacaterol maleate with a purity of 99.7%.
Comparative Example 13
Direct Conversion to Indacaterol Maleate
[0105] 8-(phenylmethoxy)-5-[(R)-2-(5,6-diethyl-indan-2-ylamino)-1-hydroxy-ethyl]-(1H)-quinolin-2-one benzoate (4 g) is dissolved in acetic acid (40 ml). Pd/C (5%, 50% wet, 0.6 g) is added and the product is hydrogenated under a hydrogen atmosphere. When the reaction is complete the catalyst is filtered off and the filtrate is vacuum distilled until a volume of 8 ml is reached.
[0106] Ethanol (40 ml) is added and the mixture is heated to 50° C. A solution of 1.2 g of maleic acid in 2.4 ml of ethanol is added and the mixture is seeded with indacaterol maleate and then slowly cooled to 0/5° C. The solid is filtered and washed with 5 ml of ethanol and 3 ml of isopropanol to obtain 6.0 g of indacaterol maleate.
[0107] 1H-NMR analysis of the solid shows the presence of acetic acid in 2-4% by integration of the peak at δ 1.88 (400 MHz, DMSO-d6) corresponding to acetic acid. | The invention relates to new and improved processes for the preparation of Indacaterol and pharmaceutically acceptable salts thereof as well as intermediates for the preparation of Indacaterol. The new process avoids the use of the epoxide compound known in the art and the impurities associated therewith and results in a higher yield. | 2 |
BACKGROUND INFORMATION
The present invention relates to a three-dimensional particle image velocimetry method in which a stream system containing light-scattering particles is continuously exposed to a laser lightsheet over a certain period or at least at two discrete points in time and the scattered light from the stream system is evaluated.
Such three-dimensional particle image velocimetry methods applied to droplets have been proposed using different approaches, the primary problem being measurement of the third velocity component in the direction of observation, i.e., perpendicular to the lightsheet. The most common approach uses stereoscopy as described in “Stereoscopic Particle Velocimetry” by M. P. Arroyo, C. A. Greated, Meas. Sci. Technol., 2, 1181-1186, 1991. The depth information is obtained by evaluating the light emitted by the lightsheet from two directions.
Another approach described in “Determination of the third velocity component with PTA using an intensity-graded lightsheet” by F. Dinkelacker, M. Schäfer, W. Ketterle, J. Wolfrum, Exp. Fluids, 13, 357-359, 1992, uses an intensity-coded lightsheet in order to determine the position of the light-scattering particle from the brightness of its image.
Another option investigated by Ch. Brtücker in “3-d PIV by spatial correlation in a color-coded lightsheet,” Exp. Fluids, 21, 312-314, 1996, uses a plurality of differently colored lightsheets that are slightly offset with respect to one another in order to determine the third component of the spectral composition of the scattered light.
Some degree of success was achieved with each of these methods, but the measuring accuracy for the third velocity component was clearly inferior to the accuracy achieved for the components in the lightsheet plane. In most applications, the absolute velocity is lowest in the direction perpendicular to the lightsheet, so that a higher accuracy is desirable in this direction.
The same velocity measurement accuracy in all three dimensions, i.e., along all spatial axes, has been attainable only via observation from two directions perpendicular to one another, which is, however, associated with a high cost.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a method with which all velocity components can be determined with essentially the same accuracy using a single direction of observation.
This object is achieved according to a method in which, in order to measure a third dimension along the direction of observation, the phase information of the scattered light is evaluated using a reference wave. With this method, the velocity component of the third dimension perpendicular to the lightsheet can be determined with interferometric accuracy.
In one advantageous method, the scattered light is holographically recorded in order to make it accessible to observation when the flow velocity is high. In evaluating the scattered light or the holographically reconstructed scattered light using laser light having a single wavelength, unambiguous measurement is obtained if the interval between exposures or, in the case of continuous exposure, the time period, is selected to be shorter than the time period in which the expected maximum path traveled by the light-scattering particle in the third dimension is smaller than the wavelength of the laser light.
Practically any desired range of unambiguousness can be obtained with respect to the velocities to be measured in the third dimension by performing two measurements with laser light having two or more different discrete wavelengths and by determining the velocity in the third dimension by the principle of multiple wavelength interferometry on the basis of a synthetic wavelength formed from the other two wavelengths. As an alternative, the reconstruction wavelength can be changed continuously.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically shows a measuring arrangement for evaluating a hologram in order to determine a velocity component of a droplet in a third dimension that is perpendicular to a lightsheet.
FIG. 2 shows the brightnesses of two droplet images recorded at different points in time as a function of the phase of a reference wave for two different wavelengths.
FIG. 3 shows another illustration of the brightness of two droplet images recorded at different points in time as a function of the phase of a reference wave for two different wavelengths.
DETAILED DESCRIPTION
FIG. 1 schematically shows a measuring arrangement for evaluating a third dimension of a droplet velocity that is perpendicular to a lightsheet, i.e., running in the direction of observation. For this purpose, hologram 1 , recorded in an essentially known manner (see the aforementioned literature) is introduced in the beam path of a reconstruction wave 2 . A beam splitter 4 is arranged further downstream along reconstruction wave 2 ; the beam splitter superimposes a reference wave 3 on the reconstructed wave image in order to generate an interference pattern, which is visualized using an image recorder 5 or a frosted-glass window.
The principle of three-dimensional velocimetry of light-scattering particles such as droplets, bubbles, or soot particles is based on initially holographically recording the PIV (Particle Image Velocimetry) data as shown by different authors (see J. K. Schaller, C. G. Stoianoff, “Holographic investigations of a Diesel jet injected into a high-pressure test chamber,” Part. & Part. Syst. Characterization, Vol. 13, pp. 196-204, 1996).
The novel concept in the present method is the superimposition of the additional coherent reference wave 3 on the reconstructed wave image. Information concerning the distance of the reconstructed images from image recorder 5 , such as a camera, is contained with interferometric accuracy in the interference pattern obtained.
The present method can be referred to as “hololexy” (integral reading) by analogy with the term “holography” (integral writing). In common holography, phase information is recorded by superimposing the wave on a coherent reference wave. In the present HIPIV (Holographic Interferometric Particle Image Velocimetry) method, phase information containing the desired distance information is read by superimposition on coherent reference wave 3 .
The approach presented above provides unambiguous results only if the shift between the two images of a light-scattering particle between two exposures is smaller than the wavelength of the laser light used. As a rule, for a distance z of an image of a CCD camera the following equation applies:
z=λ 1 ( n i +φ 1 /2π)=λ 1 ·Φ 1 (1)
where n i is the order of interference of a phase Φ 1 and a residual phase Φ 1 for a wavelength λ 1 .
The small range of unambiguity can be enlarged almost arbitrarily in the framework of the velocity components that occur and of the pulse interval of the droplets by using multiple wavelength interferometry.
If a distance z for wavelengths λ 1,2 has both phase terms Φ 1,2 , an unambiguous measurement result is obtained by combining the two results:
z =(Φ 1 −Φ 2 )Λ=ΔΦ·Λ·μ/2 (2)
where Λ is a synthetic wavelength.
Λ=(λ 1 ·λ 2 )/(λ 1 ·λ 2 ) (3)
The factor ½ takes into account the expansion/compression of the reconstructed image for different wavelengths. Factor μ takes into account the ratio of the reconstruction wavelength to the recorded wavelength.
To test the method, a partial image obtained from a reconstructed hologram via PIV data is initially used. Two bright dots show the two images of a droplet obtained at consecutive points in time, as a drop system is exposed. The velocity component that is parallel to the light used for exposure is initially estimated from the shift of the droplet images with respect to one another in the image plane using the time interval between exposures.
Two additional partial images are derived from the PIV data hologram by superimposing the initially reconstructed partial image according to FIG. 1 on additional reference wave 3 . For example, constructive interference was recognizable for both droplet images in the first partial image obtained with superimposition on reference wave 3 , which made the droplet images considerably brighter than in the partial image prior to superimposition. Destructive interference was forced, by varying the phase of reference wave 3 , in a second partial image, in which both droplet images can now be recognized as dark spots.
To verify the method, the same pair of droplets was analyzed in the reconstructed hologram of the PIV data for different wavelengths. For each wavelength, the phase of reference wave 3 was monotonously varied, and approximately 20 interference images were recorded. The multiple changes between constructive and destructive interference can be clearly seen from the oscillating brightnesses of the droplet images.
Such image series are recorded for different wavelengths and further processed using digital image processing. For this purpose, the individual droplet positions are located and the brightnesses of the droplet images are determined by adding up their grayscale values. In FIGS. 2 and 3 the brightnesses of both images of a droplet are shown for two different wavelengths λ 1 =739.3 nm and λ 2 =751.5 nm as a function of phase Φ of reference wave 3 .
The individual measured values are adjusted to a function of the type
Brightness= P 1 ·sin ( P 1 ·Φ+P 3 )+ P 4 . (4)
The difference of the phase terms P 3 of the two droplet images is denoted as phase difference ΔΦ (see eq. 2) and is shown in FIGS. 2 and 3 for both wavelengths.
FIGS. 2 and 3 clearly show the oscillating brightness of the droplet images. In FIG. 2, both droplet images oscillate almost in phase (ΔΦ 1 =0.27). For the modified wavelengths according to FIG. 3, a phase difference ΔΦ 2 =2.18 can be observed.
The two wavelengths shown in FIGS. 2 and 3 correspond to a synthetic wavelength according to eq. 3 of Λ=45.54 μm. The difference between phase terms ΔΦ=ΔΦ 1 −ΔΦ 2 =1.91 results, after normalization with 2π using eq. 3, in a shift of the droplet by Δz=7 μm along the direction of observation. The shifts in the two other dimensions x and y are determined from the single video image, for example, without superimposition of reference wave 3 and were found to be, in the given example, Δx=37 μm and Δy=36 μm with an error of approximately 10%. The three-dimensional droplet velocity can be determined from this data using the pulse interval of 10 μs between the two exposures.
The experimental investigations have shown the feasibility of the measurement principle; the measurement results, which are already satisfactory, can be drastically improved through automation. The experimental error for a problem-adjusted selection of the construction wavelengths (Λ=37 μm) is approximately 1 to 2 μm. | A three-dimensional particle image velocimetry method is described, in which a stream system containing light-scattering particles is exposed continuously over a certain period or at least two discrete points in time using a laser lightsheet, and a hologram is produced and evaluated. Increased accuracy in determining velocity is achieved by evaluating the hologram with regard to its phase information interferometrically by using a reconstruction wave and superimposing a reference wave. | 6 |
BACKGROUND
[0001] 1. Field
[0002] The present invention relates to a sheet for controlling termites, and more particularly, a sheet for controlling termites which has excellent control effect, can be easily treated and installed and is capable of prevent the place on which the sheet is installed from being damaged and deformed.
[0003] 2. Description of the Related Art
[0004] Generally, wooden structures are damaged directly or indirectly from several factors of natural environment. However, recently the damage to wooden structures caused by insects is due to the fact that the insects eat the wooden structure as nutrients.
[0005] The insects damaging wooden structures include six kinds of Isoptera, Coleoptera, Thysanura, Blattaria and Hymenoptera, and especially in Korea the damages from Isoptera, Coleoptera and Hymenoptera are observed noticeably.
[0006] And as a termite which is a representative of insects damaging wooden structure eats a pillar of a wooden structure and other structural material to give damage to the structure, it terminates the life of the structure and causes the structural instability of the structure.
[0007] Most of termites that live in Korea are Reticulitermes speratus, a kind of a subterranean termite. Reticulitermes speratus is found throughout Korea, for example Seoul, Gyeonggi, Gangwon and north part of South Korea. Generally, once damage from termites occurs, although change from the damage cannot be found outside, the cavitation phenomenon appears inside the wooden structure.
[0008] Recently as for Reticulitermes speratus living in Korea, their population has increased significantly to give more damage to wooden structures, et al., and their distribution range has widened. So the phenomena are a sign of spread of termites. In ecological aspects, a termite has characteristics similar to a cockroach. Once termites have obtained their habitat under the ground or inside a wood, they become extremely difficult to control. They mostly live under the ground and inside the wood, and move inside underground tunnel or on the ground. Therefore, after the damage was revealed outside to be checked by eyes, it is most likely that significant damage has already progressed.
[0009] According to the result of investigation by the Cultural Heritage Administration, 78 out of 231 wooden cultural properties of 16 places (33.8%) have been damaged. Also it was investigated that 43% of national treasure structures have been damaged in Japan.
[0010] In order to solve the above problem caused by the damage from termites, various research and development activities have been progressed all around the world. For example, Korean Patent Publication No.10-1996-0000019(publication date: Jan. 25, 1996) proposed a termites alarm device for detecting intrusion of termites. However, as the device could only detect intrusion of termites, it has a limit of not being able to control termites substantially.
[0011] Also, Korean Patent Publication No.10-2010-0029842(publication date: Mar. 17, 2010) proposed the technique regarding ground termites station shown in FIG. 1 .
[0012] The ground termites station is for detecting and controlling termites on the ground. The station is formed as a container with inside space, and at least a part of the container is mounted to be attached on the ground. The container of the station may be closed form or open form which allows to access to the inside space while being mounted on the ground. A cartridge has such a size and configuration that it can be inserted into and separated from the inside space. Generally, the cartridge comprises a gathering members, a bait matrix independent from the gathering members and a holder, wherein the holder is assembled with the gathering members and the bait matrix to hold at least a part of them and consequently the cartridge can be placed on the inside space of the container as a single unit.
[0013] The ground termites station is somewhat effective for detection and control of termites. However, it has too big size to be treated and be installed conveniently, and it is difficult to respond properly to satisfy complex structural characteristics of wooden structures. Also it is impossible to block the various entry routes of termites completely. Therefore, there is a limit that it cannot control completely, and consequently has a low control effect. In particular, in case of installing it on old structures such as wooden cultural properties, there is disadvantage that it causes damage and deformation to wooden structures and then gives serious adverse effect on their durability.
SUMMARY
[0014] The present invention aims to provide a sheet for controlling termites having excellent effect of controlling termites, being easily treated and installed and preventing the place on which the sheet is installed from being damaged and deformed.
[0015] In order to achieve the above object, a sheet for controlling termites according to the present invention comprises, a sheet main body being installed on the mounting surface and having planar structure; a movement route of termites being formed in the sheet main body for movement of termites; and a layer of termite pesticide comprising termite pesticide composition and being formed in the sheet main body and the movement route of termites.
[0016] Preferably, the sheet main body consists of a planar body made of paper and fabric, and a linear member fixed to be placed on the planar body, and the movement route of termites is the gap formed between the planar body and the linear member.
[0017] The linear member may consist of inorganic or organic fiber yarns, and be attached to the planar body by adhesive.
[0018] In order to achieve the above object, a sheet for controlling termites according to the present invention comprises, a sheet main body being installed on the mounting surface and having planar structure; a movement route of termites being formed in the sheet main body for movement of termites; and a layer of termite pesticide comprising termite pesticide composition and being formed in the sheet main body and the movement route of termites, wherein the sheet main body may be made of paper or fabric, and the movement route of termites may be groove-like passage formed to be concave linearly on the sheet main body.
[0019] The groove-like passage may comprise a narrow passage with narrow width and a wide passage with wider width than the narrow passage.
[0020] In addition, the groove-like passage may comprise more than one of bent portions.
[0021] According to a sheet for controlling termites according to an embodiment of the present invention, the sheet has an effect to improve control efficiency in that because the sheet main body is made of thin paper such as traditional Korean paper, the sheet can be installed to be attached to the wooden materials, also surround wooden materials to block the entry routes of termites completely and lure termites into the sheet main body through a movement route of termites to control them.
[0022] In addition, a sheet for controlling termites according to the present invention has an advantage that because it is made of paper, it can have a small size, be easily treated and installed and be attached while not giving damage to complex wooden structures. In particular, in case of installing the sheet on old structures such as wooden cultural properties, it has an advantage of preventing the structures from being damaged and deformed totally as well as being able to control termites conveniently.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a drawing illustrating a conventional sheet for controlling termites,
[0024] FIG. 2 is a schematic perspective view of a sheet for controlling termites according to an embodiment of the present invention,
[0025] FIG. 3 is a photograph substituting a drawing of the product produced from the drawing for illustrating a sheet for controlling termites according to an embodiment of the present invention,
[0026] As FIGS. 4A to 4C are drawings for explaining the operation of a sheet for controlling termites according to an embodiment of the present invention, FIG. 4A is a drawing of illustrating a test device which the sheet for controlling termites is installed on,
[0027] FIGS. 4B and 4C are photographs substituting drawings of enlarging main portions of the sheet for controlling termites after test.
[0028] FIG. 5 is a perspective view of a sheet for controlling termites according to another embodiment of the present invention.
[0029] FIG. 6 is a perspective view of a sheet for controlling termites according to a modified embodiment of the present invention.
[0030] 1 , 1 ′, 1 ″: sheet for controlling termites 11 : sheet main body
[0031] 111 : planar body
[0032] 112 : linear member
[0033] 12 , 12 ′: movement route of termites
[0034] 121 : narrow passage
[0035] 122 : a wide passage
[0036] 123 : bent portion
[0037] a: the place on which the sheet is installed
[0038] b: test device
[0039] s: termite
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0040] Hereinafter, an embodiment of the present invention would be explained in detail referring to appended drawings.
[0041] FIG. 2 is a schematic perspective view of a sheet for controlling termites according to an embodiment of the present invention, and FIG. 3 is a photograph substituting a drawing of the product produced from the drawing for illustrating a sheet for controlling termites according to an embodiment of the present invention.
[0042] Referring to FIGS. 2 and 3 , a sheet for controlling termites 1 according to an embodiment of the present invention comprises a sheet main body 11 being installed in the mounting surface (a) such as wood and having planar structure, a movement route of termites 12 being formed in the sheet main body 11 for movement of termites, and a layer of termite pesticide(not shown) comprising termite pesticide composition and being formed in the sheet main body 11 and the movement route of termites 12 .
[0043] The sheet main body 11 consists of a planar body 111 and a linear member 112 fixed to be placed on the planar body 111 . Any sheet having planar structure can be used as the planar body 111 without limitation, for example paper such as traditional Korean paper, fabric such as knitted fabric or weaved fabric, and synthetic resin sheet such as vinyl sheet.
[0044] In addition, the linear member 112 consists of inorganic or organic fiber yarns, and is attached to the planar body 111 by adhesive. Here, it is possible to use various types of adhesives, if they would have excellent adhesiveness and not be avoided by termites.
[0045] On the other hand, the movement route of termites 12 may be formed by producing a separate movement route and then attaching it to the sheet main body 11 . However, in this embodiment of the present invention, two gaps are formed on the bottom surface of the planar body 111 of both sides of the linear members 112 by attaching the linear members 112 to the planar body 111 having planar structure and then the two gaps are used as the movement route of termites 12 .
[0046] The layer of termite pesticide (not shown) is formed by coating or dipping with termite pesticide composition. Any termite pesticide composition can be used without limitation if it has effective insecticidal properties. However in this embodiment of the present invention, the layer of termite pesticide (not shown) is formed by adding bistrifluron to alcohol as a solvent to make 2 w/v % solution, and then dipping the sheet main body 11 to the solution.
[0047] Hereinafter, operation of the sheet for controlling termites according to an embodiment of the present invention is briefly described.
[0048] FIGS. 4A to 4C are drawings for explaining the operation of a sheet for controlling termites according to an embodiment of the present invention. FIG. 4A is a photograph substituting drawing of showing a test device which the sheet for controlling termites is installed on, FIGS. 4B and 4C are photographs substituting drawings of enlarging main portions of the sheet for controlling termites after test. Here FIG. 4B is showing the shape shown on plane and FIG. 4C is showing the shape shown on side.
[0049] First, as shown in FIG. 3 , traditional Korean paper is cut into a rectangular shape to produce the planar body 111 , and then the linear members 112 are attached to the planar body 111 by adhesive.
[0050] After, the layer of termite pesticide (not shown) is formed by adding bistrifluron to alcohol as a solvent to make 2 w/v % solution, and then dipping the sheet main body 11 to the solution.
[0051] As shown in FIG. 4A , experiment of attaching the sheet for controlling termites 1 produced by the above embodiment to bottom of test device (b) made of acryl and then putting Reticulitermes speratus into the sheet 1 was conducted. As a result, as shown in FIGS. 4B and 4C , it was found that the termites moved to the movement route of termites 12 formed by the linear members 112 and then died.
[0052] Hereinafter, another embodiment according to the present invention is described. However, a detailed description same or similar components as the embodiment described above will be skipped, and different components will be mainly described.
[0053] FIG. 5 is a perspective view of a sheet for controlling termites according to another embodiment of the present invention.
[0054] Referring to FIG. 5 , a sheet for controlling termites 1 ′ according to another embodiment of the present invention comprises a sheet main body 11 being installed in the mounting surface and having planar structure; a movement route of termites 12 ′ being formed in the sheet main body for movement of termites; and a layer of termite pesticide(not shown) comprising termite pesticide composition and being formed in the sheet main body and the movement route of termites 12 ′, wherein the movement route of termites 12 ′ is groove-like passage formed to be concave linearly on the sheet main body 11 .
[0055] The groove-like passage is formed as a shape of groove on the sheet main body 11 which is produced with paper such as traditional Korean paper. There is no limitation of method of producing the groove-like passage, but following forming method can be used as a representative method.
[0056] For example, the method comprises adding Bistrifluron to alcohol as solvent to make solution of 2 w/v % concentration, dipping the sheet main body into the solution, drying the sheet main body, applying adhesive to the sheet main body and thermoforming by press. Here, as heated mold (not shown) having projections for forming groove-like passage is installed on the press, the sheet main body 11 is pressed to form the groove-like passage.
[0057] FIG. 6 is a perspective view of a sheet for controlling termites according to a modified embodiment of the present invention, and shows an enlarged cross-sectional view showing a schematic cross-sectional view of the indicated portion.
[0058] Referring to FIG. 6 , the sheet for controlling termites 1 ″ according to a modified embodiment of the present invention comprises a sheet main body 11 having planar structure; and a movement route of termites 12 ′ for movement of termites, wherein the movement route of termites 12 ′ is groove-like passage formed to be concave linearly on the sheet main body, and the groove-like passage comprises a narrow passage 121 with narrow width and a wide passage 122 with wider width than the narrow passage.
[0059] In addition, the groove-like passage comprises more than one of bent portions 123 that allows termites to stay enough time within the planar body of the sheet main body although the sheet main body has limited space, and consequently large number of termites could be killed.
[0060] The groove-like passage of the sheet for controlling termites 1 ″ according to a modified embodiment of the present invention shown in FIG. 6 comprises a narrow passage 121 with narrow width and a wide passage 122 with wider width than the narrow passage. Therefore, it has an advantage in that various sizes of termites can be exposed or contact to the layer of termite pesticide and consequently the sheet improves efficiency of controlling termites.
[0061] In addition, the sheet for controlling termites is characterized in that as the groove-like passage is formed to have more than one of plural bent portions 123 , it allows large number of termites to stay in the sheet for a long time, and consequently improves the control efficiency.
[0062] Although a few exemplary embodiments have been shown and described, it will be appreciated by those skilled in the art that changes may be made in these exemplary embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
[0063] The terms used in the above described embodiments are merely used to explain particular embodiments, and are not intended to limit the scope of the present invention. Unless having different meaning contextually, singular form of words include plural form of words, too. In this description, it should be understood that the words of “comprise” or “have” are used to include characteristic, number, step, operation, elements, parts or combination thereof, but aren't be used to in advance exclude the possibility of presence or addition of another characteristic, number, step, operation, elements, parts or combination thereof. | The present invention relates to a sheet for controlling termites, and more particularly, a sheet for controlling termites which has excellent control effect, can be easily treated and installed and is capable of prevent the place on which the sheet is installed from being damaged and deformed. The sheet for controlling termites according to the present invention comprises, a sheet main body being installed on the mounting surface and having planar structure; a movement route of termites being formed in the sheet main body for movement of termites; and a layer of termite pesticide comprising termite pesticide composition and being formed in the sheet main body and the movement route of termites. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of prior filed Provisional Patent Application No. 61/768,740 filed Feb. 25, 2013.
STATEMENT UNDER 37 CFR.155 OR 1.78
This application filed on or after Mar. 16, 2013 which claims benefit or priority to an application filed before Mar. 16, 2013, contains one or more claims not entitled to a filing date before Mar. 16, 2013.
FIELD
The present invention relates generally to firearm security and more particularly to a firearm release apparatus and safe for firearms.
BACKGROUND
Laws regarding the transport of guns vary by state. In the state of Texas for example, a non-felon private citizen may transport a hand gun in his own vehicle or a vehicle under his control if the hand gun is stored out of plain sight. With this in mind, guns are frequently stored in a glove compartment, under the seat or a console between seats. This presents a problem if the gun owner requires ready access to the gun for personal protection because the hand gun cannot be accessed quickly, and in any event, is not stored in a glove compartment or console in a ready state.
Gun safes having an integrated release for a hand gun are known in the art. U.S. Pat. No. 1,557,339 to Sander describes a gun case with a spring actuated release mechanism that is tensionably held against a case door and extends a hand gun from the case when the door is opened. U.S. Pat. No. 6,570,501 describes a hand gun case with a sliding mechanism on which a hand gun rides, and which extends from the case carrying the hand gun when identity verification, i.e., fingerprint identification, is provided.
Although the foregoing provide improvements in hand gun access, problems remain. One problem involves the securing of the case doors wherein a key must be turned or biometric identification provided before the door will open and the hand gun becomes available. Biometric identification does not work in all cases and with all people. Keys can become lost or dropped.
Commonly, law enforcement officers possess a back up firearm that may be carried in a police vehicle. Such a firearm must be reasonably accessible when the officer is present yet secured when the officer is away from the vehicle.
It would be desirable to provide a gun safe/case that permits a firearm to be secured by keyed lock, combination lock or other means wherein the case contains a gun carriage supporting the hand gun in a ready-to-use state when a rail of the carriage is extended therefrom.
It would be desirable to provide a gun safe/case that is readily mountable inside a vehicle whereby ready access to the gun is obtained by tapping a release of the case.
It would be especially desirable to provide a gun safe/case including a quick release mechanism for installation on the interior driver's side of a vehicle that can be actuated without the use of hands or requiring a user to visually inspect the case as a precursor to activating the release mechanism.
SUMMARY
The present invention is an apparatus including a compartment allowing the rapid release of a firearm which is presented to a user in a ready state. The apparatus comprises a compartment that is lockable and adapted for installation in a vehicle in a preferably freestanding position. The compartment includes a quick release knob on a side of the compartment that it can be located and pressed without having to visually inspect the apparatus and without the use of hands when required.
In one aspect, a firearm secure and release apparatus comprises a compartment housing an extendable gun support and a door that can be either closed and locked, open and unlocked or closed and unlocked whereby the door in the closed and unlocked state is released by a knob sized and shaped to enable actuation by a hand or knee if a user is in a seated position and whereby the support carrying the gun is extended from an opening in the compartment.
In another aspect, a firearm secure and release apparatus comprises a compartment containing an extendable gun support and a door that can be either closed and locked, open and unlocked or closed and unlocked whereby the door in the closed and unlocked state can be released by a knob sized and shaped to enable actuation without having to visually inspect the device or feel for a handle, key or combination.
In yet another aspect, a firearm secure and release apparatus comprises a compartment housing an extendable gun support and a door that can be either closed and locked, open and unlocked or closed and unlocked whereby the door in the closed and unlocked state can be released by a knob sized and shaped to enable actuation by a hand or knee if a user is in a seated position and whereby the gun is extended from the compartment opening and presented to the user in a ready state with the grip free hanging, unencumbered and in a down position.
In still another aspect, a firearm secure and release apparatus comprises a case for housing a firearm that is a rifle or shotgun wherein the firearm is temporarily stored and secured within the case and release therefrom by extendable supports when a knob on the case is depressed by a user whereby the gun is presented in a ready state.
Advantageously, the firearm release apparatus can be used while permitting a user to keep his or her eyes on a perceived threat.
Advantageously, the firearm release apparatus installs readily in a vehicle at a desirable angle and will not interfere with the functioning of the steering, shifting or other aspects and features of the vehicle.
The foregoing and other objects, features, and advantages of the invention will become more apparent from the following detailed description, which proceeds with reference to the accompanying figures wherein the scale depicted is approximate.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a preferred embodiment according to the present invention;
FIG. 2 is a side plan view of compartment 110 according to the embodiment shown in ( FIG. 1 );
FIG. 3 is a side plan view showing a carriage assembly within compartment 110 ;
FIGS. 4 a and 4 b show a side plan view with carriage assembly of ( FIG. 3 ) partially extended;
FIG. 5 is a front view of the embodiment of ( FIG. 2 ) taken in the direction of arrow (a), with compartment door 111 closed;
FIG. 6 is a perspective view of compartment 110 with door 111 opened and spring actuated rail 130 extended therefrom;
FIGS. 7 a -7 e show in a sequence, an extended hand gun, pushing the support of the hand gun back into compartment 110 until it locks in place, shutting the compartment door, and locking the compartment with key;
FIG. 8 is a perspective view of support post 220 ;
FIGS. 9 a and 9 b show in sequence actuation of the release by a user's knee;
FIGS. 10 and 11 depict an alternate embodiment according to the present invention for the quick release of a rifle.
DETAILED DESCRIPTION OF THE INVENTION
Reference Listing:
100 release assembly 110 compartment 111 door 112 post cup 120 door release knob 122 door release 123 a compartment lock 123 b cam 124 carriage release 124 a spring pin housing 125 fixed catch 128 carriage assembly 130 rail 131 recess 132 support member 134 barrel support post 136 slide rail guide 138 spring 140 stop 142 bracket 144 strap 200 mounting post assembly 210 mounting plate 220 post 230 angle adjustment plate 240 post pin 250 angle adjustment pin 300 firearm
Definitions
In the following description, the term “gun” or “firearm” refers generally to any type of portable gun and the rapid deployment of same by an individual. The term “ready state” refers to a position that instantly permits a user's grasping the gun without having to unholster or otherwise bypass obstructions in order to manipulate the weapon. The terms “case” and “safe” or “compartment” are interchangeable and refer to housings that can house at least one weapon and which can be secured when desired. The term “hands free” refers to such features that enable actuation of features of the present invention without the use of the hands. The term “eyes free” refers to such features that enable actuation of a release mechanism that will extend the firearm from the housing without having to divert one's eyes from a perceived threat. The term “lock” can refer to keyed locks, combination locks, punch button locks and other locks which will suggest themselves to those having skill in the art and access to this disclosure. The singular terms “a”, “an”, and “the” include plural referents unless the context clearly indicates otherwise. Similarly, the word “or” is intended to include “and” unless the context clearly indicates otherwise. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of this disclosure, suitable methods and materials are described below. The term “comprises” means “includes.” All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety for all purposes. In case of conflict, the present specification, including explanations of terms, will control. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting.
Referring generally to FIGS. 1 through 9 b a ready access firearm release apparatus comprises a compartment 110 having an extendable gun support carriage 128 within the compartment that automatically extends when carriage release 124 is disengaged and release knob 120 is tapped. The carriage which includes a rail 130 , rail guide 136 and gun support member 132 with barrel post 134 extends and exposes the hand gun 300 in a ready state, i.e., with the grip unencumbered and in a vertical presentation. While in the embodiment depicted, the support carriage is spring actuated, other means to extend the gun from the compartment such as a gas piston or using elastomeric elements can be employed without departing from the present invention.
FIG. 1 shows a preferred embodiment of a firearm release apparatus with compartment 110 atop mounting assembly 200 which allows installation to the floorboard of a vehicle. An angle adjustment plate 230 allows mounting plate 210 to attach to non-level surfaces. In the figure shown, an extendable hand gun support projects from the compartment. Strap 138 is typically positioned behind the rear sight or between the hammer and back strap of the hand gun.
FIG. 2 is a side plan view of compartment 110 according to a preferred embodiment of the present invention depicting carriage release 124 , door release knob 120 and door release 122 .
FIG. 3 is a side view showing the interior of compartment 110 and carriage assembly 128 in a unextended position including extendable rail 130 , rail guide 136 , a coil spring 138 residing inside of the guide, hand gun support member 132 which is attached to an end of the extendable rail, and barrel post 134 projecting from the support member. Also shown are steady bracket 142 for cradling the rear sight and strap 144 . In order to install a hand gun in the compartment, the barrel of the gun is placed over post 134 which supports the gun substantially parallel to the extendable rail. The rear sight is placed beneath steady bracket 142 with strap 144 behind the rear sight, hammer or lower according to user preference
FIGS. 4 a and 4 b show rail 130 extended. Length of travel of support member 132 is determined by stop 140 which is a transverse peg fixed to the case walls by welding or other means.
FIG. 5 is a front plan view of the compartment showing door 111 . Typically the hinged 111 a door is held in place by door release 122 and is released by pressing against release knob 120 which forces the catching end of the door release abutting the door lip up and away from the door. When the carriage release lock 124 is disengaged, and the compartment door is closed and retained by the door release, rail 130 is tensionably forced against the rear of the door. Carriage release 124 includes a knob connected to a retractable spring pin (not shown) that when engaged, seats in recess 131 thereby arresting forward movement of the rail when the rail is in the unextended position. When it is desired that the apparatus be configured to release the hand gun when the release knob is pressed, the door must be unlocked as depicted. When the door is released, the rail is allowed to extend carrying the hand gun. In FIG. 6 for purposes of conciseness and clarity, the hand gun has been omitted. Door release 122 is a pivoting rocker plate or teeter board separate from the compartment held in place by a hinge pin (not shown) joined to the compartment. The door release is normally biased in a down position flush with the side panel of the compartment except when the proximal end is forced down by pressing release knob 120 causing the distal end of the door release normally in contact with the door lip to lift, permitting the door to swing open. The compartment door can be secured by rotating cam lock 123 a by key, which positions the cam lock plate behind fixed catch 125 .
FIGS. 7 a -7 e depict in sequence steps for compressing the extendable rail back into the compartment, which include disengaging carriage release 124 , pressing rail 130 into the compartment opening until the carriage release pin secures the rail by mating with recess 131 , and shutting the door.
FIG. 8 is an enlarged view of mounting post assembly 200 which includes a mounting plate 210 for attachment to the floor of a vehicle, angular adjustment plate 230 and support post 220 for insertion into post cup 112 of compartment 110 .
FIGS. 9 a and 9 b depict in sequence a vehicle mounted firearm release and actuation by striking release knob 120 with a knee.
Although the embodiment described herein shows a compartment sized for a hand gun, compartment 110 can be upsized to accommodate a larger firearm such as an assault rifle. In this case, the rifle would be supported transverse the carriage assembly rather than inline as depicted. Although in the embodiment depicted, extendable rail 130 is unitary, telescoping rails of whatever profile or nested tubing can be used without departing from the present invention. Likewise, although the release knob is rounded for ease of use, it is intended that other shapes and sized of release knobs or levers can be used with departing from the present invention.
FIGS. 10 and 11 depict an alternate embodiment according to the present invention for the secure retention and rapid release of a rifle. Like the embodiment intended for use with hand guns, it comprises a compartment 110 shown in dotted line and within the compartment an extendable gun support carriage 128 that automatically extends when carriage release lock is disengaged, release knob 120 is tapped and door release 122 is tilted thereby opening door 111 . The carriage which includes a rail 130 , rail guide 136 and gun support member 132 extends and exposes the rifle 300 in a ready state. No barrel post is employed with the alternate embodiment. Preferably the rifle is supported within the compartment by at least one yoke (y) as part of the support member 132 attached to the rail guide which at least partially surrounds a section of the rifle. A strap 144 of nylon webbing, plastic or other suitable material closes the gap of the yoke and ensures that the rifle is retained securely within the yoke after extension from the compartment. The strap is preferably fastened securely at one end to the yoke, while at the other end possesses a catch or fastening means which can be a snap, hook and loop fasteners, magnet, electromagnet or other means that will suggest themselves to those skilled in the art having access to this disclosure which is easily unfastened or unclasped, and which can be automatically released once the rifle is fully extended. It is conceivable that retention strap 144 can employ electromagnetic release means whereby current to an electromagnet clasp of the strap is discontinued once the pistol or rifle is fully extended from the compartment, thereby disengaging the strap from at least one attachment point. The compartment holding the rifle can be mounted on a wall, the inside roof of a vehicle, between vehicle seats or other suitable location. The compartment can possess a U-shape without side panels wherein portions of the firearm extend from the ends when stored; see FIG. 11 . In this configuration, the rifle is prevented by the yoke(s) from being removed through the ends of the compartment.
It should be understood that the drawings and detailed description herein are to be regarded in an illustrative rather than a restrictive manner, and are not intended to be limiting to the particular forms and examples disclosed. Accordingly, it is intended that this disclosure encompass any further modifications, changes, rearrangements, substitutions, alternatives, design choices, and embodiments as would be appreciated by those of ordinary skill in the art having benefit of this disclosure, and falling within the spirit and scope of the following claims. | An apparatus adaptable for use within a vehicle that secures a firearm and enables rapid release of the firearm. The apparatus possesses intuitive and accessible controls permitting hands free operation requiring no visual inspection during use so a user can maintain his or her gaze on a perceived threat and rapidly obtain access to the firearm in the ready state. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to instrumentation for rotating machinery. More particularly, the present invention relates to apparatus for monitoring and evaluating shaft vibration in terms of the ability of a bearing to withstand the vibrational motion.
A journal is that portion of a shaft which is supported by the bearings of the machinery. In a self-acting fluid film bearing, separation of the surfaces of the journal and bearing is effected by a lubricant film distributed between these surfaces by rotation of the journal. The resultant of all radial forces acting on the shaft is transmitted through this lubricant film and into the stationary structure of the apparatus through the bearings. If the resultant force exceeds the load-carrying ability of the bearing, metal-to-metal contact will occur at high relative surface speeds. This will result in catastrophic failure of the bearing and may destroy the associated apparatus.
A journal and bearing may experience both static and dynamic components of load during operation. The static component of load refers to the mean force over a large number of cycles of shaft revolution. The dynamic load refers to the rapid fluctuations of shaft radial force produced, for example, by an unbalance in the rotating shaft. The forces due to the dynamic component of load are superimposed upon the forces due to the static component of load. The time-varying dynamic forces produce alternating stresses in the bearing materials. Such alternating stresses are the primary cause of bearing metal fatigue which leads to loss of load-carrying ability in the bearing.
In the prior art, two methods have been employed to determine the severity of shaft vibrations. Seismic or accelerometer sensors have been employed casing-mounted on or near the bearings. In addition, conventional proximity probes have been employed either singly or in pairs to measure the relative motion between the bearing housing and the journal or its attached shaft.
The output of a seismic or accelerometer sensor is only indirectly related to the dynamic forces acting on the journal itself. That is, the bearing housing responds to the dynamic forces transmitted through the fluid film to the bearing housing as modified by the effective mass, stiffness and damping of the support structure. Thus, in order to determine the actual force on the journal, the result must be calibrated either through experience, test or theory to relate the level of housing vibration to the actual bearing load. Furthermore, such calibration may have to be performed on each different type of bearing housing and mounting arrangement due to the changes that these and other factors may have on the relationship between bearing housing motion and bearing load.
Measurements of shaft motion relative to the bearing housing using proximity sensors produce an ambiguous measure of bearing dynamic load. A given level of shaft vibration can correspond to a wide variety of dynamic loads. The relationship between shaft motion and dynamic load may depend on such factors as the type, size and geometry of the bearing together with its operating conditions of speed, static load and lubricant viscosity. Thus, for a given level of shaft vibration, an acceptable bearing load may be produced under certain operating conditions and an unacceptable load may be produced under another set of operating conditions.
In addition, proximity sensors as used in the prior art have produced signals related to the motion of the shaft along one axis. If this axis is not aligned with the axis of maximum displacement of the shaft, an imperfect measurement of shaft vibrational motion is produced. Shaft vibrational motion follows an elliptical path having a major and a minor axis. Thus, an arbitrarily located proximity sensor is unlikely to be aligned with the major axis and to thereby sense maximum vibratory motion. An an added complication, the axes of the ellipse may rotate under changes in conditions of shaft speed and static load. In this case, it is not possible to position a proximity sensor along an axis which is aligned with the major axis of the ellipse under all conditions.
Two proximity sensors are often employed disposed with their sensing axes 90 degrees to each other. However, in this typical arrangement, each proximity sensor still produces readings which are related only to the shaft motion along its axis and, except for temporary fortuitous orientation of the elliptical axes of shaft motion, fail to produce signals related to maximum displacement of the journal in the bearing.
The American Petroleum Institute publishes standards describing proximity probe installation requirements (API 670), allowable shaft vibration for mechanical equipment such as steam turbines (API 612), gas turbines (API 616) and gears (API 613). The information in these standards are included herein by reference.
The individual signals from a pair of proximity probes are sometimes combined by displaying them together on an instrument such as an oscilloscope. This provides a visual display of the elliptical shaft orbit for a pair of proximity probes oriented 90 degrees to each other. With such an instrument arrangement, the maximum vibratory displacement or major axis of the elliptical shaft orbit may be measured.
Even when maximum vibratory displacement is determined, however, only a partial answer to the possibility of bearing destruction is obtained. For a given bearing type and size, the magnitude of bearing dynamic force depends upon both the maximum vibratory displacement, the orientation of the elliptical orbit and the mean position of the journal relative to the bearing.
The mean position of the journal is determined by the static component of journal load. The mean journal position also establishes the dynamic bearing coefficients. These coefficients, together with the shaft vibration parameters defining the shaft orbital motion, establish the maximum force on the bearing. Conventional monitoring systems employing proximity sensors do not consider these factors and therefore are incapable of providing a measure of dynamic bearing load.
OBJECTS AND SUMMARY OF THE INVENTION
Accordingly, it is an object of the invention to provide a shaft vibration evaluator which overcomes the drawbacks of the prior art.
It is a further object of the invention to provide a shaft vibration evaluator for fluid film journal bearing shaft or journal motion along orthogonal axes to determine the parameters of an elliptical vibratory motion of the shaft or journal as well as the position of the shaft or journal due to the static component of load. Measurement of the mean journal position establishes the bearing spring and damping coefficients. From these coefficients and the parameters of motion of the vibrating shaft, the dynamic journal load can be determined and its severity evaluated.
According to an aspect of the invention there is provided a shaft vibration evaluator for evaluating dynamic loading imposed on a bearing in a fluid film journal bearing, comprising means for sensing lateral displacement of the shaft with respect to the bearing along first and second angularly spaced apart axes to produce first and second displacement signals, means responsive to the first and second displacement signals for calculating ellipse parameters of an elliptical orbit of an axis of the journal, means for calculating a set of spring and damping coefficients of the fluid film journal bearing, and means responsive to the ellipse parameters and the spring and damping coefficients of the fluid film journal bearing, and means responsive to the ellipse parameters and the spring and damping coefficients for calculating a value related to a dynamic load on the bearing.
According to a feature of the invention there is provided a method for evaluating a dynamic loading imposed on a bearing in a fluid film journal bearing comprising sensing lateral displacement of the shaft with respect to the bearing along first and second angularly spaced apart axes to produce first and second displacement signals, calculating ellipse parameters of an elliptical orbit of an axis of the journal in response to the first and second displacement signals, calculating a set of spring and damping coefficients of the fluid film journal bearing, and calculating a value related to a dynamic load on the bearing in response to the ellipse parameter and the spring and damping coefficients.
The above and other objects, features and advantages of the present invention will become apparent from the following drawings, in which like reference numerals designate the same elements.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional view of a fluid film journal bearing to which reference will be made in explaining the principle of operation of the present invention.
FIG. 2 is a schematic diagram identifying the axes and orbital parameters of a shaft center locus due to unbalance in the shaft or its load.
FIG. 3 is a cross section of a fluid film journal bearing to which reference will be made in describing the spring and damping coefficients employed in the present invention.
FIG. 4 is a simplified block diagram of a shaft vibration evaluator according to an embodiment of the present invention.
FIG. 5 is a set of curves showing the outputs of proximity sensors of FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, there is shown, generally at 10, a fluid film journal bearing wherein the clearances between the elements are exaggerated for purposes of description. Journal bearing 10 represents only one of a number of types of bearings to which the present invention may be applied. In journal bearing 10, two semi-cylindrical bearing surfaces 12 and 14 have a common center Ob. Lubricant feed grooves 16 and 18 are conventionally provided to permit the flow of lubricant between the surfaces of journal bearing 10. A journal 20 is positioned within bearing surfaces 12 and 14. A fluid film 22 of lubricant separates the surfaces of journal 20 and bearing surfaces 12 and 14 during rotation of journal 20. A static load 24 on journal 20 is indicated by an arrow for purposes of description.
When journal 20 is stationary, static load 24 squeezes lubricant fluid film 22 from between journal 20 and bearing surface 14 into the position of surface 26 shown in solid line wherein surface 26 directly contacts bearing surface 14. In this condition, a center Ojs of journal 20 is disposed along the direction of static load 24. When journal 20 begins to rotate, lubricant in fluid film 22 wedges between the surfaces to raise journal 20 a distance 28 against static load 24 and also to displace it a distance 30 to a new journal center Ojd so that the surface of journal 20 is repositioned to a location 26' shown in dashed line. The dynamic journal center Ojd is the position that the center of journal 20 would maintain in the absence of vibratory motion. In general, however, the center of journal 20 exhibits vibratory motion about its dynamic center Ojd.
If journal 20 were operated under zero load with zero vibration, the journal dynamic center Ojd would coincide with bearing center Ob. In this condition, a uniform total bearing ground clearance c would exist between the surface of journal 20 and bearing surfaces 12 and 14. Ground clearance c, in this condition, is equal to the difference between the radii of journal 20 and bearing surfaces 12 and 14. The presence of static load 24 displaces the dynamic center Ojd of journal 20 from its no-load position by a distance e. An eccentricity ratio ε is equal to e/c.
The preceding description is equally applicable to elliptical or lemon bearings, bearings with more than two lubricant feed grooves, bearings with off-set or tilting pad bearing surfaces. A full description of the geometry and mathematical development of the parameters discussed herein is given in a paper, Estimating the Severity of Shaft Vibrations within Fluid Film Journal Bearings presented at the ASME/ASLE Lubrication Conference on Oct. 5-7, 1982 in Washington, D.C. by the present inventor. The disclosure of such paper including the references cited therein is herein included by reference.
Referring now to FIG. 2, a greatly exaggerated representation of the motion of journal 20 is shown. An x axis is aligned with static load 24 and a y axis is disposed at 90 degrees thereto. At zero unbalance, the center of the journal is stationary at the journal dynamic center Ojd. In the presence of an unbalance, the center of the journal typically describes an elliptical trajectory 32 which has a major axis disposed at an angle α from the x axis and a minor axis b displaced an angle α from the y axis. For convenience, the ellipse major and minor axes are identified as rotated axes x' and y'.
For a rotation rate ω, the projections of the shaft center position along the x' and y' axes are given by the following:
x'=a cos (ωt-α)
y'=b sin (ωt-α)
It will be clear that these values for x' and y' can be converted to values in the x, y coordinate system employing functions of a, b and α.
Referring now to FIG. 3, the force transmission between journal 20 and bearing surfaces 12 and 14 can be derived employing direct damping coefficients B xx and B yy and cross coupled damping coefficients B yx and B xy as well as direct spring coefficients for the fluid film K xx and K yy with cross coupled spring coefficients for the fluid film K yx and K xy . The foregoing direct and cross coupled coefficients have the directions shown in FIG. 3. As noted in the foregoing referenced paper, the force exerted on the bearing in the x and y directions is as follow:
Fx=K.sub.xx x+B.sub.xx x+K.sub.xy y+B.sub.xy y
Fy=K.sub.yy y+B.sub.yy y+K.sub.yx x+B.sub.yx x
Where:
Fx=force along x axis
Fy=force along y axis
K xx , K yy , K xy , K yx =direct and cross coupled spring coefficient
B xx , B yy , B xy , B yx =direct and cross coupled damping coefficients.
The derivation of the direct and cross coupled spring and damping coefficients are given in a paper Calculation Method and Data for the Dynamic Coefficients of Oil Lubricated Journal Bearings presented by J. W. Lund and K. K. Thompson in an ASME Spec. Publ., Topics in Fluid Film Bearing and Rotor Bearing System Design and Optimization in 1978. Since the derivation of these coefficients is well known in the art as shown by citation of a publication, such derivation will not be given herein.
The forces along the x and y axes can be combined to produce a radial force as follows:
F.sub.r =(F.sub.x.sup.2 +F.sub.y.sup.2)1/2
Where: F r =radial force.
As described in the ASME/ASLE paper, a resulting equation relating maximum force to the ellipse parameters is as follows: ##EQU1## Where: (F r )max=maximum radial force
w=static load 24
c=bearing ground clearance
a=ellipse major axis
α=angular displacement of ellipse axes x' and y' from coordinate axes x and y
A, B, C, D: dimensionless constants.
Dimensionless constants A, B, C, and D, on the right hand of the above equation are a function of three factors:
1. The spring and damping coefficients which are a function of bearing geometry and operating conditions and, for a given bearing at a known eccentricity ratio ε, have fixed values;
2. The ratio of the major to minor axes a/b of the ellipse; and
3. The angular displacement α of the ellipse axes.
The left side of the foregoing equation contains the known quantities: bearing ground clearance c, static load W, ellipse major axis a, and angular displacement of ellipse axes α. Thus, if a maximum radial force (F r )max can be specified then the maximum vibrational amplitude represented by the ellipse major axis a may be specified for the related bearing ground clearance c and ellipse angular displacement α.
Although the invention should not be considered limited by the following parameters, it may be noted that a practical vibration trip level may be reached when shaft vibration exceeds about thirty percent of the bearing ground clearance c. For a cylindrical bearing of FIG. 1, a representative ground clearance c may be from about 0.0015 to about 0.003 times the journal diameter. For purposes of calculation, it is assumed that the ground clearance is 0.0025 and the thirty percent factor is applied. Thus, the peak-to-peak shaft vibration along the major axis a of the ellipse should be limited to about 0.00075 times the journal diameter. This rule of thumb is given for illustrative purposes only and it must be understood that such results may be modified by data from a detailed evaluation of the specific bearing type, size, static load W and operating eccentricity ratio ε.
Referring now to FIG. 4, a shaft vibration evaluator, shown generally at 34, includes first and second proximity sensors 36 and 38 mounted on the bearing housing (not shown) adjacent a shaft 40. As noted, proximity sensor 36 is disposed along the axis of static load 24 corresponding to the x axis previously described. Similarly, proximity sensor 38 is aligned on the y axis. Proximity sensors 36 and 38 may be of any convenient type but preferably are electromagnetic devices providing analog outputs related to the distance to the surface of shaft 40. This distance changes as the center of shaft 40 describes an ellipse 42 shown in dashed line due to external or internal unbalance. An analog signal from proximity sensor 36 is applied on a line 44 to an X analog to digital converter 46 wherein the proximity of shaft 40 to proximity sensor 36 is digitized and the corresponding digital values are applied on a line 48 to an input of an ellipse parameter calculator 50. Similarly, the proximity of shaft 40 to proximity sensor 38 along the y axis is applied on a line 52 to a Y analog to digital converter 54 which produces corresponding digital values on a line 56 to a second input of ellipse parameter calculator 50.
Referring momentarily to FIG. 5, the x and y outputs of proximity sensors 36 and 38 are shown. It will be noted that the peak amplitudes of these signals differ and that they are displaced in time by a phase angle difference φ. From a knowledge of the maximum values of x and y, Xmax and Ymax, and the phase angle difference φ, coupled with a knowledge of the bearing loading and the ellipse parameters, namely the major axis dimension a, the minor axis dimension b and the angular displacement α of the ellipse axes from coordinate axes x and y can be determined by ellipse parameter calculator 50 (FIG. 4). These ellipse parameters are applied on a line 58 to an input of a dynamic load calculator 60.
A bearing spring and damping coefficient calculator 62 calculates a set of four spring coefficients and four damping coefficients based on eccentricity ratio ε and the known parameters of the journal bearing. Eccentricity ratio ε may be developed in a number of different ways, one of which is shown in FIG. 4. A temperature sensor 64 produces a signal on a line 66 related to the lubricant temperature in the bearing which is applied to a bearing eccentricity calculator 68. From the known characteristics of the lubricant being used and its temperature, the lubricant viscosity may be derived in bearing eccentricity calculator 68. In addition, a measure of shaft speed is applied on a line 70 to bearing eccentricity calculator 68. Shaft speed may be sensed in any convenient manner including electrooptical, mechanical, electrostatic or other conventional means. On the assumption that shaft 40 performs its elliptical motion at the same speed as the shaft rotates, the output from proximity sensor 36 or 38 may be employed in bearing eccentricity calculator 68 to determine the rotational speed of shaft 40. Given the speed and lubricant viscosity along with bearing ground clearance and other parameters, bearing eccentricity calculator 68 is capable of calculating eccentricity ratio ε which is applied on a line 72 to bearing spring and damping coefficient calculator 62.
Referring momentarily to FIG. 1, a further way of calculating eccentricity ratio ε is illustrated. When journal 20 is stationary, the journal static center Ojs is disposed along the load line spaced apart from the bearing axis Ob by a distance equal to the ground clearance c. As journal 20 is rotated to its running speed, the average or DC position of the journal center moves to the dynamic journal Ojd. If the oscillatory component of the outputs of proximity sensors 36 and 38 are filtered to leave the remaining DC or mean component, the raise distance 28 and displacement distance 30 become known. Thus, the mean position of the journal dynamic center Ojd is also known. From this and the known of the bearing center Ob, the radial distance e from the bearing center to the mean dynamic journal center can be calculated. Since eccentricity ratio ε=e/c, and ground clearance c is known, the value of bearing eccentricity ratio ε is known. Other means for calculating or deriving eccentricity ratio ε may be employed without departing from the spirit of the present invention.
The spring and damping coefficients are applied on a line 74 to a second input of dynamic load calculator 60. Dynamic load calculator 60 performs the computations previously described to produce a measure of the dynamic load applied by the journal to the bearing surface and applies the resulting value on a line 76 to a dynamic load indicator 78. The measure of dynamic load on line 76 may be of any convenient type such as, for example, pressure, force, the ratio of load to a load limit or any other useful dynamic load parameter which may aid the operator of the system in evaluating the effect of the dynamic load on the system. For a further discussion of some of the ways in which the dynamic load calculation may be employed, reference may be had to the above cited paper by the present applicant. Dynamic load indicator 78 may be of any convenient analog or digital type or, alternatively, may include a storage or data transmission apparatus for local or remote storage and/or indication. For example, dynamic load indicator 78 may be an analog pointer-type indicator which indicates, for example, the percentage of allowable dynamic load being produced at a given time.
The signal processing in FIG. 4 may be performed by any convenient apparatus including a digital processor and, in the preferred embodiment, the calculations are performed by a microprocessor supported with appropriate conventional input and output signal conditioning devices.
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. | A shaft vibration evaluator employs measured displacement of a shaft in the vicinity of a bearing together with known or measured shaft eccentricity to calculate the dynamic bearing load so that damaging loads can be avoided. Shaft vibration or motion is assumed to be elliptical having major and minor axes which are inclined at angles with respect to the bearing displacement sensors. The magnitude of the major and minor axes and the angular displacement are calculated from the measured parameters and provide one set of inputs to the load calculator. Bearing eccentricity can be calculated from a knowledge of shaft speed, lubricant temperature and known bearing geometry. For a given eccentricity, a set of four damping coefficients and four spring coefficients of the bearing may be derived. These coefficients are the remaining inputs to the dynamic load calculator. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to an error correction device for a printer and, more particularly, to an error correction member positioning system for an error correction device in a printer which smoothly detaches an error correction member from a recording paper after erasing an error such as a mistyped character.
In conventional typewriters, various types of error correction devices have been developed for correcting errors such as mistyped characters. In general, the conventional error correction devices are operated as follows. First, a carriage carrying a printing head and the error correction device is returned at the position of a mistyped character on a recording paper by operating a back space mechanism. When the carriage reaches the position of the mistyped character, a specific key such as an erase key is depressed so that a printing type character corresponding to the mistyped character is selected from the type wheel (or an erase printing type is selected). At the same time, an error correction tape of the error correction device is lifted up to a correcting position from a normal position, and thereafter, the selected printing type is typed over mistyped character through the error correction tape, so that the mistyped character is erased.
Two types of error correction tapes are generally used for erasing the mistyped character. One is a correction tape having an adhesive material on its surface. The erasing of the mistyped character is excuted in such a manner that the ink, which forms the mistyped character, on the recording paper is removed from the recorded paper by typing the selected printing type character corresponding to the mistyped character. Because the ink on the recorded paper adheres to the adhesive material of the error correction tape, the ink is removed from the recording paper erasing the mistyped character. A second type of error correction tape includes adhesive, white pigments. The erasing of the mistyped character is excuted in such a manner that the adhesive white, pigments are attached to the typed ink on the recording paper when pressing the recording paper against the error correction tape with the selected printing type character.
After erasing the mistyped character, the error correction tape is directly moved down from the correcting position to the normal position. Following the down movement of the error correction tape, a correct printing type character corresponding to a desired character is selected and is typed, so that the correct character is typed through an ink ribbon on the position at which the mistyped character was present. The erasing operation of the error correction tape is thereby completed.
Conventionally, as soon as the error correction tape is lifted up at the correcting position and the mistyped character is erased by typing the selected printing type character through the error correction tape, the error correction tape is directly moved down. Accordingly, as shown in FIG. 1, a tape surface 2 of the error correction tape 1 which is depressed for erasing the mistyped character may become rumpled. Tension rollers 3 and 4 are provided for tensioning the error correction tape 1 in the horizontal direction. The ends of the error correction tape 1 are connected to a tape supply spool at the side of the tension roller 3 and a tape storing spool at the side of the tension roller 4.
The reason why the error correction tape may become rumpled is as follows: When the tape surface 2 carrying the adhesive, material or the adhesive white pigments is pressed into contact with the recorded paper by impacting the recording paper with the selected printing character type, the recording paper and the tape surface 2 are attached. In this condition, the error correction tape 1 is directly moved down and is forcibly removed from the recording paper. Therefore, because the tape surface 2 may become rumpled, the following problems may happen. When removing the tape surface 2 from the recording paper, the printing type character of the type wheel may become caught in the rumpled tape surface 2. Also, the error correction tape 1 may not move smoothly down, and further, may not be smoothly wound by the tape storing spool. Accordingly, the above problems impair the operation of the printer.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an improved error correction member drive system for a printer which enables a suitable error correcting operation of an error correction device in the printer.
It is another object of the present invention to provide an improved error correction member drive system in a printer which quickly carries out the movements of the error correction member without impairing the printing operation of the printer.
It is still another object of the present invention to provide an improved error correction member drive system in a typewriter which enables a suitable error correction of an error correction device without damaging the printing operation of the typewriter.
It is a further object of the present invention to provide an improved error correction member drive system in a printer for automatically separating a correction member from a recording paper after a mistyped character is removed from the typed paper, in such a manner that the correction member is automatically forwarded and backed spaced by the same distance.
Other objects and further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. It should be understood, however, that the detailed description of 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.
To achieve these objects, according to an embodiment of the present invention, a correction member drive system for a printer in which an error such as a mistyped character on a recorded member is erased by an error correction member comprises means for positioning a correction member at a first position, means for typing a type character corresponding to the character typed in error through the error correction member on the recording member to thereby erase the error, means for separating the error correction member from the recording member, and means for automatically forwarding the error correction member by a predetermined distance.
The preferred embodiment further comprises means for automatically backing the error correction member up to the erased position, and means for positioning the error correction member at normal storage position.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be better 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 perspective view of an error correction tape, illustrating the rumpled condition that occurs in conventional error correction member drive systems;
FIG. 2 is a side elevational view of a typewriter including an error correction device according to a preferred embodiment of the present invention;
FIG. 3 is a perspective view of an error correction member used in the typewriter of FIG. 2;
FIG. 4 is a block diagram for a control circuit of the typewriter of FIG. 2; and
FIG. 5 is a flowchart of the operation of the error correction device.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 2 shows in side elevation a typewriter including an error correction device according to a preferred embodiment of the present invention. FIG. 3 shows in perspective an error correction member used in the typewriter of FIG. 2.
In the typewriter of FIGS. 2 and 3, a platen 10 is rotatably provided around an axis 10'. A recording paper 100 is inserted from a paper inserting section at the back side and the upper side of the platen 10 and is forwarded to a printing position facing a printing device. The recording paper 100 is forwarded along the surface of the platen 10 by rotation of the platen 10.
Under the platen 10, a plurality of feed rollers (not shown) are rotatably provided around an axis parallel with the axis 10' of the platen 10 and are in contact with the surface of the platen 10, so that the recording paper 100 is sandwiched between the platen 10 and the feed rollers. A plurality of paper pressing rollers (not shown) are rotatably provided around an axis parallel with the axis 10' of the platen 10. The recording paper 100 is pressed on the platen 10 by the plurality of paper pressing rollers so as to position the recording paper 100 at the printing position. After printing, the recorded paper 100 is taken from the paper take-out portion at the front side and the upper side of the platen 10.
A carriage carries the printing device, an ink ribbon 14, and an error correction device including an error correction tape 15, and reciprocates along an axis parallel with the axis 10' of the platen 10. The printing device includes a type wheel 13, a hammer 11, and a driving motor 12. The type wheel 13 has a plurality of different printing types, and is rotated around an axis connected to a rotating axis of the driving motor 12. Each of the printing types corresponds to each of the keys on the keyboard. The hammer 11 hits a printing type character selected in response to the actuation of a key of the keyboard 20 to print a character corresponding to the selected printing type character on the recording paper 100.
The ink of the ink ribbon 14 prints the character by impacting the selected printing type character from the type wheel 13 against the ink ribbon 14 by the hammer 11. The error correction device includes an error correction tape 15, tape tension rollers 103 and 104, a tape supply spool, a tape storing spool, a tape lift up/down mechanism, and a tape winding mechanism. The error correction tape 15 is impacted against the printing type character of the type wheel 13 by the hammer 11 so as to remove the ink character from the recording paper 100. The error correction tape 15 is extended by the tension rollers 103 and 104 in the horizontal direction. One end of the error correction tape 15 is connected to the tape supply spool, and the other end of the error correction tape 15 is connected with the tape storing spool. The tape supply spool 104 is operated by the winding mechanism for winding the error correction tape 15. The error correction tape 15 is wound in the arrow direction A. The error correction tape is lifted up and moved down by the lift up/down mechanism. The error correction tape 15 is moved between a normal, storage position B and a correcting position C by the tape lift up/down mechanism. In the normal printing mode of the printer, the error correction tape 15 is set at the normal position B. In the error correction mode of the printer, the correction tape 15 is set at the correcting position C.
The operation of the error correction device will now be described with reference to FIGS. 3, 4, and 5.
In FIG. 4, a keyboard 20 includes a plurality of different character keys. The signal corresponding to the depressed key is inputted to the controller 21. The type wheel 13 is driven by a wheel driver 25 to select one of the printing type characters corresponding to the depressed key in response to the controller 21. The hammer 11 is driven by a hammer driver 24 in response to signals from the controller 21, so that the selected printing type is hit by the hammer 11. The carriage is moved by a carriage driver 22 by the controller 21 so that the carriage reciprocates along the platen 10. The error correction tape 15 is moved up and down by the lift up/down mechanism driven by the correction tape driver 23 according to the controller 21. The tape storing spool at the side of the tension roller 104 is rotated by a winding driver.
In the present invention, after the error correction tape 15 is placed in contact with the recording paper 100 during an erasing operation (In this condition, the error correction tape 15 is indicated by a dotted line), the error correction tape 15 with the carriage is forwarded in the direction A (or in the horizontal direction) so that the error correction tape 15 is separated from the recording paper 100. Thereafter, the error correction tape 15 is moved down to the normal, storage position B.
Further, the error correcting operation of the error correction device when the mistyped character is erased will be described with reference to the flowchart of FIG. 5.
Step S1:
The carriage is returned at the position of the mistyped character by a back space mechanism (or a forward space mechanism). The back space mechanism is responsive to a signal outputted from the controller 21 by depressing a back space key of the keyboard 20. The carriage is moved by the carriage driver 22 in response to the controller 21.
Step S2:
The same printing type chamber as the mistyped character is selected from the plurality of printing type characters of the type wheel 13. Instead of using the same type character as the mistyped character, an erase-purpose printing element can be operated. The printing type character is selected by pressing a specific key such as an erase key on the keyboard 20.
Step S3:
When the specific key such as the erase key of the keyboard 20 is depressed, the output signal from the keyboard 20 is inputted in the controller 21. The correction tape driver 23 is driven in response to the output of the controller 21, so that the error correction tape 15 is lifted up to the correcting position C, and is wound by one character space by the tape storing spool.
Step 4:
After the error correction tape 15 is lifted up, the hammer driver 24 and the type wheel driver 25 are operated by the controller 21, so that the error correction tape 15 is pressed against the recording paper 100 by impacting the selected printing type character through the error correction tape 15 by the hammer 11, so that the printed character is removed from the recording paper 100.
Step 5:
After the mistyped character is thus erased, the carriage driver 22 is moved in response to signals from the controller 21. The carriage carrying the printing device and the error correction device is automatically moved in the horizontal direction (in the arrow direction A) by a predetermined distance to thereby separate the error correction tape 15 from the recording paper 100. The carriage is automatically moved in the winding direction of the error correction tape 15.
In this case, probably, only the error correction tape 15 need be moved in the direction A without moving the carriage. However, the movement of only the correction tape 15 causes a large load to the tape winding operation. Therefore, the tape winding mechanism is required to withstand a load more than the load applied from the movement of the error correction tape 15. The cost of the tape winding mechanism may be increased.
Because the error correction device with the carriage is automatically moved in the correction tape winding direction by the predetermined distance, the error correction tape 15 is easily separated from the recorded paper 100. Any additional mechanism need not be provided for the above purpose. Because the error correction tape 15 is moved in the horizontal direction to cause detachment from the recording paper 100, the error correction tape 15 does not become rumpled.
Step S6:
After the carriage is automatically forwarded by the predetermined distance to detach the error correction tape 15 from the recording paper 100, the carriage with the error correction device is automatically returned to the erase position by the predetermined distance according to the controller 21.
Step S7:
After the carriage is returned to the erase position, the error correction tape 15 is moved down from the correcting position C to the normal position B. The lift up/down mechanism of the error correction device is driven by the error correcting tape driver 23 according to signals from the controller 21. When the error correction tape 15 is moved down, the error correction tape 15 and the recording paper 100 have previously been detached from each other, so that the downward movement of the error correction tape 15 is smoothly carried out.
Step S8:
The type wheel 13 is set at the initialized position. The type wheel 13 is driven by the type wheel driver 25 according to the controller 21.
Step S9:
A correct character is typed by hitting a desired character key selected from the type wheel 13 and the keyboard 20. The selected printing type character is hit by the hammer 11 against the ink ribbon 14. The hammer 11 is driven by the hammer driver 24. The correct character is typed at the mistyped position on the recording paper 100. The error correcting operation is completed.
In the preferred embodiment, the carriage is automatically forwarded by the predetermined distance in the arrow direction A by the forward space operation after the erasing operation, and thereafter, the carriage is automatically moved back by the back space operation. For this purpose, the spool at the side of the tension roller 104 is operated as the tape storing spool. If the spool at the side of the tension roller 103 is operated as the tape storing spool, the carriage may be automatically moved back by the predetermined distance after the erasing operation, and thereafter, the carriage may be automatically forwarded to the erase position.
As described above, in accordance with the present invention, after the erasing operation, the carriage carrying the error correction tape is automatically forwarded in the direction of the winding of the correction tape to thereby separate the error correcting tape from the recording paper, and thereafter, the carriage is automatically moved back at the erased position. The error correction tape is moved down to the normal position when the carriage reaches at the erase position. Therefore, the error correction tape is smoothly separated from the recorded paper. The surface of the correction tape cannot become rumpled when the surface of the error correction tape is separated from the recording paper. Furthermore, the downward movement of the error correction tape is smoothly carried out.
A character erasing ribbon which erases the typed character may be used in place of the error correction tape.
The present invention is not limited to a typewriter, and can be applied to various printers.
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 are intended to be included within the scope of the following claims. | A correction member driving system for a printer in which an error such as a mistyped character on a recording member is erased by an error correction member in a sequence comprising the steps of positioning a correction member at a position operatively aligned with the printing error, typing a type character corresponding to the error through the error correction member on the recording member to thereby erase the error, and separating the error correction member from the recording member by automatically forwarding the error correction member by a predetermined distance. The preferred embodiment further comprises the steps of automatically backspacing the error correction member to the erase position, and returning the error correction member to a storage position. | 1 |
FIELD OF THE INVENTION
[0001] The present invention relates to hosiery, and especially to socks, treated with a soil release composition. The treated socks are constructed from yarns comprising polyester and polyester blends with cotton and other fibers. More particularly the treated socks comprise yarns of high moisture wicking capacity further comprised of fine filaments of a cross-section which enables moisture movement.
BACKGROUND OF THE INVENTION
[0002] Compositions for the treatment of fabrics to prevent soil re-deposition properties are known. Such compositions are known from European Patent number EP1225269 B1 assigned to CIBA Specialty Chemicals. These compositions have been shown effective when used with cotton containing textiles of 30 to 100% in mixtures with either polyester or polyamide. Pure synthetic fibers of polyester or polyamide are also usually treated by such compositions. Here the benefit sought is one of enhanced retention of the white color over multiple washing cycles, along with hydrophilicity and stain release. Yarns of high moisture wicking capacity such as those sold under the COOLMAX® brand name (INVISTA S.à r.l.), comprise fine polyester filaments with special cross-sections designed to achieve enhanced moisture movement properties. Such yarns are widely used in hosiery, especially socks. Often combined with other yarns such as cotton, along with portions of nylon and spandex, these yarns fill a niche in the manufacture of white athletic socks. A deficiency of fabrics comprising special cross section fibers is a dingy appearance, or less “white” appearance, over time after repeated home washings. This poor color appearance, lack of newness retention over time with numerous wearing and washings is noted by customers and provokes some return of goods to retail stores.
[0003] Due to the high retention of white appearance required for athletics socks after repeated consumer use, treatments to enhance the release of soil have been sought. Such treatments have been sought especially for apparel and for socks knit from yarns composed of polyester fiber having specialized cross-sections aimed at enhanced moisture movement. Socks of this type sold under the COOLMAX® brand name pass strict moisture management criteria to meet brand requirements. Potential added value for socks of this type could be derived from their enhanced maintenance of a white appearance.
[0004] Thus there is a need to develop an improved foot apparel product that meets both the high moisture management standards of the industry while improving color and newness retention.
SUMMARY OF THE INVENTION
[0005] The invention provides a treated garment comprising at least 50% polyester multifilament yarns. The multifilament yarns are comprised of filaments having a profiled individual filament cross section. The treated garment is given a treatment with a fluorine containing durable soil release composition. The treated garment is characterized by a wicking height at least 75 millimeters according to a vertical water wicking test method, a stain release rating of at least 3, as measured by AATCC (American Association of Textile Chemists and Colorists) Test Method 130-2000, and at least a 1.0 unit improvement in soil re-deposition according to the soil re-deposition test method provided herein. The treated garment may further comprise a balance of yarns selected from yarns comprising non-profiled individual filaments selected from natural cotton and synthetic polymer fibers: polyester, polyamide and spandex yarns. The treated garment may further comprise a sock or at least a pair of socks.
[0006] Further provided in accordance with the invention is a process for treating garments comprising at least 50% polyester multi-filament yarns comprised of filaments having a profiled individual filament cross section, and comprising the steps of: applying a fluorine containing durable soil release treatment in an aqueous exhaustion bath at greater than 5% based on weight of garments and less than 50 to 1 garments to bath ratio; dropping the treatment bath without an intervening rinse step; drying the garments in a tumble dryer or the equivalent of an automatic dryer; and curing garments while individually boarded at a temperature between 110° C. and 190° C. for time period of about 60 to about 90 seconds.
DETAILED DESCRIPTION OF THE INVENTION
[0007] According to one aspect of the invention, the applicants have found that a fluorine containing durable soil release composition applied as a final wet treatment on garments comprising a majority of profiled cross section filament yarns promotes the retention of garment whiteness and new appearance after extended wash cycles. An effective fluorine containing durable soil release composition for this treatment process is ZONYL® SRM (CIBA SPECIALTY CHEMICALS, Textile Effects, 3400 Westinghouse Boulevard, Charlotte, N.C. 28241, USA). The garments for which the inventive process is most effective comprise a high content of polyester multi-filament yarns. The balance of yarns with less than 100% polyester further comprise portions of cotton, polyamide (e.g. nylon 66 and nylon 6) yarns, polyester circular cross section filament yarns and spandex (e.g. LYCRA® and LYCRA® T400). A high content means greater than or equal to 50% and up to 100% polyester content. The filaments of these polyester yarns most effectively treated comprising profiled filaments. Herein, profiled filaments means having a non-circular cross-sectional shape as viewed normal to the long axis of the filament. One such profiled filament type is found in COOLMAX® yarns (INVISTA, S.a r.l.; Three Little Falls Centre, 2801 Centerville Road, Wilmington, Del. 19808 USA). COOLMAX® yarns have a special cross-section which provides “4 channels” in each filament and are known for highly effective moisture wicking properties due to the presence of these channels. Fabrics of these yarns may take on a dingy appearance, or less “white” appearance, over time after repeated home washings. The processes herein and the products treated accordingly, by contrast, do not have this poor color appearance or lack of newness retention over time with numerous wearing and washings.
[0008] More generally, this invention provides a treated garment comprising at least 50% by polyester (from polyethylene terephthalate synthetic polymer) multifilament yarns. The multifilament yarns are comprised of filaments having a profiled individual filament cross section. The treated garment is given a treatment with the fluorine containing durable soil release composition, ZONYL® SRM. The treated garment is characterized by a wicking height at least 75 millimeters according to a vertical water wicking test method, a stain release rating of at least 3, as measured by AATCC Test Method 130-2000, and at least a 1.0 unit improvement in soil re-deposition according to the soil re-deposition test method provided herein. The treated garment may further comprise a balance of yarns selected from natural cotton yarns; non-profiled individual filament polyester, polyamide and spandex yarns. The treated garment may further comprise a sock or at least a pair of socks. More generally, the treatment herein is provided for socks which have a mostly white colored visual aesthetic.
[0009] The process, provided in accordance with the invention, treats garments comprising at least 50% polyester multi-filament yarns comprised of profiled individual filaments and comprises the steps of: applying a fluorine containing durable soil release treatment in an aqueous exhaustion bath at greater than 5% based on weight of garments and less than 50 to garments to bath ratio; dropping the treatment bath without an intervening rinse step; drying the garments in a tumble dryer or the equivalent of an automatic dryer; and curing garments while individually boarded at a temperature between 110° C. and 190° C. for time period of about 60 to about 90 seconds. This process is effective in promoting whiteness retention after extended wash cycles. The whiteness retention property is demonstrated using a standard washing protocol and a synthetic standardize “dirt.” The test method measures the property of the treated fabrics to appear clean and not dingy without re-deposition of soil on the fabric from the wash water. The treated garments also meet a stain release requirement of at least 3 as measured by AATCC Test method 130-2000. The treated garments also meet a strict requirement for “whiteness” retention during the “boarding” or cure process and a strict moisture management standard. The moisture management standard is measured by a 125 mm (5 inch) water wicking height and 5 square centimeter spreading area known in the art for this category of hosiery (sock) product. Furthermore, the retention of the benefits of this fabric treatment is durable. Durable means the treatment benefit persists after extended wash cycles using standard stain release tests. Generally, these stain release tests are based on soil re-deposition, and the release of corn oil and mineral oil from the fabric of the garment.
Test Methods
[0000] Oil Repellency
[0010] Oil repellency ratings were determined according to Standard Test Method 118-2002 of the American Association of Textile Chemists and Colorists (AATCC). Oil repellency was tested by placing drops of hydrocarbon liquids of varying surface tensions on the fabric, then visually determining the extent of surface wetting. This test determines how well finished fabrics resist oily stains and wetting by organic liquids. Generally, the higher the oil repellency rating, the better the finished fabric's resistance to staining by oily substances. The standard test liquids are listed in Table 2.
TABLE 2 Standard Oil Repellency Test Liquids Surface Tension at 25° C. Rating Hydrocarbon (77° F.) (dyn/cm) 1 Refined Mineral Oil 31.0 2 Refined Mineral Oil/n-Hexadecane 29.2 65/35 vol % at 21° C. (70° F.) 3 N-Hexadecane 27.3 4 n-Tetradecane 26.2 5 n-Dodecane 24.6 6 n-Decane 23.6
[0011] Different types of wetting may be encountered, depending on the fabric's finish, fiber, or construction. With many fabrics, the endpoint rating is obvious because the fabric will completely resist wetting by one test liquid, but will allow immediate penetration by the next liquid. With some fabrics, however, endpoint determination can be difficult. These fabrics will show progressive wetting by several test liquids, as shown by a partial darkening of the fabric at the liquid/fabric interface. On black or dark fabrics, wetting can be detected by a loss of “sparkle” within the drop. For fabrics where the endpoint is difficult to determine, the endpoint is considered to be the test liquid that causes complete darkening at the interface within 30 seconds.
[0012] Fabric samples were placed face up on white blotting paper which rested on a flat horizontal surface. Drops of standard test liquid, beginning with the test liquid having a rating of 1, were applied to the test fabric in five locations. Each drop was approximately 5 mm in diameter or 0.05 milliliters in volume. The drops were observed for 30 seconds from an approximate angle of 45°. If at least three of the five drops were not observed to wet or penetrate the fabric and did not show wicking around the drops, the test was repeated on an adjacent site using the test liquid having a rating of 2. The procedure was continued until at least three of the five drops wet or showed wicking into the fabric within 30 seconds. The fabric's AATCC oil repellency rating was determined to be the highest numbered liquid for which at least three of the five drops did not wet or wick into the fabric. Half point ratings may be given, for example 4.5 for a borderline pass on test liquid 5. An example of a borderline pass is where three or more of the five drops are rounded, however there is partial darkening of the specimen around the edge of the drop. In the United States, a commonly accepted level of oil repellency is a rating of 3.
[0000] Stain Release Rating
[0013] The AATCC stain release rating was determined according to Standard Test Method 130-2000 of the American Association of Textile Chemists and Colorists (AATCC). Fabric samples were placed flat on new AATCC Textile Blotting Paper on a smooth, horizontal surface. Five drops (0.2 milliliters total) of MAZOLA®D Corn Oil (ACH Food Companies Inc.) were placed on the fabric surface creating one single spot. A sheet of glassine paper was placed over the oil puddle, and a 2.27 kg (5 lb) weight was then placed directly over the glassine paper for 60 seconds. The weight and the glassine paper were removed, and the fabric sample was then washed for 12 minutes on normal wash cycle with high water level in a KENMORE® automatic using 100 grams of AATCC 1993 Standard Reference Detergent WOB. Wash temperature was 60° C., rinse temperature was cold. The total weight of the load was 4 lbs. After the final spin cycle, the entire load was placed in a KENMORE® automatic dryer and dried on high for 45-50 minutes.
[0014] Stain release ratings were determined by placing the stained, washed, and dried fabric flat in the center of a non-glare blacktop table with one edge of the table touching a Stain Release Replica (order number 08379, available from the AATCC). The fabric was viewed from a distance of approximately 76 cm (30 inches) and the residual stain was compared to the Stain Release Replica to the nearest 0.5 rating. Ratings are given from 1 (minimum) to 5 (maximum). In the United States, a commonly accepted level of stain release is a rating of 3.
[0000] Wicking Test Method
[0015] The moisture wicking of the yarns of the invention is determined by known methods, such as by a vertical wicking test or a horizontal wicking test. The vertical wicking test may be conducted by knitting the yarns into tubes, and then either scouring or treating the tubes with any desired agent and allowing the treated tubes to air dry. The tubes are then cut into 1 inch (25.4) wide strips about 8 inches (203 mm) long and suspended vertically above water with 3 inches (75 mm) in the water and 5 inches (125 mm) above the water. Observations of the height of the water being wicked up the strips are conducted visually at predetermined times, such as at 1 minute, 5 minutes, 10 minutes, 20 minutes and 30 minutes.
[0000] Individual Fluorine Percent on Weight of Fabric
[0016] The percent on weight of fabric for fluorine, represented as % owf F , is determined as follows. Fluorine on the fabric, represented here as F FAB , is measured by the well-known Wickbold torch method in parts per million (ppm). This value is then divided by the weight percent of fluorine in the fluorochemical, represented as F FC, to obtain the fluorine percent on weight of fabric for that fluorochemical:
% owf F =F FAB /F FC
When more than one fluorochemical is used, the total fluorine percent on weight of fabric is obtained by summing the individual fluorine percent on weight of fabric values for all fluorochemicals used.
Soil Re-Deposition Washing
[0017] Using a “Lab-Line” extraction mixer, prepare a 1% or 2% dispersed solution of DuPont Standard Dry Soil in 1 liter (L) of room temperature de-ionized (DI) water. Cut fabric samples 75 mm by 75 mm (3″ by 3″). Add soil solution to separatory funnel and place fabric samples in funnel, up to 6 samples per funnel. Agitate for 15 minutes at a setting of 20 cycles per minute. Drain soil solution into a 1 L beaker and discard. Rinse funnel with deionized (DI) water to remove residual soil on sides of funnel and drain. Add 1 L of 40° C. DI water to separatory funnel. Add 2.1 grams of TIDE® Free powder detergent. Agitate for 15 minutes at speed setting of 20 cycles per minute. Drain wash water into a 1 L beaker and discard. Add 1 L of 40° C. DI water to the funnel and agitate for 10 minutes at speed setting of 20 cycles per minute. Drain rinse water and discard. Add 1 L of room temperature DI water and agitate for 10 minutes at speed setting of 20 cycles per minute. Drain rinse water and discard. Remove samples and squeeze to remove excess water. Air dry for a minimum of 8 hours or until dry. Rate samples according to the Gray Scale, AATCC Evaluation Procedure 2.
[0018] Procedure for dispersing “dry soil” in water. The dispersed DuPont Soil Solution was made using a Research Model 01 Szegvari Attritor System. An 80% water/20% DuPont Dry Soil solution was made. The procedure uses 2 lbs. of 2 mm zirconium silicate grinding media at an operating pressure of 40 psi and a shaft speed of 600 rpm for two hours.
DuPont Standard Dry Soil** Component CAS Number wt % Peat Moss — 38 Cement 65997-15-1 17 Kaolin Clay, Peerless 1318-74-7 17 Amorphous Silica 7631-86-9 17 Mineral Oil 8012-95-1 8.75 Carbon Black 1.75 Red Iron Oxide 1309-37-1 0.50 **DuPont Standard Dry Soil may be purchased from Textile Innovators Corporation, 101 Forest St., Windsor, NC 27983, USA (252-794-9703) - synthetic soil prepared according to AATCC method for carpet soil tests.
EXAMPLES
[0019] In an example of the invention sock samples were knitted using the following construction details: 80% COOLMAX® (Type 729W) and 20% plating yarn consisting of 120 denier LYCRA® (902C) double covered with 70 denier 34 filament nylon 66 plus 40 denier 13 filament nylon 66 in the sock top, and 18 denier LYCRA® air jet covered with 2 plies of 70 denier 68 filament nylon 66 in the foot of the sock.
[0020] In an comparative example, sock samples were knitted using the following construction details: 63% COOLMAX® (Type 729W) in a 50/50 cotton blend and 37% plating yarns of 18 denier LYCRA® spandex air jet covered with 2 plies of with 2 plies of 70 denier 68 filament nylon 66 filament yarn.
[0021] All invention example socks were finished according to the following protocol: first a pre-scour for 15 minutes at 70° C. with 0.5 gram/liter Merol HCS (from Stepan Colo., 22 West Frontage Road, Northfield, Ill. 60063); 0.5 g/l trisodium phosphate and 0.5 g/l Lubit 64 (Lanxess Corp. 111 RIDC Park West, Pittsburgh, Pa.); next a water rinse (2 times); add water to 40/1 liquor ratio; add ZONYL® SRM based on a minimum of 5% (up to 10%) by weight of goods (garment weight); adjust pH to 5.5 with acetic acid; heat the bath to 43° C. and hold 20 minutes with agitation; drop bath; do not rinse garments and then tumble dry. Using standard boarding techniques the garments are individually boarded at 160° C. for between 90 seconds to assure product cure on the garment.
[0022] All comparative example socks were finished according to the following protocol: first a pre-scour for 15 minutes at 70° C. with 0.5 gram/liter Merol HCS, 0.5 g/l trisodium phosphate and 0.5 g/l Lubit 64; add PERMALOSE™ 3%; adjust pH to 6.0 with acetic acid; heat the bath to 60° C. and hold 10 minutes with agitation; drop bath; do not rinse garments and then tumble dry. Using standard boarding techniques the garments are individually boarded at 140° C. for 60 seconds.
[0023] Both comparative and invention example socks met the moisture wicking specifications for vertical rise of water, at least 75 mm.
[0024] The soiling ratings are given in the following tables 1 and 2. The Gray Scale ratings indicate relative “dinginess” of a white sock. In both cases where the invention examples were treated with ZONYL® SRM and challenged with a soil test of either 1% or 2% soiling, the invention examples were superior to the comparative examples.
TABLE 1 Using a 1% DuPont Soil Solution: 80% COOLMAX ® socks Gray Scale Rating Comparative Example 3.5 Treated with 5% ZONYL ® SRM 4.5 Treated with 10% ZONYL ® SRM 4.5
[0025]
TABLE 2
Using a 2% DuPont Soil Solution:
80% COOLMAX ® socks
Gray Scale Rating
Comparative Example
3.5
Treated with 5% ZONYL ® SRM
4.5
Treated with 10% ZONYL ® SRM
4.5 | A treated garment, especially white socks, treated with a soil release composition and a process for treating the garment are disclosed. A majority of polyester yarns from profiled cross section high moisture wicking capacity filaments are disclosed in a garment and sock construction which optionally includes other polyester yarns, polyamide yarns, cotton yarns and spandex. The garments so constructed and treated are rendered resistant to soil re-depositing after repeated wearing and washing cycles. | 3 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to a fan structure with externally connected circuit, and more particularly to a fan structure in which the circuit board is disposed on an outer face of the frame body.
[0003] 2. Description of the Related Art
[0004] A prior art discloses a cooling fan including a fan frame, a bearing system, a stator assembly and a rotor assembly. The rotor assembly is correspondingly disposed around the stator assembly. The rotor assembly and the stator assembly are both received in the fan frame. The fan frame includes a base section and a bearing cup upward protruding from a center of the base section of the fan frame. The top end of the bearing cup is an open end. The bearing cup is formed with a central receiving space. An annular groove is formed on inner circumference of the top end of the bearing cup in communication with the receiving space. The inner diameter of the section of the top end of the bearing cup that is formed with the annular groove is larger than the inner diameter of the other section of the bearing cup. The bottom face of the center of the base section of the fan frame is recessed to form a cylindrical receiving sink opposite to the receiving space of the bearing cup. The receiving sink is not in communication with the receiving space. The stator assembly is fitted around the bearing cup. A retainer ring is disposed on the shaft and fixed at the top end of the bearing cup. The stator assembly includes a circuit board and an armature composed of multiple stacked silicon steel sheets. A winding assembly is wound around the armature to produce alternate magnetic field. The winding assembly is electrically connected to the circuit board. Insulation plates are disposed on upper and lower sides of the armature to cover the same so as to avoid electrical contact between the armature and the winding assembly.
[0005] The above conventional cooling fan has the following shortcomings:
[0006] When the fan is driven to operate, the drive current will flow through the electronic components arranged on the circuit board. At this time, the electronic components will generate high heat. The circuit board is coaxially positioned under the armature and the space between the circuit board and the armature is limited so that the heat dissipation effect is poor. As a result, the lifetime of the electronic components arranged on the circuit board will be shortened. Moreover, the existent motor is generally designed with additional control function. Therefore, it is necessary to arrange additional components on the circuit board. In order to combine the drive function and the additional control function, it is necessary to integrate the original electronic components and the additional electronic control components onto the circuit board. However, the area of the circuit board for arrangement of the electronic components is limited to the maximum outer diameter of the motor. Therefore, it is hard to arrange the electronic components.
[0007] To overcome the above problem, another prior art discloses a cooling fan including a frame body and a fan impeller. The frame body has an air inlet face, an air outlet face, an inner wall, an axial flow passage and a support section. The air inlet face and the air outlet face are respectively formed on two sides of the frame body. The inner wall defines the axial flow passage, which passes through the frame body. The fan impeller is disposed in the frame body. Multiple blades are annularly disposed on outer circumference of the fan impeller. The support section is formed on at least one part of the frame body. The support section includes a first sidewall, a second sidewall and a support space. The first sidewall is formed of at least one part of the inner wall. The second sidewall is spaced from the first sidewall. The support space is defined between the first and second sidewalls to support a drive circuit board. Accordingly, the heat dissipation effect of the drive circuit board is enhanced and the axial thickness of the stator is increased so as to increase the output torque of the motor and the air volume of the fan.
[0008] However, the above conventional cooling fan has a shortcoming. That is, the support section is formed of a part of the frame body so that the thickness of the frame body is increased. In this case, it is difficult to arrange the fan in a limited space of a device. Moreover, the total weight of the fan is increased.
SUMMARY OF THE INVENTION
[0009] It is therefore a primary object of the present invention to provide a fan structure with externally connected circuit, in which the circuit board is disposed on an outer face of the frame body in contact with ambient air. Therefore, the room for the circuit board is increased without increasing the thickness of the frame body. In this case, more electronic components can be arranged on the circuit board. Moreover, the heat dissipation effect of the circuit board is enhanced.
[0010] To achieve the above and other objects, the fan structure with externally connected circuit of the present invention includes: a frame body having an air inlet end, an air outlet end, an inner wall, an outer wall, an axial flow passage and a seat section, the air inlet end and the air outlet end being respectively formed on two sides of the frame body, the axial flow passage being defined by the inner wall to pass through the frame body, the seat section being positioned in the axial flow passage and connected to the inner wall via multiple support sections; a stator disposed on the seat section; a fan impeller disposed on the seat section of the frame body corresponding to the stator, the fan impeller having multiple blades annularly arranged on an outer circumference of the fan impeller; and a circuit board disposed on the outer wall and electrically connected to the stator. The circuit board has a connection side snugly attached to a part of the surface of the outer wall or the entire surface of the outer wall and an outer side exposed to ambient environment. A solid body is formed between the inner wall and the outer wall.
[0011] In comparison with the conventional technique, the circuit board is disposed on an outer face of the frame body in contact with ambient air. Therefore, the room for the circuit board is increased without increasing the thickness of the frame body. In this case, more electronic components can be arranged on the circuit board. Moreover, the heat dissipation effect of the circuit board is enhanced.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The structure and the technical means adopted by the present invention to achieve the above and other objects can be best understood by referring to the following detailed description of the preferred embodiments and the accompanying drawings, wherein:
[0013] FIG. 1 is a perspective exploded view of the present invention;
[0014] FIG. 2 is a perspective assembled view of the present invention;
[0015] FIG. 3 is a sectional assembled view of the present invention; and
[0016] FIG. 4 is a perspective assembled view of another embodiment of the present invention, in which the circuit board is attached to the entire surface of the outer wall of the frame body.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] Please refer to FIGS. 1 , 2 and 3 . FIG. 1 is a perspective exploded view of the present invention. FIG. 2 is a perspective assembled view of the present invention. FIG. 3 is a sectional assembled view of the present invention. The axial-flow fan of the present invention includes a frame body 11 , which can be a square frame body or an annular frame body. The frame body has an axial flow passage 115 . When a fan impeller 13 rotates, airflow can flow through the axial flow passage 115 .
[0018] The present invention includes a frame body 11 , a stator 12 , a fan impeller 13 and at least one circuit board 14 . In this embodiment, the frame body 11 is, but not limited to, an annular frame body. Alternatively, the frame body 11 can be a square frame body. The stator 12 and the fan impeller 13 are disposed in the frame body 11 . The fan impeller 13 has multiple blades 131 annularly arranged on an outer circumference of the fan impeller 13 . The blades 131 radially outward extend from the fan impeller 13 . The fan impeller 13 is rotatable relative to the stator 12 . Each blade 131 has an air inlet side 1311 , an air outlet side 1312 and an outer side 1313 .
[0019] The frame body 11 has an air inlet end 111 , an air outlet end 112 , an inner wall 113 , an outer wall 114 , an axial flow passage 115 and a seat section 116 . The air inlet end 111 and the air outlet end 112 are respectively formed on two sides of the frame body 11 . The axial flow passage 115 is defined by the inner wall 113 to pass through the frame body 11 . The seat section 116 is positioned near the air outlet end 112 . Multiple support members 117 are connected between the outer circumference of the seat section 116 and the inner wall 113 to support and fix the seat section 116 in the axial flow passage 115 . A hollow bearing cup 1161 protrudes from the seat section 116 . A solid body is formed between the inner wall 113 and the outer wall 114 .
[0020] The stator 12 includes a silicon steel sheet assembly composed of multiple stacked silicon steel sheets. The silicon steel sheet assembly is disposed between an insulation support assembly. A winding assembly is wound around the silicon steel sheet assembly and the insulation support assembly. The stator 12 is fitted around the bearing cup 1161 and disposed on the seat section 116 .
[0021] The fan impeller 13 is disposed on the seat section 116 corresponding to the stator 12 . The air inlet sides 1311 of the blades 131 correspond to the air inlet end 111 of the frame body 11 , while the air outlet sides 1312 of the blades 131 correspond to the air outlet end 112 . The outer sides 1313 of the blades 131 correspond to the inner wall 113 .
[0022] The circuit board 14 is disposed on the outer wall 114 and electrically connected to the stator 12 . In this embodiment, the circuit board 14 has a connection side 141 snugly attached to a part of the surface of the outer wall 114 and an outer side 142 exposed to ambient environment. FIG. 4 shows another embodiment of the present invention, in which the circuit board 14 is snugly attached to the entire surface of the outer wall 114 .
[0023] The circuit board 14 can be attached to the outer wall 114 by means of adhesion.
[0024] Alternatively, a boss can be formed on the outer wall 114 and the circuit board 14 can be formed with a through hole corresponding to the boss for latching the circuit board 14 on the outer wall 114 . Still alternatively, a blind hole is formed on the outer wall 114 and a through hole is formed on the circuit board 14 corresponding to the blind hole. A screw member is passed through the through hole and screwed into the blind hole to lock the circuit board 14 on the outer wall 114 .
[0025] When the fan impeller 13 is driven by the circuit board 14 to rotate, airflow is driven to go from the air inlet end 111 of the frame body 11 through the axial flow passage 115 to the air outlet end 112 and then flow out from the air outlet end 112 . The heat generated by the circuit board 14 is partially dissipated from the outer side 142 of the circuit board 14 to the ambient air and partially transferred to the outer wall 114 in contact with the ambient air and then dissipated from the outer wall 114 to the ambient air. The circuit board 14 is not limited to be positioned on the base seat as in the conventional device. Instead, the circuit board 14 is disposed on an outer face of the frame body 11 in contact with ambient air. Therefore, there is more room for placing the circuit board 14 . In this case, more electronic components with various functions can be arranged on the circuit board 14 .
[0026] In conclusion, in the present invention, the circuit board 14 is directly disposed on the outer wall 114 of the frame body 11 . In comparison with the prior art, it is unnecessary for the frame body 11 to have additional receiving space for receiving the circuit board 14 . Therefore, neither the thickness nor the weight of the frame body 11 will be increased.
[0027] The present invention has been described with the above embodiments thereof and it is understood that many changes and modifications in the above embodiments can be carried out without departing from the scope and the spirit of the invention that is intended to be limited only by the appended claims. | A fan structure with externally connected circuit includes a frame body, a stator, a fan impeller and a circuit board. The stator and the fan impeller are disposed in the frame body. The circuit board is disposed on an outer face of the frame body in contact with ambient air. Therefore, the room for the circuit board is increased without increasing the thickness of the frame body. Moreover, the heat dissipation effect of the circuit board is enhanced. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to the use of pulverulent thermosetting coating compositions based on physical mixtures of individual isocyanato isocyanurates formed from aliphatic and (cyclo)aliphatic and/or cycloaliphatic diisocyanates and from polyesters containing hydroxyl groups and terephthalic acid for coil powder coating materials, to a process for producing such coatings, and to the metal coils coated with such coating materials.
[0003] 2. Description of the Background
[0004] Thermosetting powder coating compositions are used intensively for producing crosslinked coatings on a wide variety of substrates. Thermosetting coatings are generally harder than thermoplastic compositions, are more resistant to solvents and detergents, possess better adhesion to metallic substrates, and do not soften on exposure to increased temperatures.
[0005] Since 1970, thermosetting pulverulent materials have been known which are obtained by reacting a hydroxyl-containing resin with a blocked polyisocyanate. Of the blocked polyisocyanates, isophorone diisocyanate adducts blocked with ε-caprolactam have become established as curatives for PU powders. The PU powders prepared using these curatives are employed for coating a wide variety of articles made of metal, on account of their superior weathering stability and thermal color stability. Powders of this kind are described, for example, in DE 27 35 497. Using these powders, ready-formed metal components are coated piece by piece (post-coated metal).
[0006] Coil coating, on the other hand, is a process for coating metal coils at speeds from 60 to 200 m/min. Metal sheets, preferably of steel or aluminum, are cleaned and coated with a paint. These metal sheets are then passed on for further processing, where they acquire their actual form. The principal applications are trapezoidal profiles coated with weather-resistant paints, for roofs and facings of buildings, for example, and also doors, window frames, gates, guttering, and blinds. For the interior, coil-coated metal sheets are employed primarily for partition walls and ceiling elements. Other fields of use include steel furniture, shelving, shopfitting, and appliance casings. Lamps and light fittings form a further important application segment. There is also a broad applications pallet in the vehicle segment. Truck bodies and exterior-mounted automotive components are often manufactured from precoated materials.
[0007] For coating the substrate used, a pretreatment is generally conducted. As the first coating film, a primer is applied in a thickness of from 5 to 10 μm to what will subsequently be the visible side. Following the first pass through the dryer, the actual topcoat is applied. After drying it has a film thickness of approximately 20 μm. In some cases this surface is further laminated, while hot, with a temporary protective sheet. This is intended to protect it against mechanical injury. In parallel with the coating of the visible sides, the reverse sides as well are coated. Primers used include, for example polyester resins. For coil-coated facings and roofs under corrosive industrial atmospheric conditions, epoxy-containing systems are used as primers. As topcoat materials, liquid coating materials in innumerable colors are used primarily. Depending on the field of application, polyester, polyurethane or PVDF topcoat materials, for example, are employed. The film thicknesses of the topcoats are normally about 20 μm.
[0008] Besides the liquid primers and topcoats, powder coating materials are also used for the coil coating of metal coils. Powder coating materials have the great advantage over their liquid counterparts of being solvent-free and hence more ecological. However, their proportion among the coil coating systems has to date been relatively low.
[0009] One of the reasons was the high powder coating film thickness of more than 40 μm. This leads to optical defects, since the surface is no longer entirely free from pores. This drawback was eliminated by WO 97/47400. It describes a process for coating metal coils, with which powder film thicknesses of less than 20 μm can be obtained.
[0010] A second disadvantage as compared with liquid coating materials was the extremely slow coil speed during application of the powder coating material. Using electrostatic spray guns, metal coils can be coated with powder coating material only at line speeds of a maximum of 20 m/min. As a result of the MSC Powder Cloud™ technology, described, for example, by F. D. Graziano, XXIIIrd International Conference in Organic Coatings, Athens, 1997, pages 139-150 or by M. Kretschmer, 6th DFO Conference on Powder Coating Practice, Dresden, 2000, pages 95-100, coil speeds of from 60 to 100 m/min are now realizable.
[0011] PU powder coating materials are known, inter alia, for their high weathering stability, excellent leveling, and good flexibility. For use in coil coating, however, the flexibility of the systems known to date is often inadequate. Consequently, the search is on for new PU powder coating materials which satisfy the extreme flexibility requirement of coil coatings. Success in this search, if achieved, would remove the third critical disadvantage relative to conventional liquid coating materials.
[0012] EP 0 047 452 describes isocyanato isocyanurates, based on hexamethylene diisocyanate or isophorone diisocyanate, which following blocking of the NCO groups can be used as crosslinkers for producing flexible solvent-borne or pulverulent polyurethane coatings.
[0013] EP 0 132 518 describes a composition which is based on polyhydroxy components and trimers of 2-methylpentyl 1,5-diisocyanate, 2-ethylbutane 1,4-diisocyanate, and isophorone diisocyanate and which is a suitable binder for powder coating materials for the coating of heat-curable substrates.
[0014] DE 197 29 242 describes pulverulent binders comprising a hydroxyl-containing polyacrylate and physical mixtures of at least one aliphatic isocyanate component containing isocyanurate or urethane or biuret groups and at least one (cyclo)aliphatic isocyanate component containing isocyanurate and/or urethane groups and/or cycloaliphatic isocyanate component containing isocyanurate and/or urethane groups, whose NCO groups are blocked with ε-caprolactam.
[0015] The powder coating materials described in the aforementioned prior art are used exclusively for coating metal preforms. Their use for coating in accordance with the coil coating processes is not described.
SUMMARY OF THE INVENTION
[0016] Surprisingly it has been found that a selection of certain crosslinkers from those described above with certain hydroxyl-containing polyesters may be processed to binders which are suitable for coating metallic substrates by the coil coating process.
[0017] The invention accordingly provides for the use of polyurethane powder coating materials for coating metal coils by the coil coating process, wherein said materials comprise
[0018] A) an isocyanate component which is totally or partly blocked with ε-caprolactam and comprises physical mixtures of individual isocyanato isocyanurates of aliphatic and (cyclo)aliphatic and/or cycloaliphatic diisocyanates,
[0019] B) polyesters containing hydroxyl groups and terephthalic acid, and
[0020] C) if desired, customary auxiliaries and additives, and where there are 0.5-1.2 NCO groups of component A) per OH group of component B).
[0021] Thus, the present invention includes a process for coating metal coils, comprising:
[0022] coil coating a metal coil with a polyurethane powder coating material which is the reaction product of
[0023] A) an isocyanate component which is totally or partly blocked with ε-caprolactam and comprises physical mixtures of individual isocyanato isocyanurates of aliphatic and (cyclo)aliphatic and/or cycloaliphatic diisocyanates, and
[0024] B) one or more polyesters containing hydroxyl groups and terephthalic acid, and
[0025] wherein there are 0.5-1.2 NCO groups of A) per OH group of B).
[0026] The invention further provides metal coils coated with polyurethane powder coating materials by the coil coating process, wherein the polyurethane powder coating materials comprise
[0027] A) an isocyanate component which is totally or partly blocked with ε-caprolactam and comprises physical mixtures of individual isocyanato isocyanurates of aliphatic and (cyclo)aliphatic and/or cycloaliphatic diisocyanates,
[0028] B) polyesters containing hydroxyl groups and terephthalic acid, and
[0029] C) if desired, customary auxiliaries and additives, and where there are 0.5-1.2 NCO groups of component A) per OH group of component B).
[0030] 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.
DETAILED DESCRIPTION OF THE INVENTION
[0031] Starting compounds used for preparing isocyanate component A) are the isocyanato isocyanurates of diisocyanates of aliphatic and (cyclo)aliphatic and/or cycloaliphatic structure. By (cyclo)aliphatic diisocyanates the skilled worker understands NCO groups which are at the same time attached adequately both cyclically and aliphatically, as is the case for isophorone diisocyanate, for example. Cycloaliphatic diisocyanates, in contrast, are those which have only NCO groups attached directly to the cycloaliphatic ring. Diisocyanates of this kind are described, for example, in Houben-Weyl, Methoden der organischen Chemie, Volume 14/2, p. 61 ff. and J. Liebigs Annalen der Chemie, Volume 526, pp. 75-136, each of which is incorporated herein by reference. Preference is generally given to using the aliphatic diisocyanates which are easy to obtain industrially, such as hexamethylene diisocyanate, 2-methylpentamethylene 1,5-diisocyanate, 2-ethyltetramethylene 1,4-diisocyanate or trimethylhexamethylene 1,6-diisocyanate, especially the 2,2,4 and the 2,4,4 isomer and technical-grade mixtures of both isomers, the (cyclo)aliphatic diisocyanates such as isophorone diisocyanate, and the cycloaliphatic diisocyanates such as 4,4′-diisocyanatodicyclohexylmethane or norbornane diisocyanate.
[0032] The isocyanato isocyanurates are prepared conventionally as specified in GB 13 91 066, DE 23 25 826, DE 26 44 684 or DE 29 16 201, each of which is incorporated herein by reference. The process products are composed of isocyanato isocyanurate (trimer) with higher oligomers where appropriate. They have a total NCO content of from 8 to 22% by weight. This range for the NCO content includes all specific values and subranges therebetween, such as 10, 12, 14, 16, 18, and 20% by weight.
[0033] The isocyanate component A) employed in accordance with the invention is always composed of a physical mixture of at least one aliphatic isocyanato isocyanurate and at least one representative from the group consisting of (cyclo)aliphatic and cycloaliphatic isocyanato isocyanurates.
[0034] The ratio of the isocyanato isocyanurates of aliphatic diisocyanates to the sum of (cyclo)aliphatic and/or cycloaliphatic diisocyanates varies preferably from 70:30% by weight to 30:70% by weight. This range includes all specific values and subranges therebetween, such as 65:35, 60:40, 55:45, 40:60, and 35:65% by weight.
[0035] For carrying out the blocking reaction, the isocyanato isocyanurates are generally introduced as an initial charge and the ε-caprolactam blocking agent is added in portions. The reaction may be carried out without solvent or else in the presence of suitable (inert) solvents. It is preferred, however, to operate without solvent. The isocyanato isocyanurate mixture is heated to 90-130° C. At this temperature, the blocking agent is added conventionally. After the end of the addition of the blocking agent, the reaction is completed by heating of the reaction mixture at 120° C. for about 1 to 2 hours. The blocking agent is added in amounts such that from 0.5 to 1.1 mol of blocking agent, preferably from 0.8 to 1 mol, with particular preference 1 mol, are reacted per NCO equivalent of the isocyanato isocyanurate mixture. In order to accelerate the isocyanate polyaddition reaction it is possible to add the catalysts which are customary in polyurethane chemistry, such as organic tin compounds, zinc compounds or amine compounds, for example, in an amount of from 0.01 to 1% by weight, based on the total mixture.
[0036] The solvent-free blocking reaction may also be conducted continuously in a static mixer or advantageously in a multiscrew kneading apparatus, particularly in a twin-screw extruder.
[0037] The total NCO content of the isocyanate component blocked totally or partially with ε-caprolactam is from 8 to 22% by weight, preferably from 9 to 16% by weight.
[0038] The coating composition used in accordance with the invention is prepared using polyesters containing hydroxyl groups and terephthalic acid.
[0039] The polyesters B) containing hydroxyl groups and terephthalic acid that are to be used have an OH functionality of from 2.0 to 5, preferably from 2.5 to 4.2, a number-average molecular weight of from 800 to 8 000, preferably from 1 200 to 5 000, an OH number of from 20 to 200 mg KOH/g, preferably from 30 to 100 mg KOH/g, a viscosity at 160° C. of <80 000 mPa·s, preferably <60 000 mpa·s, and a melting point of ≧70° C. to ≦120° C., preferably ≧75° C. to ≦100° C. It is most preferable that terephthalic acid and/or esters of terephthalic acid are used as well, at least proportionally.
[0040] The proportion of the terephthalic acid, which is important to the invention, may vary greatly depending on the intended use, and so may be 1-100 mol %, preferably 5-100 mol %, based on all of the carboxylic acids or their esters or anhydrides that are used for preparing the polyester B). These ranges include all specific values and subranges therebetween, such as 2, 8, 10, 15, 20, 25, 30, 40, 50, 60, 75, 80, 85, 90, and 95 mol %.
[0041] The polyesters may be obtained conventionally by condensing polyols and polycarboxylic acids in an inert gas atmosphere at temperatures from 100 to 260° C., preferably from 130 to 220° C., in the melt or in an azeotropic regime, as described, for example, in Methoden der Organischen Chemie (Houben-Weyl), Vol. 14/2, 1-5, 21-23, 40-44, Georg Thieme Verlag, Stuttgart, 1963, in C. R. Martens, Alkyd Resins, 51-59, Reinhold Plastics Appl. Series, Reinhold Publishing Comp., New York, 1961 or in DE 27 35 497 and DE 30 04 903, each of which is incorporated herein by reference.
[0042] The mixing ratio of polyesters containing hydroxyl groups and terephthalic acid to blocked isocyanate component is generally chosen such that there are from 0.5 to 1.2, preferably from 0.8 to 1.1, with very particular preference 1.0 NCO group(s) per OH group.
[0043] For preparing PU powder coated materials the isocyanate component A) is mixed with the suitable polyester B) containing hydroxyl groups and terephthalic acid, and, where appropriate, with customary auxiliaries and additives C). Examples of auxiliaries and additives C) which can be used include catalysts, pigments, fillers, dyes, leveling agents, e.g., silicone oil and liquid acrylic resins, light stabilizers, heat stabilizers, antioxidants, glass enhancers, and effect additives. Components A), B) and C) are homogenized in the melt. This can be done in appropriate apparatus, such as in heatable kneading units, but preferably by extrusion, in the course of which temperature limits of 130 to 140° C. ought not to be exceeded. After cooling to room temperature and appropriate comminution, the extruded homogenized mass is ground to a ready-to-spray powder. Application of the ready-to-spray powder to suitable substrates can be carried out by the known methods, e.g., electrostatic powder spraying, fluidized-bed sintering or electrostatic fluidized-bed sintering. Following powder application, the coated workpieces are cured conventionally by heating in an oven at a temperature of from 160 to 250° C. for from 60 minutes to 30 seconds, preferably at from 170 to 240° C. for from 30 minutes to 1 minute. When using a coil coating oven, the curing conditions are commonly from 200 to 350° C. for from 90 to 10 seconds.
[0044] In order to increase the gelling speed of the heat-curable powder coating materials, catalysts can be added. Examples of catalysts used include organotin compounds such as dibutyltin dilaurate, tin(II) octoate, dibutyltin maleate or butyltin tris(2-ethylhexanoate). The amount of catalyst added is from 0.01 to 1.0% by weight, based on the total amount of powder coating material.
[0045] With the coating composition used in accordance with the invention it is possible to produce extremely flexible, overbakeable, and weathering-stable PU powder coatings and coil powder coatings.
EXAMPLES
[0046] Having generally described this invention, a further understanding can be obtained by reference to certain specific examples which are provided herein for purposes of illustration only and are not intended to be limiting unless otherwise specified.
[0047] A) Preparation of ε-caprolactam-blocked isocyanate components
Example 1
[0048] [0048] 699 . 8 g of Desmodur N 3300 (polyisocyanato isocyanurate based on hexamethylene diisocyanate, from Bayer) and 1 632.8 g of VESTANAT T 1890 (polyisocyanato isocyanurate based on isophorone diisocyanate, from Degussa) were heated to 100° C. 3.5 g of dibutyltin dilaurate were added. Subsequently, 1 163.9 g of ε-caprolactam were added in portions. An hour after the final portion of ε-caprolactam, the reaction was ended. Thereafter, the reaction mixture was cooled to room temperature. The reaction product had a free NCO group content of 0.4%, a total NCO content of 12.0%, and a melting range of 88-91° C.
Example 2 (Comparative)
[0049] 488.4 g of isophorone diisocyanate were heated to 110° C. with stirring and 68.3 g of monoethylene glycol were metered in. After a reaction time of 60 minutes, 249.1 g of ε-caprolactam were added. After a further 60 minutes, the product was cooled and comminuted. The reaction product had a free NCO group content of 0.2%, a blocked NCO group content of 11.4%, and a melting range of 65-75° C.
[0050] B) Polyester
[0051] A polyester of the following composition was used: as the acid component: 100 mol % dimethyl terephthalate; as alcohol components: 57.5 mol % monoethylene glycol, 0.5 mol % hexane-1,6-diol, 38.5 mol % neopentyl glycol and 3.5 mol % glycerol. The polyester had an OH number of 39 mg KOH/g, an acid number of 2.5 mg KOH/g, and a glass transition temperature of 60° C.
[0052] C) Polyurethane powder coating materials
[0053] General preparation procedure
[0054] The comminuted products—blocked polyisocyanate (crosslinker), polyester, leveling agent, devolatilizer, and catalyst masterbatch—are intimately mixed with the white pigment in an edge runner mill and the mixture is then homogenized in an extruder at up to 130° C. After cooling, the extrudate is crushed and ground to a particle size <100 μm using a pinned-disk mill. The powder thus produced is applied to degreased, iron-phosphated steel panels using an electrostatic powder spraying unit at 60 kV, and the applied coating is baked in a convection dryer or in a coil coating oven.
[0055] The formulations contain 30% by weight Kronos 2160 (titanium dioxide from Kronos), 1% by weight Resiflow PV 88 (leveling agent from Worlée-Chemie), 0.5% by weight benzoin (devolatilizer from Merck-Schuchard) and 0.1% by weight dibutyltin dilaurate (catalyst from Crompton Vinyl Additives GmbH). The OH/NCO ratio was 1:1.
TABLE 1 Data of white-pigmented PU powder coatings Crosslinker/ polyester A1/B1 A2/B1 (comparative) Baking conditions 200° C./10 min 241° C./70 sec 200° C./10 min 241° C./70 sec Film thickness (μm) 55-65 31-44 58-65 32-44 Gloss 60° angle 91 90 87 74-83 Cupping (mm) >10 — >10 — BI dir./indir. (inch · lb) >160/>160 — 80/20 — T-bend — 0 T — 1.5 T
[0056] Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
[0057] This application is based on German Patent Application Serial No. 101 59 768.1, filed on Dec. 5, 2001, and incorporated herein by reference in its entirety. | The use of pulverulent thermosetting coating compositions based on physical mixtures of individual isocyanato isocyanurates formed from aliphatic and (cyclo)aliphatic and/or cycloaliphatic diisocyanates and from polyesters containing hydroxyl groups and terephthalic acid for coil powder coating materials, to a process for producing such coatings, and to the metal coils coated with such coating materials. | 2 |
FIELD OF THE INVENTION
[0001] This invention relates generally to apparatus and methods of manufacturing and using a squeegee apparatus with machinery for applying solder paste to circuit connections, and more specifically, a method and apparatus for mounting the squeegee blade such that all four long edges are available for use instead of the typical two edges. The invention further relates to a method of setting up and aligning the squeegee blade to avoid errors due to deformation caused by clamping forces used to mount the resilient squeegee blade (typically made of rubber).
BACKGROUND OF THE INVENTION
[0002] Electrical connections between circuit components and a PCB (printed circuit board) or integrated circuit substrate are typically made by solder ball connections or by dipping the side of a board into molten solder. The PCB in combination with a screen mask or stencil is typically placed connector or back side up such that only related connections are exposed by the stencil or screen mask. The combination PCB and screen mask is placed on a machine such as a MicroStar BGA Solder Ball Attaching Machine. The machine then provides a selected volume of solder paste at one edge of the PCB in front of the squeegee apparatus. The squeegee apparatus is then placed so as to contact the PCB before it is moved across the PCB. As the squeegee moves across the PCB, it evenly distributes solder paste through apertures in the screen mask or stencil to the exposed connection points. Thus, the apertures assure that the selected connections will be coated by solder paste before they receive solder. To assure even distribution of the solder paste, the squeegee blade must be carefully aligned so that the squeegee edge contacting the PCB is parallel to the surface of the PCB. Since a straight and undamaged squeegee edge is necessary to assure the even distribution of the solder paste, the squeegee blade is frequently replaced and/or reoriented such that a new and undamaged edge is available. Further, since the squeegee blade is typically made of a resilient rubber, mounting of the squeegee blade must be accomplished with extreme care to assure that the edge of the squeegee blade that will contact the PCB is parallel to the PCB. In addition, prior art methods of mounting the squeegee blade typically require attaching the blade to holding apparatus by a plurality of bolts. However, the bolts must be carefully torqued or tightened to avoid deforming the rubber due to unequal pressure being applied by the plurality of bolts. Finally, significant amounts of solder paste may be wasted if it is allowed to flow around the ends of the squeegee and beyond the PCB.
SUMMARY OF THE INVENTION
[0003] One embodiment of the present invention provides method and apparatus for simplifying the mounting procedures to ensure a properly aligned edge of a squeegee blade and which also doubles the number of edges of the squeegee blade available for use. Another embodiment incorporates over flow end guards to prevent excess solder paste from running around the squeegee ends.
[0004] According to the present invention, there is provided methods and apparatus for applying solder paste to circuit connections comprising a squeegee blade having a pair of elongated face sides spaced apart by a selected thickness and a pair of elongated substantially parallel narrow sides spaced apart by a selected width. The elongated face sides and the elongated narrow sides join together at a squeegee operating edge. There is also included a slightly resilient clamping structure defining an elongated rectangular cavity for receiving the squeegee blade. The cavity has a depth less than the selected width of the squeegee blade's first and second longer sides which are separated by a short dimension which is less than the selected thickness of the squeegee blade. Consequently, the clamping structure can apply a gripping force to the squeegee blade when the blade is received within the cavity. Also included is a plurality of fasteners, such as threaded bolts, received by the clamping structure for adjusting the gripping force applied to the squeegee blade to hold the blade firmly into the clamping structure. Unlike the prior art squeegee blades, the squeegee blade of this invention is free of mounting apertures and consequently, each squeegee blade may be oriented such that there are four available edges to provide the squeegee action. Another embodiment of the apparatus further includes solder paste overflow guards which are located at each end of the squeegee blade and perpendicular to the squeegee blade such that solder paste cannot flow beyond the edges of the circuits and be wasted.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] [0005]FIG. 1 is a schematic or skeleton illustration of a squeegee apparatus for applying solder paste to circuit connections.
[0006] [0006]FIG. 2 is a cross-sectional illustration showing a squeegee operation of applying solder paste through a screen mask or template to selected circuit connections.
[0007] [0007]FIG. 3A is a side view and FIG. 3B is a front view of prior art squeegee apparatus.
[0008] [0008]FIG. 4 is an oblique view of the prior art squeegee blade of FIGS. 3A and 3B.
[0009] [0009]FIG. 5A is a side view and FIG. 5B is a front view of one embodiment of the squeegee apparatus of the present invention.
[0010] [0010]FIG. 6 is an oblique view of the squeegee blade of the squeegee apparatus of the present invention shown in FIGS. 5A and 5B.
[0011] [0011]FIG. 7 illustrates another embodiment of the present invention further including side guards to prevent the loss of excess solder.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0012] Referring now to FIG. 1, there is shown a schematic view of an apparatus for applying paste to connections on circuit boards which are to be electrically connected by solder. As shown, the apparatus will include a machine bed 10 for supporting at least one printed circuit board or integrated circuit 12 . Squeegee apparatus 20 is supported by holding or support apparatus 22 which moves the squeegee apparatus 20 from a first end 24 of the machine bed 10 to an opposite end 26 of the machine bed. In operation, solder is introduced in front of the squeegee blade and then the squeegee blade is dragged across one or more printed circuit boards or integrated circuits such as integrated circuits 12 , 14 , 16 and 18 so as to evenly distribute the solder paste across the circuit boards. The solder paste has been applied to PCB 12 as indicated by the solid connections 21 . The solder paste has been applied to some of the connections on PCB 14 as indicated by solid connection 21 , but not to others as indicated by the empty circuit 21 a . Solder paste has not been applied to any of the connections on PCBs 16 and 18 as indicated by all of the connections being open as indicated by 21 a.
[0013] Referring now to FIG. 2, there is shown an enlarged schematic of the squeegee blade 20 as it moves across the printed circuit board 14 as indicated by arrow 23 . As shown, there is also included a mask screen or stencil 28 which includes apertures, such as aperture 30 , which expose areas or connection points on the printed circuit board 14 where solder is to be used for making an electrical connection. As shown, the squeegee edge 32 is dragged or passes over the screen mask or stencil 28 and moves a roll of solder paste 34 across the screen mask 28 . In those areas of a circuit board where there are no apertures, such as aperture 30 , the squeegee edge 32 of squeegee 20 will typically wipe the screen mask or stencil 28 to clean off the solder paste 34 . However, where apertures exist, the solder paste will be forced down into the aperture 30 to provide a coating of the solder paste in those connection areas of the circuit exposed by the stencil 28 . Thus, it will be appreciated that the solder paste 34 will only be deposited where a connection is to be made as provided for by the screen mask or stencil. It should also be understood that although there is only a single aperture 30 that has been shown in FIG. 2, there typically will be a plurality (tens or hundreds) of such apertures on a circuit board which receives the solder paste as is better indicated by the connections 21 and 21 a of FIG. 1.
[0014] Referring now to FIGS. 3A and 3B, there is shown a side view and a front view, respectively, of a prior art squeegee apparatus. As shown, there is a clamping portion 36 typically mounted to the holding apparatus 22 shown in FIG. 1 by a bolt or mounting rod indicated at reference number 38 . The clamping portion 36 typically includes a ledge or cut-out area 40 for receiving a squeegee blade 42 as shown in FIGS. 3A and 3B. A perforated metal strip 44 shown in the left most portion of FIG. 3B or individual washers 45 receive threaded bolts 46 which are received by threaded apertures 48 in the clamping portion 36 as shown in FIG. 3A. FIG. 4 shows a prior art squeegee blade 42 , including a series of mounting apertures 50 a through 50 h , that allows for the bolts 46 which pass through the perforated strip 44 and for washer 45 to also pass through the apertures 50 a through 50 h into the threaded aperture 48 of metal clamping portion 36 of the apparatus. Thus, referring to FIG. 3A, it can be seen that if the combination clamping structure 36 and squeegee blade 42 are moved in the direction as indicated by arrow 52 , the edge 54 of squeegee blade 42 , which is in the front or forward position, will bear against the screen mask as it moves across the one or more circuit boards and evenly distributes the solder paste. Referring to FIG. 4, it is seen that there are two possible useable edges 54 and 56 for distributing the solder paste. For example, if edge 54 becomes damaged or worn, edge 56 may be used as the contact or front edge by removing squeegee blade 42 from the clamping apparatus 36 and flipping the blade 42 over (180°). The edges 58 and 60 at the top of the solder blade 42 typically are not available for use as squeegee edges because of the mounting apertures 50 a through 50 h.
[0015] It will also be appreciated by those skilled in the art that the mounting bolts 46 used to clamp squeegee blade 42 to the clamping structure 36 must be carefully tightened or torqued to avoid distortion of the resilient rubber material used in the squeegee blade 42 . As will be appreciated by those skilled in the art, if a bolt 46 is tightened an excessive amount, the rubber will deform and may likely cause a protrusion or uneven area at the squeegee edge which contacts the screen mask and thereby makes it impossible to evenly distribute the solder paste. Such an uneven edge may result in such uneven distribution that a gap is formed such that solder paste passes under the blade edge and is not moved across the face of the screen mask.
[0016] Finally, it will be appreciated that excessive solder paste indicated at reference numeral 62 in FIG. 3B accumulating in front of the edge 54 of squeegee blade 42 , may run around ends 64 and 66 and beyond the edges of the printed circuit boards such that it is not useable and will be wasted.
[0017] Referring now to side view FIG. 5A and front view FIG. 5B, there is shown the squeegee apparatus of the present invention. As shown, there is again included a squeegee blade 42 A mounted to clamping apparatus 36 A. However, as is clear, mounting apparatus and squeegee blades 42 A include significant changes and improvements over the prior art apparatus. As shown, clamping apparatus 36 A is constructed from a partially resilient material, such as for example, hard rubber, and includes a backing portion 68 and a front or clamping portion 70 . Backing portion 68 and clamping portion 70 comprising clamping apparatus 36 A are typically two separate pieces or portions, but as shown, could be molded with a thin flexible rubber hinge 72 . The backing portion 68 and clamping portion 70 define an elongated rectangular cavity 74 for receiving the squeegee blade 42 A. As seen, the backing portion 68 also includes an extension 76 which provides backing support to the more flexible squeegee blade 42 A when the squeegee apparatus with blade 42 A is moved in the direction as indicated by arrow 78 . The front or clamping portion 70 of the clamping apparatus 36 A defines a series of apertures 80 a through which threaded mounting bolts 82 pass and are received in matching apertures 80 b of backing portion 68 such that a clamping force can be provided to secure the squeegee blade 42 A within the cavity 74 discussed above. Threaded inserts 84 may be included within the apertures 80 b of the backing portion 68 for receiving the threaded bolts 82 . Front or clamping portion 70 further typically includes a lip portion 86 which bears against the full length of the squeegee blade 42 A to assure sufficient clamping force to maintain the squeegee blade in position. In addition, the partially resilient clamping apparatus allows its mounting bolts to simply be tightened down without having to carefully torque its bolts. Also as shown, the new clamping structure 36 A of the present invention further includes expansion spaces 88 a and 88 b to relieve distortion of the resilient squeegee blade 42 A.
[0018] Referring now to FIG. 6, there is illustrated the squeegee blade 42 A of the present invention. As shown, the squeegee blade 42 A of FIG. 6 is free of mounting holes which were necessary for the prior art mounting technique discussed with respect to the squeegee blade shown in FIG. 4. Consequently, in addition to the two edges 54 A and 56 A shown in FIG. 6, which are available for use for squeegee operation or activity, the present blade may also be rotated such that the squeegee blade edges 58 A and 60 A are available for use. Thus, it will be appreciated that the present invention allows or provides twice the number of available squeegee blade edges for use in squeegee operations. Further, by using the hard rubber mounting structure 36 A, the clamping forces can be more easily controlled and thereby avoid areas of excess pressure which will tend to distort or deform the squeegee edges used to contact the screen mask. Further, the expansion spaces 88 a and 88 b as illustrated in FIG. 5A allow some expansion of the top edges to further relieve excess pressure and deformation.
[0019] Referring now to FIG. 7, there is shown a further embodiment of the present invention. As shown, in addition to the improved squeegee blade apparatus 36 A as discussed above, the embodiment of FIG. 7 further includes a pair of over flow guard members 90 mounted at each end of the squeegee blade apparatus so as to prevent the excess overflow of solder paste around the ends of the squeegee blade, such as shown at 64 A. The over flow guards 90 may be mounted to either the squeegee clamping apparatus 36 A or to the holding apparatus 22 shown in FIG. 1 which supports the squeegee apparatus.
[0020] Thus, there has been described unique apparatus and methods of this invention for applying solder paste by the use of squeegee blades which methods and apparatus doubles the number of available squeegee edges on a squeegee blade and also helps eliminate distortion or deformation of the squeegee blade to assure a regular undamaged and aligned squeegee blade edge is in contact with a circuit screen mask or stencil. Further, although the invention has been described with respect to specific methods and apparatus, it is not intended that such specific references be considered limitations upon the scope of the invention except as is set forth in the following claims. | Apparatus and methods for applying solder paste to circuits, such as integrated circuits, are disclosed. The apparatus and methods comprise a squeegee blade having a pair of elongated face sides spaced apart by a selected thickness and a corresponding pair of elongated substantially parallel narrow sides spaced apart by a selected width. The elongated face sides and elongated narrow sides join together to form squeegee operating edges. The squeegee blade is free of mounting aperture as to provide four operating edges. The squeegee blade is mounted to a resilient clamping structure which applies a regular and controlled gripping force so as to avoid deformation of the squeegee blade edge due to excessive mounting force. The plurality of fasteners are received by the clamping structure for adjusting the gripping force to the squeegee blade. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 10/355,554, which is a divisional of U.S. patent application Ser. No. 10/330,853 filed Dec. 26, 2002. The disclosures of the aforementioned applications are incorporated by reference in their entireties.
ACKNOWLEDGEMENT OF GOVERNMENT SUPPORT
[0002] This invention was made in part with Government support under a grant from the National Science Foundation (Cooperative Agreement No. DMR-980677). Accordingly, the Government may have certain rights to this invention.
TECHNICAL FIELD
[0003] This invention relates generally to the depolymerization of polymers, and, more particularly relates to an organocatalytic method for depolymerizing polymers using nucleophilic reagents. The invention is applicable in numerous fields, including industrial chemistry and chemical waste disposal, plastics recycling, and manufacturing processes requiring a simple and convenient method for the degradation of polymers.
BACKGROUND OF THE INVENTION
[0004] Technological advances of all kinds continue to present many complex ecological issues. Consequently, waste management and pollution prevention are two very significant challenges of the 21 st century. The overwhelming quantity of plastic refuse has significantly contributed to the critical shortage of landfill space faced by many communities. For example, poly(ethylene terephthalate) (poly(oxy-1,2-ethanediyl-oxycarbonyl-1,4-diphenylenecarbonyl); “PET”), a widely used engineering thermoplastic for carpeting, clothing, tire cords, soda bottles and other containers, film, automotive applications, electronics, displays, etc. will contribute more than 1 billion pounds of waste to land-fills in 2002 alone. The worldwide production of PET has been growing at an annual rate of 10% per year, and with the increase in use in electronic and automotive applications, this rate is expected to increase significantly to 15% per year. Interestingly, the precursor monomers represent only about 2% of the petrochemical stream. Moreover, the proliferation of the use of organic solvents, halogenated solvents, water, and energy consumption in addressing the need to recycle commodity polymers such as PET and other polyesters has created the need for environmentally responsible and energy efficient recycling processes. See Nadkarni (1999) International Fiber Journal 14(3).
[0005] Significant effort has been invested in researching recycling strategies for PET, and these efforts have produced three commercial options; mechanical, chemical and energy recycling. Energy recycling simply burns the plastic for its calorific content. Mechanical recycling, the most widespread approach, involves grinding the polymer to powder, which is then mixed with “virgin” PET. See Mancini et al. (1999) Materials Research 2(1):33-38. Many chemical companies use this process in order to recycle PET at the rate of approximately 50,000 tons/year per plant. In Europe, all new packaging materials as of 2002 must contain 15% recycled material. However, it has been demonstrated that successive recycling steps cause significant polymer degradation, in turn resulting in a loss of desirable mechanical properties. Recycling using chemical degradation involves a process that depolymerizes a polymer to starting material, or at least to relative short oligomeric components. Clearly, this process is most desirable, but is the most difficult to control since elevated temperature and pressure are required along with a catalyst composed of a strong base, or an organometallic complex such as an organic titanate. See Sako et al. (1997) Proc. of the 4 th Int'l Symposium on Supercritical Fluids , pp. 107-110. The use of such a catalyst results in significant quantities of undesirable byproducts, and materials processed by these methods are thus generally unsuitable for use in medical materials or food packaging, limiting their utility. Moreover, the energy required to effect depolymerization essentially eliminates sustainability arguments.
[0006] Accordingly, there is a need in the art for an improved depolymerization method. Ideally, such a method would not involve extreme reaction conditions, use of metallic catalysts, or a process that results in significant quantities of potentially problematic by-products.
SUMMARY OF THE INVENTION
[0007] The invention is directed to the aforementioned need in the art, and, as such, provides an efficient catalytic depolymerization reaction that employs mild conditions, wherein production of undesirable byproducts resulting from polymer degradation is minimized. The reaction can be carried out at temperatures of at most 80° C., and, because a nonmetallic catalyst is preferably employed, the depolymerization products, in a preferred embodiment, are substantially free of metal contaminants. With many of the carbene catalysts disclosed herein, the depolymerization reaction can be carried out at a temperature of at most 60° C. or even 30° C. or lower, i.e., at room temperature.
[0008] More specifically, in one aspect of the invention, a method is provided for depolymerizing a polymer having a backbone containing electrophilic linkages, wherein the method involves contacting the polymer with a nucleophilic reagent and a catalyst at a temperature of less than 80° C. An important application of this method is in the depolymerization of polyesters, including homopolymeric polyesters (in which all of the electrophilic linkages are ester linkages) and polyester copolymers (in which a fraction of the electrophilic linkages are ester linkages and the remainder of the electrophilic linkages are other than ester linkages).
[0009] In a related aspect of the invention, a method is provided for depolymerizing a polymer having a backbone containing electrophilic linkages, wherein the method involves contacting the polymer with a nucleophilic reagent and a catalyst that yields depolymerization products that are substantially free of metal contaminants. The polymer may be, for example, a polyester, a polycarbonate, a polyurethane, or a related polymer, in either homopolymeric or copolymeric form, as indicated above. In this embodiment, in order to provide reaction products that are substantially free of contamination by metals and metal-containing compounds, the catalyst used is a purely organic, nonmetallic catalyst.
[0010] Preferred catalysts herein are carbene compounds, which act as nucleophilic catalysts, as well as precursors to carbene compounds, as will be discussed infra. As is well understood in the art, carbenes are electronically neutral compounds containing a divalent carbon atom with only six electrons in its valence shell. Carbenes include, by way of example, cyclic diaminocarbenes, imidazol-2-ylidenes (e.g., 1,3-dimesityl-imidazol-2-ylidene and 1,3-dimesityl-4,5 dihydroimidazol-2-ylidene), 1,2,4-triazol-3-ylidenes, and 1,3-thiazol-2-ylidenes; see Bourissou et al. (2000) Chem. Rev. 100:39-91.
[0011] Since the initial description of the synthesis, isolation, and characterization of stable carbenes by Arduengo (Arduengo et al. (1991) J. Am. Chem. Soc. 113:361; Arduengo et al. (1992) J. Am. Chem. Soc. 114:5530), the exploration of their chemical reactivity has become a major area of research. See, e.g., Arduengo et al. (1999) Acc. Chem. Res. 32:913; Bourissou et al. (2000), supra; and Brode (1995) Angew. Chem. Int. Ed. Eng. 34:1021. Although carbenes have now been extensively investigated, and have in fact been established as useful in many synthetically important reactions, there has been no disclosure or suggestion to use carbenes as catalysts in nucleophilic depolymerization reactions, i.e., reactions in which a polymer containing electrophilic linkages is depolymerized with a nucleophilic reagent in the presence of a carbene catalyst.
[0012] Suitable catalysts for use herein thus include heteroatom-stabilized carbenes or precursors to such carbenes. The heteroatom-stabilized carbenes have the structure of formula (I)
wherein:
E 1 and E 2 are independently selected from N, NR E , O, P, PR E , and S, R E is hydrogen, heteroalkyl, or heteroaryl, x and y are independently zero, 1, or 2, and are selected to correspond to the valence state of E 1 and E 2 , respectively, and wherein when E 1 and E 2 are other than O or S, then E 1 and E 2 may be linked through a linking moiety that provides a heterocyclic ring in which E 1 and E 2 are incorporated as heteroatoms; R 1 and R 2 are independently selected from branched C 3 -C 30 hydrocarbyl, substituted branched C 3 -C 30 hydrocarbyl, heteroatom-containing branched C 4 -C 30 hydrocarbyl, substituted heteroatom-containing branched C 4 -C 30 hydrocarbyl, cyclic C 5 -C 30 hydrocarbyl, substituted cyclic C 5 -C 30 hydrocarbyl, heteroatom-containing cyclic C 1 -C 30 hydrocarbyl, and substituted heteroatom-containing cyclic C 1 -C 30 hydrocarbyl; L 1 and L 2 are linkers containing 1 to 6 spacer atoms, and are independently selected from heteroatoms, substituted heteroatoms, hydrocarbylene, substituted hydrocarbylene, heteroatom-containing hydrocarbylene, and substituted heteroatom-containing hydrocarbylene; and m and n are independently zero or 1, such that L 1 and L 2 are optional.
[0017] Certain carbene catalysts of formula (I) are novel chemical compounds and are claimed as such herein. These novel carbenes are those wherein a heteroatom is directly bound to E 1 and/or E 2 , and include, solely by way of example, carbenes of formula (I) wherein E 1 is NR E and R E is a heteroalkyl or heteroaryl group such as an alkoxy, alkylthio, aryloxy, arylthio, aralkoxy, or aralkylthio moiety.
[0018] Carbene precursors suitable as catalysts herein include tri-substituted methanes having the structure of formula (PI), metal adducts having the structure of formula (PII), and tetrasubstituted olefins having the structure (PIII)
wherein, in formulae (PI) and (PII):
E 1 and E 2 are independently selected from N, NR E , O, P, PR E , and S, R E is hydrogen, heteroalkyl, or heteroaryl, x and y are independently zero, 1, or 2, and are selected to correspond to the valence state of E 1 and E 2 , respectively, and wherein when E 1 and E 2 are other than O or S, then E 1 and E 2 may be linked through a linking moiety that provides a heterocyclic ring in which E 1 and E 2 are incorporated as heteroatoms; R 1 and R 2 are independently selected from branched C 3 -C 30 hydrocarbyl, substituted branched C 3 -C 30 hydrocarbyl, heteroatom-containing branched C 4 -C 30 hydrocarbyl, substituted heteroatom-containing branched C 4 -C 30 hydrocarbyl, cyclic C 5 -C 30 hydrocarbyl, substituted cyclic C 5 -C 30 hydrocarbyl, heteroatom-containing cyclic C 1 -C 30 hydrocarbyl, and substituted heteroatom-containing cyclic C 1 -C 30 hydrocarbyl; L 1 and L 2 are linkers containing 1 to 6 spacer atoms, and are independently selected from heteroatoms, substituted heteroatoms, hydrocarbylene, substituted hydrocarbylene, heteroatom-containing hydrocarbylene, and substituted heteroatom-containing hydrocarbylene; m and n are independently zero or 1; R 7 is selected from alkyl, heteroalkyl, aryl, heteroaryl, aralkyl, or heteroaralkyl, substituted with at least one electron-withdrawing substituent; M is a metal; Ln is a ligand; and j is the number of ligands bound to M.
[0027] In compounds of formula (PIII), the substituents are as follows:
E 3 and E 4 are defined as for E 1 and E 2 ; v and w are defined as for x and y; R 8 and R 9 are defined as for R 1 and R 2 ; L 3 and L 4 are defined as for L 1 and L 2 ; and h and k are defined as for m and n.
[0033] The carbene precursors may be in the form of a salt, in which case the precursor is positively charged and associated with an anionic counterion, such as a halide ion (I, Br, Cl), a hexafluorophosphate anion, or the like.
[0034] Novel carbene precursors herein include compounds of formula (PI), those compounds of formula (PII) in which a heteroatom is directly bound to E 1 and/or E 2 , and those compounds of formula (PIII) in which a heteroatom is directly bound to at least one of E 1 , E 2 , E 3 , and E 4 , and may be in the form of a salt as noted above.
[0035] Ideally, the carbene catalyst used in conjunction with the present depolymerization reaction is an N-heterocyclic carbene having the structure of formula (II)
wherein:
[0036] R 1 , R 2 , L 1 , L 2 , m, and n are as defined above; and
L is a hydrocarbylene, substituted hydrocarbylene, heteroatom-containing hydrocarbylene, or substituted heteroatom-containing hydrocarbylene linker, wherein two or more substituents on adjacent atoms within L may be linked to form an additional cyclic group.
[0038] As alluded to above, one important application of the present invention is in the recycling of polyesters, including, by way of illustration and not limitation: PET; poly (butylene terephthalate) (PBT); poly(alkylene adipate)s and their copolymers; and poly(ε-caprolactone). The methodology of the invention provides an efficient means to degrade such polymers into their component monomers and/or relatively short oligomeric fragments without need for extreme reaction conditions or metallic catalysts.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] FIG. 1 illustrates the organocatalytic depolymerization of PET in the presence of excess methanol using N-heterocyclic carbene catalyst, as evaluated in Example 7.
[0040] FIG. 2 illustrates the organocatalytic depolymerization of PET in the presence of ethylene glycol using N-heterocyclic carbene catalyst, as evaluated in Example 6.
DETAILED DESCRIPTION OF THE INVENTION
[0041] Unless otherwise indicated, this invention is not limited to specific polymers, carbene catalysts, nucleophilic reagents, or depolymerization conditions. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.
[0042] As used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a polymer” encompasses a combination or mixture of different polymers as well as a single polymer, reference to “a catalyst” encompasses both a single catalyst as well as two or more catalysts used in combination, and the like.
[0043] In this specification and in the claims that follow, reference will be made to a number of terms, which shall be defined to have the following meanings:
[0044] As used herein, the phrase “having the formula” or “having the structure” is not intended to be limiting and is used in the same way that the term “comprising” is commonly used.
[0045] The term “alkyl” as used herein refers to a linear, branched, or cyclic saturated hydrocarbon group typically although not necessarily containing 1 to about 20 carbon atoms, preferably 1 to about 12 carbon atoms, such as methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, t-butyl, octyl, decyl, and the like, as well as cycloalkyl groups such as cyclopentyl, cyclohexyl and the like. Generally, although again not necessarily, alkyl groups herein contain 1 to about 12 carbon atoms. The term “lower alkyl” intends an alkyl group of 1 to 6 carbon atoms, and the specific term “cycloalkyl” intends a cyclic alkyl group, typically having 4 to 8, preferably 5 to 7, carbon atoms. The term “substituted alkyl” refers to alkyl substituted with one or more substituent groups, and the terms “heteroatom-containing alkyl” and “heteroalkyl” refer to alkyl in which at least one carbon atom is replaced with a heteroatom. If not otherwise indicated, the terms “alkyl” and “lower alkyl” include linear, branched, cyclic, unsubstituted, substituted, and/or heteroatom-containing alkyl and lower alkyl, respectively.
[0046] The term “alkylene” as used herein refers to a difunctional linear, branched, or cyclic alkyl group, where “alkyl” is as defined above.
[0047] The term “alkenyl” as used herein refers to a linear, branched, or cyclic hydrocarbon group of 2 to about 20 carbon atoms containing at least one double bond, such as ethenyl, n-propenyl, isopropenyl, n-butenyl, isobutenyl, octenyl, decenyl, tetradecenyl, hexadecenyl, eicosenyl, tetracosenyl, and the like. Preferred alkenyl groups herein contain 2 to about 12 carbon atoms. The term “lower alkenyl” intends an alkenyl group of 2 to 6 carbon atoms, and the specific term “cycloalkenyl” intends a cyclic alkenyl group, preferably having 5 to 8 carbon atoms. The term “substituted alkenyl” refers to alkenyl substituted with one or more substituent groups, and the terms “heteroatom-containing alkenyl” and “heteroalkenyl” refer to alkenyl in which at least one carbon atom is replaced with a heteroatom. If not otherwise indicated, the terms “alkenyl” and “lower alkenyl” include linear, branched, cyclic, unsubstituted, substituted, and/or heteroatom-containing alkenyl and lower alkenyl, respectively.
[0048] The term “alkenylene” as used herein refers to a difunctional linear, branched, or cyclic alkenyl group, where “alkenyl” is as defined above.
[0049] The term “alkoxy” as used herein refers to a group —O-alkyl wherein “alkyl” is as defined above, and the term “alkylthio” as used herein refers to a group —S-alkyl wherein “alkyl is as defined above.
[0050] The term “aryl” as used herein, and unless otherwise specified, refers to an aromatic substituent containing a single aromatic ring or multiple aromatic rings that are fused together, directly linked, or indirectly linked (such that the different aromatic rings are bound to a common group such as a methylene or ethylene moiety). Preferred aryl groups contain 5 to 20 carbon atoms and either one aromatic ring or 2 to 4 fused or linked aromatic rings, e.g., phenyl, naphthyl, biphenyl, and the like, with more preferred aryl groups containing 1 to 3 aromatic rings, and particularly preferred aryl groups containing 1 or 2 aromatic rings and 5 to 14 carbon atoms. “Substituted aryl” refers to an aryl moiety substituted with one or more substituent groups, and the terms “heteroatom-containing aryl” and “heteroaryl” refer to aryl in which at least one carbon atom is replaced with a heteroatom. Unless otherwise indicated, the terms “aromatic,” “aryl,” and “arylene” include heteroaromatic, substituted aromatic, and substituted heteroaromatic species.
[0051] The term “aryloxy” refers to a group —O-aryl wherein “aryl” is as defined above.
[0052] The term “alkaryl” refers to an aryl group with at least one and typically 1 to 6 alkyl, preferably 1 to 3, alkyl substituents, and the term “aralkyl” refers to an alkyl group with an aryl substituent, wherein “aryl” and “alkyl” are as defined above. Alkaryl groups include, for example, p-methylphenyl, 2,4-dimethylphenyl, 2,4,6-trimethylphenyl, and the like. The term “aralkyl” refers to an alkyl group substituted with an aryl moiety, wherein “alkyl” and “aryl” are as defined above.
[0053] The term “alkaryloxy” refers to a group —O—R wherein R is alkaryl, the term “alkarylthio” refers to a group —S—R wherein R is alkaryl, the term aralkoxy refers to a group —O—R wherein R is aralkyl, the term “aralkylthio” refers to a group —S—R wherein R is aralkyl.
[0054] The terms “halo,” “halide,” and “halogen” are used in the conventional sense to refer to a chloro, bromo, fluoro, or iodo substituent. The terms “haloalkyl,” “haloalkenyl,” and “haloalkynyl” (or “halogenated alkyl,” “halogenated alkenyl,” and “halogenated alkynyl”) refer to an alkyl, alkenyl, or alkynyl group, respectively, in which at least one of the hydrogen atoms in the group has been replaced with a halogen atom.
[0055] “Hydrocarbyl” refers to univalent hydrocarbyl radicals containing 1 to about 30 carbon atoms, preferably 1 to about 20 carbon atoms, more preferably 1 to about 12 carbon atoms, including linear, branched, cyclic, saturated, and unsaturated species, such as alkyl groups, alkenyl groups, aryl groups, alkaryl groups, and the like. The term “lower hydrocarbyl” intends a hydrocarbyl group of 1 to 6 carbon atoms, and the term “hydrocarbylene” intends a divalent hydrocarbyl moiety containing 1 to about 30 carbon atoms, preferably 1 to about 20 carbon atoms, most preferably 1 to about 12 carbon atoms, including linear, branched, cyclic, saturated and unsaturated species. The term “lower hydrocarbylene” intends a hydrocarbylene group of 1 to 6 carbon atoms. Unless otherwise indicated, the terms “hydrocarbyl” and “hydrocarbylene” are to be interpreted as including substituted and/or heteroatom-containing hydrocarbyl and hydrocarbylene moieties, respectively.
[0056] The term “heteroatom-containing” as in a “heteroatom-containing alkyl group” (also termed a “heteroalkyl” group) or a “heteroatom-containing aryl group” (also termed a “heteroaryl” group) refers to a molecule, linkage, or substituent in which one or more carbon atoms are replaced with an atom other than carbon, e.g., nitrogen, oxygen, sulfur, phosphorus or silicon, typically nitrogen, oxygen or sulfur. Similarly, the term “heteroalkyl” refers to an alkyl substituent that is heteroatom-containing, the term “heterocyclic” refers to a cyclic substituent that is heteroatom-containing, the terms “heteroaryl” and heteroaromatic” respectively refer to “aryl” and “aromatic” substituents that are heteroatom-containing, and the like. Examples of heteroalkyl groups include alkoxyaryl, alkylsulfanyl-substituted alkyl, N-alkylated amino alkyl, and the like. Examples of heteroaryl substituents include pyrrolyl, pyrrolidinyl, pyridinyl, quinolinyl, indolyl, pyrimidinyl, imidazolyl, 1,2,4-triazolyl, tetrazolyl, etc., and examples of heteroatom-containing alicyclic groups are pyrrolidino, morpholino, piperazino, piperidino, etc. It should be noted that a “heterocyclic” group or compound may or may not be aromatic, and further that “heterocycles” may be monocyclic, bicyclic, or polycyclic as described above with respect to the term “aryl.”
[0057] By “substituted” as in “substituted hydrocarbyl,” “substituted alkyl,” “substituted aryl,” and the like, as alluded to in some of the aforementioned definitions, is meant that in the hydrocarbyl, alkyl, aryl, or other moiety, at least one hydrogen atom bound to a carbon (or other) atom is replaced with a non-hydrogen substituent. Examples of such substituents include, without limitation, functional groups such as halide, hydroxyl, sulfhydryl, C 1 -C 20 alkoxy, C 5 -C 20 aryloxy, C 2 -C 20 acyl (including C 2 -C 20 alkylcarbonyl (—CO-alkyl) and C 6 -C 20 arylcarbonyl (—CO-aryl)), acyloxy (—O-acyl), C 2 -C 20 alkoxycarbonyl (—(CO)—O-alkyl), C 6 -C 20 aryloxycarbonyl (—(CO)—O-aryl), halocarbonyl (—C O)—X where X is halo), C 2 -C 20 alkyl-carbonato (—O—(CO)—O-alkyl), C 6 -C 20 arylcarbonato (—O—(CO)—O-aryl), carboxy (—COOH), carboxylato (—COO—), carbamoyl (—(CO)—NH 2 ), mono-(C 1 -C 20 alkyl)-substituted carbamoyl (—(CO)—NH(C 1 -C 20 alkyl)), di-(C 1 -C 20 alkyl)-substituted carbamoyl —(CO)—N(C 1 -C 20 alkyl) 2 ), mono-substituted arylcarbamoyl (—(CO)—NH-aryl), thiocarbamoyl (—(CS)—NH 2 ), carbamido (—NH—(CO)—NH 2 ), cyano(—C═N), cyanato (—O—C—N), formyl (—(CO)—H), thioformyl (—(CS)—H), amino (—NH 2 ), mono- and di-(C 1 -C 20 alkyl)-substituted amino, mono- and di-(C 5 -C 20 aryl)-substituted amino, C 2 -C 20 alkylamido (—NH—(CO)-alkyl), C 6 -C 20 arylamido (—NH—(CO)-aryl), imino (—CR═NH where R=hydrogen, C 1 -C 20 alkyl, C 5 -C 20 aryl, C 6 -C 24 alkaryl, C 6 -C 24 aralkyl, etc.), alkylimino (—CR═N(alkyl), where R=hydrogen, alkyl, aryl, alkaryl, etc.), arylimino (—CR═N(aryl), where R=hydrogen, alkyl, aryl, alkaryl, etc.), nitro (—NO 2 ), nitroso (—NO), sulfo (—SO 2 —OH), sulfonato (—SO 2 —O—), C 1 -C 20 alkylsulfanyl (—S-alkyl; also termed “alkylthio”), arylsulfanyl (—S-aryl; also termed “arylthio”), C 1 -C 20 alkylsulfinyl (—(SO)-alkyl), C 5 -C 20 arylsulfinyl (—(SO)-aryl), C 1 -C 20 alkylsulfonyl (—SO 2 -alkyl), C 5 -C 20 arylsulfonyl (—SO 2 -aryl), and thiocarbonyl (═S); and the hydrocarbyl moieties C 1 -C 20 alkyl (preferably C 1 -C 18 alkyl, more preferably C 1 -C 12 alkyl, most preferably C 1 -C 6 alkyl), C 2 -C 20 alkenyl (preferably C 2 -C 18 alkenyl, more preferably C 2 -C 12 alkenyl, most preferably C 2 -C 6 alkenyl), C 2 -C 20 alkynyl (preferably C 2 -C 18 alkynyl, more preferably C 2 -C 12 alkynyl, most preferably C 2 -C 6 alkynyl), C 5 -C 20 aryl (preferably C 5 -C 14 aryl), C 6 -C 24 alkaryl (preferably C 6 -C 18 alkaryl), and C 6 -C 24 aralkyl (preferably C 6 -C 18 aralkyl).
[0058] In addition, the aforementioned functional groups may, if a particular group permits, be further substituted with one or more additional functional groups or with one or more hydrocarbyl moieties such as those specifically enumerated above. Analogously, the above-mentioned hydrocarbyl moieties may be further substituted with one or more functional groups or additional hydrocarbyl moieties such as those specifically enumerated.
[0059] By “substantially free of” a particular type of chemical compound is meant that a composition or product contains less 10 wt. % of that chemical compound, preferably less than 5 wt. %, more preferably less than 1 wt. %, and most preferably less than 0.1 wt. %. For instance, the depolymerization product herein is “substantially free of” metal contaminants, including metals per se, metal salts, metallic complexes, metal alloys, and organometallic compounds.
[0060] “Optional” or “optionally” means that the subsequently described circumstance may or may not occur, so that the description includes instances where the circumstance occurs and instances where it does not. For example, the phrase “optionally substituted” means that a non-hydrogen substituent may or may not be present on a given atom, and, thus, the description includes structures wherein a non-hydrogen substituent is present and structures wherein a non-hydrogen substituent is not present.
[0061] Accordingly, the invention features a method for depolymerizing a polymer having a backbone containing electrophilic linkages. The electrophilic linkages may be, for example, ester linkages (—(CO)—O—), carbonate linkages (—O—(CO)—O)—, urethane linkages (—O—(CO)—NH), substituted urethane linkages (—O—(CO)—NR—, where R is a nonhydrogen substituent such as alkyl, aryl, alkaryl, or the like), amido linkages (—(CO)—NH—), substituted amido linkages (—(CO)—NR— where R is as defined previously, thioester linkages (—(CO)—S—), sulfonic ester linkages (—S(O) 2 —O—), and the like. Other electrophilic linkages that can be cleaved using nucleophilic reagents will be known to those of ordinary skill in the art of organic chemistry and polymer science and/or can be readily found by reference to the pertinent texts and literature. The polymer undergoing depolymerization may be linear or branched, and may be a homopolymer or copolymer, the latter including random, block, multiblock, and alternating copolymers, terpolymers, and the like. Examples of polymers that can be depolymerized using the methodology of the invention include, without limitation:
poly(alkylene terephthalates) such as fiber-grade PET (a homopolymer made from monoethylene glycol and terephthalic acid), bottle-grade PET (a copolymer made based on monoethylene glycol, terephthalic acid, and other comonomers such as isophthalic acid, cyclohexene dimethanol, etc.), poly (butylene terephthalate) (PBT), and poly(hexamethylene terephthalate); poly(alkylene adipates) such as poly(ethylene adipate), poly(1,4-butylene adipate), and poly(hexamethylene adipate); poly(alkylene suberates) such as poly(ethylene suberate); poly(alkylene sebacates) such as poly(ethylene sebacate); poly(ε-caprolactone) and poly(β-propiolactone); poly(alkylene isophthalates) such as poly(ethylene isophthalate); poly(alkylene 2,6-naphthalene-dicarboxylates) such as poly(ethylene 2,6-naphthalene-dicarboxylate); poly(alkylene sulfonyl-4,4′-dibenzoates) such as poly(ethylene sulfonyl-4,4′-dibenzoate); poly(p-phenylene alkylene dicarboxylates) such as poly(p-phenylene ethylene dicarboxylates); poly(trans-1,4-cyclohexanediyl alkylene dicarboxylates) such as poly(trans-1,4-cyclohexanediyl ethylene dicarboxylate); poly(1,4-cyclohexane-dimethylene alkylene dicarboxylates) such as poly(1,4-cyclohexane-dimethylene ethylene dicarboxylate); poly([2.2.2]-bicyclooctane-1,4-dimethylene alkylene dicarboxylates) such as poly([2.2.2]-bicyclooctane-1,4-dimethylene ethylene dicarboxylate); lactic acid polymers and copolymers such as (S)-polylactide, (R,S)-polylactide, poly(tetramethylglycolide), and poly(lactide-co-glycolide); and polycarbonates of bisphenol A, 3,3′-dimethylbisphenol A, 3,3′,5,5′-tetrachlorobisphenol A, 3,3′,5,5′-tetramethylbisphenol A; polyamides such as poly(p-phenylene terephthalamide) (Kevlar®); poly(alkylene carbonates) such as poly(propylene carbonate); polyurethanes such as those available under the tradenames Baytec® and Bayfil®, from Bayer Corporation; and polyurethane/polyester copolymers such as that available under the tradename Baydar®, from Bayer Corporation.
[0080] Depolymerization of the polymer is carried out, as indicated above, in the presence of a nucleophilic reagent and a catalyst. Nucleophilic reagents, as will be appreciated by those of ordinary skill in the art, include monohydric alcohols, diols, polyols, thiols, primary amines, and the like, and may contain a single nucleophilic moiety or two or more nucleophilic moieties, e.g., hydroxyl, sulfhydryl, and/or amino groups. The nucleophilic reagent is selected to correspond to the particular electrophilic linkages in the polymer backbone, such that nucleophilic attack at the electrophilic linkage results in cleavage of the linkage. For example, a polyester can be cleaved at the ester linkages within the polymer backbone using an alcohol, preferably a primary alcohol, most preferably a C 2 -C 4 monohydric alcohol such as ethanol, isopropanol, and t-butyl alcohol. It will be appreciated that such a reaction cleaves the ester linkages via a transesterification reaction, as will be illustrated infra.
[0081] The preferred catalysts for the depolymerization reaction are carbenes and carbene precursors. Carbenes include, for instance, diarylcarbenes, cyclic diaminocarbenes, imidazol-2-ylidenes, 1,2,4-triazol-3-ylidenes, 1,3-thiazol-2-ylidenes, acyclic diaminocarbenes, acyclic aminooxycarbenes, acyclic aminothiocarbenes, cyclic diborylcarbenes, acyclic diborylcarbenes, phosphinosilylcarbenes, phosphinophosphoniocarbenes, sulfenyl-trifluoromethylcarbene, and sulfenyl-pentafluorothiocarbene. See Bourissou et al. (2000), cited supra. Preferred carbenes are heteroatom-stabilized carbenes and preferred carbene precursors are precursors to heteroatom-stabilized carbenes. nitrogen-containing carbenes, with N-heterocyclic carbenes most preferred.
[0082] In one embodiment, heteroatom-stabilized carbenes suitable as depolymerization catalysts herein have the structure of formula (I)
wherein the various substituents are as follows:
E 1 and E 2 are independently selected from N, NR E , O, P, PR E , and S, R E is hydrogen, heteroalkyl, or heteroaryl, and x and y are independently zero, 1, or 2, and are selected to correspond to the valence state of E 1 and E 2 , respectively. When E 1 and E 2 are other than O or S, then E 1 and E 2 may be linked through a linking moiety that provides a heterocyclic ring in which E 1 and E 2 are incorporated as heteroatoms. In the latter case, the heterocyclic ring may be aliphatic or aromatic, and may contain substituents and/or heteroatoms. Generally, such a cyclic group will contain 5 or 6 ring atoms.
[0084] For example, in representative compounds of formula (I):
(1) E 1 is O or S and x is 1; (2) E 1 is N, x is 1, and E 1 is linked to E 2 ; (3) E 1 is N, x is 2, and E 1 and E 2 are not linked; (4) E 1 is NR E , x is 1, and E 1 and E are not linked; or (5) E 1 is NR E , x is zero, and E 1 is linked to E 2 .
[0090] R 1 and R 2 are independently selected from branched C 3 -C 30 hydrocarbyl, substituted branched C 3 -C 30 hydrocarbyl, heteroatom-containing branched C 4 -C 30 hydrocarbyl, substituted heteroatom-containing branched C 4 -C 30 hydrocarbyl, cyclic C 5 -C 30 hydrocarbyl, substituted cyclic C 5 -C 30 hydrocarbyl, heteroatom-containing cyclic C 1 -C 30 hydrocarbyl, and substituted heteroatom-containing cyclic C 1 -C 30 hydrocarbyl. Preferably, at least one of R 1 and R 2 , and more preferably both R 1 and R 2 , are relatively bulky groups, particularly branched alkyl (including substituted and/or heteroatom-containing alkyl), aryl (including substituted aryl, heteroaryl, and substituted heteroaryl), alkaryl (including substituted and/or heteroatom-containing aralkyl), and alicyclic. Using such sterically bulky groups to protect the highly reactive carbene center has been found to kinetically stabilize singlet carbenes, which are preferred reaction catalysts herein. Particular sterically bulky groups that are suitable as R 1 and R 2 are optionally substituted and/or heteroatom-containing C 3 -C 12 alkyl, tertiary C 4 -C 12 alkyl, C 5 -C 12 aryl, C 6 -C 18 alkaryl, and C 5 -C 12 alicyclic, with C 5 -C 12 aryl and C 6 -C 12 alkaryl particularly preferred. The latter substituents are exemplified by phenyl optionally substituted with 1 to 3 substituents selected from lower alkyl, lower alkoxy, and halogen, and thus include, for example, p-methylphenyl, 2,6-dimethylphenyl, and 2,4,6-trimethylphenyl (mesityl).
[0091] L 1 and L 2 are linkers containing 1 to 6 spacer atoms, and are independently selected from heteroatoms, substituted heteroatoms, hydrocarbylene, substituted hydrocarbylene, heteroatom-containing hydrocarbylene, and substituted heteroatom-containing hydrocarbylene; and m and n are independently zero or 1, meaning that each of L 1 and L 2 is optional. Preferred L 1 and L 2 moieties include, by way of example, alkylene, alkenylene, arylene, aralkylene, any of which may be heteroatom-containing and/or substituted, or L 1 and/or L 2 may be a heteroatom such as O or S, or a substituted heteroatom such as NH, NR (where R is alkyl, aryl, other hydrocarbyl, etc.), or PR; and
[0092] In one preferred embodiment, E 1 and E 2 are independently N or NR E and are not linked, such that the carbene is an N-heteroacyclic carbene. In another preferred embodiment, E 1 and E 2 are N, x and y are 1, and E 1 and E 2 are linked through a linking moiety such that the carbene is an N-heterocyclic carbene. N-heterocyclic carbenes suitable herein include, without limitation, compounds having the structure of formula (II)
wherein R 1 , R 2 , L 1 , L 2 , m, and n are as defined above for carbenes of formula (I). In carbenes of structural formula (II), L is a hydrocarbylene, substituted hydrocarbylene, heteroatom-containing hydrocarbylene, or substituted heteroatom-containing hydrocarbylene linker, wherein two or more substituents on adjacent atoms within L may be linked to form an additional cyclic group. L is a hydrocarbylene, substituted hydrocarbylene, heteroatom-containing hydrocarbylene, or substituted heteroatom-containing hydrocarbylene linker, wherein two or more substituents on adjacent atoms within L may be linked to form an additional cyclic group. For example, L may be —CR 3 R 4 —CR 5 R 6 — or —CR 3 ═CR 5 —, wherein R 3 , R 4 , R 5 , and R 6 are independently selected from hydrogen, halogen, C 1 -C 12 alkyl, or wherein any two of R 3 , R 4 , R 5 , and R 6 may be linked together to form a substituted or unsubstituted, saturated or unsaturated ring.
[0093] Accordingly, when L is —CR 3 R 4 —CR 5 R 6 — or —CR 3 ═CR 5 —, the carbene has the structure of formula (II)
in which q is an optional double bond, s is zero or 1, and t is zero or 1, with the proviso that when q is present, s and t are zero, and when q is absent, s and t are 1.
[0094] Certain carbenes are new chemical compounds and are claimed as such herein. These are compounds having the structure of formula (I) wherein a heteroatom is directly bound to E 1 and/or E 2 . e.g., with the proviso that a heteroatom is directly bound to E 1 , E 2 , or to both E 1 and E 2 , and wherein the carbene may be in the form of a salt (such that it is positively charged and associated with a negatively charged counterion). These novel carbenes are those wherein a heteroatom is directly bound to E 1 and/or E 2 , and include, solely by way of example, carbenes of formula (I) wherein E 1 and/or E 2 is NR E and R E is a heteroalkyl or heteroaryl group such as an alkoxy, alkylthio, aryloxy, arylthio, aralkoxy, or aralkylthio moiety. Other such carbenes are those wherein x and/or y is at least 1, and L 1 and/or L 2 is heteroalkyl, heteroaryl, or the like, wherein the heteroatom within L 1 and/or L 2 is directly bound to E 1 and/or E 2 , respectively.
[0095] Representative of such novel carbenes are compounds of formula (I) wherein E 1 is NR E , and R E is alkoxy, substituted alkoxy, aryloxy, substituted aryloxy, aralkoxy, or substituted aralkoxy. A preferred subset of such carbenes are those wherein E is N, x is zero, y is 1, and E 1 and E 2 are linked through a substituted or unsubstituted lower alkylene or lower alkenylene linkage. A more preferred subset of such carbenes are those wherein R E is lower alkoxy or monocyclic aryl-substituted lower alkoxy, E 1 and E 2 are linked through a moiety —CR 3 R 4 —CR 5 R 6 or —CR 3 ═CR 5 —, wherein R 3 , R 4 , R 5 , and R 6 are independently selected from hydrogen, halogen, and C 1 -C 12 alkyl, n is 1, L 2 is lower alkylene, and R 2 is monocyclic aryl or substituted monocyclic aryl. Examples 8-11 describe syntheses of representative compounds within this group.
[0096] As indicated previously, suitable catalysts for the present depolymerization reaction are also precursors to carbenes, preferably precursors to N-heterocyclic and N-heteroacyclic carbenes. In one embodiment, the precursor is a tri-substituted methane compound having the structure of formula (PI)
wherein E 1 , E 2 , x, y, R 1 , R 2 , L 1 , L 2 , m, and n are as defined for carbenes of structural formula (I), and wherein R 7 is selected from alkyl, heteroalkyl, aryl, heteroaryl, aralkyl, or heteroaralkyl, and is substituted with at least one electron-withdrawing substituent such as fluoro, fluoroalkyl (including perfluoroalkyl), chloro, nitro, acytyl. It will be appreciated that the foregoing list is not exhaustive and that any electron-withdrawing group may serve as a substituent providing that the group does not cause unwanted interaction of the catalyst with other components of the depolymerization mixture or adversely affect the depolymerization reaction in any way. Specific examples of R 7 groups thus include p-nitrophenyl, 2,4-dinitrobenzyl, 1,1,2,2-tetrafluoroethyl, pentafluorophenyl, and the like.
[0097] Catalysts of formula (PI) are new chemical entities. Representative syntheses of such compounds are described in Examples 13 and 14 herein. As may be deduced from those examples, compounds of formula (PI) wherein E 1 and E 2 are N may be synthesized from the corresponding diamine and an appropriately substituted aldehyde.
[0098] Another carbene precursor useful as a catalyst in the present depolymerization reaction has the structure of formula (PII)
wherein E 1 , E 2 , x, y, R 1 , R 2 , L 1 , L 2 , m, and n are as defined for carbenes of structural formula (I), M is a metal, e.g., gold, silver, other main group metals, or transition metals, with Ag, Cu, Ni, Co, and Fe generally preferred, and Ln is a ligand, generally an anionic or neutral ligand that may or may not be the same as -E 1 -[(L 1 ) m -R 1 ] x or -E 2 -[(L 2 ) n -R 2 ] y . Generally, carbene precursors of formula (PII) can be synthesized from a carbene salt and a metal oxide; see, e.g., the synthesis described in detail in Example 12.
[0100] Still another carbene precursor suitable as a depolymerization catalyst herein is a tetrasubstituted olefin having the structure of formula (PIII)
wherein: E 1 , E 2 , x, y, R 1 , R 2 , L 1 , L 2 , m, and n are defined as for carbenes of structural formula (I); E 3 and E 4 are defined as for E 1 and E 2 ; v and w are defined as for x and y; R 8 and R 9 are defined as for R 1 and R 2 ; L 3 and L 4 are defined as for L 1 and L 2 ; and h and k are defined as for m and n. These olefins are readily formed from N,N-diaryl- and N,N-dialkyl-N-heterocyclic carbene salts and a strong base, typically an inorganic base such as a metal alkoxide.
[0102] As with the carbenes per se, those catalyst precursors having the structure of formula (PII) or (PIII) in which a heteroatom is directly bound to an “E” moiety, i.e., to E 1 , E 2 , E 3 , and/or E 4 , are new chemical entities. Preferred such precursors are those wherein the “E” moieties are NR E or linked N atoms, and the directly bound heteroatom within R E is oxygen or sulfur.
[0103] The depolymerization reaction may be carried out in an inert atmosphere by dissolving a catalytically effective amount of the selected catalyst in a solvent, combining the polymer and the catalyst solution, and then adding the nucleophilic reagent. In a particularly preferred embodiment, however, the polymer, the nucleophilic reagent, and the catalyst (e.g., a carbene or a carbene precursor) are combined and dissolved in a suitable solvent, and depolymerization thus occurs in a one-step reaction.
[0104] Preferably, the reaction mixture is agitated (e.g., stirred), and the progress of the reaction can be monitored by standard techniques, although visual inspection is generally sufficient, insofar as a transparent reaction mixture indicates that the polymer has degraded to an extent sufficient to allow all degradation products to go into solution. Examples of solvents that may be used in the polymerization reaction include organic, protic, or aqueous solvents that are inert under the depolymerization conditions, such as aromatic hydrocarbons, chlorinated hydrocarbons, ethers, aliphatic hydrocarbons, or mixtures thereof. Preferred solvents include toluene, methylene chloride, tetrahydrofuran, methyl t-butyl ether, Isopar, gasoline, and mixtures thereof. Supercritical fluids may also be used as solvents, with carbon dioxide representing one such solvent. Reaction temperatures are in the range of about 0° C. to about 100° C., typically at most 80° C., preferably 60° C. or lower, and most preferably 30° C. or less, and the reaction time will generally be in the range of about 12 to 24 hours. Pressures range from atmospheric to pressures typically used in conjunction with supercritical fluids, with the preferred pressure being atmospheric.
[0105] It is to be understood that while the invention has been described in conjunction with the preferred specific embodiments thereof, that the foregoing description as well as the examples that follow are intended to illustrate and not limit the scope of the invention. Other aspects, advantages and modifications within the scope of the invention will be apparent to those skilled in the art to which the invention pertains.
[0106] All patents, patent applications, and publications mentioned herein are hereby incorporated by reference in their entireties.
EXPERIMENTAL
[0107] General Procedures. 1 H and 13 C NMR spectra were recorded on a Bruke-Avance (400 MHz for 1 H and 100 MHz for 13 C). All NMR spectra were recorded in CDCl 3 . Materials. Solvents were obtained from Sigma-Aldrich and purified by distillation. Other reagents were obtained commercially or synthesized as follows: poly(propylene carbonate), poly(bisphenol A carbonate), poly(1,4-butylene adipate), 1-ethyl-3-methyl-1-H-imidazolium chloride, ethylene glycol, butane-2,3-dione monooxime, ammonium hexafluorophosphate, pentafluorobenzaldehyde, and mesityl diamine, obtained from Sigma-Aldrich; 1,3-(2,4,6-trimethylphenyl)imidazol-2-ylidene, synthesized according to the method of Arduengo et al. (1999) Tetrahedron 55:14523; N,N-diphenyl imidazoline, chloride salt, synthesized according to the method of Wanzlick et al. (1961) Angew. Chem. 73:493 and Wanzlick et al. (1962) Angew. Chem. 74:128, and Wanzlick et al. (1963) Chem. Ber. 96:3024; 1,3,5-tribenzyl-[1,3,5]triazinane, synthesized according to the method of Arduengo et al. (1992) J. Am. Chem. Soc. 114:5530, cited supra.
Example 1
[0108] Depolymerization of Poly(propylene carbonate) (M w =50,000) with isolated carbene: 7 mg (0.02 mmol) of 1,3-(2,4,6-trimethylphenyl)imidazol-2-ylidene dissolved in toluene (0.6 mL), was added to a stirred mixture of 0.5 g of poly(propylene carbonate) in toluene (10 mL), under N 2 . After stirring for 5 minutes at room temperature, 2 mL of methanol were added to the reaction mixture and the temperature was brought to 80° C. Stirring was continued for 3 hours followed by the evaporation of the solvent in vacuo. The 1 H and 13 C NMR spectra showed the presence of a single monomer, 4-methyl-[1,3]-dioxolan-2-one. However, there were 4 peaks in the GC-MS.
[0000] GC-MS:
[0000]
a) m/z (5%) 5.099 min=106 (42), 103 (5), 91 (100), 77 (8), 65 (8), 51 (8)
b) m/z (5%) 5.219 min=106 (60), 105 (30), 103 (8), 91 (100), 77 (8), 65 (5), 51 (5)
c) m/z (85%) 6.750 min=102 (15), 87 (40), 58 (20), 57 (100). Major product.
d) m/z (5%) 9.030 min=136 (10), 135 (100), 134 (70), 120 (85), 117 (8), 103 (5), 91 (14), 77 (10), 65 (5).
[0113] 1 H NMR:1.4 (d, 3H), 3.9 (t, 1H), 4.5 (t, 1H), 4.8 (m, 1H).
[0114] 13 C NMR: 18.96, 70.42, 73.43, 154.88
Example 2
[0115] Depolymerization of Poly(Bisphenol A carbonate) (M w =65,000) with isolated carbene: 7 mg (0.02 mmol) of 1,3-(2,4,6-trimethylphenyl)imidazol-2-ylidine dissolved in toluene (1 mL), was added to a stirred mixture of 0.5 g of poly(bisphenol A carbonate) in toluene (10 mL), under N 2 . After stirring for 5 minutes at room temperature, 2 mL of methanol were added to the reaction mixture. The temperature was brought to 80° C. and stirring was continued for 18 hours followed by the evaporation of the solvent in vacuo. The 1 H and 13 C NMR spectra showed the presence of two compounds identified as, bisphenol A and carbonic acid 4-[1-hydroxy-phenyl)-1-methyl-ethyl]-phenyl ester 4-[1-(4-methoxy-phenyl)-1-methyl-ethyl]phenyl ester. However, GC-MS indicated 4 peaks.
[0000] GC-MS:
[0000]
a) m/z (5%) 5.107 min=106 (40), 103 (5), 91 (100), 77 (8), 65 (8), 51 (8)
b) m/z (5%) 5.210 min=106 (60), 105 (30), 103 (8), 91 (100), 77 (8), 65 (5), 51 (5)
c) m/z (60%) 14.301 min=228 (30), 213 (100), 119 (15), 91 (10). Major product
d) m/z (30%) 16.016 min=495 (30), 333 (10), 319 (20), 299 (5), 281 (5), 259 (25), 239 (38), 197 (40), 181 (12), 151 (12), 135 (100), 119 (10), 91 (10).
[0120] 1 H NMR: 1.6-1.8 (m), 2,4 (s), 3.96 (s), 6.7-6.8 (t), 7.0-7.3 (m).
Example 3
[0121] Depolymerization of Poly(1,4-butylene adipate) (M w =12,000) with isolated carbene: 0.006 g (0.02 mmol) of 1,3-(2,4,6-trimethylphenyl)imidazol-2-ylidine dissolved in toluene (1 mL), was added to a stirred mixture of 1.0 g of poly(1,4-butylene adipate) in toluene (10 mL), under N 2 . After stirring for 5 minutes at room temperature, 2 mL of methanol were added to the reaction mixture. The temperature was brought to 80° C. and stirring was continued for 6 hours followed by the evaporation of the solvent in vacuo. The 1 H and 13 C NMR showed the presence of a single product, and the GC-MS showed two products.
[0000] GC-MS:
[0000]
a) m/z (95%) 5.099 min=143 (80), 142 (20), 115 (20), 114 (100), 111 (70), 101 (65), 87 (12), 83 (25), 82 (12), 74 (36), 73 (26), 69 (10), 59 (72), 55 (60). Major product.
b) m/z (5%) 12.199 min=201 (4), 161 (6), 143 (100), 129 (32), 116 (12), 115 (25), 111 (70), 101 (12), 87 (10), 83 (15), 73 (34), 71 (12), 59 (14), 55 (42).
[0124] 1 H NMR: 1.67 (m), 2.32 (s), 4.08 (s).
[0125] 13 C NMR: 24.26, 25.18, 33.74, 63.75, 173.23
Example 4
[0126] Depolymerization of Poly(propylene carbonate) (M w =50,000) with in-situ carbene: To a mixture of 7 mg (0.047 mmol) of 1-ethyl-3-methyl-1-H-imidazolium chloride in tetrahydrofuran (THF) was added 4 mg (0.038 mmol) of potassium t-butoxide (t-BOK), under N 2 . After 30 min stirring, 0.1 mL of the reaction mixture was transferred to a flask that was charged with 0.5 g of poly(propylene carbonate) in 10 mL of THF. The reaction mixture was stirred for 10 min at room temperature followed by the addition of 2 mL of methanol. Stirring was continued at room temperature for 3 hours. Solvent was removed and the 1 H and 13 C NMR spectra showed the presence of a single product, 4-methyl-[1,3]-dioxolan-2-one. However, before the removal of the solvent the GC-MS of the crude reaction mixture showed 6 different compounds.
[0000] GC-MS:
[0000]
a) m/z (15%) 6.268 min=119 (4), 90 (100), 75 (4), 59 (25).
b) m/z (5%) 6.451 min=104 (40), 103 (30), 90 (5), 77 (5), 59 (100), 58 (10), 57 (10).
c) m/z (70%) 6.879 min=102 (10), 87 (25), 58 (14), 57 (100). Major product.
d) m/z (1%) 7.565 min=103 (40), 89 (5), 59 (100), 58 (5), 57 (8).
e) m/z (4%) 8.502 min=207 (14), 133 (10), 103 (35), 90 (10), 89 (10), 59 (100), 58 (12), 57 (14).
f) m/z (5%) 8.936 min=148 (8), 118 (8), 117 (15), 103 (20), 77 (60), 72 (8), 59 (100), 58 (5), 57 (5).
[0133] 1 H NMR:1.4 (d, 3H), 3.9 (t, 1H), 4.5 (t, 1H), 4.8 (m, 1H).
[0134] 13 C NMR: 18.96, 70.42, 73.43, 154.88
Example 5
[0135] Depolymerization of Poly(bisphenol A carbonate) (M w =65,000) with in situ carbene: To a mixture of 7 mg (0.047 mmol) of 1-ethyl-3-methyl-1-H-imidazolium chloride in THF (1 mL) was added 4 mg (0.038 mmol) of t-BOK, under N 2 . After 30 min, stirring 0.1 mL of the reaction mixture was transferred to a flask that was charged with 0.5 g of poly(bisphenol A carbonate) in 10 mL of THF. The reaction mixture was stirred for 10 min at room temperature followed by the addition of 2 mL of methanol. Stirring was continued at room temperature for 3 hours. The solvent was removed in vacuo and the 1 H, 13 C NMR and GC-MS spectra showed a mixture of monomer and oligomers, where the major product was bisphenol A.
[0000] GC-MS:
[0000]
a) m/z (10%) 12.754 min=212 (30), 198 (20), 197 (100), 182 (10), 181 (10), 179 (10), 178 (10), 165 (8), 152 (8), 135 (10), 119 (12), 103 (15), 91 (12), 77 (10), 65 (5).
b) m/z (5%) 13.674 min=282 (5), 281 (10), 255 (8), 229 (10), 228 (40), 214 (20), 213 (100), 208 (30), 197 (30), 191 (5), 181 (5), 179 (5), 165 (10), 152 (8), 135 (25), 134 (25), 133 (5), 120 (5), 119 (50), 115 (10), 103 (10), 99 (5), 97 (5), 96 (5), 91 (30), 79 (5), 77 (10), 65 (8).
c) m/z (35%) 14.286 min=228 (34), 214 (20), 213 (100), 197 (5), 165 (5), 135 (5), 119 (20), 107 (5), 91 (10), 77 (5), 65 (5). Major Product.
d) m/z (35%) 15.189 min=286 (20), 272 (15), 271 (100), 227 (5), 212 (5), 197 (3), 183 (2), 169 (3), 133 (3), 119 (5).
e) m/z (10%) 15.983 min=344 (20), 330 (20), 329 (100), 285 (5), 269 (3), 226 (3), 211 (2), 183 (3), 165 (3), 153 (2), 133 (6), 121 (2), 91 (2), 77 (1), 59 (3).
Example 6
[0141]
for 15 minutes. Ethylene glycol (2.3 g) and PET (0.25 g) (pellets obtained from Aldrich dissolved in CHCl 3 and trifluoroacetic acid and precipitated with methanol to form a white powder) were combined to form a PET slurry. The catalyst was added to the slurry with approximately 5 additional mL THF. After 2 hours, the solution became more transparent, indicating dissolution of the components of the depolymerization mixture. The admixture was stirred overnight, yielding a completely clear solution the following day. the THF was removed, yielding 225 mg of white solid. 1 H NMR 13 C NMR, and GC-MS were all consistent with bis(hydroxy ethylene) terephthalate.
Example 7
[0142]
[0143] Depolymerization of PET according to the above scheme: 25 mg of 1,3-dimethyl imidazole, iodide salt, and 11 mg of t-BOK were placed in a vial with 2 mL of THF and stirred for 15 min. Methanol (3.11 g) and PET (308 mg, as in Example 6) were combined with 5 mL of THF to form an insoluble mixture. The catalyst mixture was filtered into the PET/methanol mixture. After 1 hour, there was a noticeable increase in transparency. After 14 hours, the solution was completely homogeneous and clear. The solvent was removed by rotary evaporation to yield a white crystalline product (250 mg). 1 H NMR indicated complete conversion to dimethyl terephthalate.
[0144] Examples 6 and 7 may be better understood by reference to the synthetic route used to prepare the PET and the possible depolymerization products obtained therefrom. The PET obtained in each example was prepared by synthesis according to a two-step transesterification process from dimethyl teraphthalate (DMT) and excess ethylene glycol (EO) in the presence of a metal alkanoate or acetate of calcium, zinc, manganese, titanium etc. The first step generates bis(hydroxy ethylene) teraphthalate (BHET) with the elimination of methanol and the excess EO. The BHET is heated, generally in the presence of a transesterification catalyst, to generate high polymer. This process is generally accomplished in a vented extruder to remove the polycondensate (EO) and generate the desired thermoformed object from a low viscosity precursor. The reaction takes place according to the following scheme:
[0145] The different options for chemical recycling are regeneration of the base monomers (DMT and EG), glycolysis of PET back to BHET, decomposition of PET with propylene glycol and reaction of the degradation product with maleic anhydride to form “unsaturated polyesters” for fiber reinforced composites and decomposition with glycols, followed by reaction with dicarboxylic acids to produce polyols for urethane foam and elastomers.
[0146] In Example 7, PET powder was slurried in a THF/methanol solvent mixture. N-heterocyclic carbene (3-5 mol %), generated in situ, was added and within approximately 3 hours the PET went into solution. Anaylsis of the degradation product indicated quantitative consumption of PET and depolymerization via transesterification to EO and DMT. The DMT is readily recovered by recrystallization, while EO can be recovered by distillation ( FIG. 1 ). Alternatively, and as established in Example 6, if EO is used as the alcohol (˜50 to 200 mol % excess) in the THF slurry, the depolymerization product is BHET, which is the most desirable and can be directly recycled via conventional methods to PET ( FIG. 2 ). The N-heterocyclic carbene catalyst platform is extremely powerful, as the nature of the substituents has a pronounced effect on catalyst stability and activity towards different substrates.
[0147] The PET depolymerization reactions of Examples 6 and 7 are illustrated schematically below.
[0148] The following Examples 8-11 describe synthesis of new carbene precursors as illustrated in the following scheme:
Example 8
[0149] 3-Benzyl-1-methoxy-4,5-dimethylimidazolium iodide (2): Methyl iodide (0.5 mL, 7.8 mmol) was added via syringe to a solution of imidazole-N-oxide 1 (1.0 g, 4.9 mmol) in ca. 20 mL of CHCl 3 (compound 1 was prepared from 1,3,5-tribenzyl-[1,3,5]triazinane and butane-2,3-dione monooxime using the procedure of Arduengo et al. (1992), supra.) The resulting mixture was stirred at room temperature overnight. Removal of the volatiles in vacuo afforded a thick yellow oil of suitable purity in an undetermined yield. 1 H-NMR (δ, CDCl 3 ): 10.32 (s, 1H, N—CH—N); 7.39 (m, 5H, C 6 H 5 ); 5.56 (s, 2H, NCH 2 ); 4.38 (s, 3H, OCH 3 ); 2.27 (s, 3H, CH 3 ); 2.20 (s, 3H, CH 3 ).
Example 9
[0150] 3-Benzyl-1-methoxy-4,5-dimethylimidazolium hexafluorophosphate (3): Crude iodide 2 was taken up in deionized (DI) water, which separated the product from small amounts of a dark, insoluble residue. The water solution was decanted to a second flask and a solution of ammonium hexafluorophosphate (950 mg, ca. 5.8 mmol) in 10 mL of DI water was added in portions. An oil separated during the addition, and the supernatant solution was decanted out. The oil was crushed in cold (0° C.), and subsequently recrystallized in methanol. Yield: 1.3 g (73% from 1). 1 H-NMR (δ, CDCl 3 ): 8.67 (s, 1H, N—CH—N); 7.39 (m, 3H, C 6 H 5 ); 7.29 (d, 2H, C 6 H 5 ); 5.24 (s, 2H, NCH 2 ); 4.21 (s, 3H, OCH 3 ); 2.27 (s, 3H, CH 3 ); 2.17 (s, 3H, CH 3 ).
Example 10
[0151] 1-Benzyloxy-3-benzyl-4,5-dimethylimidazolium bromide (4): Benzyl bromide (1.2 mL, ca. 10 mmol) was added via syringe to a refluxing suspension of 1 (1.0 g, 5.0 mmol) in dry benzene. A dark orange oil separated after refluxing for 6 h, and cooling to room temperature. The supernatant was decanted and the remaining oil was dried under vacuum overnight, which caused the product to solidify. The solid mass was crushed in pentane, filtered and dried under vacuum. Yield: 1.34 g (63%). 1 H-NMR (δ, CDCl 3 ): 11.04 (s, 1H, N—CH—N); 7.6-7.2 (ov. m, 10H, 2×CrH 5 ); 5.59, 5.58 (s+s, N—CH 2 , O—CH 2 ); 2.09, 1.94 (s, 3H, CH 3 , CH 3 ). 3 C-NMR (δ, CDCl 3 ): 132.8 (OCH 2 - i C 6 H 5 ); 132.5 (NCN); 131.5 (NCH 2 - i C 6 H 5 ); 130.6, 130.3, 129.2, 129.0, 129.0, 128.9, 128.0 ( omp C 6 H 5 ); 124.8; 124.1 (NCCN; 83.9 (OCH 2 ); 51.2 (NCH 2 ); 8.89 (CH 3 ); 7.11 (CH 3 ).
Example 11
[0152] 3-Benzyl-1-benzyloxy-4,5-dimethylimidazolium hexafluorophosphate (5): A batch of crude bromide 4 (still as an oil before drying under vacuum) was dissolved in DI water and extracted with hexanes. The aqueous layer was separated and a solution of ammonium hexafluorophosphate (ca. 1.3 equiv.) was added dropwise with constant stirring. The yellow oil deposited on the walls of the flask was dissolved in warm methanol and a few drops of hexanes were added. Cooling to room temperature afforded off-white crystals of pure 5, which were rinsed with pentane and dried under vacuum. Yield: (82% from 1). 1 H-NMR (δ, CDCl 3 ): 8.42 (s, 1H, N—CH—N); 7.45-7.35, 7.18 (ov. m, C 6 H 5 ); 5.31, 5.20 (s+s, N—CH 2 , O—CH 2 ); 2.13 (s, 3H, CH 3 ); 2.05 (s, 3H, CH 3 ).
Example 12
[0153]
[0154] Bis(1-Benzyloxy-3-benzyl-4,5-dimethylimidazolylidene)silver(I) dibromoargentate (6). The carbene precursor 6 was prepared as follows: A mixture of silver oxide (128 mg, 0.55 mmol) and imidazolium bromide 4 (396 mg, 1.06 mmol) was taken up in dry CH 2 Cl 2 and stirred at room temperature for 90 minutes. The dark orange suspension was filtered through a pad of celite and evaporated to dryness, yielding an orange powder. Crystallization from THF afforded a white powder (2 crops). Yield: 291 mg (57%). 1 H-NMR (δ, CD 2 Cl 2 ): 7.47-7.32 (ov. m, 10H, 2×C 6 H 5 ); 5.23, 5.22 (s+s, NCH 2 , OCH 2 ); 2.01, 1.95 (s, 3H+3H, CH 3 , CH 3 ). 13 C-NMR (δ, CD 2 Cl 2 ): 136.2 (NCN); 133.3 (OCH 2 - i C 6 H 5 ); 130.8 (NCH 2 - i C 6 H 5 ); 130.7, 130.0; 129.3, 129.3, 128.5, 127.1, 123.9 ( omp C 6 H 5 +NCCN); 82.6 (OCH 2 ); 54.0 (NCH 2 ); 9.4 (CH 3 ); 7.8 (CH 3 ). Anal. Found: C, 47.56; H, 4.26; N, 5.79%. Calc. for C 38 H 40 Ag 2 Br 2 N 4 O 2 : C, 47.53; H, 4.20; N, 5.83%.
[0155] Examples 13 and 14 describe preparation of additional carbene precursors from N,N-diaryl-substituted diamines as illustrated in the schemes below.
Example 13
[0156]
[0157] Synthesis of carbene precursor 7 (2-pentafluorophenyl-1,3-diphenyl-imidazolidine): 200 mg (0.94 mmol, FW=212.12) N,N′-diphenyl-ethane-1,2-diamine was placed in a vial and dissolved in 5 mL CH 2 Cl 2 . A catalytic amount of p-toluenesulfonic acid and 50 mg of Na 2 SO 4 were added, followed by 230 mg (0.94 mmol, FW=196.07) of pentafluorobenzaldehyde. The mixture was stirred for 8 h. The Na 2 SO4 was filtered off and solvent was removed under reduced pressure to yield a light brown powder 395 mg (FW=436.2), 96% yield. 1 H NMR: (400 MHz, CDCl 3 , 25° C.) δ=3.7-3.9 (m, 2H), 3.9-4.1 (m, 2H), 6.5 (s, 1H), 6.7-6.8 (m, 2H), 6.8-6.9 (m, 1H), 7.2-7.5 (m, 2H). 19 F NMR: δ=−143.2 (s br, 2F), −153.7-−153.8 (m, 1F), 161.7-−161.8 (m, 2F).
Example 14
[0158]
[0159] Synthesis of carbene precursor 8 (2-pentafluorophenyl-1,3-bis-(2,4,6-trimethyl-phenyl)-imidazolidine): Mesityldiamine (512 mg, 1.7 mmol) was placed into a vial, equipped with a stirbar, with pentafluorobenzaldehyde (340 mg, 1.7 mmol). Glacial acetic acid (5 mL) was added and the reaction was stirred at room temperature for 24 h. The acetic acid was removed under reduced pressure and the product was washed several times with cold methanol to afford the product as a white crystalline solid (543 mg, 65%). 1 H NMR: (400 MHz, CDCl 3 , 25° C.) δ: 2.2 (s, 12H), 2.3 (s, 6H), 3.5-3.6 (m, 2H), 3.9-3.4 (m, 2H), 6.4 (s, 1H), 6.9 (s, 4H). 19 F NMR: −136.3-−136.4 (m, 1F), −148.6-−148.7 (m, 1F), −155.8-−155.9 (m, 1F), −163.0-−163.3 (m, 2F). | A method is provided for carrying out depolymerization of a polymer containing electrophilic linkages in the presence of a catalyst and a nucleophilic reagent, wherein production of undesirable byproducts resulting from polymer degradation is minimized. The reaction can be carried out at a temperature of 80° C. or less, and generally involves the use of an organic, nonmetallic catalyst, thereby ensuring that the depolymerization product(s) are substantially free of metal contaminants. In an exemplary depolymerization method, the catalyst is a carbene compound such as an N-heterocyclic carbene, or is a precursor to a carbene compound. The method provides an important alternative to current recycling techniques such as those used in the degradation of polyesters, polyamides, and the like. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation-in-part of U.S. patent application Ser. No. 08/950,218, filed Oct. 14, 1997, now U.S. Pat. No. 6,059,992 which is a continuation-in-part of U.S. patent application Ser. No. 08/541,435, filed Oct. 10, 1995, now U.S. Pat. No. 5,686,016, all of which are incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable
REFERENCE TO A “MICROFICHE APPENDIX”
Not applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to inhibiting corrosion in gas treating solutions comprised of alkanolamine solutions or other solvents used in the removal of hydrogen sulfide, carbon dioxide, mercaptans or other acid gases from natural gas or other hydrocarbon gases or liquids. Specifically, the present invention relates to passivating the metals in contact with the corrosive solutions by reducing the metal's oxidation state to a lower number. The reduced oxidation state results in a less corrosive, harder, impervious, and insoluble layer in contact with the treating solution. Additionally, the corrosion inhibitor may contain a metal oxide that will help to catalyze or increase the activity of the corrosion inhibitor and to also add passivation to pre-existing pits, crevices, or imperfections in the metal in contact with the gas treating solution.
2. General Background of the Invention
Contaminants in crude hydrocarbons subjected to refining or purification operations include acids or acid-forming materials such as CO 2 , H 2 S, mercaptans, and sulfides. These acid-forming materials must be removed from the natural and cracked hydrocarbon or refined streams (which contain such hydrocarbons as methane, ethane, propane, etc. and olefins such as ethylene, propylene, butylene, etc). One typically used method of removing the acids and acid-forming materials from hydrocarbon gases or liquids is by absorption in an amine regenerative solution absorbent unit. Regenerative amine solution units include columns with trays or other packing which are used to contact the aqueous alkanolamine solution with the hydrocarbon gases or liquids which contain the acids or acid-forming compounds. The amine solution can be regenerated by thermal stripping with steam to remove the acids or acid-forming compounds such as H 2 S, CO 2 , mercaptans and sulfides. This is accomplished in a regeneration section of the unit comprised of a column with trays or other packing in which the amine is contacted with steam, a reboiler in which the steam is formed, a reflux condenser and return system in which the steam is conserved, and other associated heat exchange equipment used for energy conservation or subsequent cooling of the amine prior to its return to the absorption section of the unit. Due to the presence of these acids and acid-forming compounds, corrosion is often observed in the equipment containing the solutions.
The metallurgy of the equipment contacting the treating solution is usually carbon steel or stainless steel. The iron in these steels are typically hydrolyzed or oxidized to any of the following iron hydroxides or iron oxides: Fe(OH)2, Fe(OH)3, FeO(OH), Fe2O3, or Fe3O4. The latter of these, Fe3O4 or magnetite, is the hardest, most impervious, and most insoluble of the iron oxides or iron hydroxides. Due to the much lower corrosion potential, it is highly desirable to maximize the conversion of iron in contact with the treating solution to the magnetite form.
Corrosion rates in the equipment sustaining the treating solution increase with increased amine concentration and acid gas concentration in solution. This usually limits the overall capacity of the treating solution for removal of more acid gas components from the gas or liquid stream it contacts. Corrosion results because the stability of the hydrolyzed or oxidized form of the steel that generally provides some passive resistance to corrosion is reduced when amine or treating solution concentration increases and when the concentration of the acid component in solution with the treating solution increases. By strengthening the passive film, the system capacity for handling more acid gas removal per unit volume of treating solution can be increased.
BRIEF SUMMARY OF THE INVENTION
The apparatus of the present invention solves the problems confronted in the art in a simple and straightforward manner.
The present invention relates to the addition of oxygen scavengers to alkanolamine solutions, blends of different alkanolamines, mixtures of alkanolamines with physical absorbents such as sulfolane or tetraglyme, and with physical solvent such as ethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, sulfolane, or dimethylethers of polyethylene glycol. The oxygen scavengers serve as corrosion inhibitors by reducing the iron oxides and hydroxides to the more corrosion resistant magnetite form. Additionally solutions of metal oxides may also be added to provide supplemental corrosion protection through additional passivation. By improving the passivation of the metal, corrosion is reduced. By lowering corrosion rates treating solution capacity can be increased without the normal limitations normally imposed by corrosion.
The oxygen scavengers can comprise quinone and an oxime, quinone and a hydroxylamine, or quinone and an oxime and a hydroxylamine. The oxygen scavengers can advantageously be mixed in deionized water. The resulting aqueous solution is preferably added to treating solution in a concentration of 0.0001-50,000 ppm, and more preferably 100-500 ppm (aqueous solution to treating solution).
The present invention includes a method of inhibiting corrosion in gas or light hydrocarbon treating systems utilizing as a treating solution alkanolamine aqueous solutions or physical solvents or combinations thereof by adding to the treating solution a mixture of oxygen scavengers in a concentration of from 0.001 to 50,000 ppm comprised of mixtures of a quinone and oximes of the formula
in which R 1 and R 2 are the same or different and are selected from hydrogen or lower alkyl groups of one to six carbon atoms. The oxime is preferably selected from a group consisting of methylethylketoxime, acetaldoxime, butyraldoxime, and propionaldoxime. The quinone is preferably hydroquinone. The alkanolamine is preferably selected from a group consisting of monoethanolamine, diethanolamine, methyldiethanolamine, triethanolamine, methylmonoethanolamine, 2-(2-aminoethoxy)ethanol, and diisopropanolamine. The treating solution preferably comprises mixtures of two or more amines or an amine and a physical absorbent from a group consisting of piperzine and sulfolane. The physical solvent is preferably a dimethylether of a polyethyleneglycol, tetraethyleneglycol, or sulfolane. Sodium molybdate is sometimes preferably added with the oxygen scavengers in a concentration of from 0.001 to 50,000 ppm to the treating solution.
The present invention also comprises a method of inhibiting corrosion in gas or light hydrocarbon treating systems utilizing as a treating solution alkanolamine aqueous solutions or physical solvents or combinations thereof by adding to the treating solution a mixture of oxygen scavengers from 0.001 to 50,000 ppm comprised of mixtures of a quinone and hydroxylamines of the formula
in which R 1 and R 2 are the same or different and are selected from hydrogen or lower alkyl groups of one to six carbons. The hydroxylamine is preferably selected from a group consisting of diethylhydroxylamine, isopropylhydroxylamine, dimethylhydroxylamine, hydroxylethylhydroxylamine, or hydroxylmethylhydroxylamine. The quinone is preferably hydroquinone. The alkanolamine is preferably selected from a group consisting of monoethanolamine, diethanolamine, methyldiethanolamine, triethanolamine, methylmonoethanolamine, 2-(2-aminoethoxy)ethanol, and diisopropanolamine. The treating solution preferably comprises mixtures of two or more amines or an amine and a physical absorbent from a group consisting of piperzine and sulfolane. The physical solvent is preferably a dimethylether of a polyethyleneglycol, tetraethyleneglycol, or sulfolane. Sodium molybdate is sometimes preferably added with the oxygen scavengers in a concentration of from 0.001 to 50,000 ppm to the treating solution.
The present invention also comprises a method of inhibiting corrosion in gas or light hydrocarbon treating systems utilizing as a treating solution alkanolamine aqueous solutions or physical solvents or combinations thereof by adding to the treating solution a mixture of oxygen scavengers comprising mixtures of a quinone, oxime, and hydroxylamine in a concentration of from 0.001 to 50,000 ppm. The oxime is preferably selected from a group consisting of methylethylketoxime, acetaldoxime, butyraldoxime, and propionaldoxime. The quinone is preferably hydroquinone. The hydroxylamine is preferably selected from a group consisting of diethylhydroxylamine, isopropylhydroxylamine, dimethylhydroxylamine, hydroxylethylhydroxylamine, or hydroxylmethylhydroxylamine. The alkanolamine is preferably selected from a group consisting of monoethanolamine, diethanolamine, methyldiethanolamine, triethanolamine, methylmonoethanolamine, 2-(2-aminoethoxy)ethanol, and diisopropanolamine. The treating solution preferably comprises mixtures of two or more amines or an amine and a physical absorbent from a group consisting of piperzine and sulfolane. The physical solvent is preferably a dimethylether of a polyethyleneglycol, tetraethyleneglycol, or sulfolane. The physical solvent is preferably a dimethylether of a polyethyleneglycol, tetraethyleneglycol, or sulfolane. Sodium molybdate is sometimes preferably added with the oxygen scavengers in a concentration of from 0.001 to 50,000 ppm to the treating solution.
The present invention also comprises a method of reducing suspended or soluble iron or other metals in gas or light hydrocarbon treating solutions or physical solvents or combinations thereof by adding to the treating solution or physical solvent a mixture of oxygen scavengers from 0.001 to 50,000 ppm comprised of a mixture of a quinone and an oxime of the formula
in which R 1 and R 2 are the same or different and are selected from hydrogen or lower alkyl groups of one to six carbon atoms. The oxime is preferably selected from a group consisting of methylethylketoxime, acetaldoxime, butyaldoxime, and propionaldoxime. The quinone is preferably hydroquinone. The treating solution preferably includes an alkanolamine selected from a group consisting of monoethanolamine, diethanolamine, methyldiethanolamine, triethanolamine, methylmonoethanolamine, 2-(2-aminoethoxy)ethanol, and diisopropanolamine. The treating solution preferably includes a mixture of two or more alkanolamines or an alkanolamine and a physical absorbent from a group consisting of piperzine and sulfolane. The physical solvent is preferably a dimethylether of a polyethyleneglycol, tetraethyleneglycol, or sulfolane. Sodium molybdate is sometimes preferably added with the oxygen scavengers in a concentration of from 0.001 to 50,000 ppm to the treating solution.
The present invention also includes a method of reducing suspended or soluble iron or other metals in gas or light hydrocarbon treating solutions utilizing alkanolamine aqueous solutions or physical solvents or combinations thereof by adding to the treating solution in a concentration of from 0.001 to 50,000 ppm a mixture of oxygen scavengers comprising mixtures of a quinone and hydroxylamines of the formula
in which R 1 and R 2 are the same or different and are selected from hydrogen or lower alkyl groups of one to six carbons. The hydroxylamine is preferably selected from a group consisting of diethylhydroxylamine, isopropylhydroxylamine, dimethylhydroxylamine, hydroxylethylhydroxylamine, or hydroxylmethylhydroxylamine. The quinone is preferably hydroquinone. The alkanolamine is preferably selected from a group consisting of monoethanolamine, diethanolamine, methyldiethanolamine, triethanolamine, methylmonoethanolamine, 2-(2-aminoethoxy)ethanol, and diisopropanolamine. The alkanolamine preferably comprises a mixture of two or more alkanolamines or an alkanolamine and a physical absorbent from a group consisting of piperzine and sulfolane. The physical solvent is preferably a dimethylether of a polyethyleneglycol, tetraethyleneglycol, or sulfolane. Sodium molybdate is sometimes preferably added with the oxygen scavengers in a concentration of from 0.001 to 50,000 ppm to the treating solution.
The present invention also comprises a method of reducing suspended or soluble iron or other metals in gas or light hydrocarbon treating solutions utilizing alkanolamine aqueous solutions or physical solvents or combinations thereof by adding to the treating solution in a concentration of from 0.00 1 to 50,000 ppm a mixture of oxygen scavengers comprising mixtures oaf quinone, oxime and hydroxylamine. The oxime is preferably selected from a group consisting of methylethylketoxime, acetaldoxime, butyraldoxime, and propionaldoxime. The quinone preferably is hydroquinone. The hydroxylamine is preferably selected from a group consisting of diethylhydroxylamine, isopropylhydroxylamine, dimethylhydroxylamine, hydroxylethylhydroxylamine,or hydroxylmethylhydroxylamine. The alkanolamine is preferably selected from a group consisting of monoethanolamine, diethanolamine, methyldiethanolamine, triethanolamine, methylmonoethanolamine, 2-(2-aminoethoxy)ethanol, and diisopropanolamine. The alkanolamine preferably comprises a mixture of two or more alkanolamines or an alkanolamine and a physical absorbent from a group consisting of piperzine and sulfolane.
Sodium molybdate is sometimes preferably added with the oxygen scavengers in a concentration of from 0.001 to 50,000 ppm to the treating solution.
As used herein, ‘MMSCFD’ means ‘million standard cubic feet per day’.
It is a principal object of the present invention to inhibit corrosion in alkanolamine or other treating solutions by adding to the solution mixture of oxygen scavengers including a quinone and oximes and/or hydroxylamines.
It is a further object of the present invention to provide the addition of the quinone, oxime, and hydroxylamine so as to reduce the iron to the magnetite form in all areas in contact with the treating solution including low temperature and higher temperature areas and in both the liquid and vapor phase.
It is a further object of the present invention to provide the addition of the quinone, oxime, and hydroxylamine so as to reduce the iron or other metals suspended or soluble in the treating solution.
It is a further object of the present invention to provide the addition of supplemental metal oxides to further affect the passivation of the treating equipment. The metal oxides can be added with the other corrosion inhibitors or by themselves.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is a method of inhibiting corrosion in gas and hydrocarbon treating solutions by adding to the solution oxygen scavengers which can comprise quinone and an oxime, quinone and a hydroxylamine, or quinone and an oxime and a hydroxylamine. The oxygen scavengers can advantageously be mixed in deionized water. When the scavengers are quinone and an oxime, they can be mixed in a ratio of 2-6 (and preferably 5) weight % quinone and 10-30 (and preferably 10) weight % oxime, with the balance deionized water. When the scavengers are quinone and a hydroxylamine, they can be mixed in a ratio of 2-6 (and preferably 5) weight % quinone and 10-30 (and preferably 10) weight % hydroxylamine, with the balance deionized water. When the scavengers are quinone, an oxime, and a hydroxylamine, they can be mixed in a ratio of 2-6 (and preferably 5) weight % quinone, 10-15 (and preferably 10) weight % oxime, and 10-15 (and preferably 10) weight % hydroxylamine, with the balance deionized water.
When sodium molybdate is used, it can be added as part of the corrosion inhibitor of the present invention, or it can be used by itself. When used as part of the corrosion inhibitor of the present invention, sodium molybdate comprises preferably 1.5%-10% (and most preferably about 3.5%) by weight of the inhibitor.
The invention is directed toward inhibiting corrosion in gas and hydrocarbon treating solutions by adding to the solution an oxime of the formula
in which R1 and R2 are the same or different and are selected from hydrogen or lower alkyl groups of one to six carbon atoms. Also added to the treating solution is a hydroxylamine of the formula
in which R1 and R2 are the same or different and are selected from hydrogen or lower alkyl groups of one to six carbon atoms. Also added to the treating solution is a quinone of the formula
in which R1 and R2 are the same or different and are selected from primarily hydrogen but may also be a lower alkyl group.
The quinone acts as a promoter so that the iron reduction reactions with the oxime and hydroxylamine occur at a lower temperature than they would unpromoted. The oxime and hydroxylamine are more aggressive toward actual reduction of the iron to magnetite. The primary but not necessarily only products of said reactions other than the magnetite are H2O, N2O, N2, CO2, low molecular weight ketones, and lower volatile amines.
The oximes may be used with the quinone, the hydroxylamines may be used with the quinone, and the oximes and hydroxylamines may be used together with the quinone. The preferred embodiments provide that the choice of oximes and hydroxylamines is such that the oxygen scavengers utilized have both vapor-liquid distribution through all operating areas of the treating equipment. The preferred hydroxylamine for use in the present invention is diethylhydroxylamine, though it is believed that isopropylhydroxylamine, dimethylhydroxylamine, hydroxylethylhydroxylamine, and/or hydroxylmethylhydroxylamine could also be used.
The hydroxylamine is advantageous as it improves preferential scavenging of oxygen in the vapor phase. In the operating units temperatures vary from less than 100 degrees F. to over 260 degrees F. and the addition of the more volatile component (hydroxylamine results in improved inhibition above the liquid phase alkanolamine solution from reactions with oxygen.
In conjunction with the oxygen scavengers, a metal oxide such as sodium molybdate may be added. The molybdate will further passivate the metal surfaces especially where an imperfection has occurred due to previous corrosive action such as pitting, cracking, or erosion. The molybdate will also help to fill and smooth out any minor imperfections or rough areas on the original metal surface.
EXAMPLE 1
Natural Gas Plant—CO2 Removal—DEA Solvent
A corrosion inhibitor (Inhibitor A) was produced by adding 5 weight % of hydroquinone, 10 weight % of methylethylketoxime, and 10 weight % of diethylhydroxylamine to deionized water.
A plant treating about 75 MMSCFD of natural gas containing about 8% CO2 uses a 27% DEA (diethanolamine) solution to reduce the treated gas content to less than 3% CO2. Until recently, the CO2 lean loadings were very high, often exceeding 0.1 mol CO2/mol of DEA. The following were some of the consequences of corrosion prior to the start of the Inhibitor A plant trial:
A total iron concentration in the solvent was increasing steadily;
A plate-and-frame lean/rich exchanger required frequent cleaning to remove iron carbonate deposits; and
Several pinhole leaks developed on the hot lean amine piping to and from the reboiler since startup about two year ago.
The solvent was becoming increasingly blue as a result of corrosion of stainless steel equipment.
Solution
Coastal Chemical recommended to treat the system with Inhibitor A. Inhibitor A is an effective corrosion inhibitor and antifoulant treatment program for amine units.
Inhibitor A was added at a rate of 8 gallons per day for three weeks to a 12,000 gallon 27 weight % alkanolamine system. The addition rate was then reduced to 2 gallons per day for the next six months and then further reduced to 1 gallon per day as the final daily addition rate.
Results
Corrosion in the system was markedly reduced as indicated by solution iron decreasing from an initial concentration of 65 ppm to less than 30 ppm within two weeks of initial dosing. System fouling due to corrosion products and leakage were also diminished within the first couple of months of usage.
The solvent iron concentration has decreased steadily from 65 PPM to a 10 to 20 PPM range despite high lean loadings.
The differential pressure across the plate-and-frame exchanger has remained steady at about 5 PSIG for several months showing no signs of fouling.
No leaks on the hot lean amine piping have occurred since startup of treatment with Inhibitor A.
EXAMPLE 2
Refinery Hydrogen Unit—CO2 Removal—MDEA-Based Specialty Solvent
An amine unit treats gas containing about 25% CO2 with a 50% solution of a specialty MDEA-based (methyldiethanolamine-based) solvent to remove acidic compounds from the incoming sour gas.
Total iron concentration in the solvent ranged from 100 PPM to over 500 PPM.
Iron carbonate fouling reduced heat transfer effectiveness and caused equipment plugging.
Corrosion rates historically ranged from 50 to over 100 mils/year as measured by electrical-resistance corrosion probes.
Several pieces of equipment developed leaks and other types of failures due to corrosion caused by carbonic acid attack.
Solution
Coastal Chemical recommended to treat the system with Inhibitor A. Inhibitor A is an effective corrosion inhibitor and antifoulant treatment program for amine units.
Inhibitor A was added at a rate of about 15 gallons per day for three weeks to an about 35,000 gallon 50 weight % MDEA-based specialty system. The addition rate was then reduced to about 10 gallons per day for the next six months and then further reduced to about 6 gallons per day as the final daily addition rate.
Results
The solvent iron concentration has decreased steadily to the lowest levels in record since continuous injection of Inhibitor A was started.
The corrosion rates as measured by corrosion probes decreased to the 0 to 5 mils/yr range.
The sodium molybdate mentioned previously can be purchased commercially in a 35% aqueous solution, and it might be added to Inhibitor A, for example, by substituting the 35% aqueous solution for 10% of the solution (substituting for deionized water), so that the sodium molybdate would comprise about 3.5% by weight of the new inhibitor (hereinafter referred to as Inhibitor B).
EXAMPLE 3
Corrosion in DEA Systems Removing CO2
Corrosion rates were measured in mpy (mils per year) in a DEA system removing CO2, with severe conditions (50% DEA, 0.5 mole CO2/mole DEA, 190 degrees F. (87.7 degrees C.), agitated for 48 hours). The corrosion rate without any inhibitor was 102 mpy. The corrosion rate with only an oxygen scavenger was 100 mpy. The corrosion rate with only a filming amine was 86 mpy. The corrosion rate with Inhibitor A was 76 mpy. The corrosion rate with Inhibitor B was 53 mpy.
EXAMPLE 4
Corrosion in MDEA Systems Removing CO2
Corrosion rates were measured in mpy (mils per year) in a MDEA system removing CO2, with the following conditions: 50% MDEA, 0.45 mole CO2/mole MDEA, 190 degrees F. (87.7 degrees C.), agitated for 48 hours. The corrosion rate without any inhibitor was 72 mpy. The corrosion rate with only a filming amine was 62 mpy. The corrosion rate with only an oxygen scavenger was 55 mpy. The corrosion rate with Inhibitor A was 25 mpy. The corrosion rate with Inhibitor B was 0.1 mpy
Sodium molybdate residuals in the treating solution are preferably maintained at about 1-5000 ppm, more preferably at about 1-500 ppm, and most preferably at about 1-50 ppm.
Hydroquinone residuals in the treating solution are preferably maintained at about 5 ppm-500 ppm.
Methylethylketoxime residuals in the treating solution are preferably maintained at about 50 ppm-1000 ppm.
Diethylhydroxylamine residuals in the treating solution are preferably maintained at about 50 ppm-1000 ppm.
All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise.
The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims. | Corrosion in aqueous alkanolamine, physical solvents, or combination of alkanolamine and physical solvent solutions used to remove acid gases from natural gas, synthetic gas, or light hydrocarbon streams can be reduced by addition of mixtures of oxygen scavengers or mixtures of oxygen scavengers and sodium molybdate. The oxygen scavengers must be promoted to reduce metal surfaces in contact with the solutions to a more passive, harder, and insoluble form at the operating temperature of the treating system. The sodium molybdate provides additional passivation especially in the imperfections on the surface of the metal where corrosion accelerates. | 2 |
REFERENCE TO RELATED APPLICATION
The subject matter of this application is related to the subject matter of U.S. patent application Ser. No. 07/523,726 (CSL-174A), entitled "Limp Material Segment Coupler" filed even date herewith.
BACKGROUND OF THE INVENTION
This invention relates to the transportation of limp material segments, such as fabric. In particular, the invention relates to an apparatus for transporting limp material segments along a work surface.
Conventional techniques for transporting limp material segments along a work surface to a workstation often utilize manual labor. In the context of the textile industry, garment assembly personnel may manually feed the fabric workpiece or workpieces along a work surface to the sewing head of a sewing machine. Although many aspects of the textile industry benefit from automation, in practice transportation of fabric workpieces for assembly at a sewing machine largely remains dependent upon manual labor.
A primary shortcoming of the use of manually controlled workpiece transport is that the technique is enormously labor intensive; that is to say, a large portion of the cost to manufacture a product from limp material is attributable to labor. To reduce cost, techniques focusing on automation of transporting a limp material segment is desirable.
There are several known techniques for precisely controlling the position of the workpiece in the near-field region of the sewing head, see, for example, U.S. Pat. No. 4,719,864. Feed dog assemblies have also been used for this function. Those controllers however are generally so limited in their range of operation that other techniques are required to feed the workpiece to the effective range of the near-field controllers.
There are also known techniques for automatically (e.g. under the control of a programmed computer) driving endless belts to transport limp material workpieces over relatively large distances to workstations, see, for example, U.S. Pat. Nos. 4,457,243, 4,512,269, 4,032,046 and 4,607,584.
However, the endless belt techniques, which are particularly effective for control of gross motion control of workpieces are limited in their applicability to relatively short range motions necessary, for example, to present fabric to the near-field controller of an automated sewing machine. Therefore, there exists a need for improved systems for controlling the transport of limp material segments, particularly for application where linear feed control is needed to drive a workpiece to a position within the range of a near-field controller for a seam joining assembly.
SUMMARY OF THE INVENTION
The present invention is an apparatus for transporting a limp material segment, for example, cloth, along a reference axis parallel to a planar work surface.
The apparatus includes a base member positioned above a work surface. A four-bar linkage assembly couples a segment coupling assembly to the base member. The four-bar linkage assembly includes a first elongated bar assembly having a length L1 and being pivotally coupled to a first point P1 on the base member. A second elongated bar assembly, extending along a link axis and having a length L2, is pivotally coupled at a first end to a second point P2 on the base member, where the first point P1 is spaced apart from the second point P2. The length L2 of the second bar assembly is controllable along the link axis in a range L2-1 to L2-2, where L2-1 is less than L2-2.
A third elongated bar assembly, having length L3, is pivotally coupled at a first end to the segment coupling assembly (wherein its coupler pivot axis is substantially parallel to the work surface and substantially perpendicular to the reference axis), pivotally coupled at a second end to the second end of the second bar assembly and pivotally coupled to the first bar assembly at an intermediate point P3 between the first and second ends. The pivot axes for all of the above-described pivoting couplings are mutually parallel and are parallel to the work surface.
In addition, the apparatus includes an actuator for selectively rotating the second bar assembly about a pivot axis extending through point P2 between a first angle A1 and a second angle A2.
The values of L1, L2, and L3, and P1, P2, and P3, and A1 and A2 are such that as the second bar assembly is rotated by the actuator between angle A1 and angle A2, the segment coupling assembly travels along a substantially straight path substantially parallel and adjacent to the reference axis when second bar assembly is L2-1. Furthermore, when second bar assembly is L2-2 and is rotated by the actuator between angle A2 and angle A1, the coupling member travels in a non-straight path.
In various forms of the invention, the first and third bar assemblies may each be single element bars or, alternatively may each be a parallelogram link assembly. With the latter configuration, the angular orientation of the segment coupling assembly may readily be maintained fixed throughout its range of motion. Thus, a planar surface on the bottom of the segment coupling assembly may be maintained substantially parallel to the work surface particularly when the length of the second segment bar assembly is substantially equal to L2-1.
In another form of the invention, the apparatus for transporting a limp material segment is incorporated into a textile assembly apparatus, for example, a seam joining apparatus including needle and bobbin assemblies at a seam joining station on the work surface, and a feed dog assembly including means for driving a limp material segment overlying the feed dog assembly along a sewing axis on the work surface. Preferably, the sewing axis is angularly offset from the reference axis along which the segment coupling assembly traverses.
In one form of the invention, the segment coupling assembly may include a rigid drive member which is pivotally coupled to the third bar assembly about the coupler pivot axis. In this form, the segment coupling assembly further includes a segment coupler having a substantially planar lower surface. The lower surface is adapted to frictionally engage a limp material segment. A spring coupler couples the segment coupler to the drive member. The spring coupler includes at least one bent sheet spring. Each bent sheet spring includes a resilient sheet extending from a first end to a second end along at least one spring axis and is bent along at least one axis substantially perpendicular to the associated spring axis, wherein each of the springs is coupled at the inner end to the drive member and at the outer end to the segment coupler. The spring axes of each of the springs are substantially parallel to the planar surface of the segment coupler.
In single spring embodiments, for example, a single annular bent spring may couple the drive member to a peripheral ring-like segment coupler. In two spring embodiments, a pair of springs may couple opposing ends of the drive member to a peripheral ring-like segment coupler, where the two springs extend along a common spring axis. A second pair of similar, but ninety degree offset, springs may be used to form a four spring configuration. The three spring configuration may be established with three springs that are mutually offset by sixty degrees. Other configurations may also be used.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects of this invention, the various features thereof, as well as the invention itself, may be more fully understood from the following description, when read together with the accompanying drawings in which:
FIG. 1A illustrates an exemplary embodiment of a limp material segment transport apparatus in accordance with the present invention;
FIG. 1B illustrates a schematic representation of the embodiment of FIG. 1A;
FIG. 2 illustrates in a perspective view the link coupling assembly for the parallelogram linkage assembly of the transport apparatus of FIG. 1;
FIGS. 3A-3D illustrate side views of the transport apparatus of FIG. 1 at various positions within its range of motion;
FIG. 4 illustrates the range of motion of the segment coupling assembly of the embodiment of FIG. 1;
FIG. 5 illustrates in a perspective view one embodiment of the segment coupling assembly of the transport apparatus of FIG. 1;
FIG. 6 illustrates in a perspective view another embodiment of the segment coupling assembly;
FIG. 7 illustrates in a perspective view the segment coupling assembly of FIG. 6 under an applied force;
FIG. 8 illustrates in a perspective view another embodiment of the spring coupler assembly;
FIG. 9 illustrates in a perspective view another embodiment of the spring coupler assembly; and
FIG. 10 shows a sewing machine together with an exemplary limp material transport apparatus of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1A and 1B show an exemplary limp material segment transport apparatus 10 in accordance with the present invention and a reference XYZ coordinate system. Apparatus 10 is shown with respect to a work platform 12 having a substantially planar upper surface 14 which is substantially parallel to the XY plane defined by the reference coordinate system. A base member 16 is fixedly positioned by a support assembly (not shown) above the work surface 14.
Apparatus 10 includes a segment coupling assembly 110 coupled by a four bar link assembly 18 to the base member 16, a pneumatic actuating extender assembly 32, a pneumatic actuating angular rotation assembly 38 (adapted to pivotally couple extender assembly 32 about pivotal coupling axis 38a), a pneumatic source unit 34 (which is connected via line 36 to extender assembly 32 and angular rotation assembly 38), and a controller 33 (which is electrically connected to extender assembly 32 and angular rotation assembly 38 via line 33a and 33b, respectively). The extender assembly 32, angular rotation assembly 38, four bar linkage assembly 18 and segment coupling assembly 110 are all coupled, directly or indirectly, to base member 16.
Segment coupling assembly 110 is comprised of a rigid drive member 112, a spring coupler assembly 117, and a segment coupler 114 having a substantially planar lower surface 116 for frictionally engaging a limp material segment. In the embodiment of FIG. 1A, the segment coupler 114 includes a fastening ring 114A affixed to a block 114B.
The four-bar linkage assembly 18 includes a first bar assembly 46, a second bar assembly 48, and a third bar assembly 50, and a fourth bar assembly (effectively provided by the sidewalls of base member 16), and associated couplers for the respective bar assemblies. In the illustrative embodiment, first bar assembly 46 includes link member 20 and link member 22. Second bar assembly 48 includes variable length link member 28. Third bar assembly 50 includes link member 24 and link member 26.
A first end of link member 20 is pivotally coupled to support member 16 about a pivotal coupling axis 20a extending in the X-direction. Similarly, a first end of link member 22 is pivotally coupled to support member 16 about a pivotal coupling axis 22a extending in the X-direction. Link member coupling assembly 40 is pivotally coupled (about an x-directed pivotal coupling axis 40a) to a first end of link member 24. Assembly 40 also is pivotally coupled (about an x-directed pivotal coupling axis 40b) to the second end of link member 20. Assembly 40 also is pivotally coupled (about an x-directed pivotal coupling axis 40c) to an intermediate point on link member 26 and to the second end of link member 22. The other end of link member 24 is pivotally coupled to segment coupling assembly 110 about X-directed pivotal coupling axis 24a. Similarly, the other end of link member 26 is pivotally coupled to segment coupling assembly 110 about x-directed pivotal coupling axis 26a.
FIG. 2 illustrates, in exploded view form four bar linkage assembly 18 including coupling assembly 40, and the link members 20, 22, 24, and 26, of assembly 10 shown in FIG. 1. In the present embodiment, link member 20 and link member 22 configured in a substantially parallel relationship, and in addition form two sides of a parallelogram having vertices defined by the pivotal coupling axes 20a, 22a, 40b, and 40c. Similarly, link member 24 and link member 26 are configured in a substantially parallel relationship, and in addition form two sides of a parallelogram with vertices defined by the pivotal coupling axes 24a, 26a, 40a, and 40c. FIG. 2 further illustrates link member coupling assembly 40 of assembly 10 shown in FIG. 1. Link member coupling assembly 40 is utilized to constrain link member 20, link member 22, link member 24, and link member 26 respectively, in the above mentioned parallelogram configurations.
Link member 28 is reciprocally coupled to extender assembly 32 whereby the length of link member 28 may be extended or retracted along axis 32a by actuating or deactivating extender assembly 32 respectively. Controller 33, via line 33b, controls the state of extender assembly 32.
When extender assembly 32 is in a deactivated state, link member 28 is in a retracted position, as shown in FIG. 1A. In the retracted position, link member 28 permits segment coupling assembly 110 to travel along a substantially straight path, at a nominal height above work surface 14, and substantially parallel to the reference axis.
In contrast, when extender assembly 32 is in an activated state, link member 28 is in an extended position. In the extended position, link member 28 causes segment coupling assembly 110 to pivot about pivotal coupling axis 40c in rising above its nominal height with respect to work surface 14.
Base member 16, link member 22, link member 28, and link member 26 are configured in an arrangement having appropriate proportions to utilize a Hoecken's straight-line motion. That is to say, with appropriate link member proportions, lower surface 116 of segment coupling assembly 110 remains at a constant height above work platform 12 during transportation of a limp material along work platform 12.
Prior to the start of operation, the actuator assembly 38 initially controls axis 32a to be offset approximately 135 degrees counterclockwise (viewed from the +X axis) from the position shown in FIG. 1A. This angle is referred to below as angle A1. Thus, in operation, the drive member 112 is in a raised position to allow for placement of a limp material workpiece directly below lower surface 116. Once the material is in place, the drive member 112 of segment coupling assembly 110 then is established at a nominal level above upper surface 14 of work platform 12 such that lower surface 116 is in vertically compliant contact with a limp material which is to be moved in the -Y direction along work surface 14. With extender assembly 32 in a deactivated state (link member 28 in a retracted position), controller 33 activates angular rotational assembly 38 causing assembly 38 to rotate approximately 135 degrees about axis 38a in clockwise direction. In response, segment coupling assembly 110 is forced in the -Y direction to the position shown in FIG. 1A. The link members rotate about their respective pivotal coupling points detailed above thereby changing angles of the previously described parallelograms; however, segment coupling assembly 110 remains at a constant level above work platform 12. The linear distance traversed by segment coupling assembly 110 is directly proportional to the aggregate rotation of angular rotation assembly 38.
After angular rotational assembly 38 rotates in the clockwise direction for approximately 135 degrees, controller 33 activates extender assembly 32 thus extending link member 28 and consequently causing segment coupling assembly 110 to rise. Pivotal coupling axis 40c is utilized as a fulcrum in a "see-saw" type configuration; that is to say the extension of link member 28 causes segment coupling assembly 110 to pivot about pivotal coupling axis 40c in rising above its nominal height with respect to work platform 12.
With link member 28 in the extended position, controller 33 commands angular rotational assembly 38 to rotate 135 degrees in counterclockwise direction. Then the actuator 32 is activated to fully retract link member 28. Controller 33 then deactivates extender assembly 32 thereby retracting the link member 28 to its normal position which corresponds to returning segment coupling assembly 110 to the original nominal height above work platform 12. The segment coupling assembly 110 thus is returned to its original position.
FIGS. 3A, 3B, 3C, and 3D depict the configuration of segment coupling assembly 110, angular rotation assembly 38, extender assembly 32, and the link members in four state of the periodic motion of apparatus 10. FIG. 3A illustrates apparatus 10 in its "initial" state wherein angular rotation assembly 38 is at position with axis 32a at its nominal position α=0 degrees, (i.e. A1 or 135° counterclockwise from the normal (N) to the surface 14) and extender assembly 32 is in a deactivated state (with link member 28 fully retracted). The "initial" state follows placement of the limp material beneath surface 116 during which link member 28 is extended.
FIG. 3B illustrates apparatus 10 after segment coupling assembly 110 completed linear travel wherein angular rotation assembly 38 is approximately at position α=135 degrees (i.e. A2 or 0° from the normal (N) to the surface 14) and extender assembly 32 remains in a deactivated state.
FIG. 3C illustrates apparatus 10 after extender assembly 32 is activated thereby extending link member 28. As detailed above, in response segment coupling assembly 110 lifts above its nominal position above work platform 12.
FIG. 3D illustrates apparatus 10 after angular rotation assembly 38 returns to the position of α=0 degrees. In addition, extender assembly 32 remains in an activated state.
FIG. 4 illustrates the cyclic motion of apparatus 10 with respect to the path traced by segment coupling assembly 110. Segment coupling assembly 110 traces a linear path horizontal to work platform 12 from Point A to Point B during which lower surface 116 of segment coupling assembly 11 is engaged with a limp material. The linear distance traversed by segment coupling assembly 110 from Point A to Point B is directly proportional to the aggregate rotation of angular rotation assembly 38 and the link member proportions. At Point B, extender assembly 32 is actuated causing segment coupling assembly 110 to lift above work platform 12 and traverse to point C. Angular rotation assembly 38 then returns to the α=0 degrees whereby segment coupling assembly 110 traces a path from Point C to Point D. At Point D extender assembly is deactivated and thus segment coupling assembly 110 returns to its original height above work platform 12.
Although the system operation description detailed a clockwise periodic motion, apparatus 10 may be operated in a counter-clockwise periodic motion. This translates into a +Y directional movement of a limp material along work platform 12. In addition, the aggregate angle traversed by angular rotation assembly 38 is user-selectable to satisfy the system constraints. For example, a shorter linear travel of segment coupling assembly 110 may be achieved when the user selects an aggregate angle less than 135 degrees. Similarly, a longer linear travel of segment coupling assembly 110 may be achieved via an aggregate angle greater than 135 degrees (e.g., up to 180°).
As mentioned above, and as illustrated in FIG. 1B, link member 22 (link L1), link member 28 (link L2), link member 26 (link L3), and base member 16 (link L4) are configured in a configuration having appropriate proportions to utilize a Hoecken's straight-line motion. The appropriate link proportions that provide linear horizontal travel of segment coupling assembly 110 are defined below:
______________________________________link L1 2.5link L2-1 (L2 extended) 2.0link L2-2 (L2 retracted) 1.0link L3 5.0link L4 2.0______________________________________
In addition, pivotal coupling axes 22a and 38a are vertically proportionally displaced from each other substantially by 0.0 and horizontally proportionally displaced from each other substantially by 2.0; and pivotal coupling axis 40c is proportionally displaced from the distal end of link member 26 substantially by 2.5 along longitudinal axis of that link member. Utilizing the aforementioned link member proportions, a linear proportional travel of segment coupling assembly 110 of 3.0 is realized for 135° rotation of angular rotation assembly 38; a linear proportional travel of 4.0 may be achieved with a full 180° rotation of assembly 38.
In one embodiment, link Ll, link L2-1 (L2 extended), link L2-2 (L2 retracted), link L3, and link L4 are substantially equal to 2.5 inches, 2.0 inches, 1.0 inches, 5.0 inches, and 2.0 inches, respectively. In addition, pivotal coupling axes 22a and 38a are vertically displaced from each other substantially by 0.0 inches and horizontally displaced from each other substantially by 2.0 inches; and pivotal coupling axis 40c is displaced from the distal end of link member 26 substantially by 2.5 inches along link member axis. Other dimensions consistent with the proportional dimensions given above may be used depending upon the desired final apparatus size.
FIG. 5 shows a limp material segment coupling assembly 110 disposed over a limp fabric workpiece F on the planar top surface 14 of work platform 12. Assembly 110 includes a rigid drive member 112, an annular segment coupler 114 having a substantially planar lower surface 116 which is adapted to frictionally engage the limp material segment F, and the spring coupling assembly 117.
It should be noted, the dimensions of segment coupler 114 may be tailored to suit the system and user needs. That is to say, the user, or system, may require segment coupler 114 to make contact with a relatively large portion of the limp material to be positioned on work platform 12. FIG. 1 depicts a segment coupler 114 including a fastening ring 114A affixed to a block 114B. Block 114B has a lower surface 116 that has a greater limp material contact area than the corresponding lower surface 116 of the segment coupler depicted in FIG. 5.
The spring coupling assembly 117 is comprised of a sheet spring 120 which is an annular resilient sheet extending from an inner peripheral edge to an outer peripheral edge. Sheet spring 120 is coupled at its inner peripheral edge to drive member 112 and at its outer peripheral edge to segment coupler 114. The sheet spring 120 has an annular region 121 which is bent about a closed circular axis. For this annular spring embodiment, spring axes are considered to extend radially outward from the center of the drive member 12. The spring axes are substantially parallel to the lower planar surface 116 of segment coupler 114.
In operation, limp material segment coupling assembly 110 substantially resists rotational and/or undesired lateral motion when engaged with and, during the transportation of, a limp material segment along work platform 12. Assembly 110 is utilized to frictionally couple a limp material workpiece and in response to an applied force to drive member 112 traverse a path substantially coherent with the direction of the horizontal component of the applied force.
In particular, limp material segment coupling assembly 110 is configured such that it is substantially resistant to torsional and/or lateral motion in the X-Y plane. That is to say, when a force is applied to drive member 112, wherein the applied force has both vertical and horizontal components, assembly 110 is resistant to torsional motion with respect to both the direction of the horizontal component of the applied force and the substantially planar surface 14 of work platform 12. However, assembly 110, in response to the applied force traverses a substantially coherent path with respect to the direction of the horizontal component of the applied force. Coupler 114 of assembly 110 is relatively vertically compliant to accommodate for variability in thickness (such as caused by cross-seams) in limp material F. Moreover, coupler 114 is substantially resistant to linear or rotational motion (relative to drive member 112) in the X and Y direction.
FIG. 6 shows the spring coupling assembly 117 for an embodiment of a limp material segment coupling assembly 110 in accordance with the present invention. In the illustrative embodiment, spring coupling assembly 117 includes three bent sheet springs 120a, 120b and 120c.
Sheet springs 120a, 120b and 120c are each comprised of a resilient sheet extending from a first end to a second end along spring axes 118a, 118b and 118c, respectively. Sheet springs 120a, 120b and 120c are coupled at the inner end to drive member 112 and at the outer end to segment coupler 114 wherein the sheet springs are bent along axes perpendicular to spring axes 118a, 118b and 118c, respectively. In the illustrative embodiment, spring axes 118a, 118b and 118c are substantially parallel to planar surface 116 of segment coupler 114, and in addition are in an equiangular configuration, although differing angular dispersions may be used in other embodiments.
FIG. 7 illustrates the reaction and motion of the assembly 110 of FIG. 6 due to an applied force F xz denoted by the force vector. As described above, sheet springs 120a, 120b, and 120c are configured to resist the torsional motion and/or the undesired lateral movement resulting from applied force 130. Segment coupler 114 traverses a path substantially coherent with respect to the direction of the horizontal component of applied force 130. In the illustrated embodiment, applied force 130 includes a vertical component (F z ) and a horizontal component (F x ). In response to applied force 130, limp material segment coupling assembly 110 traverses a direction substantially coherent with the direction of horizontal component (F x ). Note, when coupling assembly 110 is engaged with a limp material segment, sheet springs 120a, 120b, and 120c permit segment coupler 114 to tilt with respect to the planar work platform 12. This permits the assembly to accomodate for lumps in the material such as those due to cross-seams.
FIG. 8 shows the spring coupling assembly for an alternative embodiment of a limp material segment coupling assembly 110 in accordance with the present invention. In the illustrative embodiment, spring coupling assembly 117 includes four bent sheet springs 120a, 120b, 120c and 120d extending from an integral central region. A first pair of sheet springs 120a and 120b are comprised of a resilient sheet extending along spring axes 118a and 118b, respectively. A second pair of sheet springs 120c and 120d are also comprised of a resilient sheet extending along spring axes 118c and 118d, respectively.
As in the previously described embodiment, sheet springs 120a, 120b, 120c and 120d are coupled at the inner end at the central region to drive member 112 and at the outer end to segment coupler 114 wherein the sheet springs are bent along an axis perpendicular to spring axes 118a, 118b, 118c and 118d, respectively. Spring axes 118a, 118b, 118c and 118d are substantially parallel to planar surface 116 of segment coupler 114. In addition, spring axes 118a and 118b of first pair of sheet springs (120a and 120b) are substantially perpendicular to spring axes 118c and 118d of the second pair of sheet springs (120c and 120d); and, sheet springs 120a, 120b, 120c and 120d are in an equi-angular configuration.
Illustrated in FIG. 9 is an alternative form of the embodiment illustrated in FIG. 8, specifically an alternate form of spring coupling assembly 117. Sheet springs 120a and 120b may be comprised of a single resilient sheet 120a', extending along a single spring axis 118a', coupled at first distal end 120aa to segment coupler 114, at intermediate point 120ab and 120ab' to rigid drive member 112, and at second distal end 120ac to segment coupler 114. Similarly, sheet spring 120c and 120d may be comprised of a single resilient sheet 120d', extending along a single spring axis 118d', coupled at first distal end 120dd to segment coupler 114, at an intermediate point 120de and 120de' to rigid drive member 112, and at second distal end 120df to segment coupler 114. In addition, spring axes 118a' and 118d' are substantially perpendicular.
FIG. 10 shows portions of a sewing machine 200, including a pair of needles 202 and 204, presser foot 206, and feed dogs 208, disposed over the planar work surface 14. A limp material transport apparatus 10 is also positioned to drive a limp material segment F along a feed axis A toward the feed dogs and needles. In this embodiment, the feed axis A is angularly offset from the reference (or sewing) axis R.
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. | The invention is an apparatus for transporting a limp material segment, such as cloth, along a reference axis parallel to a planar work surface. The apparatus includes a base member positioned above a work surface. A four-bar linkage assembly couples a segment coupling assembly to the base member. The four-bar linkage assembly includes first and second elongated bar assemblies, each being pivotally coupled to the base member. The length of the second bar assembly is controllable within a predetermined range. A third elongated bar assembly is pivotally coupled at a first end to the segment coupling assembly, at a second end to the second bar assembly, and at an intermediate point to the first bar assembly. In addition, the apparatus includes a rotary actuator for selectively rotating the second bar assembly about a pivot axis extending through its point of connection to the base member. When the second bar assembly is in its retracted state, as that assembly is rotated by the rotary actuator, the segment coupling assembly travels along a substantially straight path substantially parallel and adjacent to the reference axis. Furthermore, when the second bar assembly is in its extended state, as the second bar assembly is rotated by the actuator, the coupling member travels in a non-straight path. | 3 |
FIELD OF THE INVENTION
The present invention generally relates to a hose clamp and more particularly to self-tightening hose clamps which compensate for minor changes in the diameter of the hose.
BACKGROUND OF THE INVENTION
Hose clamps are used to seal the connection between a hose or other cylindrical conduit and a cylindrical nipple. The clamps encircle the hose and apply a radially inward directed compressive force to cause the hose to form an elastomeric seal with the nipple.
Various types of hose clamps are employed. One of the more prevalent types has a band which extends about the portion of the circumference of the hose. A "T" bolt extends across the remaining portion . The ends of the band form retaining loops, and the "T" bolt has a "T" end which is retained in one of the retaining loops and a bolt shank which extends through the trunnion which is retained in the loop on the other end of the band. A nut is placed on a threaded end of the bolt shank. Tightening the nut forces the ends of the band toward each other which applies tensile force to the band, thereby causing the hose clamp to apply the compressive force on the hose.
One of the drawbacks of the "T" bolt type of hose clamp is what is referred to as a "cold-leak". Cold Leak is a condition brought about by the thermal cycle of the system. Initially, the system is at ambient temperature. As system temperature increases to normal operating temperature, thermal expansion of the nipple may be greater than the thermal expansion of the hose clamps. This difference in thermal expansion may cause an increase in the compressive forces applied to the hose material with a resulting displacement of the material. When the system is shut down and returns to ambient temperature, the thermal contraction of the nipple may exceed thermal contraction of the hose clamps. This difference in thermal contraction may reduce the compressive force applied to the hose to a level less than required to maintain a seal between the hose and nipple, resulting in Cold Leak.
To overcome the drawbacks of cold-leak, certain prior art devices employ a spring which circumscribes the bolt shank of the "T" bolt. The spring applies an outward directed biasing force on the nut on the end of the shank and an opposite biasing force on the trunnion end of the band through which the "T" bolt shank extends. The opposite biasing forces draw the ends of the band together.
When the hose clamp is initially installed, the springs are compressed. During cold weather and as a nipple contracts, the spring compensates for the contraction by increasing in length while continuing to exert the opposing forces on the "T" bolt and trunnion. Such hose clamps are sometimes referred to a self-tightening clamps.
One method to cause the hose clamp to supply a higher compressive force between the hose and the nipple, is to reduce the width of the band while maintain the same tensile force. The decrease in band width while applying the same total tensile force increases the force per unit area exerted on the hose and nipple. In addition, frequently space requirements necessitate a narrow hose clamp while maintaining the same compressive force. However, with the "T" bolt clamp, to decrease the width of the band, the "T" bolt must also be reduced in size.
One of the drawbacks of using a spring self-tightening clamp when reducing the size of the band is that the spring needs to be of a certain size and circumference to exert the proper total compressive force on the hose nipple connection. Thus, the spring must be maintained at a minimum size. However, upon decreasing the size of the "T" bolt to reduce the width of the band while maintaining the size of the spring, the spring may become off centered about the bolt. An off centered spring can bind or exert a non-uniform force on the band which lessens the effectiveness of the self-tightening feature.
It is therefore an object of the present invention to provide a clamping device for forcing a hose into a sealing engagement with an underlying hose, nipple or the like.
Another object of the present invention is to provide a clamping device which seals the connection between a hose and compensates for small variations in the diameter of a hose.
Yet another object of the present invention is to provide a clamping device which utilizes a spring like biasing element and a "T"-bolt feature to self-tighten the clamp. A related object is to provide such a device which maintains the biasing element centered about the bolt.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a hose clamp embodying the present invention; and
FIG. 2 is a perspective, partially exploded view of the clamp of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a hose clamp embodying the present invention is generally indicated at 10. The clamp 10 is shown circumscribing a hose 12 shown in shadow. The hose in turn is disposed about a nipple (not shown).
Referring to FIG. 2, the clamp 10 includes a band 14 having a left end 16 and a right end 18. The band 14 extends about a portion of the circumference of the hose 12 (FIG. 1). The left end 16 includes a loop 20 formed by looping back an outer end portion of the band and attaching, typically by welding, the end to the top surface of the band. The right end 18 includes a right loop 22 formed in a manner similar to the left loop 20. In the left loop 20 an aperture 24 is formed facing the right end 18 while at the right loop 22 a longitudinally extending slot 26 is formed.
A "T" bolt 28 includes a "T" end 30 which is movably secured in the left loop 20 by extending laterally through the loop. The "T" bolt 28 also includes a shank 32 which extends through the aperture 24 and across the remaining portion of the circumference of the hose 12. The shank 32 is slidably received in and extends through a hollow trunnion 34. The trunnion 34 includes a laterally extending "T" portion 36 which engages the loop 22. The "T" portion 36 is moveably secured to the right loop 22 typically by welding.
The trunnion 34 also includes a hollow longitudinally extending portion 38 through which the shank 32 of the "T" bolt 28 extends. A cap 40 having a central aperture 42 may cover the end of the trunnion 34.
The "T" bolt 28 includes a trunnion end portion 44 which extends longitudinally outward from the trunnion 34. The trunnion end portion 44 is typically threaded. Disposed about the end portion 44 and contacting the trunnion 34 at the cap 40 is a washer-like inner spring seat 46.
Circumscribing the trunnion end portion 44 and contacting and extending outward from the inner spring seat 46 is a tubular shaped spring 48. The spring 48 includes an inner end 50 which contacts spring seat 46 and an outer end 52 which contacts a washer-like outer spring seat 54.
A nut 56 threadingly engages the end portion 44 of the "T" bolt 28 and contacts the outer spring seat 54. Tightening the nut 56 forces the outer spring seat 54 toward the trunnion 34 thereby compressing the spring 48. Tightening the nut 56 also causes the "T"-bolt 28 to draw the left end 16 of the band 14 toward the right end 18 thereby tightening the hose clamp.
A substantially tubular centering means or sleeve 58 extends along the end portion 44 of the "T"-bolt shank 32 between the inner seat 46 and the outer seat 54. The sleeve is sized so that the inner surface 60 of the sleeve 58 circumscribes and contacts the end portion 44 of the "T" bolt 28 but the sleeve is able to slide along the end portion. The outer surface 62 of the sleeve 58 is coaxially aligned with the "T"-bolt shank 32 when the inner surface 60 contacts the end portion 44. The outer surface 62 is sized so that it contacts and positions the spring 48 but the sleeve can slide along the length of the spring. Thus, the sleeve 58 coaxially centers the spring 48 about the end portion 44 of the "T" bolt.
The longitudinal length of the sleeve 58 is such that when the spring 48 is fully compressed, the length of the sleeve is slightly less than the length of the compressed spring. This sizing prevents the sleeve 58 from contacting both the inner spring seat 46 and the outer spring seat 54 at the same time. If the sleeve 58 were longer than the compressed length of the spring 48, tightening of the bolt 56 after the sleeve contacts both the inner spring seat 46 and the outer spring seat 54 may cause the sleeve to buckle or otherwise deform.
The clamp 10 also includes an arcuate bridge 66 which extends from the left end 16 of the band 14 to the right end 18 between the "T"-bolt 28 and the hose 12 to prevent pinching of the hose by the ends of the band. The bridge 66 is movably secured to the left end loop 20 by having ears 68 which are bent laterally inward to contact and engage the left end 16 of the band.
Referring to FIG. 1, in operation, the clamp 10 is placed about the nipple (not shown) before the hose is positioned about the nipple. After the hose 12 has been positioned about the nipple, the hose clamp 10 is positioned at the desired location about the hose. The nut 56 is then tightened which causes the "T" bolt 28 to draw the left end 16 of the band 14 toward the right end 18.
As the nut 56 is tightened further the band 14 and bridge 66 engage the outer circumference of the hose 12. Further tightening of the nut 56 causes the band 14 and bridge 66 to apply radially inward directed compressive force about the circumference of the hose 12. The tightening also causes the spring 48 to become compressed between the inner spring seat 46 and the outer spring seat 54.
While the nut 56 is being tightened, thereby compressing the spring 48, the sleeve 58 assures that the spring is maintained coaxially centered about the end portion 44 (FIG. 2) to prevent binding of the spring, and the spring exerts a circumferentially uniform biasing force on the inner spring seat 46 and outer spring seat 54. The uniform force exerted on the inner spring seat 46 is transmitted through the trunnion 34 to the right loop 22 and the uniform force on the outer spring seat 54 is transmitted through the "T"-bolt 28 to the left loop 20.
The nut 56 is typically tightened until the spring 48 is in a fully compressed state, thereby indicating that sufficient force is being applied by the hose clamp 10 on the hose 12 to seal the hose about the nipple (not shown). Should the nipple, hose 12 and clamp 10 be subjected to cooler temperatures, the circumference of the nipple and hose 12 become smaller. As the circumference becomes smaller, the biasing force of the spring 48 on the inner spring seat 46 and outer spring seat 54 causes the right end 18 of the band to be drawn toward the left end 16 of the band to maintain the compressive force about the hose. As the spring 48 lengthens, the sleeve 58 maintains the spring coaxially centered about the end portion 44 of the "T"-bolt to prevent binding of the spring.
A specific embodiment of the novel self tightening hose clamp with centered spring according to the present invention has been described for the purposes of illustrating the manner in which the invention may be made and used. It should be understood that implementation of other variations and modifications of the invention in its various aspects will be apparent to those skilled in the art, and that the invention is not limited by the specific embodiment described. It is therefore contemplated to cover by the present invention any and all modifications, variations, or equivalents that fall within the true spirit and scope of the basic underlying principles disclosed and claimed herein. | A self tightening hose clamp is disclosed, having a band for encircling at least a portion of circumference of a hose and a bolt which extends from a left end of the band through the right end of the band and about the remaining portion of the circumference of the hose. A spring circumscribes an outer end of the bolt and applies a biasing force on the bolt and the right end of the band to maintain a clamping force between the band and the hose during contraction of the hose. A sleeve is disposed between the bolt and spring to coaxially center the spring about the bolt during compression. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims the benefit of U.S. Provisional Patent Application No. 60/831,765 filed Jul. 18, 2006, and entitled “Power Supply System For Dispenser,” which is incorporated by reference in its entirety.
BACKGROUND
[0002] The present disclosure generally relates to power supply systems, and more particularly, to power supply systems and methods to provide power to one or more dispensers.
[0003] Battery powered paper dispensers incorporating waste minimizing technology have become popular for minimizing waste, while improving sanitation and convenience of use. For battery powered paper dispensers, periodic battery replacement often becomes a nuisance. Indeed, monitoring power levels within batteries in use as well as replacing spent batteries can require important employee time that may be spent on other important job-related tasks.
[0004] FIG. 1 illustrates a paper dispenser with a conventional battery pack BP, including batteries 58 , as disclosed in U.S. Pat. No. 6,592,067. Batteries 58 within battery pack BP can be changed during a maintenance procedure. This procedure typically includes opening a dispenser housing to access and remove batteries ( 58 ) with battery pack BP for replacement or testing.
[0005] Battery testing is generally utilized to determine when batteries are nearing end of life (EOL). Sometimes, batteries within battery pack BP are replaced prior to EOL during a scheduled battery replacement. While replacing batteries nearing EOL may be efficient, this procedure can lead to replacing batteries having remaining power amounts thereby potentially wasting good batteries, increasing battery costs, and increasing battery waste. In a similar vein, replacing batteries that are spent typically occurs after batteries have been drained for some time thereby causing a dispenser to be inoperable for some amount of time.
[0006] For an array of dispensers within a location, for example, one or more restrooms, dispensers seeing more frequent use relative to others require more frequent battery replacement. It is typically a nuisance to keep battery replacement records, particularly in multi-dispenser environments. In addition, battery acquisition costs and disposal concerns, and the requirement of additional labor costs are significant limitations of current battery powered paper dispensers.
[0007] Accordingly, there is a need for improved power systems for dispensers to resolve the above-discussed and other difficulties and limitations.
BRIEF SUMMARY
[0008] Disclosed herein are power supply systems for dispensers and methods of powering dispensers.
[0009] In one embodiment, a power system for a plurality of dispensers comprises an AC transformer to receive a line voltage and generate an output voltage of about 2 volts AC to about 50 volts AC; a plurality of dispensers, each housing at least one electrical component operatively configured to dispense product through a dispensing aperture, each of the dispensers comprising a battery compartment; and a plurality of power converters adapted to be at least partially disposed within the battery compartments such that at least one power converter is associated with each dispenser, the converters disposed in communication with the AC transformer such that the power converters receive the output voltage and provide a DC voltage to one or more electrical components housed within the dispensers.
[0010] In one embodiment, a power system for a plurality of paper dispensers comprises an AC-to-AC transformer to receive an input AC voltage at a first voltage level and to provide an output AC voltage at a second voltage level; a plurality of paper dispensers, each having a dispense roller powered by a roller motor, the roller motor being a DC motor; a plurality of low voltage lines to carry the output AC voltage to the paper dispensers; and at least one AC-to-DC voltage converter disposed proximate one of the plurality of paper dispensers and coupled to at least one of the low voltage lines to receive the second voltage level, the at least one AC-to-DC voltage converter operatively configured to convert the output AC voltage to an output DC voltage.
[0011] In one embodiment, a dispenser comprises a dispenser housing having an inner chamber operatively configured to support a roll of paper and having a dispensing aperture; a DC motor operatively configured to dispense paper from the roll of paper through the dispensing aperture; a battery compartment adapted to receive a plurality of batteries; and a power converter sized to dispose at least partially within the battery compartment, the power converter comprising an input terminal receiving an AC voltage of between 2 and 50 volts, an output terminal providing a DC voltage to the motor; and a converter circuit disposed between the input and output terminals.
[0012] In one embodiment, a method to provide power to a plurality of dispensers, the method comprises providing a transformer operatively configured to receive an input voltage and to provide a supply voltage; and providing a voltage converter to receive the supply voltage and to provide an output voltage, the output voltage being provided to a dispenser to power the dispenser for dispensing operation and the voltage converter to have a predetermined size such that the voltage converter can be removably disposed within a compartment housed within the dispenser.
[0013] The above described and other features are exemplified by the following Figures and detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Various embodiments of the invention can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the various embodiments of the present invention.
[0015] FIG. 1 illustrates a conventional battery-powered dispenser that includes a battery compartment housing batteries.
[0016] FIG. 2 illustrates a perspective view of an embodiment of a dispenser used with a power supply system in accordance with some embodiments of the present invention.
[0017] FIGS. 3-6 illustrate several perspective views of an adapter housing suitable for use with a dispenser in accordance with some embodiments of the present invention.
[0018] FIG. 7 illustrates an exemplary adapter for use with a dispenser in accordance with some embodiments of the present invention.
[0019] FIG. 8 illustrates a schematic diagram of an AC-to-DC voltage conversion circuit for use in accordance with some embodiments of the present invention.
[0020] FIG. 9 illustrates a wiring diagram for a power system for one or more dispensers in accordance with some embodiments of the present invention.
[0021] FIG. 10 illustrates a power supply system wiring network for one or more dispensers of a dispenser network in accordance with some embodiments of the present invention.
[0022] FIG. 11 illustrates a logical flow diagram of a method to power one or more dispensers in accordance with some embodiments of the present invention.
DETAILED DESCRIPTION
[0023] The various embodiments of the present invention are directed to power supply systems and methods for one or more dispensers. Embodiments of the present invention may be used in conjunction with available battery-powered paper dispensers and/or new line-powered paper dispensers. In addition, embodiments of the present invention can be used to implement a network of dispensers in a location. Such locations can include, for example, an office, school, restaurant, or many other facilities where dispensers are desired.
[0024] Referring now to the figures, wherein like reference numerals represent like parts throughout the several views, exemplary embodiments of the present invention are described below in detail. Throughout this description, various components may be identified as having specific values or parameters, however, these items are provided as exemplary embodiments. Such exemplary embodiments do not limit the various aspects and concepts of the present invention as many comparable parameters, sizes, ranges, and/or values may be implemented.
[0025] Referring now to FIG. 2 , this figure illustrates a perspective view of an embodiment of a dispenser 10 that can be used with a power supply system according to some embodiments of the present invention. Other sample and possible dispensers are disclosed in U.S. Pat. Nos. 6,793,170 and 6,592,067 and US Patent Application Publication 2005/0072875, each of which are incorporated herein by reference. In addition, the dispenser 10 may be automated or user operated according to embodiments of the present invention. For example, the dispenser 10 may be operated in a hands-free mode by use of a proximity sensor, infrared sensor, capacitive-sensor, optical sensor, and many other sensors. According to other embodiments, the dispenser 10 may also respond to active input from a user to operate by dispensing material when receiving active input from a user. It is an advantage of some embodiments of the present invention to provide an AC-to-DC (Alternating Current to Direct Current) adapter system that can be implemented with existing battery powered paper dispensers.
[0026] It should be understood that the dispenser 10 can be used to dispense many types of materials in accordance with the various embodiments of the present invention. For example, the dispenser 10 may be configured to dispense sheet product material. The term “sheet products” can include natural and/or synthetic cloth or paper sheets. Further, sheet products can include both woven and non-woven articles. Examples of sheet products include, but are not limited to, wipers, napkins, tissues, and towels. Other possible types of dispensed materials can include, but are not limited to, plastic or plastic-based sheet materials and metallic or metallic-sheet materials. In addition, the dispenser may be adapted to emit various scents or scented air. As an example, this may include dispensing various fragrances to control area odors or alter scent characteristics of an area. In yet other embodiments, the dispenser may be adapted for dispensing liquids or foams (e.g., for use as a liquid or foam soap dispenser).
[0027] As shown in FIG. 2 , dispenser 10 includes a rear housing 11 and a front housing (removed to expose dispenser components) that house dispenser components. The dispenser 10 can include a carousel assembly 30 and a feed roller 50 which serves to feed material to be dispensed by the dispenser 10 . A control unit 54 can operate a feed roller motor 56 . Power can be supplied to the dispenser 10 by batteries (not shown) or a system including an AC-to-DC adapter 20 as described below in more detail. A light 59 , for example, a light-emitting diode (LED), may also be incorporated into a low battery warning system such that the light 59 turns on when battery voltage approaches or falls below a predetermined threshold.
[0028] Batteries or adapter 20 can be held within a compartment 58 . The compartment 58 may be specifically designed to hold multiple batteries or may be specifically designed to hold the adapter 20 . When batteries are used, a battery compartment cover 12 can retain one or more batteries within the compartment 58 . The cover 12 can include a pair of tabs 13 sized to engage a pair of slot openings 14 within the dispenser housing. The cover 12 can further include a latch 15 adapted to engage a portion of the dispenser or dispenser housing to secure cover 12 . Battery replacement can include engaging latch 15 to gain access to battery compartment 58 . For brevity, the other enumerated items of FIG. 2 are not discussed here in detail; however, these components are discussed in detail in U.S. Pat. No. 6,592,067 (which is incorporated herein by reference in its entirety) with reference to FIG. 1 .
[0029] As mentioned above, the adapter 20 can be used to provide power to the dispenser 10 . According to some embodiments, the adapter 20 can include AC-to-DC voltage conversion circuitry 60 (discussed below in more detail with reference to FIG. 8 ). In one embodiment, the adapter 20 is supplied with a low AC voltage, e.g., about 2 VAC (volts alternating current) to about 50 VAC, specifically about 12 VAC to 30 VAC for some embodiments, with 24 VAC particularly useful for some embodiments, and converts the low AC voltage to a low DC voltage, e.g., about 2 VDC (volts direct current) to about 24 VDC, specifically about 2 VDC to about 12 VDC for some embodiments, with 6 VDC particularly useful for some embodiments. As the adapter 20 can be sized to take the place of batteries or sized the same as a few batteries, the adapter 20 can be disposed in contact with battery electrical connections (not shown). Advantageously, embodiments of the present invention can retrofit an existing dispenser to be powered as discussed herein. Retrofitting need not alter an existing dispenser, thus enabling existing dispensers the option of still being powered by batteries.
[0030] Battery electrical connectors 73 , 74 are configured for electrical contact with batteries to receive power from batteries. The adapter 20 can have corresponding connectors 70 , 72 to connect to the battery electrical connections. The exact location of connectors 70 , 72 can vary according to different embodiments. In one embodiment, however, the adapter's 20 connectors 70 , 72 mirror the connectors 73 , 74 of the dispenser 10 to form electrical connections thereby enabling the adapter 20 to provide power to the dispenser 10 . It should be understood, that in those embodiments where the compartment 58 is not sized specifically for batteries, the adapter 20 also has connectors 70 , 72 to be coupled to the dispenser 10 to provide electrical power to the dispenser 10 .
[0031] As mentioned above, the adapter 20 can be housed within an adapter housing 21 when disposed within the dispenser 10 . As an example, the adapter housing 21 may be used when the compartment 58 is specifically configured to receive batteries. Thus, the adapter housing 21 can alter or retrofit sizing of the compartment 58 to receive the adapter 20 . Advantageously, this enables the adapter 20 to fit snugly and ensures that the adapter 20 is positioned in a desired position within the dispenser 10 .
[0032] FIGS. 2-6 illustrate the adapter housing 21 suitable for use with the dispenser 10 according to some embodiments of the present invention. The adapter housing 21 can be sized to be received into the compartment 58 . The shape and size of the adapter housing 21 can vary according to application as one advantage of the adapter housing 21 is to enable the adapter 20 to mate with the dispenser 10 . As shown, the adapter housing 21 can include a top surface 17 , a lower surface 19 , and pair of tabs 13 . The pair of tabs 13 can be sized to engage a pair of corresponding slot openings 14 of the dispenser 10 . The adapter housing 21 can further include the latch 15 adapted to engage a structure within a housing of the dispenser. The shape of the adapter 20 and the adapter housing 21 can correspond to enable quick entry and removal of the adapter 20 within the dispenser 10 should a user desire to insert or remove the adapter 20 from the dispenser 10 . In some embodiments, the adapter housing 21 may not be desired or used.
[0033] FIG. 7 (with periodic reference to FIG. 2 ) illustrates an exemplary adapter 20 for use with the dispenser 10 in accordance with some embodiments of the present invention. As mentioned herein, the adapter 20 comprises a plurality of inputs and outputs to receive one voltage and provide another. The adapter 20 can receive an input AC voltage and provides an output DC voltage. To accomplish voltage transition, the adapter 20 can comprise the AC-to-DC voltage conversion circuitry 60 . The AC-to-DC voltage conversion circuitry 60 can be configured to convert an AC voltage to a DC voltage and, in some embodiments, the AC-to-DC voltage conversion circuitry 60 may convert an input voltage to a lower voltage (e.g., a DC/DC converter). In other embodiments, the adapter 20 may also provide multiple output voltages (AC or DC) having different voltage levels so that the adapter 20 can provide different voltages to dispenser 10 components operating at different voltage levels.
[0034] The inputs and outputs of the adapter 20 can serve as interfaces with other dispenser 10 components. As such, the inputs and outputs can be positioned in various configurations and include many different interfacing mechanisms. As illustrated, the adapter 20 has an input 75 and two connectors 70 , 72 . The connectors 70 , 72 can be spaced in relation to corresponding electronic contacts within the compartment 58 . As an example, the distance between connectors 70 , 72 can approximate a battery diameter. This advantageous configuration enables the connectors 70 , 72 to provide electrical coupling between AC-to-DC voltage conversion circuitry 60 and the electrical components of the dispenser 10 , such as the feed roller motor 56 and other dispenser electronics. The connectors 70 , 72 can be many types of electrically conducting items, including for example, springs, contacts, or outwardly extending metal arms. Alternatively, the connectors 70 , 72 can be configured to connect to a wire (e.g., a jumper wire) extending between the adapter 20 and the dispenser 10 .
[0035] The input 75 of the adapter 20 enables the adapter 20 be electrically connected to an input voltage supply. Indeed, a low voltage AC line 76 , i.e., supply line, ( FIG. 8 ) can be connected at one end to a terminal which can be coupled with a barrel jack as the input 75 to AC-to-DC voltage conversion circuitry 60 . The low voltage AC line 76 can be a low voltage line, with the AC voltage being supplied by a step down transformer. Advantageously, low voltage transformers are commonly commercially available. For example the step down transformer can be a 120 VAC to 24 VAC wall-mount or box-mount transformer. In some embodiments, the low voltage AC line 76 is provided at approximately 24 VAC. This advantageous feature enables safe installations and maintenance to be performed by maintenance personnel who are not highly skilled tradesman, e.g., licensed electricians and electrical contractors. Moreover, this advantageous feature can reduce associated installation and maintenance costs and provide a safe dispenser.
[0036] FIG. 8 (with periodic reference to FIG. 2 ) illustrates a schematic diagram of the AC-to-DC conversion circuitry 60 for use in accordance with some embodiments of the present invention. It should be understood that AC-to-DC voltage conversion circuitry 60 is an exemplary conversion circuit and that many others can be used in alternative embodiments. As shown, the AC-to-DC voltage conversion circuitry 60 generally includes a bridge rectifier circuit 62 and additional signal conditioning circuitry 61 . In one embodiment, the signal conditioning circuitry 61 comprises adequate filtering capabilities so that the AC-to-DC voltage conversion circuitry 60 can power various electronic sensors with power yet not affect operational characteristics of any used sensors. For example, the signal conditioning circuitry 61 can provide a steady, filtered DC voltage that would not affect the operation of a proximity sensor (not shown) used in operating the dispenser 10 .
[0037] FIG. 8 also illustrates a plurality of inputs and outputs of the AC-to-DC voltage conversion circuitry 60 as discussed above. Indeed, FIG. 8 shows that AC-to-DC voltage conversion circuitry 60 includes connectors 70 , 72 that provide a DC voltage to power dispenser feed roller motor 56 , and that AC-to-DC voltage conversion circuitry 60 includes the input 75 . The input voltage terminal can be an input barrel jack for electrical coupling to voltage line that can be supplied by a transformer. A barrel jack connection mechanism advantageously enables the AC-to-DC voltage conversion circuitry 60 to be separated relative to dispenser 10 , such as during adapter 20 installation or replacement. It should be understood that the input 75 can be many types of connection mechanisms in accordance with the various embodiments of the present invention.
[0038] FIG. 9 (with periodic reference to FIG. 2 ) illustrates a wiring diagram for a power system for one or more dispensers in accordance to some embodiments of the present invention. The wiring diagram generally illustrates a transformer 90 providing power to multiple low voltage AC lines 76 that terminate in connection points 78 . As shown, the connection points can be male-type barrel jack connectors. Thus, the illustrated wiring diagram shows that the single transformer 90 can provide electrical power to a plurality of dispensers 10 (not shown) by connecting the connection points 78 to one or more dispensers 10 . The connection points 78 can provide power to an input of the adapter 20 .
[0039] In one embodiment, the transformer 90 receives a standard 120 VAC input and steps down this input voltage to a lower AC voltage (e.g., 24 VAC). In some embodiments, the line voltage can be about 110 VAC to about 230 VAC. Stepping down the voltage to a lower level enables an efficient yet effective power distribution network to one or more dispensers. Indeed, the transformer 90 can be located remote from (e.g., in a different room) one or more of the dispensers. Advantageously, having a remotely located transformer 90 can provide a centrally located power supply to feed multiple dispensers according to some embodiments. Further, due to the use of a low voltage AC power feed systems, distances between the transformer 90 and dispensers can range widely (e.g., less than 1 foot up to approximately 1000 feet). This advantageously enables the low voltage AC line 76 to be sized specifically according to installation requirements.
[0040] Other wiring configurations are also possible in accordance with embodiments of the present invention. For example, the connection points 78 of FIGS. 9-10 may supply power to multiple dispensers such that a dedicated supply line is not required for one dispenser. Indeed, two dispensers may be coupled together with a short connection line so that one connection point 78 can provide power to multiple dispensers. This configuration can aid in reducing low voltage AC line 76 lengths to reduce installation and product costs.
[0041] FIG. 10 (with periodic reference to FIG. 2 ) illustrates a power supply system network for one or more dispensers of a dispenser network in accordance with some embodiments of the present invention. More specifically, FIG. 10 illustrates how multiple dispensers in distinct locations (e.g., separate restrooms) can be powered. The dispensers 10 illustrated in FIG. 10 can include the dispensers 10 discussed so that dispensers house adapters 20 with AC-to-DC voltage conversion circuitry 60 .
[0042] The power supply system network generally includes an input voltage supply, the transformer 90 , multiple low voltage AC lines 76 , and several dispensers 10 . The transformer 90 may be located remotely from the dispensers 10 . Indeed, as illustrated, the transformer can be disposed remote from several restrooms in which the dispensers 10 are located. To provide power to the dispensers 10 , the transformer 90 receives the input voltage supply and steps down the input voltage. This reduced voltage is then provided to the low voltage AC line 76 .
[0043] The low voltage AC line 76 carry supply voltages to the dispensers 10 to power the dispensers 10 . The low voltage AC line 76 can be routed to the dispensers through walls and/or ceilings. The supply lines can connect to adapters 20 within the dispensers 10 so that the adapters can appropriately alter the supply voltage for use by the dispensers. In one embodiment, the low voltage AC line 76 directly connect to adapters with corresponding connectors (e.g., male and female barrel jack connectors). Although FIG. 10 shows the dedicated low voltage AC line 76 for each dispenser 10 , one low voltage AC line 76 can be used to power multiple dispensers 10 . In addition, one or more dispensers 10 can be coupled to another dispenser 10 so that one dispenser 10 can provide power to another dispenser 10 .
[0044] FIG. 11 illustrates a logical flow diagram of a method 200 to power one or more dispensers in accordance with some embodiments of the present invention. The method 200 can include installing one or more AC-to-DC adapters into existing dispensers to retrofit in use dispensers, installing a new dispenser network at a location, or combinations thereof. Those skilled in the art will understand that method 200 can be performed in various orders (including differently than illustrated in FIG. 11 ), additional actions can form part of method 200 , and that some actions pictured in FIG. 11 are not necessary.
[0045] As shown in FIG. 11 , the method 200 can initiate by providing one or more dispensers in a location 205 . A location generally refers to a place where a user, supplier, or installer may desire to dispose one or more dispensers, and can include a building, a restaurant, a room, a school, and many other such places. The method 200 can also include providing a transformer at a location at 210 . The transformer can receive a standard AC voltage supply (e.g., 120 VAC) and step down the standard AC voltage supply to a lower level AC voltage (e.g., 24 VAC). The lower level AC voltage can be provided to one or more dispensers via one or more supply lines at a location at 215 .
[0046] The method 200 can further include providing one or more adapter devices to convert the lower level AC voltage to DC voltage at location 220 . In one embodiment, the method 200 includes disposing an adapter within a dispenser placed at a location at 225 . As shown at location 230 , the adapter devices converts an AC supply voltage (e.g., 24 VAC) to a DC voltage (e.g., 6 VAC) according to method 200 . The DC voltage can then be provided to power the one or more dispensers. The provided DC voltage can be used to power dispensing mechanisms such as sensors, motors, status monitoring systems, and user interface devices.
[0047] The method 200 can also include additional features. As an example, the method 200 can include accessing a low voltage terminal of a line voltage transformer and coupling the terminal to a power converter within an adapter to provide a low-level DC voltage. The method 200 may also include extending an electrical conductor (e.g., wire) between a transformer and a power converter. The method may further include running an electrical conductor through a building wall and through a back wall of a dispenser housing.
[0048] Advantageously, in embodiments, the adapter can be conveniently integrated as a removable unit-body into a battery compartment of an existing dispenser to achieve space saving and operational conveniences. In other embodiments, the AC-to-DC converter may be incorporated within the dispenser at the time of manufacture.
[0049] It is yet another advantage of embodiments of the present invention to provide a battery adapter system utilizing low voltage, which can be safely installed and routed by routine maintenance personnel, without the need for a skilled tradesman (e.g., an electrical contractor). In comparison to DC lines, the low voltage AC lines have substantially greater permissible run lengths. Furthermore, low voltage transformers are commonly available (e.g., in telephone systems, alarm systems and the like).
[0050] The embodiments of the present invention are not limited to the particular formulations, process steps, and materials disclosed herein as such formulations, process steps, and materials may vary somewhat. Moreover, the terminology employed herein is used for the purpose of describing exemplary embodiments only and the terminology is not intended to be limiting since the scope of the various embodiments of the present invention will be limited only by the appended claims and equivalents thereof.
[0051] Therefore, while certain embodiments of this disclosure have been described in detail with particular reference to exemplary embodiments, those skilled in the art will understand that variations and modifications can be effected within the scope of the disclosure as defined in the appended claims. Accordingly, the scope of the various embodiments of the present invention should not be limited to the above discussed embodiments, and should only be defined by the following claims and all equivalents. | In one embodiment, a power system for a plurality of dispensers comprises an AC transformer to receive a line voltage and generate an output voltage of about 2 volts AC to about 50 volts AC; a plurality of dispensers, each housing at least one electrical component operatively configured to dispense product through a dispensing aperture, each of the dispensers comprising a battery compartment; and a plurality of power converters adapted to be at least partially disposed within the battery compartments such that at least one power converter is associated with each dispenser, the converters disposed in communication with the AC transformer such that the power converters receive the output voltage and provide a DC voltage to one or more electrical components housed within the dispensers. | 0 |
BACKGROUND OF THE INVENTION
The present invention falls generally within the coating arts and relates, more particularly, to components having high temperature oxidation resistant coatings thereon which provide protection in severe environments such as those associated with advanced gas turbine engines.
Coatings of the MCrAlY-type are now well known in the art, as evidenced by the U.S. Patents to Evans et al. U.S. Pat. No. 3,676,085; Goward et al. U.S. Pat. No. 3,754,903; and Talboom, Jr. et al. U.S. Pat. No. 3,542,530; all of which share a common assignee with the present invention. Typically, the MCrAlY coatings are characterized by high chromium and aluminum contents and contain yttrium in a basis metal comprising one or more of the elements selected from the group consisting of cobalt, nickel and iron. They are usually characterized as overlay coatings denoting the fact that they are deposited as the MCrAlY alloy on the surface to be protected and, thus, act substantially independent of the substrate in the performance of their protective function.
Aluminide coatings and processes for producing such coatings are also known and have been used for a number of years as the principal coating technique for gas turbine engine elements. In the U.S. Patent to Joseph U.S. Pat. No. 3,102,044, which also shares a common assignee with the present invention, aluminum rich slurry applied to a superalloy surface is reacted therewith to form a protective aluminide or aluminides. U.S. Pat. No. 3,257,230 describes another aluminizing technique, i.e. the formation of a protective aluminide on alloy surfaces by a pack cementation process.
Prior to the introduction of the MCrAlY-type coatings the superalloys were, as previously mentioned, typically protected through the formation of an aluminide directly on and by reaction with the superalloy surface by exposure of that surface at high temperature to aluminum or aluminum containing vapors. The principal aluminide formed was usually that of the basis metal of the substrate, i.e. nickel, cobalt or iron. However in addition to the principal aluminide the coating layer often included amounts of other ingredients present in the substrate alloy and, in most instances, the total coating comprised a composition which while acceptable nevertheless represented a compromise in terms of composition and something less than would be desired if the coating were to be optimized.
As engine environments and other demands on the coated aluminum increased in severity, the widely used aluminide found less acceptability in some circumstances and it became advisable to pursue further coating improvements. Coatings, of course, play a major role in engine design acceptability. The MCrAlY-type coatings were the result of such coating improvement studies and permitted the engine designer greater flexibility in his constructions in connection with the development of advanced gas turbine engines.
With the introduction of the MCrAlY coatings it was possible to preserve or increase coating and coated component lifetimes in more severe engine environments associated with the advanced engines. As previously mentioned, the MCrAlY coatings are generally deposited on the substrate surface as the MCrAlY alloy usually by vacuum vapor deposition, sputtering or plasma spray techniques. The basic protection is provided by the deposited alloy itself which may be more closely optimized for such protection since it is substantially independent of the substrate itself. There is, of course, a desirable and limited interaction of the coating with the substrate metal but this is in the nature of metallurgical bonding rather than a reaction per se, and the protective elements are derived from the MCrAlY alloy rather than from the substrate.
In later developments it was suggested that additional coating improvements were achievable through the use of multiple coating layers or composite coatings. In the U.S. Patent to Simmons U.S. Pat. No. 3,649,225 of the present assignee, for example, the use of a composite coating comprising a chromium or chromium rich interlayer adjacent a superalloy substrate with an MCrAlY layer thereover is described.
Several other developments relating to MCrAlY-type coatings have even more recently been published in the patent literature. In U.s. Pat. No. 3,849,865 a substrate to be protected is first clad with a metallic foil, such as NiCrAlSi or FeCrAlY and then that foil is covered with an aluminide layer. U.S. Pat. Nos. 3,873,347 and 3,874,901 both appear to describe somewhat similar systems, referring to coating techniques where a superalloy body is first coated with an MCrAlY-type layer which is then aluminized to provide an overlayer of aluminum or an aluminide.
SUMMARY OF THE INVENTION
The present invention contemplates a coated article comprising a superalloy substrate having an aluminide coating composed primarily of the aluminide of the basis metal with an overcoat comprising an MCrAlY-type alloy.
Preferred embodiments of the present invention have displayed the potential of lifetimes more than three times greater than those of articles without the aluminide or without the aluminide as an interlayer.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The superalloys are generally those alloys characterized as nickel, cobalt or iron base alloys which display high strengths at high temperatures. There are a number of the superalloys which are used in gas turbine engines. Of these, the greatest physical demands are usually placed on those employed in blades and vanes in such engines since the blades and vanes face the highest stress at the highest temperatures. Additionally, blades and vanes are particularly subject to the problems associated with thermal shock, differential thermal growth, fatigue, errosion, etc.
Representative of the blade and vane alloys are the following nickel-base superalloys:
a. IN-100 having a nominal composition comprising 10 percent chromium, 15 percent cobalt, 4.5 percent titanium, 5.5 percent aluminum, 3 percent molybdenum, 0.17 percent carbon, 1 percent vanadium, 0.06 percent boron, 0.05 percent zirconium, balance nickel.
b. MAR-M200 at a composition comprising 9 percent chromium, 10 percent cobalt, 2 percent titanium, 5 percent aluminum, 12.5 percent tungsten, 0.15 percent carbon, 1 percent columbium, 0.015 percent boron, 0.05 percent zirconium, balance nickel.
c. INCONEL 792 at a nominal composition of 13 percent chromium, 10 percent cobalt, 4.5 percent titanium, 3 percent aluminum, 2 percent molybdenum, 4 percent tantalum, 4 percent tungsten, 0.2 percent carbon, 0.02 percent boron, 0.1 percent zirconium, balance nickel.
Representative cobalt-base alloys used in gas turbine engines include the following:
a. WI-52 which comprises 21 percent chromium, 11 percent tungsten, 2 percent columbium plus tantalum, 1.75 percent iron, 0.45 percent carbon, balance cobalt.
b. MAR-M509 which has a nominal composition comprising 21.5 percent chromium, 10 percent nickel, 7 percent tungsten, 3.5 percent tantalum, 0.2 percent titanium, 0.6 percent carbon, 0.5 percent zirconium, balance cobalt.
In the practice of the present invention the superalloy substrate is first provided with an aluminide coating. This coating may be accomplished by slurry, pack cementation, sputtering or any of the other techniques known in the art for this purpose. Many of the advanced blades and vanes to which the invention has particular application are provided with internal cooling passages for which surface protection is suitably provided in addition to that required on the external airfoil surfaces. When both internal and external surfaces are to be aluminized, the most preferred processes are the pack cementation or gas phase techniques.
In one aluminizing method, the parts to be coated, after thorough cleaning, were embedded in a dry powder mix containing about 15 weight percent of an aluminum/12 percent silicon alloy, up to about 2.5 percent ammonium chloride, with the balance alumina. The embedded parts were then heated to a temperature of about 1400° F. and held at that time for a period sufficient to produce the desired coating thickness. Coating of external surfaces, blade roots, shroud platforms and internal passages has typically been performed in one operation. Of course, areas where coating is not desired will have been appropriately masked during the aluminizing operation.
Generally an aluminide coating thickness, including diffused zone, of 0.001-0.0025 inch has been used for all surfaces, but obviously more or less may be acceptable or even advisable in other circumstances. Usually also the aluminum content at the surface of the aluminide has been established at about 22-36 weight percent, but variations are also possible here.
There are two principal considerations in the determination of optimum aluminide coating thickness and aluminum content. The degree of protection provided is dependent to a great extent upon the amount of aluminum available in the coating. Perhaps more importantly, however, is the necessity for providing in the aluminide a firm base for the MCrAlY overcoat, an element of which requires reasonable ductility particularly in circumstances where thermal shock conditions may exist.
Parts have also been aluminized by a higher temperature pack cementation process, wherein embedded nickel-base alloy parts are heated in a pack at a temperature up to 1900° F. in a hydrogen or argon atmosphere.
Subsequent to the aluminizing operation, an MCrAlY coating is deposited thereover. A particularly preferred NiCoCrAlY coating at a composition of about, by weight, comprising 14-22 percent chromium, 11.5-13.5 percent aluminum, 0.1-0.5 percent yttrium, 20-26 percent cobalt, balance nickel has been used.
This coating has typically been applied by vacuum vapor deposition techniques, although sputtering and plasma spray processes have also been used to apply MCrAlY coatings.
Another MCrAlY coating is the CoCrAlY alloy at a composition by weight of about 15-21 percent chromium, 10-12 percent aluminum, 0.3-0.9 percent yttrium, balance cobalt.
The preferred processing involves vapor deposition from a molten pool of coating material in a vacuum chamber (10 - 4 Torr or better) onto a preheated part, with deposition continuing until the desired thickness, typically 0.001-0.005 inch is achieved.
Following deposition, the coated article is generally dry glass bead peened. Subsequently, the coated article is subjected to a diffusion heat treatment at a temperature selected to accommodate not only the particular coating involved but also the substrate. Typically for the blade and vane alloys a heat treatment of 1975° F. for about 4 hours has been found appropriate.
Testing of the coated articles, has revealed some surprising results.
In cyclic oxidation:
a. a nickel-base superalloy specimen coated with the NiCoCrAlY coating alone lasted 953 hours; to the onset of pitting;
b. a nickel-base superalloy specimen coated with the NiCoCrAlY coating with an aluminide overcoat survived 890 hours to the onset of pitting;
c. a specimen according to the present invention comprising a nickel-base superalloy having an aluminide interlayer and a NiCoCrAlY overcoat is currently still in test at 3177 hours with no sign of pitting to this time.
This represents a factor of greater than three for this embodiment of the present invention.
In another cyclic oxidation test:
a. a specimen having a CoCrAlY undercoat and an aluminide overcoat exhibited pitting at 163 hours;
b. a specimen according to the present invention having an aluminide interlayer and a CoCrAlY overcoat revealed a time to pitting of 274 hours.
The substantial and unexpected superiority of the present invention was thus conclusively demonstrated.
Although the present invention has been described in connection with certain examples and preferred embodiments, these are illustrative only. Improvements to and modification thereof may be made thereto in the true spirit and within the scope of the invention. | A protective coating is provided on gas turbine engine type superalloys comprising an interlayer adjacent the superalloy substrate a principal protective element of which comprises an aluminide of the basis metal of the substrate formed by the reaction of aluminum at high temperature with the substrate, and an overlayer comprising an MCrAlY-type coating where M is selected from the group consisting of cobalt, nickel and iron. | 1 |
This is a continuation of Ser. No. 07/693,775 filed on Apr. 26, 1991, now abandoned, which is a continuation of Ser. No. 07/117,246 filed on Nov. 4, 1987, now abandonded.
CROSS-REFERENCE TO RELATED APPLICATION
This application is related to commonly owned patent application
______________________________________SER.NO. FILED FOR APPLICANTS STATUS______________________________________812,433 12/23/85 THERMO- L. M. Maresca Abandoned PLASTIC D. C. Clagett BLENDS U. S. Wascher WITH AMORPHOUS POLYAMIDE______________________________________
FIELD OF THE INVENTION
The present invention relates to thermoplastic resin blends containing an amorphous polyamide resin and a polyester resin. More particularly, the present invention relates to thermoplastic resin blends containing an amorphous polyamide resin and a thermoplastic polyester resin substantially free of polyarylate.
BACKGROUND OF THE INVENTION
Polyester resins are well known thermoplastic materials which, due to their many advantageous physical properties, find use as thermoplastic engineering materials in many commercial and industrial applications. These resins, for example, exhibit excellent properties of toughness, flexibility, impact strength, heat resistance, chemical resistance and excellent surface appearance. In some cases these polyesters also have good barrier properties. Such resins may generally be prepared by the reaction of a dihydric alcohol and a dicarboxylic acid or chemical equivalent thereof.
For some specialized applications, i.e. automotive parts, it is important that such resins have enhanced chemical resistance to aggressive solvents, for example, acetone, aromatic solvents, gasoline, and the like, to a degree which may not be necessary in most other applications. We have found that blends of polyesters and amorphous polyamides have the excellent solvent resistance required for this application.
Although polyesters such as polyethylene terephthalate are currently used in packaging applications special processing to orient the material is necessary in order to obtain good barrier properties. It has now also been discovered that addition of amorphous polyamide to the polyesters improves barrier properties without the need for orientation.
SUMMARY OF THE INVENTION
Briefly, according to the present invention, there are provided amorphous polyamide blends with polyesters, substantially free of polyarylate, having unexpectedly improved barrier resistance to carbon dioxide and oxygen. Such blends comprise:
(i) at least one thermoplastic polyester resin, substantially free of any polyarylate; and
(ii) an amorphous polyamide resin.
The amorphous polyamide resin provides improved solvent resistance and high barrier resistance to carbon dioxide and oxygen.
DETAILED DESCRIPTION OF THE INVENTION
With respect to the polyester component (i) these are derived from an aliphatic diols, aliphatic ether or cycloaliphatic diols, or mixtures thereof, containing from 2 to about 20 carbon atoms and at least one dicarboxylic acid, such as an aliphatic dicarboxylic acid, e.g., adipic acid, sebacic acid, a cycloaliphatic dicarboxylic acid, such as cyclohexanedicarboxylic acid or aromatic dicarboxylic acid such as isophthalic acid or terephthalic acid. Preferred polyesters are derived from an aliphatic diol and an aromatic dicarboxylic acid and have repeating units of the following general formula: ##STR1## wherein n is an integer of from 2 to 6. The most preferred polyesters are poly(ethylene terephthalate) and poly(1,4-butylene terepththalate).
Also contemplated herein are the above polyesters with minor amounts, e.g., from 0.5 to about 10 percent by weight, of units derived from aliphatic polyols, to form copolyesters. The aliphatic polyols include glycols, such as poly(ethylene glycol) or poly(propylene glycol).
The polyesters derived from a cycloaliphatic diol and an aliphatic, aromatic and/or cycloaliphatic dicarboxylic acid are prepared, for example, from reaction of either the cis- or trans-isomer (or mixtures thereof), for example, 1,4-cyclohexanedimethanol, with a dicarboxylic acid or reactive derivative thereof so as to produce a polyester having recurring units of the following formula: ##STR2## wherein the cyclohexane ring is selected from the cis-and trans-isomers thereof and R represents an alkyl of 1 to 10 carbon atoms, alkylaryl, aryl, arylalkyl or cycloaliphatic radical containing 6 to 20 carbon atoms and which is the decarboxylated residue derived from a dicarboxylic acid or obvious equivalent, e.g., a diester, a diacid chloride, etc.
Examples of dicarboxylic acids represented by the decarboxylated residue R are isophthalic or terephthalic acid, 1,2-di(p-carboxyphenyl) ethane, 4,4'-dicarboxydiphenyl ether, etc., and mixtures of these. Preferably the acids contain at least one aromatic nucleus. Acids containing fused rings can also be present, such as in 1,4- or 1,5-naphthalene dicarboxylic acids. Also contemplated are aliphatic, and cycloaliphatic diacids, such as sebacic acid, adipic acid, glutaric acid, azelaic acid, and cyclohexane dicarboxylic acid. The preferred dicarboxylic acids are terephthalic acid or a mixture of terephthalic and isophthalic acids.
Another preferred polyester block may be derived from the reaction of either the cis- or trans-isomer (or a mixture thereof) of 1,4-cyclohexanedimethanol with a mixture of isophthalic and terephthalic acids. Such a polyester would have repeating units of the formula: ##STR3##
Still another preferred polyester is a copolyester derived from a 1,4-cyclohexanedimethanol, an alkylene glycol and an aromatic dicarboxylic acid. These copolyesters are prepared by condensing either the cis- or trans-isomer (or mixtures thereof) of, for example, 1,4-cyclohexanedimethanol and an alkylene glycol, such as ethylene glycol or 1,4-butanediol, with an aromatic dicarboxylic acid so as to produce a copolyester having units of the following formulae ##STR4## wherein the cyclohexane ring is selected from the cis-and trans-isomers thereof, R is as previously defined, n is an integer of 2 to 6, the x units comprise from about 10 to 90 percent by weight, and the y units comprise from about 90 to about 10 percent by weight. Preferably R is phenyl and the preferred polyesters are of the formula: ##STR5## wherein x and y are as previously defined.
Also included within this invention are polyesters derived from aliphatic ether diols, for example, tetramethyleneoxy diol, and the same diesters of diacids.
The polyesters described herein are either commercially available or can be produced by methods well known in the art, such as those set forth in, for example, U.S. Pat. Nos. 2,901,466 and 3,651,014.
The polyesters used herein have an intrinsic viscosity of from about 0.4 to about 2.0 dl/g. as measured in a 60:40 phenol/tetrachloroethane mixture or similar solvent at 23°-30° C.
The polyesters used herein must be substantially free, i.e., contain less than 2%, preferably less than 1 percent, and most preferably 0% by weight of wholly aromatic polyester, i.e., polyarylates. Such polyarylate resins to be excluded herein are aromatic polyesters containing carboxylate groups, ##STR6## and aromatic carbocyclic groups in the linear polymer chain, in which at least some of the carboxylate groups join directly ring carbon atoms of the aromatic carbocyclic groups. Polyarylate polymers, in general, are prepared by reacting a aromatic dicarboxylic acid or ester forming derivative thereof, and a dihydric phenol. They may also be polymerized from a carboxylic acid/hydroxy functional monomer in a head-tail arrangement. They should be substantially absent.
Polyamides suitable as component (ii) for the preparation of the blends of the present invention may be obtained by polymerizing a monoamino-monocarboxylic acid or a lactam thereof having at least 2 carbon atoms between the amino and carboxylic acid group; or by polymerizing substantially equimolar proportions of a diamine which contains at least 2 carbon atoms between the amino groups and a dicarboxylic acid; or by polymerizing a monoaminocarboxylic acid or a lactam thereof as defined above together with substantially equimolar proportions of a diamine and a dicarboxylic acid. The dicarboxylic acid may be used in the form of a functional derivative thereof, for example, an ester or acid chloride. The term "substantially equimolar" proportions (of the diamine and of the dicarboxylic acid) is used to cover both strict equimolar proportions and slight departures therefrom which are involved in conventionel techniques for stabilizing the viscosity of the resultant polyamides.
Examples of the aforementioned monoamino-monocarboxylic acids or lactams thereof which are useful in preparing the polyamides include those compounds containing from 2 to 16 carbon atoms between the amino and carboxylic acid groups, said carbon atoms forming a ring with the --CO--NH group in the case of a lactam. As particular examples of aminocarboxylic acids and lactams there may be mentioned: aminocaproic acid, butyrolactam, pivalolactam, caprolactam, capryllactam, enantholactam, undecanolactam, dodecanolactam and 3- and 4-aminobenzoic acids.
Diamines suitable for use in the preparation of the polyamides include the straight chain and branched, alkyl, aryl and alkyl-aryl diamines. Such diamines include, for example, diprimary and disecondary amines, e.g., those represented by the general formula:
RHN(CH.sub.2).sub.n NHR
R is hydrogen or alkyl of from 1 to 15 carbon atoms or, when both R's are taken together, (CH 2 ) n , or wherein n is an integer of from 2 to 16. Illustrative are: ethylenediamine, trimethylenediamine, tetramethylenediamine, pentamethylenediamine, hexamethylenediamine, as well as 2-methylpentamethylenediamine, isomeric trimethylhexamethylenediamine, meta-xylylenediamine, para-xylylenediamine, 1,3-bis(aminomethyl)cyclohexane, 1,4-bis (aminomethyl) cyclohexane, 1,3-diaminocyclohexane, 1,4-diaminocyclohexane, bis(4-aminocyclohexyl)methane, 2,2-bis(4-aminocyclohexyl)propane, 1,4-piperazine, meta-phenylenediamine, para-phenylenediamine, bis(4-aminophenyl) methane and the like or mixtures thereof.
The dicarboxylic acids may be aromatic or aliphatic dicarboxylic acids of the formula:
HOOC--Z--COOH
wherein Z represents a divalent aliphatic group containing at least 2 carbon atoms or aromatic group containing at least 6 carbon atoms. Examples of such acids are sebacic acid, suberic acid, glutaric acid, pimelic acid, adipic acid, azelaic acid, terephthalic acid, isophthalic acid and the like.
Typical examples of the polyamides or nylons, as these are often called, include for example copolymers of polyamides 6, 6/6, 11, 12, 6/3, 4/6, 6/4, 6/10 or 6/12; polyamides resulting from the condensation of isophthalic and/or terephthalic acid and hexamethylenediamine, of isophthalic acid and/or terephthalic acid and trimethylhexamethylenediamine; polyamides resulting from the use of adipic acid and meta-xylylenediamines; polyamides resulting from the use of adipic acid, azelaic acid and bis-(p-aminophenyl)methane; and polyamides resulting from the use of terephthalic acid and bis-(4-aminocyclohexyl)methane. Mixtures and/or copolymers of two or more of the foregoing polyamides or prepolymers thereof, respectively, are also within the scope of the present invention.
It is also to be understood that the use of the term "polyamides" herein and in the appended claims is intended to include the toughened or super tough polyamides. Super tough polyamides, or super tough nylons, as they are more commonly known, are available commercially, e.g., from E. I. DePont under the tradename Zytel®ST, or may be prepared in accordance with a number of patents including, among others, Epstein, U.S. Pat. No. 4,174,358; Novak, U.S. Pat. No. 4,474,927; Roura, U.S. Pat. No. 4,346,296; and Joffrion, U.S. Pat. No. 4,251,644. These super tough nylons are prepared by blending one or more polyamides with one or more polymeric or copolymeric elastomeric toughening agents. Suitable toughening agents are disclosed in the above-identified U.S. Patents as well as in Caywood, Jr., U.S. Pat. No. 3,884,882, and Swiger, U.S. Pat. No. 4,147,740 and Gallucci et al., "Preparation and Reactions of Epoxy-Modified Polyethylene", J. APPL. POLY. SCI., V. 27, pp. 425-437 (1982). Typically, these elastomeric polymers and copolymers may be straight chain or branched as well as graft polymers and are copolymers, including core-shell graft copolymers, and are characterized as having incorporated therein either by copolymerization or by grafting on the performed polymer, a monomer having functional and/or active or highly polar groupings capable of interacting with or adhering to the polyamide matrix so as to enhance the toughness of the polyamide polymer.
In general, it is true that all polyamides have both a crystalline and an amorphous state. However, as a practical matter, it is difficult to obtain many of the polyamides in the amorphous state. Symmetrical, hydrogen-bonded, linear polyamides are, invariably, highly crystalline with well defined x-ray patterns. Thus, it is difficult to avoid high degrees of crystallinity with polymers, e.g., nylon-6,6; -6,10; and -6, whose regular structures permit good chain alignment and high degrees of hydrogen bonding in the plane of the chains. Chain stiffness also contributes to crystallinity, rendering hydrogen bonding unnecessary for crystallinity where chain stiffness and symmetry are sufficiently high. Ring-containing polyamides, especially aromatic ring-containing polyamides such as polyterephthalamides, have high stiffness and tend to crystallinity. Thus, it is within the skill of persons knowledgeable in the art to produce amorphous polyamide through any one or a combination of several methods. Faster polyamide melt cooling tends to result in an increasingly amorphous resin. Side chain substitutions on the polymer backbone, such as the use of a methyl group to disrupt regularity and hydrogen bonding, may be employed. Non-symmetric monomers, for instance, odd-number chain diamines or diacids and meta aromatic substitution, may prevent crystallization. Symmetry may also be disrupted through copolymerization, that is, using more than one diamine, diacid or monoaminomonocarboxylic acid to disrupt regularity. In the case of copolymerization, monomers which normally may be polymerized to produce crystalline homopolymer polyamides, for instance, nylon 6; 6/6; 11; 12; 6/3; 4/6; 6/4; 6/10; or 6/12, may be copolymerized to produce a random amorphous copolymer. Amorphous polyamides for use herein are generally transparent with no distinct melting point, and the heat of fusion is about 1 cal/gram or less. The heat of fusion may be conveniently determined by use of a differential scanning calorimeter (DSC).
Blends of amorphous polyamide with polyester, substantially free of polyarylate, in any proportion will at least in some degree exhibit characterisitcs embodying the present invention. However, as a practical matter, the benefits of such blend will not be measurably significant outside a weight ratio of from about 2/98 to about 98/2 amorphous polyamide to total polyester. Preferably, this ratio is between about 10/90 to about 90/10.
Of course, the blends herein may contain other thermoplastic resins, various impact modifiers, stabilizers, flame retardants, mold release agents, reinforcing agents, pigments, and the like. Examples of the other thermoplastic resins include poly(etherimides), polysulfones, polyphenylene oxides, and the like. Generally, such other thermoplastic resins should not constitute greater than 80% by weight of total thermoplastic content. Many additives are widely used and recognized as suitable for use herein.
The thermoplastic blends of the present invention are simply prepared by standard techniques; for example, by simple melt blending or dry mixing and melt extruding at an elevated temperature. The extruded admixture is then molded into a piece of specific dimensions or further extruded into a film or sheet product.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Further illustration of this invention is set forth in the following examples. There is no intention to limit the scope of the invention to merely what is shown.
EXAMPLES 1-3
A series of amorphous nylon/polyester blends were prepared by melt blending poly (hexamethylene iso/terephthalamide), E. I. DuPont, with poly(1,4-butylene terephthalate), VALOX® 315 RESIN General Electric Company at weight ratios of 75/25, 50/50 and 25/75 in a Werner Pfleiderer ZSK, 30 mm twin screw extruder at barrel temperatures ranging from 430° F.-460° F. The resins were dried for at least 6 hours in an air circulating oven at 110° C. prior to extrusion. The resulting pelletized products were redried under similar conditions before being molded into ASTM test specimens on a 3 oz., 70 ton Newbury injection molding machine at 475° F. These materials all exhibited good mechanical properties.
EXAMPLES 4-6
Examples 1-3 were repeated except that poly(ethylene terephthalate) Cleartuf® 8006C resin, Goodyear, was substituted for the poly(1,4-butylene terephthlate). The blends were extruded at 460° F.-500° F. and injection molded at 515°-530° F. Mechanical properties on molded parts were good.
EXAMPLES 7-9
Examples 1-3 were repeated except that poly(1,4-cyclohexanedimethylene iso/terephthalate), Kodar®A150, Eastman Kodak, was substituted for poly(1,4-butylene terephthalate). The blends were extruded at 460° F.-500° F. and injection molded at 520° F.-550° F. Mechanical properties on molded parts were good.
EXAMPLES 10-12
A series of 50/50 weight percent amorphous nylon 6,I blends with PBT, poly(1,4-butylene terephthalate); PCHT, poly(1,4-cyclohexanedimethylene iso/terephthalate) and PET, poly(ethylene terephthalate), were prepared using the procedure described in Examples 1-3. The pellets were then extruded into thin films (1-2 mils) on a 1" single screw Killion extruder equipped with a 6" film die and roller system. The extrusion temperatures for film production ranged from 50° F.-550° F. Oxygen transmission rates for these films were measured on a Mocon Ox-Tran 1000 Oxygen Permeability Tester. Results are summarized in Table 1.
TABLE 1______________________________________Oxygen Barrier Properties Oxygen Transmission Rate cc* mil/Example Composition 100 in..sup.2 /D* Atm______________________________________Comparative PBT 6.5710* A10 PBT/nylon 6,I(50/50) 3.75Comparative PET 8.5111* A11 PET/nylon 6,I(50/50) 3.45Comparative PCHT 20.4212* A12 PCHT/nylon 6,I(50/50) 2.49______________________________________ *Control
Relative to the polyester resins, the nylon 6,I-containing blends show improved oxygen barrier properties.
EXAMPLES 13-21
Examples 1-9 were repeated except that poly(trimethylhexamethylene terephthalamide) Trogamid®, Dyanamit Nobel, was substituted for the polyhexamethylene iso/terephthalate Zytel® 330. Mechanical properties for these blends were good.
EXAMPLES 22-30
Examples 1-9 were repeated except that a polyamide made from bis(4-amino-3-methylcyclohexyl) methane, isophthalic acid and lauryl lactam, Grilamid® TR55, Emser Industries, was substituted for the poly(hexamethylene iso/terephthalamide) Zytel® 330. Mechanical properties for these blends were good.
The above-mentioned patents, patent applications and publications are incorporated herein by reference.
Many variations will suggest themselves to those skilled in this art in light of the above, detailed description. All such obvious variations are within the full intended scope of the appended claims. | Thermoplastic resins of enhanced solvent resistance especially useful for packaging or automotive parts comprising blends of amorphous polyamides with a thermoplastic polyester resin, substantially free of a polyarylate have excellent physical properties and barrier resistance to oxygen and carbon dioxide. Preferred blends comprise polyesters prepared by reacting a dihydric alcohol with a dicarboxylic acid, and amorphous polyamides prepared from non-symmetric monomers comprising odd-number chain diamines and diacids, and meta aromatic diamines and diacids. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application makes reference to co-pending U.S. Provisional Patent Application 60/335,326, entitled “Synthesis of Orthopaedic Implant Materials,” filed Nov. 2, 2001, the entire disclosure and contents of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the synthesis of materials using combustion in powder metallurgy and has particular application to the low pressure combustion synthesis (LPCS) of cobalt-based and other metal-based alloys used in orthopaedic implants, such as hip and knee replacements, screws, plates, dental devices, and artificial heart valves.
2. Description of the Prior Art
About 400,000 hip and knee joints are replaced annually using artificial implants in the United States alone. See Orthopaedic Network News, 11, 3 (2000), the entire disclosure and contents of which is hereby incorporated by reference. The ability of orthopaedic implants to provide rapid healing and long-term clinical performance has been proven over many decades to offer patients a high quality of life while minimizing health care costs. Cobalt-chromium-molybdenum (CoCrMo) alloys, specifically cast CoCrMo alloys or wrought CoCrMo alloys generally having an ASTM designation of F-75 or F-1537 respectively (collectively “cobalt alloys”), are used in a wide range of orthopaedic implants, such as total hip and knee replacements, as well as bone screws, plates, and wires. See D. F. Williams, Biocompatibility of Clinical Implant Materials , (CRC Press, Inc.), Boca Raton, Fla., 1981; and S. K. Yen, S. W. Hsu, J. Biomed. Mater. Res., 54, 412 (2001), the entire disclosures and contents of which are hereby incorporated by reference. Moreover, a large fraction of dental devices and some cardiovascular prostheses, for example, heart valves, may be produced from these materials. The high use of these materials is because among all implant materials, cobalt alloys demonstrate a balance of resistance to corrosion, fatigue and wear, along with strength and biocompatibility. See D. Granchi, et al., Biomater., 20, 1079 (1999), the entire disclosure and contents of which is hereby incorporated by reference.
Cobalt alloys are generally produced from elemental materials plus recycled scrap metals, employing conventional furnace technology. Due to the high melting points of the main alloy components, approximately 2,000-4,000 K, high temperature furnaces and other complex types of equipment are needed. The overall process usually takes 4-6 hours. The process, therefore, is both time consuming and energy intensive. In addition, this procedure can cause excessive porosity and carbide segregation in the alloy, which may result in microstructural defects in the alloy. Methods such as extrusion and shock-wave loading may be used to densify an alloy, and although sometimes effective, these additional steps add time and expense to the manufacture of cobalt alloys. Thus, a need exists for an improved method of producing cobalt-based alloys.
SUMMARY OF THE INVENTION
Therefore, it is an object of this invention to develop a more efficient and flexible method for production of orthopaedic implants.
A further object, based on the flexibility of the methods of the present invention, is to synthesize new alloys with superior properties.
According to one broad aspect of the present invention, there is provided a method for synthesis of a pore-free cobalt alloy, the method comprising mixing a desired quantity of cobalt oxide powder with a desired quantity of metal powder thereby creating a powder compact; and initiating a chemical reaction within the powder compact under an ambient inert gas pressure of between about 0.08 and about 1.0 atmospheres, to form a pore-free cobalt alloy.
Other objects and features of the present invention will be apparent from the following detailed description of the preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in conjunction with the accompanying drawings, in which:
FIG. 1 is a diagrammatic view of the main steps of a preferred embodiment of the present invention;
FIG. 2 is a schematic view of a reaction chamber according to a preferred embodiment of the present invention;
FIG. 3A is a diagrammatic view one of two alternate pathways in Co-alloy synthesis, showing the result of a known method (f);
FIG. 3B is a diagrammatic view a second of two alternate pathways in Co-alloy synthesis, showing the result of a method according to a preferred embodiment of the present invention (j);
FIG. 4 is a chart showing the influence of ambient gas pressure on alloy density and yield;
FIG. 5 is a chart showing the dependence of adiabatic combustion temperature and gas product evolution on a basic reactant mixture composition according to a preferred embodiment of the present invention;
FIG. 6A shows synthesized samples and machined specimens for testing;
FIG. 6B shows a typical micrograph of a pore-free CoCrMo material produced by a method according to a preferred embodiment of the present invention;
FIG. 7 shows a method according to a preferred embodiment of the present invention in which LPCS may be combined with direct casting; and
FIGS. 8A , 8 B and 8 C show the influence of different additives on hardness of Co-based alloys produced by a method according to a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
It is advantageous to define several terms before describing the invention. It should be appreciated that the following definitions are used throughout this application.
Definitions
Where the definition of terms departs from the commonly used meaning of the term, applicant intends to utilize the definitions provided below, unless specifically indicated.
For the purposes of the present invention, the term “low pressure combustion synthesis” refers to a combustion synthesis process using low ambient inert gas pressure (P) on the order of 0.08<P<0.90 atm.
For the purposes of the present invention, the term “pore-free alloy” refers to an alloy having >99% theoretical density.
For the purposes of the present invention, the term “green mixture” refers to an initial re of reactant powder(s).
For the purposes of the present invention, the term “powder compact” refers to a powder compacted into a ball or other shape.
For the purposes of the present invention, the term “inert gas” refers to the noble gases helium, neon, argon, krypton, xenon and radon gases, as well as any gas that is non-reactive, under the conditions in which the method of the present invention is practiced, with the materials that are reacted with each other to form a particular alloy of the present invention.
For the purposes of the present invention, the term “ambient inert gas pressure” refers to the pressure of an inert gas contained in a reaction chamber around a reaction sample.
For the purposes of the present invention, the term “yield” refers to the ratio of the metal product mass to the theoretical metal mass formed from the reaction.
For the purposes of the present invention, the term “reaction initiated locally” refers to the initiation of a reaction in a discrete location (approximately a volume of 1 mm 3 ) on or within a sample, such that the reaction is then self-sustainable within, on and along the sample.
For the purposes of the present invention, the term “microgravity” refers to an environment in which there is substantially little or no gravitational force.
Description
The method, referred to herein as low pressure combustion synthesis (“LPCS”), allows one to obtain, as explained in more detail below, pore-free cobalt alloy orthopaedic implant materials without applied force in a single step. Using the rapid screening ability of this technique, synthesized novel materials with unique microstructures and enhanced properties may be produced.
The present invention comprises a method for synthesis of biomedical alloys. One feature of this method is a self-sustained combustion reaction, which is initiated locally by an external heating source, such as a tungsten coil, or laser, which then propagates rapidly through a heterogeneous mixture of reactants in the form of a combustion wave. After cooling, the desired alloy is obtained.
The present invention provides benefits as compared to known combustion synthesis (CS) technologies, such as the use of basic green mixture compositions (i.e., use of oxides and reducing metals); specialized synthesis conditions using ranges of inert gas pressure in the reaction chamber; and special additives leading to enhanced material properties.
The present invention provides for LPCS, which is beneficial as compared to conventional technologies of Co-based alloy production, in that the present invention provides for energy efficiency; short production duration to achieve effectiveness; simplified equipment; and the possibility for one-step article production. For example, according to a preferred embodiment of the present invention, one pound of a CoCrMo alloy, with properties comparable to those of conventionally produced materials, may be produced in about 1 minute using electrical power of about 100 W.
A method for production of cast alloys or articles by combustion synthesis consists of three main steps: (1) preparation of a green mixture; (2) high temperature synthesis: and (3) post-synthesis treatment. A schematic diagram of these steps is presented in FIG. 1 .
The first main step 102 in FIG. 1 is similar to those commonly used in powder metallurgy, in which reactant powders (such as CO 3 O 4 , Co, CoO, CoMoO 4 , chromium (Cr), molybdenum (Mo), aluminum (Al), Magnesium (Mg), Zirconium (Zr), etc.) may be (i) dried under a vacuum at approximately 80-100° C.; (ii) weighed into appropriate amounts (for example, to produce 1 kg of alloy, one needs approximately 649.1-788.16 g, preferably approximately 649.87 g, of CO 3 O 4 ; approximately 157.56-226.72, preferably approximately 159.06 g, of Co; approximately 270-300 g, preferably approximately 296.17 g, of Cr, approximately 50-70 g, preferably approximately 67.70 g, of Mo and approximately 193.92-235.44 g, preferably approximately 194.06 g, of Al); (iii) thoroughly mixed (e.g., ball mixing) for 5 hours to homogenize reaction media; and (iv) finally, the thus prepared green mixture may be cold pressed into cylindrical pellets (e.g., approximately 20 mm in diameter and 40 mm in height) up to a density in the range of approximately 2.9-3.3 g/Cm 3 .
The second main step 112 is combustion synthesis of the alloy. For this step to eliminate horizontal spreading of liquid products, as well as to avoid possible metal splash on the reaction chamber wall, pressed pellets may be inserted in, for example, a quartz tube with, for example, a 42-mm inner diameter covered from both sides by ceramic (BN, SiO 2 , etc.) plugs. The tube may then be constrained in a specially designed fixture and placed in a stainless steel, or other corrosion resistant material, reaction chamber of, for example, 400-mm high and having an inner diameter of 320 mm.
A suitable reaction chamber 200 is shown in detail in FIG. 2 . Reaction chamber 200 includes constraints 202 that provide structural support, cover 204 , for example constructed of BN, SiO 2 , etc., holder 206 , for example constructed of BN, SiO 2 , etc., and quartz tube 208 . A sample 210 may be placed in chamber 200 for carrying out the reaction. Chamber 200 preferably does not react with any of the reagents and should be capable of withstanding the reaction processes of the present invention.
Before reaction initiation, chamber 200 may be sealed, evacuated and purged with inert gas (Argon, Helium, etc.) for approximately three cycles and then filled with inert gas to the desired pressure. A coil 212 , for example, made of tungsten, may be positioned ˜2 mm above sample 210 , and electrically heated until the reaction is initiated locally, followed by turning the power off, while the reaction wave propagates along the sample. If it is desired to produce an article of a specific shape and dimension, this process may also include alloy casting to the desired mold.
According to a preferred embodiment of the present invention, a reaction chamber may be evacuated to a pressure of between about 0.0001 atm and about 0.05 atm, preferably about 0.005 atm. The chamber may then be filled with an inert gas, such as, for example, Argon or Helium, to a pressure of between about 0.08 atm and about 1.0 atm, preferably between about 0.15 atm and about 0.18 atm, for example about 0.16 atm.
Heating of the sample may be conducted using any heating device that allows local preheating of reaction media to the reactant melting point temperature, such as 933 K for Al. Suitable heating elements include a laser or electrically heated wire. To initiate a reaction in the system of the present invention, a sample volume (˜1 mm 3 ) may be preheated locally to the temperature equal to the melting point of a reactant powder (such as Al with T m.p.=933 K). After preheating, the ignition device (electrical wire, laser, etc.) may be immediately turned off, to allow the reaction wave to propagate along the sample in a self-sustained mode. The duration of preheating is generally extremely short, such as approximately 1-5 seconds, preferably approximately 1 second or more.
In particular embodiments of the present invention, a suitable combustion synthesis temperature may be higher than the melting point of Al 2 O 3 but low enough to ensure that the process does not produce more than 0.005 mol of gas phase products.
In particular embodiments of the present invention, the ambient inert gas pressure (P) may be approximately 0.08<P<0.90 atm. Optimum pressure depends on several factors, including the amount of additives, such as carbon, nitrogen, etc., in the alloy.
The third main step 122 , i.e. post-synthesis treatment, is optional, since not all products require additional processing after synthesis. Annealing at an elevated temperature such as approximately 800-1200° C. may be used to remove residual thermal stress in CS-products. The articles may also be machined into specified shapes and/or surface finishes.
An alloy produced by a method of the present invention may preferably correspond to the requirements of the F75-98 standards for Co-based alloys.
For calculated optimum compositions, experiments conducted under normal ambient pressure, have shown that gas released in the high temperature reaction zone may lead to the formation of pores and cavities in the final products ( FIG. 3A , route a→f). Such defects are due to the crystallization of an Al 2 O 3 “cap” on top of the melt Co-alloy product at high temperature, which prevents gas escape and leads to an undesired porous microstructure.
An aspect of the present invention is that low ambient gas pressure allows one to achieve a pore-free (>99% theoretical density) alloy at high yield (>90%). The yield is defined here as the ratio of the metal product mass to the theoretical metal mass formed from the reaction. As shown in FIG. 4 , at pressures lower than 0.15 atm (region I), a pore-free alloy may be produced but the yield is only 60% or lower. On the other hand, at pressures exceeding 0.2 atm (region III), the yield is more than 90% but the material density is too low. Thus, there exists a narrow window of ambient gas pressures (region II) (0.15-0.18 atm) in which both yield and density simultaneously possess acceptably high values.
Referring to FIG. 3B showing a preferred embodiment of the present invention, the compact pressed from a composition, such as 3Co 3 O 4 +8Al+(xCo, yCr, zMo), may be placed in a container (e.g., a quartz tube) and inserted in the metal reaction chamber, preferably constructed of stainless steel. The chamber is pumped down to a pressure of approximately 10 −3 atm, followed by a step of filling the chamber with inert (Argon, Helium, etc.) gas up to relatively low pressure (such as approximately 0.16 atm). The powder compact is locally (˜1 mm 3 ) preheated for a short duration (˜1 s) by an external power source, such as a laser, up to temperature of ˜933-950 K to initiate a reaction. After initiation, the external power source is switched off, and the reaction propagates in a self-sustained manner along the compact resulting in formation of a Co-based alloy and aluminum oxide (Al 2 O 3 ) slag. Immediately after reaction, phase separation between slag and alloy takes place according to route a-b-g→j (FIG. 3 B).
If ambient gas pressure is in the range shown in region III (FIG. 4 ), phase separation occurs following route (a)→(f) as shown in FIG. 3A , with formation of an Al 2 O 3 cap on the top of a metal ingot, which introduces cavities and pores. When the ambient pressure is in the ranges shown in regions I and II (FIG. 4 ), instead of a cap, Al 2 O 3 separates from the metal alloy in the form of a thin (˜1 mm) tube coating the internal surface of the container ( FIG. 3B , route a-b-g→j). The formation of this tube, as opposed to a cap, permits released gas to fully escape from the melt alloy bulk, thus leading to a pore-free material. However, in region I (FIG. 4 ), yield is reduced owing to partial alloy-product blowout, which occurs as a result of the larger pressure gradient existing between the alloy and the ambient atmosphere. Thus, the desired proper balance between full gas release and high yield is achieved in region II (FIG. 4 ).
According to particularly preferred embodiments of the present invention, cobalt alloys may comprise approximately 63% to 68% by weight of cobalt (Co); approximately 27% to 30% by weight of chromium (Cr); and approximately 5% to 7% by weight of molybdenum (Mo). However, those skilled in the art will appreciate that the specific composition(s) of the starting materials may be altered in order to achieve the desired material and mechanical properties of the final cobalt alloy.
An exemplary reaction according to the present invention may be written as follows:
3Co 3 O 4+ 8Al+( x Co, y Cr, z Mo)4Al 2 O 3 +9(cobalt-based alloy),
wherein Al is the reducing agent, and x, y and z coefficients can be varied to obtain the desired compositions and combustion temperatures. For example, x may be 3.0, y may be 6.0 and z may be 0.7.
Thermodynamic analysis shows that the adiabatic combustion temperature (T ad ) for the above reaction at 1 atm Argon ambient atmosphere may be as high as 2,900 K (x=0; y=4.5; z=0.5) (FIG. 5 ). By increasing Co content in the initial mixture (i.e., the value of x), T ad decreases continuously, while the amount of gaseous products (including Cr, Co, Al, oxides, etc.) decreases, reaching a minimum at 0.6 mole ratio of Co to (Co+CO 3 O 4 ). Thus, having T ad higher than the melting points of Al 2 O 3 (T mp,Al 2 O 3 ˜2,300 K) and the Co-based alloy (T m.p.,alloy ˜1,768 K), provides full separation and a homogeneous composition distribution along with a low amount of gas products. In particular embodiments of the present invention, a 0.5 mole ratio of Co to (Co+CO 3 O 4 ) may be preferably used as the basic reactant composition.
FIG. 6A shows synthesized Co-alloy ingots produced by LPCS according to a method of the present invention, along with machined test specimens. FIG. 6A shows that disks with smooth surfaces may be produced. In addition, no cavities or pores are observed in the microstructure, as shown in FIG. 6 B. Chemical analysis shows that the alloy compositions match well with the ASTM F75 standard specifications and exhibit extremely low levels of impurities, see Table 1 below. Note that high purity is important in orthopaedic implants; for example, it has been reported that Ni possesses allergic potential, and Si may cause embrittlement. The present invention successfully combines two important features of self-densification and self-purification, since high-purity pore-free materials may be produced in one step using a porous mixture of lower cost oxides, instead of pure metals.
TABLE 1
Chemical composition (wt. %) of the CoCrMo alloy produced by LPCS and related
ASTM standard specifications.
Composition
Co
Cr
Mo
Si
W
C
Al
Fe
Mn
Ni
P
B
N
F75-98
min
bal
27.0
5.0
—
—
—
—
—
—
—
—
—
—
max
bal
30.00
7.00
1.00
0.20
0.35
0.30
0.75
1.00
1.00
0.020
0.01
0.25
LPCS-CoCrMo
bal
28.01
6.47
0.076
0.13
0.019
0.20
0.11
0.085
0.08
0.009
<0.0005
0.0058
As mentioned above, according to a particular embodiment of the present invention, alloys of the present invention may be cast into various desired shapes and dimensions, as shown in FIG. 7 . The desired shape may then be machined to provide a suitable finish and to fine-tune any shaping requirements.
The aforementioned concept of LPCS, i.e. achieving full release of residual gas formed during rapid high temperature reaction by adjusting ambient gas pressure, may also be used in other reaction systems to produce pore-free alloys, ceramics, intermetallics and composites. For example, synthesis of dense stainless steel based biomaterials using this technology may be done as follows:
Fe 2 O 3 +2Al+(Cr, Mo)Al 2 O 3 +stainless steel alloy.
Using the rapid screening ability of the LPCS method of the present invention, an investigation of a wide range of material compositions may be conducted. In this context, graphite, carbon black, metals, carbides and nitrides (e.g., Cr, Mo, titanium (Ti), TiC, Cr 3 C 2 , TiN, Cr 7 C 3 , Mo 2 C, etc.) may be used as additives to synthesize novel materials with superior properties, see Table 2 below for properties for various additives. For example, it is known that carbon enhances mechanical properties in cast CoCrMo alloys, which was also confirmed in FIG. 8 A. With respect to the method of present invention, it has also demonstrated that, among the various additives, Cr 3 C 2 is very effective for increasing material hardness, sec FIG. 8 B. The hardness of alloys with different amounts of Cr 3 C 2 is shown in FIG. 8 C. These values are significantly higher than those exhibited by alloys synthesized using conventional techniques, such as wrought CoCrMo alloys, see R. H. Shetty, et al., in: Encyclopedic Handbook of Biomaterials and Bioengineering , New York, part B 1, 509 (1995), the entire contents and disclosure of which is hereby incorporated by reference herein. This enhancement owes to the fine and uniform microstructure that results from the LPCS conditions of the present invention.
TABLE 2
Synthesis pressures for CS Co-alloys with additives.
Additive
Carbon Black
Graphite
Cr 3 C 2
wt. % carbon
0
0.25
0.35
0.5
0.5
0.5
Optimum pressure, atm
0.15-0.18
0.15-0.26
0.32-0.40
0.8-1.0
0.15-0.4
0.08-0.2
Yield, %
91
83
78
83
85
80
Porosity, %
<1
<1
<1
<1
<1
<1
Carbon has a high melting point (˜3,800 K) and hence does not melt under conventional synthesis or LPCS conditions, so that it is difficult to distribute formed carbides homogeneously. However, metal carbides, which have a lower melting point (e.g., the melting point for Cr 3 C 2 is 2,168 K), may be added directly to the initial reactant mixture. In this case, owing to high temperatures in the combustion wave (˜2,900 K), these carbides may be melted and distributed uniformly during LPCS, while the carbides remain in the original solid state during the relatively low temperature (˜2,000 K) involved in a conventional casting technique. These features permit LPCS-alloys to attain hardness up to 46 HRc, approximately 50% higher than conventional alloys with the same carbon content (0.33 wt. %).
It is generally believed that phase separation in thermite systems is controlled by gravity-driven buoyancy, which occurs due to the difference in densities of the products: metal (e.g., ρ Co =8.3 g/cm 3 ) and slag (e.g., ρ Al2O3 =2.7 g/cm 3 ). See V. I. Yukhvid, Pure & Appl. Chem., 64, 977 (1992); A. G. Merzhanov, V. I. Yukhvid, and I. P. Borovinskay, Dokl. Chem. Phys., 255, 503 (1979); V. I. Yukhvid, Izv. Akad. Nauk. SSSR. Metal, 6, 61 (1980); and A. M. Bulaev, Comb. Explos . & Shock Waves, 28, 395 (1992), the entire contents and disclosures of which are hereby incorporated by reference. However, the present invention may be used in microgravity environments as well.
Combustion synthesis involving various thermite systems (e.g., CO 3 O 4 —Al; MoO 3 —Al and V 2 O 5 —Al) with different ratios of metal/Al 2 O 3 densities, such as V (ρ v =6.11 g/cm 3 ), Co (ρ Co =8.92 g/cm 3 ), Mo (ρ Mo =10.22 g/cm 3 ) and (ρ Al2O3 =2.8 g/cm 3 ), were studied under different gravity conditions (in the range 10 −5 -1.7 g) to determine the effect of buoyancy on phase segregation. Since a high level (˜93%) of phase separation may be achieved under microgravity, the present invention has shown that some non-gravity-driven mechanisms play a role during CS of Co-based and Mo-based alloys. See Lau, C., Mukasyan, A. S. and Varma, A., Materials Synthesis by Reduction - Type Combustion Reaction: Influence of Gravity , Proceedings of the Combustion Institute, 29, 2002 (in press), the entire contents and disclosure of which is hereby incorporated by reference.
The present invention has shown that the two-stage phase separation process: (i) separation of immiscible liquid in the reaction front; and (ii) capillary spreading of the alloy in a solid matrix, not only helps explain the observed microstructural transformation during CS, but also helps explain the observed effect of essentially complete phase separation achieved in microgravity conditions.
Furthermore, the present invention has shown that the first three systems identified above, i.e. CO 3 O 4 —Al; MoO 3 —Al; Fe 2 O 3 —Al, possess similar behaviors and thus the methods of the present invention may be applicable for production of pore-free alloys based on such systems. However, in the latter V 2 O 5 —Al system, full phase separation may not be achieved under 1 g conditions.
This effect can be understood by taking into account two issues. First, the volume of liquid metal (e.g., Co or V) in the reaction front should exceed some critical value (the so-called percolation limit) so that metal drops may form a continuous skeleton structure. In this case, surface tension rapidly leads to the separation of two phases. For example, in the case of a CO 3 O 4 —Al system, the suggested composition range provides ˜50 vol. % of metal in the reaction front, which is above the critical value (˜45 vol. %), while for a V 2 O 5 —Al system, the amount of liquid metal is only ˜35%.
Also, specific features of the binary phase diagram (Me—Al 2 O 3 ) are important, i.e. at a particular temperature, these two phases (eg., Co and Al 2 O 3 ) should be immiscible resulting in their rapid separation. Since ternary complex oxides (V—Al—O) may exist along the entire temperature range in a V 2 O 5 —Al system, gravity driven buoyancy (and not a surface tension-based mechanism) generally leads to their full separation in a post-combustion zone. In addition, in this situation, normal gravity conditions (1 g) under relatively short process durations are not sufficient, thus additional (e.g., centrifugal) forces may need to be applied to enhance the process and reach full separation.
Although the present invention has been fully described in conjunction with the preferred embodiment thereof with reference to the accompanying drawings, it is to be understood that various changes and modifications may be apparent to those skilled in the art. Such changes and modifications are to be understood as included within the scope of the present invention as defined by the appended claims, unless they depart therefrom. | A method for synthesis of biomedical alloys has been developed based on combustion phenomena. This low pressure combustion synthesis (LPCS) technique may be used for production of Co-based and other metal-based alloys, which cover the entire range of orthopaedic implants, including total hip and knee replacements, as well as hone screws, plates, and wires. A unique aspect of the method is that combustion synthesis under low ambient gas pressure allows one to produce pore-free (>99% theoretical density) alloys with high purity and precise chemical and phase compositions. | 2 |
FIELD OF THE INVENTION
[0001] This is a Continuation-in-Part pending from patent application Ser. No. 14/256,851 filed Apr. 18, 2014, titled “A DRIVE SHAFT SPLINT JOINT” to inventor STORY. THE CIP Application Specification and Claims are added to the original application Specification and Claims and ARE DISPLAYED IN BOLD PRINT. This invention relates to a splint joint for a shaft. More specifically the invention is a splint joint for a drive shaft with the bushing receptacle ( 100 ) having a bushing receptacle body non-tapered interior ( 115 ) parallel to a bushing receptacle and shaft center line ( 140 ). In this variant a bushing ring ( 600 ) is intermediate a bushing ( 300 ) and the bushing receptacle ( 100 ).
BACKGROUND OF THE INVENTION
[0002] The need to adjust, move or remove a drive shaft can facilitate repair of equipment and installation of new equipment. The ability to disassemble or separate a drive shaft or drive shaft sections can assist in repair and installation of equipment.
SUMMARY OF THE INVENTION
[0003] The Drive Shaft Splint Joint is a receptacle ( 100 ) with a bushing receptacle body interior ( 113 ) having a receptacle tapered interior ( 114 ) or, in an obvious variant, having a bushing receptacle non-tapered interior ( 115 ) and with a drive shaft extending from the receptacle. A bushing is inserted into the receptacle interior and the bushing receptacle and bushing are irremovably affixed with bolts. The bushing has a keyed aperture which receives a keyway drive shaft. Push bolts allow the bushing to be urged away from the receptacle allowing the drive shaft to be disassembled.
[0004] Alternatively, a bushing ( 300 ) is removably affixed to a bushing ring ( 600 ) and the combined bushing ( 300 ) and bushing ring ( 600 ) is inserted into the bushing receptacle ( 100 ) and the bushing receptacle ( 100 ) and the combined bushing ( 300 ) and bushing ring ( 600 ) are inhibited by friction fit from rotation relative to the other. Persons of ordinary skill in key arts recognize that the bushing receptacle may secure a bushing ring ( 600 ) and a bushing ( 300 ) from rotation via a key or keyway or with friction and that the drive shaft extending from the bushing receptacle may likewise be keyed, be secured to a rotating drive by friction or be received into a bearing. Push bolts allow the bushing to be urged away from the bushing ring and the receptacle allowing the drive shaft to be disassembled.
[0005] In the alternative variant of this CIP the Drive Shaft Splint Joint receptacle ( 100 ) has a bushing receptacle non-tapered interior ( 115 ). This variant has a bushing receptacle body ( 110 ) bushing receptacle body non tapered interior ( 115 ) where the bushing receptacle body non tapered interior ( 115 ) is parallel to a bushing receptacle and shaft center line ( 140 ).
BRIEF DESCRIPTION OF THE FIGURES
[0006] The foregoing and other features and advantages of the present invention will become more readily appreciated as the same become better understood by reference to the following detailed description of the preferred embodiment of the invention when taken in conjunction with the accompanying drawings, wherein:
[0007] FIG. 1 illustrates a bushing receptacle ( 100 ), a bushing receptacle body ( 110 ), a bushing receptacle body exterior ( 112 ), a bushing receptacle body tapered interior ( 114 ), a bushing receptacle top ( 116 ), a bushing receptacle bottom ( 118 ), a receptacle bushing mating surface ( 120 ), at least one bushing receptacle tapped hole ( 122 ) at the said bushing mating surface ( 120 ), a bushing receptacle drive shaft aperture key ( 124 ) and a bushing receptacle and shaft center line ( 140 ); a drive shaft ( 200 ), a drive shaft key way ( 210 ); a bushing ( 300 ) having a bushing cap ( 320 ), at least one bushing cap machine bolt hole ( 322 ), at least one bushing cap push bolt tapped hole ( 324 ), a bushing cap top surface ( 326 ), a bushing cap bottom surface ( 328 ) a bushing drive shaft aperture ( 340 ), a bushing drive shaft aperture key ( 342 ), a bushing taper body ( 330 ) and a bushing taper body split ( 336 ); a drive device ( 400 ), a driven device ( 500 ), a driven device drive shaft ( 510 ) and a driven device drive shaft keyway ( 520 ).
[0008] FIGSS. 2 and 2 A show the Splint joint ( 1 ) illustrating the bushing receptacle ( 100 ), the bushing receptacle body ( 110 ), the bushing receptacle body exterior ( 112 ), the bushing receptacle body interior ( 114 ), the bushing receptacle top ( 116 ), the bushing receptacle bottom ( 118 ), the bushing receptacle mating surface ( 120 ), at least one bushing receptacle tapped hole ( 122 ), a bushing receptacle drive shaft aperture key ( 124 ) and the bushing receptacle and shaft center line ( 140 ).
[0009] FIGS. 3, 3A and 3B shows a bushing ( 300 ), a bushing cap ( 320 ), at least one bushing cap machine bolt hole ( 322 ), at least one bushing cap push bolt tapped hole ( 324 ), the bushing cap top surface ( 326 ), the bushing cap bottom surface ( 328 ), the bushing drive shaft aperture ( 340 ), the bushing drive shaft aperture key ( 342 ), the bushing taper body ( 330 ) and the bushing taper body split ( 336 ). FIG. 3A and 3B are sections from FIG. 3 illustrating the bushing drive shaft aperture key ( 342 ) extending, in FIG. 3A , part way from the bushing cap top surface ( 326 ) toward the bushing cap bottom surface ( 328 ), and in FIG. 3B , from the said bushing cap top surface ( 326 ) to the bushing cap bottom surface ( 328 ).
[0010] FIG. 4 illustrates a Splint joint ( 1 ), a bushing receptacle ( 100 ), a bushing receptacle body ( 110 ), a bushing receptacle body exterior ( 112 ), a bushing receptacle body interior ( 113 ), a bushing receptacle top ( 116 ), a bushing receptacle seal location ( 117 ), bushing receptacle bottom ( 118 ), a bushing receptacle drive shaft aperture key ( 124 ), a bushing receptacle interior ( 130 ) and a bushing receptacle and shaft center line, ( 140 ).
[0011] FIG. 4A is section A from FIG. 4 showing a bushing receptacle ( 100 ), a bushing receptacle body ( 110 ), a bushing receptacle body exterior ( 112 ), a bushing receptacle body tapered interior ( 114 ), a bushing receptacle top ( 116 ), a bushing receptacle seal location ( 117 ), bushing receptacle bottom ( 118 ), a bushing receptacle drive shaft aperture key ( 124 ), a bushing receptacle interior ( 130 ) and a bushing receptacle and shaft center line, ( 140 ).
[0012] FIG. 4B is section B from FIG. 4 showing a bushing receptacle ( 100 ), a bushing receptacle body ( 110 ), a bushing receptacle body exterior ( 112 ), a bushing receptacle body non-tapered interior ( 115 ), a bushing receptacle top ( 116 ), a bushing receptacle seal location ( 117 ), bushing receptacle bottom ( 118 ), a bushing receptacle drive shaft aperture key ( 124 ), a bushing receptacle interior ( 130 ) and a bushing receptacle and shaft center line, ( 140 ).
[0013] FIG. 4C is section C from FIG. 4 illustrating the entire structure of the Drive Shaft Splint Joint including bushing receptacle with non-Tapered Interior. Seen is the bushing receptacle ( 100 ), the bushing receptacle body interior diameter ( 110 ), the bushing receptacle body ( 111 ), the bushing receptacle body exterior ( 112 ), the bushing receptacle body interior ( 113 ), the bushing receptacle body tapered interior ( 114 ), the bushing receptacle body non tapered interior ( 115 ) the bushing receptacle top ( 116 ), the bushing receptacle seal location ( 117 ), the bushing receptacle bottom ( 118 ), the bushing receptacle bushing ring stop ( 119 ) the bushing receptacle interior bottom ( 123 ), the bushing receptacl seal location diameter ( 121 ), bushing receptacle drive shaft aperture key ( 124 ), the bushing receptacle interior ( 130 ), the bushing receptacle and shaft center line ( 140 ), the drive shaft ( 200 ), the drive shaft key way ( 210 ), the drive shaft tapped hole ( 220 ) and the drive shaft connection ( 230 ). Also shown is a bushing ring ( 600 ), a bushing ring cap ( 620 ), a bushing ring cap machine bolt hole ( 622 ), a bushing ring cap push bolt tapped hole ( 624 ), bushing ring cap top surface ( 626 ), a bushing ring cap bottom surface ( 628 ), a bushing ring drive shaft aperture ( 640 ), a bushing ring drive shaft aperture key ( 642 ), and a bushing ring interior body ( 630 ). Also illustrated is the bushing ( 300 ), the bushing cap ( 320 ), the bushing cap machine bolt hole ( 322 ), the bushing cap machine bolt ( 323 ), the bushing cap push bolt tapped hole ( 324 ), the bushing cap top surface ( 326 ), the bushing cap bottom surface ( 328 ), the bushing drive shaft aperture ( 340 ), the bushing drive shaft aperture key ( 342 ), the bushing taper body ( 330 ), and the bushing taper body split ( 336 ). Also seen is a driven device ( 500 ), a driven device drive shaft ( 510 ) and a driven device drive shaft keyway ( 520 ), a seal ( 700 ), a seal aperture ( 740 ), a seal aperture diameter ( 710 ), and a seal outside diameter ( 711 ).
DETAILED DESCRIPTION OF THE INVENTION
[0014] The splint joint ( 1 ), as seen in FIGS. 1, 2, and 2A for a shaft comprises a bushing receptacle ( 100 ) having a bushing receptacle body ( 110 ); said bushing receptacle ( 100 ) having a bushing receptacle body exterior ( 112 ), a bushing receptacle body tapered interior ( 114 ), a bushing receptacle top ( 116 ), a bushing receptacle bottom ( 118 ) distal from the said bushing receptacle top ( 116 ), a generally planar receptacle bushing mating surface ( 120 ) at the said bushing receptacle top ( 116 ), at least one bushing receptacle tapped hole ( 122 ) at the said bushing mating surface ( 120 ) penetrating the said bushing receptacle body ( 110 ). A person of ordinary skill in mechanical arts will recognize that the “bushing receptacle body tapered interior ( 114 )” may not be tapered” but that a tapered interior will provide from additional resistance to torque and rotation of the said splint joint ( 1 ) relative to an attached bushing ( 300 ).
[0015] As seen in FIGS. 1, 2 and 2A , a shaft ( 200 ) extends outwardly from and is immovably affixed, by a drive shaft connection ( 230 ), to the said bushing receptacle bottom ( 118 ). Those of ordinary skills in the drive shaft arts will understand the variety of ways that the shaft ( 200 ) may be immovably affixed to the said bushing receptacle ( 100 ) including welding. However, the preferred formation of the bushing receptacle ( 100 ) and extending shaft ( 200 ) is by machining from a single piece of rigid material including generally carbon or stainless steel. The shaft ( 200 ) is in alignment with and concentrically sharing a bushing receptacle and shaft center line ( 140 ) extending from a bushing receptacle center ( 140 ) at the said bushing receptacle interior ( 130 ).
[0016] Seen in FIGS. 3, 3A and 3B is a bushing ( 300 ) having a bushing cap ( 320 ); the bushing cap ( 320 ) having a bushing cap top surface ( 326 ) and a bushing cap bottom surface ( 328 ); said bushing cap top surface ( 326 ) and said bushing cap bottom surface ( 328 ) are generally orthogonal to the said bushing receptacle and shaft center line ( 140 ).
[0017] Seen in FIGS. 3, 3A and 3B , at least one bushing cap machine bolt hole ( 322 ) penetrates the said bushing cap ( 320 ) and is in alignment with the at least one bushing receptacle tapped hole ( 122 ). The at least one bushing cap push bolt tapped hole ( 324 ) extends from said bushing cap top surface ( 326 ) and through the said bushing cap bottom surface ( 328 ). The said at least one bushing cap push bolt tapped hole ( 324 ) is aligned to contact the said bushing mating surface ( 120 ); and a bushing drive shaft aperture ( 340 ) is sized to receive a shaft ( 200 ) and extends from said bushing cap top surface ( 326 ) through the said bushing cap bottom surface ( 328 ) and is concentrically aligned with the said bushing receptacle and shaft center line ( 140 ).
[0018] As illustrated in FIGS. 3, 3A and 3B is the bushing taper body ( 330 ) extends outwardly from the said bushing cap bottom surface ( 328 ); the bushing taper body ( 330 ) is sized to be slidably inserted into and extracted from the bushing receptacle body tapered interior ( 114 ); the bushing taper body ( 330 ) having a irremovably friction fit within the bushing receptacle body tapered interior ( 114 ); the bushing taper body ( 330 ) and the bushing receptacle body tapered interior ( 114 ) having generally the same tapered ratio; the said bushing taper body split ( 336 ) is narrow proximal the said bushing cap bottom surface ( 328 ) and is wider distal to the said bushing cap bottom surface ( 328 ). The said bushing taper body ( 330 ) has a spring function allowing the bushing taper body split ( 336 ) to close as the said bushing taper body ( 330 ) is inserted into the said bushing receptacle body tapered interior ( 114 ). In an alternative embodiment the said bushing body ( 330 ) will not be tapered. In an additional alternative embodiment there is no bushing taper body ( 330 ).
[0019] As seen in FIGS. 3, 3A and 3B , the said bushing cap bottom surface ( 328 ) is generally parallel to the said bushing receptacle mating surface ( 120 ); the at least one bushing cap machine bolt hole ( 322 ) is aligned with the said at least one bushing receptacle tapped hole ( 122 ) to receive machine screws and secure the said bushing receptacle ( 100 ) and the said bushing ( 300 ) from movement relative to the other during rotation.
[0020] As shown in FIGS. 3, 3A and 3B there is at least one bushing cap push bolt tapped hole ( 324 ) is positioned so that a threaded push bolt received by the at least one bushing cap push bolt threaded hole ( 324 ) will contact the bushing receptacle mating surface ( 120 ) and thereby urge the said bushing ( 300 ) away from and out of the said bushing receptacle ( 100 ) when the splint joint ( 1 ) disassembly is required.
[0021] Seen in FIGS. 3, 3A and 3B is a preferred embodiment of the Splint Joint ( 1 ) the shaft ( 200 ) is a drive shaft ( 200 ) having a drive shaft key way ( 210 ); the said drive shaft ( 200 ) is driven by a drive device ( 400 ); the at least one bushing receptacle tapped hole ( 122 ) at the said bushing mating surface ( 120 ) is at least two bushing receptacle tapped holes ( 122 ); and the said at least one bushing cap push bolt tapped hole ( 324 ) is at least two bushing cap push bolt tapped holes ( 324 ) spaced apart and aligned to contact the said bushing mating surface ( 120 ); and the said bushing drive shaft aperture ( 340 ) has a bushing drive shaft aperture key ( 342 ) therein to be received into a driven device drive shaft key way ( 520 ) of a drive shaft ( 200 ) which drives a driven device ( 500 ). In the preferred embodiment the bushing drive shaft aperture key ( 342 ) extends within the said bushing drive shaft aperture ( 340 ) from the said bushing cap top surface ( 326 ) to the said bushing cap bottom surface ( 328 ). In the preferred embodiment a drive shaft ( 200 ) having a said driven device drive shaft key way ( 520 ) will extend no further into the said bushing taper body ( 330 ) than from the said bushing cap top surface ( 326 ) to the said bushing cap bottom surface ( 328 ). This preferred embodiment will allow greatest movement of the said drive shaft ( 200 ) into the said bushing taper body ( 330 ) there by facilitating disassembly of the drive shaft splint joint ( 1 ). In an alternative embodiment a drive shaft ( 200 ) having a said driven device drive shaft key way ( 520 ) will extend into the bushing cap ( 324 ) and toward the said bushing cap bottom surface ( 328 ) but will be distal to the said bushing cap bottom surface ( 328 ).
[0022] Additionally, FIGS. 3, 3A and 3B in the preferred embodiment of the Splint Joint ( 1 ), the at least two bushing receptacle tapped holes ( 122 ) at the said bushing mating surface ( 120 ) is at least three bushing receptacle tapped holes ( 122 ) spaced equidistantly; the said at least one bushing cap push bolt tapped hole ( 324 ) is at least two bushing cap push bolt tapped holes ( 324 ) spaced apart 180 degrees.
[0023] An obvious variant of the Splint Joint ( 1 ) is seen in FIGS. 4, 4A and 4B showing a bushing receptacle ( 100 ), a bushing receptacle body ( 110 ), a bushing receptacle body exterior ( 112 ), a bushing receptacle body tapered interior ( 114 ), a bushing receptacle body non tapered interior ( 115 ), a bushing receptacle top ( 116 ), a bushing receptacle seal lip ( 117 ), a bushing receptacle bottom ( 118 ), a bushing receptacle drive shaft aperture key ( 124 ), a bushing receptacle interior ( 130 ), and a bushing receptacle and shaft center line ( 140 ). Also illustrated in FIG. 4A is section A-A from FIG. 4 showing the bushing receptacle body tapered interior ( 114 ) and in Fig. 4 B is section B-B from FIG. 4 showing a bushing receptacle body non tapered interior ( 115 ).
[0024] Also seen in FIG. 4 is a bushing ring ( 600 ) having a bushing ring cap ( 620 ), a bushing ring cap machine bolt hole ( 622 ), bushing ring cap push bolt tapped hole ( 624 ), a bushing ring cap top surface ( 626 ), a bushing ring cap bottom surface ( 628 ), a bushing ring drive shaft aperture ( 640 ), a bushing ring drive shaft aperture key ( 642 ) and a bushing ring taper body ( 630 ).
[0025] Also illustrated in FIG. 4 is a bushing ( 300 ) having a bushing cap ( 320 ), a bushing cap machine bolt hole ( 322 ), bushing cap push bolt tapped hole ( 324 ), a bushing cap top surface ( 326 ), bushing cap bottom surface ( 328 ), a bushing drive shaft aperture ( 340 ), a bushing drive shaft aperture key ( 342 ), a bushing taper body ( 330 ) and a bushing taper body split ( 336 ).
[0026] FIG. 4C is section C from FIG. 4 illustrating and exploded view of the entire structure of the Drive Shaft Splint Joint including bushing receptacle ( 100 ), drive shaft ( 200 ), bushing ring ( 600 ), bushing ( 300 ), seal ( 700 ) and driven device drive shaft ( 510 ).
[0027] Seen in FIG. 4C is the bushing receptacle ( 100 ) which is constructed from a rigid material including stainless steel and, for some applications, rigid plastics. Stainless steel will be preferred when used in food production or industries intent on controlling contamination in that the bushing ( 300 ), bushing ring ( 600 ), driven device drive shaft ( 510 ) will possibly be constructed of steel.
[0028] Illustrated in FIG. 4C is the bushing receptacle body interior diameter ( 110 ) which is greater than the bushing ring cap diameter ( 610 ). The bushing receptacle seal location diameter ( 121 ) is greater than the bushing receptacle body interior diameter ( 110 ) and is greater than the seal outside diameter ( 711 ). The bushing cap diameter ( 321 ) is less than or equal to the bushing ring cap diameter ( 610 ), The driven device drive shaft diameter ( 511 ) is less than the bushing drive shaft aperture diameter ( 310 ) and the seal aperture diameter ( 710 ) and is sealing fitted to the seal aperture ( 740 ).
[0029] Seen in FIG. 4C is the bushing ring cap diameter ( 610 ) is less than the bushing receptacle body interior diameter ( 110 ) and the bushing ring ( 600 ) is friction or key secured within the bushing receptacle ( 100 ) from rotation relative to the bushing receptacle ( 100 ). The preferred method of eliminating rotation between the bushing receptacle ( 100 ) and the bushing ring ( 600 ) is by friction fit. However, those of ordinary skills in the rotation prevention arts will know that friction and key methods are used to eliminate rotation between such elements.
[0030] Also seen in FIG. 4C is that the bushing ( 300 ) is irremovably affixed to the bushing ring ( 600 ) with at least one threaded bushing machine cap bolt ( 323 ) via a bushing machine bolt hole ( 322 ) aligned with a bushing ring cap machine bolt hole ( 622 ) and the interconnected bushing ( 300 ) and the bushing ring ( 600 ) are inserted into the bushing receptacle body interior ( 113 ). The bushing taper body ( 330 ) is split with a bushing taper body split ( 336 ) which extends from bushing cap top surface ( 626 ) through the bushing taper body ( 330 ). The bushing taper body split ( 336 ) allows the bushing ( 300 ) to be compressed and to expand as the bushing ( 300 ) is irremovably affixed in the bushing ring ( 600 ). The bushing ring body ( 630 ) has a bushing ring interior body taper ( 637 ) and is tapered at the interior. The bushing ring body ( 630 ) is split with a bushing ring body split ( 636 ) from bushing ring cap top surface to through the bushing ring cap bottom surface ( 628 ) allowing the bushing ring ( 600 ) to be compressed and to expand. The bushing ring cap exterior ( 629 ) is parallel to the bushing receptacle body interior ( 113 ). The interconnection of the bushing ( 300 ) and the bushing ring ( 600 ) draws the bushing taper body ( 330 ) into contact with the bushing ring interior body taper ( 630 ). As the at least one threaded bushing machine cap bolt ( 323 ) is tightened the bushing taper body split ( 336 ) is compressed and the bushing taper body split ( 636 ) is expanded thereby urging the bushing ring cap exterior ( 629 ) into friction and rotation resistant contact with the bushing receptacle body interior ( 113 ).
[0031] As additionally illustrated in FIG. 4C , the seal outside diameter ( 711 ) is less than the bushing receptacle seal location diameter ( 121 ) and is greater than the bushing cap diameter ( 321 ). The seal ( 700 ) is received into the bushing receptacle seal location ( 117 ) with a sealing fit. The driven device drive shaft ( 510 ) is sealingly inserted through the seal aperture ( 740 ) and through the bushing drive shaft aperture ( 340 ). The driven device drive shaft ( 510 ) is friction and rotation resistant by the compressed bushing taper body split ( 336 ) when combined with the bushing ring ( 600 ). The driven device drive shaft ( 510 ) is illustrated as extending from the driven device ( 500 ).
[0032] Also illustrated in FIG. 4C is the bushing receptacle bushing ring stop ( 119 ) and the bushing receptacle interior bottom ( 123 ). The bushing ring cap diameter ( 610 ) is greater than the bushing receptacle interior bottom diameter ( 122 ). The combined bushing ( 300 ) and bushing ring ( 600 ) may be inserted into the bushing receptacle ( 100 ) and into contact with the bushing receptacle bushing ring stop ( 119 ). The driven device drive shaft ( 510 ) is sized to pass through the seal aperture ( 740 ), the bushing drive shaft aperture ( 340 ), bushing ring drive shaft aperture ( 640 ) and into the bushing receptacle body interior ( 113 ) and into contact with the bushing receptacle interior bottom ( 123 ). When the bushing ( 300 ) is affixed to the bushing ring ( 600 ) with at least one bushing cap machine bolt ( 323 ) received by at least one bushing ring cap push bolt tapped hole ( 624 ), the bushing cap diameter ( 321 ) is lessened and the bushing drive shaft aperture ( 340 ) is compressed against the driven device drive shaft ( 510 ) thereby creating a friction fit inhibiting rotation of the driven device drive shaft ( 510 ) relative to the bushing ( 300 ). When the bushing ( 300 ) is affixed to the bushing ring ( 600 ) with at least one bushing cap machine bolt ( 323 ) received by at least one bushing ring cap push bolt tapped hole ( 624 ), the bushing ring cap diameter ( 610 ) is increased thereby compressing the bushing ring cap exterior ( 629 ) into contact with the bushing receptacle bushing receptacle body interior ( 113 ) thereby creating a friction fit inhibiting rotation of the bushing ring ( 600 ) relative to the bushing receptacle ( 100 ). | This invention is a splint joint for a drive shaft including a receptacle with an interior and with a drive shaft extending from the receptacle. A bushing having a bushing body is inserted into the receptacle interior and the receptacle and bushing are immovably affixed in resistance to rotation by friction. In this variation the bushing is affixed to a bushing ring with the combined bushing and bushing ring inserted into the receptacle. The process of affixing includes, in this variation, machine bolts drawing the bushing and bushing ring together. The bushing and the bushing ring each have a single split and both have a spring function. As the bushing and bushing ring are drawn together the bushing ring is expanded into friction contact with the bushing receptacle interior and the bushing is compressed into friction contact with the bushing ring thereby inhibiting rotation relative to the bushing receptacle. Push bolts allow the bushing to be urged away from the bushing ring allowing the disassembly of the shaft when repair is required. | 5 |
[0001] The present invention relates to a method for the production of hybridoma cell lines producing antibodies against C-terminal fragments of agrin, antibodies produced by the cell lines, pharmaceutical compositions containing said antibodies, and uses thereof.
[0002] Agrin is an important protein which plays a pivotal role in the synapse-formation process by assisting formation and maintenance of the postsynaptic apparatus of developing neuromuscular junctions (NMJ's) (Bezakova and Ruegg, 2003). It could be shown that agrin deficient mice die at birth due to respiratory failure. This is caused by the fact that agrin is strictly required for the proper innervation of muscle fibres and that these mice are not able to build proper NMJ's.
[0003] Agrin is not only existent in neural or neuronal tissues but can also be found in periphery tissues like the lung and the kidney which indicates that agrin plays also a role in these organs.
[0004] Agrin is a large heparan proteoglycan with a molecular weight of 400-600 kDa. (Database accession number NP — 940978). The protein core consists of about 2000 amino acids and its mass is about 225 kDa. It is a multidomain protein composed of 9 K (Kunitz-type) domains, 2 LE (laminin-EGF-like) domains, one SEA (sperm protein, enterokinase and agrin) domain, 4 EG (epidermal growth factor-like) domains and 3 LG (laminin globular) domains ( FIG. 1 ).
[0005] Agrin exists in several splice variants and can be expressed as a secreted protein, containing the N-terminal NtA (N-terminal agrin) domain, which is the most abundant form of agrin and the predominant form expressed in motor neurons. It is produced in the soma of the neurons, transported down the axon and released from the axon ending of the motor nerve into the synaptic cleft of the NMJ. Here it acts as an agonist of LRP4 (low-density lipoprotein receptor-related protein 4) and may also become a component of the basal lamina. In the CNS (central nervous system), most agrin is expressed as a type-II transmembrane protein by alternative splicing at the N-terminus lacking the N-terminal NtA domain (Bezakova and Ruegg, 2003).
[0006] In the C-terminal part of human agrin, there are 2 alternative splice sites y and z. At the y-site, there may be inserts of 0, 4, 17 or 21 (4+17) amino acids and at the z site there may be inserts of 0, 8, 11 or 19 (8+11) amino acids. The function of the four inserted amino acids in the y-site is to create a heparin binding site. Motor neurons express predominantly y4 agrin. The most important splice site of agrin in respect of NMJ maturation is the z-site, giving agrin the ability to be active as an acetylcholine-receptor clustering agent. It is well known that full length agrin containing the insertion of 8 amino acids at the z-site in presence of the 4 amino acid insert in splice site y (y4z8) generates an agrin variant with a half maximal AChR clustering activity of 35 pM in cultured myotube clustering assays. The insertion of 11 amino acids give rise to a half maximal AChR clustering activity of 5 nM while the 19 amino acid insertion results in a half maximal AChR clustering activity of 110 pM. Agrin without an insertion at this site is not active in clustering acetylcholine-receptors on the in-vitro cultured myotubes (Bezakova and Ruegg, 2003). Thus, the most active form of agrin in the clustering assay is the y4z8 variant, which is expressed by motor neurons.
[0007] A ˜45 kDa C-terminal fragment of agrin (y4z8) containing the LG2, EGF4 and the LG3 domains was found to be active in AChR clustering with an EC50 of 130 pM in the AchR clustering activity while shorter fragments have only lower activities. The C-terminal LG3 domain with the z8 insertion exhibits a half maximal AChR clustering activity of only 13 nM, which is a factor 100 fold lower than the 45 kDa fragment (Bezakova and Ruegg, 2003).
[0008] In WO 97/21811 it is proposed to use agrin or agrin fragments in methods of treatment of a disease that affects muscle. However, such attempts have up to date not shown to be successful.
[0009] Investigations of the applicant have confirmed that in vivo activity of the agrin-fragment is mainly dependent on the presence of both domains LG2 and LG3 together. WO97/21811 showed in vitro activity for AChR-clustering for LG3 alone but no in vivo activity of LG3 could be shown. As it appears activation of LRP4 alone is not sufficient to achieve full in vivo activity.
[0010] Agrin is cleaved by an enzyme called neurotrypsin which plays an important role in controlling the activity of agrin. At present, agrin is the only known target of neurotrypsin. Neurotrypsin (Stephan A, et al: The FASEB Journal. 2008; 22:1861-1873) cleaves agrin at 2 distinct sites called alpha- and beta-site. ( FIG. 1 ). The alpha-site is located N-terminal from the SEA domain and the beta-site is placed in front of the LG3 domain of agrin. Cleavage at the alpha-site generates a ˜110 kDa C-terminal agrin fragment running at ˜130 kDa in a 4-12% bis-tris SDS gel. Cleavage at the beta-site liberates the C-terminal LG3 domain running at ˜22 kDa in the gel (Molinari, Rio et al., 2002; Reif, Sales et al., 2007). Cleavage at the beta-site leads to a separation of the LG2 domain from the LG3 domain.
[0011] It was found that neurotrypsin (NT) over-expressing mice, so-called sarcopenia mice (muslik, M491S) (Stephan, Mateos et al., 2008), show an early onset of sarcopenia, a degenerative loss of skeletal muscle mass and strength associated with aging.
[0012] All C-terminal fragments could be detected in brain extracts and spinal cord extracts of mice (Stephan, Mateos et al., 2008). In neurotrypsin knock out mice, none of the fragments could be detected. As a consequence, neurotrypsin seems to be the only protease which cleaves agrin in significant amounts at the two cleavage sites. Cleavage of agrin by neurotrypsin can generate in principle five different agrin fragments, 3 of which can be detected in blood. These three agrin fragments CAF, C90 and C110. These fragments, also depending on the presence of specific inserts at the y and z position, can have different functions. A list with the various naturally occurring and artificial agrin fragments used in this patent are described in the table 1 below.
[0000]
TABLE 1
Description of different agrin fragments
Abbreviation
Description
CAF
Naturally occurring 22 kd C-terminal agrin fragment generated by
Neurotrypsin cleavage of Agrin at the beta cleavage site. The 22-kD
corresponds to the apparent running position on PAGE gel. Insert at the
Z position is not fixed. There can be no insert (CAF-z0) or inserts of 8
(CAF-z8), 11 (CAF-z11), or 19 (CAF-z19) amino acids, respectively.
Species is not determined and could be from e.g. human-derived
(human CAF), rat derived (rat CAF), mouse-derived (mouse CAF),
chicken etc. For instance, human CAF-z8 represents the 22 kd C-
terminal human-derived agrin fragment generated by Neurotrypsin
cleavage of Agrin with an 8 amino acid insert at the Z position.
C44
Artificial 44 kd C-terminal agrin fragment comprising the LG2, EGF4
and LG3 domains. Insert at the Y position can be 0, 4, 17 or 21 amino
acids. Insert at the Z position can be no insert, 8, 11 or 19 amino acid
sequence. Species is not determined and could be from e.g. human, rat,
mouse, chicken etc. For instance, human C44-y4z8 represents the
human derived 44 kd C-terminal agrin fragment comprising the LG2,
EGF4 and LG3 domains having the 4 amino acid insert at the Y position
and 8 amino insert at the Z position.
C44K/A
Artificial 44 kd C-terminal agrin fragment comprising the LG2, EGF4
and LG3 domains. The beta-cleavage site for Neurotrypsin has been
deleted by replacing the lysine (K) in the cleavage site by an alanine
(A). Insert at the Y position can be 0, 4, 17 or 21 amino acids. Insert at
the Z position can be no insert, 8, 11 or 19 amino acid sequence. Species
is not determined and could be from e.g. human, rat, mouse, chicken
etc. For instance, human C44K/A-y4z8 represents the human derived 44
kd C-terminal agrin fragment comprising the LG2, EGF4 and LG3
domains having the 4 amino acid insert at the Y position and 8 amino
insert at the Z position.
C90
Naturally occurring 90 kd agrin fragment generated by Neurotrypsin
cleavage of Agrin at the alpha and beta sites. The C90 agrin fragment is
located between the alpha and beta cleavage sites. The 90-kD size
corresponds to the apparent running position on PAGE gel. It can have
inserts at the y position. Species is not determined and could be from
e.g. human, rat, mouse, chicken etc. For instance, human C90-y4
represents the human derived 90 kd agrin fragment having the 4 amino
acid insert at the Y position. The z region is not present on this
fragment.
C110
Naturally occurring C-terminal 110 kd agrin fragment generated by
Neurotrypsin cleavage of Agrin at the alpha site. The 110-kD size
corresponds to the apparent running position on PAGE gel. Can have
inserts at the y position. Species is not determined and could be from
e.g. human, rat, mouse, chicken etc. For instance, human C110-y4z8
represents the human derived C-terminal 110 kd agrin fragment having
the 4 amino acid insert at the Y position and 8 amino insert at the Z
position.
[0013] In total 24, naturally occurring neurotrypsin derived-C-terminal agrin fragments are possible. These fragments may have different functions in the various organs, tissues. It is clear that distinguishing between these various agrin fragments for precise diagnosis is very important.
[0014] EP 1 990 420 by the same applicants as the present application, describes the use of the C-terminal 22-kDa agrin fragment (CAF) of agrin as biomarker for the in vivo activity of neurotrypsin and in diagnosis and monitoring of neurotrypsin-related disturbances. The applicants found out that the presence and an elevated amount of this fragment which is liberated after cleavage of agrin at the beta-site and can be measured in body fluids such as serum correlates with certain disturbances like e.g. sarcopenia.
[0015] The presence of elevated CAF-levels could also be shown in patients suffering from dysfunctions of the kidney and the lung or suffering from diseases of the brain like autism or mental retardation. Patients suffering from mild cognitive impairment, early dementia or Alzheimer can have elevated levels of CAF in cerebrospinal fluid (CSF).
[0016] Alternatively, CAF levels can be reduced compared to normal healthy persons in patients suffering from neuropathic pain. It was found that peripheral nerve injury decreased agrin expression in the ipsilateral spinal dorsal horn of rats displaying tactile allodynia. Agrin modulates neuropathic pain through NR1 phosphorylation in GABA neurons. NR1 is part of the NMDA receptor, the NMDA receptor forms a heterotetramer between two NR1 and two NR2 subunits. The NMDA receptor, a glutamate receptor, is the predominant factor in diseases where there is a modulation of the NMDAR function: like Ischemia, Seizures Parkinson disease, Huntington's disease, Pain, Diabetes (peripheral NMDAR involved), Multiple Sclerosis, Schizophrenia, Autism, Alzheimer Diseases and other dementias or cognitive impairments molecular device for controlling synaptic plasticity and memory function.
[0017] Agrin reduction, and subsequent reduction in CAF levels may also open new approaches for detection of not only neuropathic pain, but also epilepsy, tremors, and spasticity (Cui and Bazan, 2010).
[0018] As was reported CAF inhibits the alpha 3 subunit of NaK-ATPase which could be a common triggering factor in the observed dysfunctions or diseases respectively.
[0019] Summing up agrin mediates accumulation of acetylcholine receptors (AChRs) at the developing neuromuscular junction, but has also been implicated as a regulator of central nervous system (CNS) synapses (Matsumoto-Miyai, Sokolowska et al., 2009). It has been shown that the agrin C22 construct, which represents the naturally occurring neurotrypsin cleavage product, constitutes a well-folded, stable domain. Additionally the C-terminal region of agrin has been shown to bind to the alpha3 subunit of the sodium-potassium ATPase (NKA) in CNS neurons suggesting that alpha3NKA is a neuronal agrin receptor.
[0020] From the above it appears that especially CAF but also other C-terminal fragments of agrin which can be detected in different tissues and correlated to different pathologic and non-pathologic conditions is not only an important marker but also an important target, which can be used in treatment of patients.
[0021] However, promising medical applications using e.g. CAF as target require antibodies which:
allow a discrimination between human CAF (derived by specific neurotrypsin cleavage) and other human agrin fragments are able to bind to human CAF with high specificity and affinity and distinguish human CAF with respect to the tissue where cleavage of agrin by neurotrypsin took place.
[0023] Antibodies against various agrin fragments are available but they do not detect or only insufficiently work with human derived CAF. Monoclonal antibodies that are able to detect human CAF are not available at present.
[0024] In a Poster “Agrin serum level as a marker of sarcopenia” presented by Vrijbloed at al. on Nov. 17, 2010 and also in EP 1990420 cited above the use of specific, affinity-purified polyclonal antibodies is described which were generated by the applicants in their laboratory against a 90-kDa and the 22-kDa fragment of agrin for detection of the 22-kDa fragment (CAF). These polyclonal antibodies G92 (Goat) and R139 (Rabbit) (Stephan et al ref) were derived from goat and rabbit and recognized non human agrin fragments under special optimized laboratory conditions, however, monoclonal antibodies with their much better specificity and reproducible properties are clearly superior over polyclonal antibodies for diagnostic applications For instance, Polyclonal antibodies can not be produced in large scale and in consistent quality. Thus it can be doubted that they would work in standard applications and they clearly did not fulfill the above requirements.
[0025] The object of the invention is to provide improved antibodies against human CAF and human CAF including agrin fragments.
SUMMARY OF THE INVENTION
[0026] The applicants have found out that such improved antibodies can be obtained from hybridoma cell lines which have been produced by a method according to claim 1 in which a special C44-fragment of agrin, namely a fragment C44y≧4 is used for immunization.
[0027] The term C44-fragment shall encompass all different variants of the C-terminal portion of human agrin spanning from leucine 1637 to proline 2045, with the exact position of the proline depending on the length and presence of inserts in the y- and/or z position.
[0028] The term C44y≧4-fragment shall encompass all different variants of C44-fragments having an y-insert of at least 4 amino acids. As a rule naturally occurring C44y4, 17, 21 inserts can be used. However, also synthetic fragments having different inserts are conceivable. The suffix K/A when used in this application shall mean that the agrin-fragment in question is neurotrypsin resistant.
[0029] It has surprisingly turned out that C44-fragments having an y-insert of at least 4 amino acids show a higher immunological effect compared to other C44-fragments lacking this insert. According to the observations of the applicants fragments having an y-insert tend to form aggregates which is not the case with other C44-fragments lacking this insert and which probably is the reason for the improved immunological effect.
[0030] A C44y≧4-fragment especially preferred for immunization is the fragment C44K/A-y4z8 described in detail later on. It has turned out that immunization by using this fragment leads to hybridoma cell lines which produce very specific and effective antibodies.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1 : is a schematic representation of the C44K/A-y4z8 fragment;
[0032] FIG. 2 : shows the sequence of the C44K/A-y4z8 fragment, with the binding sites of the antibodies represented in bold italic letters and the portions of the sequence in which epitope sequences are located depicted several times if necessary (one time for each antibody);
[0033] FIG. 3 : is an ELISA showing the immunogenicity of different agrin variants in mice sera;
[0034] FIG. 4 : pepspot membranes obtained for each antibody tested after epitope mapping and corresponding schemes;
[0035] FIG. 5 : Western Blot showing the ability of different antibodies to detect CAF spiked in rat serum;
[0036] FIG. 6 : is a Western blot showing staining of CAF-z8 and CAF-z0 with antibody 13E8;
[0037] FIG. 7 : is a dot blot showing the different binding of antibodies 28H7G3 and 13E8 to CAF-z8 and CAF-z0;
[0038] FIG. 8 : shows the result of an ELISA test of the antibodies 14C5G4 and 12A11D11;
[0039] FIG. 9 : is a Western blot showing the binding of antibodies 2D7D9 and 28H7G3 to CAF-z0 and CAF-z8;
[0040] FIG. 10 : shows the result of an ELISA test of z8 specific antibodies.
DETAILED DESCRIPTION OF THE INVENTION
[0041] The C44K/A-y4z8-fragment of agrin preferably used in the method according to the invention is schematically illustrated in FIG. 1 . It can be obtained as described in Example 1.
[0042] Its sequence (SEQ ID No. 1) is shown in FIG. 2 with the binding sites of the antibodies obtained according to the invention being represented in bold italic letters.
[0043] The C44K/A-y4z8 fragment spans from leucine 1637 to proline 2045 of human agrin (Uniprot O00468-1 but with the y4-insertion KSRK (SEQ ID No. 2) between proline 1751 and valine 1752 and the z-insertion ELANEIPV (SEQ ID No. 3) between serine 1884 and glutamate 1885) and includes the LG-domains LG2 and LG3. The beta-cleavage site for Neurotrypsin has been deleted by replacing the lysine (K) in the cleavage site by an alanine (A: represented in bold in FIG. 1 ). However, the invention is not limited to this special C44 fragment, but shall encompass all different variants of C44y-fragments. It is also conceivable to use the naturally occurring C44y17-fragment with the y17-insertion having the sequence VLSASHPLTVSGASTPR (SEQ ID NO: 4), or the C44y21-fragment with the y21-insertion having the sequence KSRKVLSASHPLTVSGASTPR (SEQ ID NO: 5). The same is applicable to the z-insertion. Apart from the preferably used C44-fragment with a z-8 insertion it is also possible to use C44-fragments having no z-insertion, a z11-insertion of the sequence PETLDSGALHS PETLDSGALHS (SEQ ID NO: 6) or a z19-insertion of the sequence ELANEIPVPETLDSGALHS (SEQ ID NO: 7).
[0044] The applicants have prepared an antibody-platform containing a number of different hybridoma cell lines producing monoclonal antibodies named 28H7G3, 264E12B8, 28A6H11, 14C5G4, 12A11D11, 28F7A6, 14B7B8, 264B12A8 and 13E8 by using the method according to the invention. The method is discussed in detail in Examples 2 and 3.
[0045] Apart from the hybridoma cell line, producing antibody 13E8 (described below), all hybridoma cell lines have been deposited by the applicants under the Budapest Treaty on Jan. 11, 2011 at DSMZ—Deutsche Sammlung von Mikroorganismen and Zellkulturen GmbH, Inhoffenstraβe 7 B, 38124 Braunschweig GERMANY. The cell lines were accorded the accession numbers:
28H7G3=DSMACC3101; 264E12B8=DSMACC3102 28A6H11=DSMACC3103; 14C5G4=DSMACC3104 12A11D11=DSMACC3105; 28F7A6=DSMACC3106 14B7B8=DSMACC3107; 264B12A8=DSMACC3108
[0050] In FIG. 1 the binding sites of the antibodies on the depicted C44K/A-y4z8-fragment of agrin are schematically shown. The epitope sequences of the antibodies were determined by peptide mapping (Example 5) and are as following:
Antibody 28H7G3 (SEQ ID No. 8) Sequence: TFVEY Antibody 14B7B8 (SEQ ID No. 9) Sequence: FVEYL Antibody 28A6H11 (SEQ ID No. 10) Sequence: TFVE Antibody 264E12B8 (SEQ ID No. 11) Sequence: WLGGLPELP Antibody 264B12A8 Sequence: LPE Antibody 28F7A6 (SEQ ID No. 12) Sequence: LPELP
[0057] As it appears the epitopes mentioned above have not been described so far. It is conceivable that also the knowledge about the epitopes can lead to favorable applications. E.g. it could be conceivable to create synthetic peptides including one or more of the eptiope-sequences which could be used in therapy or prophylactic applications. Furthermore the invention is not limited to the specific antibodies mentioned above but shall also encompass other antibodies which bind to the epitopes in question.
[0058] Also antibodies 14C5G4 and 12A11D11 and the antibody 13E8 mentioned above, were obtained using the method according to the invention. For these antibodies no epitope sequences were determined.
[0059] However, it could be shown (Example 7) that antibody 13E8 binds specifically to CAF z-8 fragments indicating that its epitope-sequence must be ELANEIPV (SEQ ID No. 3) or a portion thereof. For a person skilled in the art it is evident that by using the method according to the invention also further antibodies not described in this application can be obtained which bind specifically to other inserts possibly present in the C44-fragment, like the y4, y17 or y21 or the z11 or z19 inserts.
[0060] Antibodies 14C5G4 and 12A11D11 were shown to bind to the non-CAF N-terminal portion of C44 (Example 8).
[0061] FIG. 1 sums up the different binding sites of the above antibodies. As one can see in FIG. 1 antibodies 28H7G3, 14B7B8, 28A6H11, 264E12B8, 264B12A8, 28F7A6 and 13E8 bind to sites located in the CAF-portion with antibody 13E8 binding specifically to a z8-insert possibly present in the CAF-fragment. Antibodies 14C5G4 and 12A11D11 bind to sites located in the other N-terminal portion of C44.
[0062] Consequently by using the antibodies obtained by the invention it is possible to discriminate CAF-fragments from other fragments and furthermore as will be discussed later it is also possible to determine the origin of a CAF-fragment detected.
[0063] By using e.g. antibody 28H7G3 and antibody 14C5G4 in a test system it is possible to determine whether or not the agrin fragment detected in a sample is the CAF-fragment or a larger fragment including the CAF-portion, e.g. the 110 kDa-fragment which is generated by cleavage of agrin at its alpha cleavage-site. If both antibodies bind to the fragment, this will suggest a larger agrin-fragment including the CAF-fragment; if only one of the antibodies binds this will suggest either CAF (28H7G3) or an agrin fragment lacking CAF (14C5G4).
[0064] Interestingly, 14B7B8 recognizes only CAF and no longer C-terminal agrin fragments, for instance human C44 or human C110 whereas 28H7G3 detects all CAF containing variants to human CAF, C44 and C110. Although both antibodies appear to bind to the same epitope, the antibodies have different clearly different binding characteristics. The use of 14B7B8 allows for specific detection of human CAF without interference of other agrin fragments whereas 28H7G3 can simultaneously detect all CAF containing fragments.
[0065] The use of a specific combination of the mentioned antibodies obtained according to the invention will allow for the establishment of ELISA systems discriminating the various C-terminal agrin fragments with respect to concentration and identity.
[0066] With regard to antibody 13E8 as stated above this antibody binds specifically to a z8-insert possibly present in the CAF fragment. As this z8-insert is only present in CAF fragments originating from neural tissues, the use of this antibody will allow a decision whether or not the fragment detected has been liberated in neural tissue or in other tissues.
[0067] It is clear that antibodies obtained by the method according to the invention allow a number of different applications in diagnosis but also in the treatment of CAF related disturbances.
[0068] As stated above the CAF fragment could be a toxic protein fragment as it inhibits the alpha 3-unit of Na,K,-ATPase. This could lead to intra, or extracellular toxic sodium, potassium or calcium concentrations. So one important application of the antibodies generated according to the method of the invention could be to use them for clearing the blood of patients suffering from kidney-diseases in an artificial kidney. This clearing can be achieved by attaching the antibodies to an insoluble carrier material such as Sepharose (cross-linked dextrane) or other biocompatible materials and exposing the patient's blood to the antibodies in an apheresis procedure similar as this has been described for the removal of other proteins such as low density lipoproteins (LDL) (Borberg, Gaczkowski et al., 1990). Preferably the blood is anticoagulated and freed from cells before contact with the antibody. The bound antibody can be regenerated by exposure to concentrated salt solutions and/or low pH-values.
[0069] It is also conceivable to manufacture a medicament using one or more of the antibodies which can be obtained according to the method of the invention for a direct neutralization of CAF in a patient by intravenous or intradermal injection or infusion.
[0070] There is a number of further applications conceivable so that one main aspect of the invention is directed to the use of the antibodies in pharmaceutical formulations or the use of these antibodies in the manufacturing of such formulations. This may also include a humanization procedure of the antibody in order to prevent allergic reactions or its neutralization by antibody formation.
[0071] Such formulations can be directed against elevated CAF levels in blood and can be used in for instance sarcopenia, kidney diseases, lung diseases, and diseases characterized by mental retardation like Alzheimer's disease, Parkinson disease.
[0072] It is also conceivable to use the antibodies for the detection of agrin or agrin fragments as marker or surrogate marker in clinical trials or as marker in personalized medicine. In clinical trials with CAF containing drugs the mABs can be used to detect the amount of drug in the body, for instance in blood or urine.
[0073] One such drug is e.g. a neurotrypsin-resistant C44-fragment of agrin (as described in patent application EP 09011367.1). The mABs can be used for determination of the concentration of this neurotrypsin-resistant agrin fragment in patients during clinical trials or in any other patients that the takes this fragment.
[0074] The following examples illustrate the invention, but are not limiting it. The skilled person in the field reading these examples will be able to apply other related conditions and these are also within the scope of the invention.
EXAMPLES
Example 1
Cloning, Expression and Purification of C44K/A-y4z8
a) Cloning of Neurotrypsin-Resistant Human 44-kd C-Terminal Fragment of Agrin
[0075] Initially, full length human agrin y0z0 but lacking the N-terminal NtA domain (Human agrin y0z0 deltaNTA starts at position K156 in the protein sequence of accession number NP — 940978) was cloned by PCR into the pEAK8 vector containing the coding sequence for the secretion signal of human calsyntenin-1, (Reif, Sales et al., 2007) via appropriate restriction sites and primers. As template for human agrin the vector pCMV-XL5-Agrin (purchased from Origene USA) was used.
[0076] In two subsequent steps, the corresponding codons required for the y4z8 insertions were introduced by site directed mutagenesis using standard techniques resulting in the pEAK8 vector containing full length human agrin y4z8 deltaNtA.
[0077] Using this vector as template, the gene coding for the 44-kd C-terminal fragment of human agrin was amplified introducing the coding region for a His8 tag and a prescission protease cleavage site at the N-terminus of the translated protein.
[0078] The neurotrypsin-resistant form of human Agrin C44K/A was generated in a quick change mutagenesis step using primers which introduce the codon for an alanine at the place of the codon for the lysine in the cleavage site-□ of agrin.
[0079] This plasmid generates a protein with the sequence of SEQ ID NO: 1 in the culture supernatant of transfected cells (without signal sequence) with the additional N-terminal amino acid sequence “ARVNHHHHHHHHLEVLFQGP” (SEQ ID No. 13) containing the H is 8 tag and the prescission cleavage site.
b) Expression and Purification of Human Agrin C44 and Neurotrypsin-Resistant C44K/A
[0080] 500 ml HEK 293 cells grown in Excell 293 medium to a density of 1×10 6 cells/ml were pelleted by centrifugation in a Sorvall RC5C centrifuge at 100×g for 30 min. The cells were resuspended in 500 ml RPMI1640 medium prewarmed to 37° C. 1.25 mg of pEAK8 containing the insert for the expression of neurotrypsin-resistant human AgrinC44 y4z8 were diluted in 25 ml 150 mM NaCl. 3.75 mg polyethylene imine (PEI), 25 kDa, were diluted in 25 ml 150 mM NaCl. Both solutions were pooled and incubated at room temperature for 10 min. Afterwards this solution was added to the cell suspension which was transferred to a 1000 ml spinner flask. The cell suspension was incubated for 7 days at 75 rpm on a stirring platform placed in an incubator with 5% CO 2 and 37° C. in humidified atmosphere.
[0081] After 7 days, the culture supernatant was harvested by centrifugation at 5000 rpm in a Sorvall RC5C centrifuge. Remaining particles were removed by filtration through a 0.22 μm Millipore sterile filtration device. The filtrated culture supernatant was concentrated 10 times using a Pellicon PLCGC 10 kDa cutoff tangential flow cartridge and dialyzed at least 1:1000 against 20 mM MOPS pH 8.5, 400 mM NaCl. The dialysate was subjected to immobilized metal affinity chromatography (IMAC) taking advantage of the His8 tag using a 10 ml bench top His Select column labeled with Ni 2+ . After loading of the concentrated and dialyzed cell culture supernatant, the column was washed with 100 ml dialysis buffer and bound protein was eluted with 5 times 10 ml of dialysis buffer containing 500 mM imidazole. The purification success was followed by SDS-PAGE. Positive fractions were pooled and concentrated 10 times with an AMICON 30 kDa cutoff filtration device at 3000×g in a Sigma 4K15 centrifuge and dialysed 1:10000 against 20 mM MOPS pH 8.5, 200 mM NaCl. The concentration of the purified C44K/A was determined via UV spectroscopy using the extinction coefficient of 0.725 cm 2 /mg.
c) Removal of the His8 Tag by Prescission Protease Cleavage
[0082] In case the His8 tag should be removed, the buffer of 0.5 ml protein solution was exchanged to 50 mM Tris-HCl, pH 7.2, 150 mM NaCl, 1 mM DTT, 1 mM Na 2 EDTA using a NAP-5 column pre-equilibrated with that buffer. The protein solution was eluted in 1 ml of the same buffer. 1 μl 1M DTT was added to the protein solution and mixed by flipping the tube several times. 20 μl of Prescission protease (1 U/ul) was added and the tube was mixed by flipping it several times. The reaction was done overnight at 4° C. A 0.5 ml gravity flow glutathione sepharose column was equilibrated with 5 ml PBS supplemented with 1 mM DTT. The digested protein solution was loaded and the flow through collected. The column was washed with 3 times 1 ml PBS supplemented with 1 mM DTT and the flow through was collected in the same tube as the previous flow through fraction. The collected flow-through fractions were dialysed 2 times 2 hours against 5 l of 20 mM MOPS pH 8.5, 400 mM NaCl to remove DTT and EDTA.
[0083] To remove the cleaved His8 tag a second IMAC was performed. A 1 ml Chelating sepharose FF column previously labelled with Ni 2+ ions was equilibrated with 5 ml 20 mM MOPS pH 8.5, 400 mM NaCl. The dialysed protein solution was applied onto the column and the flow through collected. The column was washed with 3 times with 1 ml 20 mM MOPS pH 8.5, 400 mM NaCl and the flow though collected in the same tube. The pooled fractions were concentrated with a AMICON 30 kDa cutoff concentrator to 0.5 ml. and the buffer was exchanged using a NAP-5 column pre-equilibrated with 20 mM MOPS pH 8.5, 200 mM NaCl. The concentration was determined via UV spectroscopy using the extinction coefficient of 0.761 cm 2 /mg. The protein was freshly used for further experiments or stored at −80° C. until usage. The protein sequence of the corresponding protein corresponds to the portion of SEQ ID NO: 1 with the additional N-terminal amino acid sequence “GP” as a result of the prescission cleavage.
Example 2
Immunization of Mice with C44K/A-y4z8
[0084] Three 6-8 weeks old female Balb/c mice were immunized with 90-150 microgram of C44K/A in complete Freund's adjuvans. After 28 days, C44K/A was administered in incomplete Freund's adjuvance. This step was repeated after 56 days. After 87 days, C44K/A was administered in PBS, which was repeated at day 90. One day later, cells from the knee lymph knots were prepared and the resulting B-cells are fused with P3-X63-Ag8 mouse myeloma cells in the presence of PEG4000.
[0085] After completion of the cell fusion the cells were plated on 24-well plates which results in 360 oligo-clones consisting of 5-10 clones. Cells were cultivated for 10 days in selective Optimem medium (GIBCO) selecting for fused cells (hybridoma) only.
[0086] Supernatants were screened by ELISA for positivity. Single clones were generated by a two fold limited dilution. Positivity of the clones was checked by ELISA with C44K/A.
Example 3
Expression and Purification of Monoclonal Antibodies
[0087] Hybridoma cells were adapted to serum free ISF-1 medium (BIOCHROME AG) and grown for 5-7 days. Approximately 100 ml conditioned medium was subjected to protein-G sepharose chromatography.
[0088] In brief, the conditioned supernatant was loaded on a 1 ml protein-G or protein-A sepharose column (GE-HEALTHCARE) with a flow rate of 1.5 ml/min. After washing with 30 column volumes (CV) with PBS/0.5M glycine pH 7.4 the bound antibody is eluted with 100 mM citrate buffer pH 2.6. Positive fractions are pooled and neutralized by an appropriate amount of 2M Tris.
[0089] The purified antibody is dialysed against PBS and stored at 4° C. until further use of it.
Example 4
Immunisation with CAF-z8 and C44K/A-y4z8 and Comparison of the Antibodies Obtained with these Immunogens
[0090] For each antigen, C44K/A-y4z8 or CAF-z8, 3 mice were used. 5 mg/kg of the corresponding agrin variant was injected subcutaneously for 24 days once a day. After this, the mice were sacrificed and the serum was prepared using standard serum tubes
Coating of ELISA Plates
[0091] Nunc MaxiSorp Immuno plates 96 well (flat bottom, polystyrene) were coated with 100 ng/well of CAF-z8. Coating was done over night (i.e. for 15 h) at 4° C. in presence of 1× Candor Coating Buffer, pH 9.6.
[0092] After aspiration of the coating buffer the plates were washed 7 times with 400 μl Na-PBS-CAS, pH 7.2 (PBS supplemented with additional 0.2 mol NaCl (“Na”) and with 0.05% casein (“CAS”)). Washing was done using a BioTek ELx405 plate washer (Witec AG). The wells of the washed plates were blocked by adding 180 μl of Candor Blocking Solution per well. The plates were subsequently incubated for 3 h at room temperature. After removal of the Blocking Solution the plates were washed 7 times with 400 μl Na-PBS-CAS, pH 7.2. Subsequently, the plates were used for an ELISA experiment.
Checking Immunogenicity of Agrin Variants
[0093] To PBS casein and Tween 20 were added to final concentrations of 0.05% (PBST-CAS buffer). Sera were 1000 fold diluted with PBS. A background control was prepared from untreated mice. Of each sample 100 μl per well were transferred to the ELISA plates coated with the corresponding agrin species. After incubation of the plates for 2 h at room temperature (RT: 20-21° C.; sealed with a sealing film) they were washed 7× with 400 μl PBST-CAS using a BioTek ELx405 plate washer (Witec AG). Subsequently, 100 ul/well of Goat-anti-Mouse, Peroxidase Labeled; KPL, 074-1806) were added, diluted 10′000× with PBST-CAS. The plates were afterwards incubated for 30 min at RT and then washed 7× with 400 μl PBST-CAS. Substrate was added (100 μl per well; “TMB Super Sensitive One Component HRP Microwell” substrate; BioFX; TMBS-1000-01) and the plates were incubated for 30 min at RT. The color development was stopped by adding 100 μl of 450 nm Stop Reagent (BioFX; #STPR-1000-01) to each well. Subsequently, the absorbance at 450 nm was measured using a Tecan infinite F200 plate reader. The results of the measurement are summarized in FIG. 3 . No good immune response was detected in sera from CAF-z8 mice. The response was just detectable above background (bckg) with an average of 0.07 OD units. Surprisingly a very high immune response was seen in mice treated with C44K/A-y4z8 as antigen. The average increase above background (bckg) was 1.6 OD units. The reason for the absence of a good immune response of CAF-z8 is not completely understood but it has been shown that the agrin C22 construct, which represents the naturally occurring neurotrypsin cleavage product, constitutes a well-folded, stable domain (tydor). In contrast the C44K/A-y4z8 is a protein that is prone to aggregate (data not shown). This aggregation could be the reason to the strong immune response in mice. The lack of a good immune response of CAF in mice might be one of the reasons that good monoclonal antibodies against human CAF are not commercially available as yet. However using C44K/A-y4z8 as antigen a strong immune response was observed which resulted in large variety of monoclonal antibodies.
Example 5
Epitope Mapping of Anti-CAF Antibodies
[0094] For the mapping of the epitopes of the antibodies against CAF a Pepspot membrane from JPT Peptide Technologies, Berlin, Germany was used: the sequence of the LG3 domain, starting with the P1′ residue of the neurotrypsin cleavage site beta of human agrin (CAF-z0) was split into peptides of 15 amino acids length with an overlap of 14 amino acids. This resulted in 172 peptides of 15 amino acids length covering the whole sequence. The peptides were N-acetylated and covalently linked via their C-termini to a cellulose-□□alanine membrane.
[0095] The membrane was incubated with antibodies at a concentration of 0.1-2 microgram/ml in PBS supplemented with 0.1% Tween 20 (PBST) for 2 hours. After 3 washing steps for 10 min with PBST, a goat-anti-mouse secondary antibody labelled with HRP was added and incubated for 30 min. After 3 times washing with PBST for 10 min, Immobilon Western chemiluminescent HRP substrate (MILLIPORE) was added and the membrane is recorded on a Stella imaging system (RAYTEST) for 1 min. Positive spots were assigned to the corresponding peptide spots and the epitope was matched.
[0096] The positive spots are assigned to the peptide sequences spotted onto the membrane. The essential amino acids contributing to the binding of the antibodies were located by determination of the first amino acid giving a signal at the N-terminal side and the last amino acid giving a signal at the C-terminal side of the protein sequence.
[0097] The results of the peptide mapping are represented in FIG. 4 and result in the following epitopes shown in Table 2.
[0000]
TABLE 2
Epitope sequences of antibodies obtained according to Example 1
Antibody
Epitope-sequence
28H7G3
TFVEY (SEQ ID No. 8)
14B7B8
FVEYL (SEQ ID No. 9)
28A6H11
TFVE (SEQ ID No. 10)
264E12B8
WLGGLPELP (SEQ ID No. 11)
264B12A8
LPE
28F7A6
LPELP (SEQ ID No. 12)
Example 6
Western Blotting of CAF Spiked in Rat Serum
[0098] To demonstrate the ability of the antibodies to detect CAF in biological samples, human CAF-z0 was spiked into rat serum, which was diluted 1:250 with PBS, to a concentration of 0.2 ng/ul. 10 μl corresponding to 2 ng CAF-z0 were loaded on a 4-12% bis-tris SDS-PAGE gel (BIORAD) and blotted on a PVDF membrane (MILLIPORE) using a semi dry blotting apparatus (BIORAD).
[0099] The blot was incubated with 1 ug/ml of the monoclonal antibodies in 10% roche blocking reagent in PBST o/N. For a comparison a commercially available antibody against CAF, ab247 from ABCAM was used.
[0100] After washing and incubation with HRP-conjugated goat-anti-mouse antibody, the chemiluminescent signals derived from the HRP reaction with chemiluminescent substrate (MILLIPORE) was recorded for 1 min in a Stella imaging system (RAYTEST).
[0101] The results are shown in FIG. 5 . Lane 1=Antibody 28H7G3; Lane 2=Antibody 14B7B8; Lane 3=Antibody 28A6H11; Lane 4=264E12B8; Lane 5=Antibody 264B12A8; Lane 6=28F7A6; 7=Abcam antibody, [Agr 247] ab12364-100; lot: 577087 and Lane 8=HRP-conjugated goat-anti-mouse IgG antibody, Socochim SA, 074-1806
[0102] Numbers and explanation correspond to the used primary antibodies. Note the bands of the heavy and light chains of the antibodies naturally present in rat serum (indicated by single line arrows at 55 kDa and 25 kDa, respectively) which are detected by the secondary anti-mouse antibody. These bands serve as a loading control and as a functionality control of the Western blot.
[0103] CAF signals indicated by the double line arrow at 22 kDa could only be detected in Lanes 1-6, i.e. for the antibodies obtained according to the invention.
Example 7
Monoclonal Antibody 13E8 Specific for the z-Splice Site
[0104] The agrin CAF-z8 specific antibody 13E8 was derived from the same immunization described in Example 1 but without limiting dilution. For the selection of this clone the following procedure was chosen:
[0105] Coating of ELISA plates: Nunc MaxiSorp Immuno plates 96 well (flat bottom, polystyrene) were coated with 100 ng/well (125 ul/well) of human CAF-z8 or human CAF-z0. Coating was done over night (i.e. for 15 h) at 4° C. in presence of 1× Candor Coating Buffer, pH 9.6.
[0106] After aspiration of the coating buffer the plates were washed 7 times with 400 μl Na-PBS-CAS, pH 7.2 (PBS supplemented with additional 0.2 mol NaCl and with 0.05% casein). Washing was done using a BioTek ELx405 plate washer (Witec AG). The wells of the washed plates were blocked by adding 180 μl of Candor Blocking Solution per well for 3 h at room temperature. After removal of the Blocking Solution the plates were washed 7 times with 400 μl Na-PBS-CAS, pH 7.2. Subsequently, the plates were used for an ELSA experiment.
[0107] For checking putative anti-agrin antibody containing hybridoma supernatants wash buffer (PBS supplemented with 0.05% Casein and Tween 20) was freshly prepared. Cell culture supernatants were 30-fold diluted with PBS. A negative control was prepared with cell culture medium only. Of each sample 100 μl were transferred to a well of the ELISA plates coated with the various agrin species.
[0108] After incubation of the plates for 2 h at room temperature (RT: 20-21° C.; sealed with a sealing film) they were washed 7× with 400 μl PBST-CAS using a BioTek ELx405 plate washer (Witec AG). Subsequently, 100 ul/well of 10000 fold diluted Goat-anti-Mouse, Peroxidase Labeled (KPL, 074-1806) were added and the plates were afterwards incubated for 30 min at RT.
[0109] The plates were washed 7× with 400 μl PBST-CAS, and substrate was added (100 μl per well; “TMB Super Sensitive One Component HRP Microwell” substrate; BioFX; TMBS-1000-01). After addition of the TMB substrate the plates were incubated for 30 min at RT. The color development was stopped by adding 100 l of 450 nm Stop Reagent (BioFX; STPR-1000-01) to each well. Subsequently, the absorbance at 450 nm was measured using a Tecan infinite F200 plate reader. The results of the measurement with clone 13E8 are summarized in FIG. 6 . It is apparent that 13E8 binds with high specificity only to CAF-z8 and not to CAF-z0, which means that this antibody is specific for the z-insert in CAF.
[0110] In a further experiment the antibodies 13E8 and 28H7G3 were compared with respect to their binding of CAF-z0 and CAF-z-8. 2 ng of CAF-z0 and CAF-z8 were loaded onto a 4-12% Bis-Tris SDS-PAGE gel (BIORAD). After separation, the proteins were blotted onto a PVDF membrane (MILLIPORE) by semi dry blotting with standard transfer buffer using a Trans blot SD cell (BIORAD) for 60 min at 24 V.
[0111] For detection of the blotted proteins the purified antibodies (13E8 and 28H7G3) in a concentration of 1 ug/ml or cell culture supernatant (1:2 diluted) were used in PBST.
[0112] The blots were blocked for 1 h with Roche blocking solution (10%) in PBST. Afterwards, the required amount of antibody was added and incubated for 2 h. After 3 times wash with PBST the secondary antibody solution (standard goat anti mouse-HRP conjugate) was added in appropriate concentration in PBST+10% Roche blocking solution. After incubation for 30 min the blots were washed 3 times with PBST and the blots were exposed with chemiluminescent substrate using a Stella chemiluminescence imager. The result is shown in FIG. 7 with the lanes 1 and 2 showing the results for antibody 28H7G3 (Lane 1: CAF-z0; Lane 2: CAF-z8) and the lanes 2 and 3 showing the results for 13E8 (Lane 3: CAF-z0; Lane 4: CAF-z8).
[0113] Also these results show that the antibody 13E8 recognizes specifically CAF-z8 while 28H7G3 recognises both variants.
Example 8
Antibodies Against the N-Terminal (Non-CAF) Part of C44
[0114] To test for antibodies raised against the N-terminal part of C44y4z8 an ELISA test was done as described in EXAMPLE 6 using C44y4z8 and CAF-z8 as proteins for coating the ELISA plates. The 2 antibodies mentioned above, 14C5G4 and 12A11D11 were tested. The result is shown in FIG. 8 . Both antibodies tested bind to C44K/A-y4z8 but not to CAF-z8, which means that they bind to the N-terminal non-CAF-portion of C44.
Example 9
Immunizing Mice to Achieve a z8 Splice Site Specific Antibody
[0115] Neuronal agrin can have different biological functions as non-neuronal agrin (Bezakova and Ruegg, 2003). For instance, neuronal-Agrin mediates accumulation of acetylcholine receptors (AChRs) at the developing neuromuscular junctions whereas non-neuronal agrin does not posses this activity. The presence of CAF-z8 in blood, serum, urine or cerebrospinal fluid is indicative for degradation of neuronal agrin. A monoclonal antibody that is able to specifically detect CAF-z8 and thus can differentiate between neuronal and non-neuronal agrin is therefore very important. In order to obtain such an antibody the peptide NH 2 -ELANEIPV (SEQ ID No.: 3) —COOH containing the amino acids present in the z8 insertion of human agrin was conjugated to mouse ovalbumin to serve as immunogen. Amino acid synthesis, conjugation, immunization and cell fusion and monoclonal antibody purification were done according to standard techniques know to the expert. Briefly, the peptide conjugated to ovalbumin was used as antigen to immunize 4 BALB/c mice. Injections of 20-30 □g+CFA (Complete Freund Adjuvant) are done at T0 (start day), while 10-15 □g+IFA (Incomplete FA) are done at T21, T28 (days) subcutaneously. Further injections follow at T42, 47, 59, 61, 72. At day T75 splenectomy was done followed by fusion of spleenocytes with myeloma cells and screening of mother hybridoma clones by ELISA testing against the peptide coupled to KLH (Keyhole Limpet Hemocyanin). Positive clones were subcloned by limiting dilution and adapted to serum free conditions in ISF-1 medium. Antibodies secreted into the culture supernatant were purified by Protein G sepharose chromatography. The best monoclonal antibody (mAB) was an IgM (2D7D9) subclone and no IgG clones were obtained.
Western Blot and ELISA Results.
[0116] A Western blot with 2D7D9 using 28H7G3 as control antibody was performed with 100 ng of CAF-z0 (lane z0) and CAF-z8 (lane z8) blotted onto a PVDF membrane with semi dry blotting technique. The membrane was blocked for 1 hour in PBST supplemented with 10% Roche blocking solution. Afterwards, 13 ng/ml biotinylated 28H7G3 or 1 ug/ml biotinylated 2D7D9 were added and incubated for additional 2 hours. After 3 times washing for 10 min with PBST, Streptavidin-poly-HRP conjugate (PIERCE, 0.5 mg/ml) was added 1:30000 diluted in PBST supplemented with 10% Roche blocking solution. After 3 times washing for 10 min in PBST, the membrane was exposed to chemiluminescent substrate and imaged in a Stella imaging system. The panel with 28H7G3 was exposed for 1 sec while the panel with 2D7D9 was exposed for 300 sec. Considering the roughly 100 fold access of 2D7D9 over 28H7G3 used as first antibody and the 300 times longer exposure time to receive a signal for 2D7D9 one can conclude that 28H7G3 is at least 30.000 times more sensitive than 2D7D9. CAF-z0 and CAF-z8 appear as double bands due to a fraction of glycosylated protein ( FIG. 9 ).
[0117] The received antibody shows only very weak signals in the Western blot without a good discrimination between CAF-z0 and CAF-z8. In ELISA, the antibody gives only weak signals with a slight discrimination between CAF-z0 and CAF-z8 ( FIG. 10 ).
[0000] ELISA with 2D7D9
[0118] ELISA plates (Nunc maxi-sorp immuno plate) were coated 30 ng/well CAF-z0 or CAF-z8. The plates were blocked with 180 □l per well Candor Blocking Buffer for 4 h at room temperature. 300 ng/ml 2D7D9 or 13E8-2C5 were added and incubated for 2 h at RT. The plate is washed 7 times with 400 μl PBST supplemented with 0.05% Tween 20 and 0.05% casein. As detector antibody, goat anti mouse IgM-HRP resp goat anti mouse IgG-HRP were used in a dilution of 1:10000. After washing, bound antibodies are detected with TMB Super Sensitive One Component HPR Microwell substrate blocked with 100 □l per well “450 nm Stop Reagent for TMB Microwell Substrates” from BioFX in a Tecan Infinite F200 96 well reader. The obtained signals are very weak and the discrimination of the CAF variants is poor. The immunization method was not successful in generating specific mAB with a high affinity. The mAB 13E8-105 (see below) obtained with immunization of C44K/A-y4z8 showed a high and specific signal for CAF-z8.
REFERENCE LIST
[0000]
Bezakova G, Ruegg M A. New insights into the roles of agrin. Nat. Rev. Mol. Cell. Biol., 2003; 4: 295-308.
Borberg H, Gaczkowski A, Oette K, Stoffel W. Immunosorptive apheresis of LDL. Prog. Clin. Biol. Res, 1990; 337: 163-7.
Cui J G, Bazan N G. Agrin downregulation induced by nerve injury contributes to neuropathic pain. J. Neurosci., 2010; 30: 15286-97.
Matsumoto-Miyai K, Sokolowska E, Zurlinden A, Gee C E, Luscher D, Hettwer S, Wolfel J, Ladner A P, Ster J, Gerber U, Rulicke T, Kunz B, Sonderegger P. Coincident pre- and postsynaptic activation induces dendritic filopodia via neurotrypsin-dependent agrin cleavage. Cell, 2009; 136: 1161-71.
Molinari F, R10M, Meskenaite V, Encha-Razavi F, Auge J, Bacq D, Briault S, Vekemans M, Munnich A, ttie-Bitach T, Sonderegger P, Colleaux L. Truncating neurotrypsin mutation in autosomal recessive nonsyndromic mental retardation. Science, 2002; 298: 1779-81.
Reif R, Sales S, Hettwer S, Dreier B, Gisler C, Wolfel J, Luscher D, Zurlinden A, Stephan A, Ahmed S, Baici A, Ledermann B, Kunz B, Sonderegger P. Specific cleavage of agrin by neurotrypsin, a synaptic protease linked to mental retardation. FASEB J, 2007; 21: 3468-78.
Stephan A, Mateos J M, Kozlov S V, Cinelli P, Kistler A D, Hettwer S, Rulicke T, Streit P, Kunz B, Sonderegger P. Neurotrypsin cleaves agrin locally at the synapse. FASEB J, 2008; 22: 1861-73. | A method for the production of a hybridoma cell lines producing monoclonal antibodies capable to specifically binding to a human C44-fragment of agrin, comprising administering to wild-type-mice an immunizing amount of C44y≧4-fragment of agrin, isolating antibody producing cells from the immunized mice, fusing them with a myeloma cell line, growing the fused cells in a selection medium, screening the antibodies in the supernatants of hybridoma cells for binding to C44-fragment of agrin and isolating the hybridoma cells producing the desired monoclonal antibodies | 2 |
BACKGROUND OF THE INVENTION
This invention relates to a sprayer which is designed to suck a liquid received in a container into a cylinder by the slide of a piston and spray the liquid under pressure.
With this type of sprayer, the pressing force of a piston and the speed at which the piston is let to fall exert a prominent effect on the condition in which a liquid is sprayed. Where the piston has an insufficient pressing force or is brought down at a low speed, then, a satisfactory spray can not be realized due to a liquid being scattered in coarse particles, droplets, or bar-like form. Further, under the above-mentioned undesirable condition, the same event arises due to pressure drop also when the spraying operation is brought to an end.
For elimination of such drawbacks, there have hitherto been proposed a variety of pressure accumulating type sprayers, which are designed to accumulate a pressing force derived from the descent of a piston in the form of the urging force of compression spring, and, when the urging force exceeds the prescribed level, to open a secondary valve, thereby spraying a highly pressurized liquid. The known sprayers of the above-mentioned type include, for example, an atomizing pump set forth in U.S. Pat. No. 3,399,836 allowed to Fred Pechstein. Fred Pechstein's atomizing pump comprises a cylinder of a larger diameter in which a piston is slidably received and a cylinder of a smaller diameter in which a plunger or valve rod is slidably received, both cylinders being arranged in series. With the atomizing pump of the U.S. Patent, a piston is brought down to pressurize a liquid. When the pressurized liquid is permitted to flow from the cylinder of the larger diameter into that of the smaller diameter, a valve rod falls at a higher speed than that at which the piston is brought down. Thus, the pressurized liquid is sprayed when a secondary valve is opened. A pressure accumulating spring is received in the cylinder of the smaller diameter behind the valve rod so as to be actuated against the force with which the valve rods descends. Many of the prior art pressure accumulating type sprayers utilize the technical concept of the above-mentioned Fred Pechstein's atomizing pump. However, the conventional sprayers based on Fred Pechstein's technical concept are inevitably accompanied with the drawbacks that since the pressurization of a liquid is effected by causing the piston to slide through the cylinder of the larger diameter to apply pressure to the valve rod received in the cylinder of the smaller diameter, the valve rod receives a lower pressure than the pressing force of the piston, failing to allow the pressure accumulate spring to accumulating a sufficiently high pressure. Since the pressure accumulating spring is disposed in a chamber of a smaller diameter, a spring having a large capacity of accumulating pressure can not be utilized for accumulation of pressure. The spray of a liquid can not be commenced at a high pressure and the liquid fails to be sprayed at a fully high pressure, because the pressure accumulating spring does not apply a sufficiently high pressure to the liquid while it is being sprayed.
It is therefore an object of this invention to provide a novel sprayer based on a technical concept entirely different from that of Fred Pechstein and which always enables a liquid to be sprayed under good condition.
SUMMARY OF THE INVENTION
According to the present invention, a sprayer has a body which comprises a piston slidably received in the body; a pressurizing cylinder for defining a liquid receiving pressurizing chamber together with the piston; a valve rod slidably received in the body; a pressure accumulating cylinder for defining a liquid receiving pressure accumulating chamber together with the valve rod; nozzle means having an ejection hole communicating with the pressure accumulating chamber; and biasing means disposed in the pressure accumulating cylinder to bias the valve rod. The sprayer is characterized in that the pressurizing cylinder and the pressure accumulating cylinder are arranged substantially in parallel; the pressure accumulating chamber has a larger diameter than the diameter of the pressurizing chamber; and
the sprayer body further comprises a lever rotatable about a pivotal point lying substantially between the pressurizing and pressure accumulating cylinders; a vertically movable push button disposed adjacent to and substantially in parallel with the pressurizing cylinder and drivingly connected to the free end of the lever, and a stationary check valve coupled between the pressurizing chamber and the pressure accumulating chamber for communicating the chambers with each other and for preventing liquid from flowing backward from the pressure accumulating chamber to the pressurizing chamber.
The above and further objects and novel features of the invention will be more fully apparent from the following detailed description when the same is read in connection with the accompanying drawing. It is to be expressly understood, however, that the drawing is for purpose of illustration only and is not intended as a definition of the limits of the invention.
BRIEF DESCRIPTION OF THE DRAWING
The accompanying drawing is a schematic fractional longitudinal sectional view of a sprayer according to one preferred embodiment of this invention.
DETAILED DESCRIPTION
Referring to the drawing showing the schematic fractional longitudinal sectional view of a push button type sprayer based on the technical concept of this invention, a sprayer 10 comprises a container 12 filled with a liquid; a body 14 of a pump or sprayer securely engaged with a mouthpiece 13 of the container 12 by an engagement member 15 whose outer peripheral surface is tapered, the edge of the mouthpiece 13 having a circular cross section; and a housing 16 so disposed as to cover the sprayer body 14. For simplification of illustration, the drawing shows a sprayer from which the housing 16 is taken off. The engagement member 15 of the sprayer body 14 whose outer peripheral surface is tapered can be smoothly engaged with the rounded edge of the mouthpiece 13 of the container 12, and moreover is securely set in place by the elasticity of the rounded edge portion of the mouthpiece 13. If, in this case, the tapered outer peripheral surface of the engagement member 15 is provided with a rounded projection 15a, then the engagement member 15 can be more firmly clamped between the rounded projection 15a and a flange 15b of the sprayer body 14. The sprayer body 14 comprises a slidably received piston 18 and pressurizing cylinder 22 both defining a pressurizing chamber 20, and also a valve rod 26 and pressure accumulating cylinder 28 both defining a pressure accumulating chamber 24 communicating with the pressurizing chamber 20. The pressurizing cylinder 22 and pressure accumulating cylinder 28 are arranged in parallel. A cover 29 is engaged with the upper end of the sprayer body 14 to close the openings of both cylinders 22, 28. A lever 31 is integrally formed with the cover 29 in a state rotatable about a hinge 30, and is bored with an elongate hole 32, through which the piston 18 is connected to the lever 31. The smaller diameter section 33 of the piston 18 is loosely inserted into the smaller diameter section of the elongate hole 32. The terminal larger diameter section 34 of the piston 18 passes through the smaller diameter section of the elongate hole 32 when pressure is applied. The larger diameter section of the elongate hole 32 admits of the relative crosswise sway of the smaller diameter section 33 of the piston 18 when the piston 18 slides substantially in a vertical direction per rotation of the lever 31 about the hinge 30. The free end of the lever 31 is drivingly connected to a push button 35 slidably provided in the housing 16. The cover 29 is prepared from plastics material such as acetal resin which excels in durability and particularly in elasticity. The push button 35 is normally set in a lifted position by the elasticity of the lever 31, that is, in such a position as corresponds to the nonrotated position of the lever 31. As the result, the piston 18 is normally kept in a lifted position, making it unnecessary to provide any extra spring for urging the piston 18 to the lifted position. Since the pressurizing cylinder 20 need not be made long, the sprayer body 14 can be injection-molded quickly. Further, the hinge 30 lies between the pressurizing chamber 20 and presssure accumulating chamber 24 and adjacent to the piston 18. Therefore, the piston 18 is depressed with a force several times as large as that with which the push button 35 is depressed by the finger.
The valve rod 26 received in the pressure accumulating cylinder 28 of the larger diameter has a vertical liquid passageway 40. Received in the pressure accumulating cylinder 28 is a compression spring 44 for urging the valve rod 26 toward the valve seat 42 to cause the liquid passageway 40 to be closed by the valve seat 42. The upper end of the valve rod 26 is connected to nozzle means 50 engaged with a nozzle cover 48. An ejection hole 51 bored in the nozzle cover 48 communicates with the vertical liquid passageway 40 through a horizontal liquid passageway 52.
The pressure accumulating chamber 24 of the larger diameter communicates with the pressurizing chamber 20 of the smaller diameter through a connector path 54. A ball valve 56 is provided in the connector path 54 to act as a secondary backward flow-stopping valve for shutting off communication between both chambers 20, 24. A cylindrical member 60 for fitting a suction pipe 58 is engaged with the sprayer body 14 on that side of the ball valve 56 which faces the pressurizing chamber 20. A primary backward flow-stopping ball valve 62 is received in the cylindrical member 60. That section of the inner wall of the pressurizing cylinder 22 which lies adjacent to the lowermost position of the piston 18 has a smaller diameter. The smaller diameter wall is bored with slits 64 to conduct the residual pressure in the pressurizing chamber 20 into the liquid container 12.
There will now be described the operation of the sprayer of this invention constructed as described above. When the push button 35 is depressed the lever 31 is rotated about the hinge 30 against its own elastic force in the direction of an arrow A . Rotation of the lever 31 leads to the fall of the piston 18, causing the air pressurized in the pressurizing chamber 20 to be brought into the pressure accumulating chamber 24 through the ball valve 56 now opened by the pressurized air. At this time, the other ball valve 62 is pressed against the valve seat by the pressurized air. Later when the push button 35 is released from fingers pressure, then the lever 31 is rotated about the hinge 30 in the direction of an arrow B. This rotation of the lever 31 leads to the rise of the piston 18, giving rise to a negative pressure in the pressurizing chamber 20. Accordingly, the liquid of the container 12 flows into the pressurizing chamber 20 through the suction pipe 58 and ball valve 56 in turn. Since, at this time, the ball valve 56 is pressed against the valve seat, the air of the pressure accumulating chamber 24 is fully prevented from its backward flow to the pressurizing chamber 20. When the piston 18 is brought downward by again depressing the push button 35 by the finger, then the residual air in the pressurizing chamber 20 and incoming liquid run into the pressure accumulating chamber 24 through the ball valve 56 opened by the flowing air and liquid.
Where positive and negative pressures are repeatedly applied to the pressurizing chamber 20 by operation of the piston 18, then air in the pressurizing chamber 20 is all gathered into the pressure accumulating chamber 24. Where pressure applied to the valve rod 26 of the pressure accumulating chamber 24 increases over the urging force of the compression spring 44, then the valve rod 26 is lifted against the urging force. The resultant removal of the valve rod 26 from the valve seat 42 causes the liquid passageway 40 to communicate with the pressure accumulating chamber 24. As the result, pressurized air in the pressure accumulating chamber 24 is drawn out from the ejection hole 51 through the liquid passageways 40, 52.
Actual spray immediately follows the removal of air from the pressurizing chamber 20 and pressure accumulating chamber 24. When, as in the discharge of air, the push button 35 is depressed by the finger, then the lever 31 is rotated in the direction of the arrow A, to let fall the piston 18. Descent of the piston 18 pressurizes the liquid of the pressurizing chamber 20. The pressurized liquid is carried into the pressure accumulating chamber 24 through the ball valve 56 now opened by the pressurized liquid. When the push button 35 is released from finger pressure to lift the piston 18 and provide a negative pressure in the pressurizing chamber 20, then the liquid of the container 12 runs into the pressurizing chamber 20 through the suction pipe 58 and ball valve 62 in turn. Since, at this time, the ball valve 56 is passed against the valve seat by the negative pressure in the pressurizing chamber 20 and the pressurized liquid in the pressure accumulating chamber 24, communication does not take place between the pressurizing chamber 20 and pressure accumulating chamber 24. Therefore, the pressurized liquid in the pressure accumulating chamber 24 is kept therein. Later when the push button 35 is depressed by the finger to bring down the piston 18 and pressurize the liquid of the pressurizing chamber 20, then the pressurized liquid flows into the pressure accumulating chamber 24 through the ball valve 56, thereby applying further pressure to the liquid of the pressure accumulating chamber 24.
When the pressurized liquid of the pressurizing chamber 20 is repeatedly supplied to the pressure accumulating chamber 24 by the repeated fall of the piston 18, then the pressurized liquid of the pressure accumulating chamber 24 is more pressurized. Since the pressure accumulating chamber 24 has a larger diameter than the pressurizing chamber 20, high pressure is applied to the pressure accumulating chamber 24 by Pascal's principle, and in consequence to the valve rod 26. Where the liguid of the pressure accumulating chamber 24 is fully pressurized, and pressure applied to the valve rod 26 overcomes the urging force of the pressure accumulating spring 44, then the valve rod 26 is detached from the valve seat 42, and the fluid passageway 40 of the valve rod 26 communicates with the pressure accumulating chamber 24. As the result, highly pressurized liquid is sprayed from the ejection hole 51 through the pressure accumulating chamber 24 and liquid passageways 40, 52.
According to this invention, the piston is made to slide through the pressurizing chamber of the smaller diameter to apply high pressure to the valve rod of the pressure accumulating chamber, and in consequence to the pressure accumulating spring disposed behind the valve rod. Further, the pressure accumulating spring received in the pressure accumulating chamber of the larger diameter is used with a large pressure accumulating capacity, enabling a liquid to be sprayed at high pressure from the beginning to the end.
It is preferred that the secondary backward flow-stopping valve be provided between the pressurizing chamber and the pressure accumulating chamber to suppress the backward flow of a liquid from the pressure accumulating chamber to the pressurizing chamber. This backward flow-stopping valve enables the pressurized liquid conducted from the pressurizing chamber to the pressure accumulating chamber to be completely separated from the nonpressurized liquid running into the pressurizing chamber by its negative pressure. Repeated supply of pressurized liquid to the pressure accumulating chamber causes the liquid received therein progressively to increase in pressure. Only when fully pressurized, the liquid begins to be sprayed.
It will be noted that all the pressurized liquid of the pressurizing chamber is not sprayed when the piston is brought down. But some of the pressurized liquid remains in the pressure accumulating chamber. The residual pressure of the remaining liquid undesirably tends to prevent the occurrence of a negative pressure in the pressurizing chamber when the piston is lifted. Since, however, the inner wall of the pressurizing chamber is bored with slits, the above-mentioned residual pressure escapes into the container through the slits, and consequently the negative pressure of the pressurizing chamber is not obstructed. The slits are formed in the peripheral wall of the pressurizing chamber at an equal circumferential angle, causing the whole of a seal strip of the piston to be uniformly deformed. Therefore, the piston can slide over a long period in liquidtightness without giving rise to fissures in the piston seal strip.
The accompanying drawing showing the preferred embodiment of the invention is simply for illustration of the technical concept of the invention. Obviously, the technical concept of the invention is applicable to a sprayer of not only the push button type but also the trigger type. | A sprayer wherein there is formed in a sprayer body a pressurizing cylinder defining a pressurizing chamber communicating with a pressure accumulating chamber defined by a pressurizing cylinder in which a valve rod is slidably received. The pressurizing cylinder has a smaller diameter than the pressure accumulating cylinder. A piston is slidably inserted into the pressurizing cylinder. When liquid received in the pressurizing chamber is pressurized by bringing down the piston in the smaller diameter pressurizing cylinder, then a higher pressure than the pressing force of the piston is applied by Pascal's principle to the valve rod against the urging force of a pressure accumulating spring disposed behind the valve rod, because the valve rod has a larger diameter than the piston. When the high pressure is applied to the pressure accumulating spring, then a highly pressurized liquid can be sprayed, though the piston itself applies a relatively low pressing force. Since the pressure accumulating spring is received in the larger diameter pressure accumulating cylinder, a spring having a large pressure accumulating capacity can be used. | 1 |
BACKGROUND
Longwall supports are disclosed, for example, in DE 42 02 246 A1. A longwall support of this type consists of a coal cutting machine or plow, which is driven by a cable, a conveyor, and longwall support units. The conveyor extends in front of the working face and includes a channel, in which an armored conveyor moves along the working face. The channel is divided into individual units. While these units are interconnected, they are able to perform a movement relative to one another in the working direction. Each of these units connects by means of a cylinder-piston unit (advance cylinder) to a longwall support unit. Each longwall support unit serves the purpose of propping the mined longwall. Each longwall support unit is mounted on runners and comprises a roof construction, which is stayed relative to the runners by cylinder-piston units, and serves to support a hanging roof.
In addition, stays are provided, which exert on the conveyor a force that is inclined in the conveying direction. These stays are typically cylinder-piston units, which are each supported on the one hand on a longwall support unit and on the other hand on the channel unit that faces an adjacent longwall support unit. As a result, these stays exert one force component that is directed against the working face, which is called advance force in the present application, and another force component in the conveying direction, which is called staying force in the present application.
The use of the stays permits compensating longitudinal forces that act upon the channel/conveyor. These are not only forces that result from the conveyance, but also weight forces, which result from the fact that the working face and, with that, also the conveying plane are inclined over the entire length of the longwall or also only over a part of the length. To compensate the forces, one may provide, for example, every third, fourth, tenth longwall support unit with such a stay, which is preferably stayed in facing relationship with the next, directly adjoining longwall support unit.
The number of the stays and the pressure adjusted therein are typically determined by computation or estimation of the extent of the forces which are to be expected and to be compensated in the longitudinal direction of the conveyor.
It is therefore an object of the invention to minimize the stays with respect to their number and with respect to the pressure that is to be adjusted in them, to keep expenditure of the systems low with respect to investment and operation, and to integrate the stays into the longwall face operation such that the stays assume an important function in the mining and conveying of rock and/or coal.
BRIEF SUMMARY OF THE PRESENT INVENTION
The present invention addresses this problem by providing a longwall support in a mine comprising a plurality of longwall support units, which are placed side by side over the length of the longwall between passages, a mining machine that is adapted for movement along the longwall face, as well as a conveyor that extends over the length of the longwall between the mining machine and the longwall support units; a plurality of stays consisting of cylinder-piston units, which are each supported between an abutment on one of the longwall support units and a step bearing on the conveyor and pivoted such that each of the stays exerts by its longitudinal force a force component against the working face (advance force) and a force component in the direction of the longwall (staying force) for absorbing the forces that act upon the conveyor in the direction of the longwall, in particular downward forces of a hanging roof; and a control system with data acquisition, data storage, and programming, which continuously permits adapting at least one of the distribution of the staying forces over the length of the longwall, the sum of the staying forces that are active over the length of the longwall (total staying force), or the distribution of the advance forces over the length of the longwall to the desired position of the conveyor.
In the present invention, the stays for the longwall support are used not only statically, but also are dynamically incorporated in the mining operation.
For reasons of optimizing investment and maintenance costs, all efforts are to be made to limit the number of the stays to a required minimum. The invention makes it possible by determining the staying forces in the individual stays/cylinder piston units to determine also the total staying force and to rate it such that the position of the conveyor remains constant. This rating of the individual staying forces and the total staying force can occur on the one hand by adjusting the pressure, which biases the cylinder-piston units. On the other hand, however, it is also possible to limit the number of the stays such that the pressure available to the individual stays permits achieving the total staying force that is maximally required for stabilizing the position of the conveyor.
The number of the stays is to be determined and to be adapted to the available maximum pressure such that the individual staying forces can still be increased, if this is needed for influencing the position of the conveyor. A further development of the invention proposes to adjust the individual staying forces and, with that, also the total staying force as a function of at least one of the end positions of the conveyor. To this end, the end position of the conveyor is measured in the region of the main drive and/or the auxiliary drive, and the staying forces are controlled as a function of the measured value such that the end position remains substantially constant, and the conveyor does not excessively extend into the passage.
One may assume that in most cases the conveyor is not laid level, but that the channel forms relative to a horizontal or inclined plane elevations and valleys. Such unevennesses may also lead to a shifting of the one and/or the other end position of the conveyor. This is avoided by providing for adjustment of not only the total staying force, but also the distribution of the force components in the direction of advance (advance forces) by adjusting the forces of the stays. With that, it is accomplished that the rock is not mined in a level working face, but that unevennesses develop in the working face in the form of convex or concave bulges. These bulges suffice to compensate and equalize not only position changes of the conveyor, unevennesses of the position of the conveyor on the ground, and the end positions of the conveyor, but also the position of the conveyor in intermediate sections as well as the elongation and elongation distribution of the conveyor.
Mining conditions in the longwall are subjected to continuous changes. Naturally, one of the causes is the progressive mining and the support that follows the working face. As a consequence, also optimally adjusted force conditions on the conveyor are subjected to a continuous change, and—when viewed over the time—significant interference factors, for example, by the development of unevennesses in the working face and/or the position of the conveyor on the ground can make themselves noticeable.
With the further development of the invention according to claim 9 it is accomplished that the invention is also able to take into account such changing situations. In particular, the introduction of force, which is applied by the stays to the conveyors in the direction of advance and conveyance, is continuously adapted to the progressive mining and support, and in particular to the advance movement of the longwall support units.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference will now be made to the accompanying drawings, wherein:
FIG. 1 is a sectional view of a longwall with a longwall support unit;
FIG. 2 is a schematic plan view of a coal cutting machine and a group of longwall support units; and
FIG. 3 is a schematic plan view of a longwall with a conveyor and longwall support units.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates one of longwall support units 1 - 18 . FIG. 2 illustrates a plurality of longwall support units 1 - 18 . The support units are arranged along a coal bed 20 . The coal bed 20 is mined in a working direction 22 with a cutting device 23 , 24 of an extraction machine 21 . In the illustrated embodiment, the extraction machine is a coal cutting machine 21 .
The coal cutting machine 21 is movable in a cutting direction 19 by means of a cable not shown. It possesses two cutting rolls 23 , 24 that are adjusted to different heights, and shear the coal face. The dislodged coal is loaded by the coal cutting machine, also named “cutter-loader,” on a conveyor. The conveyor consists of a channel 25 , in which an armored chain conveyor is moved along the coal face. The coal cutting machine 21 is adapted for moving along the coal face. The channel 25 is subdivided into individual units, which are interconnected, though, but are capable of performing a movement relative to one another in the working direction 22 . Each of the units connects to one of the longwall support units 1 - 18 by means of a cylinder-piston unit (advance piston) 29 , which is used a biasing means. Each of the longwall support units serves the purpose of supporting the longwall. To this end, a further cylinder-piston unit 30 is used, which stays a base plate relative to a roof plate. At its front end facing the coal bed, the roof plate mounts a so-called coal face catcher 48 . This catcher is a flap that can be lowered in front of the mined coal face. The coal face catcher must be raised ahead of the approaching coal cutting machine 21 . Likewise to this end, a further cylinder-piston unit not shown is used. These operating elements of the individual longwall support are shown only by way of example. While additional operating elements are present, they need not be mentioned and described for the understanding of the invention.
As aforesaid, each of the biasing means is a hydraulic cylinder-piston unit.
These cylinder-piston units are actuated via valves 44 and pilot valves 45 . The pilot valve mounts a valve control device 40 , i.e., a housing that accommodates the valve control.
In FIG. 2 , the coal cutting machine moves to the right. For this reason, it is necessary that the coal face catcher of the longwall support unit 17 be folded back. On the other hand, the unit of channel 25 on the longwall support unit 9 , which is located—in the direction of movement 19 —behind the coal cutting machine 21 , is advanced in the direction toward the mined coal face. Likewise, the following longwall support units 8 , 7 , 6 , 5 , and 4 are in the process of advancing in the direction toward the longwall or the mined coal face. The coal face catcher on these longwall support units has already been lowered again. The support units 3 , 2 , 1 have finished their approach and remain in this position, until the coal cutting machine approaches again from the right. As a function of the movements and the instantaneous position of the coal cutting machine, the control of these movements occurs in part automatically, in part by hand. To this end, a separate mining shield control device 34 is associated to each of the longwall supports 1 - 18 . A separate longwall control device 33 is associated to a group of longwall support units or mining shield control devices. Each of the mining shield control devices 34 is associated to one of the longwall supports 1 - 18 and separately connected to the pilot valves 45 and main valves 44 of all biasing means of the longwall support units 1 - 18 via a valve control device (microprocessor) 40 .
Each of the mining shield control devices serves as a central longwall support control. However, a group of a plurality of mining shield control devices can be superposed by a longwall control device 33 , or also the entirety of the mining shield control devices can be superposed by a central longwall support control system (primary central control system 50 and/or secondary central control system 51 ) that connects to the mining shield control devices. Such an arrangement is shown in FIG. 2 .
The central longwall support control system consists of the primary central control system 50 and secondary central control system 51 . The control systems include data acquisition, data storage, and programming.
A cable 58 (bus line) interconnects all mining shield control devices 34 . Each of the mining shield control devices retransmits operating commands for the longwall support. The operating command triggers in a certain mining shield a certain operating function, for example, in the sense of robbing, advancing, and setting. This mining shield operating command is received and retransmitted by all mining shield control devices 34 via the bus line 58 . All operating commands of one of the longwall control devices are directly transmitted to the mining shield control device 34 that directly connects to the longwall control device. From this mining shield control device, the operating commands then reach all other mining shield control device 34 via the bus line 58 . However, by a predetermined coding, only one of the longwall support units 1 - 18 or a group thereof is activated for carrying out the respective shield functions. The activated mining shield control device then converts the received operating command into valve control commands to the control valves or main valves that are associated to the particular mining shields.
The automatic release of the functions and operating sequences is disclosed, for example, in DE-A1 195 46 427.3.
For a centralized manual operation of the command input the control device 37 is used, which is constructed as a manually operated device, and is carried along by the operator. For inputting a command, the operator can be outside of the longwall, or at least be removed from the instant working location.
As aforesaid, the mining shield control devices 34 are interconnected by means of the cable 58 , which has in the designs of the art only two conductors, and serves for serially transmitting respectively a code word and the mining shield operating command. Only that of the mining shield control devices 34 (longwall support units) is addressed, whose stored code word is identical with the transmitted code word. Thus, the cable 58 is a two-conductor cable, which extends in the form of a bus line from one mining shield control device 34 to the next, and also interconnects the primary central control system 50 and the secondary central control system 51 via the intermediate mining shield control devices 34 .
FIG. 3 also illustrates stays 55 . The stays 55 are cylinder-piston units, which each extend between runners 54 of (for example) longwall support unit 1 and the channel 25 opposite to the adjacent (in this case) longwall support unit 2 . The next stay 55 can then extend, for example, between the runners 54 of the longwall support unit 5 and the channel facing the adjacent longwall support unit 6 . The stays need not necessarily be arranged in even distribution along the passage. The number and the distribution of the stays depend on the longitudinal forces that are active in the direction of the longwall. The fact that in accordance with the invention stay data—in particular the pressures in the cylinder as well as the staying angle relative to the direction of conveyance—are continuously acquired, makes it possible to achieve besides optimal operating conditions also an optimal layout with respect to number and size of the stays.
For reasons of space, FIG. 3.2 only indicates that the stays are controlled by a control unit 56 . The control unit 56 connects to individual control devices 57 , which are each used to control and measure the pressure, and insofar also permit a feedback to the control unit 56 . In the region of passages 52 , 53 , measuring devices 58 are provided. The measuring devices 58 determine the end position of the conveyor 25 . The measuring signal of the two measuring devices 58 is returned to the control unit 56 . With that, it is accomplished that the conveyor and the conveyor channel are aligned in the center between the passages and do not project into the one or the other passage. When the measuring devices find that the conveyor drifts in one direction, the staying forces are increased or decreased such that the conveyor is again stabilized or returned to its position.
As best seen in FIGS. 3.1 and 3 . 2 , because of their oblique position relative to the conveying direction, the stays exert a force component 59 in the conveying direction and a further force component 60 in the direction of advance. The number of stays is determined such that they permit absorbing the longitudinal forces that act upon the channel 25 . In this connection, it should be noted that such longitudinal forces are not necessarily constant over the entire length of the longwall. Rather, they can vary and lead in this case to a staying of the channel. The invention makes it possible to determine not only the staying forces and the sum of the force components 59 in the conveying direction, but also the distribution of these force components 59 , and accordingly to effect compensation by controlling the pressure.
The invention furthermore makes it possible to take into account the change of the force component 60 , which occurs during an advance movement of the channel or longwall support unit by changing the angle phi (between the piston axis and the conveying direction).
Furthermore, it becomes possible to determine the end position of the conveyor via the measuring devices 58 , and to control the staying forces as a function of the desired end position, which is shown in FIG. 3.2 , by influencing the pressure in the individual stays such that the channel and the conveyor 25 do not project into the passages 52 , 53 .
Furthermore, the invention avoids that an excessive number of stays is used. Rather, the number is to be determined such that it permits applying in any event the required staying forces for a substantially constant position of the conveyor channel 25 with the available maximum pressures. This is assisted by the fact that the individual control devices 57 permit measuring the pressures and pressure distributions constantly, and adjusting both the layout of the entire arrangement and its operation to requirements.
Finally, the invention also permits influencing the advance forces in the direction of the force component 60 . For example, when the measuring device finds that the conveyor is too long in its extension and projects on both sides into the passages 52 , 53 , the staying forces and advance forces respectively are increased and distributed over the length of the longwall such that the coal face 20 is worked with a greater bulge—note FIG. 3 . 2 —instead of a weaker bulge, which shortens the layout of the conveyor. In the same way, it is possible to compensate local staying of the conveyor, in that in the particular local range, the bulge of the coal face is also varied, so that the conveyor locally extends over a greater or shorter length. To achieve a greater bulge of the coal face in a local region, the distribution of the pressures in the stays is varied accordingly.
Many modifications and other embodiments of the invention set forth herein will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. | A longwall support in a mine that comprises a plurality of longwall support units. The longwall support units are supported relative to a conveyor by stays that comprise cylinder-piston units. A control system with data acquisition, data storage, and programming is used to adapt the distribution of the staying forces over the length of the longwall, the sum of the staying forces acting upon the length of the longwall (total staying force), and the distribution of the advance forces over the length of the longwall continuously to the desired position of the conveyor. As a result, it is possible to influence the total staying force by the number of the stays with respect to an adjustable maximum, or the total staying force by controlling the longitudinal forces of the individual stays, or the total staying force as a function of at least one of the end positions of the conveyor. | 4 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to the ability to provide a uniform application of polymeric diphenylmethane diisocyanate (pMDI) onto cellulose gypsum panels, boards and other surfaces, to create a substrate with increased strength and water resistance.
[0002] Exterior wall cladding is used as a barrier to keep exterior air and moisture out of the wall cavity. If water and moisture penetrate the wall cladding surface damage will result to the cladding board itself. Prior art exterior wall cladding was made out of gypsum sheathing or water-resistant gypsum board. It was found that the application of pMDI to a cellulose/gypsum based board greatly increased the board's strength and water resistance. The disclosed invention applies the pMDI to the cellulose/gypsum based board with an apparatus that provides a uniform coating across the board which results in increased water resistance and flexural strength.
SUMMARY OF THE INVENTION
[0003] The disclosed invention consists of an improved cellulose/gypsum based board, and means for conveying a gypsum and cellulosic board or panel to a spray station where pMDI resin is delivered through a series of spray nozzles to the face and back of the gypsum board or panel. A resin distribution system is used to supply the spray nozzles with pMDI. Optionally, to assist in the spreading of the pMDI resin over the surface of the cellulose/gypsum board to achieve complete coverage of the cellulose/gypsum-based substrate, a second spray system can be included. The nozzles of the second spray system may be adjusted to cover areas of the face and back of the board that are not covered by the first spray system. The resulting panel exhibits dramatically improved water resistance and flexural strength. Atmospheric moisture is sufficient to cure the pMDI matrix.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] [0004]FIG. 1 is a schematic drawing illustrating a production line for forming cellulose/gypsum board having a head box, dewatering vacuums, a dewatering primary press, a secondary press, a drying kiln and a resin distribution system all for processing a rehydratable gypsum fiber slurry upon a conveyor;
[0005] [0005]FIG. 2 is a front view of the resin distribution system including a resin drum, a metering pump and the spray system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0006] The present invention is directed to an improved cellulose/gypsum based board and to a method for applying polymeric diphenylmethane diisocyanate (pMDI) to a cellulose/gypsum based board, and in particular, the use of one or more spray systems to provide a uniform application of pMDI onto the cellulose/gypsum based board. The forming system, generally designated with the numeral 10 and shown in FIG. 1, includes a head box 12 , vacuum boxes 14 , a wet (primary) press 16 , a secondary press 18 , and a drying kiln 20 . The function of the primary press 16 is 1) to nip a gypsum/cellulose fiber filter cake mat to a desired thickness and 2) to remove 80-90% of remaining water. The function of the secondary press 18 is to compress the board during setting to a calibrated final thickness and to aid in achieving flexural strength in the final product. The secondary press 18 has a continuous belt 22 that also aids in achieving smoothness to the board surface as the rehydrating mat expands against the belt 22 . The head box 12 is used to uniformly disperse a calcined slurry having at least about 70% liquid by weight, across the width of the forming table 24 , where vacuum boxes 14 are used to dewater the slurry into a mat of generally 2841 % moisture content (wet basis) (40-70% moisture content on a dry basis). The forming table 24 includes side dams to contain the slurry pond and a conveyor or forming wire 26 to move the slurry away from the head box 12 and towards the primary press 16 . As the slurry moves along the forming table 24 , the vacuum boxes 14 dewater the slurry into a mat, creating a decreasing water content gradient in the slurry going from the head box 12 towards the primary press 16 . At some point along this gradient, there is a zone referred to as the wet line, where it is observable that the slurry is changing into the wet mat. Put another way, one can see that the slurry is no longer fluid as the water is removed.
[0007] In the preferred embodiment, the slurry pond is further dewatered and formed into a filter cake by the application of additional vacuum boxes 14 . With reference to FIG. 1, the conveyor or forming wire 26 carries the filter cake to the primary press 16 which further dewaters the filter cake and nips the material to a desired thickness. During this time, the board begins setting and expands to fill the nip gap. The board exits the primary press 16 and is carried on the conveyor 26 to the secondary press 18 . The secondary press 18 shapes the board to a final calibrated thickness. The board expands against the smooth belt 22 of the secondary press 18 which further aids in rendering a smooth surface and increased flex strength.
[0008] After exiting the secondary press 18 , the board is dried in a kiln 20 . A non-aqueous pMDI resin is spray-applied to the face and backside of the cellulose/gypsum board by using a spray system 28 that sprays at a preferable rate from about 9 to about 25 pounds per 1000 square feet of cellulose/gypsum board. The pMDI penetrates efficiently into the board. As the pMDI migrates through the board, a reaction takes place between water that is in the ambient air, plus any remaining/evaporating water in the board, and the pMDI that permeates into the board. The interaction between the pMDI and the water transforms the pMDI into polyurethane, which forms urethane linkages with the cellulosic fibers at and slightly below the surface of the board to seal the faces of the board. The polyurethane does not increase the overall thickness of the board but rather seeps into the board. The resin applied to the board by the spray system 28 thus does not remain suspended to cure as a mere coating on the surface due to the polymeric resin, like pMDI, interacting with the cellulosic fibers. Water from the ambient surroundings is sufficient to start the curing of the pMDI, and, thus the resin is applied to a dried board, which may have a small percentage of evaporating remaining free water that has not yet evaporated. The non-aqueous resin soaks into the board and reacts with the cellulosic fibers in the board. A polyurethane/cellulose matrix is formed. By treating the entire cellulose/gypsum board with pMDI, a polyurethane/cellulose matrix is formed that completely seals the board.
[0009] The resultant cellulose/gypsum board treated with the pMDI has an increase in flexural strength of 20-35% over the non-treated board. The typical curing time to allow for complete transportation of the pMDI into the polyurethane cellulose matrix within the board is approximately three days, but may vary depending upon ambient conditions.
[0010] The polyurethane/cellulose matrix formed does not increase the overall thickness of the board. The matrix becomes a water resistant layer of the board that is approximately ⅛ inch thick. A cellulose/gypsum board treated with pMDI on one side, allowed to cure, and completely submersed in water resulted in the deterioration of the untreated portion of the board. The treated portion of the board remained intact and was about ⅛ inch thick.
[0011] A water absorption test was performed on the surface of both an untreated cellulose/gypsum board and a board treated with pMDI to determine the quantity of water absorbed by the board. During the test, 100 square centimeters of the surface of the board was subjected to 100 milliliters of 70° F. water for two hours. The untreated board absorbed 92-100 grams of water during the two hour test period. The board treated with pMDI absorbed 0.5 grams of water for the 2 hour test period which is well below the acceptable limit for exterior cladding. Boards treated with pMDI were more scuff resistant than untreated boards and were less dusty when handled. These desirable qualities are beneficial because they enhance the marketability of the resultant product.
[0012] The spray system 28 , as shown in FIG. 2 includes a horizontal spray bar 30 equipped with equally spaced spray nozzles 32 , a manifold 34 , feed tubes 36 , a filtering system 40 , a positive displacement pump 38 and a storage container 42 . The spray bar 30 is an elongated tube that spans the width of the board. Typical sheets of cellulose/gypsum board are 48 inches in width. In the preferred arrangement, the spray nozzles 32 are attached to the spray bar 30 in three inch intervals. It has been found that placing the spray nozzles 32 three inches apart provides for enough spray overlap to adequately wet the board with pMDI. The spray nozzles 32 spray in a fan pattern and are positioned 8-10 inches above the board. Placing the nozzles 32 close to the board reduces the amount of overspray that is typically associated with spray systems. The spray nozzles 32 are not air assisted since it is desirable to reduce atomization of the pMDI so overspray can be kept to a minimum. Overspray decreases the pMDI transfer rate onto the board, which increases the amount of pMDI required to coat the cellulose/gypsum board and the amount of overall product required. The spray bar 30 is connected to the manifold 34 that delivers pMDI to different locations on the spray bar 30 by use of feed tubes 36 . The feed tubes 36 are vertically oriented and connect the spray bar 30 to the manifold 34 . The manifold 36 is supplied with pMDI under pressure from a positive displacement pump 38 . The pump 38 is connected to the storage container 42 by use of a supply line 44 . The supply line 44 also connects the pump 38 to the filter system 40 and the filter system 40 to the manifold 34 . The storage container 42 is typically a storage drum that is positioned upon a drum cart 46 . The storage container 42 also includes a valve 48 and a breather 50 to allow for the removal of pMDI. The breather 50 is utilized to allow air to displace the pMDI removed from the storage container 42 . The pump 38 is adjusted to the desired flowrate and pumps the pMDI through the filter system 40 and to the manifold 34 . The filter system 40 includes two filters 41 connected in parallel to filter out any particles that may clog the nozzles 32 . The filter system 40 is equipped with valves 52 to allow the supply line 44 to be closed off to prevent the leakage during the replacement of the filters 41 . By utilizing two filters 41 that are large enough handle the flowrate of the pMDI from the pump 38 , one filter 41 can be taken off-line for a filter replacement while the other filter 41 remains in service.
[0013] The invention is also useful for paper coated gypsum board wherein the paper provides the cellulosic fibers for forming the urethane linkages with the curing pMDI.
[0014] Various features of the invention have been particularly shown and described in connection with the illustrated embodiments of the invention. However, it must be understood that these particular arrangements, and their method of manufacture, do not limit but merely illustrate, and that the invention is to be given its fullest interpretation within the terms of the appended claims. | The disclosed invention consists of an improved gypsum based, cellulosic containing board and method for applying a resin to an untreated board at a spray station where pMDI resin is sprayed onto the front and back side of the board. A resin distribution system is used to supply the spray nozzles with pMDI. Optionally, a second spray station is included, if desired, to add additional pMDI resin over the surface of the board to achieve complete coverage. The improvement is an increased water resistance and flexural strength. | 1 |
CONTINUING DATA
This application is a divisional of application Ser. No. 08/887,568, filed Jul. 3, 1997, now U.S. Pat. No. 6,024,692 entitled Fluid Circulator For Nonlinear Compliant Circuits.
FIELD OF THE INVENTION
The invention includes methods and apparatus to achieve and/or maintain predetermined fluid flow conditions in nonlinearly compliant fluid circuits, including circuits having relatively localized, nonlinear leaks and nonuniform flow resistance. In particular, methods and apparatus are described to minimize leak rates at predetermined flow rates in such nonlinearly compliant circuits.
BACKGROUND
Physiology of Blood Circulation
Blood is normally pumped from the heart through a circulatory system comprising a plurality of fluid circuits, each fluid circuit substantially comprising, proximally to distally, arteries of progressively smaller size, capillaries, and veins of progressively larger size. Blood enters capillary beds from precapillary arterioles which normally act as resistance vessels. Having emerged from the heart's left ventricle at (relatively high) arterial pressures, most blood returns to the heart's right atrium via the central veins (the superior and inferior vena cavae) at relatively low pressures. Circulatory system peripheral resistance to blood flow is normally substantially controlled primarily through contraction or relaxation of precapillary arteriolar walls, flow resistance in such arterioles being inversely related to the fourth power of arteriolar radii. Thus, while arterial blood pressures are substantially maintained upstream of capillary beds, capillary blood flow typically occurs at pressures only slightly higher than mean central venous pressure (CVP). And CVP is commonly a small fraction of mean arterial pressure.
Because veins contain blood at relatively lower pressures than arteries of comparable size, venous system vessel walls are generally thinner than arterial walls of similar vessel diameter. Veins are thus more compliant than arteries of comparable diameter, meaning that they are more easily distended by increased intravascular pressure and that they tend to collapse when intravascular pressure falls. These conditions are easily observed as the distended neck veins of a person speaking loudly suddenly flatten while the person pauses to take a breath. Loud speech requires relatively high intrathoracic pressures to expell air forcefully through the vocal cords, but intrathoracic pressure (and thus CVP) drops precipitously as the diaphragm moves downward during inspiration. Veins relatively close to the chest cavity are regularly filled and drained by this intermittent respiratory action. More peripheral veins contain valves which assist in moving blood from dependent areas toward the heart in conjunction with muscle contractions. In all cases, prolonged periods of sustained high venous (and thus high capillary) pressures are avoided to maintain normal capillary function. Note, however, that hemodynamic stability normally requires sufficiently positive CVP to maintain adequate blood flow from the central veins into the heart.
Because of the relatively low blood pressures normally existing in the capillaries and veins, only small pressure gradients normally tend to drive fluid out through capillary and venous walls. Nevertheless, small amounts of fluid can and do leak from the circulating volume (the total volume contained in the heart, arteries, capillaries and veins) into interstitial spaces between the cells of tissues surrounding the blood vessels. A portion of this interstitial fluid can then exchange with intracellular fluids before it is mobilized through lymphatic drainage and eventually returned to the circulating volume through the thoracic duct. Because capillary walls are especially thin (to facilitate gas exchange and the movement of metabolic products and substrates), capillaries tend to be much more compliant than arteries and they leak relatively easily. Thus, relatively small increases in hydrostatic, hydrodynamic and/or osmotic pressure gratients across capillary walls can significantly affect fluid movement through the walls (that is, fluid leaks). In addition to their effect on leaks, pressure changes also cause changes in intravascular volume which for each vessel are described by the vessel compliance (internal volume change per unit internal pressure change).
The human and animal circulatory systems described above are nonlinearly compliant, meaning that vessel compliance is not constant throughout the circulatory system, nor does vessel compliance vary linearly with distance from the heart. Additionally, highly localized nonlinear leaks (usually greatest in the capillaries for given pressures) and nonuniform flow resistance characterize these circulatory systems. This helps explain why maintaining predetermined circulatory system blood flows in the absence of normal heart pumping action (as during total cardiopulmonary bypass) is a complex process which is not achieved without significant time-dependent morbidity with any currently available device.
Venous Pressures During Cardiopulmonary Bypass
During a conventional total cardiopulmonary bypass, pumping and gas exchange functions of a patient are temporarily totally replaced by a pump-oxygenator system. For purposes of this description, a pump-oxygenator system will be considered to comprise one or more pumps and one or more oxygenator/gas exchanger units interconnected as well known to those skilled in the art so as to provide blood withdrawn from a patient with physiologically adequate gas exchange and pressurization before the blood is returned to the patient. Besides gas exchange and pressurization, an additional function performed by extracorporeal apparatus is accumulation of sufficient circulating fluid volume to ensure that, despite fluid losses, sufficient fluid is always available for return (under pressure) to the patient to maintain a desired arterial blood pressure. Thus, the function of a fluid accumulator comprises addition of any fluid volumes necessary to allow performance of the pressurization and gas exchange functions. Note that the three functions described above (gas exchange, pressurization, and accumulation) may take place in any order and in components which are either concentrated or distributed. For purposes of the description herein, pressurization and gas exchange may be accomplished by any apparatus, such as any of the commercially-available pump-oxygenators, known to those of skill in the art to perform those functions. The collective apparatus for pressurization and gas exchange is designated as a pump-oxygenator and represented in flow diagrams herein as a single block, even though its component parts may in fact be distributed.
Whatever the pump-oxygenator configuration, it should be noted that even though the pump-oxygenator pressurizes the blood for return to the patient's arterial circulation, the normally rhythmic rise and fall of intrathoracic pressure associated with spontaneous breathing is eliminated during total cardiopulmonary bypass. Instead, the chest is open and intrathoracic pressure is simply (substantially constant) ambient pressure. This means that the normal rise and fall of CVP during breathing is virtually eliminated, and since the patient is usually paralyzed with a muscle relaxant, circulatory assistance normally provided to venous blood flow by muscle action is also absent. CVP during total bypass is thus usually substantially zero (or even negative) as the patient's venous blood is drained by gravity siphon into a blood accumulator for conveyance through a pump-oxygenator before being returned to the patient's arterial circulation.
Because CVP is substantially zero or negative in conventional total cardiopulmonary bypass (due to withdrawal of a portion of the venous blood volume by siphon into the accumulator), veins throughout the body tend to collapse. Venous flow resistance then rises due to the reduced cross-section of venous flow channels, but arterial flow resistance tends to fall during cardiopulmonary bypass unless it is altered pharmacologically. Since the artifically raised venous system flow resistance adds algebraically to generally falling arterial flow resistance, the result may be a relatively small change in total peripheral resistance. But instead of being concentrated in the precapillary arterioles, much of the flow resistance moves downstream from the capillary beds into the venous system. Thus, with their drainage artificially impeded by a substantially collapsed venous system, capillary beds during total cardiopulmonary bypass are exposed to a much greater proportion of arterial pressure than they would normally experience. The result is that fluid under the influence of artificially high intracapillary pressures tends to shift from the intravascular space to the interstitial space. Excessive amounts of interstitial fluid, in turn, produce the tissue swelling characteristic of edema.
While maintaining minimum recommended total blood flow rates needed to support gas exchange and other aspects of cellular metabolism, attempts may be made to reduce capillary leak by reducing systemic blood pressures. For example, vasodilators may be administered to the patient to reduce total peripheral resistance in the circulatory system to lower the mean arterial pressure required to maintain adequate blood flow. But the pharmacological effect of vasodilators is primarily to lower arteriolar flow resistance while venous resistance remains artificially high and substantially unaffected. So even if systemic vascular resistance is reduced pharmacologically, mean intracapillary pressure may well remain high enough to significantly increase capillary leaks and their related deleterious effects.
One adverse effect of capillary leaks is that, because high intracapillary pressures tend to drive fluid from the vascular system into the tissues' interstitial space (the “third space”), the patient's edema fluid load increases; it must eventually be mobilized by the patient's lymph system during recovery from the operation.
As intravascular fluid is driven into the tissues by elevated capillary pressures, a second adverse effect becomes apparent. Declining intravascular volume must be replaced by additional fluid, which is usually a combination of crystalloids and colloids. While colloids are desirable to maintain normal colloid osmotic pressure of the intravascular and interstitial fluids, colloids driven into the interstitial spaces are relatively difficult for a patient to mobilize. Crystalloids, on the other hand, are easier to mobilize but tend to move more readily into the intracellular space and to disrupt preferred intravascular and intracellular electrolyte levels (with possible neurological sequelae). Cellular swelling may occur, which adversely affects cellular metabolism and the movement of substrates and products into and out of the cells. Such a reduction in effective contact between cells and circulating blood may effectively create a circulatory shunt which predisposes the patient to cellular hypoxia and lactic acidosis.
A third adverse effect of the capillary leakage described above is the generalized tissue swelling caused primarily by edema fluid. Tissue swelling increases external pressure which tends to collapse the venous drainage channels for capillary beds, raising the channels' flow resistance. In a manner analogous to the air-trapping commonly seen in patients with severe emphysema, fluid tends to become trapped in the capillary beds. When emphysematous patients try harder to exhale, the resulting raised intrathoracic pressure closes the airways ever more tightly and leaves air trapped in the lungs. Similarly, as pump pressure is raised to maintain a predetermined blood flow rate during total cardiopulmonary bypass, capillary leak is further exacerbated, resulting in more edema which eventually calls forth even higher pump pressures.
Thus, edema fluid retention aggravated by excessive capillary blood pressures during total cardiopulmonary bypass can become a significant source of intraoperative and postoperative morbidity and moitality. Costs of supportive care can be significantly increased, and greater susceptibility to other complications (e.g., infections, inflammatory responses, blood clotting abnormalities) reduces the likelihood of a smooth postoperative course.
SUMMARY OF THE INVENTION
The present invention includes methods of minimizing fluid leaks while circulating fluid in nonlinearly compliant leaky fluid circuits comprising, for example, a human or animal cardiovascular system subject to transvascular leakage during cardiopulmonary bypass. In a preferred embodiment, the method comprises directing substantially all fluid flowing from the leaky fluid circuit to a fluid accumulator while maintaining (gage) fluid pressure in substantially all portions of the leaky fluid circuit substantially above zero. Pumping fluid from the fluid accumulator into the leaky fluid circuit under the condition of substantially above-zero fluid pressures substantially throughout the fluid circuit minimizes fluid leaks which would otherwise occur if fluid pressure in the more compliant portions of the fluid circuit were allowed to remain substantially at zero or negative values. The latter condition would tend to cause at least partial collapse of the fluid circuit and lead to increases in both fluid flow resistance and fluid leakage from the circuit.
Substantially above-zero fluid pressures may be maintained substantially throughout the fluid circuit during pumping of fluid through the circuit by, for example, restricting return fluid flow from the leaky fluid circuit through one or more fluid inlet lines to the accumulator. Such fluid inlet line fluid flow restrictions may in turn comprise accumulator pressurization and/or by adjustments of static and/or dynamic fluid flow resistance of one or more fluid inlet lines. Each fluid inlet line entrance is connected to the leaky fluid circuit, at which point fluid pressure substantially above zero may be maintained by restriction of return fluid flow; each fluid inlet line exit, of course, is connected to deliver fluid to the accumulator.
Static fluid flow resistance may be provided as a (preferably adjustable) elevation through which the fluid moves from the fluid inlet line entrance to the accumulator. Such an elevation will result in a fluid pressure head proportional to the amount of elevation (an elevation pressure head) which is measurable at the fluid inlet line entrance. Adjustment of elevation pressure head is possible through adjustment of fluid level within the accumulator (see discussion of FIGS. 2 (A-E) below) and/or through adjustment of accumulator height. An inlet line elevation pressure head, if present, will add algebraically to any pressure head attributable to accumulator pressurization which may be present in the inlet line. A negative inlet line elevation pressure head would indicate siphon action tending to move fluid through the fluid inlet line from entrance to exit and must be counteracted by another pressure head (such as that resulting from pressurization of the accumulator and/or a fluid inlet line fluid flow restriction) to maintain a fluid inlet line entrance pressure substantially above zero. An elevation pressure head which itself is substantially above zero will suffice for practice of the present invention, although optimal values will in general be derived empirically. Thus, a method for minimizing fluid leaks as above comprises directing substantially all fluid flowing from the fluid circuit to a fluid accumulator through a fluid inlet line having an elevation pressure head; maintaining the elevation pressure head substantially above zero; and pumping fluid from the fluid accumulator into the fluid circuit to minimize fluid leaks.
One or more pumps may also or alternatively be inserted in series with the fluid inlet line to provide another (preferably adjustable) pressure head which is also measurable at the fluid inlet line entrance and which adds algebraically to any elevation pressure head and/or to any accumulator pressurization pressure head which may be present. The series connected pump(s) may comprise a centrifugal pump (such as a vortex pump) and/or a positive displacement pump (such as a roller pump). Finally, one or more (preferably adjustable) fluid flow resistors may also or alternatively be inserted in series with the fluid inlet line to provide a dynamic pressure head proportional to fluid flow rate which is also measurable at the fluid inlet line entrance and which will add algebraically to to any elevation pressure head and/or to any pump pressure head and/or to any accumulator pressurization pressure head that may be present. Where fluid is returned to the accumulator through a plurality of inlet lines, one or more of the above devices for introducing an inlet line fluid pressure head may be applied to one or more of the inlet lines to maintain fluid pressure in substantially all portions of the fluid circuit substantially above zero. Thus, a method for minimizing fluid leaks as above comprises directing substantially all fluid flowing from the fluid circuit through a plurality of fluid inlet lines to a fluid accumulator and adjusting fluid flow resistance in at least one of the plurality of fluid inlet lines to maintain fluid pressure in substantially all portions of the fluid circuit substantially above zero. To more closely approximate physiological conditions, each fluid flow resistance may optionally be altered periodically between upper and lower limits to maintain fluid pressure in substantially all portions of the fluid circuit substantially above zero. Fluid is then pumped from the fluid accumulator into the nonlinearly compliant fluid circuit to minimize fluid leaks. Similarly, another method for minimizing fluid leaks as above comprises directing substantially all fluid flowing from the fluid circuit through a plurality of fluid inlet lines to a fluid accumulator; connecting a pump in series with at least one of the plurality of fluid inlet lines, each pump providing an adjustable pump pressure head, and adjusting each pump fluid pressure head to maintain fluid pressure in substantially all portions of the fluid circuit substantially above zero. To more closely approximate physiological conditions, each pump pressure head may optionally be altered periodically between upper and lower limits to maintain fluid pressure in substantially all portions of the fluid circuit substantially above zero. Fluid is then pumped from the fluid accumulator into the nonlinearly compliant fluid circuit to minimize fluid leaks.
Yet another method for minimizing fluid leaks as above comprises directing substantially all fluid flowing from the fluid circuit through a plurality of fluid inlet lines to a fluid accumulator; connecting a pump in series with at least one of the plurality of fluid inlet lines, each pump providing an adjustable pump pressure head; adjusting each pump fluid pressure head to maintain fluid pressure in substantially all portions of the fluid circuit substantially above zero; adjusting fluid flow resistance in at least one of the plurality of fluid inlet lines to maintain fluid pressure in substantially all portions of the fluid circuit substantially above zero; and pumping fluid from the fluid accumulator into the nonlinearly compliant fluid circuit to minimize fluid leaks. The manner in which adjustments to fluid flow resistances and pump pressure heads are made is determined empirically, recognizing that achieving fluid pressures substantially above zero in substantially all portions of the fluid circuit may preferably be accomplished primarily through adjustments to either fluid flow or pressure at each fluid inlet line entrance.
In addition to the above methods, the present invention comprises a fluid circulator for circulating fluid in a nonlinearly compliant leaky fluid circuit. The fluid circulator comprises a pump-oxygenator to pump fluid to the leaky fluid circuit; a fluid accumulator to receive fluid from the leaky fluid circuit, the fluid accumulator being connected to deliver fluid to the pump-oxygenator; at least one fluid inlet line, each fluid inlet line comprising an entrance and an exit, each fluid inlet line entrance being connectable to receive fluid from the leaky fluid circuit, and each fluid inlet line exit connected to deliver fluid to the fluid accumulator; and a fluid inlet line fluid flow restriction to restrict fluid flow in at least one fluid inlet line.
The above fluid circulator may comprise an inlet line fluid flow restriction which itself comprises a (preferably adjustable) fluid flow resistor connected in series within the fluid inlet line to add fluid flow resistance to the fluid inlet line. The fluid flow restriction may alternatively comprise a pressurization pressure head provided to the accumulator by a (preferably adjustable) pressure source for changing the pressurization pressure head at the accumulator or a (preferably adjustable) pump connected in series within the fluid inlet line to alter pump pressure head at the fluid inlet line entrance. Such a pump may comprise a centrifugal pump or a positive displacement pump (preferably a roller pump). Additionally, the fluid circulator may comprise an adjustable fluid source/drain to add fluid to the circulating volume or withdraw fluid from the circulating volume as required to maintain an effective accumulator fluid level. An effective accumulator fluid level is that which is sufficient to supply the pump-oxygenator and which does not interfere with operation of fluid inlet lines. Certain preferred embodiments may also include an accumulator height adjustment for changing the elevation pressure head.
Enhancement of the above fluid circulators with an electronic controller provides circulatory support apparatus to provide fluid circulation from the systemic venous circulation of a patient (hereinafter “venous circulation”) to the systemic arterial circulation of the patient (hereinafter “arterial circulation”). The apparatus comprises a pump-oxygenator to oxygenate fluid and pump such fluid to the arterial circulation of the patient, and a fluid accumulator to receive fluid from the venous circulation of the patient, the fluid accumulator being connected to deliver fluid to the pump-oxygenator. At least one fluid inlet line carries fluid to the accumulator, each fluid inlet line comprising an entrance and an exit. Each fluid inlet line entrance is connectable to receive fluid from the venous circulation of the patient, and each fluid inlet line exit is connected to deliver fluid to the fluid accumulator. An adjustable pressure source may be included to pressurize the fluid accumulator to provide an accumulator pressurization pressure head, and/or an accumulator height adjustment may be included to provide an elevation pressure head. An electronic controller is included to adjust the accumulator pressurization pressure head (and/or the elevation pressure head) to maintain substantial euvolemia in the patient's systemic circulation (hereinafter “circulation”) or to minimize fluid loss therefrom. With the addition of flow meters to measure output and input fluid flow, the electronic controller may use a stored program to adjust the accumulator pressurization pressure head (and/or the elevation pressure head) to minimize fluid loss from the patient's circulation by calculating estimated net change in intravascular volume through time-delayed differencing of the inlet fluid flow and the outlet fluid flow and minimizing net negative change. Analogously, the electronic controller may use a stored program to adjust the accumulator pressurization pressure head (and/or the elevation pressure head) to maintain substantial euvolemia in the patient's circulation by calculating estimated net change in intravascular volume through time-delayed differencing of the inlet fluid flow and the outlet fluid flow and minimizing net (absolute) change.
Another preferred embodiment of circulatory support apparatus to provide fluid circulation from the venous circulation of a patient to the arterial circulation of the patient comprises the following: a pump-oxygenator to pump output fluid flow to the arterial circulation of the patient; a fluid accumulator to receive input fluid flow from the venous circulation of the patient, the fluid accumulator having a fluid level and being connected to deliver fluid to the pump-oxygenator; an adjustable fluid source/drain connected to the fluid accumulator for adjusting the accumulator fluid level; at least one fluid inlet line, each fluid inlet line comprising an entrance and an exit, each fluid inlet line entrance being connectable to receive fluid from the venous circulation of the patient, and each fluid inlet line exit connected to deliver fluid to said fluid accumulator. An electronic controller adjusts the accumulator fluid level (by adding or draining fluid using an adjustable fluid source/drain) to minimize fluid loss from the patient's circulation, the electronic controller comprising a stored program to calculate estimated net change in intravascular volume as a function of rate of change of the accumulator fluid level and/or CVP and minimize net change in intravascular volume through adjustment of the fluid source/drain. Note that CVP may be estimated from fluid inlet line entrance pressure.
Yet another preferred embodiment of circulatory support apparatus to provide fluid circulation from the venous circulation of a patient to the arterial circulation of the patient comprises the following: a pump-oxygenator to pump output fluid flow to the arterial circulation of the patient; a fluid accumulator to receive input fluid flow from the venous circulation of the patient, the fluid accumulator being connected to deliver fluid to the pump-oxygenator; an accumulator height adjustment for adjusting elevation pressure head of the fluid accumulator; at least one fluid inlet line, each fluid inlet line comprising an entrance and an exit, each fluid inlet line entrance being connectable to receive fluid from the venous circulation of the patient, and each fluid inlet line exit connected to deliver fluid to the fluid accumulator. An electronic controller adjusts the accumulator elevation pressure head (for example, by raising or lowering the accumulator using a powered jack) to minimize fluid loss from the patient's circulation, the electronic controller comprising a stored program to calculate estimated net change in intravascular volume as a function of the accumulator elevation pressure head and minimize net change in intravascular volume through adjustment of the accumulator elevation pressure head.
The present invention also includes methods of performing total cardiopulmonary bypass from a patient's venous circulation to the patient's arterial circulation. One such method comprises directing substantially all blood flowing from the patient's venous circulation to a blood accumulator, maintaining blood pressure in the patient's venous circulation substantially above zero, and pumping blood from the blood accumulator via a pump-oxygenator into the patient's arterial circulation. If blood is directed from the patient's venous circulation to a blood accumulator via a fluid input line having an elevation pressure head, then the elevation pressure head is maintained (preferably adjustably about 1 cm to about 20 cm) substantially above the patient's venous circulation, the level optionally being conditioned on minimizing fluid loss from the patient's circulation into adjacent tissues in preferred embodiments. In still other preferred embodiments, the elevation pressure head may be changed as a function of time with respect to the patient's venous circulation to minimize fluid loss as above. Note that the elevation pressure head can preferably be so changed while it is maintained (preferably about 1 cm to about 20 cm) substantially above the patient's venous circulation.
Another preferred method of performing total cardiopulmonary bypass from a patient's venous circulation to the patient's arterial circulation comprises directing substantially all blood flowing from the patient's venous circulation to a blood accumulator, restricting the flow of the patient's venous blood to maintain pressure in the patient's venous circulation substantially above zero, and pumping blood from the blood accumulator through a pump-oxygenator and into the patient's arterial circulation. If blood is directed from the patient's venous circulation to a blood accumulator via a fluid input line having an elevation pressure head, then the elevation pressure head is maintained (preferably adjustably about 1 cm to about 20 cm) substantially above the patient's venous circulation. Venous blood flow is then restricted or facilitated (for example, pumped) so as to minimize fluid loss from the patient's circulation into adjacent tissues in preferred embodiments. In still other preferred embodiments, the elevation pressure head may be changed as a function of time with respect to the patient's venous circulation to control venous blood flow rate within a predetermined range. Note that the elevation pressure head can preferably be so changed while it is maintained (preferably about 1 cm to about 20 cm) substantially above the patient's central venous circulation.
In alternative embodiments of the invention of the above paragraph, venous blood flow may be restricted so as to control venous blood flow rate within a predetermined range, while the elevation pressure head is changed as a function of time with respect to the patient's venous circulation to minimize fluid loss from the patient's circulation into adjacent tissues.
Another preferred method of performing total cardiopulmonary bypass from a patient's venous circulation to the patient's arterial circulation comprises directing substantially all blood from the patient's venous circulation to a blood accumulator, maintaining substantial euvolemia in the patient's venous circulation, and pumping blood from the blood accumulator via a pump-oxygenator and into the patient's arterial circulation to perform total cardiopulmonary bypass. If blood is directed from the patient's venous circulation to a blood accumulator via a fluid inlet line having an elevation pressure head, then the elevation pressure head is maintained (preferably adjustably about 1 cm to about 20 cm) substantially above the patient's circulation while maintaining substantial euvolemia in the patient's venous circulation. In still other preferred embodiments, the elevation pressure head may be changed as a function of time with respect to the patient's venous circulation (while being maintained above the venous circulation) to maintain substantial euvolemia in the patient's venous circulation. Alternatively, the elevation pressure head may be changed as a function of time with respect to the patient's venous circulation (while being maintained either above or below the venous circulation) to control central blood flow rate and/or pressure within a predetermined range. In the latter case, the patient's central venous blood flow may be dynamically restricted (for example, by tubing flow resistance elements) so as to maintain a substantially positive (albeit adjustable) pressure in the patient's venous circulation to maintain substantial euvolemia in the patient's venous circulation. Such flow restriction may also be applied in methods where the changing step is not present.
Note also that any of the above methods may comprise an additional directing step between the directing and maintaining steps, the additional directing step comprising directing substantially all collected shed blood from the patient to the blood accumulator. Still other preferred methods may comprise a substantially equalizing step immediately following (or alternatively in place of) the additional directing step, the substantially equalizing step comprising substantially equalizing a flow rate of blood from the patient's central venous circulation to said blood accumulator with a time-delayed flow rate of blood pumped from said blood accumulator through a pump-oxygenator and into the patient's arterial circulation.
Other methods of the invention for minimizing leaks within nonlinearly compliant leaky fluid circuits comprise directing substantially all fluid flowing from the leaky fluid circuit through one or more fluid inlet lines to a fluid accumulator and pressurizing the accumulator to maintain an accumulator pressurization pressure head in the fluid flowing from the fluid circuit. Briefly increasing the accumulator pressurization pressure head to form a fluid pressure pulse applies the pulse through the fluid inlet lines to the leaky fluid circuit, after which one may detect transient fluid pressure changes in fluid flowing from the fluid circuit. The pressurization pressure head may then be adjusted to critically damp the transient fluid pressure changes, assuring that substantially all fluid pressures in the leaky fluid circuit are substantially above zero. Fluid may then be pumped from the fluid accumulator into the nonlinearly compliant fluid circuit to minimize leaks.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A schematically illustrates a fluid circulator comprising a single fluid inlet line.
FIG. 1B schematically illustrates a fluid circulator comprising a plurality of fluid inlet lines.
FIGS. 2 (A-E) schematically illustrate various configurations of fluid circuit elements providing different elevation pressure heads.
FIG. 3 schematically illustrates a fluid circulator electronic controller comprising a programmable digital computer.
DETAILED DESCRIPTION
The invention includes methods and apparatus to achieve and/or maintain predetermined fluid flow conditions in nonlinearly compliant leaky fluid circuits analogous to or comprising in part a human or animal circulatory system. Use of the present invention can alleviate a variety of problems associated with surgery requiring total cardiopulmonary bypass, including problems associated with capillary leaks and higher-than-normal capillary intravascular pressures. Depending on the nature and extent of surgery, desired intravascular flow conditions may differ significantly. For example, one might simply wish to avoid venous collapse through maintenance of a positive intravascular pressure at substantially all points of the venous system. But such positive pressure can be maintained in different ways. The present invention includes manual and electronic controllers operating on control variables (such as accumulator pressure head, fluid inlet line elevation pressure head, fluid inlet line flow resistance, fluid inlet line pump pressure head, and pump-oxygenator pressure head) in portions of a fluid circuit external to but communicating with a circulatory system to achieve desired fluid flow conditions within the circulatory system. Fluid flow parameters such as flow rates, pressures, and estimated bandwidth are optionally measured at various points within a fluid circuit during use of the present invention.
An ability to minimize relatively localized nonlinear leaks while meeting minimum flow requirements in circuits having nonuniform flow resistance makes the present invention useful in supporting a patient on total cardiopulmonary bypass. Substantial reduction of the venous portion of total peripheral circulatory resistance without over-dilation of the venous system is aided by achieving and/or maintaining effective positive pressures in an external fluid pathway (such as those schematically illustrated in FIGS. 1 A and 1 B), particularly at points where blood enters the external pathway (that is, at points where blood leaves the venous system of a patient and enters a fluid inlet line of the present invention), as well as where blood leaves the external pathway under pressure provided by the pump-oxygenator to enter a patient's arterial system. Such effective positive pressures can maintain a plurality of venous blood vessels sufficiently open to avoid significantly raising venous system blood flow resistance due to size reduction and/or collapse of the veins.
Thus, the invention comprises methods of minimizing fluid leaks in nonlinearly compliant leaky fluid circuits. One such method comprises directing substantially all fluid flowing from the fluid circuit to a fluid accumulator, as schematically illustrated in FIG. 1A where fluid enters the accumulator 70 via a single fluid inlet line 50 ′. Note that fluid inlet line 50 ′ is schematically illustrated as comprising tube 49 (having an entrance 51 and an exit 52 ) together with pressure sensor 54 for estimating fluid pressure within tube 49 proximate tube entrance 51 and flow rate sensor 53 for estimating fluid flow rate within tube 49 proximate tube entrance 51 . In other preferred embodiments of the invention, including those having a plurality of fluid inlet lines as schematically illustrated in FIG. 1B, inlet lines may also comprise one or more (preferably adjustable) fluid flow resistance elements 55 , 55 ′ and/or one or more (preferably adjustable) fluid pump elements 56 , 56 ′. Both fluid flow resistance elements and fluid pump elements may be substantially concentrated at one or more locations along a fluid inlet line, or they may be substantially distributed along a fluid inlet line. Fluid pressure in substantially all portions of the fluid circuit is then maintained substantially above zero by ensuring that pressures measured by pressure sensors 54 , 54 ′ and 57 (while maintaining adequate fluid flow rates as indicated by sensors 53 , 53 ′ and 58 ) are sufficiently high to ensure the desired substantially above-zero fluid pressures substantially throughout the fluid circuit. There follows pumping of fluid by pump-oxygenator 60 from fluid accumulator 70 into the leaky fluid circuit to minimize fluid leaks. Note that while two fluid inlet lines are schematically illustrated in FIG. 1B, additional fluid inlet lines may be added to aid in accomplishing the objective of minimizing fluid leaks by maintaining fluid pressure in substantially all portions of the fluid circuit substantially above zero.
Another method of the present invention comprises directing substantially all fluid flowing from the fluid circuit to a fluid accumulator 70 through a fluid inlet line (such as the single fluid inlet line 50 ′) having an elevation pressure head, followed by maintaining the elevation pressure head substantially above zero and pumping fluid from fluid accumulator 70 into the fluid circuit under pressure provided by pump-oxygenator 60 as indicated in FIG. 1A to minimize fluid leaks. Alternative position configurations for tube 49 , which is schematically illustrated in FIG. 1A as a straight horizontal tube, can be associated with different elevation pressure heads. Several of these alternative tube position configurations are themselves schematically illustrated in FIGS. 2 (A-E).
In FIG. 2A, the level of fluid 71 in accumulator 70 (the portion of accumulator 70 facing the reader is assumed to be transparent for purposes of illustrating the interior fluid levels and the position of exit 52 of tube 49 relative to the fluid surface) is at an elevation L above entrance 51 of tube 49 , L being substantially equal to the elevation pressure head. Note that since exit 52 of tube 49 is below the surface of fluid 71 , the distance below the surface is not relevant to determination of the elevation pressure head of the tube 49 . However, in the case schematically illustrated in FIG. 2B, exit 52 of tube 49 is above the surface of fluid 71 and thus the elevation pressure head for tube 49 is the vertical distance L measured between entrance 51 and exit 52 . In FIG. 2C, there is zero vertical distance between entrance 51 and exit 52 of tube 49 , so the elevation pressure head of tube 49 is substantially zero. In FIG. 2D, the vertical distance between entrance 51 and exit 52 is negative L and so the elevation pressure head of tube 49 is substantially negative L. The position of the surface of fluid 71 is irrelevant to the elevation pressure head in FIG. 2D since exit 52 of tube 49 is above the fluid surface. Note, however, that while elevation pressure head in FIG. 2E is also negative, it is estimated as the vertical distance L from entrance 51 of tube 49 to the surface of fluid 71 because exit 52 of tube 49 is below the fluid surface.
Adjustment of elevation pressure head in fluid accumulator 70 may be accomplished by altering accumulator fluid level as schematically illustrated in FIGS. 2 (A-E) and/or by adjusting accumulator height through accumulator height adjust 73 . Extra fluid may be added to the accumulator in addition to that flowing through the input fluid lines to raise the fluid surface and thus alter the elevation pressure head as in position configurations analogous to those schematically illustrated in FIGS. 2A and 2E. Similarly, extra fluid may be withdrawn from the accumulator in addition to that flowing through the pump-oxygenator to lower the fluid surface and thus alter the elevation pressure head as in FIGS. 2A and 2E. The physical elevation of the accumulator 70 with respect to the elevation of the entrance 51 of a (fluid inlet) tube 49 may also be altered (as by clamping the accumulator at a different height on a vertical pole with respect to a patient on an operating table). The choice of how elevation pressure head is to be altered in accumulator 70 in response to a manual or electronic command will often depend on the clinical condition of the patient and/or the physical arrangement of apparatus in an operating room. Those of skill in the art may choose from the above options or equivalents thereto to alter the accumulator elevation pressure head within the scope of the invention described herein.
Another method of minimizing fluid leaks in nonlinearly compliant leaky fluid circuits comprises directing substantially all fluid flowing from the fluid circuit through a plurality of fluid inlet lines 50 to a fluid accumulator as schematically illustrated in FIG. 1 B. Note that each fluid inlet line of the plurality is capable of carrying fluid from a different portion of a nonlinearly compliant leaky fluid circuit to a fluid accumulator 70 , and may in general comprise a different combination of the fluid inlet line elements described herein. Fluid flow resistance and/or fluid pump pressure head may be adjusted in at least one of the plurality of fluid inlet lines to maintain fluid pressure in substantially all portions of the fluid circuit substantially above zero and further may be altered periodically over time to aid in achieving the same objective in light of physiological conditions present in individual patients. Fluid from fluid accumulator 70 may then be pumped into the nonlinearly compliant fluid circuit to minimize fluid leaks.
To achieve the objectives of the invention, control variables of fluid circulators analogous to those schematically illustrated in FIGS. 1A and 1B can be manually controlled (in whole or in part) or electronically controlled (in whole or in part). Both manual and electronic control involve estimating values for fluid flow parameters (fluid pressures and/or flow rates) based on signals from fluid pressure sensors 54 , 54 ′, 57 and/or fluid flow rate sensors 53 , 53 ′, 58 . These parameter estimates are used to operate on control variables, including fluid inlet line flow resistance and fluid inlet line pump pressure head, as well as accumulator pressurization pressure head and elevation pressure head when present. Feedback pathways for control variables are preferably present to allow for closed-loop control of these variables.
Because of the complexity of control algorithms and the need for rapid adjustment of control variables in certain cases, use of an electronic controller comprising a programmable digital computer is often preferred. Such a computer is schematically illustrated in FIG. 3 and comprises a central processor unit linked by two-way communication lines to a keyboard/mouse input, a memory, a display, and an input/output unit. The input/output unit receives and processes input signals (indicated schematically in FIG. 3 by labeled arrows directed toward the unit) from the following signal sources or a subset thereof: fluid flow rate sensors 53 , 53 ′, 58 and fluid pressure sensors 54 , 54 ′, 57 , as well as feedback signals indicating the state of fluid flow resistance elements 55 , 55 ′ (fluid flow resistance), fluid pump elements 56 , 56 ′ (pump pressure head), accumulator 70 (elevation pressure head as a function of fluid level and accumulator height), accumulator 70 (fluid level), adjustable pressure source 71 (accumulator pressurization pressure head), and pump-oxygenator 60 (pump-oxygenator pump pressure head), adjustable fluid source/drain 72 (fluid added or drained), and accumulator height adjust 73 (accumulator height). Initial signal processing includes analog-to-digital signal conversion where analog input signals are present. Following this, a program stored in the computer memory generates control outputs to actuate devices corresponding to the following control variables or a subset thereof: 55 , 55 ′ (inlet line fluid flow resistance elements), 56 , 56 ′ (inlet line fluid pump elements), 71 (accumulator pressurization pressure source), 70 (fluid accumulator elevation pressure head as an accumulator-based function of fluid level and accumulator height), 60 (pump-oxygenator pump), 72 (accumulator fluid addition/drainage), and 73 (accumulator height adjustment). Control outputs are provided in digital and/or analog form according to the actuators' respective requirements.
A method of assuring through compliance measurements that fluid pressures are substantially above zero in substantially all portions of the fluid circuit during operation of a fluid circulator of the present invention is well adapted for computer control. The method comprises adjusting (that is, increasing or decreasing) one or more of the control variables elevation pressure head, pressurization pressure head, pump pressure head, and fluid flow resistance in one or more fluid inlet lines while measuring any resulting volume change in a leaky fluid circuit to which the circulator is connected (as in FIGS. 1A or 1 B). Relating such a volume change to a change in fluid inlet line entrance pressure as measured by sensors 54 , 54 ′ provides a first estimate of compliance of the leaky fluid circuit. Further adjusting the above control variables to raise the fluid inlet line entrance pressure and repeating the estimation of leaky fluid circuit compliance provides a second estimate of compliance. Repeating the above inlet line entrance pressure adjustment and compliance measurements will provide a characteristic describing change in compliance with respect to change in inlet line entrance pressure. When a portion of the leaky fluid circuit (for example, a circulatory system) is at least partially collapsed due to insufficient internal fluid pressure, the above compliance characteristic will be substantially linear as inlet line entrance pressure is slightly raised. However, when the leaky fluid circuit is substantially fully dilated due to the presence of substantially above-zero fluid pressures in substantially all portions of the fluid circuit, the above compliance characteristic will become substantially nonlinear. To avoid significant over-distention of the leaky fluid circuit, the present invention may be used to ensure that fluid inlet line entrance pressures are maintained less than or equal to values where the above compliance characteristic becomes substantially nonlinear.
In addition to the above methods, the present invention comprises a fluid circulator for circulating fluid in a nonlinearly compliant leaky fluid circuit. The fluid circulator, which may take the general form schematically illustrated in FIG. 1A or 1 B, comprises a pump-oxygenator 60 to pump fluid to the leaky fluid circuit; a fluid accumulator 70 to receive fluid from the leaky fluid circuit, the fluid accumulator being connected to deliver fluid to the pump-oxygenator 60 ; at least one fluid inlet line 50 , each fluid inlet line comprising an entrance 51 and an exit 52 , each fluid inlet line entrance 51 being connectable to receive fluid from the leaky fluid circuit, and each fluid inlet line exit 52 connected to deliver fluid to the fluid accumulator 70 ; and a fluid inlet line fluid flow restriction (for example, flow resistance due to a flow resistance element 55 and/or a pump pressure head due to a fluid inlet line pump element 56 , as described below, and/or manipulation of the elevation pressure head) to restrict fluid flow in at least one fluid inlet line.
The above fluid circulator may comprise an inlet line fluid flow restriction which itself comprises a (preferably adjustable) fluid flow resistor 55 connected in series within the fluid inlet line 50 to add fluid flow resistance to the fluid inlet line 50 . The fluid flow restriction may alternatively comprise a pressurization pressure head provided to accumulator 70 by adjustable pressure source 71 for changing pressurization pressure head at the accumulator 70 or a (preferably adjustable) pump 56 connected in series within the fluid inlet line 50 to alter pump pressure head at the fluid inlet line entrance 51 . Such a pump may comprise a centrifugal pump or a positive displacement pump (preferably a roller pump). Additionally, the fluid circulator may comprise an adjustable fluid source/drain 72 to add fluid to the circulating volume or withdraw fluid from the circulating volume as required to maintain an effective accumulator fluid level. An effective accumulator fluid level is that which is sufficient to supply the pump-oxygenator 60 and which does not interfere with operation of fluid inlet lines 50 , 50 ′. Certain preferred embodiments may also include an accumulator height adjust 73 (such as a motorized jack) for adjusting the accumulator height and thus the elevation pressure head.
Enhancement of the above fluid circulators with an electronic controller as schematically illustrated in FIG. 3 provides circulatory support apparatus to provide fluid circulation from the venous circulation of a patient to the arterial circulation of the patient. The apparatus comprises a pump-oxygenator 60 to pump fluid to the arterial circulation of the patient and a fluid accumulator 70 to receive fluid from the venous circulation of the patient, the fluid accumulator 70 being connected to deliver fluid to the pump-oxygenator 60 . At least one fluid inlet line 50 , 50 ′ carries fluid to the accumulator 70 , each fluid inlet line 50 , 50 ′ comprising an entrance 51 and an exit 52 . Each fluid inlet line entrance 51 is connectable to receive fluid from the venous circulation of the patient, and each fluid inlet line exit 52 is connected to deliver fluid to the fluid accumulator 70 . An adjustable pressure source 71 is included to pressurize the fluid accumulator to provide an accumulator pressurization pressure head, and an electronic controller (as in FIG. 3) is included to adjust the accumulator pressurization pressure head to maintain substantial euvolemia in the patient's circulation or to minimize fluid loss therefrom. With the addition of flow meters to measure output fluid flow 58 and input fluid flow 53 , 53 ′, the electronic controller may use a program stored in memory (see FIG. 3) to adjust the accumulator pressurization pressure head (by sending control outputs to adjustable pressure source 71 ) to minimize fluid loss from the patient's circulation by calculating estimated net change in intravascular volume through time-delayed differencing of the inlet fluid flow and the outlet fluid flow and minimizing net negative change. Analogously, the electronic controller of FIG. 3 may use a program stored in memory to adjust the accumulator pressurization pressure head to maintain substantial euvolemia in the patient's circulation by calculating estimated net change in intravascular volume through time-delayed differencing of the inlet fluid flow and the outlet fluid flow and minimizing net (absolute) change.
Another preferred embodiment of circulatory support apparatus to provide fluid circulation from the venous circulation of a patient to the arterial circulation of the patient comprises the following: a pump-oxygenator 60 to pump output fluid flow to the arterial circulation of the patient; a fluid accumulator 70 to receive input fluid flow from the venous circulation of the patient, the fluid accumulator 70 having a fluid level and being connected to deliver fluid to the pump-oxygenator 60 ; an adjustable fluid source/drain 72 which is connected to the fluid accumulator 70 for adjusting the accumulator fluid level; at least one fluid inlet line, each fluid inlet line comprising an entrance and an exit, each fluid inlet line entrance being connectable to receive fluid from the venous circulation of the patient, and each fluid inlet line exit connected to deliver fluid to the fluid accumulator 70 . An electronic controller (as in FIG. 3) adjusts the accumulator fluid level (by adding or draining fluid using an adjustable fluid source/drain) to minimize fluid loss from the patient's circulation, the electronic controller comprising a program stored in memory to calculate estimated net change in intravascular volume as a function of rate of change of the accumulator fluid level and minimize net change in intravascular volume through adjustment of the fluid source/drain 72 .
Yet another preferred embodiment of circulatory support apparatus to provide fluid circulation from the venous circulation of a patient to the arterial circulation of the patient comprises the following: a pump-oxygenator 60 to pump output fluid flow to the arterial circulation of the patient; a fluid accumulator 70 to receive input fluid flow from the venous circulation of the patient, the fluid accumulator 70 being connected to deliver fluid to the pump-oxygenator 60 ; an accumulator height adjust 73 for adjusting elevation pressure head of the fluid accumulator 70 ; at least one fluid inlet line 50 , 50 ′, each fluid inlet line 50 , 50 ′ comprising an entrance 51 and an exit 52 , each fluid inlet line entrance 51 being connectable to receive fluid from the venous circulation of the patient, and each fluid inlet line exit 51 connected to deliver fluid to the fluid accumulator 70 . An electronic controller (as in FIG. 3) adjusts the accumulator elevation pressure head by sending control outputs to the accumulator height adjust 73 (which acts, for example, by raising or lowering the accumulator using a powered jack) to minimize fluid loss from the patient's circulation, the electronic controller comprising a program stored in memory to calculate estimated net change in intravascular volume as a function of the accumulator elevation pressure head and minimize net change in intravascular volume through adjustment of the accumulator elevation pressure head.
The present invention also includes methods of performing total cardiopulmonary bypass from a patient's venous circulation to the patient's arterial circulation. One such method comprises directing substantially all blood flowing from the patient's venous circulation to a blood accumulator 70 , maintaining blood pressure in the patient's venous circulation substantially above zero, and pumping blood from the blood accumulator 70 via a pump-oxygenator 60 into the patient's arterial circulation. If blood is directed from the patient's venous circulation to a blood accumulator 70 via a fluid input line 50 , 50 ′ having an elevation pressure head, then the elevation pressure head is maintained (preferably adjustably, using accumulator height adjust 73 , about 1 cm to about 20 cm) substantially above the patient's venous circulation, the level optionally being conditioned on minimizing fluid loss from the patient's circulation into adjacent tissues in preferred embodiments. In still other preferred embodiments, the elevation pressure head may be changed as a function of time with respect to the patient's venous circulation to minimize fluid loss as above. Note that the elevation pressure head can preferably be so changed as noted above while it is maintained (preferably about 1 cm to about 20 cm) substantially above the patient's venous circulation.
Another preferred method of performing total cardiopulmonary bypass from a patient's venous circulation to the patient's arterial circulation comprises directing substantially all blood flowing from the patient's venous circulation to a blood accumulator 70 , restricting the flow of the patient's venous blood (using fluid inlet line fluid flow restrictions described herein or equivalents thereto) to maintain pressure in the patient's venous circulation substantially above zero, and pumping blood from the blood accumulator 70 through a pump-oxygenator 60 and into the patient's arterial circulation. If blood is directed from the patient's venous circulation to a blood accumulator 70 via a fluid input line 50 , 50 ′ having an elevation pressure head, then the elevation pressure head is maintained (preferably adjustably about 1 cm to about 20 cm) substantially above the patient's venous circulation. Venous blood flow is then restricted or facilitated (for example, pumped) so as to minimize fluid loss from the patient's circulation into adjacent tissues in preferred embodiments. In still other preferred embodiments, the elevation pressure head may be changed as a function of time with respect to the patient's venous circulation to control venous blood flow rate within a predetermined range. Note that the elevation pressure head can preferably be so changed while it is maintained (preferably about 1 cm to about 20 cm) substantially above the patient's venous circulation.
In alternative embodiments of the invention of the above paragraph, venous blood flow may be restricted so as to control venous blood flow rate within a predetermined range, while the elevation pressure head is changed as a function of time with respect to the patient's venous circulation to minimize fluid loss from the patient's circulation into adjacent tissues.
Another preferred method of performing total cardiopulmonary bypass from a patient's venous circulation to the patient's arterial circulation comprises directing substantially all blood from the patient's venous circulation to a blood accumulator 70 , maintaining substantial euvolemia in the patient's venous circulation, and pumping blood from the blood accumulator via a pump-oxygenator 60 and into the patient's arterial circulation to perform total cardiopulmonary bypass. If blood is directed from the patient's venous circulation to a blood accumulator 70 via a fluid inlet line 50 , 50 ′ having an elevation pressure head, then the elevation pressure head is maintained (preferably adjustably about 1 cm to about 20 cm) substantially above the patient's circulation while maintaining substantial euvolemia in the patient's venous circulation. In still other preferred embodiments, the elevation pressure head may be changed as a function of time with respect to the patient's venous circulation (while being maintained above the venous circulation) to maintain substantial euvolemia in the patient's venous circulation. Alternatively, the elevation pressure head may be changed as a function of time with respect to the patient's venous circulation (while being maintained either above or below the venous circulation) to control blood flow rate and/or pressure within a predetermined range. In the latter case, the patient's venous blood flow may be dynamically restricted (for example, by flow resistance elements 55 , 55 ′) so as to maintain a substantially positive (albeit adjustable) pressure in the patient's venous circulation to maintain substantial euvolemia in the patient's venous circulation. Such flow restriction may also be applied in methods where the changing step is not present.
Note also that any of the above methods may comprise an additional directing step between the directing and maintaining steps, the additional directing step comprising directing substantially all collected shed blood from the patient to the blood accumulator. Still other preferred methods may comprise a substantially equalizing step immediately following (or alternatively in place of) the additional directing step, the substantially equalizing step comprising substantially equalizing a flow rate of blood from the patient's venous circulation to said blood accumulator with a time-delayed flow rate of blood pumped from said blood accumulator through a pump-oxygenator and into the patient's arterial circulation.
Other methods of the invention for minimizing leaks within nonlinearly compliant leaky fluid circuits comprise directing substantially all fluid flowing from the leaky fluid circuit through one or more fluid inlet lines to a fluid accumulator and pressurizing the accumulator to maintain an accumulator pressurization pressure head in the fluid flowing from the fluid circuit. Briefly increasing the accumulator pressurization pressure head to form a fluid pressure pulse applies the pulse through the fluid inlet lines to the leaky fluid circuit, after which one may detect transient fluid pressure changes in fluid flowing from the fluid circuit. The pressurization pressure head may then be adjusted to critically damp the transient fluid pressure changes, assuring that substantially all fluid pressures in the leaky fluid circuit are substantially above zero. Fluid may then be pumped from the fluid accumulator into the nonlinearly compliant fluid circuit to minimize leaks.
Note that the venous system comprises a plurality of vessels, and while some may be maximally dilated due to positive venous pressure, others may be less dilated. Thus, the effectiveness of any positive pressure within the venous system (due to pressure maintained in apparatus connected thereto) in reducing or substantially eliminating high post-capillary flow resistance is preferably established empirically through clinical observations. Such observations may include estimates of fluid flow parameters such as vascular resistances and flow rates as well as pressure measurements (instantaneous and over time) and bandwidth estimates derived from harmonic analysis of circulatory system responses to fluid pressure pulses. When a fluid circulator of the present invention is connected to a patient to act as a circulatory support apparatus as above, electrical impedence measurements along portions of the circulatory system, and estimates of blood gas partial pressures may become additional useful parameters on which a circulator controller may operate.
Note also that reference to positive pressure or pressure greater than zero in this description means fluid pressure measured with respect to ambient pressure proximate the vessel at the point in question (that is, gage pressure). Using this convention, a positive intravascular pressure means a pressure tending to open a compliant vessel or to maintain the vessel in a substantially open state. Note also that fluid pressure has a static component analogous to pressure head and a dynamic component associated with fluid flow. In the absence of fluid flow, static pressures throughout a fluid circuit are substantially constant, but in the presence of fluid flow, static pressure components may be algebraically increased or decreased by dynamic pressures resulting from inertial effects of fluid flow and/or flow-associated frictional pressure losses (as in a fluid inlet line). And while instantaneous flow rate in some portions of a vascular system may be substantially zero, average flow rate over time must always be greater than zero but is, in general, not a fixed quantity. It is time-varying, multifactorial condition which depends, for example, on the metabolic needs of the particular cells in question.
Thus, fluid flow in a vascular system can not be reduced to a level inconsistent with cell survival, although the minimum perfusion over time has no fixed value. To simplify calculations, avoid cellular damage, and for a variety of other reasons, above-minimum perfusion is commonly maintained. However, fluid flow rate into the arterial portion of a circulatory system may often be decreased temporarily to reduce bleeding and thereby facilitate a surgical procedure (as, for example, by providing better visualization). Various embodiments of the controllers of the present invention are therefore configured using criteria which assure blood flow rates meeting or exceeding minimum cellular metabolic needs (including physiologically required gas exchange, provision of metabolic substrates, and removal of metabolites and/or waste products) while facilitating temporary flow adjustment to attain one or more additional objectives.
Additional objectives, which may be associated with conflicting flow condition requirements, include minimization of capillary leak rate and maintenance of a substantially euvolemic condition in a patient's circulatory system (that is, maintaining substantially normal levels of intravascular volume). Depending on factors such as a patient's position and preoperative fluid status, the cardiac history, and duration of the operation, the relative priority of maintaining euvolemia may or may not be lower than minimizing leak rate. So while minimizing leak rate to reduce postoperative complications will be a common objective, conditions such as a relatively short operative time may reduce leak rate minimization to a secondary objective. Indeed, other objectives such as detoxification or the achievement of a desired blood-borne drug delivery rate may take precedence in such cases. Controllers of the present invention provide for prioritization of objectives consistent with meeting minimum conditions dictated by physiological requirements and/or by medical judgment. | Flow in nonlinearly compliant leaky fluid circuits is controlled by alteration of control variables in fluid pathways external to the leaky circuits. In analogous practical applications, blood flow in patients undergoing total cardiopulmonary bypass is modified to limit transvascular fluid loss from the circulatory system into body tissues by altering control variables in an external fluid pathway through which venous blood from the patient passes before being oxygenated and returned under pressure to the patient's arterial system. A controller uses predetermined rules operating on control variables to achieve objectives which may include minimization of fluid leak rates and/or maintenance of euvolemic conditions in a patient's circulatory system while circulatory system flow rates are maintained at or above physiologically-established minimums. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention is directed to the stacking performance of a catch tray of a stack alignment device for stacking recording sheets on which printing has been performed by an image forming apparatus, and also directed to a sheet discharge device and an image forming apparatus that include the stack alignment device.
[0003] 2. Description of the Related Art
[0004] Such image forming apparatuses are used in a variety of ways, and as a result, are generally required to be capable of accommodating the successive use of sheets of different sizes (for example, from A3 size to A6 size). Sheets of different sizes, on which images have been formed inside an image forming apparatus, are discharged from a discharge outlet of the image forming apparatus and then stacked on a catch tray large enough to hold sheets of normal sizes.
[0005] As for such a catch tray, the best known structure is that a downwardly inclined tray is provided below the discharge outlet so as to receive sheets discharged from the image forming apparatus. According to this structure, the leading edge of a first discharged sheet is caught by a stopper provided at the lower end of the catch tray and accordingly, the sheet is placed inside the catch tray. However, it is sometimes the case that the rear edge of a sheet is positioned halfway in the tray along the longitudinal direction.
[0006] If multiple sheets are stacked in this manner, the leading edge of a subsequently discharged sheet strikes against the rear end of the stacked group of sheets having an increased thickness, or a preceding sheet is pushed out by a succeeding sheet due to surface friction. As a result, a nicely aligned stack of sheets cannot be obtained.
[Patent Document 1] Japanese Laid-open Patent Application Publication No. H09-208106 [Patent Document 2] Japanese Laid-open Patent Application Publication No. H09-086755 [Patent Document 3] Japanese Patent No. 3373656 [Patent Document 4] Japanese Laid-open Patent Application Publication No. H08-259082 [Patent Document 5] Japanese Patent No. 3744704
[0012] The present invention aims at providing a catch tray formed in a simple structure at low cost, which catch tray has a stopper made of a wire rod material or another elastic material for catching the leading edges of transfer sheets, causes no sheet jam, and allows transfer sheets of different sizes to be stacked inside.
SUMMARY OF THE INVENTION
[0013] In order to resolve the above-mentioned problems, one embodiment of the present invention may be a catch tray for stacking thereon sheets discharged from an apparatus. The catch tray includes a first sheet-stacking area disposed upstream of a sheet discharging direction and having a sloping surface extending upwardly from the upstream side to the downstream side of the sheet discharging direction; a second sheet-stacking area extending from an end of the sloping surface on the downstream side; a first regulation part disposed, within the second sheet-stacking area, on the downstream side of the sheet discharging direction, and configured to regulate edges of the discharged sheets of a largest size allowed to be stacked on the catch tray; and a second regulation part disposed in the first sheet-stacking area, and configured to regulate edges of the discharged sheets of a size smaller than the largest size and elastically deform in the sheet discharging direction when a sheet of the largest size is discharged so as to allow the first regulation part to regulate an edge of the sheet of the largest size.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a schematic diagram showing an entire structure of an image forming apparatus according to a first embodiment of the present invention;
[0015] FIG. 2 illustrates operation of a spring stopper of the first embodiment of the present invention;
[0016] FIG. 3A is an overall view of the spring stopper; FIG. 3B is an enlarged view of a rear anchor part of the spring stopper; and FIG. 3C is an enlarged view of a tip part of the spring stopper;
[0017] FIG. 4 is a diagram illustrating the second embodiment of the present invention;
[0018] FIG. 5 is a diagram illustrating the third embodiment of the present invention;
[0019] FIG. 6 is a diagram illustrating the fourth embodiment of the present invention;
[0020] FIG. 7 is a diagram illustrating the fifth embodiment of the present invention;
[0021] FIG. 8 is a diagram illustrating the sixth embodiment of the present invention; and
[0022] FIG. 9 is a diagram illustrating a modification of the sixth embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] Embodiments that describe the best mode for carrying out the present invention are explained next with reference to the drawings.
First Embodiment
[0024] FIG. 1 is a schematic diagram showing the entire structure of an image forming apparatus according to the first embodiment of the present invention. In FIG. 1 , the reference numeral 1 indicates an image forming apparatus main body. The main body 1 has an image reading device 2 on its upper side and a table-like sheet bank 3 on its underside. On the image reading device 2 , an automatic document feeder 4 is provided in an openable and closable manner.
[0025] The main body 1 includes a drum-shaped photoreceptor 10 which functions as an image carrier. Around the photoreceptor 10 , a charging device 11 (left-hand side of the photoreceptor 10 in FIG. 1 ), a developing device 12 (lower side), a transfer device 13 (right-hand side) and a cleaning device 14 (upper side) are disposed sequentially in the rotational direction A (counterclockwise direction) of the photoreceptor 10 . In the transfer device 13 , a transfer belt 17 is wound around an upper roller 15 and a lower roller 16 . The transfer belt 17 is pressed against the circumference of the photoreceptor 10 at a transferring site B.
[0026] In FIG. 1 , a toner supply device 20 for supplying new toner to the developing device 12 is provided on the left-hand side of the charging device 11 and the cleaning device 14 . Inside the main body 1 , a sheet conveying device C is provided for sending out a sheet, such as paper or an OHP sheet, from a supplying site and conveying the sheet to a stacking site via the transferring site B. The sheet conveying device C includes a supply pathway R 1 , a manual feeding supply pathway R 2 and a sheet conveying pathway R to be described below. The sheet conveying pathway R extends in a substantially L-shaped fashion, going through between the photoreceptor 10 and the transfer device 13 , extending upward and then curving toward the left-hand side of FIG. 1 .
[0027] In the sheet conveying pathway R, resist rollers 21 are provided upstream of the photoreceptor 10 , and a fixing device 22 is provided downstream of the photoreceptor 10 . The fixing device 22 includes a pair of fixing rollers (fixing roller rotation bodies). A fixing heater is provided inside a first roller of the fixing rollers. A pressurizing spring, a pressurizing arm and the like are provided around a second fixing roller. Using the pressurizing spring and pressurizing arm, the second fixing roller is pressed against the right-hand side of the first fixing roller. In addition, a thermistor and a thermostat are provided in the first fixing roller. The temperature of the paired fixing rollers is measured by the thermistor, and the fixing heater is switched on and off by the thermostat so as to maintain the fixing rollers at a predetermined temperature.
[0028] Further downstream of the fixing device 22 , a discharge branching claw 34 , a discharge roller 35 , a first pressurizing roller 36 , a second pressurizing roller 37 and a sheet deflection roller 38 are provided. Then, further on the left-hand side in FIG. 1 , a discharge stack unit (discharge site) 39 is provided for stacking sheets having images formed on their surfaces. On the front side or left-hand side (the downstream end in the discharging direction) of the main body 1 , an open section is provided so that the stacked sheets in the discharge stack unit 39 can be taken out. In order to prevent the sheets from falling out of the open section, an end stopper 30 is provided in the discharge stack unit 39 at the downstream end in the discharging direction so that sheets having a maximum length allowed to be laid in the discharge stack unit 39 hit the end stopper 30 . The end stopper 30 can be housed inside the discharge stack unit 39 , or can be rotated and raised as indicated by the arrow in FIG. 1 . A regulating member is provided so as to prevent the end stopper 30 being raised from rotating and moving in the sheet discharging direction.
[0029] In the main body 1 , a switch-back device 42 is provided on the right-hand side in FIG. 1 . The switch-back device 42 includes a sheet conveying device D having a reverse pathway R 3 and a re-conveying pathway R 4 . The reverse pathway R 3 starts from the point of branching off by the discharge branching claw 34 and extends to the switch-back site 44 provided with a pair of switch-back rollers 43 . The re-conveying pathway R 4 starts from the switch-back site 44 and extends to the resist rollers 21 of the sheet conveying pathway R. The sheet conveying device D includes multiple sheet conveying rollers 66 (sheet conveying rotation bodies) for conveying sheets.
[0030] On the left-hand side of the developing device 12 in FIG. 1 , a laser writing device 47 is provided. The laser writing device 47 includes a laser light source (not shown), a scanning rotating polygon mirror 48 , a polygon motor 49 , a scanning optical system 50 , such as an θe lens, and the like. The image reading device 2 includes a light source 53 , multiple mirrors 54 , an optical lens for image formation 55 , an image sensor 56 , such as a CCD, and the like. In addition, a contact glass 57 is provided on the top surface of the image reading device.
[0031] The automatic document feeder 4 disposed on the contact glass 57 includes a loading stage (not shown) at a location for loading originals and a discharge stage (not shown) at a discharging location. The automatic document feeder 4 also includes a sheet conveying device having an original conveying pathway (not shown) in which sheets, e.g. originals, are conveyed from the loading stage to a reading site on the contact glass 57 of the image reading device 2 , and subsequently to the discharge stage. The sheet conveying device includes multiple sheet conveying rollers (sheet conveying rotation bodies) (not shown) for conveying sheets, e.g. originals.
[0032] The sheet bank 3 includes multi-tier sheet cassettes 61 which are a supplying site of sheets S. Each sheet cassette 61 includes a fetch roller 62 (feeding roller), a supply roller 63 (feeding roller) and a separating roller 64 (feeding roller). On the right-hand side of the multi-tier sheet cassettes 61 in FIG. 1 , the supply pathway R 1 connected to the sheet conveying pathway R of the main body 1 is formed. The supply pathway R 1 includes the sheet conveying rollers 66 (sheet conveying rotation bodies) for conveying sheets.
[0033] The main body 1 includes a manual feeding supply unit 68 on the right-hand side in FIG. 1 . In the manual supply unit 68 , a manual feeding tray 67 (supply site) is provided openably and closably. The manual supply unit 68 also includes the manual feeding supply pathway R 2 for conveying manual sheets set on the manual feeding tray 67 to the sheet conveying pathway R. Like the sheet cassettes 61 , the manual feeding tray 67 also includes the fetch roller 62 (feeding roller), the supply roller 63 (feeding roller) and the separating roller 64 (feeding roller).
[0034] In order to make a copy using a copying function, a main switch (not shown) is switched on, and an original is set on the automatic document feeder 4 . Alternatively, the automatic document feeder 4 is lifted, and the original is set on the contact glass 57 of the image reading device 2 . Then, the automatic document feeder 4 is closed, thereby holding the original in place.
[0035] In the case of setting the original on the automatic document feeder 4 , when a start switch (not shown) is pressed, the original is transported, through the original conveying pathway by the sheet conveying rollers, onto the contact glass 57 . Subsequently, the image reading device 2 is driven to read the original, which is then discharged to the discharge stage. On the other hand, in the case of setting the original directly on the contact glass 57 , the image reading device 2 is immediately driven.
[0036] When driven, the image reading device 2 moves the light source 53 along the contact glass 57 . At the same time, light emitted from the light source 53 is reflected on the surface of the original on the contact glass 57 . The reflected light is then reflected into the image sensor 56 by the multiple mirrors 54 via the image-formation optical lens 55 , and the image sensor 56 reads the original.
[0037] Simultaneously, the photoreceptor 10 is rotated by a photoreceptor drive motor (not shown) During the rotation, the photoreceptor is uniformly charged by the charging device 11 . Then, the laser writing device 47 emits laser light corresponding to an image of the original read by the image reading device 2 to form a latent image on the surface of the photoreceptor 10 . The developing device 12 subsequently develops the latent image into a visible image using toner.
[0038] At the same time when the start switch is pressed, the sheets S are sequentially sent out by the fetch roller 62 from an appropriate sheet cassette 61 of the multi-tier sheet cassettes 61 in the sheet bank 3 . The sheets S are conveyed by the supply roller 63 while separated from one another by the separating roller 64 , and sent one by one to the supply pathway R 1 . Each sheet S is conveyed by the sheet conveying rollers to the sheet conveying pathway R, and then stopped when hitting the resist rollers 21 . Subsequently, the resist rollers 21 rotate at a timing according to the rotation of the visible image on the photoreceptor 10 , so as to send the sheet S to the right-hand side of the photoreceptor 10 .
[0039] Alternatively, the manual feeding tray 67 of the manual feeding supply unit 68 is unfolded, and sheets set in the manual feeding tray 67 are sent out by the fetch roller 62 . The sheets are conveyed by the supply roller 63 while separated from one another by the separating roller 64 , and sent one by one to the manual feeding supply pathway R 2 . Each sheet is conveyed by the sheet conveying rollers 66 to the sheet conveying pathway R. Then, the resist rollers 21 rotates at a timing according to the rotation of the photoreceptor 10 , so as to send the sheet to the right-hand side of the photoreceptor 10 .
[0040] Next, the transfer device 13 having the transfer belt 17 transfers the image on the photoreceptor 10 at the transferring site B to a sheet S sent to the right-hand side of the photoreceptor 10 , thereby forming an image on the sheet S. Remaining toner not transferred and left on the photoreceptor 10 is removed and cleaned by the cleaning device 14 . Then, a remaining potential on the photoreceptor 10 is removed by a neutralization device (not shown) to make the photoreceptor 10 ready for the next image formation starting again at the charging device 11 .
[0041] On the other hand, the sheet S to which an image has been transferred is conveyed by the transfer belt 17 , and passed through between paired fixing rollers 24 a and 24 b of the fixing device 22 , which apply heat and pressure to fix the transferred image onto the sheet S. Subsequently, the sheet S is then deflected by the discharge roller 35 , first pressurizing roller 36 , second pressurizing roller 37 and sheet deflection roller 38 , and ejected to the discharge stack unit 39 .
[0042] In the case where images are transferred to both sides of the sheet, the discharge branching claw 34 is switched. A sheet to one side of which an image has been transferred is introduced from the sheet conveying pathway R to the reverse pathway R 3 . The sheet is conveyed by the sheet conveying rollers 66 to the switch-back site 44 , at which the sheet is switched back and reversed in the re-conveying pathway R 4 . The sheet is then conveyed by the sheet conveying roller 66 to the sheet conveying pathway R, and an image is then transferred to the other side of the sheet in the same manner as described above.
[0043] FIG. 2 illustrates a spring stopper 200 according to the present embodiment. The spring stopper 200 is provided in such a manner that one end of the spring stopper 200 is secured in a depression 100 on the slope of the discharge stack unit 39 and the other end, formed as a free end, protrudes from the sheet stacking surface of the discharge stack unit 39 . FIG. 2 shows that the leading edges of the sheets S of A 4 size discharged sideways by the discharge roller 35 , first pressurizing roller 36 , second pressurizing roller 37 and sheet deflection roller 38 are blocked by the spring stopper 200 attached to the discharge stack unit 39 serving as a catch tray. In this way, the stack alignment of the sheets is improved (“S” in FIG. 2 indicates multiple stacked sheets).
[0044] That is, even if a preceding sheet is pushed out by a succeeding sheet due to surface friction of these sheets, the pushed-out preceding sheet is bounced back toward the upstream side of the sheet discharging direction due to the elasticity of the spring stopper 200 . Thus, since a pushed-out sheet is returned to the upstream side of the sheet discharging direction along the sloping surface of the discharge stack unit 39 in such a manner, no sheets are positioned halfway in the discharge stack unit 39 . As a result, a nicely aligned stack of sheets can be obtained. In order to prevent the stopping force of the spring stopper 200 from being overwhelmed by the sheet conveyance force, the diameter of the wire rod of the spring stopper 200 is preferably Φ0.1 mm to Φ1.0 mm. In an example of FIG. 2 , the diameter of the wire rod is Φ0.6 mm. Since being provided for improving the stack alignment of the sheets S, the spring stopper 200 is positioned in the downstream side of a point in the discharge stack unit 39 , the point of which is located a sheet length away from paired discharging rollers 201 . In addition, since being made of a wire rod material, the spring stopper 200 is capable of improving the stack alignment of the sheets S without damaging the leading edges of the sheets S, thereby improving the discharge stack performance. Furthermore, even if the user catches his/her hand on the spring stopper 200 when he/she picks up the sheets S from the catch tray or the discharge stack unit 39 , the spring stopper 200 made of a wire rod material freely bends, thereby ensuring safety.
[0045] FIG. 3A is an overall view of the spring stopper 200 ; FIG. 3B is an enlarged view of a rear anchor part of the spring stopper 200 ; and FIG. 3C is an enlarged view of a tip part of the spring stopper 200 . In the wire-rod rear anchor part to be attached to the discharge stack unit 39 , a mounting coil portion 202 is formed by winding the wire rod several turns into a coil spring, as shown in FIGS. 3A and 3B . Of the wire rod which functions as a stopper part, the tip part includes a tight loop portion 203 . By providing the coil spring (mounting coil portion 202 ), it is possible to readily adjust the stopping force of the spring stopper 200 . Also, by making the tip part round by looping the wire rod, it is possible to prevent the user from getting hurt when he/she picks up sheets from the discharge stack unit 39 . Furthermore, since the loop is tightly formed, it is possible to prevent several springs from getting tangled with one another during parts assembly and the like, thereby improving the assembly performance.
Second Embodiment
[0046] Next is described the second embodiment of the present invention with reference to FIG. 4 . According to the present embodiment, two spring stoppers 200 are provided substantially parallel to the main scanning direction of the sheet S (substantially perpendicular to the sheet surface in FIG. 4 ). Note that, since FIG. 4 shows a view seen from a direction along the main scanning direction, it appears that only one spring stopper 200 is provided. The length of the stopper part of each spring stopper 200 is preferably 5 mm to 100 mm (appropriate length may be determined in such a manner as to accommodate sheets of various different sizes and improve the stack alignment of the sheets). Each spring stopper 200 is inclined at an angle between 45° and 90° in the reverse direction of the sheets S being discharged. By inclining the spring stoppers 200 , the sheets S can be stacked along the slope of the upper surface of the discharge stack unit 39 , thereby improving the discharge stack performance. Note that, in the example of FIG. 4 , an inclination angle e of each spring stopper 200 is 75° in the reverse direction of the sheets S being discharged, and a length of the stopper part k is 55 mm. Using this structure of FIG. 4 in an experiment associated with the present invention, it was found possible to significantly improve the stack alignment when 500 sheets were stacked together. That is to say, by providing multiple spring stoppers 200 parallel to a direction substantially perpendicular to the sheet conveying direction, it is possible to prevent the spring stoppers 200 from moving and rotating when a sheet S hits the spring stoppers 200 . Furthermore, even a sheet S discharged in a skewed manner can be aligned properly, thus improving the discharge stack performance and further improving the stack alignment of sheets.
Third Embodiment
[0047] FIG. 5 illustrates the third embodiment of the present invention. The present embodiment shown in FIG. 5 relates to the installation of the spring stoppers 200 . Boss sections 39 a for fixing the fitting coil portions 202 are formed in the depression 100 of the discharge stack unit 39 , and the fitting coil portions 202 are fitted on the boss sections 39 a so that the boss sections 39 a engage the coil windings of the fitting coil portions 202 . According to this structure, the number of required parts can be reduced, which results in a reduction in the cost. That is to say, the number of parts is reduced by integrally forming the boss sections 39 a, to which the spring stoppers 200 are attached, with the discharge stack unit 39 functioning as a catch tray. Stopper catch portions 210 are also provided in the depression 100 of the discharge stack unit 39 , and the spring stoppers 200 can be put away by catching the spring stoppers 200 with the stopper catch portions 210 . Each stopper catch portion 210 has a substantially L-shaped configuration so as to catch the spring stopper 200 on the lower face, thereby preventing the spring stopper 200 from rising back. In addition, the stopper catch portions 210 are provided in such a manner as not to stick up from the upper surface of the discharge stack unit 39 .
[0048] According to such a structure, the spring stoppers 200 can be bent in the sheet discharging direction and put away in the depression 100 when not used. Note that the parts to which the spring stoppers 200 are attached do not have to be integrally provided, and they may be provided by separate parts. This allows the boss sections 39 a to be changed (for example, when maintenance is performed, or in the case where it is desired to select the boss section 39 a having a diameter in accordance with the diameter of the coil portion 202 ).
Fourth Embodiment
[0049] FIG. 6 illustrates the fourth embodiment of the present invention. According to the present embodiment shown in FIG. 6 , a part of the elastic spring stopper 200 which is fixed to the discharge stack unit 39 is an elastic snap-fitting portion 204 formed by extending the end portion of the mounting coil portion 202 . On the discharge stack unit 39 , slits 205 and 206 are provided at positions corresponding to sheet sizes. An indication representing a sheet size is provided near each slit 205 and 206 . The spring stopper 200 is installed by inserting the snap-fitting portion 204 into the slit 205 / 206 . In the example shown in FIG. 6 , the slits 205 and 206 are provided at positions corresponding to A4 size and B4 size, respectively.
[0050] Herewith, by changing the position of the spring stopper 200 in accordance with a sheet size, it is possible to further improve the stack alignment. In addition, the user is able to readily identify the location for installing the spring stopper 200 since the sheet size is clearly indicated near each slit.
Fifth Embodiment
[0051] Next is described the fifth embodiment of the present invention with reference to FIG. 7 . The spring stopper 200 of the present embodiment has a structure in which two of the above-mentioned string stoppers 200 are integrated, and a coupling portion 207 in the shape of, for example, a semi-rectangle is provided by extending the fitting coil portions 202 on the rear anchor side. The spring stopper 200 of the present embodiment is formed of a single wire rod. On the lateral faces of the depression 100 of the discharge stack unit 39 , boss sections 208 and 209 are provided to which the fitting coil portions 202 are attached. In addition, the stopper catch portions 210 (only one of them is shown in FIG. 7 ) are also provided on the lateral faces so as to catch arm portions of the spring stopper 200 . Note that, as in the case of the fourth embodiment, indications corresponding to sheet sizes (“A4” and “B4” in this example) are provided near the boss sections 208 and 209 .
[0052] According to the spring stopper 200 of the present embodiment, like the spring stopper 200 of the second embodiment of FIG. 4 , the two arms of the spring stopper 200 stands up substantially parallel to the main scanning direction of the sheet S when used for the stack alignment. When the spring stopper 200 is not used, the tip portions are pushed down by rotating the spring stopper 200 around the boss sections 208 and 209 , and put away by catching the arm portions of the spring stopper 200 with the stopper catch portions 210 (indicated by the broken line in FIG. 7 ). That is, since the spring stopper 200 is made of an elastic wire rod material, coils and loops (fitting coil portions 202 and tight loop portions 203 ) can be formed by simply bending and winding the tips of the wire rod. In addition, the coil portions allows the spring stopper 200 to be used on multiple bosses (boss sections 208 and 209 ) of the catch tray (discharge stack unit 39 ) by simply detaching the spring stopper 200 from one paired boss sections and attaching it to another. Thus, a single spring stopper 200 can deal with sheets of different sizes. Furthermore, since the spring stopper 200 made of a wire rod material is elastic, it is possible to deal with sheets of non-standard sizes by engaging the arm portions of the spring stopper 200 with the engaging portion (stopper catch portions 210 ) so that the spring stopper 200 is hidden below the sheet stacking surface of the discharge stack unit 39 . This structure also allows the spring stopper 200 to accommodate the situation where the use of the spring stopper 200 is not desired, for example, when sheets of various sizes are stacked together on the discharge stack unit 39 .
[0053] In the present embodiment, if the spring stopper 200 has been set for, for example, A4 landscape, the spring stopper needs to be removed or changed to a different position in order to discharge sheets whose length is greater than that of A4 landscape (e.g. B4). Note, however, that since A4 sheets in landscape orientation are used very often, it is preferable that the spring stopper 200 be usually set to a position corresponding to A4 landscape, and the position of the spring stopper 200 be changed in the case of using sheets whose length is greater than that of A4 landscape. Thus, the spring stopper 200 of the present embodiment, which is formed by integrating multiple sheet contact units (spring stoppers), has a structure allowing easy attachment and detachment and achieving good stack alignment performance.
Sixth Embodiment
[0054] Next is described the sixth embodiment of the present invention with reference to FIGS. 8A and 8B . The present embodiment allows the stacking of sheets of different sizes by combining the spring stopper 200 and the end stopper 30 described in the first through fifth embodiments. Since the structure of the spring stopper 200 according to the present embodiment adopts those of the spring stoppers 200 described in the first through fifth embodiments, the description is omitted to avoid repetition.
[0055] FIG. 8A illustrates A4 sheets S being stacked, and FIG. 8B illustrates sheets S′ of larger size (e.g. A3) being stacked over the A4 sheets S. In the case of A4 size, each sheet S after discharge directly slides down on the sloping surface provided in the discharge stack unit 39 on the upstream side, or hits the spring stopper 200 and then slides down on the sloping surface. Herewith, the edges of the sheets S are aligned. The spring stopper 200 is provided in such a manner that, even if a sheet S hits the spring stopper 200 , the sheet S does not go over the spring stopper 200 and reach downstream of the discharging direction.
[0056] In the case of A3 size, when the leading edge (in the discharging direction) of a sheet S′ hits the spring stopper 200 , the elastic spring stopper 200 is overwhelmed by the conveyance force of the sheet S′ and brought down in the discharging direction, as shown in FIG. 8B . Accordingly, the sheet S′ passes over the bent spring stopper 200 and are then laid on the discharge stack unit 39 .
[0057] In the present embodiment, the diameter of the wire rod of the spring stopper 200 , the inclination angle e and the elasticity of the spring stoppers 200 are designed such that the spring stoppers 200 are able to withstand the hitting impact of each A4 sheet S and align the sheets S while allowing A3 sheets S′ to pass overhead and be then laid on the discharge stack unit 39 .
[0058] Specifically, the spring stopper 200 is installed in such a manner that the boss section 39 a of FIG. 5 does not fully pass through the mounting coil portion 202 . More preferably, the spring stopper 200 is fit onto the boss section 39 a only at the lower part of the coil portion 202 . At this point, by changing the fitting amount of the coil portion 202 onto the boss section 39 a, it is possible to adjust the degree of elastic deformation of the spring stopper 200 when hit by a sheet S′. According to this structure, when a sheet S′ hits the spring stopper 200 , the upper part of the spring stopper 200 , which includes a part of the coil portion 202 not engaged with the boss section 39 a, elastically bends toward the downstream side of the discharging direction, as shown in FIG. 8B . While in the first embodiment, the inclination angle e of the spring stopper 200 is 75° in the reverse direction of the discharge of the sheets S, the inclination angle θ in the present embodiment is 135° in the reverse direction of the discharge of the sheets S so that the spring stopper 200 is readily brought down by the conveyance force of a sheet S′. Furthermore, the diameter of the wire rod of the spring stopper 200 is determined in such a manner that the spring stopper 200 is brought down by the hitting impact of a sheet S′ but not brought down by the hitting impact of a sheet S. According to this structure, it is possible to deal with sheets of different sizes without removing the spring stopper 200 .
[0059] Note that the spring stopper 200 of FIG. 6 or FIG. 7 may be used instead in the present embodiment. In this case, the direction in which the spring stopper 200 is brought down in relation to the winding direction of the coil portion 202 is different from that in the first embodiment. Therefore, the spring stopper 200 of FIG. 6 or FIG. 7 should be installed with consideration of the inclination angle θ, the diameter of the wire rod and the like according to the elasticity. Herewith, it is possible to achieve the same effects as described above.
[0060] The spring stopper 200 may be made of an elastic material other than a wire rod. For example, FIG. 9 illustrates a plate-shaped elastic sheet 200 ′ made of Mylar (registered trademark), for example. For purposes of facilitating the description, FIG. 9 illustrates the elastic sheet 200 ′ provided only on the right-hand boss section 39 a, as in the case of FIG. 5 ; however, the elastic sheet 200 ′ is also provided on the left-hand boss section 39 a in the same manner. Each elastic sheet 200 ′ is inserted into a slit 39 b on the boss section 39 a. The thickness, the angle and the length (vertical direction in FIG. 9 ) of the elastic sheets 200 ′ are designed such that the spring stoppers 200 ′ are able to withstand the hitting impact of each A4 sheet S and align the sheets S while allowing A3 sheets S′ to pass overhead and be then laid on the discharge stack unit 39 . The slit 39 b is provided in the direction perpendicular to the sheet discharge direction and extends to the bottom of the boss section 39 a. Accordingly, each elastic sheet 200 ′ is simply shaped into a rectangle and does not have to be shaped to conform to the shape of the slit 39 b, thus allowing a simple structure. According to this structure, when a sheet S′hits the elastic sheets 200 ′, the elastic sheets 200 ′ elastically bend (are brought down) toward the downstream side of the discharging direction and allows the sheet S′ to pass overhead and be then laid on the discharge stack unit 39 . Hence, it is possible to deal with sheets of different sizes without removing the spring stoppers 200 . Note that as in FIGS. 5 and 7 , the elastic sheets 200 ′ can be put away inside the depression 100 by bringing down the elastic sheets 200 ′ toward the downstream side of the discharging direction and catching the elastic sheets 200 ′ on the lower faces of the stopper catch portions 210 .
[0061] Note that the above-described embodiments can be applied to catch trays of not only image forming apparatuses but also post-processing apparatuses having a punching function or a stapling function. Also, the members of the depression 100 (i.e. the boss sections 39 a, boss sections 208 and 209 , and stopper catch portions 210 ) may be unitized as a single assembly discrete from the catch tray so as to be detachable from the catch tray. According to this structure, the unitized assembly can be provided only for users seeking sheet size convertibility or requiring the stacking performance for sheets of different sizes.
[0062] As has been described above, according to a stack alignment device of an embodiment of the present invention, even if a preceding sheet is pushed out by a succeeding sheet sue to surface friction of these sheets, the preceding sheet is pushed back upstream in the sheet discharging direction by the elasticity of the stopper member. Hence, using such a simple and low-cost structure, it is possible to align a stack of sheets in the catch tray without a jam.
[0063] This application is based on Japanese Patent Applications No. 2008-031067 filed on Feb. 12, 2008 and No. 2008-260297 filed on Oct. 7, 2008, the contents of which are hereby incorporated herein by reference. | A disclosed catch tray for stacking thereon sheets discharged from an apparatus includes a first sheet-stacking area disposed upstream of a sheet discharging direction and having a sloping surface extending upwardly from an upstream side to a downstream side of the sheet discharging direction; a second sheet-stacking area extending from an end of the sloping surface on the downstream side; a first regulation part disposed, within the second sheet-stacking area, on the downstream side of the sheet discharging direction, and configured to regulate edges of the discharged sheets of a largest size allowed to be stacked on the catch tray; and a second regulation part disposed in the first sheet-stacking area, and configured to regulate edges of the discharged sheets of a size smaller than the largest size and elastically deform in the sheet discharging direction when a sheet of the largest size is discharged so as to allow the first regulation part to regulate an edge of the sheet of the largest size. | 1 |
1. TECHNICAL FIELD
This invention relates to a specialized mat used as a ground engaging platform for supporting heavy equipment, or to a mat used as a road surface for supporting vehicular traffic. Both uses are intended to be temporary, with the mats being reusable.
2. BACKGROUND DISCUSSION
Mats are used as a platform and/or as a road surface. Mat configurations vary in size and shape. Some mats are discrete units, which when assembled form the platform and/or the road surface. The most common configuration comprises a series of logs attached laterally by cables, bar stock or ropes. FIG. 1 shows such a configuration. The logs 1 are connected by cables, bar stock or ropes 2. A transport cable or rope 3 is provided for positioning the assembled logs.
The discrete unit configuration is popular as it is readily adaptable to many situations. Terrain and work conditions may vary widely [i.e., mud versus rocks and/or soft soil, hills, valleys, short versus long traverses with various widths in the platform or road, etc . . . ]. Therefore, the discrete unit configuration is more adaptable than other configurations, such as the surfacing or the track-way system described in U.S. Pat. No. 4,488,833 issued to Perry, et al., showing a plurality of rectangular planks joined to each other by hinge members so that the system may be stored by folding the planks in an accordion fashion. The discrete unit configuration has an individual, modular-like capability, making it more versatile and more easily changeable to meet the many unique terrain and surface conditions.
In the past, the most desirable material used for constructing discrete unit configuration mats has been wood since it is readily available and is easy to work with. Other materials have been introduced, but, these are more difficult to handle when forming the desired configuration. Durability is also an important consideration. With mats made of wood, the problem of durability becomes especially acute because over time the wood is subject to deterioration due to weather and other environmental conditions. This adverse effect can be somewhat mitigated by specially treating the wood. However, this adds considerably to the cost of fabricating the mats. Additionally, the mats are easily cracked and gouged by the steel tracks of the equipment using them.
Since these mats are often somewhat large in dimension [some averaging up to 40 feet by 10 feet], heavy lifting and moving equipment is typically necessary to transport and then arrange the mat at the site where it is to be used. Also, since construction of the mat at the site where it is to be used is practically impossible, transporting the mat to the site is a factor which must be addressed.
Prior discrete mat inventions require manual labor to some extent when they are being moved and arranged. Typically, workers must physically attach a cable or other pulling mechanism from the mat to the moving equipment, creating an unsafe working condition. The attached cable may break causing a lifted mat to fall, damaging or possibly destroying the mat and anything in its path.
It would be desirable, therefore, to have a mat which possesses a number of capabilities, one of which is that each mat should be readily transportable in a safe manner from the fabrication site to the use site, and then easily and safely arranged in assembly with other mats to form the completed platform and/or road surface. Also, the mat must be made of durable material, capable of withstanding the heavy loads required by its use as a platform and/or road surface. It should also be capable of being made of material which is not significantly impacted by environmental conditions and is relatively inexpensive to fabricate.
SUMMARY OF THE INVENTION
An object of the invention is to provide the existing state-of-the-art with a mat which satisfies the desired capabilities noted above.
The mat need be nothing more than a plate-like structure having a planar extent and a thickness, the thickness being less than the planar extent. The mat in this invention further comprising an opening defined in the thickness direction. The opening is dimensioned so that it can receive a lifting device, such as the front end of an excavator bucket. With this invention, the operator of the excavator can use the excavator bucket to safely, easily and efficiently move and arrange each mat at the work site without direct manual intervention.
The mat can be constructed to include elongated beam members and a top plate connected to the beam members. An opening is defined through the top plate and traverses through the beam members. The opening serves to receive a lifting device, such as the bucket of an excavator, for lifting, transporting and placing the mat safely and efficiently at the use site.
The mat may also include stiffener members which extend transversely of the beam members, a channel member at each longitudinal end of the beam members, and a bottom plate with an opening being registerably aligned with the opening in the top plate so that an excavator bucket may pass therethrough. The top plate may include a non-skid diamond pattern over substantially its entire planar extent. The top plate may also include anti-skid cleats and lateral skid retaining bars extending over part of the planar extent with, or without, the non-skid diamond pattern.
BRIEF DESCRIPTION OF THE DRAWINGS
Six figures have been selected to illustrate the present invention. It is believed that those skilled in the art when considering these figures and the ensuing description will be sufficiently advised to practice the invention.
FIG. 1 illustrates an example of a known mat made from wood logs;
FIG. 2 illustrates a mat according to the present invention being positioned in assembly with other mats by an excavator widely used in the construction industry;
FIG. 3 is a perspective view of the mat according to the present invention;
FIG. 4 is a plan view of the mat showing the beam, stiffener and channel members according to the present invention;
FIG. 5 is a cross-sectional enlarged view of the mat in FIG. 3 taken along line 5--5 of FIG. 3; and
FIG. 6 is a partial isometric view of a corner of the mat according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Generally
The mat according to the present invention is preferably constructed of durable material such as aluminum or steel. The construction essentially comprises a square or rectangular shape having a series of intersecting beam members forming a rigid frame structure and a top plate having an upper surface. The top plate and frame structure also define an opening which is dimensioned to receive the front end of an excavator bucket as shown in FIG. 2. A bucket of similar construction equipment such as a backhoe or front-end loader may also be used.
In addition, the mat may be provided with components which are removable and which would be useful as an alternative when lifting or hoisting the mat onto, for example, a flatbed truck for transport.
Specifically
Referring to FIGS. 2-6, a specific preferred embodiment is illustrated. A mat 10 is shown having the construction illustrated in FIGS. 3-6. FIG. 2 shows a piece of heavy equipment, an excavator 50 with a bucket 5 including a front end 6 with teeth 7. In FIG. 2, a platform is shown, or the beginning of a road surface on which the excavator 50 is supported. The excavator 50 is shown as lifting and balancing the mat 10 with its bucket 5. Note that the front end 6 of the bucket 5 extends through an opening 18 defined substantially in the center of the mat 10. The excavator 50 has lifted the mat 10 from a storage area (not shown) and is transporting it to arrange it into assembly with already assembled mats 10', 10" and 10'". The mat being transported will form mat 10 iv of the assembly.
The mat 10 has a discrete structural unit as shown in FIGS. 3-6. Turning first to FIG. 4, there is shown the mat 10 which comprises a plurality of longitudinally extending beam members 12, transversely extending channel members 14 and transversely extending stiffener members 16. The channel members 14 receive the longitudinal ends of the beam members 12, as best seen in FIGS. 4 and 6. The stiffener members 16 are formed into parallel rolls as shown in FIG. 4, and extend between adjacent beam members 12. Of course it is not necessary that each roll of stiffener members 16 be continuous. The determining factor being the material used, the size of the members being used and the use to be made of the mat. For example, if it is intended for heavy track equipment, such as track drilling equipment, excavators or loaders, the configuration shown in FIG. 4 might be desirable. On the other hand, if the equipment is not as large or if the mat is intended for use on a road surface for handling the movement of small vehicles, then the number of stiffener members 16 can be reduced. In fact, this also applies to the number of beam members 12.
Viewing FIG. 5, the mat 10 is preferably provided with a top plate 22 mounted on one side of the beam members 12. In the preferred embodiment, a bottom plate 24 is mounted on the opposite side of beam members 12, as shown. Opening 18 is formed in the mat 10 in the thickness direction, supported by lateral and longitudinal frame members 34 and 35, respectively, along with one of the beam members as shown in FIGS. 4 and 5. It is only necessary to dimension the size of the opening 18 so that it can receive the front end 6 of an excavator bucket 5, or any equivalent equipment bucket that could be used for lifting and moving the mat 10 as shown in FIG. 2. Opening 18 must be large enough to receive the bucket 5 of the excavator 50 so that the teeth 7 of the bucket 5 can firmly engage the bottom plate 24, or the underside of mat 10 if a bottom plate is not used.
The top plate 22 has, preferably, a non-skid diamond pattern 32 formed in the upper surface of the top plate or applied to the upper surface of the top plate as seen in FIGS. 3 and 6. In addition, one or more rolls of anti-skid cleats 30 and lateral skid retaining bars 28 may be provided on the non-skid diamond pattern 32. The non-skid features of the present invention are intended to improve traction and ensure safety when using the mat 10, especially with vehicles or equipment having a track.
An eye-bolt 26 may be provided at each of the four corners as shown in FIG. 3, or any other location along the frame. The eye-bolts 26 are removably secured to the mat 10 at treaded holes 27, best shown in FIG. 6. These eye-bolts 26 can be used for hoisting the mat 10 onto, for example, a flatbed truck for transporting the mat 10 from the fabrication or storage site to the use site. They can also be used to remove the mats 10 from the transporting vehicle at the use site and even to place the mats 10 in assembly if other lifting equipment, such as an excavator, is not available.
The beam members 12, as well as the stiffener members 16 can be box-shaped, as shown in FIGS. 5 and 6. Of course, any desired shape is possible.
The beam members 12, stiffener members 16, channel members 14, bottom plate 24 and top plate 22 can be fabricated of wood or preferably some metal, such as aluminum or steel, or even plastic. In the case of wood or plastic, the individual members can be assembled into a discrete unit by using screws or an adhesive. In the case of metal, the assembly can be achieved by, for example, welding.
A single plate is shown in the figures to form the top plate 22 and a single plate may be used to form the bottom plate 24, However, a plurality of plates can be assembled and welded together to form the top plate 22, as well as the bottom plate 24 in a similar manner. The only requirement is that the opening 18 be formed essentially as shown, either through one or more of the plurality of plates forming the top plate 22 and bottom plate 24.
The mat 10, according to the present invention, when constructed is very adaptable for use alone or in assembly with other mats. The assembled mats can be any size to accommodate light or heavy equipment, or to form a road surface. As discussed herein, some advantages of the mats according to the present invention are that they are reusable, reversible, easily and more safely transportable at the work site, safer and more efficient to lift and place and have the structural strength to support and absorb significant loads. | A mat is used as a ground engagement platform for supporting heavy equipment or as a road surface for supporting vehicular traffic. The use is intended to be temporary, with the mats being reusable. The mat, in its basic construction, includes a flat plate-like structure having a thickness and planar extent and an opening defined in the flat plate-like structure which extends in the thickness direction and is dimensioned to receive a lifting device for lifting and transporting the mat. | 4 |
This application is a continuation of Ser. No. 07/024,508 filed on Mar. 11, 1987 now abandoned.
This invention relates to carbon fiber in the form of filamentary tows comprising a multitude of continuous filaments and, more particularly, carbon fiber made from polyacrylonitrile (PAN) precursor and suitable for use in making composites. This invention, even still more particularly, relates to such a carbon fiber having a novel combination of advantageous physical properties.
Carbon fiber is a well known material that enables manufacture of very strong, lightweight composites comprising the fiber and a resinous or carbonized matrix. Carbon fiber, also known as graphite fiber, as used herein refers to filamentary materials having at least about 93% by weight carbon and in the form of filamentary tows having a multitude of individual filaments. The particular carbon fiber to which this invention relates has greater than 96% by weight carbon.
The mechanical properties of carbon fiber (e.g. modulus, tensile strength) available to the art have been improved over the past several years. Also, the types of carbon fiber available, once limited to high modulus but low tensile strength carbon fiber or higher tensile strength but lower modulus carbon fiber, are now diverse. For example, a series of intermediate modulus carbon fibers (i.e. modulus between 40 and 50 million psi that is between that of high and lower modulus carbon fiber) and tensile strengths equal to that (i.e. above 600 thousand psi) of lower modulus carbon fiber are now available. These intermediate modulus carbon fibers have been made through better appreciation of the changes in morphology in the materials undergoing conversion to the carbon fiber. See, for example, U.S. Ser. No. 520,785 filed Aug. 5, 1982 in the name of Schimpf, Hansen, Paul and Russell.
High modulus carbon fiber available to the art, however, still has low tensile strengths. For example, the high modulus pitch-based carbon fiber, Thornel™ P-755, has a reported modulus of 75 million psi but a reported tensile strength of only 300 thousand psi. on the other hand, high modulus pan-based carbon fiber "GY-70" has a reported modulus of 75 million psi but a reported tensile strength of only 270 thousand psi. Moreover, the compressive strengths of this type of material has been quite low, a serious detriment for aerospace applications. See also U.S. Pat. No. 4,301,136 to Yamamoto, et al. wherein carbon fiber having a modulus of about 56 million psi and a tensile strength of about 370 thousand psi is disclosed.
The disadvantage of the intermediate modulus materials was dramatically illustrated in the take-off of the "Voyager" aircraft where the wings, heavily laden with fuel, sagged so much during takeoff as to scrap along the run-way. Clearly, a higher modulus composite wing would not suffer such a risk of catastropic failure. Moreover, the wings, when made with a carbon fiber composite that has high tensile strength and high compressive strength, should be better able to sustain the tension and compression loads such as seen by the "Voyager" in flight.
Now, in accordance with this invention, it has been discovered that the modulus in carbon fiber can be increased over 30% higher than in intermediate modulus carbon fiber while still maintaining exceptional tensile and adequate compressive strengths and suitable surface activity for use in composites. Thus, the carbon fiber of this invention has a modulus and tensile strength, as defined in a Tow Test (hereinafter described), respectively between about 59 and 75 million psi and 500 and 750 thousand psi and a short beam shear strength, as defined in a Laminate Test (hereinafter described), between 6 and 15 thousand psi.
The carbon fiber comprises filaments each having a diameter between 3 and 6 microns and a coefficient of variation (C v ) ranging typically up to 5%. The strain (calculated) of the carbon fiber ranges between 0.8% and 1.3% wherein strain is calculated by dividing the tensile strength by modulus. The carbon fiber has a composite compressive strength, according to ASTMD 695, that is between 120 and 200 thousand psi at 62% fiber volume.
BRIEF DESCRIPTION OF THE DRAWINGS
The procedures of the Tow and Laminate Tests are described in the Appendices I an II appearing at the end of this specification.
FIGS 1, 2, 3a, 3b, 4a-4d, 5a-5d, 6a-6e, 7a-7c, 8a-8c, 9a, 9b, 10, 11, 12, 13, 14, 15a, 15b, 16, 16a, 17, 18a, and 18b depict apparatus and fixtures used in these procedures. The Tow Test values hereof are properties of carbon fiber that is not surface treated. The Laminate Test values hereof are properties measured on the carbon fiber which has been surface treated, typically by electrolytic surface treatment.
FIGS. 19 and 20 illustrate temperature profiles of furnaces used in producing carbon fiber described in certain of the examples of this invention. In particular, FIG. 19 depicts a tar remover temperature profile.
FIGS. 21, 22 and 23 depict apparatus and procedure in connection with characterizing the polyacrylonitrile precursor (as to dry heat tension (DHT) and dry heat elongation (DHE) by the methods of Appendices III and IV.
FIG. 21 depicts a schematic of a running heat tension checker, FIG. 22 an apparatus for measuring dry heat elongation and FIG. 23 a model chart of a load-time (elongation) curve.
FIG. 24 is a thermal responsive curve for polyacrylonitrile precursor.
DETAILED DESCRIPTION OF THE INVENTION
The process of making the carbon fiber hereof comprises stretching a previously stretched and oxidized polyacrylonitrite precursor to a certain extent as it passes through low temperature and first high temperature furnaces followed by stretching the resulting carbonized precursor again as it passes through a second, still higher temperature furnace. The partially carbonized precursor undergoing carbonization in the first high temperature furnace is allowed to shrink or at least is not increased in length as it passes through this first high temperature furnace but is stretched, or at least not allowed to shrink in the second high temperature furnace.
In a first embodiment, a polyacrylonitrile precursor is heated to a temperature below 200° C., preferably between about 150° C. and 170° C. in air or other gaseous medium while it is stretched between about 5 and 100% its original length followed by passing it into one or more oxidation ovens at temperatures between about 200° and 300° C. whereat it is optionally stretched once more. In a second embodiment, a similar or preferably smaller denier polyacrylonitrile precursor is used, e.g. below about 0.7 (denier per filament), and it is stretched between zero and 30% (preferably 10 to 25%) its original length while undergoing oxidation in the oxidation ovens at temperatures between about 200° C. and 300° C.
The polyacrylonitrile precursor which is useful in making carbon fiber hereof comprises a polymer that is made by addition polymerization, either in solution or otherwise, of ethenic monomers (i.e. monomers that are ethylinically unsaturated), at least about 80 mole percent of which comprise acrylonitrile. The preferred polyacrylonitrile precursor polymers are copolymers of acrylonitrile and one or more other ethenic monomers. Available ethenic monomers are diverse and include, for example, acrylates and methacrylates; unsaturated ketones; and acrylic and methacrylic acid, maleic acid, itaconic acid and their salts. Preferred comonomers comprise acrylic or methacrylic acids or their salts, and the preferred molar amounts of the comonomer ranges between about 1.5 and 3.5%. (See U.S. Pat. No. 4,001,382 and U.S. Pat. No. 4,397,831 which are hereby incorporated herein by reference.)
The polyacrylonitrile precursor polymers suitable for making carbon fiber hereof are soluble in organic and/or inorganic solvents such as zinc chloride or sodium thiocyanate solutions. In a preferred practice of making a polyacrylonitrile precursor for use in making the carbon fibers hereof, a solution is formed from water, polyacrylonitrile polymer and sodium thiocyanate at exemplary respective weight ratios of about 60:10:30. This solution is concentrated through evaporation and filtered to provide a spinning solution. The spinning solution comprises about 15% by weight of the polyacrylonitrile polymer.
The spinning solution is passed through spinnerets using dry, dry/wet or wet spinning to form the polyacrylonitrile precursor. The preferred polyacrylonitrile precursor is made using a dry/wet spinning wherein a multitude of filaments are formed from the spinning solution and pass from the spinneret through an air gap or other gap between the spinneret and a coagulant preferably comprising aqueous sodium thiocyanate. After exiting from the coagulant bath, the spun filaments are washed and then stretched to several times their original length in hot water and steam. (See U.S. Pat. No. 4,452,860 herein incorporated by reference and Japanese Application 53-24427 [1978].) In addition, the polyacrylonitrile precursor is treated with sizing agents such as silane compounds (see U.S. Pat. No. 4,009,248 incorporated herein by reference).
The polyacrylonitrile precursor (preferably silane sized) is in the form of tows in bundles comprising a multitude of filaments (e.g. 1,000, 10,000 or more). The tows or bundles may be a combination of two or more tows or bundles, each formed in a separate spinning operation. A thermal response curve in air of a polyacrylonitrile precursor suitable for use in making the carbon fibers of this invention is shown in FIG. 24.
The denier per filament of the polyacrylonitrile precursors desirably ranges between 0.5 and 3.0. The particular denier of the polyacrylonitrile precursor chosen influences subsequent processing of the precursor into carbon fiber hereof. For example, larger denier precursor, e.g. 0.8 denier per filament or above precursor is preferably stretched at temperatures below 200° C. (e.g. about 150°-160° C.) to reduce its denier to less than 0.8 prior to significant oxidation.
Through stretching at temperatures between 100° and 200° C., the resultant precursor is up to 3.5 times or more its original length; and due to the minimal reaction at temperatures within this range may be in amounts selectively calculated in advance to provide the denier desired for subsequent oxidation and stabilization. For example, a 0.8 denier per filament precursor may be stretched 17% to yield a 0.68 denier per filament material by a Stretch Ratio (S.R.) of 1.176 according to the following formula: ##EQU1## L o is length out, L i is length in, d S is original denier and d N is new denier. Desired stretch ratio (S.R.) may be achieved by drawing the precursor faster through the desired heated zone (e.g. temperature between 150° C. and 170° C.) that it is permitted to enter this zone.
The polyacrylonitrile precursor is oxidized in one or more ovens maintained at temperatures between 200° C. and 300° C. The polyacrylonitrile precursor is stretched during oxidation.
A variety of oven geometries are known to provide appropriate oxidation in making carbon fiber and any of these ovens may be suitably employed in accordance with this invention. Preferably, however, a series of ovens are employed according to this invention with the precursor that is undergoing oxidation in these ovens passing around rollers positioned in steps on either side of the exterior of each oven. In this way the polyacrylonitrile precursor undergoing oxidation passes through a single oven several times.
After oxidation, the oxidized precursor is passed through a tar removal furnace (also called low temperature furnace) maintained at temperatures (between 400° C. and 800° C.) that increase relative its travel through the furnace. The heat up rate in the low temperature furnace is between 500° and 1000° C./minute. ("Heat up rate" as used herein refers to the rate of temperature increase the fiber undergoes as it passes through an oven or furnace. The rate is an average rate for the fiber as fibers in the middle of an oven or furnace typically are heated faster than those close to the sides.)
The low temperature furnace contains a non-oxidizing atmosphere and is vented of gaseous products resulting from the ongoing carbonization in this furnace. Nitrogen gas nominally at atmospheric pressure is preferred as the non-oxidizing atmosphere and may be used to draw the gaseous products from the furnace through a slight positive pressure thereof.
After exit from the low temperature furnace, the partially carbonized precursor enters a first high temperature furnace. The temperature in this first high temperature furnace is preferably between 1200° C. and 1800° C. and the pressure is nominally atmospheric or slightly above, e.g. up to 20 mm Hg above atmospheric. The heat up rate in this first high temperature furnace is preferably between about 3500° and 5000° C./minute to the first 1000° C.
The precursor undergoing carbonization in the low temperature and first high temperature furnaces is maintained under a tension such that it is between -5% and 20% longer in length after exit from the first high temperature furnace as compared to its length at entry to the low temperature furnace. Preferably, such a change in length is accomplished through stretching the precursor undergoing carbonization primarily in the low temperature (tar removal) furnace. Thus, the fiber which has passed through the tar removal or low temperature furnace is between 1% and 30% longer in length at the exit from such low temperature furnace. A small shrinkage or no shrinkage relative to the precursor undergoing carbonization in the first high temperature furnace is permitted where shrinkage in the first high temperature furnace is defined relative the lengths of the carbonized fiber entering and exiting this first high temperature furnace.
After leaving the first high temperature furnace, the carbonized precursor passes into a second high temperature furnace. The furnace has a temperature between about 1800° C. and 3000° C. The heat up rate of the carbonized precursor fiber to 1800° C. in this second high temperature furnace is between about 1200° C./minute and 4000° C./minute. The carbonized precursor passing through this second high temperature furnace is stretched so that it is between about 1/2% and 10% greater in length after it has passed through the second high temperature furnace, such increase in length being based on the length of the carbonized precursor (carbon fiber) entering the second high temperature furnace. The second high temperature furnace has a non-oxidizing atmosphere that is preferably nitrogen or the like and kept at a slight positive pressure (e.g. about one atmosphere).
Stretching is accomplished in the second high temperature furnace as well as in the low temperature furnaces and oxidation ovens through use of rollers drawing the filaments at rates greater than the rates driven by the rollers positioned at the entry of the furnace or oven. These rollers may be positioned in at a variety of locations to achieve similar results. Preferably, however, rollers are positioned at the entry and exit of the oxidation ovens, including particularly at entry and exit of the first oxidation oven, if there is more than one oven. Similarly, rollers for stretching the oxidized precursor are positoned at the entry and exit of the tar removal furnace. Still further, in especially preferred embodiments, rollers are positioned for stretching at the entry and exit of the first high temperature and of the second high temperature furnaces.
The rollers at the entry and exit of the first high temperature furnace are desirably adjusted to allow minor shrinkage or keep the carbonized fiber from shrinking in the first high temperature furnace. The rollers at the entry and exit of the second high temperature furnace are adjusted preferably to cause stretching in the second high temperature furnace.
Alternatively, rollers may be positioned for stretching across the span of entry to the low temperature furnace and exit from the second high temperature furnace.
After exit from the second high temperature furnace the carbonized fiber is surface treated. A variety of surface treatments are known in the art. Preferred surface treatment is an electrolytic surface treatment. The preferred electrolytic surface treatment comprises passing the fiber through a bath containing an aqueous sodium hydroxide solution, (0.5-3% by weight). The current is applied to the fiber at between about 1 and 5 columbs/inch of fiber per 12,000 filaments. The resulting surface treated fiber is then preferably sized with an epoxy compatible sizing agent such as Shell epoxy Epon 834.
The following examples are intended to illustrate this invention and not to limit its broader scope as set forth in the appended claims. In these examples, all temperatures are in degrees Centrigade and all parts are parts by weight unless otherwise noted.
EXAMPLE 1
Polyacrylonitrile precursors were made using an air gap wet spinning process. The polymer of the precursor had an intrinsic viscosity between about 1.9 and 2.1 deciliters per gram using a concentrated sodium thiocyanate solution as the solvent. The spinning solution and coagulants comprised an aqueous solution of sodium thiocyanate. The polymer was made from a monomer composition that was about 98 mole % acrylonitrile and 2 mole % methacrylic acid. Table 1 shows the characteristics of the resulting precursor.
TABLE 1______________________________________Precursor Properties______________________________________Denier 0.6Tensile Strength (g/d) 6.0Tensile Modulus (g/d) 105DHT (g/d).sup.1 0.168DHE (%).sup.2 57Boil-off Shrinkage (%) 5.8US Content (%).sup.3 1.14Sodium Content (ppm) 558Residual Solvent (%) 0.006Moisture Content (%) 0.79Filament Diameter Cv (%) 4.8C═N Orientation Function 0.599Fiber Density (g/cc) 1.182______________________________________ .sup.1 Dry heat tension. Procedure described in Appendix III. .sup.2 Dry heat elongation. Procedure described in Appendix IV. .sup.3 Sizing content in weight percent.
Table 2 describes the process conditions that yielded carbon fiber having characteristics set forth in Tables 3 and 4. The precursor fiber used in making the carbon fiber had the characteristics shown in Table 1.
TABLE 2______________________________________FIBER RUN CONDITIONS______________________________________PAN Type: 0.6 dpf 12kOXIDATION CONDITIONS:Oxidation Oven No. 1 - 65 minutes at 233° C.Oxidation Oven No. 2 - 106 minutes at 236° C.Oxidation Stretch = 9.2%LOW TEMPERATURE FURNACE (LTF):6 Equal ZonesZone Temperature Setpoints:Zone 1 - 450° C.Zone 2 - 610° C.Zone 3 - 710° C.Zone 4 - 600° C.Zone 5 - 500° C.Zone 6 - 450° C.LTF Residence Time = 5.2 minutesLTF Initial Heat-up rate = 630° C./minFiber Stretch in LTF = +9.8%HIGH TEMPERATURE FURNACE (HTF):1 ZoneTemperature Setpoint = 1750° C.HTF Residence Time = 2.0 minutesHTF Initial Heat-up Rate (to 1000° C.) = 4240° C./minFiber Stretch in HTF = -4.1%HIGH MODULUS FURNACE (HMF):1 ZoneTemperature Setpoint = 2600° C.HMF Residence Time = 1.6 minutesHMF Initial Heat-up Rate (to 1000° C.) = 2675° C./minFiber Stretch in HMF = +2.6%CALCULATED OVERALL STRETCH THROUGHTHE THREE FURNACES = +7.4%SURFACE TREATMENT:Electrolyte: Aqueous 1.0% by weight NaOH solutionCurrent = 110 AmpsVoltage = 12 V DCSurface Treatment Level per Tow = 2.85 coul/in per12000 filaments.______________________________________
TABLE 3__________________________________________________________________________FIBER TOW TESTINGMade from 0.6 dpf PAN of Table 1Overall Fiber Fiber Tensile Tensile Tensile TensileCarb. Stretch Density WPUL Strength Modulus Modulus Elonga-% lb/in.sup.3 lb/in × 10.sup.-6 ksi 1/2 load 6-1 secant tion %__________________________________________________________________________+12% .0675 17.19 702 68.8 66.7 1.08 10% .0675 17.53 663 66.1 64.3 1.06+8% .0675 18.20 660 66.0 63.8 1.05 .0675 17.81 700 65.7 64.1 1.11+5% .0670 18.42 656 66.3 63.7 1.04+3% .0674 18.89 637 64.7 63.0 1.03+0% .0676 20.04 647 63.9 62.4 1.04-5% .0673 19.97 510 59.7 N/A .90 .0672 21.10 497 59.9 59.1 .82__________________________________________________________________________ Note: -5% fiber is surface treated. All others are unsurface treated.
TABLE 4______________________________________CARBON FIBERFiber Surface Treated in1.0% (by weight) NaOH at 2.8 coul/inchper 12,000 filamentsCarbonization Stretch +8% 0% -5%______________________________________Fiber Density, lb/in.sup.3 .0675 .0677 .0671Fiber weight/length, 17.99 19.35 21.33lb/in × 10.sup.-6Tow TestingTow Tensile Strength, ksi 615 598 507Tow Tensile Modulus, Msia 65.9 61.5 58.8Tow Elongation, % 1.08 1.01 .91Laminate Testing - 3501-6 ResinTensile Strength, ksi* 522 515 274Tensile Modulus, Msi* 64.9 60.4 56.2Tensile Elongation, % .82 .85 .50Flex Strength, ksi** 176 167 164Flex Modulus, Msi** 31.6 31.5 29.1Compression Strength, ksi** 150 n/a 147Short Beam Shear Strength, ksi 12.2 9.4 11.2Unidirectional CTE.sup.b, -.35 -- -.45in/in/°F. × 10.sup.-6______________________________________ *Normalized to 100% fiber volume. **Normalized to 62% fiber volume. .sup.a Half Load Tangent Modulus. .sup.b Coefficient of thermal expension.
EXAMPLE 2
Carbon fiber of this invention was made from a polyacrylonitrile precursor made to have properties shown in Table above.
The temperature profiles of the low temperature (tar removal) and first high temperature furnaces are shown in FIGS. 19 and 20. In FIG. 19, the furnace settings are as follows: Zone 1=50° C., Zone 2=650° C. and Zone 3=111° C.
The time spent at temperature during initial processing of the precursor was as follows:
______________________________________Temperature Time (min.)______________________________________158° C. 4234° C. 72249° C. 16______________________________________
where the precursor passed through air ovens during this oxidation. The oxidized precursor was 105% longer after exit from the oxidation ovens.
The processing undertaken in the low temperature first and second high temperature furnaces is illustrated below in Table 5. Runs R and S were made using the oxidized precursor described in this Example 2. Table 6 shows the tensions (in grams) of the fiber undergoing oxidation and undergoing carbonization in the first low temperature furance. The tensions were measured by strain gage transducers.
TABLE 5______________________________________(% ELONGATION)Furnace R S______________________________________Low.sup.1 13.3 15.5First High.sup.2 -4.4 -4.4Second High.sup.3 +1.1 1.2Overall +9.4 +11.8______________________________________ .sup.1 See FIG. 19. .sup.2 1300° C. Maximum Temperature. .sup.3 2500° C. Maximum Temperature.
TABLE 6______________________________________(TENSIONS IN GRAMS)Run R S______________________________________Oxidation 2613 2613Low Temperature Furnace 1041 1116______________________________________ The properties of the carbon fiber resulting from Runs R and S are shown below in Table 7.
TABLE 7*______________________________________ Modulus Tensile Strength DensityRun (psi × 106) (psi × 103) (gm/cm)______________________________________R 60.2 673 1.805S 62.5 571 1.812______________________________________ *Properties measured according to procedures shown for Tow Test like that shown in Appendices.
EXAMPLE 3
In this example, a 0.8 denier precursor was used. The properties of this 0.8 denier precursor are shown in Table 8. Oxidation and stretching was similar to that described in Example 2.
TABLE 8______________________________________DPF (NOMINAL)Precursor Properties______________________________________Tow Denier (g/9000 m) 9,570Tow Tenacity (g/d) 5.6Tow Modulus (g/d) 102DHT (g/d) 0.166Boil-off Shrinkage (%) 5.7US COntent (%) 0.88Sodium Content (ppm) 568Residual Solvent (%) 0.0073Moisture Content (%) 0.60Filament Diameter Cv (%) 4.4Monster Filaments 0______________________________________
Processing details used after oxidation and the mechancial properties (Tow Test) of the resultant carbon fibers are shown in Table 9, below.
TABLE 9__________________________________________________________________________ Overall StretchC1.sup.2 Temp C2.sup.3 Temp TR.sup.1 /C1.sup.2 /C2.sup.3 TR.sup.1 C1.sup.2 C2.sup.3 T.S. E. DensityRun (°C.) (°C.) Planned % Actual % (%) (%) (%) (Msi) (MMsi) (g/cc)__________________________________________________________________________65-3 1300 2780 5 3.8 7.3 -4.7 1.5 533 65.6 1.8865-4 1300 2780 7 7.1 8.8 -4.6 3.2 490 59.6 1.7767-1 1300 2780 1.0 2.4 7.9 -0.4 443 62.2 1.86__________________________________________________________________________ .sup.1 Low Temperature Furnace (tar removal) .sup.2 First High Temperature Furnace .sup.3 Second High Temperature Furnace
EXAMPLE 4
In this example, a series of carbon fiber was made starting from 0.8 denier polyacrylonitrile precursor. The precursor had properties like that shown in Table 8. Table 10 shows the properties of the resultant carbon fiber and the process conditions used in making the carbon fiber with these properties.
TABLE 10.sup.a__________________________________________________________________________ Fiber Properties Oxidation TR C1 C2 Tensile Modulus DensityRun Stretch Stretch Stretch Stretch/Temp Msi MMsi g/cc__________________________________________________________________________155-317% 1.1% -5.1% 0.9%/2500° C. 626 60.0 1.836155-4 17 -3.0 -5.2 0.9/2500 635 59.6 1.837 17 3.5 -5.0 0.9/2500 595 58.5 1.843 57-2s 20 4.0 -4.7 0.9/2600 488 59.3 1.828 57-4s 20 8.8 -4.6 1.1/2600 616 63.4 1.832 57-5s 20 10.4 -4.6 1.1/2600 617 61.7 1.831 59-1s 20 8.7 -4.6 1.5/2700 525 67.4 1.868__________________________________________________________________________ .sup.a See Table 9 for meaning of TR, C1 and C2.
EXAMPLE 5
In this example, a 0.6 dpf polyacrylonitrile precursor was used in making carbon fiber. The properties of the 0.6 denier precursor are like those shown for the precursor fiber of Example 1. The conditions used in making the carbon fiber and the resultant properties of the carbon fiber are shown in Table 11, below.
TABLE 11.sup.a__________________________________________________________________________Oxida- Carbonizationtion C1 C2 C.F. Properties at TR/C1/C2 Stretch (%)Run Stretch Temp. Temp. 0%.sup.b 21/2%.sup.b 5%.sup.b 71/2%.sup.b 10%.sup.b 121/2%.sup.b 15% 171/2%.sup.b 20%.sup.b__________________________________________________________________________161-1 8 +5% 1300° C. 2000° C. 652/49.0 660/51.8 654/51.7 686/52.2 713/54.1 722/53.2 -- 707/54.1 737/55.1161-1 9 +5% 1300° C. 2500° C. 520/56.3 585/56.6 646/57.7 614/58.6 673/60.2 671/62.5 681/64.8 560/62.2 621/63.5__________________________________________________________________________ .sup.a See Table 9 for meaning of TR, C1 and C2. .sup.b Calculated based on length exiting C2 oven length entering TR.
EXAMPLE 6
Polyacrylonitrile precursor was made generally according to the conditions previously described except that it had no steam stretching and its denier was 1.2 dpf. The 1.2 dpf. polyacrylonitrile precursor fiber was stretched 100% its original length at a temperature of 158° C. and wound around a spool and stored.
The precursor was then oxidized by passing it through air circulation ovens at temperatures for the times shown in the following Table 12.
TABLE 12______________________________________Temperatures Time (minutes)______________________________________158° C. 2.05240° C. 17.73245° C. 14.43248° C. 17.72250° C. 17.72250° C. 4.43______________________________________
The oxidized precursor passed from the last oxidation oven through a low temperature (tar removal) furnace having a temperature profile like that shown in FIG. 20. Then the partially carbonized fiber passed through a first low temperature furnace held at 1425° C. and then a second high temperature furnace held at 2500° C.
The stretch in each of the low temperature, first high and second high temperature furnaces are shown (values are %) for four distinct runs in Table 13 below.
TABLE 13______________________________________Run Overall TR C1 C2______________________________________135-1 0.1 4.5 -5.3 0.9135-2 2.4 6.9 -5.1 0.9135-3 4.9 9.3 -5.0 1.0135-4 6.9 11.3 -4.1 0.2______________________________________
Table 14, below, shows the properties of carbon fiber made according to the procedures of this example.
TABLE 14______________________________________ TensileRun Modulus.sup.a Strength.sup.b Density______________________________________135-1 58.2 606135-2 60.1 615135-3 61.5 628135-4 61.4 558______________________________________ .sup.a 10.sup.6 psi .sup.b 10.sup.3 psi
APPENDIX I
Test Methods (Including Impregnated Strand Test) for Determining Physical Properties of Carbon Fiber Tows
1. SCOPE.
Test methods for determining the density, weight per unit length, ultimate tensile strength (Impregnated Strand Test), Young's modulus of elasticity (Impregnated Strand Test), ionic impurities, and size content of tows of carbon fiber.
2. EQUIPMENT AND DOCUMENTS.
2.1 Drawings
FIG. 1 schematically depicts impregnation of tow 10 of carbon fiber in accordance with the Impregnated Strand Test. Resin solution 12 is in pan 14. Pan 14 is carried on base 16 to which is mounted stand 17. Clamp 20 mounts cross member 18 to stand 17. Clamp 22 mounts wire coil 24 to cross member 18. Clamp assembly 26 carries tow 10 so it can be drawn from resin solution 12 through coil 28 of wire coil 24. FIG. 2 further details cross member 18, wire coil 24 and coil 28. The wire of wire coil 24 is 0.060 inches in diameter. The inner diameter of coil 28 is 0.050 inches.
FIGS. 3 (A) and 3 (B), 4 (A) through 4 (D) and 5 (A) through 5 (D) illustrate the specimen curing rack and clamps used therewith for hanging and curing resin impreganted tows of carbon fiber. FIG. 3 (A) shows clamp 10 which corresponds to the clamping device of clamp assembly 26 of FIG. 1. Clamp 30 has adjustable clamp rod 32 which binds the tow of carbon fiber to the base (not shown) on which clamp 30 is mounted. Threaded member 34 is movable through nut 35 mounted on lever arm 38 for adjusting rod 32. Manual activator arm 40 causes lever arm to rotate in clamping the tow of carbon fiber with adjustable clamping arm 38. Bolts 42 bolt clamp 30 to its base.
Clamp 30 can mount to either long base 44 (FIGS. 4 (A) and 4 (B)) or short base plate 46 (FIG. 3 (B)). Short base plate 46 is welded to frame 48 (FIGS. 5 (A) and 5 (B)) of the specimen curing racks through four holes 50 in the short base plate. Base plate 46 can accommodate several clamps for permanent mounting to frame 48.
Frame 48 (FIGS. 3 (B) and 5 (A) and (B)) is made of aluminum and is rectilinear. Frame 48 comprises aluminum angles 52, 54, 56, and 58 which are welded together at their ends.
FIGS. 5 (A) and 5 (B) are respective top and side view of frame 46 of the specimen curing rack. Supports (not shown) mounted on the bottom of frame 46 permit the specimen curing rack to be carried and spaced from a laboratory bench (not shown).
Cylindrical rod 60 is mounted to frame 46 through metal dolls 62, 64. Cylindrical rod 60 is made of aluminum and has grooves 66 (25 in rod 60) which are Teflon® coated. FIG. 5 (D) is a cross section of a groove 66.
The dimensions (a), (b) and (C) in FIG. 5 (D) are 0.10 inch, 0.15 inch and 0.05 inch respectively.
FIGS. 6 (A) through (E) illustrate impregnated tows of carbon fiber. FIG. 6 (A) shows a well collimated tow which can be used to finish test. FIG. 6 (B) shows a tow with some catenary which can be cut to permit use of well collimated portion. FIG. 6 (C) shows tow having extreme catenary which is to be discarded entirely. FIG. 6 (D) shows tow having cut filaments in gauge length and is to be discarded entirely. FIG. 6 (E) shows tow having extreme fuzziness to be discarded entirely.
FIGS. 7 (A), (B), and (C) show schematically a specimen tab mold 68 in three view, 7 (A) taken at A--A of FIG. 7(B) and 7 (C) taken at C--C of FIG. 7 (B). Tab mold 68 has tab troughs 70 into which is poured resin from resin dispenser 75 (FIG. 9). Troughs 70 have a 6°±2° angle in their walls shown by x in FIG. 6 (A). Troughs 70 are 3/8±1/64 inch wide at the top and 2.125±0.01 inch long with a radius of 7/32 at grooves 72.
FIGS. 8 (A), (B), and (C) illustrate schematically carrier plate 74 which carried two tab molds 68, 68' as described in connection with FIG. 7. Carrier plate 74 has orifice 76 for mounting plate 74 in the oven. Tab molds 68', 68' are spaced 5.0±0.01 inches apart on carrier plate 74 and permanently affixed thereto.
FIG. 9 shows schematically resin dispenser 75 having heating block 78 in front (A) and side (B) views. Heating block 78 has cavity 80 for carrying molten resin heated by heating coils with heating block 78. Temperature probe 82 is mounted within heating block 78 and sensing temperature for a temperature control unit for heating block 78. The resin in cavity 80 is kept under nitrogen, the inlet therefor being shown as 84.
Resin cavity 80 communicates with 1/4" orifice 86 at the bottom of heating block 78 for dispensing resin into cavities 70 (FIGS. 7 and 8) of the tab mold part. Dispenser pin 88 moves in and out of orifice 86 in response to movement of spring loaded filling lever assembly 90.
FIG. 10 schematically shows the extensometer calibration fixture 92 comprising stand 94, extensometer 96 and micrometer 98. FIG. 11 shows schematically the grips 100, 102, pneumatically controlled, and tensile specimen 104 having end tabs 106, 108. End tabs 106, 108 fit between grip faces 110, 112, 114, and 116 respectively.
FIG. 12 shows a typical elongation curve having breaking load 118, stress, strain curve 120 and tangent line 122 drawn tangent to curve 120 at point approximately one-half of the breaking load 118.
2.2 American Society for Testing and Materials
ASTM D 638-68 Tensile Properties of Plastics.
3. PROVISIONS
3.1 Equipment calibration.
Testing instrumentation and equipment shall be calibrated in accordance with applicable suppliers operating instructions or manuals and requirements of the test facility.
4. MATERIALS AND EQUIPMENT.
______________________________________ Description*______________________________________MaterialsTonox 6050 Amine BlendERL 2256 Resin Epoxy ResinDER 330 Epoxy Resin, Dow ChemicalDER 332 Epoxy Resin, Dow ChemicalBF.sub.3 MEA Boron Trifloride monoethanol amine, Miller-StevensonMethanol ACS Reagent GradeMethylene Chloride ACS Reagent GradeResin Versalon 1200 (General Mills), or equivalent Macromelt 6300Solvent Toluene, Reagent GradeRubber .85 ± .20 × .85 ± 20 × .03 ± .01Nitrogen 0.01N, Type SS-1, Beckman Instrument Co., or equivalentMethyl ethyl ketone ACS Reagent Grade(MEK)Release agent Carr #2, or equivalentEquipmentToggle clamps FIG. 3, 4Rack, specimen curing FIG. 5Heating block, resin FIG. 9Melting pot, resin FIG. 9Grips, specimen FIG. 11Specimen mold FIG. 7, 8Specimen-preparation FIG. 1, 2equipmentPycnometer Hubbard Type, or equivalentForced air oven Blue M Power-O-Matic 60 (Blue M Electric Co.) Blue Island Illinois, equivalentExtensometer Instron Catalog Number (no.) G-51-11Balance Analytical balance, Mettler B-5, or equivalentVacuum desiccator Pyrex, A. H. Thomas catalog no. 4443, or equivalentVacuum source Water aspirator or air pump, A. H. Thomas catalog no. 1038-B, or equivalentCentrifuge International Clinic Centrifuge Model CL, or equivalentConstant temperature Capable of maintaining 25° C. ± 0.1° C.bath (± 0.2° F.)Thermometer Graduated in 0.1° C. subdivisionsTensile tester Instron, floor model, Model FM, or bench modelWire coil FIG. 2Conductivity meterConductivity cell 0.1 cell constantExtraction flask 500 ml, ground jointpH meterOven Capable of maintaining 163° C. ± 3°______________________________________ C. NOTE: Equipment shown on applicable drawings is also required. *(Unless otherwise indicated, source is commercial.)
5. TEST PROCEDURES
5.1 Determination of tow density.
The tow density shall be determined in accordance with the following:
5.1.1 Calibration of pycnometer. The pycnometer shall be calibrated as follows:
a. Clean the pycnometer thoroughly using sodium dichromate cleaning solution.
b. Dry the interior by rinsing it successively with tap water, distilled water, and either alcohol and ether or acetone.
c. Expel the solvent vapors with a current of air which has been passed through absorbent cotton and Drierite. Do not subject pycnometer to any considerable elevation of temperature.
d. Prior to weighing, wipe the entire pycnometer first with a piece of clean moist cloth and then with a dry cloth. Weigh the empty pycnometer immediately.
e. Carefully fill the pycnometer with freshly boiled distilled water which is slightly below the temperature of the bath.
f. Insert the pycnometer plug with a rotary motion to avoid the inclusion of air bubbles and then twist until it seats firmly but not so tight that it locks.
g. Place the pycnometer in a constant temperature bath maintained at 25°±0.1° C. Leave the pycnometer in the bath at least 30 minutes.
h. Check the bath to be certain the temperature has not changed. Then remove the pycnometer from the bath and wipe the excess water from the top of the plug using one stroke of the hand or finger.
i. Wipe the surface of the pycnometer with absorbent material giving special attention to the joint where the plug enters the pycnometer.
j. At this point, examine the pycnometer to be certain that it is entirely filled with water. (If any air bubbles are present, fill the pycnometer again and replace it in the bath.)
k. Remove the pycnometer from the bath and wipe the entire surface with a piece of clean moist cloth and then with a dry cloth. Special attention should be given to the area around the joint where the plug enters the pycnometer. Weigh the pycnometer immediately.
5.1.2 Density determination. The density of the tow shall be determined as follows:
a. Accurately weigh enough of the sample into the pycnometer to fill the pycnometer approxiamtely one-third full (approximately 2 gram sample).
b. Carefully fill the pycnometer with boiled, distilled water. Place the pycnometer in a beaker within a vacuum desiccator. Evacuate until the water boils. Release the vacuum and again evacuate until bubbles appear, then seal the desiccator and leave the samples under vacuum for 5 minutes.
c. Remove the pycnometer from the desiccator. If necessary, add more boiled, distilled water and centrifuge the pycnometer for 5 to 10 minutes.
d. Insert the pycnometer plug such as to avoid the inclusion of air bubbles, then twist until the plug seats firmly but not so tight that it locks.
e. Place the pycnometer in a beaker filled with boiled, distilled water such that the pycnometer is submerged.
f. Place the beaker containing the pycnometer in a constant temperature bath maintained at 25° C.±0.1° C. Keep the beaker covered with a watch glass.
g. Leave the pycnometer in the bath at least 30 minutes. After 30 minutes, the pycnometer may be removed from the bath for weighing if the temperature has not changed for 10 minutes or if the fluctuation has been less than 0.1° C. (0.2° F.).
h. Remove the pycnometer from the bath and wipe the excess water from the top of the plug using one stroke of the hand or finger. Wipe the surface of the pycnometer with absorbent material with special attention given to the joint where the plug enters the pycnometer. Weigh the pycnometer immediately.
i. Calculation: ##EQU2## Where: A=weight of sample, g.
B=weight of pycnometer plus water, g.
D=weight of pycnometer plus water plus sample, g.
T=temperature of bath. Unless otherwise stated, maintain bath at 25° C.±0.1° C.
E=density of water at temperature T° C. Unless otherwise stated, T° C. shall be 25° C. and the density (E) is 0.9971 g/ml.
5.2 Weight per unit length determination.
Determination of the weight per unit length of the tow shall be in accordance with the following:
a. Remove and discard a minimum of one complete layer of fiber from the spool. Then select a test length of fiber by pulling the tow off the spool in such a manner so as to prevent any side slippage of the tow as it is pulled off the spool. Smooth and collimate fiber specimen with gentle action of the fingers.
b. Cut tows into 48 inch (nominal) lengths. A minimum of 1 specimen is required.
c. Measure the actual length of each piece of tow to the nearest 1/32 inch.
d. Weigh each piece of tow to the nearest 0.1 milligrain.
e. Calculation: Weight per unit length (pounds/inch) ##EQU3## Where: Wd=weight of each specimen of dry tow, g.
Ws=weight of each specimen of sized tow, g.
B=length of each specimen, inches.
% size=wt. percent size from 5.6
f. Record the weight per unit length of each tow specimen.
5.3 Determination of ultimate tensile strength and Young's Modulus of elasticity using Impregnated Strand Test.
The ultimate tensile strength and Young's modulus of elasticity of the tow shall be determined in accordance with the following:
5.3.1 Tow impregnation. Tow impregnation shall be in accordance with the following:
a. Prepare the impregnating resin solution I. as shown in Table I. Mix well. Do not heat.
TABLE I______________________________________Impregnating resin solutionIngredient Parts by weight______________________________________Resin, ERL 2256 300Tonox 6040 88.5 ± 1.5Toluene 66.6 ± 2.0______________________________________
As alternatives to the above resin solution, the following can be used.
II. Mix 150, grams methylene chloride with 250 grams DER 332 resin to form component;
Mix 54.6 grams Tonox 60/40 with 345.4 grams methylene chloride to form component B; and
Mix A and B for impregnating solution; or
III. Mix 600 grams DER 330 with 246 grams methylene chloride to form component A;
Mix 18 grams BF 3 MEA with 30 grams methyl ethyl ketone (MEK) to form component B; and
Mix A and B for impregnating solution.
b. Transfer the resin solution into a pan as shown in FIG. 1. The resin solution shall be used within one hour after preparation.
c. Cut tow specimens to length (49.0±2.0 inches long). Attach a clamp (See FIG. 1) to one end. Coil the tow in the pan of resin solution to within 1.5±0.5 inches from the clamp. Raise the claim until the start of the impregnated section of the tow is next to the coil. (See FIG. 1) Wind that area of the tow into the coil.
d. Remove and collimate the resin-wet tow by pulling it slowly (approximately 1 foot/second) through the wire coil.
e. Hang impregnated tow horizontally on a specimen rack (See FIG. 5). Lay the clamp which has been attached to the tow (See FIG. 4) over the grooved roller (See FIG. 5(c)) and fix the loose or other end in the clamp, which is attached to the rack.
f. Examine strands for filament collimation in accordance with FIG. 6. Discard and remake all strands which are not acceptable.
g. Cure samples in a preheated oven at 350°±10° F. (177°±5° C.) for a minimum of one hour if resin I is used. If resin II is used, cure at 130° C. for 45 minutes followed by 175° C. for four hours. If resin II is used, cure at 85° C. for 45 minutes followed by 175° C. for four hours.
h. Repeat c. through g. for each tow specimen (5.2). Impregnate enough tows to satisfy 5.3.6-b. A maximum of two tows per spool should be sufficient.
5.3.2 Resin content determination. The resin content of the cured impregnated tows shall be determined in accordance with the following:
a. Cut each impregnated tow into three equal lengths (for 13 inch samples) or, four equal lengths (for 10 inch samples). Accurately measure lengths of each piece to the nearest 1/32 inch and weigh each piece to the nearest 0.1 mg. Calculate and record the weight per unit length of each impregnated tow in lb/in.
b. Calculation; Resin content (weight percent)= ##EQU4## Where: Wi=weight per unit length of impregnated tow, lb/inch.
Wf=weight per unit length of dry tow (from 5.2), lb/inch.
c. Report the resin content of each 48 inch length of impregnated tow. Discard sample if resin content is less than 40 weight percent or greater than 60 weight percent.
5.3.3 Attachment of end-piece tabs. End-piece tabs shall be in accordance with the following:
a. Place the cut lengths (10" or 13") (5.3.2-a) of impregnated tows in the specimen mold (FIG. 7). This allows a span of 5.0±1/16" long between the end tabs. The end tab or grip piece will be about 1/4"×3/8"×2.0", and molded on each end of the cut lengths.
b. Run Macromelt 6300 (or equivalent) Polyamide resin into the mold cavities from nitrogen blanketed reservoir (FIG. 9), containing molten resin maintained at 300°±5° C. (600°±20° F.).
5.3.4 Calibration of extensometer ana load. Calibrate the extensometer (10% maximum strain capability) and load as follows:
a. Set the extensometer on the special calibration fixture (FIG. 10). Adjust the micrometer to give a gap separation of exactly one inch. Adjust the strain recorder to give zero reading on the chart.
b. Open the extensometer 0.020 inches by rotating the micrometer. Adjust the strain recorder to register the proper chart travel depending on scale used. Use actual scale that will be used for testing samples (scale 500/1 is preferred). Do not let the extensometer swing or rotate on the fixture when turning the micrometer.
c. Repeat until zero, 0.005, 0.010, and 0.020 inch recordings register without adjusting.
d. Calibration of the extensometer should be done before testing begins, after a maximum of 48 specimens have been tested, or when Instron operators change.
e. Calibration of load shall be by dead weight at the beginning of testing. Use a 10 pound weight on a 20 pound full scale load. Load calibration must be done after 48 specimens have been tested or when operators change. Shunt calibration may be substituted for dead weight for subsequent calibrations.
5.3.5 Test procedure. The following should be used.
a. Mount the specimen in the pneumatic grips of the Instron tensile tester (FIG. 11). The end tabs should be aligned in the grips parallel to the side of the grips and perpendicular to the crosshead.
b. Apply light tension (up to 48 pounds) to the specimen gently by extending the crosshead.
c. Attach a one inch gage length strain gage extensometer (Instron catalog No. G-51-11) with 10 percent maximum strain capability to the impregnated tow (FIG. 10).
d. Use a 0.5 inch per minute crosshead speed.
e. Select a load scale 200 or 500 lbs. which best measures the type of fiber being tested.
f. Load the specimen to failure while simultaneously plotting the load versus elongation as shown in FIG. 12.
g. Discard all results from any specimen in which failure occurs in an inordinate manner, i.e., jaw breaks, slipped end tabs, sample breaks while removing extensometer, etc. A minimum of four good tests are required for calculations.
5.3.6 Ultimate tensile strength. The ultimate tensile strength of the tow shall be calculated as follows:
a. Calculation: ##EQU5## Where: P max =ultimate breaking load of impregnated tow, pounds/inch
Af=cross sectional area of tow (WF/pf), square inch
Wf=weight/unit length dry tow (5.2), pounds/inch
pf=density of tow (5.1), pounds/cubic inch
b. Report the median of a minimum of four determinations.
5.3.7 Young's modulus of elasticity. The Young's modulus of elasticity of the tow shall be determined in accordance with the following:
a. Using the load elongation chart produced by the Instron Tensile Tester (5.3.5) determine the following parameters:
L=incremental strain determined by inspection, inches.
P=load increment at the selected incremental strain, pounds
b. Calculation: ##EQU6## Where: Af=cross sectional area of tow (5.3.6) square inches.
L=gage length over which strain is measured (1 inch)
c. By arranging L to be 0.01 inch by setting the chart magnification ration to 500/1 and taking P at a chart distance of five inches, the calculation can be simplified to: ##EQU7## The value of P can be determined by drawing a modulus slope from the load-elongation curve by extending a line tangent to the linear portion of the curve at a point approximately one-half the obtained breaking load (See FIG. 12).
d. Report the average of a minimum of four determinations.
5.4 Ionic impurities determination (conductivity).
Ionic impurities of surface treated carbon or graphite fibers are determined by measuring the conductivity of water extracts in accordance with the following:
5.4.1 Preparation of conductivity water.
a. Run distilled water through a demineralizer.
b. Determine the conductance of the water at 20°±0.5° C. Continue to take the readings until a constant reading is obtained.
c. The conductance is measured by dipping the cell in the solution and balancing the meter. Make sure no bubbles adhere to the electrodes.
d. The conductance of the water should be less than 10 umho/cm.
5.4.2 Calibration of cell constant.
a. Condition of KCl standard to 20°±5° C.
b. Determine the conductance as described in 5.4.1.
c. Calculate the cell constant as follows: ##EQU8##
5.4.3 Conductance of water samples.
a. Condition the water to 20° C.±0.5° C.
b. Measure the conductance as described in 5.4.1.
c. Calculate as follows:
Conductance (umho/cm)=K×observed reading
5.4.4 Graphite or carbon fiber samples.
a. Weigh 10 grams of sample into a 500 ml extraction flask.
b. Add 200 ml of conductivity water.
c. Connect to a reflux condenser and bring rapidly to a boil.
d. Disconnect and remove the flask while the solution is still boiling. Close immediately with a glass stopper preferably fitted with a stopcock.
f. Cool rapidly to 20°±0.5° C. Filter sample through sharkskin filter paper.
g. Transfer some of the extract to a beaker and determine the conductance of the solution as in 5.4.1. Calculate the conductance as in 5.4.3.
h. Run a blank solution along with the fiber samples and subtract the blank conductance from the sample conductance.
i. Report the conductance of the sample extract and the temperature of determination.
5.4.5 pH of extract. If requested, use the remaining sample extract not used for conductivity to determine the pH with a pH meter. Report the pH for each conductivity test.
5.5 Sizing content. The sizing content of the fiber shall be determined as follows:
a. Weigh 2 to 3 grams (f) of fiber to nearest 0.1 milligram (mg).
b. Place specimen in 250-milliliter (ml) Erlenmeyer flask, and add 100 to 125 ml of methylene chloride.
c. Place rubber stopper on flask, and shake flask gently for approximately 1 minute.
d. Decant methylene chloride, being careful not to lose any fiber.
e. Repeat steps b, c, and d two additional times.
f. Remove specimen from flask.
g. Place specimen in oven for minimum of 5 minutes at 177±5 degrees Celsius (°C.).
h. Remove specimen from oven, cool to room temperature, and weigh to nearest 0.1 mg.
i. Calculate sizing content as follows: ##EQU9## Where: W 1 =original weight of sample, g.
W 2 =weight of sample after removal of sizing, g.
ADDENDUM TO TOW TEST
Correction of Calculations
SCOPE.
The tensile strength and elastic modulus calculations (5.3.6 and 5.3.7) assume that all of the load on the test specimen is carried by the carbon or graphite fiber. While the values calculated using this assumption closely approximate the properties of the tow, an even closer approximation may be made by correcting the breaking load and the incremental load used in the elastic modulus calculation to account for the load carried by the resin. Typical correction methods are as follows:
A.1 Tensile strength correction. Fiber tensile strength corrections for resin contribution are complicated by the fact that the impregnating resin does not show a constant stress/strain relationship as does the fiber. There is no "typical" modulus for the resin because the stress/strain relationship is curved rather than linear. The curvature of the stress/strain curve also varies from lot to lot, can to can, and even mix to mix. Ideally, then one should know the stress/strain curve for the particular mix used to impregnate the test specimens, but this is not economically feasible. What has been determined to be reasonable practice is to use the average secant modulus of the resin at the average breaking strain for the particular fiber being tested. The tensile strength correction is, therefore, calculated as follows:
a. Average secant modulus values (E r ) for ERL 2256/Tonox are as shown in Table II.
TABLE II______________________________________Secant Modulus for ERL 2256/Tonox Fiber E.sub.r, 10.sup.3 psi______________________________________ Type A 458______________________________________
b. Calculate average cross-sectional area of resin (A r ) in the impregnated tow: ##EQU10## Where: W i =weight per unit length of impregnated fiber, lbs/inch
W f =weight per unit length of dry fiber, lbs/inch
p r =resin density (0.0455 for ERL 2256/Tonox), lbs/inch 3 lbs/inch 3
c. Calculate the load carried by the resin (Pr) at breakage: ##EQU11## Where: P max =breaking load, lbs.
Py=total specimen load at 1% strain, lbs.
E r =resin secant modulus (Table II), psi
d. Calculate the corrected tensile strength, (S c ) of the fiber: ##EQU12## Where: A f =cross-sectional area of fiber (5.3.6), square inch.
A.2 Modulus of elasticity correction. The modulus of elasticity correction for the resin contribution is also calculated using the average secant modulus of the resin at the average strain for the particular fiber being tested as discussed in A.1. The calculation is made as follows:
a. Calculate the resin load at 1% strain (P r1 ):
P.sub.r1 =(0.01 E.sub.r) (A.sub.r)
b. Calculate the corrected modulus of elasticity (E e ) of the fiber as follows: ##EQU13##
APPENDIX II
Test Methods for Determining Properties of Carbon Fiber Tows Using the Laminate Test
1. SCOPE
Methods for determining the density, length per unit weight, ultimate tensile strength (Laminate Test), percent elongation at failure, Young's modulus of elasticity (Laminate Test), twist and size content of graphite tows and short beam shear strength (Laminate Test).
2. DEFINITIONS
2.1 Lot.
A lot shall consist of carbon fiber produced from one continuous production operation under one set of operating conditions. This lot may be produced with interruptions in processing of up to 72 hours assuming all fiber is produced under the same process conditions and is processed at steady state conditions.
2.2 Sampling.
Randomly select a minimum of six spools of fiber from each doff or two spools for every 8-hour production shift for testing to yield lot averages for fiber density, weight per unit length, sizing level, and workmanship. Randomly select one sample per lot for twist testing. Enough samples will be selected from the first and last doffs to allow a set of laminates to be made. If the fiber run exceeds six days, laminate tests shall be performed on a midrun doff.
3. PROVISIONS
3.1 Equipment Calibration
Testing instrumentation and equipment shall be calibrated in accordance with applicable suppliers operating instructions or manuals and requirements of the test facility.
3.2 Drawings
FIGS. 13-18 illustrate procedures and equipment used in the Laminate Test for determining Tensile Strength, Modulus and Short Beam Shear Strength. In FIG. 13 is shown lay up device 130 for laying up specimens for the Tensile and Modulus tests. In FIG. 13 is depicted aluminum base plate 132 which has a thin uniform coat of Frekote 33 release agent, cork dam 134 which has a pressure sensitive Corprene adhesive backing, prepreg panel 136 with thermocouple 138, peel plies (top and bottom) 140, Teflon release film 142, Caul plate 144, pressure sensitive green polyester silicone tape 146, air bleeder 148 of four plies of Style 1581 fiberglass, vacuum bag 150 of Film Capron 80, nylon (0.002 inches thick and high) temperature sealant 152. For tensile specimens the prepreg lay up is nominally 0.040 inches thick while shear specimens are nominally 0.080 inches thick. Further, the release fabric 140 is Engab TX 10-40 release (porous) fabric in making the shear specimens.
FIG. 14 schematically depicts trimming of the Tensile Panel 154 where 156 is the Kevlar tracer yarn. During trimming, borders 158, 160, 162 and 164 are removed from around specimen 154 where 158, 162, and 164 are 1/4 inch wide and 160 is 3/4 inches wide.
FIGS. 15 (A) and (B) illustrate tensile specimen 170 having end tabs 172, 174 adhered to each end. End tabs 172, 174 have orifices 176, 178 and extend beyond the ends of tensile specimen 170. Tensile specimen 170 is of 0.040 nominal thickness, 9 inches long (0° fiber direction) and 0.50 inches wide. Tensile specimen 170 is shown in FIG. 15 (A) with strain gauge 180.
FIG. 16 shows schematically the 0° test arrangement in which modified Instron grips 182, 184 along with rods 186, 188 are shown aligned with their positions on end tabs 172, 174 during testing. FIG. 16A illustrates the shape of the wire of 5.5.4.1.9(b).
FIG. 17 shows a stress strain curve wherein 190 is the maximum load, 192 is one-half the maximum load, 194 the empirical stress strain curve and 194 is the line drawn tangent to the curve 194 at one-half maximum load. The slope of curve 194 is the tensile modulus of the Laminate Test.
FIGS. 18 (A) and (B) depict the tabbing mold assembly having side rails 190, 192, adjustable end rails 194, 196 and 198, 200 and base plate 202. Adjustable end rail 194 has slots 204, 206 and adjustable end rail 196 has slots 208, 210. Bolts such as bolt 212 fits in each of slots 204, 206, 208 and 210 to allow end rails 194, 196, 198, 200 to slip fore and aft in aligning the test specimen. The test specimen, see in FIG. 18 (B) as 214 has tabs 216, 218, 220 and 222 which are under caul plate 224.
______________________________________ Description______________________________________Materials3501-5A Resin Hercules, Epoxy Resin (HS-SG-575)MY-270 Ciba-Geigy, tetraglycidyl methylene dianilineDDS Ciba-Geigy bis (para amino phenyl) sulfoneBF.sub.3 MEA Harshaw Chemical Boron Trifluoride monoethanolamineDichloromethane (MeCl.sub.2) MIL-D-6998Scotchbrite 3M CompanyTracer yarn 190 Denier Kevlar RovingPlastic sheet 1/8" thickChlorobenzene ACS Reagent GradeHigh temperature Schnee MorheadsealantRelease film Teflon, nonperforated, 0.001 to 0.004 inch thickCork dam Cork 1/8" by 1" with pressure sensitive adhesive backing (Corprene) (or equivalent).Tape Pressure sensitive, green polyester silicone 1" and 2"Air bleeder Style 1581 Fiberglass or equivalentVacuum bag Film, Capran 80 High Temp. nylon 0.002 inchMasking tape 2" wide and 1" wideSand paper 100 and 320 gritAdhesive American Cyanamid, FM-123-2 .05#/ft.sup.2Fiberglass tabbing 7 ply, 0.065", Scotchplyplates 1002Adhesive Eastman 910, Eastman Chemical Products (HS-CP-150)Strain gages SR-4, FAE-12S-12S13, BLH Electronics, Inc.Solder 0.020 Energized resin core F, Alpha Metals Inc.Peel ply Release fabric ply B, AirtechMEK ACS reagent gradeNitrogen Compressed, 180 psi min.Wire 1101 3/C #32 7/40 DVE cond. twisted, Alpha Wire Corp.Filter paper Whatman No. 41Alcohol ACS Reagent GradeEther ACS Reagent GradeAcetone ACS Reagent GradeGage Kote #'s 1, 2, 3, and 4 kit, Wm. T. Beam Co.Emery Cloth No. 220 GritTransparent tape Scotch type - 1/2"Teflon tape 1/2"H.sub.2 O DistilledEquipmentGrit Blaster Iron-Constantan No. 30 or equivalentThermocoupleThermocouple readout Any standard millivolt recorderPlaten press Wabash hydraulic press, Model 20-12 2TMB, 800° F. maximum temperature or equivalentSaw Micromatic - precision wafering or equivalentOhmmeter Fluke Model #810 or equivalentSoldering iron Small tip 115 volt, 25 watt or equivalentBase plate Aluminum, 1/4 to 1/2" thickCaul plate Aluminum, .080" thickKnives X-acto type and single edge razor bladeBeakers 250 mlFlask 250 ml ErlenmeyerPycnometer Hubbard type, or equivalentPycnometer Side arm, 50 mlForced air oven Blue M Power-P-Matic 60 (Blue M Electric Co.) Blue Island, Illinois, or equivalent.Oven Vacuum, capable, 85° C.Balance Analytical balance, Mettler B-5, or equivalentVacuum desiccator Pyrex, A. H. Thomas catalog no. 4443, or equivalentVacuum source Water aspirator or air pump, A. H. Thomas catalog no. 1038-B, or equivalentCentrifuge International Clinic Centrifuge Model CL, or equivalentConstant temperature Capable of maintaining 25° ± 0.1° C.bath (77° ± 0.2° F.)Thermometer Graduated in 0.1° C. subdivisionsTensile tester Instron, floor model, or equivalentWire coil 1" long, 18 gage copper wire, 1/4" inside diameterSuspending wire Stainless 300 series, .008" diameterPlatform Aluminum, 41/2" × 4" approximately two 1" ends bent 90°Autoclave Capable of a programmed heat rate ±2° F. to 400° F., minimum vacuum holding of 23" Hg in part with simultaneous autoclave pressure of 100 +10, -0 psi. Capable of maintaining 400° ± 5° F.Vacuum tube Minimum of 8" × 1/4" copper tube with 1/4" tube fitting on one end. Air bleed wrapped around the last 21/2" of end of tube.Ballpoint micrometer IKL .0001 display, model #1-645-2P, or equivalentFixture Drilling, 3/16 bushingFixture Tabbing, 6" wide______________________________________
5. TEST PROCEDURES.
5.1 Weight per Unit Length Determination.
Determination of the weight per unit length of the tow shall be in accordance with the following:
a. Select a test length of fiber by pulling the tow off the spool in such a manner so as to prevent any side slippage of the tow as it is pulled off the spool. Smooth and collimate fiber specimen with gentle action of the fingers.
b. Cut tows into 48" (nominal) lengths. A minimum of one (1) specimen is required per spool.
c. Measure the actual length of each piece of tow to the nearest 1/32".
d. Weigh each piece of tow to the nearest 0.1 milligram.
e. Calculation: Weight per unit length (yds./lb.) ##EQU14## Where: W d =weight of each specimen of unsized tow, g.
W s =weight of each specimen of sized tow, g.
B=length of each specimen, inches
% size=weight percent size from 5.2.
To convert length/wt. yds./lb. weight/length lbs./inch:
L w =0.0278/L f
f. Record the required value of each tow specimen.
5.2 Sizing Content.
The sizing content of the fiber shall be determined as follows:
a. Weigh 2 to 3 grams (g) of fiber to nearest 0.1 milligrams (mg).
b. Place specimen in 250 milliliter (ml) Erlenmeyer flask, and add 100 to 125 ml of methylene chloride.
c. Place rubber stopper on flask, and shake flask gently for approximately 3 minutes.
d. Decant methylene chloride, being careful not to lose any fiber.
e. Repeat steps b, c, and d, two additional times.
f. Remove specimen from flask.
g. Place specimen in oven for minimum of 15 minutes at 177±5 degrees Celsius (°C.).
h. Remove specimen from oven, cool to room temperature, and weigh to nearest 0.1 mg.
i. Calculate sizing content as follows: ##EQU15## Where: W 1 =original weight of sample, g.
W 2 =weight of sample after removal of sizing, g.
5.3 Determination of Tow Density. (Shall be determined by Method A or B).
5.3.1 Method A, density by immersion of chlorobenzene.
a. Determine the density of the chlorobenzene with a side arm pcynometer. Record density. Rerun density about once a week or when the density of the chlorobenzene is; suspected to have changed.
b. Weigh saddle in air. Record weight.
c. Weigh the saddle immersed in chlorobenzene. Record weight.
d. Roll masking tape around end of a fiber tow. Do the same to the other end of the tow sample. A tow sample four to five inches is desirable.
e. If the sample has been exposed to unusually high humidity or contains; more than 2 percent moisture, place the sample in a 85° C. vacuum oven and pull a vacuum for one hour.
f. Remove sample from oven and thread the tow through the inside diameter of the saddle. Cut tow at both ends with a razor blade so that the center bore of the saddle contains the sample.
g. Weigh saddle and sample in air. The sample, itself, should weigh between 0.2 to 0.3 g. Record weight.
h. Place the saddle and sample in a 250 ml beaker containing chlorobenzene.
i. Place the beaker, saddle, and sample in a vacuum desiccator. Pull vacuum until no air is entrapped in the sample. It is essential that all air be removed from the sample.
j. Remove beaker, saddle, and sample, and place in a constant temperature bath for 20 minutes or until the chlorobenzene is 23° C.±0.1° C. Check chlorobenzene with a thermometer.
k. Remove from bath and suspend sample from balance beam while chlorobenzene rests on Al platform. Record weight.
1. Calculation: ##EQU16## Where: A=density of chlorobenzene, g/cc.
B=weight of sample and saddle in air, g.
C=weight of saddle in air, g.
D=weight of sample and saddle in chlorobenzene, g.
E=weight of saddle in chlorobenzene, g.
P=density of fiber, g/cc.
5.3.2 Method B, density by water pycnometer.
5.3.2.1 Calibration of pycnometer. The pycnometer shall be calibrated as follows:
a. Clean the pycnometer thoroughly using sodium dichromate cleaning solution.
b. Dry the interior by rinsing it successively with tap water, distilled water, and either alcohol and ether or acetone.
c. Expel the solvent vapors with a current of air which has been passed through absorbent cotton and Drierite. Do not subject pycnometer to any considerable elevation of temperature.
d. Prior to weighing, wipe the entire pycnometer first with a piece of clean moist cloth and then with a dry cloth. Weigh the empty pycnometer immediately.
e. Carefully fill the pycnometer with freshly boiled distilled water which is slightly below the temperature of the bath.
f. Insert the pycnometer plug with a rotary motion to avoid the inclusion of air bubbles and then twist until it seats firmly but not so tight that it locks.
g. Place the pycnometer in a constant temperature bath maintained at 25.0°±0.1° C. Leave the pycnometer in the bath at least 30 minutes.
h. Check the bath to be certain the temperature has not changed. Then remove the pycnometer from the bath and wipe the excess water from the top of the plug using one stroke of the hand or finger.
i. Wipe the surface of the pycnometer with absorbent material giving special attention to the joint where the plug enters the pycnometer.
j. At this point, examine the pycnometer to be certain that it is entirely filled with water. (If any air bubbles are present, fill the pycnometer again and replace it in the bath.)
k. Remove the pycnometer from the bath and wipe the entire surface with a piece of clean moist cloth and then with a dry cloth. Special attention should be given to the area around the joint where the plug enters the pycnometer. Weigh the pycnometer immediately.
5.3.2.2 Density determination. The density of the tow shall be determined as follows:
a. Accurately weigh enough of the sample into the pycnometer to fill the pycnometer approximately one-third full (approximately 2 gram sample).
b. Carefully fill the pycnometer with boiled, distilled water. Place the pycnometer in a beaker within a vacuum dessicator. Evacuate until the water boils. Release the vacuum and again evacuate until bubbles appear, then seal the desiccator and leave the samples under vacuum for 5 minutes.
c. Remove the pycnometer from the desiccator. If necessary, add more boiled, distilled water and centrifuge the pycnometer for 5 to 10 minutes.
d. Insert the pycnometer plug such as to avoid the inclusion of air bubbles, then twist until the plug seats firmly but not so tight that it locks.
e. Place the pycnometer in a beaker filled with boiled, distilled water such that the pycnometer is submerged.
f. Place the beaker containing the pycnometer in a constant temperature bath maintained at 25.0° C.±0.1° C. Keep the beaker covered with a watch glass.
g. Leave the pycnometer in the bath at least 30 minutes. After 30 minutes, the pycnometer may be removed from the bath for weighing if the temperature has not changed for 10 minutes or if the fluctuation has been less than 0.1° C. (0.1° F.).
h. Remove the pycnometer from the bath and wipe the excess water from the top of the top of the plug using one stroke of the hand or finger. Wipe the surface of the pycnometer with absorbent material with special attention given to the joint where the plug enters the pycnometer. Weigh the pycnometer immediately.
i. Calculation: ##EQU17## Where: A=weight of sample, g.
B=weight of pycnometer plus water, g.
D=weight of pycnometer plus water plus sample, g.
T=temperature of bath. Unless otherwise stated, maintain bath at 25° C.±0.1° C.
E=density of water at temperature T° C. Unless otherwise stated, T° C. shall be 25° C. and the density (E) is 0.9971 g/ml.
5.4 Twist Test.
This test is used to determine the number of twists per inch of the carbon fiber tow.
a. Remove any frayed surface fiber from the package to be tested.
b. Attach free end of carbon fiber spool to the fixed clamp on the top of the "U" frame. While holding the fiber package horizontal.
c. Unspool the fiber from the package while keeping the package horizontal. (Do not twist the package while unspooling.) Rest package on the base of the "U" frame.
d. Attach the free clamp directly under the 36" wire. (Do not cut sample free from package.)
e. Insert a fine, pointed, polished stylus into the center of the sample at the top fixed clamp.
f. Draw the stylus down the sample, splitting the tow to the 36" wire. (Watch for rotation of the movable clamp.)
g. Hold stylus at the 36" wire, cut fiber from spool below the movable clamp. Count the number of rotations of the movable clamp.
h. Twist/in=number of rotations of movable clamp/36. Report to 2 significant digits. Example=1.5 rotations/36 in.=0.04 tpi.
5.5 Tensile Strength, Modulus, and Short Beam Shear Determination.
5.5.1 Prepreg. Samples selected from the lot shall be converted to prepreg using 3501-5A resin. Prepreg fiber areal weight shall be 0.0315±0.00084 lbs/ft 2 . Prepreg resin content shall be 35±3%. Prepreg will include a Kevlar tracer yarn located 0.25±0.10" from either edge. In lieu of 3501-5A, combine 100 parts by weight MY-720, 36.75 parts by weight DDS and 0.5 parts by weight BF 3 MEA such that the epoxy to diamine functionality ratio is 1:0.75.
5.5.2 Prepreg Test Procedure.
5.5.2.1 Prepreg resin content, areal weight, and laminate fiber volume. The fiber volume of the laminate shall be determined as follows:
a. Cut 12.000±0.030 inches of 3" tape.
b. Weigh cut tape to nearest 0.0001 grams (W 1 )
c. Place prepreg and 100 ml methylene chloride in 250 ml Erlemeyer flask.
d. Place stopper in flask.
e. Place flask on shaker and shake 1 minute minimum.
f. Decant solvent off.
g. Repeat steps c through f two additional times.
h. Dry in oven at 177°±10° C. for 15 minutes.
i. Remove from oven and allow sample to cool.
j. Reweigh sample to nearest 0.0001 gram (W 2 ).
k. Calculate as follows: ##EQU18## Where: W 1 =weight of 36 in. 2 of prepreg, g.
T f =fiber thickness/ply, (inches)
T p =cured ply thickness of prepreg measured from panel (inches)
W 2 =dry fiber weight from prepreg, g.
F v =fiber volume (%)
A w =prepreg areal weight, (lb/ft 2 )
pf=fiber density, (lb/in. 3 )
5.5.3 Test panel preparation FM 123-2. Test specimens shall be prepared for testing per the following requirements.
a. The panel tensile and shear shall be layed up for cure as shown in FIG. 13, as described.
b. The cure cycle is as follows:
1) Place vacuum bagged layup in autoclave and close autoclave.
2) Apply minimum vacuum of 23 inches Hg.
3) At a rate of 3° to 5° F. per minute, raise the laminate temperature to 350°±5° F. During the heat up, apply 85+10, -0 psi when the laminate temperature reaches 275°±5° F.
4) Hold at 23 inches Hg (minimum), 85 +10, -0 psi, and 350°±5° F. for 60 +5 minutes.
5) At a rate of 13°±2° F. per minute, lower laminate temperature to 150°±5° F.
6) Release autoclave vacuum and pressure.
7) Remove layup from autoclave.
8) Remove panel from vacuum bag.
5.5.4 Mechanical Test Procedures
5.5.4.1 Tensile strength and modulus test. The tensile strength and tensile modulus of elasticity of laminates shall be determined in accordance with the following:
5.5.4.1.1 Tensile panel tabbing. End tabs shall be applied to tensile panels as follows:
5.5.4.1.2 Preparing the panel.
a. Trim 1/4" off one end of 10" panel length.
b. Cut other end of panel to a length of 9.0±0.1"
c. True up edges of panel, so panel will fit into tab mold. Make sure there are no high edges that will interfere with the seating of the end tabs.
d. Remove peel ply from both sides approximately 21/4" back from each end, Leave peel ply attached in center .
e. Determine the mid-point between ends, then measure out 2.75 inches each way and draw parallel lines that are transverse to 9" dimension. This will allow equal spacing on the ends and maintain the 5.5 inch spacing of the end tabs.
f. Wash panel ends by flooding with MEK solvent applied from a squeeze bottle.
g. Allow the panel to air dry while preparing end tabs for bonding.
5.5.4.1.3 Preparation of tabs for room temperature tests using FM-123-2.
a. Remove FM-123-2 adhesive from freezer and allow to warm to room temperature.
b. Cut fiberglass tab plates so that width is 4 inches for a 3 inch panel and 7 inches for a 6 inch panel.
c. Grit blast the flat tab surface uniformly until no gloss remains.
d. Degrease thoroughly by scrubbing with MEK wet cloths until a clean cloth no longer shows a residue. Then rinse surface by flooding with MEK. Air dry 15 minutes minimum before using.
e. Then place prepared surface down on a sheet of FM-123-2. Press down firmly with thumb to make good contact between tab and resin. Trim closely around tab with a sharp knife. Care should be taken not to contaminate the resin during handling.
f. Place bottom tabs into position in fixture, aligning beveled edges with ends of the side bars. Hold in position by positioning the bottom mold end plate snugly along the backside of the tab and tighten outside screws.
g. Remove release paper from bottom tabs then position the panel over the tabs aligning the index marks with the ends of the side bars. Press panel firmly onto tab adhesive.
h. Remove release paper from top tabs and place top tabs into position over panel, aligning beveled edge with ends of the side bars. Adjust top end plates snugly along the ends of the top tabs and tighten inside screws.
i. Assemble tabbing fixture pressure plate over tabs.
5.5.4.1.4 Press cure cycle.
a. Place mold assembly into press preheated to 250° F.
b. Apply pressure of 40 to 50 pounds per square inch calculated for actual bond area. Maintain this pressure throughout cure cycle.
c. Cure for 1 hour.
d. Cool press platens while maintaining pressure to a temperature below 150° F.
e. Remove pressure and remove mold assembly.
f. Cut the test specimens to the configuration shown in FIG. 15.
5.5.4.1.4.1 Test specimen preparation. The specimen shall be cut from laminate panels in accordance with the following:
a. Set up the panel cutting machine to accept the diamond cutting wheel.
b. Clean indexing table surface until free of dirt and water.
c. Take a piece of 1/8" thick plastic sheet, larger than the panel to be cut, and fasten to the indexing table with double-faced masking tape.
d. Adjust the cutting wheel to make a 1/32 to 1/16 inch cut in the plastic sheet.
e. Apply double-faced masking tape on one side of the laminate panel to be cut (tape in tab area).
f. Place the panel on a cut-free surface of the plastic sheet on the indexing table, aligning the panel with tracer yarn to ensure that machine cuts will be 90°, 0°±0.250° to the unidirectional orientation of the fiber.
g. Trim 1/8 inch from each side.
h. Index table to provide proper width of specimen and cut. Be sure to allow for the width of the diamond cutting wheel in indexing for all cuts.
i. Repeat process to obtain required test specimens.
j. Machine spindle speed for cutting shall be 1100 to 4200 rpm.
k. Use feed rate of 1 to 3 feet per minute.
l. Use water liberally as a collant during cutting unless otherwise directed.
5.5.4.1.5 Drilling holes in tabs.
a. Place tabbed and cut test specimen in drilling fixture. Tighten sides down to ensure proper alignment.
b. Using 3/16" carbide tipped bit, drill through tabbing material.
5.5.4.1.6 Application of Strain Gages. Strain gages shall be applied to test specimens in accordance with the following:
5.5.4.1.7 Preparation of specimen surface.
a. Remove remaining peel ply from both sides of specimen, then, using 220 grit emery cloth, sand area in which strain gage is to be located just enough to smooth the surface.
b. Thoroughly degrease the area with MEK.
c. Using a cotton swab soaked in a neutralizer, wipe sanded area in one direction. Using gauze or cheesecloth, wipe off neutralizer.
d. Using a pencil, mark centering lines for location of gage.
5.5.4.1.8 Application of gage.
a. Remove gage from package. Do not touch surface of gage which is to be bonded.
b. Using a strip of transparent tape, touch top of gage so that it adheres to the tape. The tape will be used to transfer the gage to the specimen.
c. Apply a thin coat of Eastman 910 catalyst to the gage only and allow to dry.
d. Set gage on specimen, aligning with pencil centering lines and rub tape down.
e. Peel back one end of the transparent tape so that the gage is pulled back and is not touching specimen.
f. Apply just enough Eastman 910 to form a bead at the junction of the tape still adhering to the specimen and the specimen.
g. Place thumb on secured end of tape and push forward rolling the gage onto the specimen.
h. Use finger pressure to hold gage against specimen for a minimum of one minute. Allow to dry 2 to 3 minutes.
i. Remove transparent tape slowly at a 180° peel angle to ensure gage will not lift off.
j. Remove excess adhesive with an X-acto knife.
5.5.4.1.9 Connecting lead wires.
a. Lead wire should be approximately 13 inches in length and soldered and trimmed both ends.
b. Bend the end of the wire that is to be connected to the gage into the shape shown in FIG. 16A.
c. Put a small amount of flux onto gage tabs and solder a small dot of solder onto each tab.
d. Holding lead wire down on top of the solder dot, touch iron on wire. This will solder the lead to the tab. Repeat for the other lead.
e. Remove any flux left with a cotton swab or soft brush soaked in MEK.
f. Using 1/2" tape, fold a loop in the wire and tape it down 1/4" from gage.
g. Apply one coat of Gagekote and allow to dry.
h. Trim excess Gagekote from sides of specimen.
i. Check resistance using an ohmmeter.
j. Each specimen shall be visually and dimensionally inspected prior to testing. Any flaws or irregularities in fiber orientation, fiber spacing, etc., are to be recorded as part of the test data. Use a suitable ball type micrometer reading to at least 0.001 inch to measure specimen. Use minimum measurements of each specimen for calculating values.
5.5.5 Strain Gage Calibration. Each strain gage attached to the specimen must be calibrated prior to running the test. The gages are actually fine wire which stretch or compress with the specimen and thus increase or decrease in diameter. This changes the electrical resistance of the wire, and when calibrated, can be related to strain in the gage by changing one of the normally constant resistors in the measurement system a known amount. By interpreting this resistance change as though it were occuring at the strain gage, calculations can be made to determine the amount of strain the resistance change represents. The exact procedure is as follows:
a. A 10,000 ohm resistor will be used for shunt calibration.
b. Determine the elongation range needed for practical strain measurement by noting the expected elongation at failure. Note also the gage factor and resistance of the gage.
c. Convert this expected elongation at failure to strain in inches per inch by dividing by 100.
R cal =selected calibration resistance, ohms=10,000
Where:
R g =gage resistance, ohms (given)
N=number of active arms (variable resistors). This will normally be one (1), the resistance gage.
GF=gage factors (given)
L/L=selected strain, inches per inch (% expected elongation divided by 100)
d. From the formula below, determine the strain that this selected resistance represents:
L/L=R.sub.g N (GF) R.sub.cal
e. Set the recorder pen to read this strain directly on chart. Thus, if the calculated strain is 0.00126 inches per inch (0.126%), then pen is set to 1.26 inches on the chart. A one inch deflection on the chart would then represent a 0.001 inch/inch strain and a direct readout of strain is possible.
f. It may be in some cases desirable to set the pen at some multiple of the calculated strain. For a 0.00126 inch per inch calculated strain, the pen may be set to 2.52 inches on the chart. Then the direct readout would be such that a two inch deflection would represent a 0.001 inch/inch strain.
g. Repeat the calibration for each gage on the sample.
h. When no gages are attached to the sample, this calibration of strain does not apply.
5.5.5.1 Longitudinal tensile test. The 0° tensile test procedure shall be as follows:
a. Mount the test specimen (see FIG. 15) into the modified Instron grips as shown in FIG. 16. Manually lower the crosshead until the Instron grips contact the specimen. Allow the specimen to align itself by the self-tightening action of the Instron grips.
b. The crosshead speed shall be 0.5 inch/minute unless otherwise specified.
5.5.5.2 Tensile strength. Calculate the tensile strength of the 0° laminate specimens as follows (see FIG. 17): ##EQU19##
5.5.5.3 Elongation at failure. The elongation at failure is read directly from the axial strain gage curve at the point of failure and reported as percentage (see FIG. 17). % elongation=reading at failure from axial strain gage curve.
5.5.5.4 Tensile modulus of elasticity. Determine the tensile modulus as follows:
a. Construct a line tangent to the axial strain gage curve at 0.4% strain (see FIG. 17).
b. Determine the load at 0.4% strain on the chart and calculate the slope of the line. ##EQU20## c. Use this value to calculate the tensile modulus as follows: ##EQU21## d. Tensile strength and modulus shall be normalized to 100% fiber volume by dividing numbers obtained by fiber fraction in the panel.
5.5.5.5 Short Beam Shear Strength. The short beam shear strength of the laminates shall be determined in accordance with the following:
5.5.5.6 Test specimens. Test specimens shall be prepared in accordance with the following:
a. Cut specimens to finished dimensions from unidirectional laminates with plies parallel to the longitudinal axis.
b. Each specimen shall be visually and dimensionally inspected prior to testing. A suitable ball type micrometer reading to at least 0.001 inch shall be used. Any flaws or irregularities in fiber orientation, fiber spacing, etc., are to be recorded as part of the test data. Use minimum measurements of each specimen for calculating values.
c. Specimen shall be 0.080 nominal thick, 0.250±0.005" wide, 0.60±0.05" long.
5.5.5.7 Short beam shear test. The short beam shear test procedure shall be as follows:
a. Set the crosshead speed at 0.05 inch/minute unless otherwise specified.
b. Adjust the support noses to a span 4 times the average specimen thickness for the lot being tested unless otherwise specified. Span is to be measured with a rule.
c. The loading nose shall have a 0.250 inch diameter and support noses shall have a 0.125 inch diameter unless otherwise specified. Run test at 77°±5° F.
d. Using forceps, install the specimen in the test fixture on the support noses. Align the specimen by pushing specimen back until it rests against the rear stops on the support noses, and center it on the two noses.
e. operate the machine to specimen failure according to the Instron Instructions manual.
f. Calculate the short beam shear strength at failure as follows: ##EQU22## Where: A=short beam shear stress, psi
p=total load at failure, lbs.
b=specimen width, in.
t=specimen thickness, in.
5.6 Compressive Strength--Determine according to ASTMD 695. The resin used was Hercules 3501-6 resin. An alternate resin is shown in 5.3.1 (II) and (III).
APPENDIX III
Determination of Dry Heat Tension
1. Scope
1.1. This test method covers the dry heat tension of acrylic filament yarn as a carbon precursor from 1 Kf to 12 Kf, which is related to extensibility under oxidation process.
2. Requirements
2.1. Equipments (FIG. 21)
2.1.1. A set of yarn running device including a heat plate and an electric furnace.
2.1.2. Temperature control device.
2.1.3. 3.0 Kg tension meter.
2.1.4. A recorder.
2.1.5. A cheese holder.
3. Test Procedure
3.1 Preparation for measurement.
3.1.1. Adjust measuring conditions. Standard conditions are as follows:
______________________________________running speed of sample yarn 0.7 m/minstretch ratio 1.20 ×temperature of heat plate 280° C.chart speed of recorder 2 cm/minfull scale of recorder chart 500 g for 1000 filaments 1500 g for 3000 filaments 3000 g for 12000 filaments______________________________________
3.2. Measurement
3.2.1. Check the reproduceability of tension level by measuring a blank sample.
3.2.2. Set the sample yarn on the yarn running device as shown in FIG. 21.
3.2.3. Start yarn running, then record the tension time relation for about 10 minutes.
3.3. Calculation
3.3.1. Read mean value of tension for each 1 cm on the chart.
3.3.2. ##EQU23## where Z=sum of the individual tension datum (g)
n=number of tension data
D=nominal tow denier
APPENDIX IV
Determination of Dry Heat Elongation
1. Scope
1.1. This test method covers the dry heat elongation of acyrlic filament yarn as a carbon precursor from one to twelve thousand filaments per bundle.
2. Requirements
2.1 Equipment
2.1.1. Apparatus for measuring of Dry Heat Elongation, including
electric furance, 600 mm in length, having an effective length of 400 mm.
stretching unit,
tension meter,
temperature programing and control unit, and
recorder.
3. Test Procedures
3.1. Preparation for measuring
3.1.1. Adjust the measuring conditions as follows,
Temperature program: temperature increased from room temperature to 160° C. where stretching starts and then increased to 225° C.
Stretching speed: 16 mm/min.
Chart speed: 10 mm/min.
Initial weight: 0.02 g/d
Full scale:
1 Kg for 1 Kfilaments
2 Kg for 3 Kfilaments
5 Kg for 6 Kfilaiments
10 Kg for 12 Kfilaments
3.1.2. Set the sample yarn to the apparatus as shown in FIG. 22.
3.2. Measurement
3.2.1. Start heating to 160° C. at the constant rate of heating.
3.2.2. Measure the length between ribbons attached to the sample yarn.
3.2.3. Start stretching at 160° C. and continue stretching until yarn beaking. Write a check mark on the cart at 10% elongation.
3.3. Calculation
3.3.1. Thermal Stress at 10% Elongation (THS) ##EQU24## where F=load at 10% elongation as shown in FIG. 23.
D=nominal denier
3.3.2. Dry Heat Elongation (DHE) ##EQU25## where BL=breaking elongation on chart (mm)
SS=stretching speed (mm/min)
CS=chart speed (mm/min)
EL=effective length of electric furnace (mm)
(d)L=length change between ribbons of samples yarn by heating from room temperature to 160° C. (mm) | Novel carbon fiber in the form of a plurality of tows or bundles comprising a multitude of continuous filaments is disclosed. The novelty of the carbon fiber resides in its unique combination of mechanical properties that make it admirably suited for use in composites comprising an organic matrix. Such composites are particularly useful in aerospace applications that have designs in which weight and performance are critical. | 3 |
CROSS REFERENCE TO RELATED APPLICATION
This is a continuation of application of Ser. No. 09/457,421, filed on Dec. 7, 1999, which is a continuation-in-part of Ser. No. 08/276,289, filed on Jul. 20, 1994, now abandoned, which is a continuation-in-part of Ser. No. 08/105,232, filed on Aug. 11, 1993, now abandoned, which is a continuation-in-part of Ser. No. 07/926,491, filed on Aug. 7, 1992, now abandoned.
BACKGROUND OF THE INVENTION
A major goal of biomedical research is to provide protection against viral disease through immunization. One approach has been to use killed vaccines. However, large quantities of material are required for killed vaccine in order to retain sufficient antigenic mass. In addition, killed vaccines are often contaminated with undesirable products during their preparation. Heterologous live vaccines, using appropriately engineered adenovirus, which is itself a vaccine, seems like an excellent immunogen [Chanock R., JAMA, 195, 151 (1967)]. Our invention concerns vaccines using adenovirus as a vector.
Presently marketed adenovaccine comprises live, infectious adenoviruses in an enteric-coated dosage form. Upon administration to the patient to be vaccinated, the virus is carried past the upper-respiratory system (where disease-producing infection is thought to occur), and is released in the intestine. In the intestine, the virus reproduces in the gut wall, where, although it is not capable of causing adenoviral disease, nevertheless induces the formation of adenovirus antibodies, thus conferring immunity to adenoviral disease. In our invention, live, infectious adenovirus which has been engineered to contain genes coding for antigens produced by other disease-causing organisms. Upon release the virus will reproduce and separately express both the adenoviral antigen and the pathogen antigen, thereby inducing the formation of antibodies or induce cell mediated immunity to both adenovirus and the other disease-causing organism. By “live virus” is meant, in contradistinction to “killed” virus, a virus which is, either by itself or in conjunction with additional genetic material, capable of producing identical progeny. By “infectious” is meant having the capability to deliver the viral genome into cells.
Roy, in European Patent Publication 80,806 (1983), proposed a method for producing immunity to microbial diseases by the administration of a microbe containing a foreign gene which will express an antigen of a second microbe to which immunity is conferred. He states that preferred oral preparations are enteric coated. Dubelcco proposed recombinant adenovirus vaccines in which the surface protein of adenovirus is modified to contain in its structure a segment of foreign protein which will produce a desired biological response on administration to animals. [PCT International Publication WO 83/02393 (1983)]. Davis discloses oral vaccines derived from recombinant adenoviruses. [UK Patent GB 2166349 B].
Human immunodeficiency virus type 1 (HIV-1) has been etiologically associated with acquired immunodeficiency syndrome (AIDS) and related disorders. [Barre-Sinoussi, F., Science 220: 868 (1983); Gallo, R., Science 224: 500 (1984); Popovic, M., Science 224: 497 (1984); Sarngadharan, M., Science 224: 506 (1984)]. AIDS is now a worldwide epidemic for which, currently, there is no vaccine or cure. Most of the effort for vaccine development has focused on the envelope (env) glycoprotein as an antigen which might provide protective immunity. Antisera prepared against purified gp 120 can neutralize HIV-1 in vitro. [Crowl, R., Cell 41: 979 (1985); Putney, S., Science 234: 1392 (1986); Ho, D., J. Virol. 61: 2024 (1987); Nara, P., Proc. Natl. Acad. Sci. USA 84: 3797 (1987)]. HIV-1 envelope antigen has been produced in different expression systems including Escherichia coli [Crowl, R., Cell 41: 979 (1985); Chang, T., Bio/Technology 3: 905 (1985); Dawson, G., J. Infect. Dis. 157: 149 (1988)] as well as mammalian [Chakrabarti, S., Nature 320: 535 (1986); Dewar, R., J. Virol. 63: 129 (1989); Rekosh, D., Proc. Natl. Acad. Sci. USA 85: 334 (1988); Whealy, M., J. Virol. 62: 4185 (1988)] yeast [Barr, P., Vaccine 5: 90 (1987)] and insect cells [Hu, S., Nature 328: 721 (1978); Rusche, J., Proc. Natl. Acad. Sci. USA 84: 6294 (1987)].
Live recombinant vaccinia virus expressing the entire HIV-1 env glycoprotein [Hu, S., J. Virol. 61: 3617 (1987)] or purified recombinant gp 120 env glycoprotein [Berman, P., Proc. Natl. Acad. Sci. USA 85: 5200 (1988)] were evaluated in chimpanzees as vaccine candidates. Active immunization with these vaccines induced a good cell-mediated immune response as well as cytotoxic T-cell activity to the env antigen [Zarling, J., J. Immunol. 139: 988 (1987)]. All experimental animals seroconverted as assayed by ELISA and Western blotting. However, immunized chimpanzees developed no or only low titers of neutralizing antibody to HIV-1. Challenge with live virus failed to protect chimpanzees against these vaccines. Type-specific HIV-1 neutralizing antibodies were found in chimpanzees early in infection against a variable domain (V3) within the C-terminus half of gp 120 [Goudsmit, J., Proc. Natl. Acad. Sci. USA 85: 4478 (1988)]. The recombinant gp 120 made in insect cells has also been shown to induce humoral immune response in goat (Rusche J., Proc. Natl. Acad. Sci. USA 84: 6294 (1987)]. Zagury [Nature 332: 728 (1988)] have demonstrated both anamnestic humoral and cellular immune reaction in humans using a vaccine virus recombinant expressing gp 160 [Chakrabarti, S., Nature 320: 535 (1986); Hahn, B., Proc. Natl. Acad. Sci. USA 82: 4813 (1985)]. Both group-specific cell-mediated immunity and cell-mediated cytotoxicity against infected T4 cells were also found. These results indicate that an immune state against HIV-1 can be obtained in humans using recombinant env-based vaccine. Recently, Desrosiers has shown that vaccination with inactivated whole simian immunodeficiency virus (SIV) can protect macaques against challenge with live SIV. [Proc. Natl. Acad. Sci. USA 86: 6353 (1989)]. These data provide hope that vaccine protection against human AIDS virus, HIV-1, infection may be possible.
Chanda discloses high level expression of the envelope glycoproteins of HIV-1 in the presence of rev gene using helper-independent adenovirus type 7 recombinants. [Virology 175: 535 (1990)]. Vernon discloses the ultrastructural characterization of HIV-1 gag subunit in a recombinant adenovirus vector system. [J. Gen. Virology 72: 1243 (1991)]. Vernon also discloses the preparation of the HIV-1 recombinant denoviruses Ad7-rev-gag and Ad4-rev-gag.
SUMMARY OF THE INVENTION
This invention provides a method of producing antibodies or cell mediated immunity to an infectious organism in a warm blooded mammal which comprises administering to said warm blooded mammal intranasally, intramuscularly, or subcutaneously, live recombinant adenoviruses in which the virion structural protein is unchanged from that in the native adenovirus from which the recombinant adenovirus is produced, and which contain the gene coding for the antigen corresponding to said antibodies or inducing said cell mediated immunity. The warm blooded mammal is preferably a primate, most preferably a human.
In its preferred embodiments, this invention provides a method of producing antibodies to human immunodeficiency virus (HIV-1), hepatitis B, hepatitis C, human papilloma virus, respiratory syncytial virus, rotavirus, or parainfluenza virus in a warm blooded mammal which comprises administering to said warm blooded mammal intranasally, intramuscularly, or subcutaneously, live recombinant adenoviruses in which the virion structural protein is unchanged from that in the native adenovirus from which the recombinant adenovirus is produced and which contain the gene coding for, respectively, human immunodeficiency virus, hepatitis B, hepatitis C, human papilloma virus, respiratory syncytial virus, rotavirus, or parainfluenza virus.
This invention also provides composition for producing antibodies or cell mediated immunity to an infectious organism in a warm blooded mammal, comprising live recombinant adenoviruses in which the virion structural protein is unchanged from that in the native adenovirus from which the recombinant adenovirus is produced, and which contain the gene coding for the antigen corresponding to said antibodies or inducing said cell mediated immunity, said composition being formulated in an intranasal, intramuscular, or subcutaneous dosage form.
Although this specification specifically refers to adenovirus of types 4, 5, or 7, live, infectious adenovirus of any type may be employed in this invention. Additionally, while the specification specifically refers to adenoviruses having an early region 3 (E3) deletion, adenoviruses which are attenuated, contain a temperature sensitive lesion, or a E1 deletion may also be used as a vector. Similarly, although specific reference has been made to vaccines producing antibodies to HIV, hepatitis B, hepatitis C, human papilloma virus, respiratory syncytial virus, rotavirus, or parainfluenza virus, our invention provides vaccines against any infectious agent containing an antigen to which a warm-blooded animal will produce antibodies or cell mediated immunity, and which antigen is coded for by a gene composed of up to about 3000 base pairs. Thus, for example, included within the scope of the invention are immunization against such diseases as influenza, hepatitis A, cholera, E. coli, pertussis, diphtheria, tetanus, shigellosis, gonorrhea, mycoplasma pneumonia, and the like.
In one embodiment, the method of treatment includes administering the recombinant adenovirus both prophylactically to an HIV-1 susceptible mammal and as immunotherapy following detection of HIV in said mammal. Regimens containing the following recombinant adenoviruses were used to produce the anti-HIV responses.
In a preferred embodiment, the method is a method of protecting a primate against HIV-1 infection comprising intranasal or intramuscular administration to said primate of an intranasal or intramuscular dosage of a recombinant adenovirus having a deletion in the E3 gene and an expression cassette containing a major late promoter, a tripartite leader sequence, part or all of the HIV-1 gp160 sequence and a polyadenylation signal sequence. Preferably the primate is a human. The expression cassette is inserted into the recombinant adenovirus between the E4 promoter and the inverted terminal repeat. Optionally the intranasal or intramuscular administration of recombinant adenovirus is followed by one or more intranasal or intramuscluar booster administrations of the recombinant adenovirus. The recombinant adenovirus is a serotype 4, 5 or 7 serotype adenovirus and optionally the expression cassette additionally comprises part of all of the coding sequence for the HIV-1 rev gene inserted in frame after the HIV-1 gp160 sequence and before the polyadenylation signal sequence. The HIV-1 gp160 sequence can be from the MN strain gp160 sequence or the LAV strain gp160 sequence. In an alternative embodiment, the HIV-1 gp160 sequence is replaced by a sequence encoding the gag-pro region of HV-1. In either embodiment, when the initial administration is followed by one or more intranasal or intramuscular booster administrations of the recombinant adenovirus, the last booster administration may be followed by an intramuscular injection of at least one booster immunization with an HIV-1 subunit antigen preparation, preferably containing an HIV-1 gag and/or env polypeptide sequence. For intranasal administration, the intranasal dosage administered is in the range of 1×10 7 pfu of virus and for intramuscular administration, the intramuscular dosage administered is in the range of 1×10 7 to 2×10 9 pfu of virus. The intranasal booster is administered in a dosage in the range of 1×10 7 to 1×10 8 pfu of virus and the intramuscular booster is administered in a dosage in the range of 1×10 10 to 8×10 10 pfu of virus. When a subunit antigen booster is employed, the subunit antigen preparation contains between 200 μg and 0.5 mg of HIV-1 polypeptide.
Virus Name
Descriptive Name
ATCCName
Ad7-env
Ad7-tplenv-tplHrev
VR-2299
Ad7-gag
Ad7-tplgag-tplHrev
VR-2393
Ad7-gag-1
Ad7-rev-gag
VR-2392
Ad4-env
Ad4-tplenv-tplHrev
VR-2293
Ad4-gag
Ad4-tplgag-tplHrev
VR-2391
Ad4-gag-1
Ad4-rev-gag
VR-2390
Ad5-env
Ad5-tplenv-tplHrev
VR-2297
Ad5-gag
Ad5-tplgag-tplHrev
VR-2298
Ad7-env MN
Ad7-tplenv MN -tplHrev
VR-
Ad4-env MN
Ad4-tplenv MN -tplHrev
VR-
Ad5-env MN
Ad5-tplenv MN -tplHrev
VR-
Referring to the above table Ad4, Ad5, and Ad7 refer to human adenoviruses types 4, 5, and 7 respectively in which the E3 region has been deleted. Env refers to the HIV envelope glycoprotein (gp 160) gene. Gag refers to the HIV gag/pro gene. Rev refers to the HIV regulatory gene. Hrev refers to an altered version of the rev gene where the nucleotide sequences were changed without changing the amino acid sequence employing codons that were frequently used in human genes. The sequence of Hrev is set forth in FIG. 2 . Tpl refers to the upstream adenovirus tripartite leader sequence with an intervening sequence between the first and second leaders that are positioned in front of the recombinant genes. The constructs designated Ad7-env, Ad7-gag, Ad7-gag-1, Ad4-env, Ad4-gag, Ad4-gag-1, Ad5-env, and Ad5-gag contain either the gag or the env gene from the LAV strain of HIV and the constructs Ad7-env MN , Ad4-env MN , and Ad5-env MN contain the env gene from the MN strain of HIV. The recombinant adenoviruses made from the LAV and MN strains of HIV-1 are illustrative of recombinant adenoviruses covered by this invention. This invention also covers recombinant adenoviruses which include the env and/or gag genes from other strains of HIV-1.
Both the Ad-env and Ad-env MN adenoviruses were shown to replicate in human A549 cells and expressed recombinant env antigen in vitro demonstrating their capability of generating cell mediated, humoral, and secretory immunity in a mammal.
As described in detail below, intranasal administration of Ad-HIV recombinant viruses to naive chimpanzees resulted in both priming and boosting of both humoral and cell-mediated immune responses directed at HIV recombinant antigens. The recombinant adenoviruses administered to chimpanzees were shown to produce antibodies to the env and gag proteins of HIV. IgG antibodies specific for HIV were observed in nasal, saliva, and vaginal secretions following administration of the recombinant adenoviruses and IgA antibodies specific for HIV were observed in nasal and saliva secretions. The first set of recombinant viruses (Ad7) appeared to be shed the longest period of time and induce the best anti-Ad antibody response. The results also showed that administration of Ad-HIV vaccines by the intranasal route was superior to administration of enteric-coated recombinant viruses by the oral route.
Optimum immune responses directed at HIV antigens required primary infection one booster immunization with a heterotypic recombinant Ad-HIV to elicit strong anti-HIV binding antibodies. Intranasal administration of the Ad-HIV viruses effectively primed chimpanzees to respond with high titered neutralizing antibodies to HIV-1 following subsequent HIV-1 subunit protein booster immunization.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the inhibition of gp120 binding to CD4 by sera induced in dogs by recombinant Ad-HIV vaccines.
FIG. 2 illustrates the DNA sequence of the expression cassette containing the HIV gp160 coding sequence and the Hrev coding sequence inserted into the E3 deleted region of Adenovirus serotype 7 as described in Example 6.
DETAILED DESCRIPTION OF THE INVENTION
Preparation of Representative Recombinant Adenoviruses
The following Examples show the construction of representative recombinant adenoviruses of this invention. The recombinant viruses were propagated on A549 cells and subsequently titered on A549 cells.
EXAMPLE 1
Ad7-gag-1
The construction of recombinant adenoviruses containing the gene for the HIV envelope protein has been described [Chanda, P., Virology 175: 535 (1990)]; a similar procedure was used to incorporate gag and pro [see Vernon, S., J. Gen. Virology 72: 1243 (1991)]. Briefly, a DNA fragment containing the entire gag and pro coding regions (bp 335 to 2165) of HIV-1 strain LAV [Wain-Hobson, S., Cell 40: 9, (1985)] was constructed with a unique Sa/I site in front of the AUG codon of the gag gene and an XbaI site at bp 2165, for the insertion of the viral rev-responsive element (rre; bp 7178 to 7698). A 2.37 kb Sal fragment containing the three HIV-1 sequences was inserted at a SaI site in an expression cassette containing the adenovirus type 7 (Ad7) major late promoter (MLP), the tripartite leader (TPL) with an intervening sequence between the first and second leaders, and the hexon polyadenylation site (poly A) as described in Chanda [Virology 175: 535 (1990)]. The cassette was inserted 159 bp from the right end of an Ad7 genome [Sussenbach, The Adenoviruses, Ginsberg, ed., Plenum Press, pp. 34-124 (1984)] containing the HIV-1 rev gene [Feinberg, M., Cell 46: 807 (1986); Sodroski, J., Nature 321: 412 (1986)] in a deleted [79.5 to 88.4 map units (m.u.)] E3 region [Chanda, P., Virology 175: 535 (1990)].
EXAMPLE 2
Ad4-gag-1
Following the procedure for the construction of the Ad7-gag-1 recombinant adenovirus in Example 1, a similar expression cassette containing analogous Ad4 sequences and the three HIV coding regions were inserted at a site 139 bp from the right end of an Ad4 genome which contained HIV-1 rev in an E3 deletion between 76 and 86 m.u.
EXAMPLE 3
Ad5-env
Ad5-tplenv-tplHrev contains the entire coding sequence of HIV-1 (LAV strain) gp160 and a modified version of the rev gene, called Hrev. Both the env as well as rev gene are preceded by a synthetic copy of the Ad5 tripartite leader (Ad5-tpl). Ad5-tpl was chemically synthesized and was cloned in pTZ vector. Then the gp 160 DNA sequence was inserted behind the Ad5-tpl to create Ad5 -tplenv/PTZ18R clone. The Hrev (˜360bp) was also chemically synthesized where the nucleotide sequences were changed without changing the amino acid sequence with the help of the codon usage. This was done to avoid homologous recombination as some identical sequences exist between env and rev. In an analogous way like Ad5-tplenv construct, Hrev gene was also inserted behind tpl in pTZ18R vector to create the plasmid, Ad5-tplHrev. The entire sequence containing Ad5-tplHrev was excised out and then inserted behind Ad5-tplenv to create the plasmid, Ad5-tplenv-tplHrev. This plasmid was then inserted in the deleted E3 region of Ad5 Marietta strain (78.8-85.7 mu deletion) at 78.8 mu. This plasmid was linearized with BglI enzyme and then mixed with 0-87 mu SnaB1 fragment that was derived from the wild-type purified Ad5 virus. After A549 cells were transfected with the DNA mixtures, recombinant virus plaques were picked, plaque purified three times, and their genomic structures were confirmed by restriction endonuclease site analysis of DNA extracted from infected cells by the method of Hirt. [J. Mol Bio. 26: 365 (1967)].
EXAMPLE 4
Ad5-gag
Ad5-tplgag-tplHrev contains the entire gag and pro region as well as the modified rev gene, Hrev. A copy of the Ad5 synthetic tripartite leader was placed in front of the gag and Hrev genes. A DNA fragment containing the entire gag and pro regions (bp 335 to 2165 of LAV strain of HIV-1) was constructed with a unique SalI site in front of AUG codon of the gag gene and an xba site at bp 2165, for the insertion of the viral rev-responsive element (rre; bp 7178-7698). Two separate plasmids Ad5-tplgag as well as Ad5-tplHrev were constructed in a similar way as described for Ad5-tplenv-tplHrev. Then the Ad5-tplHrev fragment was inserted behind Ad5-tplgag to create the plasmid Ad5-tplgag-tplHrev. Then the fragment Ad5-tplgag-tplHrev was inserted at the unique Xbal site at map position 78.8 of the Ad5 Marietta strain with an E3 deletion (78.8-85.7 mu E3 deletion). Then the final plasmid containing the Ad5 sequence was linearized and then mixed with the 0-87 mu SnaBl viral fragment for transfection. Recombinant plaques were picked up, plaque purified three times, and were checked by Hirt analysis of DNA extracted from the infected cells.
EXAMPLE 5
Enteric Coated Capsules
Recombinant adenoviruses were grown in A549 cells and harvested following 3 cycles of freeze-thawing. Clarified infected cell lysates were lypholized and 60 to 100 mg were packed into #2 gelatin capsules using a 1 ml syringe plunger under dehumidified conditions. The capsules were coated with a 10% cellulose acetate phthalate in acetone/100% Ethanol (1:1) by manually dipping each end 6 times with air drying between dips. A coating between 69 to 77 mg of cellulose acetate phthalate was formed under these conditions. Sample capsules were tested for resistance to simulated gastric fluid (0.32% pepsin, 0.2% NaCl pH 1.2) at 37 C using a VanKel Disintegration Testor apparatus for 1 hr. The capsules were inspected for holes or cracks and transferred to a 15 ml tube containing 10 ml of simulated intestinal fluid (1.0% pancreatin, 0.05 M monobasic potassium phosphate pH 7.5) and rotated at 37° C. All capsules tested were resistant to simulated gastric fluid for 1 hr at 37° C. with agitation and began to dissolve within 15 min. in simulated intestinal fluid. The amount of virus was titrated on confluent A549 cell monolayers by a plaque assay and the viral DNA stability confirmed by Hirt analysis.
EXAMPLE 6
Ad7-env MN
The construction of recombinant adenoviruses containing the coding sequence of the env (gp 160) gene of MN strain of HIV-1 is described briefly as follows: The 125 bp (6243 to 6367) fragment of the amino (NH 2 ) terminus of the env (gp160) gene including the initiation codon (ATG) as well as consensus Kozak sequence was amplified by polymerase chain reaction (PCR) from the clone pMNST 1-8-9. This fragment was then cloned in pGEM vector and the resultant clone was designated as pGEMMNenv. The following fragments of DNA were isolated by digesting with the restriction enzymes KpnI and Xbal from the clone PAd5tpl MN env 223 (6367 bp to 8816 bp), XhoI+KpnI fragment from PGEMenv and salI+Xbal fragment from pAd7tpl 18RD. All of these fragments were ligated together and the resultant clone was designated as pAd7tpl MN env. This plasmid was then digested with XbaI and treated with calf intestine alkaline phosphatase (CIAP). The NheI+Xbal fragment of Hrev gene was then isolated from the plasmid, pAd7tplHrev 18RD. The clone that was obtained after ligating these two fragments together was designated as pAD7tpl MN envtplHrev. This plasmid was then digested with NheI+ Xbal and then ligated to the E3 deletion plasmid of Ad7, pAd7ΔE3 (68 m.u. to 100 m.u. deletion) that was also digested with XbaI and then treated with CIAP. The resultant plasmid was designated as pAD7ΔE3tpl MN envtpl MN Hrev. This plasmid was digested with EcoRI and mixed with the EcoRI (0-87 m.u.) fragment of the Ad7 genomic DNA. A549 cells were then transfected with these DNAs. Recombinant plaques obtained from in vivo recombination were identified by the appropriate restriction digestion analyses of the Hirt DNA. The plaques were also identified by the production of gp160, gp120, and gp41 using appropriate antibodies on Western blots.
FIG. 2 illustrates the complete DNA sequence of the expression cassette containing the HIV gp160 coding sequence and the Hrev coding sequence inserted into the E3 deleted region of Adenovirus serotype 7 as described above. The first 200 bp tripartite leader sequence begins at bp 88, the HIV gp 160 sequence extends from bp 306 through bp 2879, the second tripartite leader sequence extends from bp 2886 through bp 3085 and the Hrev sequence extends from bp 3099 through 3449 in the Ad7 deleted E3 region.
EXAMPLE 7
Ad4-env MN and Ad5-env MN
The construction of Ad4 and Ad5 recombinants are the same as that of Ad7-env MN except that for Ad4, EcoRI digested DNA from pAd4ΔE3tpl MN envtplHrev was combined with the BclI (0-87 m.u.) fragment from the Ad4 genomic DNA to produce the recombinant Ad4 virus. Similarly for Ad5, MluI-digested DNA from pAd5ΔE3tpl MN vtplHrev was combined with the Spel (0-75 m.u.) fragment of Ad5 genomic DNA to produce the recombinant Ad5 adenovirus. Like Ad7, both Ad4 and Ad5 recombinants were obtained from A549 cells.
EXAMPLE 8
Subunit Antigen Preparation
gp-120 MN was prepared according to Kaufman, R. J., Nucleic Acid Res. 19: 4485 (1991) and was used in SAF-m adjuvant (Allison, A. C., J. Imm. Meth. 95: 157 (1986). gp-120 SF2 was prepared according to Scandella, C. J., AIDS Res. Human Retroviruses 9: 1233 (1993) and was used in MF-59 adjuvant (Keitel, W., Vaccine 11: 909 (1993)). HA-env K17K was prepared according to Kalayan, N., Vaccine 12: 753 (1994) and was used in SAF-m adjuvant.
Measurement of Replication and Antigen Expression
Human A549 cells were infected (MOI 10:1) with recombinant adenovirus types 4, 5, and 7 that contained either the LAV or MN env genes. At 34 hours post-infection, virus titer and env antigen expression was determined in duplicate samples. One dish of infected cells was subjected to 3 cycles of freeze thawing and the cell lysate was tested for the presence of infectious virus by plaque assay. The second culture dish was washed, detergent solubilized, and an aliquot of the cell lysate was loaded on to a 10% polyacrylamide gel. Following electrophoresis, the separated proteins were transferred to nitrocellulose by a Western blot apparatus. The transferred proteins were immunostained with anti-env reagents. A known standard, recombinant gp160, was added prior to electrophoresis. The resulting immunoblot was scanned by a densitometer and the amount of recombinant env determined. There were no significant differences seen between wild type adenoviruses and the recombinant adenoviruses expressing either the LAV or MN env gene. Both types of recombinant adenoviruses, LAV or MN, produced similar amounts of env antigen. Therefore, both types of Ad-env recombinants, LAV and MN, were able to grow in human A549 cells as well as their corresponding wild type adenovirus, and were able to express recombinant env antigen. These results therefore demonstrate that both the LAV and MN adenovirus recombinants are capable of generating cell mediated, humoral, and secretory immunity in a mammal. The data obtained are summarized in the table below.
ADENOVIRUS REPLICATION AND ANTIGEN EXPRESSION
Adenovirus
pfu/cell × 10 2
μg env/10 6 cells
Ad4 wild type
5.4
0
Ad4-env
9.1
2.1
Ad4-env MN
6.8
2.7
Ad5 wild type
22
0
Ad5-env
86
5.4
Ad5-env MN
18
5.7
Ad7 wild type
18
0
Ad7-env
11
3.1
Ad7-env MN
7.8
3.6
Treatment Regimens
Immunogenicity of the recombinant adenoviruses for HIV was evaluated in chimpanzees under four treatment regimens (1, 2, 3, and 6), and in dogs two treatment regimens (4 and 5). Protection against HIV-1 infection was evaluated in chimpanzees in the sixth treatment regimen. The first regimen consisted of administering the recombinant adenovirus orally via an enterically coated capsule (Example 5) at 0, 7, and 26 weeks followed by an env+gag subunit protein booster using alum as an adjuvant. The second regimen consisted of further treating the chimpanzees that received regimen 1 at 46 and 58 weeks with additional boosters of recombinant adenovirus administered intranasally. The third treatment regimen consisted of administering recombinant adenovirus intranasally to naive chimpanzees at weeks 0, 24, and 52 followed by an env subunit booster at week 75. The fourth treatment regimen consisted of administering recombinant adenoviruses derived from both the LAV and MN strains of HIV-1 to dogs.
The fifth treatment regiment consisted of administering env subunit boosters to either previously immunized or control dogs. Each treatment group consisted of 6 previously immunized dogs and 2 control dogs. Of the previously immunized dogs, six had received Treatment Regimen 4 (Group A); six had received Treatment Regimen 4 (Group D); six had received Ad-env HXB2 (expressing a portion of the HIV env V3 loop, derived from the LAV strain of HIV); and twelve had previously received Ad-env HXB2 (expressing a portion of the HIV env V3 loop, derived from the MN strain of HIV) (prepared according to Robert-Guroff, M., J. Virol 68: 3459 (1994) and Veronese, F. D., J. Biol. Chem. 268: 25894 (1993)).
The sixth treatment regimen consisted of administering Ad-env MN recombinants to chimpanzees, followed by 0, 1 or 2 Ad-env MN booster immunizations using heterologous Ad vectors. The chimpanzees were then given one or two booster immunizations with env (gp 120 SF2 ) subunit antigen preparations, followed by a challenge with the SF2 strain of HIV.
The following table summarizes treatment regimens 1 and 2.
TREATMENT REGIMENS 1 AND 2
Immunization
Time
Chimpanzees 1 and 2
Chimpanzee 3
Regimen 1
Primary*
0 weeks
1.5 × 10 7 pfu Ad7-env
1.5 × 10 7 pfu Ad7-env
2.0 × 10 9 pfu Ad7-gag-1
1st Booster*
7 weeks
1.1 × 10 10 pfu Ad4-env
1.1 × 10 10 pfu Ad4-env
1.0 × 10 10 pfu Ad4-gag-1
2nd Booster*
26 weeks
7.9 × 10 10 pfu Ad5-env
7.9 × 10 10 pfu Ad5-env
3rd Booster +
34 weeks
200 ug env in 0.2% alum
200 μg env in 0.2% alum
500 ug env in 0.2% alum
Regimen 2
1st Intranasal Boost
46 weeks
1.0 × 10 8 pfu Ad7-env
1.0 × 10 8 pfu Ad7-env
1.0 × 10 8 pfu Ad7-gag
2nd Intranasal Boost
58 weeks
1.0 × 10 8 pfu Ad4-env
1.0 × 10 8 pfu Ad4-env
1.0 × 10 8 pfu Ad4-gag
*Each dose was administered in enteric-coated gelatin capsules on 3 consecutive days.
+ Administered intramuscularly.
The following table summarizes treatment regimen 3.
TREATMENT REGIMEN 3
Immuniza-
tion
Time
Chimpanzees 4 and 5
Chimpanzee 6
Primary*
0 weeks
1.0 × 10 7 pfu Ad7-env
1.5 × 10 7 pfu Ad7-env
1.0 × 10 7 pfu Ad7-gag
1st Booster*
24 weeks
1.0 × 10 7 pfu Ad4-env
1.5 × 10 7 pfu Ad4-env
1.0 × 10 7 pfu Ad4-gag
2nd Booster*
52 weeks
1.0 × 10 7 pfu Ad5-env
1.5 × 10 7 pfu Ad5-env
1.0 × 10 7 pfu Ad5-gag
3rd Booster +
75 weeks
0.5 mg env
0.5 mg env
*Administered intranasally.
+ Administered intramuscularly.
The following Table summarizes treatment regimen 4.
TREATMENT REGIMEN 4
Group A
Group B
Group C
Group D
Immunization
Time
(n = 6)
(n = 3)
(n = 3)
(n = 6)
Primary*
0 weeks
Ad7-env MN
Ad7-env
Ad7-env MN
Ad5-env MN
+ Ad7-env
1st Booster*
12 weeks
Ad5-env MN
Ad5-env
Ad5-env MN
Ad4-env MN
+ Ad5-env
*Each recombinant adenovirus was administered intratracheally at a dose of 1 × 10 9 per dog.
The following summarizes treatment regimen 5. Each group consisted of 6 dogs that were previously immunized, as described above, and 2 control dogs. Each group received 50 μg of the subunit in adjuvant at 0 weeks (20-28 weeks from the last Ad-env administration). Group A received gp120 SF2 in MF59 adjuvant; Group B received CHO-derived gp120 MN (antibody purified) in SAF-m; Group C received Ad5-gp160 MN -derived gp160 MN (lentil lectin purified) in SAF-m; Group D received Ad5-gp160 MN -derived gp160 MN (lentil lectin purified) in MF59; and Group E received HA-env K17K (expressing a portion of the HIV env V3 loop). Twelve weeks later dogs were identically boosted with the same subunit, with the exception of Group D dogs which were reboosted with the HA-env K17K .
The following table summarizes treatment regimen 6.
TREATMENT REGIMEN 6
Time
Chimpanzee Number
Immunization
(weeks)
7
8 & 9
10
11
12
Primary
0
Ad5-env MN +
Ad5-env MN
Ad5-env MN ,
AD5-env MN
Ad5 wild type
Ad7-env MN ,
Ad4-env MN
1st Booster
12
—
Ad7-env MN
Ad5-env MN ,
Ad7-env MN
Ad7 wild type
Ad7-env MN ,
Ad4-env MN
2nd Booster
24
—
—
—
Ad4-env MN
Ad4 wild type
Subunit Boost
26
gp120 SF2 *
—
—
—
—
Subunit Boost
38
gp120 SF2
gp120 SF2
gp120 SF2
—
Subunit Boost
48
—
—
—
gp120 SF2
MF59
Challenge
#
HIV SF2
HIV SF2
—
HIV SF2
HIV SF2
+ All Ad-env and Ad viruses were administered at a dose of 1.0 × 10 7 pfu/virus intranasally.
*50 μg HIV gp120 SF2 formulated in MF59 adjuvant was administered intramuscularly.
# Chimpanzees 7, 8, and 9 were challenged at 40 weeks; 11 and 12 were challenged at 52 weeks, and 10 was not challenged.
Measurement of Immunogenicity: Treatment Regimen 1
Chimpanzee Inoculations
Three chimpanzees (2 males and 1 female) that were screened negative for the presence of neutralizing antibodies to human adenoviruses type 4, and 7 were evaluated using treatment regimen 1. Enteric-coated capsules containing recombinant adenoviruses were given using a stomach tube under anesthesia on three consecutive days. Two chimpanzees (1 and 2) received both env and gag recombinant viruses while the third chimp (3) received only env recombinant viruses.
Adenovirus-derived subunit preparations containing env or gag gene products were purified from infected A549 cell cultures [see Vernon, S., J. Gen. Virology 72: 1243 (1991) and Natuk, R., Proc. Natl. Acad. Sci. USA 89: 7777 (1992)]. Recombinant antigens were formulated with alum adjuvant and administered intramuscularly, 200 ug/dose env and 500 ug/dose gag particles.
Whole blood, serum, and stool samples were collected at different times during the course of the experiment. Whole blood was processed to obtain white blood cell populations for FACS, HIV CTL (using recombinant vaccinia viruses expressing HIV-env, HIV-gag, or the lac gene products), and for lymphoproliferative assays to purified HIV recombinant gp160, gp120, and p24. Serum and stool specimens were stored at −70° C. until use.
Detection of Recombinant Adenoviruses in Stool Specimens
Chimpanzee stool specimens were thawed and 10% (V/V) suspensions were made into antibiotic containing DMEM. Clarified stool suspensions were used to infect confluent A549 cell monolayers in 60 mm tissue culture dishes. After a 1 hr adsorption period the unbound material was washed away and the monolayers were overlaid with an 0.5% agar overlay medium. Plaques were allowed to develop for 7-10 days and plaques were visualized by neutral red staining, counted and the agar overlay was gently removed taking care not to disturb the cell monolayer. The cell sheet was transferred to nitrocellulose filter membranes (Millipore Type HA, 0.45 um), presoaked in 20× SSC and placed on the cell layer and left in contact with the cell monolayer for 2 to 4 minutes. The filters were peeled off, air-dried, and baked for 2 hr in a vacuum oven at 80° C. Nitrocellulose filters were washed twice in 3× SSc/0.1% SDS at room temperature and prehybridized and hybridized according to standard procedures [Poncet, D., J. Virol. Methods 26: 27 (1989)]. 32 P-labeled oligoprobes were added to the hybridization buffer (1×10 6 CPM) and incubated overnight at 42° C. DNA probes were prepared by which could detect either Ad4 fiber, Ad5 fiber, Ad7 fiber, HIV-env or HIV-gag specific sequences. [Wain-Hobson, Cell 40: 9 (1985)]. The filters were washed, autoradiographed, and hybridization signals were counted.
Adenovirus Neutralization Test Procedures
Serial 2-fold dilutions (starting with 1:4) of heat-inactivated (56 C fdor 30 min.) dog serum were made in 96-well microtiter plates (0.05 ml/well) and were mixed with 0.05 ml media containing 30-100 TCID 50 virus for 1 hr at 37° C. To each well 0.05 ml of media containing 2×10 4 A549 cells were added and the plates were incubated at 37° C. 5% CO 2 for 7-10 days. All samples were done in duplicate. Virus and uninfected cell controls were included in each assay for determining the end point in test sera. Titers were expressed as the reciprocal of the lowest dilution at which 50% cytopathic effect was observed.
Detection of Anti-HIV Antibodies by ELISA and Western Blotting
Detection of anti-HIV antibodies Chimpanzee antibody responses to HIV-1 antigens were measured by testing various dilutions by commercial ELISA and Western blot kits as instructed by the manufacturers (DuPont, Wilmington, Del.).
Results
Feces were collected from each chimpanzee prior to and after virus inoculation and stored at −70° C. Ten percent suspensions were prepared from each sample and were used to infect confluent A549 cell monolayers. After 7-10 days viral plaques were identified by neutral red staining and the cell monolayers were transferred to nitrocellulose membranes. Representative samples were hybridized with various labeled oligo-probes to detect sequences specific for Ad4, Ad5, Ad7, HIV-env, or HIV-gag genes. Identification of specific recombinant Ad-HIV viruses could be determined by this plaque hybridization technique. None of the recombinant viruses were shed into the feces for longer than 7 days p.i. Peak titers were always associated with 1-3 day samples and most likely represented the non-adsorbed virus inoculum. Previous chimp studies using Ad-HBsAg recombinants had indicated that Ad-HBsAg recombinants could be detected for 30-40 days p.i. With the enteric capsule route of administration, it appeared that these recombinant viruses did not replicate well in vivo.
Seroconversion to the serotype of the adenovirus vectors employed was determined by neutralization test procedures. Very low to modest anti-adenovirus serum titers were measured to all 3 serotypes used in each of the chimpanzees.
Seroconversion to recombinant HIV gene products were determined by either ELISA or Western blotting techniques. No ELISA response was detected in any of the chimpanzees prior to the second booster inoculation with the Ad5-env recombinant. Two weeks following Ad5-env inoculation anti-env responses could be measured in 2 of the 3 animals. Intramuscular injection of gag and/or env preparations had a slight boosting effect in 1 of the 3 animals. Western blot analysis appeared to be much more sensitive than the ELISA and had the further advantage of identification of which env and/or gag gene products were being recognized as being inmmunogenic. Low serum antibody titers were measured following both the primary Ad7 recombinant and first booster with Ad4 recombinants viruses. A significant increase in serum titer to env gene products was observed following the second booster immunization with the Ad5-env recombinant. Significant increases in the 2 animals which received gag gene products were seen following injection with subunit preparations. Despite relatively good Western blot titers to HIV antigens, only 1 of the 3 animals responded with serum neutralizing antibodies. This response in chimpanzee 2 was very low (titer of 10 to 20). These results are summarized in the following table.
RESULTS OBTAINED USING TREATMENT REGIMEN 1
RESULTS OBTAINED USING TREATMENT REGIMEN 1
Recombinant
Western Blot Peak
Chimp
Virus Shedding
Peak Anti-Adeno
anti-HIV Titers
Peak Anti-HIV
Number
Recombinant Virus
Stools (Days)
Neutralizing Titer
env
gag
Neutralizing Titer
1
Ad7-env, Ad7-gag-1
2, 2
128
—
20
<10
Ad4-env, Ad4-gag-1
2, 2
8
—
20
<10
Ad5-env
7+
128
100
—
<10
subunit: env + gag
100
1000
<10
2
Ad7-env, Ad7-gag-1
3, 2
64
—
20
<10
Ad4-env, Ad4-gag-1
1, 7
128
20
100
<10
Ad5-env
7+
64
10000
—
20
subunit: env + gag
1000
10000
10
3
Ad7-env
2
6
20
N/A*
<10
Ad4-env
1
128
20
N/A
<10
Ad5-env
7+
512
1000
N/A
<10
subunit: env
100
N/A
<10
*N/A = not applicable.
Cell-mediated immunity was measured in peripheral blood mononuclear cell population obtained from chimpanzees. HIV specific CTL activity was measured by determining lysis of syngenic target cells that were infected with vaccinia virus recombinants that express either the HV-env gene products, the HIV-gag gene products, or the lac gene product (control for nonspecific cytotoxicity). A hint of HIV specific CTL-like activity was measured in this way.
Lymphoproliferative assays were performed to determine whether purified recombinant env (gp160, gp120) or gag (p24) preparations were capable of stimulating blastogenesis. No proliferation was measured after the primary inoculum and only 1 of the 3 animals show a lymphoproliferative response following administration of the first boost with Ad4 recombinant viruses. All 3 animals responded with proliferative responses after the second booster (Ad5-env) and the third boost (subunit preparations).
Measurement of Immunogenicity: Treatment Regimen 2
Chimpanzee Inoculations and Collection of Data
Three chimpanzees (2 males and 1 female) that were previously inoculated with Ad-HIV recombinant viruses in enteric-coated capsules and boosted with adenovirus-derived gag and/or env subunits (treatment regimen 1) were infected intranasally with Ad7-HIV viruses (week 46) and 12 weeks later (week 58) with Ad4-HIV viruses. Recombinant adenoviruses were given in tissue culture media diluted with phosphate saline buffer dropwise into the nostrils of chimpanzees under anesthesia. Two chimpanzees (numbers 1 and 2) received both env and gag recombinant viruses while the third chimp (number 3) received only env recombinant viruses.
Whole blood, serum, and stool samples were collected at different times during the course of the experiment, and processed as described in Regimen 1. Adenovirus detection in stool samples or nasal swabs, adenovirus neutralization test procedures, and detection of anti-HIV antibodies were performed according to the procedures described in Regimen 1.
Results
The first intranasal booster with Ad7 recombinants was given in one dose of 1×10 8 pfu's/chimpanzee. At the time of virus administration chimpanzees 3, 1, and 2 had serum anti-Ad7 neutralization titers of <4, 8, and 64 respectively from previous oral immunizations. Nasal swabs and stool samples were examined for the presence of shed recombinant viruses by a plaque hybridization technique. Recombinant Ad7-env was detected in nasal swabs up to 7 days p.i. in two of the animals. Recombinant Ad7-env and Ad7-gag were found to be present in stool samples from 5 to 12 days p.i. There was a correlation between the serum titer to Ad7 and the ability to detect recombinant viruses in nasal swabs and stool specimens. The two animals which displayed marginal anti-HIV antibody response were greatly augmented by the intranasal boost. The third animal was boosted to a lesser extent. Low titered neutralizing antibodies directed at HIV could now be detected in all three animals. Secretory antibodies were detected in nasal swab specimens which contained anti-gag and/or env binding antibodies. No signs or symptoms of respiratory disease were observed in these animals as a result of intranasal administration of the Ad7 recombinant viruses.
Three months later these chimpanzees were immunized with Ad4 recombinants at a single dose of 1×10 8 pfu's/chimpanzee/virus. These animals had serum anti-Ad4 neutralization titers between 128 to 256 from previous oral immunization at the time of intranasal challenge. At 3 days post-infection 2 of the animals (2 and 3) had a slight cough. The third animal (number 1) died on day 5 from a bacterial pneumonia ( Streptococcus pneumoniae was isolated). The other two animals presented harsh sounds by auscultation and S. pneumoniae was isolated from both chimpanzees. Antibiotic treatments were initiated and both chimpanzees recovered.
Upon retrospective examination of this situation several observations could be made. At the time of intranasal administration chimpanzee number 1 was already experiencing a fever and an abnormal Complete Blood Count. There was a disproportionate number of polymorphonuclear cells present and a 5% level of band cells (immature polymorphonuclear cells) taken together, this information indicated that there was a significant bacterial infection taking place prior to virus inoculation. Autopsy specimens taken from the lung, liver, spleen, and serum all tested negative for the presence of infectious adenovirus by tissue culture using 3 blind passages on susceptible A549 cell monolayers. Similar findings were obtained by plaque hybridization techniques. Lung and liver paraffin embedded samples tested negative for the presence of adenovirus antigens using a commercial immunofluorescent kit for adenovirus antigens. Inclusion bodies were observed in H&E stained lung sections. There was a disagreement by experts as to whether these inclusions were caused by adenovirus or not. Several weeks later another chimpanzee experienced a similar fate at the same primate center and died. While it was likely that administration of recombinant adenoviruses had a only a minor role, if any, in causing the death of chimpanzee number I it was considered prudent to administer antibiotics prophylactically prior to and after any further intranasal administration of adenovirus recombinants to chimpanzees.
The following table shows the results obtained using treatment Regimen 1 and the Ad7-recombinants in Regimen 2.
RESULTS OBTAINED USING TREATMENT REGIMENS 1 AND 2
RESULTS OBTAINED USING TREATMENT REGIMENS 1 AND 2
Recombinant
Western Blot Peak
Chimp
Recombinant
Virus Shedding
Peak Anti-Adeno
anti-HIV Titers
Peak Anti-HIV
Number
Virus
Stools (Days)
Neutralizing Titer
env
gag
Neutralizing Titer
1
Regimen 1
Ad7-env, Ad7-gag-1
2, 2
128
—
20
<10
Ad4-env, Ad4-gag-1
2, 2
8
—
20
<10
Ad5-env
7+
128
100
—
<10
subunit: env + gag
100
1000
<10
Regimen 2
Ad7-env, Ad7-gag
12
512
10000
10000
10
2
Regimen 1
Ad7-env, Ad7-gag-1
3, 2
64
—
20
<10
Ad4-env, Ad4-gag-1
1, 7
128
20
100
<10
Ad5-env
7+
64
10000
—
20
subunit: env + gag
1000
10000
10
Regimen 2
Ad7-env, Ad7-gag
9
8192
1000
10000
20
3
Regimen 1
Ad7-env
2
6
20
N/A*
<10
Ad4-env
1
128
20
N/A
<10
Ad5-env
7+
512
1000
N/A
<10
subunit: env
100
N/A
<10
Regimen 2
Ad7-env
7
256
10000
N/A
10
*N/A = not applicable.
Measurement of Immunogenicity: Treatment Regimen 3
Chimpanzee Inoculations and Collection of Data
Three chimpanzees (2 males and 1 female) that were screened negative for the presence of neutralizing antibodies to human adenoviruses type 4, 5, and 7 were evaluated using treatment regimen 3. Two chimpanzees (numbers 4 and 5) received both env and gag recombinant viruses while the third chimp (number 6) received only env recombinant viruses. Antibiotics were administered prophylactically to the chimpanzees and no respiratory disorders were observed.
Whole blood, serum, and stool samples were collected at different times during the course of the experiment, and processed as described in Regimen 1. Adenovirus detection in stool samples or nasal swabs, adenovirus neutralization assays, and detection of anti-HIV antibodies were performed according to the procedures described in Regimen 1.
Detection of Inhibition of Gp120 Binding to CD4 Binding Sites
This assay is designed to measure the ability of chimpanzee anti-env antibodies to block the interaction of the HIV gp120 antigen with in natural ligand CD4. Various dilutions of chimpanzee sera were incubated with purified recombinant gp120 (1 ug/ml) 37° C. for 1 hour. HeLa CD4 positive cells (5×10 5 ) were added to this mixture and incubated at 4 ° C. for 1 hour. The cells were washed 3 times with PBS-5%BSA and mixed with a FITC-labeled monoclonal antibody directed at the CD4 antigen (same site the gp120 binds to) and incubated at 4° C. for 1 hour. The cells were washed three times with the PBS-5% BSA and analyzed by flow cytometry.
Results
1st Immunization with Ad7-recombinants: Recombinant viruses were shed into feces for 22 to 34 days post-infection. No recombinant viruses were detected in nasal secretions taken at 2 weeks post-infection. Seroconversion to the serotype of the adenovirus vectors employed was determined by neutralization assays. Excellent anti-adenovirus serum titers were measured in all 3 chimpanzees to Ad7 serotypes used in each of the chimpanzees. Seroconversion to recombinant HIV gene products were determined by Western blotting. Four weeks following the primary immunization with Ad7-recombinants anti-env and anti-gag responses could be measured in 2 of the 3 chimpanzees. By 20 weeks post-infection all 3 animals had measurable antibodies to HIV antigens. Secretory antibodies were not found in nasal swabs taken within the first 4 weeks following primary immunization. All 3 chimpanzees failed to mount detectable anti-HIV neutralizing antibody responses.
1st Booster Immunization with Ad4-recombinants: Recombinant Ad4 viruses were shed into feces for 14-28 days post-infection. Examination of nasal swabs indicated that recombinant Ad4 viruses could be detected in all 3 chimpanzees for at least 7 days post-infection. Significant anti-Ad4 responses were mounted against the Ad4 serotype following intranasal administration . The magnitude was slightly lower then that measured against the Ad7-recombinant viruses. Excellent booster responses to gag and/or env antigens were measured in all three animals. Low titered (1:2) anti-gag and/or anti-env responses were measured in nasal swabs from Chimpanzees 4 and 5. Still no anti-HIV neutralizing antibodies were measured in any of the animals.
2nd Booster Immunization with Ad5-recombinants: Recombinant Ad5 viruses were shed into feces for 8 days post-infection. No recombinant viruses could be detected in nasal swabs at 0, 1, or 2 weeks post-inoculation. Anti-HIV IgG and IgA antibody response against env and gag could be measured in nasal swabs taken from 2 of 3 chimpanzees following Ad5-recombinant booster immunization by Western blot analysis. IgG and IgA anti-env and/or anti-gag antibodies were detected in saliva samples collected from 2 of 3 chimpanzees. Anti-env and -gag antibodies of the IgG class were detected in vaginal swabs taken from the single female chimpanzee.
Several samples which contained the greatest amount of anti-HIV antibodies of the IgA class were examined for the presence of secretory component. This was accomplished by substitution of polyclonal anti-secretory component (human) for polyclonal anti-IgA (human) in the HIV Western blot assay. Secretory anti-HIV IgA, containing secretory component, was detected in both nasal swabs and saliva samples in 1 of 3 chimpanzees.
3rd Booster Immunization with env Subunit: The strongest anti-env antibody responses were measured following subunit administration of these chimpanzees that had been primed with live recombinant adenoviruses. Anti-env antibody responses were detected in both serum and in various secretory samples collected from the nasal-oral cavity, vagina, and rectum. Peak antibody titers were detected at 4 weeks post administration with env subunit.
Serum anti-HIV neutralizing antibody titers of 320-640 were observed in all 3 chimpanzees. Antibodies directed against the gp120 V3 loop were detected by ELISA and against the gp120 CD4 binding site were detected by a FACS blocking assay. All three chimpanzees produced high ELISA titers (1000-9000) directed at the V3 loop (a region which contains the major neutralization determinant for HIV).
Chimpanzee sera collected at the height of the neutralizing response was evaluated for the presence of anti-CD4 binding site antibodies. All three animals had acquired antibodies that were capable of blocking the interaction between gp120 with CD4. The CD4 binding site is a conformational epitope and antibodies directed at this site are believed to be important in blocking uptake up cell-free HIV and perhaps capable of inhibiting gp120-CD4 syncytium induction. The results are shown in FIG. 1 .
Nasal swab anti-env antibody titers of the IgG and IgA classes of immunoglobulins were boosted in 3 of 3 and 2 of 3 chimpanzees, respectively, following booster immunization with the env subunit. Similar results were observed in the saliva samples taken from these chimpanzees. Two of three chimpanzees had IgG anti-env antibodies present in rectal swabs and the single female chimpanzee had a strong IgG anti-env booster response measured in vaginal swabs. The presence of anti-HIV antibodies in mucosal secretions is critical because certain mucosal surfaces represent major sites for HIV infection.
Summary Tables: The following table shows the results obtained using treatment regimen 3.
RESULTS OBTAINED USING TREATMENT REGIMEN 3
RESULTS OBTAINED USING TREATMENT REGIMEN 3
Recombinant
Western Blot Peak
Chimp
Recombinant
Virus Shedding
Peak Anti-Adeno
anti-HIV Titers
Peak Anti-HIV
Number
Virus
Stools (Days)
Neutralizing Titer
env
gag
Neutralizing Titer
4
Ad7-env, Ad7-gag
22, 22
1024
100
1000
<10
Ad4-env, Ad4-gag
14, 14
128
10000
10000
<10
Ad5-env, Ad5-gag
8, 8
32
10000
10000
20
subunit: env
N/A*
N/A
>10000
10000
640
5
Ad7-env, Ad7-gag
34, 27
1024
100
10000
<10
Ad4-env, Ad4-gag
14, 14
512
10000
10000
<10
Ad5-env, Ad5-gag
8, 8
32
10000
10000
20
subunit: env
N/A
N/A
1000
10000
320
6
Ad7-env
34
1024
100
N/A
<10
Ad4-env
28
512
10000
N/A
<10
Ad5-env, gag
8, 8
32
10000
N/A
40
subunit: env
N/A
N/A
>10000
N/A
320
*N/A = not applicable.
The following table summarizes anti-HIV responses detected in chimpanzee secretions following intranasal booster immunization with the Ad5-HIV recombinants and after the intramuscular subunit boost (week 23 post boost).
ANTI-HIV RESPONSES DETECTED IN SECRETIONS
Secretion Analyzed
Chimp
Antigen
Weeks
Nasal
Saliva
Vaginal
Number
Recognized
Post Boost**
IgA
IgG
IgA
IgG
IgA
IgG
4
env
0
—*
360
—
—
—
—
1
180
360
—
—
—
90
2
180
2880
20
20
—
90
4
720
1440
—
20
—
360
23
—
—
—
80
—
—
24
90
720
—
—
—
—
25
90
2880
20
160
—
180
27
90
1440
—
160
—
720
gag
0
—
180
—
—
—
—
1
360
360
—
20
—
90
2
720
2880
—
20
—
90
4
720
720
—
20
—
90
23
90
—
—
—
—
—
24
90
90
—
—
—
—
25
—
90
—
—
—
—
27
90
360
—
—
—
—
5
env
0
—
—
—
—
N/A +
N/A
1
—
90
—
—
N/A
N/A
2
—
2880
—
—
N/A
N/A
4
—
360
—
—
N/A
N/A
23
—
—
—
—
N/A
N/A
24
—
360
—
20
N/A
N/A
25
90
2880
20
80
N/A
N/A
27
—
720
—
320
N/A
N/A
gag
0
—
—
—
—
N/A
N/A
1
—
90
—
—
N/A
N/A
2
90
1440
—
—
N/A
N/A
4
—
360
—
—
N/A
N/A
23
90
—
—
—
N/A
N/A
24
90
—
—
—
N/A
N/A
25
90
90
—
—
N/A
N/A
27
—
—
—
—
N/A
N/A
6
env
0
—
—
—
—
N/A
N/A
1
—
—
—
—
N/A
N/A
2
—
1440
20
20
N/A
N/A
4
—
360
—
—
N/A
N/A
23
—
—
—
—
N/A
N/A
24
—
180
—
—
N/A
N/A
25
—
720
—
20
N/A
N/A
27
—
720
—
—
N/A
N/A
*equals less than 90 for nasal and vaginal swabs and less than 20 for saliva samples.
+ N/A = not applicable.
**Post Ad5-boost. Subunit boost was administered 23 weeks after Ad5 boost.
Measurement of Immunogenicity: Treatment Regimen 4
Dog Inoculations and Collection of Data
Recombinant adenovirus was administered according to the table shown above for Treatment Regimen 4. Serum was collected at different times during the course of the experiment, and processed as described in Regimen 1. Adenovirus neutralization test procedures were performed according to the procedures described in Regimen 1. Detection of anti-HIV antibodies was performed according to the procedure described in Regimen 1 except that biotinolylated goat anti-dog IgG (H+L) was substituted for biotinylated goat anti-human IgG (H+L) .
Serum samples were taken from immunized dogs at regular intervals after primary immunization and booster immunizations. Seroconversion to the serotype of the adenovirus vector employed was determined by neutralization test procedures. All of the dogs responded with strong anti-adenovirus titer to Ad7 vectors. Weaker anti-Ad5 responses were seen following Ad5 primary or booster inoculation. Seroconversion to env antigens was measured by Western blot and by HIV neutralization assays. Some dogs were able to produce low titer anti-env antibodies following primary immunization with recombinant Ad-env (LAV or MN). Significant booster responses to env antigen were observed in almost all of the dogs following heterotypic boosting with another recombinant Ad-env (LAV or MN) virus expressing the same type of env antigen.
Dogs that were primed with Ad7-env MN and boosted with Ad5-env MN had an average anti-HIV MN serum titer of >180 (range 45->270) at 4 weeks post-boost. Dogs receiving the Ad5-env MN and Ad4-env MN combination had an average anti-HIV MN serum titer of >170 (range 45->270) at this same time. There were no cross protective antibodies directed at the HIV LAV strain in any of these dogs. Dogs receiving the Ad7-env and Ad5-env combination had an average anti-HIV LAV serum titer of 55 (range 20-85) at 4 weeks post-boost and none of these dogs had anti-HIV MN titers. In at least one of the three dogs receiving the “recombinant cocktail” that contained both MN and LAV recombinant viruses had a anti-HIV MN serum titer of 90 and an anti-HIV LAV titer of 50. The other two dogs had anti-HIV LAV titers of 45 and 15.
These results demonstrate that the recombinant Ad-HIV NM viruses all elicit neutralizing antibodies directed at the MN strain of HIV. Low neutralizing titers were seen in 2 of 6 dogs in Groups 1 and 1 of 6 in Group 4 following the first immunization with Ad-env MN recombinants. Low to high neutralization titers were measured in all of the dogs in these two groups following booster immunization with heterotypic recombinant viruses. The neutralization titers produced were type specific and did not cross react with the LAV strain of HIV. When compared directly to other dogs treated with LAV recombinant Ad-env viruses, Ad-env MN recombinant viruses appeared to elicit higher type-specific neutralization titers in the dog standard pharmacological test procedure. Finally, the use of a “recombinant cocktail” which contains both MN and LAV recombinants appears to be capable of eliciting neutralizing antibodies to both strains of HIV.
Measurement of Immunogenicity: Treatment Regimen 5
HIV Subunit Administration in Dogs
Thirty laboratory dogs that were either previously immunized twice with Ad-env recombinants (12-18 week intervals, with the 2nd immunization 20-28 weeks prior to the 1st subunit immunization) and ten (10) control dogs that have never been exposed to Ad-env recombinants were injected with one of five different HIV-env subunit preparations according to the description shown above for Treatment Regimen 5. All immunizations were administered by the subcutaneous route. Serum was collected at different times during the course of the experiment, and processed as described in Regimen 1. Adenovirus neutralization test procedures were performed according to the procedures described in Regimen 1.
Results
The results that were obtained are described below and provided in a summary table that follows.
1st Subunit Administration. All subunit vaccines administered to Ad-env “primed” dogs boosted anti-HIV MN neutralizing antibody responses. Two subunit preparations, A and C, were both examined for their ability to induce cross neutralizing responses to HIV SF2 . Heterologous boosting (i.e., Ad-env MN primed and gp- 120 SF2 boost) as well as homologous boosting (Ad-env MN primed and gp160 MN boost) both stimulated anti-HIV SF2 neutralizing antibody responses. Control dogs from groups B and C produced anti-env binding antibodies to HIV-env. Neutralizing antibody responses were not observed in control dogs following the first subunit administration.
2nd Subunit Administration. Administration of the second subunit did not appear to be as effective as a boosting agent compared to the first subunit administration. Group B dogs exhibited the greatest serum neutralizing antibody response (3-4 fold increase) of the five groups following the second booster immunization. Groups A and C showed two-fold increases following their second subunit administrations, while the HA-env antigen failed to significantly alter the geometric mean neutralizing titer of either Group D or E. Controls from all five groups produced anti-env binding antibodies. Functional neutralizing anti-HIV antibodies were observed only in the groups B, C, and D controls. Group A and E controls still failed to produce neutralizing antibody responses after the second subunit administration.
In summary, these results demonstrate that strong neutralizing antibody responses were elicited in all groups that were previously “primed” with Ad-HIV recombinants. After priming, high neutralizing antibody titers were observed in groups that were boosted heterologously (with gp120 SF2 ) and homologously (with gp120 MN ). In the primed dogs, neutralizing antibodies were generated to both the MN and SF2 strains of HIV. Neutralizing antibody titers were still observed at twelve weeks, prior to the second boost. After the second boost, significant increases in neutralizing antibodies were observed in both gp120-boosted groups (Groups A and B).
Summary Table
The following table shows the results obtained using Treatment Regimen 5.
HIV SUBUNIT IMMUNIZATION IN Ad-HIV PRIMED DOGS
Peak Titer
First
Second
After
Anti-HIV MN Responses*
Group +
n
Subunit
Subunit
2nd Ad-HIV
0 wk
2 wk
12 wk
14 wk
A
6
gp120 SF2
gp120 SF2
122
16
357
84
270
2
gp120 SF2
gp120 SF2
—
—
—
—
—
B
6
gp120 MN
gp120 MN
141
17
883
229
472
2
gp120 MN
gp120 MN
—
—
—
—
156
C
6
gp160 MN
gp160 MN
88
29
369
55
68
2
gp160 MN
gp160 MN
—
—
—
—
100
D
6
gp160 MN
HA-env
88
25
391
87
83
2
gp160 MN
HA-env
—
—
—
—
93
E
6
HA-env
HA-env
189
41
431
62
110
2
HA-env
HA-env
—
—
—
—
—
+ Each group consisted of 6 dogs that were previously immunized twice with Ad-Env MN and 2 control dogs that were not immunized.
*Reciprocal geometric mean neutralization titer to HIV MN . Reciprocal genometric mean neutralization titers to of 98 and 42 to HIV SF2 were observed for the previously immunized dogs of groups A and C respectively, at 2 weeks.
Measurement of Immunogenicity: Treatment Regimen 6
Chimpanzee Inoculations and Collection of Data
Six female chimpanzees were selected on the basis of their serological profiles to human adenoviruses types 4, 5, and 7, and were treated according to the table shown above for Treatment Regimen 6. Their selection was based on a “best fit” for having the lowest possible serum neutralization titers directed at the various Ad-env vaccine combinations that were designated to be administered. Four chimpanzees that were either seronegative or weakly seropositive received either 1, 2, or 3 consecutive intranasal immunizations with recombinant Ad-env (12 week intervals) (Chimpanzees 7, 8, 9, and 1 1). One chimpanzee that was strongly seropositive (titers of 128 to all 3 Ad serotypes; Chimpanzee 10) was given a mixture of all 3 recombinants (each at a dose of 1×10 7 pfu) as a primary immunization and boosted 12 weeks later with the same mixture. All of the Ad-env immunized chimpanzees received an intramuscular immunization boost with 50 μg of gp120 SF2 HIV-env subunit formulated in MF59 adjuvant (MF59 adjuvant is described in Vaccine 11: 909 (1993)). One control chimpanzee (number 12) received 3 consecutive intranasal immunizations with wild-type human adenoviruses (12 week intervals) and an intramuscular immunization with the MF59 adjuvant alone at week 48. Antibiotics were administered prophylactically to all of the chimpanzees and no respiratory disorders were observed.
Whole blood, serum, and stool samples were collected at different times during the course of the experiment, and processed as described in Regimen 1. Adenovirus detection in stool samples, nasal or pharyngeal swab samples were done either by a plaque hybridization assay (described in Regimen 1) or by PCR technology (see below). Adenovirus neutralization assays and detection of anti-HIV antibodies were performed according to the procedures described in Regimen 1. Chinese hamster ovary cell (CHO)-derived gp120 or commercially purchased (American Biotechnologies, Cambridge, Mass.) HIV V3 MN peptides were used as substitute antigen reagents in antibody binding assays.
PCR detection of recombinant Ad-env in chimpanzee stool samples was carried out with a commercially purchased PCR kit according to the supplier's instructions (Perkin Elmer Cetus, Norwalk Conn.). Briefly, about 250 μl of the stool samples was heated to 95° C. for 5 minutes and centrifuged in a microfuge at top speed for 2-3 minutes. The supernatant was saved. 1-10 μl per PCR reaction was used. Several tubes of master mix were prepared from the PCR kit and kept frozen at −20° C. For a 10 reaction tube, sterile water (615 μl), 10× buffer (100 μl), dATP (20 μl), dCTP (20 μl), dGTP (20_μl), and dT7P (20 μl) were mixed to make up the master mix. For each reaction, 79.5 μl of the master mix were used. On the day of the first PCR, a tube of master mix (10 rx) was thawed. To the master mix were added 10 μl of each of the oligomers, 5 μl of native Taq DNA polymerase, 50 μl water. The solution was mixed and about 90 μl was distributed to each reaction tube. The PCR was carried out in a 0.5 ml eppendorf tube. To each tube was added 10 μl of the stool supernatant. Thirty (30) cycles of PCR amplification were run at 95° C. for 1 hour, 45° C. for 1.5 hours, and 72° C. for 2 hours. A second PCR was performed with a 2.5 μl aliquot of the first PCR product as a DNA template and a corresponding oligo pair as primers. After 30 cycles of amplification, 10 μl of the reaction product was run on a 1.2% argose gel. A 800 bp DNA band was observed as a positive control for Ad7-env. The following primer pairs were used for nested PCR.
Template Gene
1st PCR
2nd PCR
DNA Size
HIV-1 gp120 MN
5166/5209
5164/5208
800 bp
Ad4 fiber
5467/5468
5469/5470
782 bp
Ad5 fiber
5625/5523
5624/5522
423 bp
Ad7 fiber
5505/5504
5503/5502
978 bp
HIV specific CTL activity was measured by determining lysis of syngenic target cells that were infected with vaccinia virus recombinants that express either the HIV-env gene products, the HIV-gag gene products, or the lac gene product (control for nonspecific cytotoxicity).
Results
1st Immunization with Ad5-recombinants: Recombinant Ad5 virus was shed into fecal, pharyngeal, and/or nasal specimens for 0-7 days collected from chimpanzees that were seronegative or weakly seropositive to Ad5. Only the Ad5 recombinant was detected in the strongly seropositive chimpanzee immunized with the mixture of three recombinants. Wild-type adenovirus was shed for 56 days in the control chimpanzee that was weakly seropositive to Ad5. Significant anti-Ad5 responses were produced in most of the chimpanzees, with the strongest response produced in the control animal immunized with the wild-type Ad5. Three of the four chimpanzees (numbers 7, 9 and 11) immunized with the single Ad5 recombinant produced weak anti-env antibody responses. Functional serum neutralizing anti-HIV antibodies were detected only in chimpanzee 5, which was originally seronegative to Ad5. Secretory anti-IgG anti-env antibodies were detected in vaginal, nasal, and saliva specimens collected from chimpanzee 11. Sporadic detection of env-specific CTL activity (specific lysis=10%) was observed in in vitro stimulated peripheral blood lymphocyte (PBL) populations obtained from chimpanzees 7, 8, 9, and 10 following the primary immunization with Ad5-env. Significant CTL responses were not observed in PBL obtained from chimpanzee 11.
2nd Immunization with Ad7-recombinants. Recombinant Ad7 viruses were shed into fecal, pharyngeal, and/or nasal specimens for 7-10 days in the three chimpanzees (numbers 8, 9, and 11) that were immunized with the Ad7-env alone and for 7 days in the chimpanzee (number 10) that was strongly seropositive to all 3 recombinant adenoviruses. Wild-type Ad7 was shed for 14 days in the control chimpanzee (number 12). Significant anti-Ad7 responses were developed in all Ad7 immunized animals with the best response observed in the control chimpanzee immunized with wild-type virus. Significant anti-env responses were boosted in 2 (numbers 9 and 11) of the 3 chimpanzees boosted with Ad7-env alone, while insignificant changes were observed in the animal given the mixed adenovirus preparation. Importantly, the two chimpanzees both contained functional neutralizing antibodies to HIV MN . Chimpanzee 11 also had a very low cross-negative neutralizing antibody response directed at HIV SF2 . Nasal and saliva specimens collected from this chimpanzee also became positive for anti-env IgG antibodies. Vaginal anti-env IgG antibody responses were also boosted in chimpanzee 11. Still, anti-env antibody responses were not observed in any of the secretory fluids collected from the other chimpanzees. Again, only sporadic detection of env-specific CTL responses were detected in in vitro stimulated PBL populations prepared from chimpanzees 8, 9, and 10. As before, significant CTL responses were not observed in PBL populations obtained from chimpanzee 11.
3rd Immunization with Ad4-env recombinants. Recombinant Ad4-env was shed in stools for up to 3 days in the single animal (number 11) that was immunized with the Ad4-env alone. Ad4-env shedding was not detected in the strongly anti-Ad seropositive chimpanzee (number 10) after either immunization with the mixed Ad-env preparation. Wild-type Ad4 was shed for 7 days in chimpanzee 12. Both chimpanzees 11 and 12 made excellent anti-Ad4 antibody responses. The second booster immunization in chimpanzee 11 resulted with a significant boost in the anti-env antibody responses, including anti-HIV MN neutralizing antibody response. Nasal, vaginal, and saliva anti-env IgG antibody responses were boosted in samples collected from chimpanzee 11. Despite the generation of an excellent humoral anti-env immune response in chimpanzee 11, significant CTL responses were not observed.
1st Subunit boost. The heterologous gp120 SF2 subunit antigen preparation was administered to chimpanzee 7, 26 weeks after the primary Ad5-env immunization. The subunit immunization was very successful in boosting the anti-env antibody response. A high titered neutralizing anti-HIV MN response (>400)was observed along with a lower anti-HIV SF2 response (100). The subunit administration also elicited strong anti-env IgG antibody responses in nasal and vaginal secretions, as well as weaker anti-env responses in rectal secretions. One (chimpanzee 9) of the two animals given the (Ad5-env)/(Ad7-env) combination also showed excellent anti-env booster antibody responses following subunit administration. This animal had similar anti-HIV MN and anti-HIV SF2 neutralizing titers as seen in chimpanzee 1. Weak anti-env IgG responses were observed in nasal, rectal, saliva, and vaginal secretions collected from this animal. The other chimpanzee (number 8) had a much weaker, but still significant anti-env response induced following subunit administration, but this response did not include functional neutralizing antibodies to HIV. Nor were anti-env antibodies detected in any of the secretions collected from this chimpanzee. Chimpanzee 11 which received the (Ad5-env)/(Ad7-env)/(Ad4-env) combination also showed an excellent anti-env antibody booster response. This included a very high neutralization titer (>1400) to HIV MN and high (>400) titers to HIV SF2 . Excellent anti-env IgG antibody responses were observed in vaginal, nasal, and saliva specimens. A weak anti-env response was observed in pharyngeal secretions. The subunit did not have a significant effect on the anti-env antibody response (serum or secretory) of chimpanzee 10 (the strongly anti-Ad seropositive animal), Sporadic anti-env CTL activity was detected in in vitro stimulated PBL populations collected only from chimpanzees 7 and 8 following subunit administration. Similar analysis of in vitro stimulated lymph node cells (obtained from a lymph node biopsy located in close proximity to the subunit inoculation site) revealed that cells obtained only from chimpanzee 8 (basically a non-humoral responder) contained significant CTL activity directed at both env SF2 and env MN .
2nd Subunit boost. Only chimpanzee 7 received a second subunit immunization. This second immunization resulted with a significant boost in the anti-env antibody response, including high titered anti-HIV MN (>200) and low (<100) anti-HIV SF2 neutralizing antibody responses. Excellent anti-env IgG responses were observed in vaginal, nasal, and rectal specimens. Sporadic anti-HIV CTL activity was also seen in PBL populations.
HIV SF2 Challenge of Immunized and Control Chimpanzees. A cell-free HIV SF2 challenge was administered intravenously to five of the six chimpanzees (7, 8, 9, 11, 12). The challenge stock dilution of 1/40 was shown to productively infect control chimpanzees within 3 to 4 weeks. The chimpanzees were monitored for signs of HIV infection for a period of 10 weeks. HIV could be co-cultured from PBLs obtained from control chimpanzee 12 collected at 4 and 6 weeks post-challenge. Anti-gag antibody responses were readily measurable (another indication of HIV infection since the recombinant vaccines lacked gag determinants) in serum samples collected at 6, 8, and 10 weeks post-challenge. All other chimpanzees were protected from the HIV challenge at 10 weeks.
These results demonstrate that the intranasal administration of the Ad-env recombinants (particularly Ad7-env MN , Ad5-env MN , Ad4-env MN or a combination thereof) elicited the production of neutralizing antibodies against HIV-1. Neutralizing antibodies were produced following the first administration of the Ad-env recombinants, and the titer was increased through the use of one or more booster intranasal immunizations with the Ad-env recombinants. Antibody response to both the MN and SF2 strains of HIV was farther boosted through the administration of one or more inoculations with an env (gp120) subunit antigen preparation (particularly gp120 SF2 ). Most importantly, protection against HIV-1 infection was demonstrated following the administration of the Ad-env/subunit booster treatment regimen.
1
1
3655
DNA
Adenovirus
1
agacccttcc tcctctgatc caggactcta actctacctt accagcacca tccactacta 60
accttcccga aactaacaag cttctagcac tgtcttccgg atcgctctcc aggagcgcca 120
gctgttgggc tcgcggttga gaaggtattc ttcgtgatcc ttccagtact cttcgagggg 180
aaacccgtct ttttctgcac ggtactccgc gcaaggacct gattgtctca agatccacgg 240
gatctgaaaa cctttcgacg aaagcgtcta accagtcgca atcgcaagaa gcttgtcgag 300
ccaccatgag agtgaagggg atcaggagga attatcagca ctggtgggga tggggcacga 360
tgctccttgg gttattaatg atctgtagtg ctacagaaaa attgtgggtc acagtctatt 420
atggggtacc tgtgtggaaa gaagcaacca ccactctatt ttgtgcatca gatgctaaag 480
catatgatac agaggtacat aatgtttggg ccacacaagc ctgtgtaccc acagacccca 540
acccacaaga agtagaattg gtaaatgtga cagaaaattt taacatgtgg aaaaataaca 600
tggtagaaca gatgcatgag gatataatca gtttatggga tcaaagccta aagccataac 660
cccactctgt gttactttaa attgcactga tttgaggaat actactaata ccaataatag 720
tactgctaat aacaatagta atagcgaggg aacaataaag ggaggagaaa tgaaaaactg 780
ctctttcaat atcaccacaa gcataagaga taagatgcag aaagaatatg cacttcttta 840
taaacttgat atagtatcaa tagataatga tagtaccagc tataggttga taagttgtaa 900
tacctcagtc attacacaag cttgtccaaa gatatccttt gagccaattc ccatacacta 960
ttgtgccccg gctggttttg cgattctaaa atgtaacgat aaaaagttca gtggaaaagg 1020
atcatgtaaa aatgtcagca cagtacaatg tacacatgga attaggcaac tcaactgctg 1080
ttaaatggca gtctagcaga agaagaggta gtaattagat ctgagaattt cactgataat 1140
gctaaaacca tcatagtaca tctgaatgaa tctgtacaaa ttaattgtac aagacccaac 1200
tacaataaaa gaaaaaggat acatatagga ccagggagag cattttatac aacaaaaaat 1260
ataataggaa ctataagaca agcacattgt aacattagta gagcaaaatg gaatgacact 1320
ttaagacaga tagttagcaa attaaaagaa caatttaaga ataaaacaat agtctttaat 1380
caatcctcag gaggggaccc agaaattgta atgcacagtt ttaattgtgg aggggaattt 1440
ttctactgta atacatcacc actgtttaat agtacttgga atggtaataa tacttggaat 1500
aatactacag ggtcaaataa caatatcaca cttcaatgca aaataaaaca aattataaac 1560
atgtggcagg aagtaggaaa agcaatgtat gcccctccca ttgaaggaca aattagatgt 1620
tcatcaaata ttacagggct actattaaca agagatggtg gtaaggacac ggacacgaac 1680
gacaccgaga tcttcagacc tggaggagga gatatgaggg acaattggag aagtgaatta 1740
tataaatata aagtagtaac aattgaacca ttaggagtag cacccaccaa ggcaaagaga 1800
agagtggtgc agagagaaaa aagagcagcg ataggagctc tgttccttgg gttcttagga 1860
gcagcaggaa gcactatggg cgcagcgtca gtgacgctga cggtacaggc cagactatta 1920
ttgtctggta tagtgcaaca gcagaacaat ttgctgaggg ccattgaggc gcaacagcat 1980
atgttgcaac tcacagtctg gggcatcaag cagctccagg caagagtcct ggctgtggaa 2040
agatacctaa aggatcaaca gctcctgggg ttttggggtt gctctggaaa actcatttgc 2100
accactactg tgccttggaa tgctagttgg agtaataaat ctctggatga tatttggaat 2160
aacatgacct ggatgcagtg ggaaagagaa attgacaatt acacaagctt aatatactca 2220
ttactagaaa aatcgcaaac ccaacaagaa aagaatgaac aagaattatt ggaattggat 2280
aaatgggcaa gtttgtggaa ttggtttgac ataacaaatt ggctgtggta tataaaaata 2340
ttcataatga tagtaggagg cttggtaggt ttaagaatag tttttgctgt actttctata 2400
gtgaatagag ttaggcaggg atactcacca ttgtcgttgc agacccgccc cccagttccg 2460
aggggacccg acaggcccga aggaatcgaa gaagaaggtg gagagagaga cagagacaca 2520
tccggtcgat tagtgcatgg attcttagca attatctggg tcgacctgcg gagcctgttc 2580
ctcttcagct accaccacag agacttactc ttgattgcag cgaggattgt ggaacttctg 2640
ggacgcaggg ggtgggaagt cctcaaatat tggtggaatc tcctacagta ttggagtcag 2700
gaactaaaga gtagtgctgt tagcttgctt aatgccacag ctatagcagt agctgagggg 2760
acagataggg ttatagaagt actgcaaaga gctggtagag ctattctcca catacctaca 2820
agaataagac agggcttgga aagggctttg ctataatcta gcactgtctt ccggatcgct 2880
gtccaggagc gccagctgtt gggctcgcgg ttgagaaggt attcttcgct gtccaggagc 2940
gccagctgtt gggctcgcgg ttgagaaggt attcttcgtg atccttccag tactcttcga 3000
ggggaaaccc gtctttttct gcacggtgtg atccttccag tactcttcga ggggaaaccc 3060
gtctttttct gcacggtact ccgcgcaagg acctgattgt ctcaagatcc acgggatctg 3120
aaaacctttc gacgaaagcg tctaaccagt cgcaatcgca agaagcttgt cgactatggc 3180
aggaagaagc ggagacagcg acgaagacct cctcaaggca gtcagactca tcaagtttct 3240
ctatcaaagc aaccccccac ctaaccctga aggcacaagg caagctaggc ggaacaggag 3300
gaggcggtgg agggaaaggc aaaggcaaat tcactccatc tccgagagga ttctgtccac 3360
ctacctcggc aggtccgcgg aacccgtccc cctgcaactg ccccccctgg aaagactgac 3420
cctggactgc aatgaagact gcggcacctc cggaacccaa ggagtcggct ccccccagat 3480
cctggtcgag tcccccaccg tgctggaatc cggcaccaag gagtagtcga ctctagaagg 3540
tgcacctaca ccctgctaaa gaccctatgc ggcctaagag acctgctacc catgaattaa 3600
aaattaataa aaaatcactt acttgaaatc agcaataagg tctctgtttg gaaat 3655 | This invention provides a method of protecting a primate from an infectious organism by stimulating the production of antibodies or cell mediated immunity to the infectious organism which comprises administering to said primate intranasally, intramuscularly, or subcutaneously, live recombinant adenoviruses in which the virion structural protein is unchanged from that in the native adenovirus from which the recombinant adenovirus is produced, and which contain the gene coding for the antigen corresponding to said antibodies or inducing said cell mediated immunity. Preferably, the infectious organism is HIV and the primate is a human. | 2 |
REFERENCES CITED
[0001] The following cited references to REFERENCE TO RELATED APPLICATIONS and specifically referenced in this specification as “Ref.” followed by the sequence number:
REFERENCE TO RELATED APPLICATIONS
[0002] The present application claims the priority of the following provisional applications, incorporated herein by reference:
[0003] Ref. 1: PPA Ser. No. 60/339,959 entitled “Internet based, virtual machine utilizing artificial intelligence to locate resources by geographic location”, filed Dec. 5, 2001.
[0004] Ref. 2: PPA Ser. No. 60/341,147 entitled “Artificially intelligent fulfillment system”, filed Dec. 14, 2001.
[0005] Ref. 3: PPA Ser. No. 60/355,743 entitled “Internal processing of artificially intelligent fulfillment system”, filed Feb. 5, 2002.
PATENT DOCUMENTS US 6182050 B1 Jan., 2001 Ballard 5724521 Mar., 1998 Dedrick WO 01/09772 A1 Feb., 2001 Puram et al. 6049776 Apr., 2000 Donnelly et al. US 6324534 B1 Nov., 2001 Neal et al. 5832497 Nov., 1998 Taylor 5283731 Feb., 1994 Lalonde et al. 5197004 Mar., 1993 Sobotka et al. 5164897 Nov., 1992 Clark et al. WO 01/25897 A1 Apr., 2001 Dupree US 6266659 Jul., 2001 Nadkarni 5416694 May 1995 Parrish et al. US 6289340 B1 Sep., 2001 Puram et al. 5884270 Mar., 1999 Walker et al. US 2001/0042000 A1 Nov., 2001 Defoor
SEQUENCE LISTING OR PROGRAM
[0006] A complete list of the source code required to create the hierarchical database is contained in the CD-ROM provided, entitled “AIFS source code—May 12, 2002”. All assumptions are included as comments in the source code. The source code is written is in the PL/SQL and SQL*PLUS proprietary programming languages of Oracle Corporation, and Unix Korn shell script, and contains all necessary components to install and operate the alternate embodiment of the invention, as described below.
BACKGROUND
[0007] 1. Field of the Invention
[0008] The invention generally relates to the field of intelligent document storage and retrieval. More specifically the system, through a plurality of algorithms, selectively engages a plurality of expert systems, to retrieve and qualify electronic records (or profiles) describing surplus (or supply), containing known, and previously unknown, words or phrases (or patterns) in natural language, of relative significance or strength, in relation to the significant patterns in natural language, in records describing demand. The relative score between a supply and demand profile obtained by factoring a plurality of supply pattern to a plurality of demand pattern, with reference to a knowledge base (or expert system), is the basis for qualification and ranking.
[0009] Further, the system relates to the field of interactive advertising. A plurality of algorithms determines the availability of a supply or demand, on a personal match list for the owner of a particular supply or demand, for a particular knowledge base. Such match list, deliverable in electronic form, enables the owner of a profile, to interact with ranked supply or demand profiles: access to detailed descriptive information in a plurality of electronic media formats; update a plurality of indicators visible to owner of profile; transmission of an electronic message to the owner of the profile.
[0010] 2. Prior Art
[0011] Third-party services generally provide supply to meet demand on a per-item commission basis. Fees are generally paid by demander, in arrears and often subject to qualification, or engagement of that supply for a probationary period. Other services may be provided, such as background checks, and references. Pricing varies according to the need of the Demander.
[0012] Advertisement of a demand via newspaper or trade press also provides less than optimal performance, as it will not ensure that the supply accurately meets the demand. Suppliers tend to respond in terms of their need and not necessarily that of the demander. Fees are paid in advance by demander, irrespective of the results. Pricing is based on the physical restrictions of the publishing and distribution process, such as lineage or relative page size, often combined with an advertising credit system.
[0013] Other services currently available, such as online search databases, whilst easily accessible, are often taxonomical in operation, resulting in information loss as natural language is reduced to categories, keywords, or Boolean data. As a result they are difficult to operate with user performing the search having to second guess the particular taxonomy used by the originator of a profile. Prices are often based on the quantity of the return.
OBJECTS AND ADVANTAGES
[0014] The invention provides an excellent alternative, incorporating the above described traditional methods of fulfillment into one artificially intelligent solution. The system is programmed to record patterns in documents submitted in the context of a particular expert system, in a hierarchical database; to learn from interaction; to qualify and rank supply and demand; and deliver services electronically.
[0015] In the course of submitting a profile a plurality of electronic documents may be submitted in a plurality of written languages, superimposed by a plurality of coded formats. The system performs reduction of the document to a common format, as a pre-requisite of the expert system to be used. A plurality of patterns in such documents is given a plurality of relationships in the expert system by a plurality of expert operators. The expert operators define and record the relationships between newly encountered patterns and patterns in the expert system in use; and may modify existing relationships to accommodate; providing a learning capability tending to increase accuracy.
[0016] The creator of a demand or supply profile reviews a list of matched profiles. The supplier must be pre-qualified by the expert system, in order to be placed on a list of matching supply for a particular demand profile. This assures that the list of suppliers meets the minimum requirements of demander; the system provides qualified matching.
[0017] Suppliers may only respond to a demand profile on their match list, to indicate an interest in fulfilling the demand; the system provides qualified response.
[0018] The demander, after having reviewed matched profiles, including response of the matching supplier profile owner may receive supplier contact information for a fee; fees are paid for the results of the search for identity (or contact information) for a plurality of matching profiles, as required of the demander. The system introduces no bias, for or against the supplier, since they create their own profile for free, and cannot contact demanders.
SUMMARY
[0019] The invention provides intelligent matching of natural language; supply and demand documents employing a plurality of expert systems, incorporating a learning capability tending to increase the efficiency of the matching process over time.
DRAWINGS
[0020] Ref. 1—Drawings
[0021] Drawing 1 : Illustration of the various inputs and outputs to and from the invention in the normal course of events for the alternative embodiment of the invention.
[0022] Ref. 2 Drawings:
[0023] Drawing 1 : The creation of a new supply or demand profile and extraction of natural language.
[0024] Drawing 2 : The removal of identity information.
[0025] Drawing 3 : Expert operator processes new patterns and updates expert system hierarchical database.
[0026] Drawing 4 : Indexing of the profile.
[0027] Drawing 5 : Scoring of a supply profile to a demand profile.
[0028] Drawing 6 : Electronic message notification of new matches.
[0029] Drawing 7 : Dynamic match page generation.
[0030] Drawing 8 : Downloading of matched profile.
[0031] Drawing 9 : E-commerce in exchange for supplier identity.
[0032] Drawing 10 : Deactivation of a profile by reply to electronic notification, or user input.
[0033] Drawing 11 : Replication of the data and expert system to other virtual machines of the same nature.
[0034] Ref. 3 Drawings:
[0035] Drawing 1 : Illustrates the Group and Equivalence relationships, and Keys (or patterns) that comprise the expert system.
DETAILED DESCRIPTION
[0036] 1. Preferred Embodiment
[0037] 1.1. Description
[0038] Ref: 2 Describes the Foundation of the Preferred Embodiment.
[0039] The preferred embodiment of this invention employs: a plurality of database (supply and demand) with a corresponding expert system, in tandem, to provide a plurality of intelligent searches capabilities; independence from electronic document format; independence from natural language, to the extent that semantics may be preserved during translation.
[0040] The system is computerized, comprising a CPU and a hierarchical database wherein is stored the document repository, supply and demand profiles, indexing, matching and transactional data, and a plurality of expert system data.
[0041] The architecture of the computer system can be described in terms of the components:
[0042] Firewall—a device for securing an internal network from external access, except as required for operation of the invention, as configured by a person skilled in Network Administration. The purpose of the firewall is to permit communication with users on an electronic network.
[0043] Web server—a device for delivering electronic forms, static and dynamic web pages, and performing procedure calls to the application server, as configured by a person skilled in Web Administration. The purpose of the web server is to respond to requests by users over an electronic network.
[0044] Application server—a device for performing the programmatic algorithms of the application, controlling access to data, accessing the hierarchical database on the database server, as configured by an Applications Administrator. The purpose of the application server is to perform programmatic algorithms in response to: user input via the Web Server; a periodic schedule for autonomous background processes.
[0045] Database server—a device for storing and retrieving hierarchical data, as configured by a Database administrator. The database server is a repository for the supply and demand data, including any references to external data, indexing data, matching data, and the patterns and relationships comprising the expert system.
[0046] Mail server (or MTA)—a device for relaying electronic messages, configured by a Systems Administrator. The mail server relays electronic messages and acts as an interface to the application by responding with programmatic algorithms for some incoming addresses.
[0047] 1.2 Operation
[0048] Users submit a profile via electronic form, which consists of a number of free form text fields and a mechanism for uploading a plurality of documents electronically. In return they receive a login and password via electronic message. An electronic record of the match list for their demand or supply profile is created in the hierarchical database. The electronic form comprising a representation of that match list (or match page), is dynamically updated with status information. An electronic message is sent to the user periodically via email, containing a hypertext link to the match list. The profile owner for the match list must provide a valid user name and password to view and interact with the match list.
[0049] A dynamic match page displays the list, with reference to the current matches recorded in the hierarchical database, including a plurality of devices for navigating and otherwise interacting with the list, user may:
[0050] view and download profile information;
[0051] request profiles via electronic messaging;
[0052] provide feedback on interest in a match;
[0053] additionally, demander may:
[0054] purchase supplier identity;
[0055] send a request for feedback to supplier.
[0056] A user creating a supply sees a current list of demand (matched and ranked by the system), and vice versa. Demanders may contact suppliers by purchasing their identity (contact information), via electronic commerce, and downloading electronically.
[0057] A number of autonomous background processes provide necessary supporting functions:
[0058] Write Email—periodically, transfer email messages from the hierarchical database to the file system for subsequent processing by the “Mail Agent” as described below; record in the hierarchical database.
[0059] Mail Agent—periodically, read email messages from file system and send to the Mail Server (as described in 1.1 above), for delivery.
[0060] Key New Demand—periodically, read newly approved demand profiles and index with reference to the expert system; record in the hierarchical database.
[0061] Key New Supply—periodically, read newly approved supply profiles and index with reference to the expert system; record in the hierarchical database.
[0062] Match New—periodically, read newly indexed demand profiles and iteratively match new supply profiles, according to the recorded indices; record in the hierarchical database.
[0063] Feedback—periodically, read request by users (demand and supply profile owners) for delivery of selected matching profile. Create an email record in the hierarchical database to be serviced by the “Write Mail” process, described above.
[0064] Notify Daily—daily, notify profile owners with new matches recorded in the hierarchical database. Create an email record in the hierarchical database to be serviced by the “Write Mail” process, described above.
[0065] Notify ASAP—periodically, notify profile owners with new matches recorded in the hierarchical database. Create an email record in the hierarchical database to be serviced by the “Write Mail” process, described above.
[0066] A number of supporting functions are available to a user (the creator of a demand or supply profile), via a menu system, implemented in the electronic interface of the application server, to support electronic commerce, provide account history, and auditing, profile options, settings and preferences, including customizing of the matching process on a system, user and profile level. It is anticipated that the user functions will evolve, to accommodate ancillary functions.
[0067] A number of supporting functions are available to the administrator including: the approval or denial of submitted profiles; a plurality of statistical functions pertaining to financial and other activities; updates and corrections to the expert system patterns and relationships; modification of system level parameters; periodic requests for re-indexing of profiles; updates to Frequently Asked Questions database; updates to electronic mail templates. It is anticipated accommodate further ancillary functions.
[0068] A menu is available to an expert operator including: listing of the expert system relationships; visual identification of new patterns in a new document where recognized patterns are highlighted; update of the expert system patterns and relationships. It is anticipated that the expert operator menu will evolve, to accommodate ancillary functions.
[0069] The effect of preferences on the operation of the system is described in Ref. 3 (section “OPERATION OF THE INVENTION”, para. 1-5.).
[0070] 2. Alternate Embodiment
[0071] 2.1 Description
[0072] Ref. 1 Describes the Foundation of the Alternative Embodiment of this Invention.
[0073] The alternate embodiment is the application of the invention to recruiting or head-hunting for Information Technology personnel, where the patterns are skills in word or phrase form. The expert system uses American English words or phrases (or patterns) and reduces source documents to decoded American English (ASCII) text, for indexing and matching. The accompanying CD-ROM contains the source code for construction of the database; seeding of data; stored procedures, functions and scripts for operation.
[0074] 2.2 Operation
[0075] In this embodiment the supply is Information Technology personnel, with skills representing the patterns. The demand is Information Technology jobs. Suppliers submit their candidate profile, containing geographic location, compensation requirements and descriptive document (a resume), electronically. Demanders submit a job profile in a similar manner and upload a descriptive document (a job description), electronically.
[0076] New patterns are identified by expert operators and added to the expert system (skill database) together with hierarchical relationships. This relative number of hops, measure in equivalence (zero hops) or group (one hop) between the source and destination skill in the expert system, along with the user, and system preferences, determine the relative strength of the match, or score.
[0077] Ref. 1 (drawing 1 ) represents a visual depiction of this activity. In the drawing the virtual machine comprises all the components of 1.1 above.
[0078] As described here and in the alternate embodiment the invention analyzes data as submitted. That is, the data is wholly contained within a hierarchical database, as data submitted via electronic medium to the invention, in the form of a supply or demand profile. However, this is not a necessary feature of the invention. All that is required is access to the source data for reading. Therefore, all functions, described herein may be performed on data that is externally accessible containing, at minimum, a natural language descriptive document. This would include external repository that may be parsed a plurality of times, such as a URL. | A plurality of machines matching documents by natural language content over a publicly accessible electronic network. Advertising of demand and surplus profiles and matching same, utilizing expert matching with learning capability. Electronic notification of search results to profile owner. Electronic commerce for purchase of identity and contact information. Self-replication of expert knowledge and data electronically to other machines of the same class. | 8 |
This application claims benefit of the priority application, European Patent Application No. 14151337.4, filed on Jan. 15, 2014, which is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
The present invention relates to a reverser for a timepiece, in particular for a self-winding watch.
BACKGROUND OF THE INVENTION
French patent no. 1,079,576 published in 1954 relates to a self-winding device for a clockwork mechanism. In said device, a winding wheel drives an output wheel, depending on the direction of rotation thereof, in one or the other of the following ways:
either by means of a pinion which it carries and which acts as a satellite engaged with another pinion meshing with the output wheel, or by meshing with another wheel likewise carrying a pinion which forms another satellite engaged with another pinion meshing with the output wheel.
German patent no. 952,879 published 1956 describes a freewheel clutch for a self-winding watch. This clutch comprises two input wheels driven in opposite directions by a winding wheel. Each of these input wheels is integral with a pinion around which a satellite forming a pawl which is mounted on a lower wheel can move. The two lower wheels mesh with one another and one of them is integral with an output wheel. Thus, depending on the direction of rotation of the winding wheel, the output wheel is driven:
either by a first input wheel, a first pinion, a first satellite and a first lower wheel which forms a first satellite carrier, said first lower wheel being engaged with a second lower wheel which is integral with the output wheel; or by a second input wheel, a second pinion, a second satellite and the second lower wheel, the latter carrying the second satellite carrier and being integral with the output wheel.
In other words, in this German patent, each satellite is mounted on a lower wheel, the lower wheels serve as a satellite carrier, they mesh with one another, always rotate in opposite directions and just one, the one rotating in the rewinding direction of the spring barrel, is integral with the output wheel.
BRIEF DESCRIPTION OF THE INVENTION
The above-stated mechanisms in particular have the drawback of occupying a large amount of space and it would seem that despite almost 60 years having elapsed since the publication thereof, no-one has yet managed satisfactorily to solve this problem of space.
The applicant's inventors have now succeeded in developing a substantially smaller reverser.
One particular feature of this mechanism, in comparison with the clutch of the above-stated German patent DE 952,879, is that it comprises just one satellite carrier for its two satellites.
More specifically, the reverser according to the invention comprises:
a first input moving part comprising a first receiving toothing and integral with a first transmission toothing; a second input moving part comprising a second receiving toothing and integral with a second transmission toothing; at least one first satellite cooperating with the first transmission toothing in such a manner as to be capable of rotating in a single direction; at least one second satellite cooperating with the second transmission toothing in such a manner as to be capable of rotating in a single direction, said satellite being freely rotatable relative to the first satellite; a satellite carrier carrying the second satellite; an output moving part integral with the satellite carrier;
and is characterised in that the first satellite is also carried by the single satellite carrier.
The reverser according to the invention furthermore has the advantage of allowing the majority of the component parts thereof to be arranged coaxially.
The advantageous features of the reverser according to the invention are stated in the following points:
Notably, the first and second input moving parts of the reverser are coaxial.
Likewise, the first and second transmission toothings of the reverser may be internal toothings. In this case, the first and second satellites may preferably also be coaxial.
According to another embodiment of the present invention, the satellite carrier of the reverser is coaxial with the output moving part.
Notably, the satellite carrier of the reverser is coaxial with the first input moving part and/or the second input moving part.
According to another embodiment of the present invention, the first and second satellites of the reverser may have separate pivot axes.
Notably, the first and second satellites are arranged to cooperate with their respective second transmission toothing so as to rotate in opposite directions.
Likewise notably, the first and second input moving parts, the satellite carrier and the output moving part are all coaxial.
According to still another embodiment of the present invention, the satellite carrier carries a plurality of pairs of first and second satellites.
The invention also relates to a self-winding watch comprising a reverser as previously defined, said watch furthermore possibly comprising a mechanism capable of driving the input moving parts in rotation in opposite directions.
BRIEF DESCRIPTION OF THE DRAWINGS
Other characteristics and advantages of the invention will now be described in detail in the following description which is provided with reference to the appended drawings which show schematically:
FIG. 1 : a diagram showing the principle of operation of the mechanism which, for the purposes of the present invention, is designated “reverser”;
FIG. 2 : a reverser according to a first embodiment of the invention in perspective and sectional view from above;
FIG. 3 : the reverser of FIG. 2 in sectional side view;
FIG. 4 : a cutaway detail of FIG. 2 ;
FIGS. 5 and 6 : illustrations of the operation of the reverser according to FIGS. 2 to 4 ;
FIG. 7 : a reverser according to a second embodiment of the reverser according to the invention in sectional side view;
FIG. 8 : a variant of the reverser of FIG. 7 in sectional side view;
FIGS. 9 to 11 : a variant of the reverser according to the first embodiment of the invention, in plan view, sectional side view and sectional side and perspective view;
FIGS. 12 and 13 : an illustration of the directions of rotation of the parts of the reverser according to the first embodiment of the invention;
FIGS. 14 and 15 : diagrams showing locking or otherwise of satellite-input wheel drive; and
FIGS. 16 to 21 : various methods for attaching a satellite to a satellite carrier.
DETAILED DESCRIPTION OF THE INVENTION
In the present specification, a “reverser” is taken to mean a mechanism which makes it possible to convert the rotational movements in two directions of a moving part into a rotational movement in a single and invariable direction.
The principle of operation such a mechanism is illustrated by FIG. 1 .
FIGS. 2 and 3 show a first embodiment of the reverser according to the present invention. As can be seen, said reverser comprises a shaft 1 , a lower end of which comprises a lower toothing 2 , in order to constitute an output moving part capable of being connected in known manner, generally by a kinematic chain which is not shown, to the spring barrel of a timepiece to be rewound.
On the shaft 1 , above the lower end thereof, a satellite carrier 3 has been driven on from above which assumes the overall form of a hollow cylinder provided with a portion which forms a disc in such a manner that the plane of said disc is perpendicular to the longitudinal axis of the hollow cylinder. The bottom of said cylinder abuts against the lower toothing 2 of the shaft 1 . The portion which forms the disc is passed through longitudinally by a peg 4 onto the upper part of which has been driven a first satellite 5 . The peg 4 is freely rotatable relative to the portion which forms the disc of the satellite carrier 3 and about an axis parallel to that of the hollow cylinder.
On the top of the hollow cylinder of the satellite carrier 3 , a first input wheel 6 is freely rotatably mounted and held in place axially by a locking ring 7 , the lower face of which first input wheel comprises a first internal toothing 8 which may be the toothing of a ring attached in known manner (welding, brazing etc.). Said internal toothing 8 is provided to cooperate with the first satellite 5 .
On the bottom of the hollow cylinder of the satellite carrier 3 , a second input wheel 12 is freely rotatably mounted and held in place axially by a locking ring 9 , the upper face of which second input wheel comprises a second internal toothing 10 which may be the toothing of a ring attached in known manner (welding, brazing etc.).
A second satellite 11 is arranged freely rotatably about the peg 4 , being sandwiched between, from below, the second input wheel 12 and, from above, the portion which forms the disc of the satellite carrier 3 . Said second satellite 11 is provided to cooperate with the second internal toothing 10 .
Cooperation between the satellites 5 and 11 and, respectively, the internal toothings 8 and 10 can be seen in FIG. 4 . The satellites 5 and 11 form pawls, i.e. they have teeth, the asymmetrical shape of which is provided to allow them to rotate only in a single direction. Such a shape is well-known to a person skilled in the art and is represented, in particular, in FIGS. 3 and 4 of the above-stated French patent (parts numbered 4 and 5 ). As a variant, it is possible to provide that it is the teeth of the internal toothings 8 and 10 which form pawls, like the teeth of wheels 30 and 40 in FIG. 1 of the above-stated German patent.
It is also possible to provide for both an internal toothing and the teeth of a satellite to have specific shapes which cooperate with one another in order to permit rotation in one direction and locking in another direction, as taught by Swiss patent no. 321,237.
Thus, for a given direction of rotation of the internal toothing 8 , meshing and therefore driving of the satellite 5 in rotation is possible, whereas in the other direction said satellite locks.
Likewise, for a given direction of rotation of the internal toothing 10 , meshing and therefore driving of the satellite 11 in rotation is possible, whereas in the other direction said satellite locks.
The unidirectional satellites 5 and 11 are arranged in reversed manner and they are not identical, such that one input wheel can only rotate in one direction and the other can only rotate in the opposite direction. More particularly, the shape of the teeth of the two satellites 5 and 11 is reversed so as to ensure rotation in one direction and locking in the other direction.
Operation
Operation of the reverser according to the invention is illustrated in FIGS. 5 and 6 .
Upstream of the reverser according to the invention there is provided a geartrain which compels the input wheels 6 and 12 to rotate in opposite directions.
In FIG. 5 , the shaft 1 is provided to rotate only in the usual direction of the hands of a watch, or “clockwise” direction. The first input wheel 6 is driven in counter-clockwise direction and must therefore have no effect on the shaft 1 . To achieve this, when said input wheel rotates it drives the first internal transmission toothing 8 , which is engaged with the first satellite 5 . The latter is arranged appropriately such that rotation of the internal toothing 8 , and therefore of the toothed wheel 6 , allows the satellite to mesh with the internal toothing 8 . Rotation of the latter will then bring about rotation of the satellite 5 and of the peg 4 about the longitudinal axis of the latter. Such rotation proceeds independently of the satellite carrier 3 and has no effect on it. The satellite 5 is said to rotate “in thin air”.
At the same time, the second input wheel 12 rotates in the opposite direction to that of the input wheel 6 , that is to say in the one direction in which the shaft 1 can rotate. The arrangement or orientation of the satellite 11 is such that it cannot mesh with the second internal transmission toothing 10 integral with the input wheel 12 and consequently, it cannot rotate about itself and locks. It is then driven in rotation by the second internal toothing 10 , not about the longitudinal axis of the peg 4 , but about the longitudinal axis of the shaft 1 . In this rotational movement, the satellite 11 then drives the peg 4 in rotation and therefore the assembly of the satellite carrier 3 together with the shaft 1 integral with the latter. Accordingly, the input wheel 12 , the second internal toothing 10 , the satellite 11 , the peg 4 , the satellite carrier 3 and the shaft 1 behave as if they were just a single part.
FIG. 6 shows the reverse situation. This time, it is the input wheel 6 which rotates in the direction in which the shaft 1 is intended to rotate. The satellite 5 cannot mesh with the first internal transmission toothing 8 . Locking which prevents the satellite 5 from rotating about itself therefore occurs. Rotation of the input wheel 6 then brings about rotation of the satellite 5 , the peg 4 , the satellite carrier 3 and the shaft 1 about the longitudinal axis of the shaft 1 . In this case, the input wheel 6 , the first internal toothing 8 , the satellite 5 , the peg 4 , the satellite carrier 3 and the shaft 1 behave as if they were just a single part.
Thus, whatever the direction of rotation of the input wheels 6 and 12 , the shaft 1 is always driven in rotation in the same direction.
FIGS. 9 to 11 show a variant of the reverser according to the invention, in which the input wheels 6 and 12 are attached by means of bushes 19 and 20 integral with the shaft 1 , the satellites, here six in number, rotating freely relative to the satellite carrier and being axially confined on one side by the satellite carrier and on the other side by an input wheel 6 or 12 .
FIGS. 7 and 8 show a second embodiment of the present invention which differs from the first embodiment as follows:
the first and second transmission toothings are no longer internal toothings but external toothings 13 and 14 , for example provided on pinions integral with the first and second input wheels 6 and 12 ; and the first and second satellites 5 ′, 11 ′ are no longer coaxial: they are offset angularly, preferably diametrically opposed on the portion which forms a disc of the satellite carrier 3 .
These differences aside, the reverser operates in the same way as in the first embodiment, the assembler of the mechanism merely needing to ensure that the asymmetrical teeth of the satellites are appropriately oriented.
In FIG. 7 , it can be seen that the satellites 5 ′ and 11 ′ are formed by a single part with one portion forming a peg passing through the portion which forms the disc of the satellite carrier. The bottom (satellite 5 ′) or the top (satellite 11 ′) of the respective peg is provided with a washer to keep the respective satellite 5 ′ or 11 ′ on the satellite carrier 3 .
In FIG. 8 , it can be seen that the satellites 5 ″, 11 ″ are mounted pivotably about studs 15 , 16 driven into holes provided in the portion which forms the disc of the satellite carrier 3 .
In FIGS. 14 and 15 , it can be seen that when the external toothings 13 , 14 rotate in a first direction S1, locking of the satellites 11 ′, 11 ″ occurs whereas when the external toothings 13 , 14 rotate in a second direction S2, they drive the satellites 11 ′, 11 ″ in rotation.
In general and whatever the embodiment, the satellite carrier carries, as can be seen in FIGS. 5 and 6 , a plurality of first satellites and a plurality of second satellites and preferably, for reasons of balancing, as many first satellites as second satellites. At this point, it should be noted that increasing the number of satellites is generally useful for reducing play during a reversal in direction. Consequently, adjusting the number of satellites relative to the number of teeth makes it possible to reduce (or alternatively to increase) backlash (i.e. play) during a reversal in direction as required.
Upstream of the Reverser
As previously stated, a mechanism is provided for driving the input wheels 6 and 12 in rotation in opposite directions.
In order to achieve this, a person skilled in the art may consider any appropriate mechanism, in particular a geartrain such as that shown in FIGS. 12 and 13 .
A winding pinion 17 driven in rotation by the self-winding weight (not shown) meshes with the first input wheel 6 . At the same time, this pinion 17 meshes with a transfer pinion 18 which itself meshes with the second input wheel 12 . The toothing of the shaft 1 meshes with an output wheel 21 which thus always rotates in the same direction.
Other Variants
FIGS. 16 to 21 show variants for attaching satellites to a satellite carrier, with axial limitation of satellite displacement ( FIGS. 19 to 21 ) or without such limitation ( FIGS. 16 to 18 ; in this case, axial displacements are limited on either side by the satellite carrier and an input wheel). | A reverser for a timepiece including a first input moving part having a first receiving toothing and integral with a first transmission toothing, a second input moving part having a second receiving toothing and integral with a second transmission toothing, a first satellite cooperating with the first transmission toothing configured to rotate in a single direction, a second satellite cooperating with the second transmission toothing configured to rotate in a single direction, the satellite being freely rotatable relative to the first satellite, a satellite carrier carrying the second satellite and an output moving part integral with the satellite carrier in which the first satellite is carried by the satellite carrier. | 6 |
BACKGROUND OF THE INVENTION
[0001] The present invention generally relates to intravascular procedures, such as treating carotid arteries and percutaneous transluminal coronary angioplasty (PTCA), and particularly to an intravascular catheter which can be utilized in a rapid-exchange (RX) or over-the-wire (OTW) operating mode.
[0002] In typical PTCA procedures utilizing over-the-wire mode, a dilation catheter is advanced over a guide wire slidably disposed within an inner lumen of the dilation catheter into a patient's coronary artery until the balloon on the distal extremity of the dilation catheter is properly positioned across the lesion to be dilated. Once properly positioned across the lesion, the flexible, relatively inelastic dilatation balloon on the catheter is inflated to a predetermined size with radiopaque liquid at relatively high pressures (e.g., generally 4-20 atmospheres) to dilate the stenosed region of the diseased artery. One or more inflations of the balloon may be required to complete the dilation of the stenosis. After the last dilation, the balloon is deflated so that the dilatation catheter can be removed from the dilated stenosis and so that blood flow can resume through the dilated artery.
[0003] One significant improvement in dilatation catheters has been the introduction of rapid-exchange type dilatation catheters. These catheters have a short guide wire receiving sleeve or inner lumen extending through the distal portion of the catheter which extend from a distal guide wire port in the distal end of the catheter to a proximal guide wire port spaced proximal to the proximal end of the dilatation balloon. The proximal guide wire port is usually located at least about 10 cm. and usually not more than about 50 cm. from the distal guide wire port. A slit is preferably provided in the catheter wall which extends from the second guide wire port, preferably to a location proximal to the proximal end of the inflatable balloon to aid in the removal of the catheter from a guide wire upon withdrawal of the catheter from the patient. The structure of the catheter allows for the rapid exchange of the catheter without the need for the use of an exchange wire or adding a guide wire extension to the proximal end of the guide wire. The design of this catheter has been widely praised by the medical profession and has met with much commercial success in the market place because of its unique design. The RX type dilation catheters of the assignee for the present invention, Advanced Cardiovascular Systems, Inc., have had a significant impact in the market for rapid-exchange type dilation catheters. Such products include dilatation catheters sold under the tradenames—The Alpha, The Streak, and The Ellipse.
[0004] However, there is one significant inconvenience with the use of RX type dilatation catheter systems, namely, the inability to remove a guide wire already in place within a patient's vasculature during an angioplasty procedure without losing access to the vascular location. There has been no convenient way in which to withdraw an in-place guide wire and then advance a replacement guide wire without losing access to the location of the distal end of the RX type dilatation catheter the short guide wire receiving inner lumen in the distal extremity of a RX type dilatation catheter. These instances occur when there is a need to replace an in-place guide wire with another guide wire having a different structure, e.g., an intermediate or standard wire with a core wire which extends to the distal tip of the guide wire. The need to withdraw an in-place guide wire also occurs when the distal tip of the in-place guide wire needs to be reshaped.
[0005] U.S. Pat. No. 5,807,355 (Ramzipoor et al.), which has been assigned to the present assignee, Advanced Cardiovascular Systems, Inc., describes an intravascular catheter with both RX and OTW operative modes. The Ramzipoor et al. patent is incorporated herein by reference. While this catheter provides for RX and OTW modes of operation, which is by choice of the operating physician, only one mode may be used at a time thus limiting the effective usefulness of the device. Additionally, the Ramzipoor dual mode catheter does not provide for a smooth RX guide wire exit port for used during RX modes. During such use, the RX guide wire will deform during passage through the expanded helical coil guide wire port. The need still exists therefore for a catheter which allows for simultaneous dual mode operation and which provides for a smooth exit notch. The present invention satisfies these and other needs.
SUMMARY OF THE INVENTION
[0006] This invention is directed to an elongated intravascular catheter which can be utilized in a rapid-exchange (RX) and/or an over-the-wire (OTW) mode of operation to perform an intravascular procedure, and particularly to a balloon dilatation catheter which can be used within the coronary arteries of a human patient during an angioplasty procedure.
[0007] The intravascular catheter of the invention generally comprises an elongated shaft with proximal and distal ends, a port in the distal end, a first lumen extending through the catheter from the port in the catheter distal end to a location spaced proximal to the proximal end of the balloon, and a second lumen extending through the catheter from the proximal end to the port in the distal end of the catheter. The catheter shaft has an elongated proximal section, an intermediate section, a relatively short distal section and a balloon or other means to perform an intravascular procedure on the distal section.
[0008] In the RX mode, the intravascular catheter can be advanced over an in-place guide wire within the first guide wire lumen while holding onto the proximal extremity of the guide wire extending out of the patient, until the distal end of the catheter is disposed within a desired location of the patient's vascular system. The in-place guide wire is external of the catheter proximal to the opening in the intermediate shaft section of the catheter. In this manner, the in-place guide wire can be removed by pulling on the proximal extremity thereof which extends out the patient and a replacement guide wire can be introduced into the proximal end of the catheter shaft, advanced through the catheter shaft in the second guide wire lumen in the OTW mode and then out the port in the distal end of the catheter.
[0009] For coronary artery use, the opening in the intermediate shaft section is preferably spaced longitudinally at least 30 cm from the distal end of the catheter shaft to ensure that it remains within a guiding catheter when the distal shaft section extends out into the patient's coronary artery.
[0010] In one embodiment, the distal shaft section of the catheter includes dual guide wire lumens, a first guide wire lumen entering the RX guide wire port in the intermediate shaft section, extending throughout the intermediate shaft section, the distal shaft section and then out the opening in the distal end of the catheter, and a second guide wire lumen extending throughout the entire catheter from the proximal shaft section to the distal shaft section and then out the port in the distal end of the catheter. The first guide wire lumen slidably receives an RX guide wire and the second guide wire lumen slidably receives an OTW guide wire.
[0011] In another embodiment of the invention, a y-section inner member having a slidable insert jacket provides a first (RX) guide wire lumen and a second (OTW) guide wire lumen of the proximal shaft section to communicate, forming a notch junction in the intermediate shaft section, wherein a single lumen, the distal section guide wire lumen, is formed which extends throughout the distal shaft section of the catheter and then out the port in the distal end of the catheter. The slidable insert jacket allows the physician to dictate the mode of operation. For the RX mode, the slidable insert jacket is pushed forward blocking off the second guide wire lumen at the notch junction and allowing the first guide wire lumen to be in fluid communication with the distal section guide wire lumen of the distal shaft section. For the OTW mode, the slidable insert jacket is slightly pulled back thus allowing the second guide wire lumen to be in fluid communication with the distal section guide wire lumen of the distal shaft section. Therefore, by a simple pull or push of the slidable insert jacket, the physician may choose either RX or OTW modes of operation.
[0012] In yet another embodiment, the proximal shaft section of the catheter comprises a lumen having a “peel-away” slit. The peel-away proximal shaft section serves both OTW and RX modes of operation. The guide wire lumen of the proximal shaft section has a slit which allows for the guide wire to be “peeled-away” and removed from the guide wire lumen, wherein the slit width is slightly smaller than the guide wire diameter thereby allowing the guide wire to remain within the lumen during the OTW mode of operation. The guide wire lumen slit, because of the deformable character of the material used, allows for the guide wire to be “peeled-away” or pulled out of the guide wire lumen via the guide wire lumen slit, thus allowing the RX mode of operation. The guide wire lumen slit runs throughout the proximal shaft section and ends in a location proximal to the distal shaft section at the intermediate shaft section. The intermediate shaft section is reinforced with a peel-away strain relief which ensures that the guide wire lumen slit will not propagate distally into the distal shaft section of the catheter.
[0013] Other features and advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 is an elevational view, partially in section, of one embodiment of the invention.
[0015] [0015]FIG. 2 is a transverse cross-sectional view of the embodiment shown in FIG. 1 taken along lines 2 - 2 .
[0016] [0016]FIG. 3 is a transverse cross-sectional view of the embodiment shown in FIG. 1 taken along lines 3 - 3 .
[0017] [0017]FIG. 4 is an elevational view, partially in section, of another embodiment of the invention.
[0018] [0018]FIG. 5 is a transverse cross-sectional view of the embodiment shown in FIG. 4 taken along lines 5 - 5 .
[0019] [0019]FIG. 6 is a transverse cross-sectional view of the embodiment shown in FIG. 4 taken along lines 6 - 6 .
[0020] [0020]FIG. 7 is a transverse cross-sectional view of the embodiment shown in FIG. 4 taken along lines 7 - 7 .
[0021] [0021]FIG. 8 is an elevational view, partially in section, of the embodiment shown in FIG. 4, configured for use in over-the-wire mode in which the insert sleeve is slightly pulled back.
[0022] [0022]FIG. 9 is an elevational view, partially in section, of another embodiment of the invention.
[0023] [0023]FIG. 10 is a transverse cross-sectional view of the embodiment shown in FIG. 9 taken along lines 10 - 10 depicting the peel-away slit of the proximal shaft section.
[0024] [0024]FIG. 11 is a transverse cross-sectional view of the embodiment shown in FIG. 9 taken along lines 11 - 11 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] The present invention provides for treatment of diseased vessels and arteries by giving the physician the option to utilize either an OTW or RX mode operation using the same catheter. In keeping with the invention, reference is made to FIGS. 1 - 3 which depict one embodiment of the current dual guide wire lumen catheter invention. In particular, the catheter 10 includes an elongated catheter shaft 12 with a relatively long proximal shaft section 14 , an intermediate shaft section 16 , and a relatively short distal shaft section 18 . The catheter shaft 12 has a first guide wire lumen 20 which begins at the RX guide wire port 26 located near the distal end of the intermediate shaft section 16 and extends throughout the distal shaft section 18 and then out the distal end guide wire port 34 in the distal end of the catheter 10 . The catheter also includes a second guide wire lumen 22 which extends throughout the catheter shaft 12 from the proximal end (not shown) of the proximal shaft section 14 to the distal end of the distal shaft section 18 and then out the distal end guide wire port 34 . An inflation lumen 24 extends throughout the catheter shaft 12 from the proximal end of the proximal shaft section 14 to balloon opening 32 located at one end of the distal shaft section 18 . A guide wire port 34 is provided in the distal end of the distal shaft section 18 which is in fluid communication with the first guide wire lumen 20 and the second guide wire lumen 22 . Both the first guide wire lumen 20 and the second guide wire lumen 22 are capable of slidably receiving a guide wire. The distal shaft section 18 is further provided with a dilatation balloon 28 which has an interior 30 in fluid communication with the inflation lumen 24 through balloon opening 32 .
[0026] As seen in FIG. 1, the proximal shaft section 14 and the distal shaft section 18 are interconnected at the intermediate shaft section 16 . The proximal shaft section 14 is coupled to the distal shaft section by any means of adhesion, including laser bonding or fusion, glueing or melting. The communication between the proximal shaft section 14 and the distal shaft section 18 is provided by RX guide wire port 26 . Additionally, the distal shaft section is in fluid communication with a dilatation balloon 28 , the proximal end of the balloon is in communication with the distal shaft section via the balloon opening 32 and the distal end 31 of the balloon is attached to the distal end of the distal shaft section 18 .
[0027] [0027]FIG. 2 depicts a cross-sectional view of the intermediate shaft section 16 of FIG. 1 taken along lines 2 - 2 wherein the intermediate shaft section encompasses the first guide wire lumen 20 and the proximal shaft section 14 , which encompasses the second guide wire lumen 22 and the inflation lumen 24 . FIG. 3 illustrates a cross-sectional view of the distal shaft section 18 which encompasses the first guide wire lumen 20 , the second guide wire lumen 22 and the inflation lumen 24 .
[0028] [0028]FIGS. 4 through 8 depict a preferred embodiment of the current invention. In particular, FIG. 4 depicts a notch junction catheter having an elongated catheter shaft 52 with a relatively long proximal shaft section 54 , an intermediate shaft section 56 , and a relatively short distal section 58 . The catheter shaft 52 has a first guide wire lumen 60 which begins at the RX guide wire port 66 , located near the proximal end of the intermediate shaft section 56 , and which extends throughout the intermediate shaft section 56 . The first guide wire lumen communicates with the distal section lumen 68 at the lumen y-junction 72 . A second guide wire lumen 62 , which begins at the proximal end of the proximal shaft section 54 , extends throughout the proximal shaft section 54 and the intermediate shaft section 56 and communicates with the distal section lumen 68 at the lumen y-junction 72 . A distal section lumen is in fluid communication with the first guide wire lumen 60 and the second guide wire lumen 62 at the lumen y-junction 72 . The distal section lumen 68 extends from the lumen y-junction 72 throughout the distal shaft section 58 to the distal end of the catheter shaft 52 .
[0029] As seen in FIG. 4, insert jacket 70 is used to determine the mode of operation, either the RX or OTW models. During use, insert jacket 70 is inserted into the RX guide wire port. For the RX mode of operation, the insert jacket is pushed distally into the first guide wire lumen until there is closed communication with the distal section guide wire lumen 68 , thus allowing a guide wire to be slidably received by the distal section guide wire lumen 68 through the insert jacket 70 placed within the first guide wire lumen 60 . As depicted in FIG. 8, for the OTW mode of operation, the insert jacket is pulled proximally or placed slightly proximal to the distal section guide wire lumen 68 within the first guide wire lumen 60 , thereby allowing the second guide wire lumen 62 to be in fluid communication with the distal section guide wire lumen 68 . This fluid communication between the second guide wire lumen 62 and the distal section guide wire lumen 68 allows for a guide wire to extend throughout the catheter shaft 52 in the OTW mode of operation.
[0030] For further clarification, FIGS. 5 - 7 depict cross-sectional views taken at various locations along the catheter shaft 52 . FIG. 5 depicts a cross-sectional view of the proximal shaft section 54 of FIG. 4 taken along lines 5 - 5 wherein the proximal shaft section 54 encompasses the second guide wire lumen 62 and the inflation lumen 64 . The insert jacket 70 is located externally of the proximal guide wire lumen. FIG. 6 depicts a cross-sectional view of the intermediate shaft section 56 of FIG. 4 taken along lines 6 - 6 wherein the intermediate shaft section 56 encompasses the first guide wire lumen 60 which further encompasses the insert jacket 70 and the proximal shaft section 54 , which encompasses the second guide wire lumen 62 and the inflation lumen 64 . FIG. 7 depicts a cross-sectional view of the distal shaft section 58 of FIG. 4 taken along lines 7 - 7 wherein the distal shaft section 58 encompasses the distal section guide lumen 68 and the inflation lumen 64 .
[0031] FIGS. 9 - 11 illustrate yet another embodiment of the invention. In particular, FIG. 9 depicts the peel-away catheter having an elongated catheter shaft 82 with a relatively long proximal shaft section 84 , an intermediate shaft section 86 , and a relatively short distal section 88 . The catheter shaft 82 has a guide wire lumen comprised of the proximal section guide wire lumen 90 and distal section guide wire lumen 92 , an inflation lumen 98 , a balloon 100 located in the distal shaft section 88 , and an optional support mandrel 110 providing support for the catheter shaft 82 . The proximal shaft section comprises an inflation lumen 98 , a proximal section guide wire lumen 90 and a guide wire lumen slit 94 . The guide wire lumen slit 94 is aligned parallel to and along the length of the proximal shaft section 84 and provides the peel-away mechanism of the proximal shaft section 84 . The guide wire lumen slit 94 is smaller in width than the diameter of the typical guide wire, therefore during use, the guide wire is retained within the proximal section guide wire lumen unless force is exerted by the physician to pull the guide wire out of the guide wire lumen slit 94 and peel it away from the catheter.
[0032] The intermediate shaft section 86 includes the proximal section guide wire lumen 90 wherein the proximal section guide wire lumen 90 comes into fluid contact with the distal section guide wire lumen 92 , the inflation lumen 98 , and the peel-away strain relief 96 . The peel-away strain relief 96 is positioned on the outside circumference of the intermediate shaft section 86 and provides resistance from the propagation of the guide wire lumen slit 94 of the proximal shaft section 84 into the distal shaft section 88 . The peel-away strain relief may be constructed of the same material as the catheter shaft.
[0033] The distal shaft section 88 includes the inflation lumen 98 , the balloon 100 and the distal section guide wire lumen 92 . The distal section guide wire lumen 92 is in continuous contact and in fluid communication with the proximal section guide wire lumen 90 at the intermediate shaft section 86 as described above. The balloon is located at the distal end of the distal shaft section and is defined by a proximal end, distal end, and an interior. The proximal end of the balloon 100 is in fluid communication with the inflation lumen 98 via the balloon opening 104 , the distal end of the balloon defines the end of the catheter shaft and ends at the distal end guide wire port 112 . The proximal end of the balloon 100 is permanently connected to the distal shaft section 88 at a location slightly proximal to the end of the catheter shaft 82 .
[0034] For further clarification, FIGS. 10 and 11 depict cross-sectional views taken at various locations along the catheter shaft 82 . FIG. 10 depicts a cross-sectional view of the proximal shaft section 84 of FIG. 9 taken along lines 10 - 10 wherein the proximal shaft section 54 encompasses the proximal section guide wire lumen 90 and the inflation lumen 98 . The guide wire lumen slit 94 allows for an opening in the proximal section guide wire lumen 90 , however, because the guide wire lumen slit 94 typically is closed or at least defines a very narrow gap that is smaller than the diameter of the typical guide wire to be used with this catheter, the guide wire is retained within the proximal section guide wire lumen 90 unless force is exerted by the operating physician to pull the guide wire out of the guide wire lumen slit 94 . FIG. 11 depicts a cross-sectional view of the distal shaft section 88 of FIG. 9 taken along lines 11 - 11 wherein the distal shaft section 88 encompasses the distal section guide wire lumen 92 and the inflation lumen 98 . Both FIGS. 10 and 11 illustrate the optional support mandrel which adds stiffness to the catheter shaft which allows for easier handling of the catheter during introduction into the patient's vasculature.
[0035] From FIG. 9 it is seen that for the RX mode of operation, the guide wire is inserted in the proximal end of the proximal shaft section 84 and into the proximal section guide wire lumen 90 . The guide wire traverses the length of the proximal section guide wire lumen 90 into the distal section guide wire lumen 92 and out the distal end guide wire port 112 . After the catheter is in place in the patient's vasculature, the guide wire lumen slit 94 in the proximal shaft section guide wire lumen 90 allows for the guide wire to be quickly removed by pulling it out of the guide wire lumen slit. Furthermore, as seen from FIG. 9, for the OTW mode of operation, the guide wire is inserted in the proximal end of the proximal shaft section 84 into the proximal section guide wire lumen 90 . The guide wire traverses the length of the proximal section guide wire lumen 90 into the distal section guide wire lumen 92 and out the distal end guide wire port 112 . After the catheter is in place in the patient's vasculature, the guide wire remains in the proximal section guide wire lumen 90 and may be removed by pulling it out of the catheter shaft by the operating physician, at the proximal end of the proximal shaft section 84 .
[0036] The use of the catheters of the invention for the most part follow the procedures described in U.S. Pat. No. 5,135,535 (Kramer), assigned to the present assignee (Advanced Cardiovascular Systems, Inc.). The Kramer patent is incorporated herein by reference.
[0037] The catheter shaft of the invention can be formed by conventional techniques well known in the art, e.g., extruding from a variety of polymer materials already found useful in intravascular catheters such as polyethylene, polyimide, polyamide, PVC, polyester (e.g., Hytrel) and high strength polymers such as polyetheretherketone (PEEK). The various components of the catheter can be joined by conventional adhesives, such as acrylonitrile based adhesives, heat shrinking, fusion bonding and the like.
[0038] The traverse dimensions of the catheter shaft and the guide wire lumens are for the most part determined by the transverse dimensions of the guide wire to be used in the catheter. Typically, the guide wire is about 0.008 to about 0.035 inch (0.2-0.9 mm) in diameter. The guide wire lumen is configured to slidably receive the guide wire, i.e., it should be about 0.001 to about 0.005 inch (0.025-0.13 mm) larger than the guide wire diameter. The catheter shaft is sufficiently long to extend from outside the proximal end of the guiding catheter, which likewise extends out of the patient during the procedure, to a vascular location where the procedure is to be performed. Typically, the catheter is about 135 cm in length. In the peel-away catheter embodiment, the guide wire lumen slit 94 should have a width smaller than that of the guide wire diameter in order to retain the guide wire within the proximal section guide wire lumen 90 for the OTW mode of operation. Additionally the slit width should be sufficiently wide enough to allow deformation when force is applied by the operating physician in order to pull the guide wire out of the proximal section guide wire lumen via the guide wire lumen slit for the RX mode of operation.
[0039] While the invention is described herein in terms of a dilatation catheter, those skilled in the art will recognize that it is applicable to a variety of intravascular catheters. Additionally, while several particular forms of the invention have been illustrated and described, it will be apparent that to those skilled in the art that various modifications can be make without departing from the spirit and scope of the invention. Although individual features of embodiments of the invention may be shown in some of the drawings and not in others, those skilled in the art will recognize that individual features of one embodiment of the invention can be combined with any or all the features of another embodiment. | An intravascular catheter capable of both rapid-exchange and over-the-wire modes of operation having a relatively long proximal shaft portion, a relatively short distal section and an intermediate shaft section, which connects the proximal shaft section and the distal shaft section. In one embodiment, the intermediate shaft section includes a guide wire port and a first guide wire lumen which extends throughout both the intermediate and distal shaft section, and a second guide wire lumen which extends throughout the entire catheter shaft. In another embodiment, the intermediate shaft section includes a y-lumen junction which allows a first guide wire lumen introduced at the intermediate shaft section and a second guide wire lumen extending from the proximal end of the catheter shaft throughout the proximal shaft section to merge and communicate with a single distal guide wire lumen which extends from the intermediate shaft section to the distal end of the catheter shaft. In another embodiment, the catheter shaft includes a single guide wire lumen extending from the proximal end to the distal end wherein the guide wire lumen is defined by a proximal section and a distal section. The proximal section guide wire lumen includes a slit which allows a guide wire to be removed for rapid-exchange mode of operation or retained for over-the-wire mode of operation. | 0 |
FIELD OF THE INVENTION
The present invention relates to a semiconductor processing equipment; and, more particularly, to a device for moving doors of substrate carriers, e.g., for use in a semiconductor processing equipment such as a batch-type vertical apparatus for performing a diffusion or a CVD (chemical vapor deposition) process to form diffusion, dielectric or metallic layers on semiconductor wafers.
BACKGROUND OF THE INVENTION
In a semiconductor processing equipment such as a batch-type vertical apparatus for performing a diffusion or a CVD process, semiconductor wafers are loaded into and unloaded from the apparatus while being kept in cassettes. Two kinds of carriers have been conventionally used. One is a box-shaped cassette having a pair of openings on two opposite sides and the other is a box-shaped FOUP (front opening unified pod; hereinafter, pod) having an opening on one side thereof with a pod door removably mounted thereon.
In the semiconductor processing equipment using the pod as the carrier, the wafers can be kept protected from contaminations of ambient atmosphere while being transferred since the pod containing the wafers is airtightly closed. Accordingly, the degree of cleanliness required for a clean room of the semiconductor processing equipment may be lowered, which in turn reduces cost for the maintenance of the clean room. For such reasons, the pod is gaining popularity as the carrier in the semiconductor processing equipment recently.
The semiconductor processing equipment using the pod as the wafer carrier is provided with a pod door opener for remaining and restoring the pod door. One example of such conventional pod door opener is disclosed in U.S. Pat. No. 5,772,386, wherein the pod door opener is disposed on a wafer loading port and equipped with a closure capable of frictionally engaging with a door of the pod located on the wafer loading port. The pod can be uncovered by lowering down the closure while the closure engages with the door.
However, since the conventional semiconductor processing equipment is provided with only a single wafer loading port, the lead time required in preparing wafers for an actual process increases due to replacement of a pod on the wafer loading port with another, which in turn lengthens the overall processing time of the semiconductor manufacturing process, thereby reducing the throughput thereof.
Another equipment having a multi-stage pod door system is disclosed in U.S. Pat. No. 6,042,324. Since, however, the pod doors of the equipment are simultaneously opened as a single unit by a vertical actuator, the lead time may not be reduced and the height of the equipment increases.
SUMMARY OF THE INVENTION
It is, therefore, a primary object of the present invention to provide a semiconductor processing equipment capable of increasing the throughput thereof.
In accordance with one aspect of the present invention, there is provided a semiconductor processing equipment comprising:
a plurality of wafer loading ports for seating carriers containing a number of wafers, the wafer loading ports being vertically stacked; and
a same number of carrier door openers as the wafer loading ports for opening doors of the carriers while the carriers are disposed respectively on the wafer loading ports, the pod door openers being operated independently of each other,
wherein, while one carrier on one of the wafer loading ports is under wafer loading or unloading process, other carriers are prepared for the wafer loading or unloading process on other wafer loading ports.
In accordance with another aspect of the present invention, there is provided a method for processing wafers for use in a method for processing substrates for use in a semiconductor processing equipment having at least two loading ports, a plurality of carriers each of which contains a portion of the substrates, a carrier shelf for storing the carriers, a reaction chamber and a boat for loading and unloading the substrates into and out of the reaction chamber, the method comprising the step of transferring the substrates between the carriers and the boat, wherein the transferring step includes the steps of:
conveying one carrier between the carrier shelf and one loading port; and
carrying the portion of the substrates contained in the carrier between the carrier and the boat,
wherein, while the carrier on the loading port is under the transferring step, another carrier is transferred between the carrier shelf and another loading port.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and features of the present invention will become apparent from the following description of preferred embodiments given in conjunction with the accompanying drawings, in which:
FIG. 1 schematically shows a semiconductor processing equipment in accordance with the present invention;
FIG. 2 illustrates a perspective front view of a pod door opener;
FIG. 3 is a perspective view of the pod door opener with pods disposed on the wafer loading ports;
FIG. 4 describes a schematic perspective rear view of the pod door opener with some parts eliminated;
FIG. 5 represents a perspective view of the eliminated parts V in FIG. 4;
FIG. 6A shows a plan view of a mechanism for mapping with the arm retracted;
FIG. 6B shows a plan view of a mechanism for mapping with the arm in operation position;
FIG. 7 illustrates a sequence for wafer loading and unloading in accordance with a first preferred embodiment of the present invention;
FIG. 8 illustrates another sequence for wafer loading and unloading in accordance with a second preferred embodiment of the present invention;
FIG. 9 illustrates still another sequence for wafer loading and unloading in accordance with a third preferred embodiment of the present invention; and
FIG. 10 illustrates still another sequence for wafer loading and unloading in accordance with a fourth preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A preferred embodiment of the present invention will now be described with reference to the accompanying drawings.
FIG. 1 shows a semiconductor processing equipment 1 having a batch-type vertical apparatus for performing, e.g., a diffusion or a CVD process. The semiconductor processing equipment 1 is provided with an airtightly sealed housing 2 . At an upper portion of the rear side of the housing 2 , a heater unit 3 is vertically installed and a process tube 4 is concentrically disposed within the heater unit 3 . The process tube 4 has a gas supply line 5 for supplying a process gas or a purge gas into the process tube 4 , and an exhaust line 6 for use in evacuating the process tube 4 . A boat elevator 7 is installed below the process tube 4 to move a boat 8 having a boat receptacle 8 a up and down, thereby loading or unloading the boat 8 into or from the process tube 4 . A plurality of wafers 9 can be loaded in the boat 8 in such a manner that the centers of the wafers are vertically aligned while maintaining a predetermined distance between two neighboring wafers.
Formed on a front wall of the housing 2 is a pod load/unload opening (not shown) through which pods 10 can be loaded into or unloaded from the housing 2 . The pod load/unload opening can be open and closed by a shutter (not shown). In front of the pod load/unload opening, a pod stage 11 is provided for receiving multiple, e.g., two, pods at a time.
At the upper central portion of the semiconductor processing equipment 1 , a rotatable pod shelf 12 is arranged. The pod shelf 12 is capable of holding, e.g., eight pods 10 . The numbers of pods that the pod shelf 12 can support is not limited to eight but may be increased, e.g., up to sixteen. The pod shelf 12 has two vertically disposed swastika-shaped pod supporting plates, each being capable of holding, e.g., 4 pods simultaneously. The pod shelf 12 is uni-directionally rotatable in a horizontal plane on a pitch-by-pitch basis by a rotary actuator (not shown), e.g., a stepping motor.
Below the pod shelf 12 , there is provided a two pod openers 20 each of which includes a wafer loading port 13 , bulkhead 21 and a closure 40 . The wafer loading ports 13 through which the wafers are carried into or out of the pod 10 are vertically stacked.
Inside the housing 2 , a pod handler 14 is installed between the pod stage 11 and the pod shelf 12 . The pod handler 14 is adapted to transfer pods between the pod shelf 12 and the wafer loading ports 13 and between the pod shelf 12 and the pod stage 11 . Pod transfer may also be conducted between the pod stage 11 and the wafer loading ports 13 , if necessary. Moreover, a wafer carry assembly 15 is provided between the boat 8 and the wafer loading ports 13 to transfer wafers 9 therebetween.
Details of the pod opener 20 will now be described with reference to FIGS. 1 to 6 B.
As shown in FIG. 1, the semiconductor processing equipment in accordance with the present invention includes a vertically oriented bulkhead 21 which is used by both of the pod openers 20 in common. The wafer loading ports 13 are vertically provided on the front surface of the bulkhead 21 facing the pod stage 11 and the corresponding closures 40 are provided on the rear surface of the bulkhead 21 facing the wafer carry assembly 15 as shown in FIGS. 2 and 3. The bulkhead 21 has rectangular-shaped openings 22 through which pod doors 10 a are coupled with the corresponding door openers 20 . The size of an opening 22 is larger than that of the pod door 10 a , which also has a rectangular shape, as shown in FIGS. 6A and 6B. The rectangular-shaped openings 22 are vertically provided in the bulkhead 21 .
As shown in FIG. 2, a support 23 for each of the wafer loading ports 13 is horizontally provided on the front surface of the bulkhead 21 below each opening 22 . The plan view of the support 23 is of a substantially square frame shape having some cutout portion at the distal end thereof away from the bulkhead 21 . A pair of parallel guide rails 24 are mounted on an upper plate of the support 23 , the rails 24 running normal to the front surface of the bulkhead 21 . A loading platform 27 is slidably mounted on the guide rails 24 through guide blocks 25 . The loading platform 27 can move toward and away from the opening 22 , i.e., in a to-and-fro direction, by an air cylinder 26 mounted on the upper plate of the support 23 .
The loading platform 27 also has a substantially square frame shape with some cutout portion at the distal end thereof away from the bulkhead 21 . On the upper surface of the loading platform 27 , vertically oriented alignment pins 28 provided at locations corresponding to, e.g., three corner points of an equilateral triangle. These pins are adapted to match with corresponding holes (not shown) formed at a bottom surface of the pod 10 .
As shown in FIG. 4, a guide rail 30 for each of the pod openers 20 is mounted on the rear surface of the bulkhead 21 below the corresponding opening 22 . The guide rail 30 is extended horizontally parallel to the rear surface of the bulkhead 21 , i.e., along the left-right direction. An angle-shaped slider 31 is slidably supported by the guide rail 30 and movable in the left-right direction. An air cylinder 32 is mounted on a vertical portion of the angle-shaped slider 31 along the left-right direction. An end portion of a piston rod 32 a of the air cylinder 32 is anchored to the bulkhead 21 . The movement of the angle-shaped slider 31 is controlled by the retraction and extension of the air cylinder 32 .
As shown in FIG. 5, a pair of parallel guide rails 33 running along the to-and-fro direction are installed on an upper surface of a horizontal portion of the angle-shaped slider 31 . A back/forth slider 34 is slidably mounted on the guide rails 33 . The back/forth slider 34 has a guide hole 35 which extends in the left-right direction in one end portion along the left-right direction, e.g., a left end portion of the back/forth slider 34 . A bracket 36 is fixedly mounted on the left side portion of the angle-shaped slider 31 and a rotary actuator 37 is vertically mounted on the bracket 36 . A circularly moving guide pin 38 provided at an arm 37 a of the rotary actuator 37 is slidably engaged with the guide hole 35 . Therefore, the back/forth slider 34 is driven to move toward and away from the bulkhead 21 linearly along the to-and-fro direction by the rotating movement of the rotary actuator 37 .
Mounted on the top surface of the back/forth slider 34 is a bracket 39 . A square-shaped closure 40 larger than the opening 22 is vertically fixed to the bracket 39 . The square-shaped closure 40 is movable in the to-and-fro direction by the movement of the back/forth slider 34 and in the left-right direction by the movement of the angle-shaped slider 31 . The front surface of the closure 40 facing toward the wafer loading ports 13 has a peripheral region and a central region thicker than the peripheral region. That is, the distance from the front surface at the central region (hereinafter, referred to as central front surface) to the rear surface of the closure 40 is greater than that for the front surface at the peripheral region (hereinafter, referred to as peripheral surface) of the closure 40 . The size of the central region of the front surface of the closure 40 is slightly smaller than the opening 22 , so that the central region can get into the opening 22 .
By such configuration, a peripheral front surface of the closure 40 can firmly abuts with the periphery of the opening 22 by moving forward the back/forth slider 34 against the bulkhead 21 and the opening 22 can be closed.
Further, as shown in FIGS. 5 to 6 A, a packing member 55 , e.g., an O-ring, may be provided around the peripheral surface of the closure 40 in order to air-tightly seal against the rear side wall of the bulkhead 21 around the opening 22 when the closure 40 abuts with the bulkhead 21 . Another packing member 56 may be provided on the peripheral region of the central front surface in order to seal against the pod door 10 a lodged on the wafer loading port 13 when the closure 40 abuts with the bulkhead 21 . The packing member 56 serves to prevent potential contaminants on the door 10 a of the pod 10 from entering into the processing area where the wafer carry assembly 15 is located. An additional packing member 54 may also be provided on the region of the front side wall of the bulkhead 21 around the opening 22 in order to seal against the door frame of the pod 10 when the pod 10 is arranged to move against the bulkhead 21 .
As shown in FIGS. 2 and 4, a pair of rotatable keys 41 are arranged on the left and the right sides of the central front surface of the closure 40 . The keys 41 are located along the horizontal centerline on the central front surface. Each key is coupled with a pulley 42 provided on the rear surface of the closure 40 . Both pulleys 42 are connected by a belt 43 which has a connection plate 44 . An air cylinder 45 is horizontally mounted above one of the pulleys 42 and a piston rod thereof is connected to the connection plate 44 such that extension and retraction of the air cylinder 45 can produce a reciprocating rotary motion of the pulleys 42 , thereby inducing the keys 41 to rotate. In addition, each key 41 includes a coupling member 41 a at the end portion thereof for engaging with a locking mechanism (not shown) on the door 10 a of the pod 10 .
As shown in FIG. 2, a pair of suction elements 46 capable of holding the pod door 10 a by vacuum suction are diagonally provided on two corner regions of the central front surface of the closure 40 . Each suction element 46 has a suction pipe 47 and the suction pipe 47 is connected with an air exhaust/supply pipe (not shown). End portions of the suction pipes 47 are adapted to match with aligning holes in the pod door 10 a . Therefore, the suction pipes also act as supporting members for holding the pod door 10 a.
Referring to FIGS. 2, 4 , 6 A and 6 B, on the front side wall of the bulkhead 21 , a rotary actuator 50 having a vertically oriented rotary shaft 50 a is installed beside the opening 22 . A C-shaped arm 51 is provided to pass through an opening 52 in the bulkhead 21 . One end of the C-shaped arm 51 is connected to the rotary shaft 50 a and a mapping device 53 for detecting the locations of wafers in the pod 10 is installed at the other end. The C-shaped arm 51 can be rotated in a horizontal plane.
In operation, the pods 10 are loaded onto the pod stage 11 through the pod load/unload opening and then transferred by the pod handler 14 to predetermined positions on the pod shelf 12 for temporary storage as shown in FIG. 1 .
FIG. 7 illustrates the pod transferring process between the pod shelf 12 and the wafer loading ports 13 and also the wafer transferring process between the pods on the wafer loading ports 13 and the wafer boat 8 in accordance with the first embodiment of the present invention.
The two pod openers 20 are arranged to close the openings 22 such that the packing member 55 seals against the rear side wall of the bulkhead 21 . One pod 10 is transferred from the pod shelf 12 to, e.g., the upper wafer loading port 13 by the pod handler 14 and disposed on the loading platform 27 . The three alignment pins 28 on the loading platform 27 engage with the corresponding three holes (not shown) formed under the pod 10 to thereby complete the alignment of the pod 10 on the loading platform 27 .
The pod 10 provided on the loading platform 27 is moved toward the bulkhead 21 by the extension of the air cylinder 26 in such a manner that the respective packing members 54 and 56 are airtightly in contact with the pod door 10 a and the pod frame therearound as shown in FIG. 6 A. The keys 41 and the suction pipes 47 of the closure 40 are also inserted in the key holes (not shown) and the aligning holes provided on the door 10 a , respectively. The pod transferring process described above is generally represented as a process “A” at the first stage in FIG. 7 .
After completing the pod transferring process “A”, a negative pressure is applied through the air exhaust/supply pipes 47 inside the suction elements 46 so that the suction elements 46 hold the door 10 a by vacuum suction. Thereafter, the keys 41 are rotated by the air cylinder 45 so that the coupling members 41 a unlock the door 10 a.
Next, the back/forth slider 34 is moved away from the bulkhead 21 by the rotary actuator 37 and then the angle-shaped slider 31 is moved away from the opening 22 by the air cylinder 32 so that the closure 40 holding the pod door 10 a by the suction elements 46 is moved to a retreated position. By such movement of the closure 40 , the door 10 a is separated from the pod 10 and the pod is opened as shown in FIG. 6B, thereby the wafers 9 loaded in the pod 10 is put under a condition that the wafer carry assembly 15 can access thereto. The pod door opening process described above is represented as a process “B” at the first stage in FIG. 7 .
Thereafter, as shown in FIG. 6B, the mapping device 53 is moved to the wafers inside the pod 10 through the opening 22 by the rotary actuator 50 and performs mapping by detecting the positions of the wafers, i.e., by identifying slots holding the wafers. After mapping is completed, the mapping apparatus 53 is returned to its initial position by the rotary actuator 50 . The mapping process described above is generally represented as a process “C” at the first stage in FIG. 7 .
Next, the wafers in the pod 10 on the wafer loading port 13 are transferred to the wafer boat 8 by the wafer transfer assembly 15 . The wafer transferring process described above is generally represented as a process “D” at the first stage in FIG. 7 .
While the wafer transferring process is performed at the first, e.g., the upper wafer loading port 13 , the pod transferring process “A”, the pod door opening process “B” and the mapping process “C” are sequentially carried out at the second, e.g., the lower wafer loading port 13 . the second wafer loading port 13 waits (process E) until the wafer transferring process “D” at the first wafer loading port 13 is completed.
Accordingly, upon the completion of the wafer transferring process “D” of the first wafer loading port 13 at the second stage, the wafer transferring process “D” can be started at the second wafer loading port 13 as shown in FIG. 7 (third stage). As a result, the wafer transferring operation can be alternatively performed by the wafer loading port 13 without interruption due to the replacement of the pods 10 and thus the system efficiency or the throughput of the semiconductor processing equipment can be improved.
During the third stage shown in FIG. 7, where the wafer transferring process “D” is carried out by the second wafer loading port 13 , a pod door closing process “E”, a pod changing process “A”, the pod door opening process “B”, the mapping process “C” and the waiting process “F” are sequentially carried out in that order, so that the wafer transferring process “D” can be started by the first wafer loading port 13 immediately after the completion of the process “D” at the second wafer loading port 13 .
The pod door closing process is carried out as follows. The closure 40 holding the pod door 10 a is removed from the retreated position toward the opening 22 by the air cylinder 32 and then toward the empty pod 10 by the rotary actuator 37 to close the pod 10 by the pod door 10 a thereafter, the keys 41 are rotated by the air cylinder 45 to actuate the locking mechanism of the pod door 10 a . After locking, the negative pressure inside the suction element 46 is removed by supplying a positive pressure through the pipe 47 and the closure 40 . The closure 40 remains in that position until the pod door opening process “B” is resumed.
The pod changing process “A” is carried out as follows. After the pod door 10 a is restored on the empty pod 10 by the pod door closing process “E”, the loading platform 27 of the first wafer loading port holding the empty pod is moved away from the bulkhead 21 by the air cylinder 26 . The empty pod 10 is then stored back to the pod shelf 12 and a new pod holding wafer therein is transferred to the first wafer loading port. Thereafter, the newly supplied pod is provided to the closure 40 in an identical manner as in the pod transferring process “A”. The remaining process “B”, “C” and “F” are identical to those of the second stage.
The wafer loading processes are repeated until the described number of wafers are loaded from the pods 10 to the wafer boat 8 . After transferring the described number of wafers, the last two empty pods may be removed to the pod shelf 12 or stayed on the wafer loading ports 13 . Alternatively, only one empty port 13 may remain at the one wafer loading port 13 . The number of wafers which the wafer boat 8 can hold for one batch process is, e.g., 100 to 150, which is several times greater than that of wafers which one pod can contain therein, e.g., 25.
After the predetermined number of unprocessed wafers are loaded on the wafer boat 8 , the boat elevator 7 lifts the wafer boat 8 into the process tube 4 . When the wafer boat 8 is introduced into the process tube 4 , a lower end opening of the process tube 4 is hermetically sealed by the boat receptacle 8 a.
Next, the process tube 4 is evacuated through the exhaust pipe 6 to reduce the pressure therein down to a predetermined vacuum level. Thereafter, a desired wafer process, e.g., a diffusion or a CVD process, is carried out on the loaded wafers by controlling temperatures at desired levels by using the heater unit 3 while supplying predetermined process gases into the process tube 4 through the gas supply line 5 .
After a predetermined processing time has elapsed, the wafer boat 8 holding processed wafers is discharged from the process tube 4 and returned to its initial position. During the period in which the wafer boat 8 is loaded into and unloaded from the process tube 4 and the wafers are processed in the process tube 4 , either one or both of the pods 10 may be prepared at the corresponding wafer loading ports 13 in order to receive the processed wafers.
Thereafter, the wafer transfer assembly 15 transfers a portion of the processed wafers held in the wafer boat 8 to one empty pod 10 disposed on, e.g., the first wafer loading port 13 (upper loading port) with the door 10 a opened. This process corresponds to the wafer transferring process “D” at the second stage shown in FIG. 7 . After completing the wafer transferring process “D” at one wafer loading port, the same process is carried out at the other wafer loading port with the door thereof being opened. This process corresponds to the process “D” at the third stage in FIG. 7 .
While the wafer loading process “D” is carried out at the second wafer loading port, the pod door closing process “E”, the pod changing process “A”, the pod door opening process “B” and the waiting process “F” are carried out at the first wafer loading port as in the third stage of FIG. 7 . The mapping process “C” is not performed because the processed wafers are transferred into an empty pod at this time.
The process “E”, “A”, “B” and “F” are identical to those described with respect to the wafer loading process from the pods 10 to the wafer boat 8 , excepting that the pod changing process “A” represents the process transferring a pod containing the processed wafers to the pod shelf 12 from a wafer loading port and moving an empty pod from the pod shelf 12 to the wafer loading port 13 .
In case all the empty pods have been transferred from the wafer loading ports 13 to the pod shelf 12 after loading all the wafers onto the boat 8 , the processed wafer unloading process can be accomplished as follows. First, one empty pod is transferred from the pod shelf 12 to one of the wafer loading ports and the pod door 10 a thereof is opened. These correspond to the process “A” and “B” of the first stage in FIG. 7 . The timing of the processes “A” and “B” can be controlled such that the wafer transferring process “D” at the second stage can be started immediately after completing the pod door opening process “B” at the first stage. Of course, the mapping process “C” is omitted at the first stage because the pod is empty.
Thereafter at the second stage, the wafer transferring process “D” is carried out at the first wafer loading port 12 , while the process “A”, “B” and “F” are sequentially performed at the second wafer loading port. Then, the process at the third stage can be carried out as described above.
The processes are repeated until transferring all the processed wafers from the wafer boat 8 to the empty pods, which in turn are returned to the pod shelf 12 .
As described above, since the wafer transfer assembly 15 can transfer the processed wafers from the wafer boat 8 to the pods 10 continuously without having to wait for the replacement of the pods 10 on the wafer loading ports 13 , the throughput of semiconductor processing equipment 1 can be substantially increased.
The pods 10 containing the processed wafers are temporarily stored in the pod shelf 12 and then transferred to the pod stage 11 by the pod handler 14 . Next, the pods on the pod stage 11 are transferred through the pod load/unload opening (not shown) to another equipment for a subsequent process and new pods containing unprocessed wafers are charged on the pod stage 11 .
The processes of transferring pods between the pod shelf 12 and the pod stage 11 and charging and discharging pods into and from the semiconductor processing equipment 1 can be carried out while wafers are being processed in the process tube 4 and transferred between the wafer boat 8 and the pods 10 on the wafer loading ports 13 . As a result, the total process time of the semiconductor processing equipment 1 can be reduced.
Referring to FIGS. 8 to 10 , there are illustrated wafer transferring sequences in accordance with further preferred embodiments of the present invention. In the sequences shown FIGS. 8 to 10 , wafer mapping is completed at least for the pods containing wafers required for one batch process before the continuous wafer loading process begins for that batch process, e.g., by transferring the corresponding pods from the pod stage 11 to the wafer loading ports 13 in order to carry out the mapping and then moving them to pod shelf 12 . Therefore, the process sequences in FIGS. 8 to 10 will be described by assuming that the wafer mapping has been completed for the pods stored on the pod shelf 12 containing wafers needed for one batch process. The processes identified as reference numerals “A” to “F” and “A” in FIGS. 8 to 10 are basically identical to those of FIG. 7 .
The wafer transferring sequence in accordance with the second embodiment of the present invention will be described with reference to FIG. 8 . At the first stage of the sequence for transferring unprocessed wafers to the wafer boat 8 , a first pod containing unprocessed wafers is transferred from the pod shelf 12 to a first wafer loading port (process “A”) and the door of the first pod is opened (process “B”).
Immediately thereafter at the second stage, wafer transferring from the first pod to the wafer boat 8 (process “D”) starts and, at the same time, a second pod containing the unprocessed wafers are transferred to a second wafer loading port (process “A”) and waits until the wafer transferring process “D” at the first wafer loading port is completed (process “F”).
At the third stage, the door of the second pod is opened (process “B”) and the wafers therein are transferred to the boat 8 (process “D”) and the door is restored on the empty first pod (process “E”), which is then replaced with another pod carrying unprocessed wafer (process “A”), the new pod remaining at the first wafer loading port until the wafer loading process at the second wafer loading port is completed (process “F”). The processes described in connection with the third stage are alternately carried out until all the required wafers for one batch process are transferred to the wafer boat 8 .
As described above in the second embodiment of the present invention, the pod transferring process “A” and the pod changing process “A” for one wafer loading port are carried out during the wafer transferring process “D” at the other wafer loading port; and the pod door opening process “B” for one wafer loading port and the pod door closing process “E” for the other wafer loading port are simultaneously conducted.
The process sequence of the second embodiment for transferring processed wafers to empty pods is identical to that for transferring unprocessed wafers to the wafer boat 8 , excepting that the pod changing process “A” in the process sequence for transferring processed wafers represents the process of transferring a pod containing the processed wafers from a wafer loading port to the pod shelf 12 and then moving an empty pod from the pod shelf 12 to that wafer loading port. The process “A” of transferring a first empty wafer to one of the wafer loading ports is controlled in such a manner that the wafer transferring from the boat to the first empty pod can be conducted immediately after completing the opening of the door of the first pod.
The sequence shown in FIG. 9 in accordance with the third embodiment of the present invention is identical to that of the second embodiment shown in FIG. 8, excepting that the pod door opening process “B” at one wafer loading port is conducted during the wafer transferring process “D” at the other wafer loading port in such a manner that the process “D” at one wafer loading port can be started upon the completion of the process “D” at the other wafer loading port. Also, the door closing process “E” at one wafer loading port and the wafer transferring process “D” at the other wafer loading port start simultaneously.
FIG. 10 illustrates a wafer transferring process in accordance with the fourth embodiment of the present invention. The process sequence shown in FIG. 10 is identical to that of the third embodiment shown in FIG. 9, excepting that the sequence of the waiting process “F” and the pod door opening process “B” is reversed at every stage.
Following advantages can be achieved in accordance with the present invention.
1) By vertically installing a pair of the pod door openers each of which is capable of independently opening and restoring the door of a pod on each wafer loading port, the wafer transferring process can be independently conducted at one wafer loading port while the other loading port is preparing for the subsequent wafer transferring process. As a result, the total process time can be considerably reduced and therefore the throughput of the semiconductor processing equipment can be increased.
2) By vertically arranging the wafer loading ports, the system efficiency can be improved without increasing the floor area or footprint of the semiconductor processing equipment.
3) The vertically arranged wafer loading ports eliminates the need for the left-right movement of the wafer carry assembly 15 , thereby simplifying the structure thereof and improving the system efficiency without increasing the width of the processing equipment.
4) The independently operable mapping devices provided to the respective wafer loading ports enables the mapping process at one wafer loading port and the wafer transferring process at the other to be conducted simultaneously. As a result, the loading time needed for the subsequent wafer transferring process can be eliminated and therefore the total process time of the semiconductor processing equipment can be considerably reduced, thereby increasing the system efficiency.
5) Simplified and small sized mapping device can be obtained by employing the rotary actuating mechanism therefor, wherein the rotary actuator is mounted on the front side wall of the bulkhead and the arm fixedly coupled thereto passes through the opening in the bulkhead and the mapping device is attached at the end of the arm, enabling the mapping device to approach the wafers in a pod by the rotation of the rotary actuator.
6) Any vertical component in the motion of the pod openers would result in the height increase thereof, which in turn makes the pod shelf located above the pod openers to be disposed at a higher position and increases the height of the semiconductor processing equipment. The increased number of vertically arranged pod openers would impose the multiplicative effect in the vertical position of the pod shelf and the height increase of the processing equipment itself. The higher vertical position of the pod shelf will entails the increase of the pod-transfer time, thereby decreasing the throughput of the equipment.
In contrast, the pod openers 20 in accordance with the present invention solely operate along horizontal directions and do not contribute at all to the height increase of the equipment and the pod-transfer time. Further, the pod shelf is arranged to receive two columns of pods along the width direction of the processing equipment, whereas only one column of wafer transferring ports is provided under the pod shelf. As a result, the purely transitional lateral motion of the pod openers can be accommodated by the reserved space under the pod shelf and, therefore, the system efficiency and the throughput can be improved without increasing the pod transfer time and sacrificing the floor area of the processing equipment.
It is to be appreciated that the configuration of the semiconductor processing equipment may be varied appropriately if necessary.
For instance, the number of the wafer loading ports is not limited to two but more than two wafer loading ports can be installed vertically of if the height increase can be accommodated.
In addition, in lieu of the rotary actuator for actuating the mapping device, another mechanism using an X-Y axis robot can be employed. Moreover, the mapping device can be omitted if so required.
Furthermore, the processing equipment can be of the type capable of processing other substrates, e.g., photo masks, printed circuit boards, liquid crystal panels, compact disks and magnetic disk, than the semiconductor wafers.
The processing equipment can be of the type adapted to perform, e.g., oxide formation, diffusion process and other types of heat treating process in place of the CVD. The present invention is also applicable to other types of semiconductor processing equipments than the batch type vertical processor.
While the invention has been shown and described with respect to the preferred embodiments, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention as defined in the following claims. | A substrate processing equipment comprises two pod supporting stages and two independently operable pod door openers. Each pod supporting stage is capable of placing thereon a pod for containing substrates therein. Each pod door openers having means for permitting access to the substrates inside the pod placed on a corresponding pod supporting stage. | 8 |
FIELD OF THE INVENTION
The present invention concerns a protective helmet with a strapless breathing protection mask in a detachable connection.
BACKGROUND OF THE INVENTION
In the case of a known protective helmet, plug-in and lockable holding means are provided in detachable connection on both side surfaces of the protective helmet and of the breathing protection mask as described in German patent DE-PS 2640 701, (corresponding to U.S. Pat. No. 4,136,403 Walthor et al.).The holding means consists of a tension slide arranged on the protective helmet with an oval/funnel-shaped reception part and a coupling pin on the breathing protection mask. In order to establish the connection between the breathing protection mask and the protective helmet, the coupling pins, provided with unlockable locking balls, are inserted into the funnel-shaped reception parts and are locked there. For individual adjustment and tightening of the mask to the surrounding sealing line on the face, the tension slides have to be moved backwards from the face, whereby, with the aid of a roller pushed along a slanted plane, the breathing protection mask is locked in a corresponding position at the wall of the protective helmet. This type of locking is positive and form-fitting, however; there is the danger that in the course of time when worn this way, the connection between the mask and the protective helmet will loosen, so that the surrounding sealing line of the mask on the face will become leaky. Another disadvantage of this version of protective helmet is that the plugged-in connecting elements represent a relatively rigid connection between the mask and the protective helmet. Facial movements, movements when the user is speaking or possible occurring displacement movements caused by the effects of forces on the helmet, cannot be compensated for.
It is therefore the purpose of this invention to create a protective helmet with a strapless breathing protection mask in a detachable connection, where during use the connection between the mask and the protective helmet guarantees a permanent safe sealing of the mask on the face, and where all movements occurring between the mask and the protective helmet are compensated for.
The advantages achieved with the invention are particularly due to the fact that when the protective helmet is worn, the mask can be connected to the protective helmet in a fast and uncomplicated manner, whereby the individual adjustment and sealing of the mask to the face can be accomplished automatically with the means provided in the connecting element, and where all movements of the detachable assembled parts can be compensated for in a harmonic fashion.
SUMMARY OF THE INVENTION
The present invention pertains to a protective helmet with a strapless breathing protection mask in a detachable connection. The detachable connection is formed by plug-in type and lockable connecting elements arranged on both sides of the helmet and the mask. The improvement to the detachable connection includes each connecting element having a flexible plug-type part capable of limited rotation which is arranged on the breathing protection mask, and of a plug receptacle part arranged on the protective helmet. The plug receptacle part has an adjusting device which can be adjusted to a number of different positions, and which holds the plug-type part in the plug receptacle part with positive force. The plug-type part is inserted into the plug receptacle part to form the detachable connection and the adjusting device allows the mask and helmet to be arranged with a tight fit on the face of a user.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings, preferred embodiments of the invention and preferred methods of practicing the invention are illustrated, in which:
FIG. 1 is a lateral view of the protective helmet with breathing protection mask and a connecting device according to the invention, in the condition as used by the wearer.
FIG. 2 is a lateral view of the protective helmet with breathing protection mask and connecting device, where the helmet and the mask are separated from each other.
FIG. 3 is a lateral view of a cross-section of the connecting device, where a plug part of the breathing protection mask is engaged in a plug receptacle part of the protective helmet in a first locking position.
FIG. 4 is a sectional view along the line IV--IV of FIG. 3.
FIG. 5 is a lateral view of a cross-section of the connecting device, where the plug part is engaged in the plug receptacle part in another possible locking position.
FIG. 6 is a sectional view along the line VI--VI of FIG. 5.
FIG. 7 is a front and lateral view of the locking element.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there is shown a protective helmet 1, worn by a user, with a breathing protection mask 2 in position, where, arranged on either side of the mask 2, is a detachable connecting element A which provides connection between the protective helmet 1 and the breathing protection mask 2. The connecting element A essentially consists of two parts, namely of a plug part 3 mounted in articulated fashion on the breathing protection mask 2 at the frame of the looking glass 2a, and of the plug receptacle part 4 arranged on the protective helmet 1 (see FIG. 2).
The plug receptacle part 4 consists of a housing 4a having a U-shaped cross-section. A moveable slide 4b is disposed in the U-shaped cross-section of the housing as is a spring 10. The slide 4b is moveable against the force of a spring 10 and is so arranged, that it can be moved optionally into predetermined positions, where it is locked with positive force (see FIGS. 3 to 6). In the slide 4b, a moveable locking element 6, being under the pressure of a second spring 5, is arranged transverse to the longitudinal axis 4c of the slide 4b. The locking element 6 has a sawtooth-shaped point 6a, which, interacts with positive force with toothed recesses 4a', provided in the locking 4a. The sawtooth-shaped point 6a of the housing element 6, during a longitudinal move of the slide 4b against the force of the spring 10 in the direction towards the protective helmet 1, engages automatically into the recess 4a', corresponding to the desired position (see FIGS. 4, 6 and 7). p The release of the locking element 6 from the respective recess 4a', and therefore the release of the slide 4b locked in the housing 4a and the move to another position within the housing takes place by means of a key 11 which is unilaterally supported in a bearing 12 in the slide (FIG. 3 and 5). The key 11 has an L-shaped design and is supported in the bearing 12 with one end of the long leg section 11a of the key 11, whereas the short leg section 11b of the key 11 has a protruding pin 13. The pin 13 interacts with a longitudinal hole 6b which is provided at a slant angle in the locking element 6.
When the key 11 is pressed down, the pin 13 guided in the slanted longitudinal hole 6b of the locking element 6 moves vertically downwards against the force of the spring 5 from the respective recess 4a and releases the locking element, which is arranged transverse to the longitudinal axis of the slide 4b. The slide 4b with the locking element 6 is thus released from its locking position in the housing 4a and is pressed by the force of the spring 10 into a final position, locking in a forward direction (see FIGS. 3 and 4).
Below the key 11, a leaf spring 14 interacting with the key 11, is arranged in the slide 4b. The leaf spring 14, mounted with one end 14a in the slide 4b, pushes with the free end 14b with spring action against the short leg section 11b of the key 11 and holds it in a resting position.
On the leaf spring 14, near the mounted end 14a, a cog 15 is arranged on which the plug part 3 by means of a tongue-like plug element 3d engages the plug receptacle part 4 in order to connect therewith. The plug element 3d has a through-hole, 3d' into which the cog 15 captively engages, namely when the plug element 3d is inserted through an opening 4b' provided in the slide 4b. The connection of the plug part 3 with the plug receptacle part 4 established in this way can be released by pressing down the spring loaded key 11. In this case the cog 15 arranged on the leaf spring 14 moves out of the through-hole 3d and releases the plug element 3d of the plug part 3.
As shown in FIGS. 5 and 6, the plug part 3 consists of a two-part hoop arm having a first part 3a and a second part 3b, whose parts can be plugged into each other and can be pulled out against the force of a third spring 7 connecting the two parts. The plug part 3 also consists of a socket 3c which is capable of limited rotation. The socket 3c is arranged on the frame of the looking glass 2a and attached thereto with a first pin 17. The second part of the hoop arm 3b is attached in articulated fashion with a socket pin 16 to the socket 3c, and the plug element 3d is attached to the free end of the first part of the hoop arm 3a in moveable fashion by means of a second pin 19. The rotational mobility of the plug element 3d about the second pin 19 is limited by two stops 3d" which are provided in the plug element 3d and which make damped contact with a third pin 20 surrounded by an elastic ring 9 arranged in the hoop arm 3a. (See FIG. 6).
A torsion spring 8 is provided on the socket pin 16 which interacts with the second part of the hoop arm 3b and moves it automatically towards or against the mask 2. In this way the lateral two-part hoop arm 3a and 3b is forcibly moved close to the mask 2 when the breathing protection mask 2 is not connected to the protective helmet 1 by the user. The hoop arms 3a and 3b are thus protected from damage, on the one hand, and they cannot inflict injuries upon the user, on the other hand.
The plug receptacle part 4 provided in a lateral recess of the protective helmet (not shown) is covered with a cover 18. The cover 18 is provided with a handle part 18a which the user can grasp with his fingers when attaching the mask 2 to the helmet 1, in order to be able to adjust the mask 2 attached to the protective helmet 1 tightly to the surface of the face.
The operation of the connecting element A is described in the following:
The connection of the strapless breathing protection mask 2 with the protective helmet 1 is established in such a way that the user, while wearing the protective helmet inserts the tongue-like plug elements 3d of the breathing protection mask 2 into the plug receptacle part 4. During this process, the leaf spring 14, with the cog 15, arranged in the slide 4b is pressed down by way of the key 11 and the cog 15 engages with spring action and captively into the through-hole 3d' of the plug element 3d. The breathing protection mask 2 is then connected with the protective helmet 1. In order to adjust the edge of the breathing protection mask 2 tightly to the shape of the head and face of the user, the breathing protection mask 2, coupled to the moveable slide 4b, has to be pushed towards the face, whereby the slide 4b in the housing 4a of the plug receptacle part 4 is locked automatically in the respective position by means of the locking element 6. This locking takes place with positive force.
In order to be able to compensate for speaking or facial movements of the wearer or for displacement movements due to possible effects of force on the helmet, the plug part 3 has a certain elasticity and flexibility. This is accomplished, one the one hand, by the fact that the telescoped two-part hoop arm 3a and 3b of the plug part 3 can be pulled out against the force of the spring 7 and can be made longer when the breathing protection mask 2 is adjusted, and on the other hand by the fact that the plug element 3d has limited rotation and makes damped contact with the elastic ring 9, and that the socket 3c of the plug part 3 at the frame of the looking glass 2a of the breathing protection mask 2 also has limited rotation. Thus, the movements between the breathing protection mask 2 and the protective helmet 1 can be compensated for harmonically by the wearer, assuring convenient wear of the two different components now detachably combined to form one unit. Furthermore, no movements coming from the protective helmet 1 are transferred to the breathing protection mask 2, which in the case of the known versions would lead to leaks at the edge of the breathing protection mask 2.
The release of the plug part 3 with the breathing protection mask 2 from the plug receptacle part 4 of the protective helmet 1 is accomplished by pressing down the spring loaded key 11. When this is done, the slide 4b in the housing 4a of the plug receptacle part 4 is released from its locking position and is pushed in a forward direction by the force of the spring 10 into a non-locking position, whereas on the other hand, the cog 15 arranged on the leaf spring 14 moves out of the through-hole 3d' of the plug element 3d and vacates it. The key 11, when it is pressed down, releases two functions simultaneously.
Although the invention has been described in detail in the foregoing embodiments for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be described in the following claims. | A protective helmet with a strapless breathing protection mask which is in detachable connection therewith. The detachable connection is formed by connecting elements that can be plugged into each other and locked, and these connecting elements are located at both sides of the helmet and of the mask. The connecting elements include a flexible plug-type part capable of limited rotation and arranged on the breathing protection mask and a plug receptacle part with an adjusting device arranged on the protective helmet. In order to establish the detachable connection of the mask with the protective helmet, the plug part is plugged into the plug receptacle part becoming automatically locked therewith. | 8 |
COPYRIGHT NOTICE
[0001] A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the patent and trademark office patent file or records, but otherwise reserves all copyright rights whatsoever.
APPENDIX MATERIALS
[0002] The appendix contains duplicate copies of one compact disk that provides software and database files. The contents of the compact disk are hereby incorporated by reference.
BACKGROUND
[0003] To a significant extent, the structural characterization of proteins relies on determining the primary structure (amino acid sequence and covalent modifications) of proteins as they are expressed under native cellular conditions. Once a protein is translated from mRNA, the primary structure of the protein is often covalently modified through the action of enzymes. These modifications include the addition of a new moiety to the side chain of an amino acid residue, such as the addition of phosphate to a serine or proteolytic cleavage, such as removal of an initiator methionine or a signal sequence. Thus, the structural characterization of a protein includes both the linear organization of the amino acid sequence (as affected by alternative splicing and polymorphisms) and the presence of any modification that may arise within the sequence.
[0004] Mass spectrometry (MS) is an analytical technique that is used to identify unknown compounds, to quantify known compounds, and to ascertain the structure of molecules. A mass spectrometer is an instrument that measures the masses of ions that have been converted from individual molecules. This instrument measures the molecular mass indirectly, in terms of a particular mass-to-charge ratio of the ions. The charge on an ion is denoted by the fundamental unit of charge of an electron z, and the mass-to-charge ratio m/z is mass of the ion divided by its charge. For singly-charged ions, the m/z ratio is the mass of a particular ion in Da.
[0005] The sample, which may be a solid, liquid, or vapor, enters the vacuum chamber of the instrument through an inlet. Electrostatic and/or magnetic filters are used to sort the ions according to their respective m/z ratios, and the ions are focused on the detector. In the detector, the ion flux is converted to a proportional electrical current. The instrument then records the magnitude of these electrical signals as a function of m/z and converts this information into a mass spectrum.
[0006] Tandem mass spectrometry (MS/MS) is a specific type of MS in which mass measurements of an intact ion and its constituent fragments are made in a single step. Generally in MS/MS, the intact mass of a protein ion is measured and the ion is isolated. Next, the instrument bombards ions of a sample with high intensity photons, electrons or neutral gas, breaking bonds, resulting in the formation of fragment ions from the molecular ions of the intact molecule. Although both positive and negative ions are generated with MS, only one polarity of an ion is detected with a particular instrumental set-up. Formation of gas phase sample ions allows the sorting of individual ions according to mass and their detection.
[0007] The masses measured by MS/MS may be used to identify a protein assuming it is contained in a database. One identification algorithm, absolute mass searching, allows the unambiguous identification and at least partial characterization of a protein from a sequence database using the intact mass in combination with fragment ion masses. Identification is achieved by selecting all candidate sequences from an annotated database that are within a user specified tolerance of an observed average or monoisotopic intact mass.
[0008] Each candidate sequence is scored against the observed fragment ions. This process involves calculating all theoretical b/y or c/z● type fragment ion masses (average or monoisotopic) from each candidate sequence and counting the number of observed fragment ions that are within a user specified tolerance (absolute or part per million) of any theoretical fragment ion. The number of observed fragment ions and the number of observed fragment ions that correspond to theoretical fragment ions are used to calculate the probability that the identification is spurious. All calculated scores are multiplied by the number of candidate sequences considered to yield a probability-based expectation value. The candidate protein with the lowest expectation value (and thus the lowest probability of being a spurious identification) is then considered the most likely candidate protein.
[0009] Living organisms are constantly synthesizing and degrading proteins. The degradation products of proteins are often found in various fluids of the organism, such as blood, urine, spinal fluid, cerebral spinal fluid, joints, saliva and serum. Many disease states include the production of an increased amount of a protein, the production of a protein form not normally produced, or a decrease in production of a protein. It is therefore possible to correlate the presence of the degradation products of proteins, also referred to as protein fragments or biomarkers, with disease states.
[0010] Precisely identifying biomarkers by MS, and deducing from which proteins they originated, presents significant challenges. Biomarkers are usually present in relatively low concentrations, which results in a low signal to noise ratio for the peaks in MS spectrum. Furthermore, this low signal to noise ratio usually results in fewer clearly identifiable fragment ions.
SUMMARY
[0011] In one aspect, the present invention is a method of preparing a first set of candidate fragments from a sample protein fragment and a protein sequence, comprising selecting a first candidate sequence comprising a terminal amino acid of the protein sequence; generating a further candidate sequence from each candidate sequence, except a last candidate sequence; and including any candidate sequences having a mass which is equal to the mass of the sample protein fragment within a third tolerance, in the first set of candidate fragments. The generating of the further candidate sequences from each candidate sequence is by adding a portion of the protein sequence farther away from the terminal amino acid than the candidate sequence, if a mass of the sample protein fragment is equal to or greater than the mass of the candidate sequence within a first tolerance, or deleting a portion of the candidate sequence from an end closest to the terminal amino acid, if the mass of the sample protein fragment is less than the mass of the candidate sequence within a second tolerance. The candidate sequences are subsequences of the protein sequence.
[0012] In a second aspect, the present invention is a method of preparing a second set of candidate fragments from a sample protein fragment and a plurality of protein sequences, comprising preparing a plurality of first sets of candidate fragments, where each first set is prepared from the sample protein fragment and each protein sequence; and including the first sets of candidate fragments in the second set of candidate fragments.
[0013] In a third aspect, the present invention is a method of preparing a first set of candidate fragments from a sample protein fragment and a plurality of protein sequences, comprising including in the first set of candidate fragments subsequences of the protein sequences in the plurality of protein sequences, where the candidate fragments have a mass which is the same as a mass of the sample protein fragment within a tolerance; and scoring the candidate fragments, by comparing mass spectrometry fragment ion masses of the candidate fragments with mass spectrometry fragment ion masses of the sample protein fragment.
[0014] In a fourth aspect, the present invention is a computer program product, comprising a computer readable medium having computer readable program code for preparing a first set of candidate fragments from a sample protein fragment and a protein sequence. The preparing of the first set comprises selecting a first candidate sequence comprising a terminal amino acid of the protein sequence; generating a further candidate sequence from each candidate sequence, except a last candidate sequence; and including any candidate sequences having a mass which is equal to the mass of the sample protein fragment within a third tolerance, in the first set of candidate fragments. The generating of the further candidate sequences from each candidate sequence is by adding a portion of the protein sequence farther away from the terminal amino acid than the candidate sequence, if a mass of the sample protein fragment is equal to or greater than the mass of the candidate sequence within a first tolerance, or deleting a portion-of the candidate sequence from an end closest to the terminal amino acid, if the mass of the sample protein fragment is less than the mass of the candidate sequence within a second tolerance. The candidate sequences are subsequences of the protein sequence.
[0015] In a fifth aspect, the present invention is a computer program product, comprising a computer readable medium having computer readable program code for preparing a second set of candidate fragments from a sample protein fragment and a plurality of protein sequences. The preparing of the second set of candidate fragments comprises selecting a first candidate sequence for each protein sequence comprising a terminal amino acid of said each protein sequence; generating a further candidate sequence from each candidate sequence, except a last candidate sequence of said each protein sequence; and including any candidate sequences having a mass which is equal to the mass of the sample protein fragment within a third tolerance, in the second set of candidate fragments. The generating of the further candidate sequences from each candidate sequence is by adding a portion of said each protein sequence farther away from the terminal amino acid of said each protein sequence than the candidate sequence, if a mass of the sample protein fragment is equal to or greater than the mass of the candidate sequence within a first tolerance, or deleting a portion of the candidate sequence from an end closest to the terminal amino acid of said each protein sequence, if the mass of the sample protein fragment is less than the mass of the candidate sequence within a second tolerance. The candidate sequences are subsequences of said each protein sequence, each further candidate sequence comprises one more or one less amino acid than the candidate sequence from which the further candidate sequence was generated, and the first, second and third tolerances are equal.
[0016] In a sixth aspect, the present invention is a computer program product, comprising a computer readable medium having computer readable program code for preparing a first set of candidate fragments from a sample protein fragment and a plurality of protein sequences. The preparing the first set of candidate fragments comprises including in the first set of candidate fragments subsequences of the protein sequences in the plurality of protein sequences, where the candidate fragments have a mass which is the same as a mass of the sample protein fragment within a tolerance; and scoring the candidate fragments, by comparing mass spectrometry fragment ion masses of the candidate fragments with mass spectrometry fragment ion masses of the sample protein fragment.
[0017] Definitions
[0018] The term “fragment ions” is used when referring to fragments of a polypeptide generated by mass spectrometry.
[0019] The term “nascent polypeptide” refers to the initial translation product of a mRNA.
[0020] The term “modification,” as used herein, refers to any chemical change in the primary structure of a nascent polypeptide. “Modification” of a protein includes: (i) a polymorphism at a codon position that results in a different amino acid within the primary structure of the protein; (ii) alternative splicing or RNA editing of a mRNA transcript that results in a different primary structure of a protein upon translation of the spliced or edited mRNA; and (iii) a chemical modification of the protein following its translation that results in a change in the molecular mass of the protein. Chemical modifications include naturally-occurring post-translational modifications as they arise in cells (e.g., proteolytic cleavage, protein splicing, N-Met and signal sequence removal, ribosylation, phosphorylation, alkylation, hydroxylation, glycosylation, oxidation, reduction, myristoylation, biotinylation, ubiquination, iodination, nitrosylation, amination, sulfur addition, peptide ligation, cyclization, nucleotide addition, fatty acid addition, acylation, etc.) as well as modifications that occur from sources not endogenous to biological cells (e.g., environmental mutagens, chemical carcinogens, experimentally-induced artificial modifications, etc.).
[0021] Shotgun annotation expands a database to include protein forms containing the designated modifications, and all combinations of these modifications (Pesavento, 2004). Shotgun annotation includes any type of modification, as the term “modification” is used herein.
[0022] The phrase “dynamically modify” refers to creating a change to a software program or database during the performance of a search.
[0023] The phrase “dynamic shotgun annotation” refers to creating shotgun annotations to protein structures in a database during the performance of a search.
[0024] The term “peptide” as used herein refers to a compound made up of a single chain of D- or L-amino acids or a mixture of D- and L-amino acids joined by peptide bonds. Preferably, peptides contain at least two amino acid residues and are less than about 50 amino acids in length.
[0025] “Polypeptide” as used herein refers to a polymer of at least two amino acid residues and which contains one or more peptide bonds. “Polypeptide” encompasses peptides and proteins, regardless of whether the polypeptide has a well-defined conformation.
[0026] The term “protein” as used herein refers to a compound that is composed of linearly arranged amino acids linked by peptide bonds. Proteins, as opposed to peptides, preferably contain chains of 50 or more amino acids. Although proteins are referred to throughout in the text, it is generally understood that the invention is applicable to all polypeptides.
[0027] The phrase “protein form” refers to a single species of a polypeptide or protein, including any modification. Thus, a single gene may encode many protein forms, depending upon the structure of the gene, the structure of the transcribed mRNA(s), and the nature of any modification(s).
[0028] The phrase “RNA splicing” refers to the removal of at least one intervening sequence of RNA by phosphodiester bond cleavage of two non-contiguous phosphodiester bonds within a given RNA and the joining the flanking exon RNA sequences by phosphodiester bond ligation.
[0029] The phrase “RNA editing” refers to an alteration in the nucleotide composition of an RNA sequence wherein at least one nucleobase of the transcribed RNA is replaced by another nucleobase of a different hydrogen bonding specificity. The resultant edited RNA may encode for a polymorphism, an extended polypeptide sequence (e.g., by eliminating a stop codon or by introducing an initiator codon), or a truncated polypeptide sequence (e.g., by introducing a stop codon).
[0030] The phrase “RNA processing” refers to any reaction that results in covalent modification of an RNA sequence. “RNA processing” encompasses both RNA splicing and RNA editing.
[0031] “Structure” as used herein with regard to proteins refers to the primary amino acid sequence of a protein, including modifications. The term “structure” and the phrase “primary structure” have the same meaning as used herein.
[0032] The phrase “warehouse database” refers to a collection of one or more protein forms.
[0033] A protein fragment results from degradation within an organism, or by intentional use of a protease.
[0034] A fragment ion is produced in the gas phase by MS/MS.
[0035] The term “subsequence” means a single contiguous piece of a sequence, such as a protein sequence.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] FIG. 1 is a flow chart of the slider search mode.
[0037] FIG. 2 is a flow chart of a slider algorithm.
[0038] FIGS. 3A and B show the output from the slider algorithm for retrieval of a peptide fragment from ubiquitin-conjugating enzyme E2 N.
[0039] FIGS. 4A and B show the output from the slider algorithm run performed on MS/MS data for a yeast peptide: (A) ten fragment ion masses match up to a peptide from 60S ribosomal protein L27; (B) five fragment ion masses match to a probable membrane protein, NCBI protein accession no. Q12697.
DETAILED DESCRIPTION
[0040] The present invention makes use of a new search mode methodology and software platforms to determine protein fragment structure and origin. This new search mode, referred to as a slider search mode, uses the mass of the protein fragment (also referred to as the biomarker) to define the size of a window. This window scans across the length of the sequences of known proteins to identify candidate sequences which may correspond with the biomarker, and collects these as a set of candidate fragments. Then, optionally, the theoretical fragment ion masses of these candidate fragments is compared to the actual fragment ion mass values of the biomarker, scoring each candidate fragment, to thereby identify the structure and origin of the biomarker.
[0041] The slider algorithm reduces the number of candidate sequences compared to the observed intact mass from O(n 2 ) to O(n), where n is the number of amino acids in the protein sequence. An algorithm that considers all possible candidate sequences, must consider O(n 2 ). This is done for the ith starting reference by considering all n-(i−1) possible ending references. In contrast, the slider algorithm compares 2(n−1) candidate sequences masses with the observed intact mass, as one mass is computed for each reference movement and each reference is moved exactly (n−1) times.
[0042] Slider Search Mode Methodology
[0043] The slider search mode ( 2 ) is illustrated in FIG. 1 . First, the sample is prepared for MS ( 4 ). Next, the MS/MS spectrum of the biomarker is collected ( 6 ). The intact mass of the biomarker is then identified ( 8 ). Optionally, the mass of the biomarker may be determined by methods other than MS. The intact mass of the biomarker, together with a chosen tolerance, is used to define a mass window size ( 10 ). Next, a slider algorithm generates a set 40 (shown in FIG. 2 ) of candidate fragments from a protein database ( 12 ). Then, optionally, the theoretical fragment ion masses of the candidate fragments are compared to the fragment ion mass values of the biomarker, to give each candidate fragment a score ( 14 ). Finally, the set of candidate fragments with its score is returned, or a subset of candidate fragments selected based on the scores is returned ( 16 ). The putative biomarker with the best score may identify the actual biomarker, and the protein from the database from which the putative biomarker originated may identify the protein from which the actual biomarker originated. The set of candidate fragments may include zero, one, or a plurality of candidate fragments.
[0044] Slider Algorithm
[0045] A slider algorithm ( 18 ) flowchart is shown in FIG. 2 . To start, a first protein sequence is selected from a protein database 42 , and at an arbitrary terminus of the protein are set two references (a leading reference and a trailing reference) to the first amino acid in the protein ( 20 ). Optionally, the protein may be annotated or a set of annotated proteins may be generated ( 44 ). The references define a subsequence within the protein sequence. The subsequence defined by the two references is hence referred to as the candidate sequence. The leading reference signifies the candidate sequence beginning and the trailing reference signifies the candidate sequence end. At the start of the algorithm both references are at the starting terminus amino acid and define a candidate sequence containing one amino acid. Optionally, the references may be started at different amino acids, as long as one reference is set at a terminal amino acid.
[0046] Next, the mass window is compared to the mass of the candidate sequence ( 22 ). If the mass of the candidate sequence is the same as the mass window within a first user specified tolerance, then the candidate sequence is added to the set 40 of candidate fragments ( 24 ).
[0047] If the candidate sequence mass is less than or equal to the mass window within a second user specified tolerance ( 30 ), then the leading reference is set to a subsequent amino acid in the protein ( 32 ). If a subsequent amino acid does not exist (i.e. the leading reference is at the end of the candidate sequence) ( 34 ) then the algorithm continues at 26 . Assuming that a subsequent amino acid exists, moving the references defines a new candidate sequence including one or more more amino acid than the previous candidate sequence and the algorithm continues at 22 . At 26 if there are more proteins sequences in the protein database (or annotated versions of the protein sequence) the algorithm begins again at 42 , otherwise the algorithm terminates 28 .
[0048] If the candidate sequence mass is greater than the mass window within a third user specified tolerance ( 30 ) the trailing reference is set to a subsequent amino acid ( 36 ). If the leading and trailing references are set at the same amino acid, ( 38 ), then the algorithm continues at 32 , otherwise the references defines a new and smaller candidate sequence including at least one fewer amino acid than the previous candidate sequence and the algorithm continues at 22 .
[0049] The references are moved to subsequent amino acids at 32 and 36 . Preferably, the references are moved to the next subsequent amino acid, so that each candidate sequence contains one more or one less amino acid.
[0050] Scoring Candidate Fragments
[0051] One way to further analyze candidate fragments generated by a slider algorithm is to compare the theoretical fragment ion masses of the candidate fragments with the fragment ion masses of the biomarker ( 14 ). Each comparison is scored, and those candidate fragments that score above a threshold value are included in a set of putative biomarkers ( 16 ). The putative biomarker with the best score identifies the actual biomarker, and the protein from the database from which the putative biomarker originated identifies the protein from which the actual biomarker originated. Any scoring method may be used.
[0052] Mass Window Tolerance
[0053] The mass window size is based on the intact biomarker mass, which is identified from the MS/MS data. An absolute or relative tolerance is then selected, for example ±30 ppm or ±0.1 Da. A protein form is retrieved, and then the window moves along the length of the protein form to identify all possible candidate sequences within the protein form that have the same mass as that of the intact biomarker, and are within the selected tolerance. Three tolerances are selected, as noted above. Preferably, all three have the same value.
[0054] Warehouse Database of Protein Forms
[0055] The unannotated forms of proteins are available as FASTA files on publicly accessible databases throughout the world, such as SWISS-PROT, NCBI (National Center for Biotechnology Information) protein database, GenBank, and the like. These databases may be mined to enable one to create the desired warehouse database of protein forms tailored for the particular project at hand. Preferably, PERL scripts are used to convert FASTA files to the files that populate the warehouse database. While the FASTA file is converting, necessary information such as average and monoisotopic mass calculation and the number of amino acids in the sequence are added to the basic sequence from the FASTA file.
[0056] Shotgun Annotation of the Warehouse Database
[0057] Given that the absence in the database of the correct protein form from which the biomarker originated can hinder identification, a database warehouse of annotated sequences is created using the nomenclature of RESID, which is an authoritative database of known modification types (Garavelli, 2003). Having a database of protein forms allows one to consider known and putative modifications that may be indicated by the occurrence of distinctive sequence motifs.
[0058] Post-translational modification events that may be annotated in the databases include N-terminal acetylation, signal peptide prediction, phosphorylation, lipoylation, GPI anchoring, ribosylation, alkylation, hydroxylation, glycosylation, oxidation, reduction, myristylation, biotinylation, ubiquination, nitrosylation, amination, sulfur addition, peptide ligation, cyclization, nucleotide addition, fatty acid addition, acylation, proteolytic cleavage, etc. (about 150-200 post-translational modifications are known for polypeptides (Garavelli, 2003) and may be considered as annotations). One can obtain modification annotations from publicly available databases, such as SWISS-PROT, or by manually entering the modification annotations into the warehouse database.
[0059] Preferably, each warehouse database has three tables that incorporate gene attributes, protein form attributes, and modification attributes. The gene attributes include gene identification information and a detailed description of the structure of the gene. The protein form attributes include gene identification, protein form identification, monoisotopic mass, average mass, number of amino acids, and flags to any known attributes, such as a signal sequence, initiator methionine, etc. The modification attributes include modification (RESID) identification, average mass, monoisotopic mass, and RESID code attributes.
[0060] The main job of the warehouse database is to handle the queries from the window search algorithm. The database should return sequences quickly so as not to decrease the speed of the entire system. The table of protein forms contains most of the information that the window search algorithm needs. Since the table of protein forms already contains all the annotated sequences, one may obtain rapid responses from the database to queries from the window search algorithm.
[0061] Although sites of modification may be theoretically predicted from the genetic sequence of the protein, it is often not desirable to populate the annotation database with all potentially possible annotations. The inclusion of such annotations will yield unwieldy databases from the standpoints of their sheer size. Annotations should be selected based on the organism from which the sample originated, the specific fluid of the organism sampled, the condition of the sample, etc.
[0062] Once the window search algorithm selects a protein, then an expanded collection may be generated containing all possible annotations for those particular proteins. Therefore, a dynamic shotgun annotation of the warehouse database may be included in the window search approach.
[0063] Ion Predictor
[0064] The ion predictor predicts theoretical b/y and c/z ions, and is included in the software and system. Such calculations are useful for calculating errors, as expressed in terms of Daltons or parts-per-million.
[0065] Data Reduction Tool
[0066] A data reduction tool to remove redundant peaks resulting from multiple charge states and water/ammonia losses from reduced fragmentation data is included in the software and system. Such tools are useful for rapid analysis of the acquired MS data prior to its analysis by the retrieval algorithm.
[0067] Database Management System
[0068] Any database management system can be used with the warehouse database. Preferably, the database management system includes MySQL. This popular database system was selected because it has many useful supporting tools and APIs, and the system is readily available to the public. The software provided in the appendix uses version 11.18 distribution 3.23.52 MySQL for Linux.
[0069] Graphical Viewer Interface Tool
[0070] In all search methods, a collection of candidate protein fragments is returned with varying scores. A graphical viewer interface tool for viewing a collection of candidate protein fragments is included in the software and system. Optionally, the graphical viewer interface tool is incorporated into a local work station that includes the other features of the invention. Optionally, the graphical viewer interface tool is adapted for viewing data obtained via the internet from remote servers.
[0071] Databases Supported
[0072] The support databases can be configured for any organism. One embodiment supports databases for nine organisms, including: Saccharomyces cerevisiae, Escherichia coli, Arabidopsis thaliana, Bacillus subtilis, Methanococcus jannaschii, Mycoplasma pneumoniae, Shewanella oneidensis, Mus musculus and Homo sapiens . The yeast organism Saccharomyces cerevisiae database contains the most extensive annotations with known and predicted modification information.
[0073] Database Scalability
[0074] Of particular interest is how the database and search times scale with increasing modification information. A given gene and set of putative modifications results in an exponential number of protein forms where each form contains a subset of possible modifications. Thus, with n proteins and m possible processing events per protein, one embodiment includes a database containing O(n2 m ) protein forms. With a database of known and putative protein forms, an observed protein form may be identified and characterized, preferably with some modifications correctly predicted. An increase of spurious information in publicly accessible protein databases will render ambiguous some searches based upon sparse MS/MS data. However, the number of matching fragment ion masses will increase with more extensive and accurate modification information used during the query step.
[0075] Computer Interface With Mass Spectrometry Instrumentation
[0076] Optionally the components are organized on a computer system in communication with a mass spectrometer. In one embodiment, the computer is a local work station. In another embodiment, the computer is a server located off-site. In the latter embodiment, the components may be stored on the server and accessed using internet-based interface tools. The MS data generated from the mass spectrometer is transmitted to the computer for data acquisition and storage. The central processing unit of the computer coordinates analysis of the acquired MS data using the sliding window algorithm operating in one of the preferred embodiments to search the warehouse database of protein forms. Operator-specified tolerances are selected from options provided by the algorithm software to permit collection of protein candidates from the warehouse database of protein forms for further analysis of modifications.
[0077] Sample Preparation
[0078] Blood serum is one of the most common samples from which naturally occurring proteolytic products may be found. The slider algorithm allows identification of these peptides in their naturally occurring state, without further digestion by trypsin, etc.
[0079] To prepare a serum sample, the whole serum is first depleted of the highly abundant proteins that make up the vast majority of the protein matter in blood (e.g., albumin and IgG). This may be done either through commercially available affinity depletion protocols, or by ultrafiltration with a low molecular weight cut-off membrane (˜50 kDa). The depleted serum is then fractionated by reversed phase liquid chromatography (RPLC) with either on-line or off-line electrospray ionization MS (ESI-MS). With an on-line liquid chromatography MS (LC-MS) (for example, using an LTQ-FT mass spectrometer, Thermo Electron Corp., Waltham, Mass.), fragmentation of detected species is accomplished on the fly using a normalized collision energy. The fragment ions are then analyzed using the Fourier transform analyzer in order to obtain isotopic resolution. For off-line RPLC followed by ESI-MS, a similar FTMS instrument is used to isolate and fragment each species in each fraction in an automated fashion.
[0080] The intact ion and fragment ion masses are then run through the slider algorithm for each species fragmented. The high mass accuracy afforded by FTMS instruments (typically <20 ppm) allows for highly specific and unambiguous identifications of each species.
[0081] Medical Applications
[0082] Some disease states are correlated with the presence of certain biomarkers. Other disease states are known to result in the production of proteins not normally produced. By identifying a biomarker which is a fragment of one of these proteins that is not normally produced, it may be concluded that the anomalous protein is being synthesized, and the presence of this protein may be correlated with the associated disease state.
[0083] Biomarker Discovery Algorithm: Software and Structure
[0084] The appendix contains a compact disk that provides all the necessary software tools and sample annotated warehouse database of protein forms to perform the disclosed aspects and embodiments. The system titled “Biomarker Discovery Algorithm” is a preferred embodiment.
[0085] Time-critical tasks, such as database retrieval and scoring, were written using an object-oriented design in C++ on Linux using the iODBC libraries for database connectivity. The data reduction tool is written in OCaml (chosen for language expressivity) while the visualization tool is written in PERL using the GD module for rendering images.
EXAMPLES
Example 1 (Prophetic Example)
[0086] The human protein NCBI protein accession no. P61089, Ubiquitin-conjugating enzyme E2 N, was chosen as a test case. A 61 amino acid peptide was chosen at random from this protein (RIIKETQRLLAEPVPGIKAEPDESNAR YFHVVIAGPQDSPFEGGTF KLELFLPEEYPMAAP)(SEQ ID NO:1), which has a theoretical mass of 6807.51 Daltons. Twelve theoretical b- and y-type fragment ion masses, and 12 other fragment ion masses that did not correspond to theoretical fragments, were included in the fragment ion mass list, entitled “.UCEslider.pkl”. This mass list was run through the slider algorithm, using a tolerance of ±30 ppm for both the intact and fragment ion masses. The data was run against the basic protein sequences in the NCBI protein database, and a minimum number of 5 fragment ion masses were required for a peptide to be retrieved.
[0087] FIGS. 3A and B show the output from the slider algorithm. FIG. 3A shows tabular results for the mass matches of the input fragment ion masses (“Observed Mass” column) vs. the calculated fragment ion masses (“Theoretical Mass” column). FIG. 3B is a graphical representation of the fragment ion mass matches for the retrieved peptide. The correct peptide was returned and all 12 theoretical fragment ion masses were matched to the peptide. None of the spurious fragment ion masses matched, and no other peptide was retrieved with 5 or greater fragment ion mass matches.
Example 2
[0088] The next example is of actual MS/MS data collected on a yeast proteolytic product from NCBI protein accession no. P38706, 60S ribosomal protein L27. The sample was generated by a multidimensional separation of a yeast whole cell lysate prior to Fourier transform MS (FTMS) analysis. Fragmentation via collisionally activated dissociation of the isolated intact species yielded 23 fragment ions. The masses of these ions, along with the intact mass of 10870.28 Da, were input into the slider algorithm and searched against the yeast protein database. Search parameters included a tolerance of ±40 ppm for the intact and fragment ion masses, the proper fragment type for the fragmentation method, and the minimum number of 5 fragment ion mass matches for a returned peptide.
[0089] The slider algorithm output returned two peptides with five or more fragment ion masses matching a mass list of 23 fragment ion masses. One peptide shows 10 of the 23 fragment ion masses matching, unambiguously identifying this peptide as belonging to 60S ribosomal protein L27 (NCBI protein accession no. P38706, peptide sequence: AKFLKAGKVAVVVRGRYAGKKVVIVKPHDEGS KSHPFGHALVAGIERYPLKVTKKHGAKKVAKRTKIKPFIKVVNYNHLLPT RYTLDVEAFKSVVSTE) (SEQ ID NO:2). The results for this match are seen in FIG. 4A . FIG. 4B shows the next best match: a peptide with five fragment ion mass matches (from protein NCBI protein accession no. Q12697, a probable membrane protein; peptide sequence: HFHCDVRVLRDKFWTTISSSELVPGDIY EVSDPNITILPCDSILLSSDCIVNESMLTGESVPVSKFPATEETMYQLCDDFQ STQISSFVSKSFLYNG) (SEQ ID NO:3). As shown in FIG. 4B , two of the five fragment ion masses matched are actually duplicates and should not be counted as real matches (B78/Y80 and B89/Y90).
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FIELD
The field of disclosure of relates to methods for analyzing melt curve data, especially as the analysis relates to data for which the melting temperatures of the plurality of samples varies by only a fraction of a degree.
BACKGROUND
DNA amplification methods provide a powerful and widely used tool for genomic analysis. Polymerase chain reaction (PCR) methods, for example, permit quantitative analysis to determine DNA copy number, sample source quantitation, and transcription analysis of gene expression. Melting curve analysis is an important tool used to discriminate real amplification products from artifacts, for genotyping, and for mutation scanning. DNA analysis methods allow the detection of single base changes in specific regions of the genome, such as single nucleotide polymorphisms (SNPs). SNP analysis and other techniques facilitate the identification of mutations associated with specific diseases and conditions, such as various cancers, thalassemia, or others.
Statistical assay variations in melt curve data result from system noise in an analysis system, such as the thermal non-uniformity of a thermocycler block in a thermal cycler apparatus. For certain genotyping applications, the melting point shift between samples may be only fractions of a degree. In the case of SNP analysis, the SNP mutations may shift the melting point temperature by no more than 0.2° C.
Accordingly, there is a need in the art for methods of analyzing small differences in melting curves in the presence of the inherent noise of the analysis.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow chart that depicts various embodiments of methods for the analysis of dissociation melt curve data.
FIG. 2 is a flow chart that depicts various embodiments of methods for the analysis of dissociation melt curve data.
FIG. 3A and FIG. 3B depict a generalized schematic of a thermal cycler system.
FIG. 4 depicts a series of dissociation melt curves for a set of calibration data.
FIG. 5 depicts the series of graphs of FIG. 4 taken over an estimated temperature range according to various embodiments of methods for the analysis of dissociation melt curve data.
FIG. 6A and FIG. 6B illustrate estimating an asymptote according to various embodiments of methods for the analysis of dissociation melt curve data for the low temperature region of graphs, such as those shown in FIG. 5 .
FIG. 7 depicts the series of graphs of FIG. 5 redrawn according to various embodiments of methods for the analysis of dissociation melt curve data shown in FIG. 6A and FIG. 6B .
FIG. 8 depicts a series of dissociation melt curves for a set of experimental data according to various embodiments of methods for the analysis of dissociation melt curve data.
FIG. 9 depicts the series of graphs of FIG. 8 which have been corrected for assay system variance or noise according to various embodiments of methods for the analysis of dissociation melt curve data.
FIG. 10 is a set of experimental data that has been analyzed according to various embodiments of methods for the analysis of dissociation melt curve data.
FIG. 11 is a set of experimental data that has been analyzed according to various embodiments of methods for the analysis of dissociation melt curve data.
FIG. 12 is a graphical form of the experimental data of FIG. 11 .
DETAILED DESCRIPTION
What is disclosed herein are various embodiments of methods for analyzing dissociation melt curve data, or as it is used throughout herein, melt curve data (MCD), where the differences in the melting points between various samples are small. For example, various embodiments of methods for analyzing dissociation melt curve data address samples sets where the differences in melting points may vary by only fractions of degrees. According to various embodiments of methods for the analysis of dissociation melt curve data, a calibration set of melt curve data may be used as a basis for correcting experimental sets of melt curve data, for example, with respect to assay system variance or noise. According to various embodiments, the melt curve data may be processed using curve-fitting techniques. In various embodiments of methods for analyzing dissociation melt curve data, different attributes of dissociation melt curve data, such those generated using a difference plot, may be used as the basis of cluster analysis of experimental melt curve data.
One known approach for DNA melting curve analysis utilizes fluorescence monitoring with intercalating double-strand-DNA specific dyes, such as for example, SYBR Green. The SYBR Green dye attaches to the DNA as double-stranded DNA amplification products are formed, and continues to bind to the DNA as long as the DNA remains double-stranded. When melting temperatures are reached, the denaturation or melting of the double-stranded DNA is indicated and can be observed by a significant reduction in fluorescence, as SYBR Green dissociates from the melted strand. The detected dye fluorescence intensity typically decreases about 1000-fold during the melting process. Plotting fluorescence as a function of temperature as the sample heats through the dissociation temperature produces a DNA melting curve. The shape and position of the DNA melting curve is a function of the DNA sequence, length, and GC/AT content.
Further, various approaches for validating the integrity of PCR reactions rely on melting curve analysis to discriminate artifact from real amplification product. Melting curve analysis can also be used to differentiate the various products of multiplexed DNA amplification, and to extend the dynamic range of quantitative PCR. DNA melting curve analysis is also used as a powerful tool for optimizing PCR thermal cycling conditions, because the point at which DNA fragments or other material melts and separate can be more accurately pinpointed.
In some embodiments, dissociation curve analysis methods calculate and display the first derivative of multi-component dye intensity data versus temperature, i.e., the differential melting curve. The melting temperature, T m , at a peak of the differential melting curve can be used to characterize the product of a biochemical reaction. A sample with multiple amplification products will show multiple peaks in the differential melt curve. In some embodiments, melting curve detection involves very precise measurements of temperature and allows for the identification of a sample using the melting temperature, T m . The determination of T m using various embodiments of methods for differential dissociation and melting curve detection is disclosed in related in U.S. patent application Ser. No. 12/020,369, which is incorporated herein by reference in its entirety.
According to various embodiments as shown in FIG. 3A and FIG. 3B , a sample can be loaded into a sample support device. In various embodiments, as shown in FIG. 3A , a sample support device 10 comprises a substrate 11 having substantially planar upper and lower surfaces, 13 , 15 , respectively. Various embodiments of a sample support device may have a plurality of sample regions 14 on a surface 13 . In various embodiments, the substrate 11 may be a glass or plastic slide with a plurality of sample regions 14 , which may be isolated from the ambient by cover 12 . Some examples of a sample support device may include, but are not limited by, a multi-well plate, such as a standard microtiter 96-well, a 384-well plate, or a microcard, as depicted in sample support device 20 of FIG. 3B , having a plurality of sample regions or wells 24 , which may be isolated from ambient by cover 22 . The sample regions in various embodiments of a sample support device may include depressions, indentations, ridges, and combinations thereof patterned in regular or irregular arrays on the surface of the substrate. In FIG. 3A and FIG. 3B , a sample support device is shown placed in a thermal cycler system. In various embodiments of a thermal cycler system, there may be a heat block, 60 , and a detection system 51 . The detection system 51 may have an illumination source 52 that emits electromagnetic energy 56 , and a detector 54 , for receiving electromagnetic energy 57 from samples in sample support devices 10 and 20 in FIG. 3A and FIG. 3B , respectively.
In various embodiments, replicate aliquots of a sample can be loaded into the plate to determine the melting temperature, Tm, of the each well. Ideally, these temperatures should be identical throughout the wells, given that the samples are replicates, In practice, variations in the analysis system, for example, non-uniformity of heating elements of the analysis system, create variations in the set of replicates. According to various embodiments of methods for the analysis of dissociation melt curve data, such melt curve data using replicates may be used as a calibration set of data. In FIG. 1 , step 10 , such a plurality of melting points comprises a plurality or set of calibration melt curve data (CMCD). Similarly, as indicated in step 20 of FIG. 1 , in a separate sample plate, unknown samples of interest for analysis may be dispensed into a plurality of support regions of a sample support device to determine the melting temperature of the unknown samples. Such a plurality of melting points comprises a plurality or set of experimental melt curve data (EMCD).
According to various embodiments of methods for the analysis of dissociation melt curve data, as depicted in step 30 of FIG. 1 , signal processing steps may be applied to the raw dissociation melt curve data in advance of subsequent steps, such scaling, curve fitting, and cluster analysis. Such signal processing steps may include the correction of the EMCD with respect to assay system variance or noise. Sources of assay systems noise may include, for example, but not limited by, thermal non-uniformity, excitation source non-uniformity, and detection source noise.
According to various embodiments as indicated in FIG. 1 step 40 , melt curve data may be processed to remove information that is not relevant for defining true differences among dissociation melt curves having melting temperatures that are different by only fractions of a degree, by scaling the data over an estimated temperature range.
For example, in FIG. 4 , by using a set of CMCD, various embodiments of step 40 of FIG. 1 may be illustrated. The CMCD shown in FIG. 4 represents 96 replicates of a sample, where intensity of the signal is plotted as a function of temperature. Between 50° C. and 55° C., in the low temperature region of the curve, there are deviations from linearity that are artifacts, which are irrelevant to the melt curve data. Further, by inspecting FIG. 4 , it is apparent that the melting occurs in a region of between about 70° C. to about 90° C. and that intensity approaches zero at temperatures above the melt. Additionally, the region from about 55° C. to about 80° C. a monotonic decrease in intensity is apparent. This is due to a decrease in the light emitted from the replicates as a result of the temperature dependence of dye emission, which is known to be an inverse relationship (i.e. dye emission decreases as temperature increases).
According to various embodiments of methods for the analysis of dissociation melt curve data as depicted in step 40 of FIG. 1 , curve-fitting of the calibration data may be done based on the observations that the region between about 50° C. to about 55° C. contains artifacts, the region between 55° C. to about 80° C. should be linear, the melt occurs between about 70° C. to about 90° C., and the high temperature region above the melt approaches zero. In various embodiments, the curve-fitting of the calibration data may additionally use the information from a reference well in the calibration set. For example, a reference well may be selected as the initially brightest well in a calibration set before the melt curve analysis is run. A first derivative may be taken on the reference well melt curve data after the analysis is complete. The width of the first derivative peak of a reference well may be used in conjunction with the observation that the melting occurs in a region of between about 70° C. to about 90° C. to define the abscissa. Additionally, given that it is known that the region between 55° C. to about 80° C. should be linear, the ordinate may be scaled using a relative scale, wherein a maximum value of the ordinate scale is set by an intercept of the low temperature end of the melt curve data with the ordinate, and should approach zero at the high temperature range of the melt curve profile.
According to various embodiments of step 40 of FIG. 1 , for the purpose of illustration, the CMCD of FIG. 4 has been scaled to produce the melt curve data shown in FIG. 5 . For FIG. 5 , the calibration data of FIG. 4 have been fit to an abscissa scaled to between about 70° C. to about 88° C. Additionally, the linear portion of the low melt end of the CMCD have been fit to 100 at intercept at the low temperature end of the scale, and approach zero at the high temperature range of the melt curve profile.
In various embodiments of methods for the analysis of dissociation melt curve data, in addition to the curve-fitting of step 40 of FIG. 1 , additional curve-fitting steps maybe applied to the calibration data. For example, as indicated in step 50 of FIG. 1 , according to various embodiments, it may be desirable to estimate an asymptote at the low temperature end of the curve for the purpose of detecting differences in data sets of melt curve data that have melting temperatures that vary by only fractions of a degree. Various embodiments for estimating an asymptote for the low temperature end of the melt curve data are depicted in FIGS. 6A and 6B .
In FIG. 6A , line B may be extrapolated from a melt curve A by selecting a linear portion over a narrow region of the low temperature melt range. The linear portion may be selected, according to various embodiments, by an interval of a temperature change at a defined temperature point. According to various embodiments, the defined temperature point may be selected using the first derivative data, and defining a transition region, as for example, but not limited by, the full width at half the maximum of the first derivative peak. As one of ordinary skill in the art is apprised, such a transition region corresponds to an interval of two standard deviations about the midpoint of the first derivative curve. As such, other intervals about the curve may also be selected. In various embodiments, a temperature point may be selected at the low temperature end of the defined transition region, as the low temperature region is known to be linear. According to various embodiments, after a temperature point is selected, an interval from the point containing enough data points to extrapolate a line is selected. In that regard, the interval would correspond to at least two data points. According to various embodiments, the interval may be at least about 0.1° C. In various embodiments, the interval may be at least about 0.5° C. In still other embodiments, the interval may be at least about 1° C.
For example a temperature point of about 70.0° C. may be selected, with an interval of plus or minus 0.5° C. around the temperature point. From this narrow linear region, a line, such as line B in FIG. 6A can be extrapolated. An algorithm, such as the subtraction of melt curve A and line B, can be used to evaluate a point where the two functions deviate by preset limit. For example, but not limited by, when the difference between the two curves is at least as great as, for example, twice the assay noise, then the calculated difference may indicate a significant difference. Alternatively, in various embodiments, other methods for determining a point where the two functions deviate by preset limit, such as the method for detecting nonlinearity in analog circuit analysis, may be used. Such a preset limit is designated as point C in FIG. 6A . Point C defines a point through which line D is drawn horizontally through the ordinate, thereby defining an estimated asymptote for the low temperature region. The calibration melt curve A is then fit accordingly to this asymptote, line D, as shown in FIG. 6B . In FIG. 7 , the calibration data of FIG. 5 have been fit to an estimated low temperature asymptote.
Step 40 and step 50 in FIG. 1 can be applied to a set of experimental data generated using test samples. The data presented in FIG. 8 represent a set of experimental data that have been fit according to various embodiments of methods described by step 40 and step 50 of FIG. 1 . The EMCD in FIG. 8 have been clustered according genotype. In inspecting the EMCD of FIG. 8 , there appears to be significant overlap of the melt curve data for the genotypes.
As previously mentioned, as depicted in step 30 of FIG. 1 , according to various embodiments, signal processing steps may be applied to the raw dissociation melt curve data in advance of steps, such as steps 40 and 60 of FIG. 1 . Such signal processing steps may include the correction of the EMCD with respect to assay system variance or noise, such as, but not limited by, assay system thermal non-uniformities inherent in thermal cycler systems.
As previously stated, the calibration melt curve data set is generated from replicates of the same sample dispensed in support regions of a sample support device, the variations in the calibration data are due to the inherent assay system noise. Accordingly, the information in the calibration melt curve data can be used to correct the experimental melt curve data for system noise. For example, a reference sample region in the EMCD may be selected. According to various embodiments, the frequency plot of the intensities of the sample regions, such as a well, in a sample support device may be determined, and a sample region within two standard deviations of the peak intensity of the EMCD may be selected as a reference sample region. In various embodiments, the reference sample region of the EMCD corresponding to the greatest intensity may be selected, however any sample region within two standard deviations would not be an outlier; i.e. either too dim or to bright, for the purpose of selecting a reference sample region, such as a well. According to various embodiments for correcting system noise as indicated in step 20 of FIG. 1 , the corresponding sample region for the CMCD is then selected as a CMCD reference sample region, such as a well. In various embodiments, a difference from the CMDC reference sample region to any sample region on the sample support may be calculated for any point along the melt curve data, or any form of the melt curve data, such as, but not limited by, derivative data. This correction of the variation of the sample support regions over the sample support device due to assay system noise may then be applied to the EMCD. Other types of approaches may be used to determine a correction factor. For example, an average of the intensities of the CMCD may be taken over the entire CMCD sample set. For any specific sample region of the CMCD, a correction may be determined by subtracting the sample region intensity from the average. That correction may then be applied to the corresponding sample region of the EMCD.
A correction as described above for step 20 of FIG. 1 was applied to FIG. 8 , and the result is demonstrated in FIG. 9 . It is apparent that the correction of the experimental data as displayed in FIG. 9 results in the ready clustering of the genotypes. A set of EMCD shown in tabular form is presented in FIG. 10 . In FIG. 10 , the first column displays the previously verified genotype of the samples. The second column represents the call made based on experimental data that was not corrected for assay system noise using calibration data. Finally, the third column represents the call made based on experimental data that was corrected for assay system noise using calibration data. As can be seen in the heading, the calls made using the uncorrected experimental data were correct 40% of the time, while the calls made using the corrected experimental data were correct 90% of the time. Moreover, the samples marked “ntc” are no-template controls, are negative controls for which no melt curve would be expected. The corrected MCD consistently assigns the negative controls correctly. Accordingly, various embodiments of methods for the analysis of dissociation melt curve data as depicted in FIG. 1 are effective in making determinations of genotyping, where the melting temperatures in an experimental set of data are different by only fractions of a degree.
According to various embodiments of methods for the analysis of dissociation melt curve data, the experimental melt curve data can be further analyzed to detect true differences in data that are different by only fraction of a degree. According to various embodiments, in step 150 of FIG. 2 , difference data may be generated using the experimental data. A plot of difference data for a set of experimental data is displayed in FIG. 12 , and the corresponding samples are shown in the table of FIG. 11 . In FIG. 12 , the melt curve data for the wild type sample is taken as the data from which all other melt curve data for all other samples will be compared. The differences are taken between the melt curve data, and the wild type, and plotted in FIG. 12 . The scale on the abscissa is set as previously described. The ordinate scale is a relative scale based on the reference melt curve data defined as zero, by definition, and the minimum and maximum values set by greatest magnitude offset in the difference data. The data of interest corresponds to the attributes of the peaks in the positive region of the scale. The difference plots in FIG. 12 are labeled with respect to the corresponding samples listed in the table of FIG. 11 .
In the table of FIG. 11 , the melting temperature, T m , is shown in the first column for the samples. In the second column, designated Delta Max, the values entered in that column refer to the value on the relative scale of the difference between the wild type and a sample peak, for the peaks in the positive region of the scale. In the third column, T Deltamax is the corresponding temperature at Delta Max. In the last column, the sum of the absolute difference (SAD) is the area under the sample peak. Therefore, various embodiments of step 150 of FIG. 2 are demonstrated in FIG. 11 and FIG. 12 , in which the creation of difference data, as shown in the plots of FIG. 12 , becomes the basis of generating feature vectors in addition to the melting temperatures, such as Delta Max, T Deltamax , and SAD.
According to various embodiments of methods for the analysis of dissociation melt curve data as indicated by step 160 of FIG. 2 , the feature vectors can be used to further discriminate differences in a set of data, where the melting temperatures are different by only a fraction of a degree. For example, in the table of FIG. 11 , the samples are known to be samples that should not be clustered. That is, unlike the data represented in FIG. 9 , for which there were multiple samples, or clusters of samples, for a genotype, for the data represented in FIG. 11 , the samples should be distinct. Using the features vectors provides more information for which samples having melting temperatures that are different by only a fraction of a degree may be further discriminated. Through the inspection of the data in the table of FIG. 11 , it is apparent that sample 2, having a T m of 84.1° C. is different from samples 3 and 4, which have the same T m of 84.2° C., by only 0.1° C. However, the Delta Max for the three samples is strikingly different, and clearly differentiates them. In this regard, the use of an additional feature vector may be used to further discriminate the samples.
Likewise, the block of data indicated with hatching; samples 5-10, all have melting temperatures of 84.5° C. Though most of the samples may be further discriminated by using Delta Max, samples 8 and 9 are only distinguished using the SAD feature vector. According to various embodiments of methods for the analysis of dissociation melt curve data in step 160 of FIG. 2 , some or any combination of the feature vectors may be used to further evaluate EMCD. In various embodiments of step 160 of FIG. 2 , the EMCD may be sorted by feature vectors sequentially, and an evaluation of fit may be made at after each iteration. According to various embodiments of step 160 of FIG. 2 , the EMCD may be sorted by one feature vector or any combination of feature vectors as an iterative process, and an evaluation of the data may be evaluation of fit may be made after each iteration
While the principles of this invention have been described in connection with specific embodiments of methods for analyzing dissociation melt curve data, it should be understood clearly that these descriptions are made only by way of example and are not intended to limit the scope of the invention. What has been disclosed herein has been provided for the purposes of illustration and description. It is not intended to be exhaustive or to limit what is disclosed to the precise forms described. Many modifications and variations will be apparent to the practitioner skilled in the art. What is disclosed was chosen and described in order to best explain the principles and practical application of the disclosed embodiments of the art described, thereby enabling others skilled in the art to understand the various embodiments and various modifications that are suited to the particular use contemplated. It is intended that the scope of what is disclosed be defined by the following claims and their equivalence. | Methods are provided that operate on raw dissociation data and dissociation curves to generate calibrations of the detected data and to further improve analysis of the data. The data can be taken from each support region of a multi-region platform, for example, from each well of a multi-well plate. Each support region can be loaded with portions of the same sample. In some embodiments, a dissociation curve correction can be calibrated for the sample, prior to a run of an experiment using such sample. In some embodiments, a method is provided for generating a melting transition region of dissociation curves that show the melting characteristics of the sample. In some embodiments, dye temperature dependence correction can be performed on the dissociation curve data to further improve analysis. In some embodiments, a feature vector can be derived from the melt data, and the feature vector can be used to further improve genotyping analysis of the dissociation curves. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the pyrochemical processing of nuclear waste products. It particularly relates to the achieving of high efficiencies in the electroseparation of actinide and rare earth metals.
2. Background Information
A pyrochemical process has been proposed to recover 99% of the remaining transuranium (TRU) materials (Np, Pu, Am, Cm) from plutonium-uranium extraction (PUREX) waste to simplify nuclear waste management and reduce the cost involved. The high-level PUREX nuclear waste is separated into a TRU-rich stream and a TRU-depleted stream. The TRU-rich stream could be stored indefinitely or, if sufficiently pure, could be fissioned in a fast reactor or accelerator or similar device to thereby convert a large fraction of the waste to a low-TRU high-level waste (HLW). After storage of the depleted TRU HLW for a period of time to allow the fission products to decay to low levels, this waste could be disposed of as low-level waste (LLW) thus substantially reducing disposal costs compared to those involving TRU-rich waste.
Many processes have been proposed for reprocessing and separating spent nuclear fuels. See for example, U.S. Pat. Nos. 4,399,108, 4,880,506, and 4,892,684. In U.S. Pat. No. 5,041,193, a pyrochemical process is utilized for recovering actinide metals from spent nuclear fuel oxides. This pyrochemical process includes electrorefining the metal complex from an anode by electrolytically oxidizing actinides into a salt and electrodepositing actinides onto a cathode to form an actinide metal deposit. The actinide metal deposit is then melted to separate the salts and the actinide metals.
In order to achieve the desired economies in the use or disposal of the nuclear waste products, it is essential that high efficiencies be achieved in the electrochemical separation of actinide and rare earth metals as part of the pyrochemical process.
It is, therefore, an object of the present invention to provide an improved electrochemical process utilizing a molten salt electrolyte for the more complete electroseparation of actinide and rare earth elements.
It is a further object to provide an improved electrochemical process which may be utilized in conjunction with other chemical or electrochemical processing steps to further enhance such more complete electroseparation.
SUMMARY OF THE INVENTION
In general, the pyrochemical separation of actinides and various rare earth elements derived from reprocessed spent nuclear fuel offers economic advantages over other methods of disposal or reuse of these elements. One step of the overall pyrochemical process involves the electrochemical separation (electrorefining) of these waste components.
In its broadest aspects, the present invention uses at least a solid anode and a solid cathode in the electrochemical separation step to electrorefine in single or multiple steps. Where multiple electrorefining steps are used to obtain more complete electroseparation, this may be achieved by employing in the multiple complete electroseparation, this may be achieved by employing in the multiple operation steps both a solid anode, suitably an inert anode such as graphite, and a molten metal anode containing a mixture of the actinide and rare earth elements. This achieves greater separation than can be realized through electroseparation with either anode alone.
The sequential electroseparation process involving multiple electrorefining steps may employ the solid cathode together with either the solid anode or the molten metal anode in the first step. However, it is an essential feature of the present invention that both a solid anode and a solid cathode be used during the electrorefining, whether in a single separation step or as part of multiple sequential operations.
The use of a solid anode, e.g., graphite, is particularly advantageous when the material being electrorefined is already dissolved in the electrorefining medium, such as a molten salt. While a solid anode may be used in each of the multiple steps, using a molten metal anode, e.g., Cd, Bi, Zn, Sn, or various molten metal alloys, during one of the steps is advantageous during electrorefining, particularly when the molten metal is used as a solvent for the materials being electrorefined.
DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention finds its principal utility in the treatment of plutonium-uranium extraction (PUREX) waste by a proposed pyrochemical process which includes an electrorefining step. In this pyrochemical process the long-lived actinides present in the nuclear waste are separated from the rare earth metals for conversion of these actinides into short-lived fission products. This process involves six basic steps to convert the aqueous metal nitrates (including the actinides) present in the PUREX waste to metal chlorides, and then separating the actinides as metals from the chloride salt. In the proposed pyrochemical partitioning process,
(1) the PUREX nuclear waste residue solution is microwaved, denitrated, and converted to a solidified oxide.
(2) This oxide is then chlorinated.
(3) The chlorinated residue is next dissolved in a LiCl-KCI molten salt.
(4) It is then chemically partitioned to separate out at least 99% of each actinide (U, Np, Pu, and Am) into an actinide-rich product. This partitioning step consists of LiCd reduction where the actinides along with some rare earths are reduced to metals dissolved in the molten Cd.
(5) This is followed by electrochemical partitioning (electrorefining) where the actinides are separated from the rare earths by electrochemically transferring the actinides from the molten Cd through an electrolyte (LiCl-KCI eutectic) and depositing the actinides on a solid cathode (Ta, Fe, U).
(6) The final step involves processing the residue waste to a non-TRU waste form.
The present invention is particularly directed to an improvement in the electrochemical partitioning step (step 5) of the overall pyropartitioning process. It has now been shown that by using at least a solid anode and a solid cathode in the electrochemical separation step, more than 99% of each actinide (U, Np, Pu, and Am) can be stripped from the molten metal anode, with most of the actinides stripped from the molten metal being deposited on the cathode (i.e., Ta, Fe and uranium-coated tantalum). However, at the end of the molten metal stripping, 15-30% of the actinides (depending on the initial concentrations of rare earths and/or actinides in the salt) remains in the salt. These actinides are then stripped from the salt using a solid anode (lithium aluminide (LiAl), lithium antimonide (Li 2 Sb), iron, graphite or lanthanum).
The cell design ordinarily utilized for the test generally provides for the solid anode to be located outside of the main electrochemical refining cell. Thereby the anodized products or the anode, itself, cannot interfere with the electrorefining actions. In one cell design, a 12.7 mm tantalum tube is used as the primary cell component. This tube contained a liquid cadmium anode, a small 1 mm tantalum wire stirrer and a solid 1 mm tantalum cathode surrounded by a 6.4 mm Ta tube with a window in it to catch any nonadherent deposits. The 12.7 mm tube had an ionic induction hole drilled in it leading to the larger outside compartment.
Where use of a graphite anode and iron cathode is contemplated, it is considered that iron would not make a good anode co-located with the cathode since it would immediately plate out at the cathode in preference to actinides once it is dissolved electrochemically from the anode. In contrast, the rare earth metals (particularly Y and La) make effective anodes because once dissolved electrochemically from the anode, they preferentially remain in the salt while the actinides are deposited electrochemically at the cathode.
Use of iron as an anode requires it to be located in a separate anode compartment in a LiCl-KCl molten salt. The relative number of Li+ and Fe++atoms in the salt in the separate compartment would predominantly allow Li+ions to carry the current into the cathode compartment and substantially reduce the Fe deposition at the cathode.
The following examples illustrate the practice of one or more aspects of this invention. However, they should not be construed as limitations on the scope thereof.
EXAMPLE 1
Stripping Actinides from Cd Anodes Using Molten Cd as the Anode and a Solid Cathode
The purpose of this series of tests was to illustrate a standard electrorefining separation test utilizing uranium and the rare earths in their PUREX proportions followed by removal of UCE 3 (NpCl 3 . PuCl 3 and/or AmCl 3 and AmCl 2 ) from their molten salt. Both the data from the Cd anode-Ta cathode electrorefining and the final removal of the uranium using a Li 2 Sb anode are presented. The last three depositions (after about 95 coulombs had been passed through the cell) were the tests using a Li 2 Sb anode to remove the U (Np, Pu, Am) from the salt after the U (Np, Pu, Am) had been removed from the Cd anode.
In all of these tests, it was demonstrated that over 98% of each actinide (except Pu where the analytical instrument was not sensitive enough) could be electrorefined from the Cd anode in the electrochemical cell. In most of these tests (about 10), solid Ta cathodes were used for the total actinide deposit. In one test each, solid Fe wire or Ta wire coated with U was used to demonstrate that other cathodic materials could also be used.
Table 1 illustrates the results obtained.
TABLE 1______________________________________STRIPPING ACTINIDES FROM Cd ANODESFOLLOWED BY STRIPPING THE REMAININGACTINIDES FROM THE SALT U Np.sup.(a) Pu Am______________________________________Initial Wt. Actinide Added (mg) 66.2 12.8 1.4 10.2Actinide Removal from Cd 98.sup.(c) 98.7 >96.sup.(b) 99Anode (%)Actinide Removal from System UsingLi.sub.2 Sb Anode (%) 99.4 99 >95.sup.(b) 99Graphite Anode (%) 98.2Iron Anode (%) 98.7Rare Earth Anodes (%) 98.0 99 >95.sup.(b) 99.3______________________________________ .sup.(a) Pr omitted in Np tests to avoid overlap or Pr--Np peaks during analysis. .sup.(b) Removal was grater; limit of analytical detection. .sup.(c) When a solid Ta cathode coated with U was used, 99% U was removed; when a solid iron cathode was used, 97% U was removed.
EXAMPLE 2
Use of Solid Anodes to Strip Actinides from the Salt
After about 99% of each actinide was stripped from the Cd anode in the tests shown in Example 1, essentially the remainder of the actinide in the system was stripped from the salt using principally the Li 2 Sb solid anode outside the cell. LiAl, graphite, Fe and rare earth solid anodes were also used. In general, the solid anode was located in the salt surrounding the electrochemical cell.
In these tests, about 15-30% of the initial amount of actinide present in the system remained in the salt when the salt stripping tests were begun. In all cases except for Pu (where the analytical instrument was not sensitive enough), it was demonstrated that essentially all of the remaining actinide in the system was stripped from the salt.
In the tests where different solid anodes were used (five U tests and one or more of Np, Pu and Am tests), the salt was initially stripped using the solid Li 2 Sb anode. About 15% of the actinide initially present was added back to the cell as actinide chloride and the salt was re-stripped using a different anode (see Table 1). Again, except for Pu, it was demonstrated that essentially all of the actinide could be stripped from the salt. These tests verified that all of the different anodes gave essentially identical results, i.e., the various anodes were equally effective in removing actinides from the salt. Greater than 99% removal of Pu could not be verified since the analytical limit of detection was only about 95%.
EXAMPLE 3
Further Use of Solid Anodes to Strip the Actinides from Salt
Salt solutions of ˜1 wt. % actinide, Gd and Nd were prepared. Gd was used since it is the rare earth with the potential closest to the actinides and therefore will be the rare earth most difficult to separate from the actinides. Neodymium was used since it is the rare earth with the greatest fission yield (it will be the rare earth in greatest concentration in PUREX residue), has the second closest potential to the actinides (it will be the major contaminant in the actinide deposit), and it is the rare earth with the greatest dual valent character (it will be the rare earth with the least predictable chemistry).
A solid Li 2 Sb anode was used in these tests. Several tests were conducted with each actinide (U, Np, Pu, and Am). In all cases, approximately 99% (from 98.4 to 99.6%) of each actinide was electrochemically removed from the salt electrolyte (LiCl-KCl eutectic).
EXAMPLE 4
Recycle of the Last Portion of the Actinide Deposit to Improve the Overall Purity of the Actinide-Rich Deposit
The last 10-20% of the actinide deposit recovered from PUREX residue by the pyrochemical process contains a substantial amount (up to about 90% for Am deposits) of non-actinide rare earth impurity. Re-electrorefining this last 10-20% of the deposit will substantially reduce the impurity content of the overall actinide-rich deposit.
Am is the most difficult material to separate from PUREX residue because Am's electrochemical potential is closest to the rare earth's potentials. It is possible to re-electrorefine the last 10-20% of other actinide deposits, as well at Am, except the improvement in product purity will be less than that for Am. The U and Np electrodeposits are sufficiently pure without recycle, but recycling the last 5% of the Pu deposit would improve the overall Pu-rich product purity about 3% (from 95.3% Pu to 98.6% Pu).
EXAMPLE 5
Multiple Steps Utilizing a Solid Anode and a Solid Cathode for at Least One of the Electrorefining Steps
Mixed actinide tests were run utilizing two steps. In the first step, the actinides are removed from the molten liquid molten metal anode. In the second step, the remaining actinides which are in the molten salt solvent are removed from the salt. During actinide removal from the anode, a solid Ta wire contacted the liquid Cd anode containing the mixed actinides. The actinides are transferred electrochemically through the molten salt and plated out on a solid Ta cathode.
In the second step, the actinides are electrochemically transferred out of the salt and plated on a solid Ta cathode. Different anodes have been used for this step. In several runs a solid Li 2 Sb anode was used. In other tests, a solid Li 2 Sb anode was used followed by a solid wire anode. In another run Ce metal additions were made to the liquid Cd anode so that it could continue to be used as the anode during the salt stripping.
The initial composition was essentially the same for all tests. For final compositions (anode stripping and salt stripping), in most cases U, Np, and Pu were stripped to a concentration below their limit of detection. Since Am is more difficult to strip from either the Cd anode or the salt than U, Np, or Pu, the actual stripping efficiency of U, Np, and Pu from the Cd anode and salt can be assumed to be greater than that of Am, i.e., in one run the stripping efficiency of Am was >99.5% and 99.3% respectively from the anode and salt. Thus the actual stripping efficiency for U, Np, and Pu can be assumed to be >99.5% and 99.3% for the anode and salt respectively.
EXAMPLE 6
Use of Li 2 Sb, LiAl, Graphite and Iron Anodes and Fe, Ta, and U/Ta Cathodes
LiAl anodes were used for several potential measurement experiments for U, Np, Pu and Am. In these tests, the concentration of actinides was reduced between one and two orders of magnitude (from about 1 wt % to about 0.01 Wt %). The goal of these tests was to measure potential as a function of concentration and not salt stripping; therefore in many cases the salt was only stripped by 95 to 98%. Several tests were run for each element and the degree of stripping varied from test to test.
The rare earth metals (particularly Y and La) make effective anodes because once dissolved electrochemically from the anode, they preferentially remain in the salt while the actinides are deposited electrochemically at the cathode.
EXAMPLE 7
Dissolution of Material to be Electrorefined in Molten Electrorefining Media
In several of the foregoing examples, the actinides were dissolved as metals in molten Cd and the rare earths were dissolved as chlorides in molten salt primarily because very pure actinide metals and very pure rare earth chlorides were used. As soon as the Cd and salt solvents containing actinides or rare earths are melted together and stirred, the actinides and rare earths equilibrate (some actinides are oxidized to chlorides and dissolved in the salt and a corresponding amount of rare earths are reduced to metals and dissolved in the molten Cd).
The foregoing examples are to be considered as merely illustrative of the present invention and not as restrictive thereof. Variations and specific materials and techniques may be made by those skilled in the art in the light of the present disclosure, which are to be considered to be within the scope of the present invention. The present invention therefore should be understood to be limited only as is indicated in the appended claims. | A pyrochemical process is utilized to recover 99% of the remaining transuranium materials from plutonium-uranium extraction waste. One step of the overall pyrochemical process involves the electrochemical separation of the waste components. A solid anode and a solid cathode are used in this electrochemical separation step to electrorefine in single or multiple steps. The solid anode and solid cathode are selected from certain preferred anodic and cathodic materials. Where multiple electrorefining steps are used to obtain more complete electroseparation, this is achieved by employing in the multiple electrorefining steps both a solid anode, suitably graphite, and a molten metal anode containing a mixture of the actinide and rare earth elements. This results in greater separation than can be realized through electroseparation by use of either anode alone. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a punching apparatus, preferably for punching intermittently moving webs made of synthetic thermoplastics, which apparatus comprises top and bottom tools, which are mounted in a machine frame and at least one of which is connected to a drive for moving said one tool up and down.
2. Description of the Prior Art
Punching apparatuses of various kinds are known in different embodiments. But they usually cut like shears so that the cooperating cutting edges of the top and bottom tools do not strike against each other but move one beside the other with a clearance so that the punching cut is effected into an unsupported portion of the material being punched.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a punching apparatus which is of the kind described first hereinbefore and which is capable of making neat cuts.
In accordance with the invention that object is accomplished is a punching apparatus of the kind described first hereinbefore in that the tools for making the punching cut consist of a knife late or a knife ring and a backing plate or a backing ring and at the end of the punching cut strike against each other or almost contact each other. The punching apparatus in accordance with the invention comprises punching tools having hard surfaces striking against each other and the use of such apparatus will be particularly desirable and suitable when webs of thermoplastic material are to be punched, e.g., in the manufacture of bags or sacks.
In accordance with a further feature of the invention a carrier member of the movable tool assembly is provided with a guide for a connecting member used to move said movable die, and a hard-elastic and/or hard-plastic pad is provided for holding said connecting member against a stop, which when viewed in the direction in which it is driven is disposed at the rear end of the guide. During a punching cut in which hard parts strike against each other said pad ensures not only the required yieldability but will also act as a shock absorber so that the vibrational load on the apparatus will be decreased.
In numerous applications two punching apparatuses must be mounted one beside the other in the machine frame so that said two apparatuses will mutually independently perform punching cuts in a web, which is preferably intermittently conveyed. But two punching apparatuses which make punching cuts independently of each other will give rise to vibrations in the machine frame and said vibrations will adversely affect the respective other punching apparatus or other processing apparatus, such as welding means.
For this reason it is a further object of the invention to provide means for supporting and movably mounting two or more punching apparatuses in a machine frame in such a manner that they will not be adversely affected in operation by shock stresses produced by them. This means that mounting means are to be provided by which a plurality of mutually independently acting punching apparatuses are mounted in such a manner that shocks or vibrations will be decreased or damped by each mounting means.
This object is accomplished in a manner for which independent protection is claimed and which resides in that two punching apparatuses are provided in the machine frame, the top tools and the bottom tools, respectively, of said punching apparatuses are associated with each other and are respectively secured to two parallel frame plates, which are separate from each other, or to side bars carrying said frame plates, those of said frame plates which carry top tools and bottom tools, which are respectively associated with each other, are respectively interconnected by upper crossbeams, and all frame plates are fixedly interconnected at their lower ends. In that mounting arrangement in accordance with the invention the tools of each punching apparatus are movably mounted or supported on frame plates or on side bars which carry frame plates and said frame plates and/or side bars constitute independent sub-frames, which at their top ends are interconnected by beams and are jointly connected only at their bottom ends. Because the machine frame is thus composed of pairs of frame plates, which constitute parts of sub-frames, the shock and vibrational stresses are considerably reduced in a surprising manner. This may be due to the fact that the vibrations offset each other at the joint fixing means provided at the bottom, or this may be due to different reasons, which still have to be investigated. The frame plates of a given sub-frame may contact each other or may be spaced apart.
In a preferred arrangement, each pair of juxtaposed frame plates constitute an outer frame plate and an opposite inner frame plate, which constitute carrying plates for associated top and bottom tools. Owing to that staggered arrangement the distance between the frame plates for carrying a given punching apparatus will always be the same.
In accordance with a further feature of the invention, three or more punching apparatuses are provided, two parallel groups of frame plates are associated with each punching apparatus and the outer frame plate of one group and the inner frame plate of the other group and the succeeding ones constitute the sub-frames for mounting a punching apparatus.
The associated frame plates or side bars are suitably provided on their top and bottom sides with raised portions, which are consecutively arranged in the longitudinal direction, and the top and bottom tools are longitudinally slidably guided on and adapted to the fixed to the raised portions. Each sub-frame suitably comprises two parallel side bars for holding and guiding top and bottom tools, which are respectively associated with each other.
The top and bottom tools may be mounted on carriages which are slidable on and adapted to be fixed to the frame plates or the associated side bars.
The upper carriages may comprise laterally protruding arms, which by means of sliders and/or rollers are supported on the sliding surfaces which are constituted by the raised portions. The lower carriages may be supported by upper rollers or sliders carried only by upper arms and riding on the tracks which are constituted by the elevated portions in an arrangement in which the carriage is urged against the rails by a resilient cantilever arm, and a screw is provided for a longitudinal adjustment of the lower carriage. The resilient retaining arm may be secured to a lower crossbeam, by which the groups of left-hand and right-hand sub-frames or frame plates are interconnected. The adjusting screw can be used to effect a fine adjustment of the punching tools during operation if the punching cut is inaccurate.
The movable punching tool is usually moved up and down by a pneumatic piston-cylinder unit. But such piston-cylinder unit inherently cannot be used to provide a desired motion characteristic. For this reason it is a further object of the invention to provide a punching tool drive which will impart a desired motion to the moving punching tool.
That object is accomplished in accordance with the invention in that preferably the upper tool assembly is carried by a guide member that is axially slidably and non-rotatably guided in a slide bushing of a holder and is provided with a peripheral groove, which has side faces that constitute tracks for slide cams or slide rollers, which are secured to axles of a pressure-applying head, which is mounted in the frame to be rotatable about the axis of the guide member and is axially fixed and which ia connected to drive means for imparting a continuous rotation or a reciprocating motion to said head, and the tracks are so shaped that the pressure-applying head by its rotation or pivotal movement will impart the desired up end down motion to the guide member.
In that case the tracks may be so designed that the guide member will be operated with a motion characteristic which is optimally adapted to the desired cutting operation.
The pressure-applying head is desirably rotatably mounted on a pin, which is secured to a yokelike carrier of frame or the carriage and is formed with a central bore, in which a pinlike top extension of the guide member is axially slidably guided.
In accordance with a further feature of the invention, associated axles of the pressure-applying head include an angle of 90 degrees, with each other, cam follower rollers are coaxially mounted on mutually opposite axles, two of said cam follower rollers ride only on the lower track and two only on the upper track of the track groove, the lower side face is provided with mutually opposite raised portions, the upper side face is provided with mutually opposite, complementary recesses, and said raised portions and recesses are spaced 90 degrees apart. The raised portions and recesses can be so designed that the desired drive motion will be imparted to the guide member. That drive motion is preferably performed in such a manner that a higher acceleration is imparted at the beginning of the movement and the movement is performed only at a lower velocity toward its end so that the punching tools will strike against each other at a reduced velocity. Each roller bears on the upper or lower side face of the peripheral groove in such a manner that the rollers hold and guide the guide member substantially without a backlash in the axial direction.
The guide member is suitably provided around its periphery with axially extending multiple splines, which are guided in corresponding grooves of the guide bushing of the carriage.
The design cf the punching apparatus in accordance with the invention can similarly be adopted for twin presses, which differ from twin punching apparatuses merely in that cooperating press tools are provided rather than cooperating punching tools. For this reason, protection is also claimed for similarly designed twin presses, in which the punching tools have been replaced by compression molds consisting each of a punch and die.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation showing a twin press, partly in section.
FIG. 2 is a sectional view taken on line II--II in FIG. 1 and showing the twin press.
FIG. 3 is a sectional view taken on line III--III in FIG. 1 and showing the twin press.
FIG. 4 is a longitudinal sectional view showing the development of the cam portion for controlling the stroke of the press.
FIG. 5 shows the frame which carries the press in a perspective view, in which the frame parts are exploded for clearer representation.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An illustrative embodiment of the invention will now be explained more in detail with reference to the drawing.
The apparatus which will be explained will be described hereinafter as a twin press even though the apparatus is used to make punching cuts. The term "twin press" has been adopted because the punches 29 and the dies 50 may consist of punching tools or of compression molds.
In FIG. 1 the two top parts of the twin press are designated 1 and 1' and the two base parts of the press are designated 2 and 2'. The frames which carry said parts are apparent from FIG. 5 and are designated 3, 4, 5 and 6. It is apparent from FIGS. 2 and 3 that the frames 3 and 4 contact each other and so do the inner and outer frames 5 and 6. The frame parts 3 and 4, on the one hand, and 5 and 6, on the other hand, are shown spaced apart in FIG. 5 only for sake of a clear showing. The frames are fixedly interconnected in their bottom portion by bars 7 and 8, which are rectangular in cross-section. The top portions of the frames 3 and 5 are fixedly interconnected by bars 9 and 10. The top portions of the frames 4 and 6 are fixedly interconnected by bars 11 and 12. It is also apparent from FIG. 5 that the frames 3 and 5 are identical and so are the frames 4 and 6.
it is apparent from FIG. 2 that the base part 2 rests on the two frames 3 and 5 and, as is apparent from FIG. 3, the base part 2' rests on the frames 4 and 6. As a result, any loads which are applied to the base part 2 and resulting slight resilient defection of the two frame parts 3 and 5 cannot be transmitted to the base part 2' because the latter, as has been mentioned, rests on the frames 4, 6 rather than on the frames 3, 5. The top part 1 which is associated with the base part 2 consists of a frame 13, which by means of the cantilever arms 15 of the holder 14 and by clamping members 16 connected to the frame 13 is clamped to the top portions of the two frames 3 and 5. When the clamped joints have been loosened or released, the top part 1 can be displaced like a carriage on the associated side bars of the frame. The identical other top part 1' is analogously clamped to the upper portions of the two frames 4 and 6 by the cantilever arms 15' and the two clamping members 16'.
The holder 14 contains a guide member 17, which is slidably guided in the holder 14 by means of a key 18. A connecting member 19 is screwed from below into the guide member 17 and carries a depending extension 20, which is disposed behind a cover 21, which defines a cylindrical space 22 in a carrier 23. A hard rubber buffer 24 rests on the bottom of the cylindrical space 22 and at that end which faces away from the bottom of the cylindrical space bears on the extension 20.
Pins 25 are fixed to the carrier 23 and extend with a small clearance through an upper arm 26 of a tool-holder that is generally designated 27. The pressure-applying plate 28, which carries the punch 29, is provided at the bottom end of the pins 25.
The guide member 17 is fixed to a cover 30, which is provided with an internal cam track 31. Another cover 32 is provided, which is spaced from the cover 30 and is also provided with an internal cam track 33. The two covers 30 and 32 are fixed to each other by a member 34, which has been turned on a lathe. The control assembly which is constituted by the two covers 30 and 32 and the lathe-turned member 34 is provided with an upstanding pin 35, which is movably mounted in a bore 36 of a retaining pin 37, which is fixedly secured by a screw 37' into the frame 13.
A pressure-applying head 38 is rotatably mounted on the retaining pin 37. A gear segment 39 is screw-connected to the head 38 and meshes with a pinion 40 of a gearmotor 41 so that the latter is operable to rotate the pressure-applying head. The pressure-applying head 38 has at its bottom a recess 42, which has been turned with a lathe and which receives the control assembly that consists of the covers 30 and 32 and the member 34. Four rollers 44, 45, 46 and 47 are rotatably mounted in the annular wall 43 of the pressure-applying head 38. The rollers 44 and 45 are disposed opposite to each other in a plane. The rollers 46 and 47 are disposed opposite to each other in a somewhat more elevated plane. This will be apparent from FIG. 4, in which the member 34 and the lower and upper cam tracks as well as the covers 30 and 32 are shown in developed views. During an operation of the motor 41 the pressure-applying head 38 will rotate in unison with the rollers 44 to 47, which ride on the tracks 31 to 33. As soon as the rollers 44 and 45 reach the raised portions 48 and the upper rollers 46 and 47 reach the recesses 49 the punch 29 will be forced down against the die 50 to an extent which depends on the height of the raised portions by a movement which is transmitted by the guide member 17, the connecting member 19, the hard rubber plate 24, the carrier 23, the pin 25 and the pressure-applying plate 28. As a result, the film lying between the punch 29 and the die 50 will be punched by parts striking hard against each other.
An exact adjustment is effected in that the connecting member 19 is screwed into the guide member 17 to a larger or smaller depth and is fixed in its adjusted position by the clamp ring 51. It is apparent from FIGS. 1 and 2 that the punch 29 is mounted by the pins 25 in the upper arm 26 of the toolholder 27 and the die 50 is mounted in the lower arm 53 of the toolholder 27. As the toolholder 27 is laterally movable out of the press in the direction of the arrow A, another toolholder carrying another set of tools can be inserted in a simple manner. The press shown in FIG. 3 has the same design as the press which has previously been described with reference to FIG. 2 so that a more detailed description of the present illustrative embodiment is not required. It is merely pointed out that the cam tracks 31' and 33', which correspond to the internal cam tracks 31 and 33, are shown after their rotation to a position in which the punching apparatus is in its closed position whereas the punching apparatus is shown in its open position in FIG. 2.
The right-hand side of FIG. 1 corresponds to the left-hand side so that further explanations are not required.
Upon a comparison of FIGS. 2 and 3 it is apparent that the base part 2 and the top part 1 are supported on the frames 3 and 4 and the base part 2' and the top part 1' in FIG. 3 are supported by the frames 4 and 6. That separate support is necessary because a so-called "hard-on-hard" press must be operated with a very exact adjustment and the two presses must not disturb each other, as would be the case, e.g., if the two presses were mounted on a common frame so that any resilient deflections adjacent to one press would inevitably result in a slight change of the position of the other press. | A punching apparatus, preferably for punching intermittently moving webs of synthetic thermoplastics, comprises top and bottom tools, which are mounted in a machine frame and at least one of which is connected to a drive for moving said one tool up and down. The tools for making the punching cut consist of a knife plate or a knife ring and a backing plate or a backing ring and at the end of the punching cut strike against each other or almost contact each other. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of application Ser. No. 09/071,118 filed May 4, 1998 now abandoned.
This application claims the priority of German Patent Application No. 297 07 908.5, filed May 2, 1997, the subject matter of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention was made for the purpose of constructing a flexible conduit element, especially for the exhaust systems of combustion engines in vehicles, and in particular, the invention is directed to helically or annularly corrugated metal bellows equipped with cylindrical end fittings and a metal hose which is located coaxially inside the bellows, where the outside diameter of the metal hose is smaller than the free (smallest) inside diameter of the bellows and the ends of the metal hose are lying inside the end fittings of the bellows, are flush with those fittings, and are fixed to them, with at least one hollow cylindrical element made of metal wire being arranged between the bellows and the metal hose. In this well-known type of conduit element, a braided hose is used as the metal wire element arranged between the bellows and the metal hose in order to improve the damping of vibrations. At least one of the ends of the braided hose is fixed inside an end fitting of the corresponding bellows. The damping effect of this design, however, was found to be quite low since the braided hose lies loosely in the cavity between the bellows and the metal hose and is in contact only with the bellows in order to have a damping effect. The damping effect is therefore subject to accidental conditions in the operation of the conduit element. Furthermore, the braided hose requires the fixing of at least one of its ends. In addition thereto, the braided hose causes a comparably high material consumption due to its design. Finally, the braided hose is particularly incapable of keeping the metal hose in a radially constant position inside the bellows. Under unfavorable operating conditions the metal hose may collide with the interior walls of the bellows. Conventionally, additional elements are to be packed into the cavity between the metal hose and the bellows to avoid such effects. As a consequence, the manufacturing costs of such a conventional conduit element are high and its installation is difficult.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide an improved conduit element of the above-described type in which only one element made of metal wire is used for the purpose of vibration damping in the conduit element, and filling the cavity between the bellows and the metal hose at least locally without gaps. It is a further object to reduce considerably the quantity of material required for the element.
These objects are achieved according to the invention by using a metal wire knit as a damping insert which totally fills the cavity between the bellows and metal hose in a radial direction.
As a consequence of these measures, the metal hose is prevented from colliding with the interior wall of the bellows, since the cavity between these two parts is filled by the knit element flexibly, elastically and without gaps. In this design, the element is always in direct contact with both the bellows and the metal hose which will ensure a permanent damping of vibrations. Further, the use of a metal wire knit allows a considerable reduction of material consumption, compared with the conventional design, and the structure of the knit will avoid the contact between the bellows and the metal hose on one hand, and the element on the other hand, with the exception of a few small contact spots, which will reduce the wear between the components respectively. Nevertheless, the knit will, altogether, not have any negative effect on the flexibility of the bellows and the metal hose as it is a characteristic feature of a wire knit that its length may change in an axial direction without changing its radial dimensions. Thus, the characteristic of wire knit allows a considerable increase in the inherent damping of the metal wire element.
The installation of the knit will also not cause any problems, since the knit, due to its hose-like shape, can be pushed onto the metal hose. Another possibility, however, is the simultaneous manufacturing and installation of the knit which allows the immediate availability of an assembly, consisting of metal hose and metal wire knit, for further installation.
In this context, radial pre-setting of the element or its installation into the cavity is in pre-set relation to the bellows and/or the metal hose. As a consequence, there will be an additional mutual support between the bellows and the metal hose and also a desired damping effect, depending on the selected value of pre-setting adjustment.
As a principle, the structure of the knit, either narrow-meshed or wide-meshed, will have an influence on the damping effect and the elastic supporting properties of the knit element.
There are numerous possible versions of this element. In one version, the element may include a wire knit hose or wire knit ring covering at least a part of the axial length of the cavity. Depending on individual requirements, it is possible to fill the cavity in its total axial length with a wire knit hose. In another embodiment, several shorter hose sections with axial distances between them may be installed which may finally lead to the application of one or several wire knit rings, if very short hose sections are selected.
In yet another embodiment, the element may include at least one wire knit strip formed by helical windings and installed in the cavity, perhaps with axial distances between the neighboring windings. Depending on the design of the element, at least one of the element's ends can be fixed between the corresponding end fitting of the bellows and the end of the metal hose. Another possibility of fixing the element in an axial direction is to clamp an end of the knit element between the bellows and the metal hose by suitably profiling the bellows and/or the metal hose. Such a profiling may be a protuberance which is provided on the metal hose and which projects toward the knit element.
For the purpose of an appropriate adaptation of the damping and spring characteristics of the wire knit to individual requirements, the wire knit, of which the element consists, can be at least partly compressed, i.e. the basic wire knit is subject to compression before installation, in order to ensure high radial supporting and spring characteristics and also to increase both the internal friction of the element and the friction between the element on one hand, and the bellows and the metal hose on the other hand. Such compression can also be provided to the wire knit hose locally, for example to one or several sections of its overall length.
Another possibility of a sensitive setting of the wire knit element can be obtained by means of a profiled cross section in this element or of the wire knit from which it is made. This profiling of the wire knit can be formed by helical windings in radial direction in the cavity between the bellows and the metal hose, so that the element comes in alternating contact with either the bellows or the metal hose. There will always be an axial distance between individual contact spots. The profiled cross-section can also be the result of the corrugated geometric form of the wire from which the knit is made, which will have an interlocking effect on the neighboring individual meshes, and will also have a corresponding influence on the spring characteristics of the wire knit element.
In the wire knit itself, the metal wire which forms the knit may include several wire threads. On the one hand, this fact allows the use of especially thin threads, and on the other hand, threads of different materials or with different properties can be applied. Further, additional materials may be included with the wire of the knit, for example ceramic fibers or plastic fibers of high temperature resistance.
There is, however, also the possibility of applying a coating of another metal, a plastic material with high thermal resistance or graphite to the wire which forms the knit or to its threads, in order to adapt its operational characteristics to exterior influences such as temperature and corrosive substances, and to influence the sliding properties of the wire knit element, if required, and also its manufacturing costs, despite such differentiated operational characteristics.
Altogether, the subject of this invention is directed to at least one element arranged in the cavity between the bellows and the metal hose, which has a low weight due to the small amount of material required, but allows a high variety of versions or embodiments, for a sensitive and individual adaptation of its operation mode to individual conditions.
With respect to the general design of the conduit element, it can be conventionally provided with an external braided hose which is made of metal wire and which directly contacts the bellows. The ends of the bellows and the braided hose are connected within a cylindrical supporting ring and are pressed together with the ring to form the end fittings of the conduit element, with the parts connected with each other by means of fastening at single spots. Such an exterior braided hose is used for the protection of the bellows from exterior influences, and also as a support to prevent an undesirable longitudinal expansion of the bellows. For the manufacturing of the metal hose, it can be provided that this hose is wound from a metal strip, perhaps without a sealing insert, with the ends of the metal hose which are situated inside the end fittings of the bellows being radially expanded and with the hose profile being compressed simultaneously, thus compensating the tolerances between the hose ends and the bellows end fittings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1, 1 a , 2 , 3 and 4 show side elevations, partly in section, of a conduit element, with differing arrangements of the wire knit element.
FIGS. 5, 6 , 7 , 8 and 9 show side elevations, partly in section, of a conduit element, with differing arrangements of the wire knit element.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a conduit element for the exhaust system of a vehicle. The conduit element includes an exterior, annularly corrugated metal bellows 1 with cylindrical end fittings 2 , 3 . The height of the exterior radial corrugation crests of the metal bellows 1 decreases towards these end fittings. This design allows the gradual adaptation of the diameter of an external braided hose 4 to the diameter in the zone of the end fittings, with the braided hose 4 being situated inside exterior supporting rings 5 , 6 and being connected, together with these supporting rings, with the end fittings 2 , 3 of the metal bellows 1 for example by spot welding 7 . At the ends facing each other, the supporting rings 5 , 6 are provided with rims 8 , 9 , in order to avoid compression of the edges between the supporting rings 5 , 6 and the braided hose 4 .
FIG. 1 shows that the inside diameter of the cylindrical end fittings 2 , 3 of the metal bellows 1 is considerably smaller than the smallest inner diameter R 1 of the corrugated section of the bellows 1 . The smallest inner diameter R 1 of the corrugated section is also referred to hereafter as the “free inside diameter” of the bellows 1 .
A strip wound metal hose 10 with an interlocked profile and without a sealing insert is installed in the bellows 1 . The outside diameter of the hose 10 is equal to the inside diameter of the bellows end fittings 2 , 3 . A radial distance exists between the largest outside diameter R 2 of the metal hose 10 and the free inside diameter R 1 of the bellows 1 in the corrugated section of the bellows 1 , and thus a cylindrical space or cavity is provided between the parts 1 and 10 .
Also referring to FIG. 1 a, a wire knit hose 11 is inserted in the cylindrical cavity defined between the bellows 1 and the metal hose 10 . The wire knit hose 11 hose radially fills the cylindrical cavity and, as may be observed, for example, in FIG. 1, it does not radially project beyond the cavity it occupies between the bellows 1 and the metal hose 10 . Thus, the wire knit hose 11 acts as a support between bellows 1 and metal hose 10 . According to the structure of the wire knit hose, the direct contact between the wire knit hose 11 and the metal hose 10 as well as the radial inward corrugations of the bellows is limited to individual spots, so that there is only a low mutual friction in the case of relative movements between bellows 1 and metal hose 10 . On the other hand, this friction will cause a damping of these relative movements which will not only de-couple vibrations entering from outside but will also compensate for the vibrations caused by the natural frequency of both the bellows 1 and metal hose 10 .
Additionally, the wire knit hose 11 acts as an elastic radial support between bellows 1 and metal hose 10 , so that there is no impediment to their relative movements even if the conduit element is bent as a whole. As another effect of the elastic support, the direct contact between the wire knit hose on the one hand, and the bellows 1 and the metal hose 10 on the other hand is maintained, especially when the radial dimension of the wire knit hose requires installation between the bellows 1 and the metal hose 10 in a state of radial spanning (bias).
In the embodiment shown in FIG. 1, the ends of the wire knit hose 11 are fixed between the metal hose 10 and the end fittings 2 , 3 of the bellows 1 . Additionally, the metal hose 10 , as can be seen from the alterations 12 , 13 of the inside diameter of the metal hose 10 , can be expanded in a radial direction by compressing the interlocked profile, and can then be pressed together in a radial direction with the end fittings 2 , 3 , the ends of the braided hose 4 and with the supporting rings 5 , 6 .
The embodiment according to FIG. 2 corresponds substantially to the embodiment according to FIG. 1 . In this embodiment, however, only the left end of the wire knit hose 14 is fixed to the corresponding end of metal hose 10 and end fitting 2 , whereas the right end 15 of the wire knit hose 14 lies free before the corresponding end of the conduit element. This design reduces the supporting effect of wire knit hose 14 in respect to axial movements of bellows 1 and metal hose 10 , which may be desirable in individual cases. Further reduction of a wire knit hose 16 is provided in the embodiment according to FIG. 3, which shows that, at both axial sides, the wire knit hose ends at a considerable distance from the end fittings of the conduit element, so that both ends 17 , 18 of wire knit hose 16 are free. As a consequence, the wire knit hose can yield at a high rate to the axial forces to which it is exposed within its range of axial mobility between the ends of the conduit element.
If, for certain reasons, a shorter wire knit hose 16 of the embodiment shown in FIG. 3 is to be fixed against axial movements, this can be done by the positive locking of an end of the wire knit hose by means of a corresponding interior profiling of bellows 1 or an exterior profiling of metal hose 10 . FIG. 4 shows such an exterior profiling of metal hose 10 , constituted by radial protuberances 19 and 20 extending toward the wire knit hose 16 . Thus, the wire knit hose 16 is fixed (clamped) at its ends between the bellows 1 and the metal hose 10 by virtue of the protuberances 19 and 20 .
In the embodiments according to FIGS. 1 to 4 , the wire knit element 11 , 14 , 16 that is arranged in the cavity between bellows 1 and metal hose 10 has the shape of a hollow cylindrical hose. Each of the FIGS. 5 to 10 shows an axial section of the conduit elements described according to the FIGS. 1 to 4 , partly in section, showing further design details of the wire knit element.
FIG. 5 shows a section of the conduit element described according to the FIGS. 1 to 4 , with a hose-shaped wire knit element 11 , 14 , 16 in the cavity between the bellows 1 and the metal hose 10 .
The embodiment according to FIG. 6 provides the use of wire knit rings 21 , 22 , 23 arranged with an axial distance between the individual rings. As a result, a mutual supporting effect in a radial direction and a damping effect will only occur in certain axial sections. The wire knit rings 21 , 22 and 23 can move freely in an axial direction. If the potential displacement of these rings is to be avoided, this can be done by spanning (biasing) the rings radially in the cavity. It is also possible to apply the principle described according to FIG. 4, that is, to clamp an end of the knit rings 21 , 22 , 23 between the bellows 1 and the metal hose 10 .
In the embodiment according to FIG. 7, a wire knit hose 24 is provided. As a difference to the embodiments previously described, the wire which forms the knit hose includes several threads. Such a multi-thread design may include several thin metal wires and additional materials, such as ceramic fibers, plastic fibers, and similar parts. The operational characteristics of the wire knit can thus be influenced in different ways, either in respect to its interior or exterior friction, its resistance to abrasion or to exterior influences such as thermal stress or corrosive influences of the environment.
FIG. 8 shows the embodiment according to FIG. 7 in a bent conduit element. This Figure shows, as is applicable to all embodiments, that the wire knit element or hose is not an obstacle to movement of the conduit element, since the individual meshes connected with each other allow mutual displacement axially to the conduit element with only an insignificant change in the cross-section or the diameter of the wire knit element or hose. For this reason, the wire knit hose 24 within a bent conduit element according to FIG. 8 can be compressed at the interior bend and extended at the exterior bent without any difficulties.
In the embodiment according to FIG. 9, the wire knit element is in the shape of a wire knit strip 25 which is wound helically around metal hose 10 . At least one of the ends of such a wire knit strip can be fixed according to the methods described according to FIGS. 1 and 2. There is, however, also the possibility of fixing the end according to the method described according to FIG. 4, if this should be required or desired in individual cases.
The various preferred embodiments of the wire knit element can be applied individually or in combination within one conduit element. Special reference shall be made to the embodiment in which a wire knit element, consisting of a wire knit which has been compressed during manufacturing and has been kept in this condition by pressing, is applied. This design is shown in the versions according to FIGS. 6 and 9 by means of the narrow structure of the wire knit shown in these figures.
It will be apparent to those skilled in the art the various modifications can be made to the described, preferred embodiments of the invention without departing from the scope or spirit of the invention. The scope of the invention is to be construed in accordance with the following claims. | A flexible conduit includes a corrugated tubular metal bellows having a minimum inner diameter; cylindrical end fittings secured to the bellows; a metal hose disposed coaxially within the bellows and having a maximum outer diameter which is less than the minimum inner diameter of the bellows; and a free annular cylindrical space situated between the bellows and the metal hose. The cylindrical space has an outer diameter equaling the minimum inner diameter of the bellows and an inner diameter equaling the maximum outer diameter of the metal hose. The conduit further has a hollow cylindrical knit wire element positioned in the cylindrical space. The knit wire element radially fully occupies the cylindrical space without projecting radially therefrom. | 5 |
FIELD OF THE INVENTION
The present invention relates to breakwaters generally, and more particularly to submerged modular breakwaters.
BACKGROUND OF THE INVENTION
Modular breakwaters have been placed on sea bottoms in the vicinity of eroding shorelines to protect the shorelines from further erosion. However, it has been found that when such breakwaters are employed in areas where they are fully submerged, i.e., where the barrier or reef is placed in about seven to eight feet of water, concerns arise in assembling the breakwater and with toe scour adjacent the beachward face.
Specifically, due to reduced visibility at depths where the barrier would be submerged, which reduced visibility can result from sand suspended in the water, proper alignment of the modules can be difficult. When adjacent modules are improperly aligned, interlocking mechanisms therebetween can be rendered nonfunctional. Accordingly, a further attempt to properly align the modules can be necessary. Therefore, there is a need to provide an interlocking modular breakwater that can be readily aligned, while being submerged.
Further, when an artificial reef is completely submerged some of the wave energy directed at the seaward face can be redirected down the beachward face. This phenomenon creates beachward toe scour, which is not readily apparent from studying shoreline breakwaters where the breakwater is not completely submerged.
The beachward face of typical reef-forming modules is substantially sloped and smooth. It has been found that when these modules are fully submerged, current flows over the modules, and down the beachward face toward the beachward toe of the modules. The current flowing over and down the beachward face of the modules develops a relatively high velocity and causes severe scouring of the sand adjacent to the beachward toe. Such scouring, which could extend ten to twenty feet from the modules, increases the slope of the adjacent sea bottom. As the slope of the sea bottom is increased, the tendency for shoreline erosion increases.
The problem of stabilizing the sea bottom adjacent the beachward face is exacerbated in man-made beaches, i.e., where sand has been pumped in to build-up the beach. These replenished beaches have relatively steep slopes in the area where they meet the natural sea bottom and have a very high tendency toward erosion. In these instances, scouring of the sea bottom adjacent the beachward toe of a submerged reef tends to diminish the erosion protection advantages of the reef and eventually reduces the stability of the artificial reef structure.
Therefore, there is a need to provide a modular breakwater that minimizes or eliminates scouring of sand adjacent to its beachface toe when the breakwater is submerged.
SUMMARY OF THE INVENTION
The present invention is directed to a modular breakwater that avoids the problems and disadvantages of the prior art. The invention accomplishes this goal by providing a breakwater construction including a plurality of modules. Each module includes a base portion for supporting the module on a seabed, a gently sloping seaward face extending above the base portion, and a beachward face extending above the base portion. The beachward face includes a deflector for deflecting downwardly directed fluid currents away from the beachward face. This deflection advantageously prevents current from reaching and scouring the seabed adjacent to the beachward toe of the breakwater. Absent this deflection such scouring would take place and the beach would erode to fill in the scoured portion. The deflector also reduces the velocity of the downwardly directed fluid currents, thereby minimizing the scouring effect of current that reaches the seabed adjacent to the beachward toe of the breakwater.
The seaward face also includes a recessed portion that forms a transversely extending concave surface adjacent to the top edge for directing fluid currents over the top edge and away from the beachward face. Accordingly, the concave surface in the seaward face also prevents currents from reaching the seabed adjacent to the beachward toe of the breakwater. This concave surface further reduces the velocity of the wave passing over the breakwater, thereby minimizing the velocity of currents that may reach the seabed adjacent to the beachward toe of the breakwater to greatly reduce the degree of beachward toe scour.
When the modules are positioned in side-by-side relation, adjacent modules are coupled together by cooperating mortise and tenon members. The tenon members are L-shaped and extend from one side of a respective module. The mortises have an L-shaped configuration and are formed in the bottom surface of a respective base adjacent to a side of the base parallel to the one side. This arrangement permits the assembler to align and couple the reef-forming modules by feel. In this way, the modules can be readily assembled to form a submerged breakwater in low visibility water, while the assembler remains above the waterline.
Terms such as "seabed" and the like are used in this specification. These terms are chosen to aid disclosure, rather than limit the invention, and use of such terms is not intended to limit the use of the present invention to, e.g., ocean beaches, salt water beaches, etc. Such terms are used herein to generically describe all bodies of water having beaches or the like where the present invention can be used.
The above is a brief description of some deficiencies in the prior art and advantages of the present invention. Other features, advantages and embodiments of the invention will be apparent to those skilled in the art from the following description, accompanying drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of the breakwater module in accordance with the principles of the present invention;
FIG. 2 is a perspective view of the module illustrated in FIG. 1;
FIG. 3 is a top plan view of the module illustrated in FIG. 1; and
FIG. 4 is a front elevational view of the module illustrated in FIG. 1.
DETAILED DESCRIPTION
Referring to the drawings in detail, wherein like numerals indicate like elements, reef-forming module I is illustrated in accordance with the principles of the present invention. Reef-forming module preferably having a generally triangular prismatic shape, includes base 10, seaward face 20 and beachward face 30.
Base 10, which is designed to rest on the sea bottom, is equipped with anchoring structures to anchor reef-forming module 1 on the seabed. These anchoring structures preferably are in the form of feet such as anchoring or gripping feet Il, which, as illustrated, mechanically depend from the bottom surface of base 10, have a saw tooth configuration and extend across the width of the module. Because objects positioned on the sea bottom have a tendency to be drawn to sea, anchoring or gripping members are configured such that they point away from beachward face 30 or toward seaward face 20 of reef-forming module 1. For purposes of illustration, the seaward and beachward toes or edges of the modules are designated with reference numerals I5 and 16, respectively.
Construction of the artificial reef to the desired length can be carried out by laying down reef forming modules 1 in side-by-side relation. Adjacent reef-forming modules 1 are coupled through tenon members 12 and mortises 13. As shown in the drawings and, in particular FIG. 4, tenon members 12 are L-shaped and extend generally perpendicularly from one side surface of base 10. Mortises 13, shown in phantom, are formed in the bottom of base 10 adjacent the surface opposite the surface from which tenon members 12 extend. Accordingly, base 10 is thicker in the regions of mortises 13 as designated by reference line 4.
As evident from the drawings, mortises 13 also have an L-shaped configuration corresponding to the configuration of tenon members 12. However, mortises 13 are dimensioned such that they are slightly larger than tenon members 12 so that they will readily slide over the tenon members during assembly. It has been found that when the mortises are dimensioned to be 2 inches larger than the tenons in all directions, the desired effect results. The relative space between the mortise and tenon is exaggerated in FIG. 4 to emphasize this concept.
Preferably two tenon members I2 and two mortises 13 are used to optimize installation efficiencies and module stability. When only one mortise-tenon pair is used, relative movement between adjacent reef-forming modules 1 may occur and undesirably affect the contour of the artificial reef. On the other hand, when more than two tenon-mortise pairs are used, not only are manufacturing costs increased, but it becomes more difficult to align these tenon-mortise pairs when adjoining adjacent reef-forming modules 1.
The above reef-forming module coupling configuration has proven exceptionally effective when assembling the artificial reef in waters over 8 feet in depth and having low visibility. The above mortise-and-tenon configuration permits the assembler to feel the mortises over the tenon members. The tapered configuration of the tenons, as shown in the drawings, also facilitates assembly. Accordingly, the assembler can couple reef-forming modules without having the mortise-and-tenon joints in view. In this way, the modules can be readily assembled to form a submerged breakwater in low visibility water, while the assembler remains above the waterline.
However, when assembling the artificial reef in waters having very high visibility, the module coupling mechanism disclosed in U.S. Pat. No. 4,913,595, which is hereby incorporated herein, can be used.
Seaward face 20 of reef-forming module 1 is provided with wave force dissipation means as disclosed in U.S. Pat. Nos. 4,502,816 and 4,913,595. The wave dissipation means serve to dissipate wave energy as waves run up the seaward face without creating secondary reflective forms of wave energy. Such force dissipation means also serve to release silt or sand that has been suspended in the water such that the released silt or sand slides down the seaward face to replenish sand that has been removed adjacent to the seaward toe of the reef-forming module. A form of wave force dissipation means on the seaward face is illustrated in the drawings as a set of parallel, transverse groves 21 extending across the seaward face. A washboard configuration or a system of small surface protrusions or bumps are also useful. The above dissipation means has been found to provide a rate of solid deposition to the toe of the module that substantially exceeds any tendency to toe scour.
Reef-forming module also is provided with deflectors arranged to deflect currents away from the beachward face such that high velocity currents do not develop along the surface of the beachward face and scour sand adjacent to the beachward toe.
Seaward face 20 is provided with deflector 22 which is formed at the upper portion of the seaward face at the juncture of the seaward and beachward faces. A concave recessed portion in seaward face 20 forms deflector 22. As can be seen in FIGS. 1 and 2, concave deflector 22 extends transversely along the entire width of seaward face 20 and has a substantially constant radius of curvature. Referring to FIG. 1, the slope of deflector 22 at its upper-most portion must be of a value such that current 23 is deflected over top edge T of reef-forming module 1 and away from the seabed adjacent to beachward face 30. To this end, the line tangent to the uppermost portion of deflector 22 adjacent to top edge T, forms an angle α with the vertical line that is normal to the bottom surface of base 10 of 16 at least 30 degrees. In this way, deflector 22 deflects current away from beachward face 30 and the beachward toe.
Beachward face 30 is still subject to current flow. First, components of current 23 deflected by deflector 22 can return toward beachward face 30 generally at a region about mid-way down the beachward face. Further, currents not deflected by deflector 22 can reach beachward face 30. Accordingly, beachward face 30 also is provided with deflectors.
The upper portion of beachward face 30 is generally not subject to a relatively high degree of current relative to the lower portion of beachward face 30. Whatever currents that do reach the upper portion of beachward face 30 generally do not gain sufficient velocity to warrant concern. Accordingly, the upper portion of beachward face 30, designated with reference numeral 31, can be generally planar. However, the lower portion of beachward face 30 is provided with deflectors 33 to form a current deflecting portion 32.
Deflectors 33 can be formed by providing projections or raised portions 34 on beachward face 30. These projections extend transversely along beachward face 30. The upper surface of each projection 34 has a concave configuration, generally designated by reference numeral 38. Referring FIG. 1, it can be seen that downwardly directed current 35 is deflected by deflectors 33 away from beachward face 30 before the current can develop sufficient momentum to develop a velocity that would warrant concern. Further, it can be seen that deflectors 33 deflect the current far enough away from the beachward toe of reef-forming module I such that fluid activity at the beachward tow is greatly reduced and sand adjacent thereto is not scoured or removed.
Another feature that protects the beachward tow from currents running in the vicinity of the beachward face of reef-forming module I is beachward edge face 36 which is substantially perpendicular to the bottom surface of base 10. The orientation of edge face 36 further reduces the possibility of currents reaching the beachward tow of reef-forming module I.
Reef-forming modules 1 are provided with frustoconical holes 40 which are configured to cooperate with a clamshell type lifting device. Two such holes are provided at the upper portion of the seaward face and two holes are provided in the beachward face. These holes preferably have at their surface a six inch diameter. It should be understood that other lifting methods can be used. For example, reef-forming module 1 can be provided with through holes in the same area as holes 40. Lifting straps or lifting cables can be inserted through the seaward hole and then through the beachward hole to lift or lower the reef-forming module. Referring to FIG. 4, each reef forming module is also provided with a bore that extends through the upper region of the module and through the entire width thereof. Such a bore is illustrated in phantom and designated by reference numeral 50. Thus, when the modules are coupled in side-by-side relation, thereby forming the artificial reef, post-tensioning cable 51 can be passed through cable bore 50 to tie the upper portions of the reef forming modules together. The outer modules can be connected by reinforced concrete beams or the like to assist in stabilizing the outer modules.
The modular structures are assembled on filter fabric which is designated in FIG. 2 with reference character F. This fabric is placed on the seabottom and underneath the reef forming modules. Filter fabric conventionally permits fluid passage therethrough, while not permitting the passage of particulate.
Obviously, the sizes and materials used to make up each reef-forming module may be selected from a wide variety of sizes and/or materials. Merely to exemplify a preferred makeup of these components which has been found to produce the desired effects the following example may be recited.
The modules are prepared using micro-silica concrete having a compressive strength of 8,000 psi. Long life for the reinforced concrete modules is thereby assured even in salt water.
Base member 10 is about 17 feet in length and each module is about 5 feet in height. The seaward face forms an angle of about 25 degrees with base 10, while the beachward face forms an angle of about 40 degrees with base 10. Tenon members I2 extend about 2 feet from the side surface of base 10 to cooperate with mortises 13 which have a maximum depth of about 2 feet. Deflector 22 has a radius of curvature of about 36 inches, while Deflectors 33 each have a radius of curvature of about 12 inches. Each module weighs about 12 tons.
The above is a detailed description of a particular embodiment of the invention. It is recognized that departures from the disclosed embodiment may be made within the scope of the invention and that obvious modifications will occur to a person skilled in the art. The full scope of the invention is set out in the claims that follow and their equivalents. Accordingly, the claims and specification should not be construed to unduly narrow the full scope of protection to which the invention is entitled. | A modular artificial reef effective to prevent shoreline erosion is constructed of reef-forming modules placed in side-by-side relation and coupled together to prevent relative movement therebetween. The modules, preferably having a triangular prismatic shape, include a gently sloping seaward face, a beachward face and a base which rests on the sea bottom. The modules are configured to deflect currents, approaching from the sea, away from the beachward face. This configuration prevents currents from flowing at high velocity along the beachward face and toward the beachward toe. Accordingly, scouring of the seabed adjacent to the beachward toe of the artificial reef is minimized or eliminated. | 4 |
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