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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a divisional of U.S. patent application Ser. No. 10/636,812 entitled “Putter,” filed on Aug. 8, 2003, now U.S. Pat. No. 7,004,849, which is a continuation-in-part of U.S. patent application Ser. No. 10/051,007 entitled “Adjustable Putter,” filed on Jan. 22, 2002, now U.S. Pat. No. 6,663,497, which claims priority from Provisional Patent Application No. 60/263,709, filed Jan. 25, 2001. All of these documents are incorporated herein by reference in their entireties.
BACKGROUND OF THE INVENTION
1. Field of The Invention
The invention relates to an improved golf club construction. More particularly, the invention is related to a putter with adjustable loft and weighting or a putter with a high moment of inertia.
2. Description of the Related Art
The design of putters is typically viewed as a pursuit of an aesthetically pleasing club that promotes a golfer's confidence in his or her stroke. As such, many putters have been designed irrespective of the mechanics inherent in the putting swing. Furthermore, many putters lack a design that accounts for an individual golfer's characteristics and characteristic playing style (i.e., stance, grip, etc.).
The lack of attention to technical details in many putter designs results in clubs that are not aimed or balanced properly. Such technical considerations, for example, include heel and toe weight distribution, location of the putter head's center of gravity or “sweet spot,” putter length, shaft flexibility, grip, head weight and total club weight, loft, and lie. Because the USGA Rules of Golf permit significant latitude in the design of putters, i.e., the shaft, neck or socket of a putter may be fixed at any point in the head, many putter designs are possible. And, because significant deviation in the intended path of a putt can be experienced for even slightly off-center hits, careful attention to these design factors can result in a putter that is more likely to perform well in use.
Various adjustable club constructions are known. For example, U.S. Pat. No. 2,305,270 to Nilson discloses a golf club with a hosel that has an extension on which the head is slidably and pivotally mounted. The extension is embedded in a shallow depression in the back of the head and runs substantially the entire length of the head. The head further includes lugs with inner serrated portions, and when a desired angle has been selected for the face, serrated portions on the extension are engaged with the lugs to lock the position.
U.S. Pat. No. 4,778,180 to Guenther discloses a golf club having a reversible head for use either as a putter or chipper, and for use by either a left handed or right handed player. In operation, the head is rotatable by 180° on a pin to present either a chipper face or putter face. A lever with side cam surfaces permits releasable locking of the head in position.
U.S. Pat. No. 4,194,739 to Thompson discloses an adjustable golf putter with a body and a separate putter face that is initially adjustable relative to the body prior to permanent securement. The putter includes an elongated tapered body having a plane of symmetry extending in the direction of the putting motion. The face is rotatably mounted on the head about a pin, and a pair of screws secure the face to prevent rotation. A bubble level is also recessed in the putter face. If the putter face is not level, the golfer loosens the screws, pivots the putter face about the pin to adjust the angle between the upper surface of the putter face and the shaft, and when the bubble level indicates level for the preferred putting stance of the golfer, the screws are tightened. The weight of the putter head is adjustable by disposing cylindrical weight inserts in a bore in the body located behind and perpendicular to the face.
In addition, U.S. Pat. No. 4,067,572 to Coleman discloses a golf club with a hollow main body, thereby providing a chamber into which liquid or granular weighting material may be placed. The main body is preferably spherical, and a movable, disc-shaped face portion is provided on its rear with a portion that is contoured to complement the spherical shape of the body. A clamping member and retaining bolt are provided; loosening the bolt permits the club face portion to be repositioned through an arc of 360°, while tightening the bolt fixes the face portion in the desired position.
Despite these developments, there exists a need for an improved putter construction. In particular, there is a need for an improved putter with adjustable loft and weighting and there is a need for an improved putter with a high moment of inertia.
SUMMARY OF THE INVENTION
The present invention is related to a golf putter head adapted for attachment to a club shaft. The head includes a face member having a strike face and a cylindrical back cavity, and a body member configured to fit and rotate in at least one plane or direction within the back cavity. Selective rotation of the body member within the back cavity sets a loft of the putter head. In one embodiment, a weight member is coupled to the body member, and is symmetrically disposed about a longitudinal center of the body member. The weight member may have a generally arcuate shape and may be disposed on the back portion of the body member.
The back cavity of the face member may include two recessed wing portions and a recessed generally cylindrical portion disposed therebetween, while the body member may include a front portion with a generally cylindrical projecting portion and a cylindrical passage extending parallel therethrough. The front portion of the body member further includes opposing sections separated by a slit that extends along the length of the cylindrical passage, the opposing sections being connected by a threaded hole. Threadable engagement of a fastener in the threaded hole changes the separation of the opposing sections.
A generally cylindrical insert is configured and dimensioned to be received within the cylindrical passage of the body member, with the insert further including a base portion configured to be received in fixed orientation within the wing portions.
The body member may be generally rectangular and have a side flange with a bore therein, the bore being configured and dimensioned to receive the shaft. The body member also may include a front portion, a back portion, and a pair of sides, the sides each having a lower edge with at least two edge portions that are crooked with respect to each other at an angle of between about 0° and about 30°.
The present invention is further related to a golf putter head adapted for attachment to a club shaft. The putter head includes a face member having a strike face and a back cavity, the back cavity including at least one keyway portion, and a body member configured to fit and rotate in at least one plane or direction within the back cavity, the body member including a passage therein. In addition, the putter head includes an insert configured to fit and rotate in at least one plane or direction within the passage, the insert including at least one keyed portion. When the keyed portion is disposed in the keyway portion, selective rotation of the body member about the insert sets a loft of the putter head.
The present invention is also related to a golf putter head, adapted for attachment to a club shaft, having a high moment of inertia. The putter head comprises a face member, a body member, and a weight member. The face member has a strike face and a rear surface opposite the strike face. The body member has a first end and a second end. The body member first end is coupled to the face member rear surface. The weight member is coupled to the body member second end.
The weight member has a first weight, and the club head has a second weight. The first weight is preferably at least 25% of the second weight. More preferably, the first weight is at least 50% or 75% of the second weight. The weight member may be curved toward said face member, and ends of the weight member are from 0 inch to approximately 1.5 inches from the strike face. Alternatively, the ends of the weight member may contact the face member.
The putter head contains a shaft mount for connecting a shaft to the club head. The shaft mount preferably is offset from the face member such that the shaft attaches close to the club head center of gravity. The body member preferably comprises the shaft mount, either coupled thereto or as an integral part thereof. The shaft may be bent to give it a straight, no offset appearance at address. The shaft mount is preferably positioned a distance of approximately 1.5 inches to approximately 2 inches from the strike face. Alternatively, the shaft mount is preferably positioned between the midpoint of the putter head length and the strike face, and more preferably is positioned a distance of approximately 25% of the putter head length to approximately 50% of the putter head length behind the strike face. The club head center of gravity is preferably located a distance of approximately 1 inch to 4 inches from the strike face. More preferably the center of gravity is approximately 1.5 inches to approximately 2 inches from the strike face, and most preferably approximately 1.7 inches from the strike face. Alternatively, the center of gravity is preferably located between the midpoint of the club head length and the weight member. Alternatively, the center of gravity is located a distance of approximately 50% of the club head length to approximately 75% of the club head length behind the strike face.
The body member preferably is coupled to the face member in a substantially perpendicular fashion such that the putter has a “T-frame” shape. The face member preferably is coupled to the body member such that the face member is lower than the body member. This will help reduce grounding of the club during the swing. The face member leading edge may be beveled for the same reason. The club head is balanced such that it is stable when placed on a substantially flat surface.
A measure of the putter head moment of inertia about a vertical axis passing through the club head center of gravity preferably is greater than approximately 550 kg·mm 2 . More preferably, the moment of inertia is within a range of approximately 600 kg·mm 2 to approximately 800 kg·mm 2 , and most preferably is within a range of approximately 700 kg·mm 2 to approximately 750 kg·mm 2 .
The moment of inertia of the club head as measured about a vertical axis passing through the shaft mount preferably is greater than approximately 550 kg·mm 2 . More preferably, the moment of inertia is within a range of approximately 600 kg·mm 2 to approximately 900 kg·mm 2 , and most preferably is within a range of approximately 800 kg·mm 2 to approximately 850 kg·mm 2 .
The moment of inertia of the club head as measured about a longitudinal axis of the body member preferably is greater than approximately 350 kg·mm 2 . More preferably, the moment of inertia is within a range of approximately 400 kg·mm 2 to approximately 600 kg·mm 2 , and most preferably is within a range of approximately 500 kg·mm 2 to approximately 550 kg·mm 2 .
The face member preferably comprises aluminum. The body member preferably comprises aluminum. The weight member preferably comprises steel.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred features of the present invention are disclosed in the accompanying drawings, wherein similar reference characters denote similar elements throughout the several views, and wherein:
FIG. 1 shows a top view of a putter head according to the present invention with back weighting;
FIG. 2 shows a back view of a face member for a putter head according to the present invention with a cavity therein;
FIG. 3 shows a cross-section of the face member of FIG. 2 taken along line III-III;
FIG. 4 shows a cross-section of the face member of FIG. 2 taken along line IV-IV;
FIG. 5 shows a bottom, perspective view of an insert member for a putter head according to the present invention;
FIG. 6 shows a top, perspective view of the insert member of FIG. 5 ;
FIG. 7 shows a side view of the insert member of FIG. 5 ;
FIG. 8 shows a top view of a body member for a putter head according to the present invention;
FIG. 9 shows a side view of the body member of FIG. 8 ;
FIG. 10 shows a partial perspective view of the body member according to the present invention with an insert member housed therein;
FIG. 11 shows a top view of another putter head of the present invention;
FIG. 12 shows a rear view of the putter head of FIG. 11 ; and
FIG. 13 shows a bottom view of the putter head of FIG. 11 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1-10 , the putter construction according to the present development is shown. Putter head 20 includes a face member 22 , a body member 24 , and a back weight member 26 , each of which are secured together as will be discussed. A shaft bore 28 is provided for attachment of putter head 20 to a club shaft.
As shown in FIGS. 2-4 , face member 22 has a generally flat ball-striking front portion 30 and a back portion 32 . A recessed region or back cavity 34 is formed in back portion 32 , and preferably has a generally cylindrical contour. A pair of recessed wing portions 36 are formed at opposite ends of back cavity 34 , creating a keyway that preferably has a depth less than the maximum depth of back cavity 34 . A hole 40 is formed in each wing portion 36 for receiving a threaded fastener. Preferably, back cavity 34 is substantially symmetric about line ALI, which is also generally parallel to the ground.
Turning to FIGS. 5-6 , in one embodiment of the present invention, an insert 42 is provided for coupling body member 24 to face member 22 . Insert 42 includes a central, generally cylindrical projecting portion 44 , along with a base portion 46 which creates a keyed portion that is adapted to be received within wing portions 36 of back cavity 34 of face member 22 . A generally cylindrical, tapered portion 45 is also provided, and serves as a further keyed region for aiding in insertion of insert member 42 into body member 24 . More particularly, the overall longitudinal geometry of insert 42 is cylindrical, such that it can rotate in at least one plane or direction within body member 24 as will be described shortly. Base portion 46 includes a pair of holes 50 , which preferably include recessed portions 51 so that the head of a screw or other fastener may be recessed therein.
The loft of the putter is defined as the angle of the face and a line perpendicular to the sole line measured to a point that is half of the distance of the face height and located on the center of the face. In order to provide adjustment of the loft, the angle of body member 24 related to face member 22 is adjusted by rotation within cylindrical back cavity 34 of face member 22 . With an insert member 42 disposed in body member 24 , and with base portion 46 disposed within wing portions 36 , the loft may be changed to a suitable amount.
More particularly, with reference to FIGS. 8-10 , body member 24 is generally rectangular and hollow, and includes cylindrical front portion 52 , back portion 54 , and side portions 56 , 58 . Front portion 52 receives an insert member 42 in cylindrical passage 53 . Front portion 52 further includes a slit 55 extending along the length of cylindrical passage 53 , and thus providing a loose fit of insert member 42 when placed in cylindrical passage 53 , which runs parallel to line ALI when front portion 52 contacts back cavity 34 . During setting of the desired loft, body member 24 , with an insert member 42 housed in passage 53 , is loosely coupled to face member 22 . With the insert member 42 resting in wing portions 36 , the body member 24 may be rotated with respect to face member 22 ; the body member rotates about insert member 42 , which is fixed in location and angle with respect to face member 22 . When a desired loft has been set, the insert member 42 may be tightly coupled to face member 22 using screws or other fasteners, which extend through holes 50 , 40 in insert member 42 and face member 22 , respectively. In addition, the rotation of body member 24 with respect to insert member 42 may be arrested through the use of a threaded fastener that extends through threaded hole 57 and connects opposing portions of front portion 52 separated by slit 55 . When the fastener is tightened, the separation between these portions may be decreased such that the gap provided by slit 55 is closed. In turn, the diameter of passage 53 is slightly decreased, locking insert member 42 in place.
A side flange 66 is provided on a side 56 , 58 , depending on whether the golfer is right-handed or left-handed. A shaft bore 28 for receiving a club shaft extends at least partway through flange 66 , which is oriented at an angle α with respect to a flat edge 68 of body member 24 . Preferably, angle α is between about 5° and about 85°. The desired loft may be set by rotating body member 24 with respect to face member 22 .
As shown in FIG. 9 , edge 68 is disposed opposite an edge 78 of body member 24 . Edge 78 includes straight potions 80 , 82 which are crooked with respect to each other. Preferably, straight potions 80 , 82 are disposed at an angle β between about 0° and about 30°.
Body member 24 also includes bores 70 through side walls 56 , 58 . Weight removed from side walls 56 , 58 due to the presence of bores 70 may be redistributed in putter head 20 , such as with back weight member 26 as shown in FIG. 1 . Further to this end, a hole 72 is provided in back portion 54 of body member 24 so that back weight member 26 with a similarly disposed hole 74 may be secured thereto, as with a fastener such as a screw. More than one hole 74 may be provided so that several fasteners may be used. Preferably, back weight member 26 is generally arcuate in shape, and is symmetrically disposed with respect to line CEN along the longitudinal center of body member 24 . Back weight member 26 may further include a central recessed region, so as to conform to the geometry of body member 24 .
FIG. 11 shows a top view of another putter head 100 of the present invention. FIG. 12 shows a rear view of putter head 100 . FIG. 13 shows a bottom view of the putter head 100 . Club head 100 is designed to have a high moment of inertia MOI. Putter head 100 includes a face member 110 , a body member 120 , and a weight member 130 .
Face member 110 is elongate, with the length being greater than the width. The width of face member 110 may be substantially uniform along its length (there may be an inset for seating body member 120 ). Face member 110 has a generally flat ball-striking front surface 112 , a rear surface 114 , and a bottom surface 115 . Rear surface 114 may contain holes 116 for inserting weights 117 . Preferably, there is a hole 116 and a weight 117 toward each end of rear surface 114 . Face member 110 is preferably made of aluminum.
Front surface 112 has a leading edge 113 . Leading edge 113 is preferably beveled to create a smooth transition between face surface 112 and bottom surface 115 . Beveling reduces the likelihood of snagging the club on the ground, or “grounding” the club, during a putting stroke. Bottom surface 115 may also be angled at ends thereof to further reduce the likelihood of grounding the club in the event of a toe-up or toe-down stroke.
Face member 110 has a loft angle within a range of approximately 0° to approximately 10°. As used herein, “within a range” includes the end values. Face member 110 preferably has a loft angle of approximately 4° or less with shaft 140 in the vertical position. A 4° loft angle has been determined the ideal loft angle for a putting stroke. See the inventor's U.S. patent application Ser. No. 09/156,540, now pending and which is incorporated herein by reference, for further discussion regarding putter loft angle. The presence of weight member 130 and the location of the club head center of gravity CG behind face member 110 creates a dynamic loft angle effect, which causes the ideal loft angle to be less than 4°. The loft angle preferably is approximately 3.5° or less, and more preferably is approximately 3° or less. This angle may be varied according to the needs of the individual user. For example, if the user has a 2° forward press, face member 110 will be designed with a loft angle of 2° greater, resulting in the proper dynamic loft angle during use. Likewise, if the user has a rearward press, the loft angle of face member 110 can be reduced to produce the proper dynamic loft angle.
Body member 120 is coupled to rear surface 114 and extends away from rear surface 114 in a substantially perpendicular fashion. Body member 120 has a length and a width, the length being greater than the width. In a preferred embodiment, the length of club head 100 is substantially the same as the length of face member 110 . Body member 120 is coupled to face member 110 such that face member 110 is slightly lower than body member 120 . This encourages proper contact between strike surface 112 and the ball, and further minimizes the likelihood of grounding the club during the swing. Body member 120 is preferably made of aluminum.
The illustrated embodiment of body member 120 contains a plurality of holes 122 to reduce its weight. This gives body member 120 the appearance of having rails, and helps to increase the MOI, as discussed below. In an alternative embodiment, body member 120 contains no holes.
Body member 120 contains shaft mount 124 for connecting a shaft 140 to club head 100 . Shaft mount 124 may be positioned toward a side of body member 120 as shown in the figures, or it may be formed within the rectangular frame of body member 120 . For example, shaft 140 may be coupled to body member 110 within one of holes 122 . Shaft mount 124 is positioned behind face member 110 approximately at the midpoint along the length of body member 110 . This location, which is near the club head center of gravity CG, provides for a more flowing stroke. Shaft mount 124 may be positioned a distance L S behind strike face 112 . Distance L S is preferably approximately 1.5 inches to approximately 2 inches. Club head 100 has a length L having a midpoint MP. Shaft mount 124 may alternatively be positioned between midpoint MP and strike face 112 , and more preferably is positioned a distance of approximately 25% of putter head length L to approximately 50% of putter head length L behind strike face 112 .
Shaft 140 may preferably by bent to give a straight, no offset appearance at address. Shaft 140 is preferably coupled to produce a 71° lie angle. Shaft 140 may be of any standard length, including a length of approximately 35 inches or more. Alternate preferable lengths for shaft 140 include approximately 37 inches and approximately 53 inches.
Face member 110 and body member 120 are coupled to form a “T-frame” shape. In addition to increasing MOI, as discussed below, the T-frame allows for improved accuracy. During the putting stroke, body member 120 provides the user with a visual alignment of the putt. Any slight misalignment of club head 100 that may likely go unnoticed with a traditional putter may be readily apparent via the T-frame design of club head 100 . By aligning elongate body member 120 with the intended ball path, the user can ensure the putter is aligned as desired. By doing so, the user is more likely to hit the intended shot.
Weight member 130 is coupled to body member 120 at the opposite end from face member 110 . This placement of weight member 130 increases the MOI of club head 100 . Inertia is a property of matter by which a body remains at rest or in uniform motion unless acted upon by some external force. MOI is a measure of the resistance of a body to angular acceleration about a given axis, and is equal to the sum of the products of each element of mass in the body and the square of the element's distance from the axis. Thus, as the distance from the axis increases, the MOI increases. By placing weight member 130 at the distal end of body member 120 relative to face member 110 , MOI can be significantly increased without substantially altering the overall weight of club head 100 . This MOI increase is greater than that possible with heel-to-toe weighting of conventional putters, due to operational weight limits. When a club, such as a putter, strikes a ball off-center, there is a tendency for the club to rotate about a vertical axis passing through the club head center of gravity CG. This club rotation causes the shot or putt to deviate from the intended course by either a push/pull (straight ball path), slice/hook (curved ball path), or combination thereof. Increasing the MOI about this axis, such as through use of weight member 130 , increases the resistance to club head rotation and creates more accurate off-center shots.
During an ideal putting stroke, the putter head is not rotated. That is, face member 1 10 is kept substantially perpendicular to the intended putt path. During actual putting strokes, however, golfers frequently rotate the putter about a vertical axis, resulting in the ball being sent awry. Increasing the MOI about the vertical axis passing through club head center of gravity CG also helps prevent this unintended and undesired rotation of club head 100 .
Club head 100 has a center of gravity CG. Center of gravity CG is the point at which the entire weight of club head 100 may be considered as concentrated. This is also the point through which club head 100 will rotate if a force not passing through center of gravity CG is exerted thereon. Moving center of gravity CG away from strike face 112 increases the MOI and stability of club head 100 . Center of gravity CG is preferably located a distance L CG behind strike face 112 . Distance L CG preferably is approximately 1 inch to 4 inches. More preferably distance L CG is approximately 1.5 inches to approximately 2 inches, and most preferably distance L CG is approximately 1.7 inches. Center of gravity CG is preferably between midpoint MP and weight member 130 . Center of gravity CG is preferably located a distance of approximately 50% of length L to approximately 75% of length L behind strike face 112 . Shaft mount 124 is preferably positioned between midpoint MP and strike face 112 , and more preferably is positioned a distance of approximately 25% of length L to approximately 50% of length L behind strike face 112 . Club head 100 has a weight. Approximately 50% of the weight to approximately 75% of the weight is located on a weight member side of shaft mount 124 . This positioning of center of gravity CG and shaft mount 124 , along with the weights of face member 110 , body member 120 , and weight member 130 , give club head 100 a MOI as measured about a vertical axis passing through center of gravity CG that is preferably greater than approximately 550 kg·mm 2 . More preferably, the moment of inertia is within a range of approximately 600 kg·mm 2 to approximately 800 kg·mm 2 , and most preferably is within a range of approximately 700 kg·mm 2 to approximately 750 kg·mm 2 .
An off-center hit may also tend to make club head 100 rotate about shaft mount 124 . That is, the club tends to rotate about shaft 140 . The placement of weight member 130 , however, also tends to increase the MOI about shaft mount 124 more than is possible with heel-to-toe weighting of conventional putters. The MOI of club head 100 as measured about a vertical axis passing through shaft mount 124 preferably is greater than approximately 550 kg·mm 2 . More preferably, the moment of inertia is within a range of approximately 600 kg·mm 2 to approximately 900 kg·mm 2 , and most preferably is within a range of approximately 800 kg·mm 2 to approximately 850 kg·mm 2 .
Another common problem resulting in misaligned putts is rotation of the club head through a horizontal axis substantially perpendicular to face member 110 . That is, about an axis collinear with the intended path of the putt. This toe-up or toe-down misalignment frequently occurs during the putting stroke. The position of weight member 130 and its arcuate design increase the MOI about the horizontal axis. Club head 100 preferably has a MOI as measured about a longitudinal axis of body member 120 that is preferably greater than approximately 200 kg·mm 2 . More preferably, the moment of inertia is within a range of approximately 200 kg·mm 2 to approximately 400 kg·mm 2 , and most preferably is within a range of approximately 250 kg·mm 2 to approximately 300 kg·mm 2 .
Weight member 130 also helps produce more accurate results for on-center shots by helping the user “swing through” the ball rather than decelerating or “slapping” the ball. Since weight member 130 is separated from strike surface 112 by body member 120 , weight member 130 will be traveling downward (i.e., working with gravity) when club head 100 strikes the ball. This results in a smoother putting stroke, and a more accurate shot.
Placing weight member 130 further towards the rear of club head 100 increases the MOI, but also has the undesired effect of increasing instability. If weight member 130 is placed too far away from face member 110 , the club head can become “tipsy.” That is, placing weight member 130 too far back may cause club head 100 , when the club is placed on a level surface, to tilt backward. Thus, club head 100 must be designed to simultaneously maximize MOI and ensure adequate stability.
One way to achieve this balance is by using the proper ratio of the weight of weight member 130 to the overall weight of club head 100 . Weight member 130 preferably comprises at least 25% of the entire weight of club head 100 . More preferably, weight member 130 comprises at least 50% or at least 75% of the entire weight of club head 100 . Weight member 130 is preferably made of steel, which has a greater density than aluminum. In a preferred embodiment, weight member 130 has a weight within a range of approximately 10 g to approximately 200 g, and more preferably within a range of approximately 125 g to approximately 170 g. The overall weight of club head 100 preferably is within a range of approximately 200 g to approximately 600 g, and more preferably within a range of approximately 300 g to approximately 500 g. Alternatively, the overall weight of club head 100 may be similar to the weight of conventional club heads.
Stability of club head 100 is also increased by weights 117 in face member 110 . Stability may also be increased by bending weight member 130 such that its ends are curved toward face member 110 , as shown in the figures. The illustrated horseshoe shape moves the center of gravity WCG of weight member 130 forward, toward face member 110 , and provides a pleasing appearance for club head 100 . Weight member 130 is symmetrically disposed about body member 120 . The ends of weight member 130 may be curved forward to any desired amount, including such that it contacts face member 110 . The ends of weight member are preferably bent such that they are a distance L WM from strike face 112 . Distance L WM is preferably from 0 inch to approximately 1.5 inches, and more preferably from 0 inch to approximately 1 inch. Extending the ends of weight member 130 to face member 110 gives club head 100 a mallet-like appearance, which may be desirable to some golfers. In a preferred embodiment, weight member 130 has a circular cross section. Center of gravity WCG is located behind center of gravity CG, and is a distance L WCG from strike face 112 . Distance L WCG is preferably from 0 inch to approximately 3 inches.
While various descriptions of the present invention are described above, it should be understood that the various features can be used singly or in any combination thereof. Therefore, this invention is not to be limited to only the specifically preferred embodiments depicted herein.
Further, it should be understood that variations and modifications within the spirit and scope of the invention may occur to those skilled in the art to which the invention pertains. For example, in an alternate embodiment, the mating portions of face member 22 and body member 24 may include a series of facets along a generally cylindrical shape, instead of smooth cylindrical surfaces. Such facets may provided a more positive engagement of the components during fitting. In addition, in another embodiment, body member 24 may be secured to face member 22 without an insert member 42 . Front portion 52 of body member 24 may be provided with projections that mate with wing portions 36 in face member 22 . Accordingly, all expedient modifications readily attainable by one versed in the art from the disclosure set forth herein that are within the scope and spirit of the present invention are to be included as further embodiments of the present invention. The scope of the present invention is accordingly defined as set forth in the appended claims.
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A golf putter head adapted for attachment to a club shaft is provided with a face member having a strike face and a cylindrical back cavity, and a body member configured to fit and rotate within the back cavity is disclosed. Selective rotation of the body member within the back cavity sets a loft of the putter head. The weighting of the putter is adjusted by securing a weight member to the body member. A golf putter head having an increased moments of inertia is also disclosed. The putter head includes a face member, a body member, and a weight member. Placement of the weight member is such that the moments of inertia are increased and the putter head is stable.
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This is a division of application Ser. No. 08/013,756, filed Feb. 4, 1993, now U.S. Pat. No. 5,379,518.
BACKGROUND OF THE INVENTION
This invention relates to a method of producing a window sash and an associated product and more particularly to a window sash that eliminates the need to provide a parting bead.
Conventional window sashes are made by a process which involves several interrelated steps. The first step is to produce framing members that will be used to form the window sash frame. These framing members can be made of aluminum, vinyl or other material. For example, four vinyl extrusions can be used to form a rectangular window sash frame. The four vinyl extrusions typically have mitered corners and are joined by corner keys, welding or other joining methods.
After the window sash frame is formed, the glazing panel (usually a pane of glass) is dropped into the space formed by the four framing members. The glazing is supported by elongated flanges on the inside of each of the framing members. In order to secure the glazing panel in the window sash frame, four separate elongated parting beads are placed on top of the glass panel, on the opposite side of each of the elongated flanges. The parting bead is secured to the glazing panel by adhesive glazing tape or a rigid polyvinyl chloride ("PVC") employing soft vinyl fingers known to those skilled in the art as dual durometer.
There are several disadvantages associated with the parting bead. If the window sash is installed in a building opening with the parting bead facing the outside, it is easy for a thief or other intruder to forcibly separate the parting beads from the window sash and remove the glazing so as to create access into the building in which the window sash is mounted. If the parting bead faces the inside of the building, the aesthetics of the window are affected by the presence of a line in the window sash frame. Furthermore, with the parting bead on the inside there is an increase of water and air filtration into the home. When a parting bead is secured by using a glazing tape, it is very costly to reglaze the window sash and in addition the glazing can shift in the sash which can cause stress breakage in the glazing. Finally, there is a vinyl window industry test, known to those skilled in the art as Test No. D-4099 for de-glazing. Most glazings secured by a parting bead with a dual durometer will fail this test.
There have been some suggestions in the prior art as to the formation of window sash frames without parting beads. U.S. Pat. No. 3,455,080 discloses plastic extrusions used for window frames. The extrusion is made having a channel with flexible ribs and portions having respective teeth-like projections. The portions are joined by a frangible connecting web. The window sash formed with the extrusions is assembled as shown in FIG. 4 Three mitered extrusions are placed in a U-shaped configuration and a pane of glass is inserted into the channel portions thereof. After this, pressure is exerted on wall portion to break the web and thus cause the base portions to engage each other by means of the teeth thereon. This also causes deformation of ribs. The corners of the frame are heat sealed or connected with adhesives. The top extrusion is connected to the rest of the extrusions by means of corner keys. See also U.S. Pat. Nos. 3,918,231 and 4,539,243.
Despite the prior art methods and products, there remains a need for an improved method of making a window sash and an improved window sash.
SUMMARY OF THE INVENTION
The present invention has met the hereinbefore mentioned needs. The method comprises providing a window sash frame and cutting the window sash frame longitudinally to create a first frame portion and a second frame portion. The method further comprises securing connection means in the first frame portion and placing a glazing member into one of the frame portions. The method then comprises securing the second frame portion to the first frame portion by means of the connection means to form the window sash. An associated product is also disclosed and claimed.
It is an object of the invention to provide an effective and efficient method to produce a window sash without the use of a parting bead.
It is a further object of the invention to provide a vinyl window sash frame which not only is connected by a connection means, but which is also reinforced by the connection means.
It is a further object of the invention to provide recesses in the framing members which receive portions of the connection means.
It is still a further object of the invention to provide complementary barbs in the recesses which engage teeth in the connection means.
It is a further object of the invention to provide a window sash which is more intruder resistant than prior art window sashes.
It is still a further object of the invention to provide a window sash which is more weather resistant and easier to reglaze than prior art window sashes.
These and other objects of the invention will be more fully understood from the following description of the invention with reference to the drawings appended to this application.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of a vinyl window sash frame.
FIG. 2 is a cross-sectional view taken along line 2--2 of FIG. 1.
FIG. 3 is a perspective view of the window sash frame of FIG. 1 showing where the window frame is cut in accordance with the method of the invention.
FIG. 4 is a perspective view of the window sash frame after it is cut into two framing portions.
FIG. 5 is a cross-sectional view taken along line 5--5 of FIG. 4.
FIG. 6 is a perspective view of an embodiment of the connection means of the invention.
FIG. 7 is a front elevational view showing the connection means of FIG. 6 and a glazing panel placed in a first window sash framing portion.
FIG. 8 is a cross-sectional view taken along line 8--8 of FIG. 7.
FIG. 9 is a front elevational view similar to FIG. 7 only showing the second window sash framing portion connected to the remainder of the window sash frame.
FIG. 10 is a cross-sectional view taken along line 10--10 of FIG. 9.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, an exploded perspective view of a window sash frame 10 is shown. The window sash frame 10 consists of an upper extrusion 12, lower extrusion 14, left side extrusion 16 and right side extrusion 18. The extrusions are all made from vinyl by a process well known to those skilled in the art.
FIG. 2 shows a cross-sectional view of left side extrusion 16. The left side extrusion 16 consists of a pair of elongated opposed inturned U-shaped flanges 20 and 22 which are connected to elongated rectangular flanges 24 and 26. Flanges 24 and 26 strengthen the window sash frame and also provide a structure for mounting certain types of window hardware (handles, locks etc.). The rectangular flanges 24 and 26 have sides 24a, 24b, 24c, and 24d and sides 26a, 26b, 26c and 26d. Sides 24c and 26c are joined by bridging flange 28.
Sides 24a and 26a form part of elongated longitudinal flanges 30 and 32. A second bridging flange 34 joins longitudinal flanges 30 and 32. Extending generally perpendicularly from longitudinal flange 30 and generally towards longitudinal flange 32 are elongated barb flanges 35 and 36. Extending generally perpendicularly from longitudinal flange 32 and generally towards longitudinal flange 30 are elongated barb flanges 38 and 39. Each barb flange 35, 36, 38 and 39 has a straight edge, such as straight edge 39a of barb flange 39 and toothed edge, such as toothed edge 39b of barb flange 39. Toothed edge 39b defines teeth, such as tooth 39c on flange 39. Tooth 39c consists of a bevelled leading edge 39d and a horizontal straight edge 39e.
It will be appreciated that four locking recesses 50, 51, 52 and 53 are formed by (i) the toothed edge of barb flanges 35, 36, 38 and 39; (ii) flanges 24d, 26d, the upper portion of flange 34 and the lower portion of flange 34; and (iii) longitudinal flanges 30 and 32, respectively. These locking recesses 50-53 will be described further hereinbelow with respect to FIGS. 7 and 9. Finally, three elongated weatherstripping strips 60, 61 and 62 are extruded to longitudinal flange 30 and three elongated weatherstripping strips 66, 67, 68 are extruded to longitudinal flange 32. These weatherstripping strips are preferably made of rigid PVC. Weatherstripping strips 60, 61, 62, 66, 67 and 68 are known in the industry as soft vinyl fingers, also known as dual durometer. As is known, the soft PVC flows into slots (not shown) formed in the longitudinal flanges 30 and 32. Once the PVC hardens, the strips 60-62 and 66-68 are formed. The end portions of longitudinal flanges 30 and 32 containing the weatherstripping strips 60-62 and 66-68, respectively, form a recess 69 in which is disposed a glazing panel as will be described hereinafter with respect to FIG. 7.
FIG. 3 shows the window sash frame 10 in its joined configuration. As was explained hereinbefore, the mitered corners of the window sash frame members 12, 14, 16 and 18 can be joined by welding. The welding can be accomplished by a welding machine such as a welding machine sold by Urban or Wegoma. The welding machine heats the mitered corners of the window sash frames to bond the corners together. The welds on the joined window sash frame 10 then can be cleaned by using a cleaning machine such as a cleaning machine which is sold by Wegoma or Urban.
In accordance with the invention, the joined window sash frame 10 is then cut longitudinally along line A of FIG. 3. As used herein, the term "longitudinally" means passing through a plane which is generally parallel to the glazing panel (FIGS. 7 and 8) even though the glazing panel is not present in the window sash frame. The cutting of the window sash from is accomplished using a circular saw equipped with fixtures and power rollers to pull the window sash towards the saw to produce an even and clean cut. After cutting, two generally symmetrical and mirror image halves 10a and 10b of the window sash frame 10 are created as is shown in FIG. 4. Half frame 10a consists of half frame members 12a, 14a, 16a and 18a and half frame 10b consists of half frame members 12b, 14b, 16b and 18b. As can be seen in FIG. 5, the longitudinal cut-line A through half frame member 16b severs bridging flanges 28 and 34.
Once the window sash frame 10 is cut, connection means are then secured into one of the half members 10a, 10b of window sash frame 10. A connection means 80 in accordance with the invention is shown in FIG. 6. The connection means 80 is preferably made of extruded aluminum and has a generally H-shape and is preferably an integral extrusion. The connection means 80 can be made of other rigid materials and can be formed of separate pieces that are secured together. The connection means 80 also serves to reinforce and rigidize the window sash frame 10.
The connection means 80 shown in FIG. 6 has two generally parallel opposing vertical flanges 82, 84 joined by a generally horizontal flange 86. The vertical flanges 82 and 84 each have an upper portion 82a, 84a and a lower portion 82b, 84b. Disposed between upper portions 82a, 84a and horizontal flange 86 is an extension portion 88, 89, respectively. Each upper and lower portion 82a, 84a, 82b, 84b, such as lower portion 84b has a toothed portion 84d and a straight edge 84e. The toothed portion 84d contains two teeth, such as 84g, which has a bevelled leading edge 84h and a horizontal trailing edge 84i.
The connection means 80 is secured into locking mechanical interengagement with half member 16a as is shown in FIGS. 7 and 8. As can be seen from FIG. 7, a connection member is used in each half member. It is preferred that the horizontal connection members 80a and 80c have mitered corners and extend the entire length of the horizontal sash frame members 12a and 14a. The vertical connection members 80b and 80d are preferably cut to a length of at least 75% of the overall sash height, as shown in FIG. 7. These configurations for the connection members 80a, 80b, 80c and 80d not only provide the necessary structural support but also reduce the amount of scrap in manufacturing.
Referring to FIG. 8, lower portions 82b and 84b of connection member 80b are secured into recesses 52 and 53 of half member 16a so that the lower portions 82b and 84b are in substantial intimate surface-to-surface contact with the surfaces of half member 16a which define recesses 52 and 53. This is accomplished by mechanical interengagement of the toothed portions of lower portions 82b and 84b with the recesses 52 and 53. It will be appreciated that the connection member 80b is secured to the half member 16a by effecting relative movement of the connection member 80b and the half member 16a so that, for example, bevelled edge 84h of tooth 84g rides on bevelled edge 39d of tooth 39c on flange 39 and over the bevelled edge of the bottom tooth of flange 39 until horizontal trailing edge 84i of tooth 84g snaps into surface-to-surface engagement with the horizontal trailing edge of the bottom tooth of flange 39. This provides positive mechanical interengagement between connection member 80b and half member 16a.
Once the connection and reinforcement members are secured to half member 10a as shown in FIG. 7, a glazing panel 90 is dropped into the window sash half member 10a as shown in FIGS. 7 and 8. The glazing panel 90 rests on weatherstripping strips 66-68 and against the lower portion of cut bridging flange 34 as is shown in FIG. 8.
Referring now to FIGS. 9 and 10, half member 10b is then ready to be secured to the connection members in half member 10a to form the completed window sash. This is done by merely positioning the upper portions of connection members in the recesses of half member 10b and effecting relative movement of half member 10b and the connection members similar to that shown and described with respect to FIGS. 7 and 8. For example, as is shown in FIG. 10, upper portions 82a and 84a of connection and reinforcement members 80 are positioned in recesses 50 and 51 of half member 16b and are snapped into place similar to lower portions 82b and 84b into recesses 52 and 53 so that the upper portions 82a and 84a are in substantial intimate surface-to-surface contact with the surfaces of half member 16b which defines recesses 50 and 51. In this way, half member 10b will be secured to the connection and reinforcement members in half member 10a to form the window sash.
It will be appreciated that the method of producing a window sash and the resulting product provides a window sash that does not have a parting head. The window sash of the invention has smooth pleasing lines and is also less susceptible to tampering by intruders or the like and is more weathertight than prior art window sashes.
Whereas a particular embodiment of the invention has been described hereinabove, for purposes of illustration, it would be evident to those skilled in the art that numerous variations of the details may be made without departing from the invention as defined in the appended claims.
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A method of producing a window sash by first providing a window sash frame and then cutting the window sash frame longitudinally to create a first frame portion and a second frame portion. A connection member is secured to the first frame portion and a glazing member is placed into one of the frame portions. After this, the second frame portion is secured to the first frame portion by virtue of the connection member to form the window sash. An associated product is also disclosed.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is the US National Stage of International Application No. PCT/EP2006/063754, filed Jun. 30, 2006 and claims the benefit thereof. The International Application claims the benefits of European application No. 05014473.2 filed Jul. 4, 2005, both of the applications are incorporated by reference herein in their entirety.
FIELD OF INVENTION
[0002] The present invention relates to a ceramic component with surface resistant to hot gas and method for the production thereof. In addition the present invention relates to a combustion space, especially a gas turbine combustion chamber.
BACKGROUND OF THE INVENTION
[0003] The walls of combustion spaces which conduct hot gases such as those of the combustion chambers of gas turbine installations required a thermal shielding of the supporting wall structure against attack by the hot gases. The thermal shielding can for example be implemented by a lining resistant to hot gases placed in front of the actual wall structure in the form of a ceramic heat shield. Ceramic materials offer the ideal solution compared to metallic materials for constructing this type of heat shield because of the ability to withstand higher temperatures, resistance to corrosion and their lower thermal conductivity. The heat shield is generally constructed from a number of ceramic heat shield elements, which form a flat lining for the combustion space. A ceramic heat shield of this type is described in EP 0 558 540 B1 for example.
[0004] For operation of a combustion space and especially for operation of gas turbine combustion chambers the heat shield is exposed to extreme stresses. As well as thermal and mechanical stresses the heat shield elements are also exposed to heavily corrosive stresses as a result of the flow of hot gas. The corrosive loads can result in a loss of material on the heat shield element which reduces its lifetime. This loss of material is attributable to a combination of corrosion, subsequent post-sintering of the surface and erosive stress resulting from the high mass flow rate of flowing hot gas. In gas turbine combustion chambers the loss of material on the surface of ceramic heat shield elements is especially great in the transition area from the combustion chamber to the turbine.
SUMMARY OF INVENTION
[0005] The object of the present invention is thus to make available an advantageous ceramic component for use in a combustion space, especially in a gas turbine combustion chamber. It is a further object of the present invention to make available a combustion space with an improved heat shield. Finally it is an object of the present invention to make available a method for producing an advantageous ceramic component.
[0006] The first object is achieved by a ceramic component as claimed in the claims, the second object by a combustion space as claimed in the claims and the third object by a method in accordance with the claims. The dependent claims contain advantageous embodiments of the invention.
[0007] An inventive ceramic component features a ceramic body as well as a surface which is resistant to hot gas. The ceramic body can for example be made of a basic material comprising up to 50% by weight mullite (3Al 2 O 3 ×2SiO 2 or 2Al 2 O 3 ×SiO 2 ) and more than 50% by weight corundum (Al 2 O 3 ). In addition the basic material can contain small amounts of glassy phase (SiO 2 ), i.e. with a proportion of maximum 5% by mass. A surface which is resistant to hot gas is provided with a poorly reactive mineral coating in the inventive ceramic component. In particular coatings which include as one of their main coating materials corundum (aluminum oxide Al 2 O 3 ), zirconia (zirconium oxide, ZrO 2 ) or spinel (MgAl 2 O 4 ) can be considered as poorly reactive mineral coatings. It is especially advantageous in this case for the coating to contain at least 90% by mass of the major coating material. For stabilization of the coating and/or to increase its temperature stability it can contain a suitable doping, for example elements of lanthanide or titanium.
[0008] As a result of the poorly reactive mineral coating chemical reactions which increase the susceptibility of the ceramic material to erosion can be effectively suppressed. The loss of material when subjected to a flow of hot gas is attributable in ceramic components made up of a basic material comprising mullite and corundum, to the following two reactions: 1. Degradation of the mullite, 2. Grain growth and post-sintering.
[0009] The water vapor which is normally present in the hot gas flow leads to the SiO 2 in the mullite of the basic material being able to escape as SiO X in the gas phase, which leads to the degradation of mullite. The Al 2 O 3 from the mullite remains in the coating and forms fine corundum grains there, the so-called secondary corundum. The secondary corundum grains show grain growth and post-sintering. Grain growth and post-sintering increase over the duration of operation i.e. as the time during which the ceramic component is exposed to the flowing hot gas increases. These processes thus lead, as the length of time during which the system is operated increases, to a weakening of the surface, through the formation of microcracks for example. The result of the weakening of the surface is surface particles—or even whole surface areas—of the ceramic component are removed by the flow of hot gas. As soon as a certain amount of surface material is removed or eroded, the corresponding ceramic components must be replaced, since their functional integrity can no longer be guaranteed.
[0010] By sealing the surface with the poorly reactive mineral coating (EBC Environmental Barrier Coating) the corrosive phases of the basic material SiO 2 on the surface of the component can be effectively suppressed when the surface is subjected to hot gas. This makes the surface less susceptible to erosion. Thus for example a surface coating based on corundum can extend the service life of a ceramic component in the hot gas stream significantly before it has to be replaced. Post-sintering can be suppressed even more effectively with a coating based on spinel than with a coating based on corundum. The lifetime of the ceramic component can thus be extended even more with a spinel-based coating. Both the corundum-based coating and the spinel-based coating retain their basic material characteristics, for example a high resistance to changes in temperature, even when attacked by heat and high temperatures over a long period.
[0011] Especially advantageous are the material characteristics of the coating, if the proportion of the material on which the coating is based amounts to at least 90 percent by mass and the glassy component is less than 2 percent by mass. Preferably no glass at all is present in the coating material.
[0012] An inventive combustion space which can in particular be embodied as a gas combustion chamber, has a wall structure and a ceramic heat shield located in front of the wall structure facing towards the inside of the combustion space. The ceramic heat shield is constructed from a number of inventive ceramic components, i.e. from a number of ceramic heat shield elements.
[0013] The maintenance intervals can be increased and the replacement rate of heat shield elements reduced as a result of the increased resistance of the heat shield to erosion.
[0014] In the inventive method for producing a ceramic component with a surface resistant to hot gases a poorly reactive mineral coating is applied to the surface which is resistant to hot gases. In particular coatings based on corundum, coatings based on zirconia and also coatings based on spinel enter into consideration as coatings here.
[0015] As already described previously in relation to the inventive ceramic component, the poorly reactive coating increases the resistance properties of the ceramic component equipped with it. For the poorly reactive mineral coating used in the inventive method what has already been stated in relation to the poorly reactive mineral coating of the inventive ceramic component similarly applies.
[0016] The poorly reactive mineral coating can be applied to both a sintered ceramic component and also to an unsintered ceramic component known as a green body. In both cases the coating process involves applying a material compound and subsequent sintering. When the coating is applied to a green body this sinter process can be undertaken together with the sintering of the green body. It is also possible to apply the poorly reactive mineral coating to an existing ceramic component which already has a certain service life behind it. In this way a ceramic combustion space lining might be retrofitted with the poorly reactive mineral coating. The coating can however also be applied when a new ceramic component is produced.
[0017] The material compound can be applied to the surface of the component in numerous ways, for example by painting, spraying, such as plasma injection or flame injection, applying as putty, dipping, through physical deposition from the gas phase etc. However the material is preferably applied by spraying it on or by spin coating.
[0018] The material compound which is applied to the surface to be coated can essentially consist entirely of corundum. Alternatively it is however also possible to add to the material compound further components in addition to corundum, for example magnesium oxide (MgO). Especially if the compound has a proportion of at least 60 percent by mass corundum and a proportion of at most 40 percent by mass magnesium oxide, the subsequent sinter process leads to a spinel-based coating.
[0019] The material compound for the coating also features further components such as zirconia. It is however also possible for zirconia to be the only component of the material compound so that a coating based on zirconia is produced.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Further features, characteristics and advantages of the present invention emerge from the description of an exemplary embodiment given below which refers to the enclosed figures.
[0021] FIG. 1 shows a gas turbine installation in a partly cutaway side view.
[0022] FIG. 2 shows a ceramic heat shield arranged on a combustion space wall.
[0023] FIG. 3 shows an inventive ceramic component in a cutaway side view.
DETAILED DESCRIPTION OF INVENTION
[0024] The invention is described below with reference to a ceramic heat shield element for constructing a ceramic heat shield on the wall of a gas turbine combustion chamber.
[0025] A gas turbine installation 1 comprises a compressor section 3 , a turbine section and a burner section 7 . In the compressor section 3 and in the turbine section 5 compressor blades 4 or turbine blades 6 are arranged on common shaft 8 which is also referred to as the turbine rotor. The turbine rotor 8 is supported to allow rotation around a central axis 9 .
[0026] The burner section comprises a numbers of burners 10 which come out into a combustion chamber 12 which in its turn comes out into the turbine section 5 . In the present exemplary embodiment the combustion chamber 12 is embodied as an annular combustion chamber, i.e. it extends in a ring around the turbine rotor, and is lined with a ceramic heat shield.
[0027] During operation of the gas turbine installation 1 surrounding air U is sucked in via the compressor, compressed to a high pressure and output into the burner section 7 as so-called compressor air. In the burner section 7 the compressor air enters the burner 10 and is mixed with the fuel fed to the burner 10 and is burned in the combustion chamber 12 . The combustion gases arising in this process form a working medium A which flows through the combustion chamber to the turbine section 5 and in the turbine section, by expanding and cooling down, imparts impulses to the turbine blades 6 . The geometry of the turbine blades ensures in such cases that the impulse causes the turbine rotor 8 to start rotating. The rotating turbine rotor 8 on the one hand drives the compressor and is also coupled to a load (not shown), for example an electrical generator for generating current.
[0028] A section from the combustion chamber wall is depicted in FIG. 2 . The figure shows an overhead view of the combustion chamber wall seen from inside the combustion chamber. The combustion chamber wall is provided with a ceramic heat shield which is constructed from a number of ceramic heat shield elements 20 . The heat shield elements 20 are arranged to cover the entire surface of the actual combustion chamber wall such that they are located facing towards the inside of the combustion chamber. Between adjacent heat shield elements 20 there are gaps 22 to allow the individual heat shield elements to expand on contact with the flowing hot gas without them hitting each other.
[0029] A ceramic heat shield element 20 is shown in FIG. 3 in a cutaway schematic side view. The heat shield element 20 comprises a hot side 24 which faces the flow of hot gas, if the heat shield element 20 is built into a heat shield and which represents a surface of the heat shield element 20 which is resistant to hot gas. Opposite the hot gas side 24 the heat shield element 20 has a cold side which faces the supporting wall structure of the combustion chamber 12 if the heat shield element is built into a heat shield. Extending between the hot side 24 and the cold side 26 are circumferential sides 28 .
[0030] The ceramic body 30 of the heat shield element 20 is made of a basic material which comprises around 10% by mass to around 50% by mass mullite (3Al 2 O 3 ×2SiO 2 or 2Al 2 O 3 ×SiO 2 ) and around 50% by mass to around 90% by mass corundum (Al2O 3 ) as well as maximum 5% by mass glassy phase (SiO 2 ). Such a body can for example be produced by a molding compound which comprises Al 2 O 3 and SiO 2 in powder form, being pressed or molded into shape and subsequently sintered.
[0031] The molding compound can for example comprise a proportion of 80% or more by mass Al 2 O 3 and 20% or less by mass SiO 2 . During sintering a ceramic is produced from this which has a proportion of mullite of up to appr. 50% by mass and a proportion of corundum of over appr. 50% by mass. Instead of Al 2 O 3 and SiO 2 in powder form the compound can also already contain corundum and mullite in powder form. In addition the molding compound can also contain an additive, for example zirconium oxide (ZrO 2 ) in the range of up 30 percent by mass.
[0032] The hot combustion gases flowing through the combustion chamber 12 contain a certain amount of water vapor. This water vapor can lead to removal of mullite and glassy phase if these are exposed directly to the hot exhaust gases. To suppress the removal of mullite and glassy phase the hot side 24 of the heat shield element 20 is provided with a poorly reactive mineral coating 32 . In the present exemplary embodiment this coating 32 includes spinel, i.e. MgAl 2 O 4 as its main component. Its thickness amounts to less than 1 mm, preferably less than 0.5 mm.
[0033] This poorly reactive mineral coating restricts the post-sintering in the area of the hot gas side 24 . The removal of material described at the start in relation to the prior art can thus be effectively reduced by means of the coating. The use of spinel as the main component of the coating thus leads to the basic material characteristics, such as resistance to changes in temperature for example, being maintained, even after long exposure to hot gas. Overall this allows the lifetime of the heat shield element 20 to be extended.
[0034] To produce the spinel-based coating a material compound is applied to the surface of an already pressed heat shield element to be produced, known as the green body, prior to sintering, which contains Al 2 O 2 with a proportion of over 60% by mass and magnesium oxide (MgO) with a proportion of up to 40% by mass. When sintering at temperatures of up to a maximum of around 1650° C. is subsequently carried out, the coating compound turns into a spinel-based coating, in which the proportion by mass of spinel is over 90%.
[0035] Preferably the material compound contains very little to almost no silicon oxide for the coating. Very little silicon oxide should be viewed in this case as a proportion of not more than 2% by mass.
[0036] In a variation of the production method for the inventive ceramic heat shield element the coating mass is applied to an already sintered ceramic body. In a further sinter process with temperatures of up to a maximum of 1650° C. the compound is then converted into the spinel-based coating. In this manner ceramic heat shield elements which are already in service can especially be upgraded with poorly reactive mineral coating.
[0037] As an alternative to producing the spinel-based coating containing Al 2 O 2 and MgO, the production of the coating can also be undertaken by applying a suspension containing spinel to the green body or the already sintered ceramic body and subsequent sintering.
[0038] To apply the coating compound or the suspension to the surface of the pressed or of the already fired ceramic body all methods can be used with which coating masses or suspensions can be applied to surfaces. In particular the coating compound or the suspension can be applied by spin coating, spraying or injection. Thermal injection methods such as plasma injection or flame injection are suitable for example.
[0039] In the described exemplary embodiment spinel forms the basis of the poorly reactive mineral coating 32 . In alternative embodiments however corundum or zirconium oxide can also form the base of the poorly reactive mineral coating. The production of the coatings based on corundum or zirconium oxide is undertaken like the production of the coating based on spinel, however the sinter conditions are to be adapted to the other material compound of the coating.
[0040] The coating can essentially be applied, regardless of the materials on which it is based, to all types of ceramic components.
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The invention relates to a ceramic component comprising a surface which is resistant to hot gas, and a method for the production thereof. Said ceramic component comprises a ceramic body and a surface which is resistant to hot gas. According to the invention, the surface which is resistant to hot gas is provided with a poorly reactive mineral coating.
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FIELD OF THE INVENTION
[0001] The present invention relates to optical sights, in particular to an optical gun sight with reticle patterns switchable for adaptation to various shooting conditions. More specifically, the invention relates to an optical sight, such as, e.g., a gunsight or a camera viewfinder, in which reticle patterns are switched electronically without mechanical movements.
BACKGROUND OF THE INVENTION
[0002] Optical sights are used in viewfinders for aiming photocameras or in firearms for accurate aiming of rifles, pistols, shotguns and the like. In firearms, these optical sights are typically mounted in an elongated tubular barrel or housing carrying conventional ocular and objective lens systems. An erector-lens system is provided between the ocular and objective systems to provide an erect target image for viewing by the shooter. Windage and elevation adjustments permit the sight to be compensated for targets at varying ranges.
[0003] For example, a conventional optical sight includes a reticle, typically of cross hair or post form, which is seen by the shooter in silhouette and superimposed over the target image. The position of the firearm is adjusted until the reticle is positioned on a target-image aiming point. The primary advantage of an optical sight is that the target image and reticle are in the same focal plane, eliminating any need for the shooter to shift eye focus between sight and target as must be done with conventional open sights on a rifle. The optical sight may provide fixed or variable magnification of the target image, but such magnification is not an essential feature and is subsidiary to the primary goal of providing a target image and aiming reticle in a single focal plane.
[0004] Conventional reticles are highly satisfactory during conditions of full daylight, but most hunting for game animals is done under restricted lighting conditions before sunrise or just before dark. This is because most game animals are nocturnal feeders, and their search for food is made in darkness or in the relatively short periods just before or after full darkness. A conventional optical sight is difficult to use in these conditions of subdued lighting because the reticle is seen in silhouette against a low-contrast dimly lit image of the target and target background. It is not uncommon for a hunter to lose sight of the reticle entirely while attempting to aim at a game animal standing or moving against a dark background of brush or trees. In such conditions, the firearm cannot be accurately sighted, and the animal will probably escape.
[0005] The “fading reticle” problem is solved by illuminating the reticle itself (e.g., electrically heated incandescent reticles have been proposed), or preferably by providing a luminous dot or other mark at the aiming point of the sight. Details of the latter solution are shown in U.S. Pat. No. 3,672,782 issued in 1972 to A. Akin. This patent shows a an optical sight with a battery-operated internal lamp, which projects a luminous reticle pattern (dot, cross hair, circle, etc.) on the sight field of view and centered on the sight aiming point. The optical sight of this patent is provided with multiple reticles, which can be selectively switched to a working position in compliance with the shooting conditions. This is achieved with the use of a flexible strip of a plastic material wound on extends between a pairs of shafts. The strip is generally opaque but defines specific transparent zones forming a plurality of reticles. Rotation of the shafts moves strips in certain fashion within a chamber in the mounting leg, and rotation is continued until a selected reticle is positioned for projection onto an ocular focal plane of the sight. Positions of the reticles are fixed with the use of spring-loaded knobs.
[0006] A disadvantage of the device of U.S. Pat. No. 3,672,782 consists in that the sight contains moveable parts and that the strip moves back and forth. Such a system, normally, has significant plays, which impair positioning of the reticles in the focal plane, and thus impairs accuracy of shooting.
[0007] U.S. Pat. No. 4,554,744 issued in 1985 to C. Huckenbeck is directed to an improved illuminated-reticle optical sight having a very compact battery-housing and actuating-switch assembly, which enhances the styling of the instrument, and is simple and convenient for the shooter to use. Though the optical sight of this device does not have moveable parts, it also does not have selectivity of reticles.
[0008] U.S. Pat. No. 4,618,221 issued in 1986 to R. Thomas describes an adjustable telescopic sight having objective lenses, intermediate lenses, and an eyepiece. The sight is provided with an adjustable reticle device, which is disposed in the second focal plane intermediate, the eyepiece and the intermediate lenses. The adjustable reticle device is provided with a fixed centerline reticle and two identical moveable reticles located on opposite sides of the centerline reticle. The moveable reticles are each supported by a carrier, which is moveable in two orthogonal directions by means of two threaded stems carried by the body of the adjustable reticle device. The stems are each provided with knurled knobs, each of which has two arrows thereon disposed at right angles to each other on the side of the knob facing the shooter so that the shooter can readily determine the direction of movement of bullet impact upon rotation of a knob in any specific direction.
[0009] Although this device is capable of adjusting position of a reticle with relatively high accuracy due to micrometric movements and of selecting reticles of a few types, the choice of reticles is very limited and the adjustment is carried out due to movement of reticle parts.
[0010] International Patent Publication WO 00/50836 of Aug. 31, 2000 issued to K. Gunnarsson, et al. describes an optical sight with a reticle produced by projecting a reticle image from a transparent media onto a concave semitransparent mirror. The source of light is a light emitting diode (LED), which is located on a sidewall within a tubular casing of the optical sight. The LED, the transparent media with the reticle image, the semitransparent concave mirror, and the eye of the viewer form an optical system, in which the reticle image is reproduced on the eye retina, while the image of the reticle is located on the optical axis of the optical system and is seen by the eye as if it is located in the infinity or in a very remote zone. During shooting, the reticle is aligned with the image of the target, which is also seen by the viewer's eye. Such a system ensures accurate aiming and is free of moveable parts. However, this system has only one reticle and cannot be adjusted for different shooting conditions.
[0011] In order to solve the above problem, American Technologies Network Corporation, South San Francisco, Calif., has developed an optical sight of the type described in WO 00/50836, but with a turret head that contains a plurality of reticle images, which can be selectively switched to a position aligned with the optical axis by rotating the turret head. Such a system makes it possible to select reticles in compliance with the shooting conditions, shooter's vision conditions, shooter's hunting habits, type of the target, etc. Nevertheless, the turret-type reticle switching mechanism has moveable parts and therefore has inevitable plays in the rotary mechanism. Since the image of the reticle is projected to the infinity and is seen as a virtual image, even slightest deviations of the reticle image projection from the optical axis will impair accuracy of shooting. Thus, all known switchable optical sights of the types described above cannot ensure stability in positioning of the reticle with respect to the center of the partially transparent mirror or pellicle, and hence, with respect to the ballistic trajectory of the bullet. This is because the plays existing in the switching mechanisms with the moveable reticles or reticle elements cannot provide aforementioned positioning accuracy.
OBJECTS OF THE INVENTION
[0012] It is an object of the invention is to provide an optical sight for use in viewfinders of photocameras, or in aiming devices of fire arms, which is simple in construction, inexpensive to manufacture, has no moving parts, and ensures selection of reticle types and images in a wide range in compliance with the shooting conditions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a general schematic side view of the optical sight of the invention.
[0014] [0014]FIG. 2A is a view of the LED in the direction of arrow A of FIG. 1.
[0015] [0015]FIG. 2B is a sectional view along the line IIB-IIB of FIG. 2A.
[0016] [0016]FIG. 3 is a more detailed image of the pattern of reticle elements with an electrical circuit.
[0017] [0017]FIGS. 4 and 5 illustrate examples of other patterns of reticle elements.
SUMMARY OF THE INVENTION
[0018] An optical sight for a photocamera viewfinder or for an aiming device of a firearm comprises a combination of a light emitting diode (LED) with a plurality of reticle patterns applied onto the surface of the LED and selectively illuminated by connecting various portions of the reticle patterns to the source of electric power supply. The switching from one reticle pattern to another is carried out electrically without the use of moving parts of the reticles or reticle images. This ensures high accuracy in positioning of reticle elements with regard to each other, e.g., with regard to the front sight center of the partially transparent mirror, and hence, with regard to the ballistic trajectory of the bullet.
DETAILED DESCRIPTION OF THE INVENTION
[0019] A general schematic side view of the optical sight of the invention is shown in FIG. 1. In the embodiment shown in FIG. 1, the optical sight 20 of the invention is implemented as a firearm sight or a firearm-aiming device. The device consists of a mounting plate 22 , which is attachable to a firearm, e.g., with the use of a dovetail connection and locking screw (not shown). The mounting plate 22 has on its distal end 24 (which is the end nearest to the target) a vertically arranged partially transparent pellicle or mirror 26 with a red-light reflection coating 28 applied onto a slightly concave surface of the mirror 26 formed on the side of the mirror facing a viewer. In FIG. 1 the viewer is represented by an image of a human eye 30 . The aforementioned coating 28 may have properties of a narrow-band mirror which passes all wavelengths except for the wavelength of 650±10 nm, which is seen as a red light.
[0020] On the proximal side 32 , the mounting plate 22 supports a vertical bracket 34 with an opening 36 through which the viewer's eye 30 can see the target (not shown) through the partially reflecting mirror 26 . An eyepiece 38 can be attached to the rear side of the bracket 34 for convenience of the viewer.
[0021] A light-emitting diode (LED) 40 is installed on the mounting plate 22 in the proximal part of the optical sight 20 and in a position offset from the optical axis X-X. The LED 40 is spaced from the coating 28 at a distance equal to half the radius of the curvature on the concave surface of the mirror so that the light beam B 1 emitted from the LED 40 is reflected from the mirror coating 28 as a collimated beam B 2 . It is understood that the mirror coating 28 is perpendicular to beam B 2 . If beam B 2 carries an image (reticle), this image will be localized on the retina of the viewer's eye and will be seen as if it is located in the infinity. When the target appears in the vision field of the viewer, the latter moves the reticle image, and hence the rifle, to which the sight 20 is attached, and aims the weapon to the target by superposing the reticle image onto the target image. Reference numeral 42 designates a power source, e.g., a lithium battery, which supplies electric current to the LED 40 . To this point of the explanation, the optical sight is generally the same as the conventional optical sight with a reticle illuminated by a LED.
[0022] A distinguishing feature of the optical sight of the invention is a set of reticle elements and a method of generation of selected reticles, which can be aligned with the optical axis of the sight by using electric means, i.e., without moving any parts of reticles or reticle combinations.
[0023] More specifically, as shown in FIG. 2A, which is a view of the LED 40 in the direction of arrow A of FIG. 1, the reticle is formed on the outer surface of the LED 40 . FIG. 2B is a sectional view along the line IIB-IIB of FIG. 2A. The arrangement of the LED shown in FIG. 2B is known as TO-CAN. The LED unit consists of a metallic LED holder 41 which supports the LED 40 . The LED 40 is covered with a cup-shaped cover 43 . The upper electrodes (which will be described later) of the LED 40 are connected to output terminals 45 a , 45 b , 45 c which protrude outside the LED assembly through insilators 47 a , 47 b , 47 c (FIG. 2A).
[0024] A more detailed image of the reticle and of the pattern of reticle elements is shown in FIG. 3. As can be seen from FIG. 3, the reticle consists of a central light spot 46 and a plurality of luminous bars, in this case of four luminous bars 48 , 50 , 52 , and 54 . These luminous bars constitute the aforementioned upper electrodes of the LED 40 . The bars 50 and 54 are arranged symmetrically on both sides of the light spot 46 on a horizontal line X 1 -X 1 , while the bars 48 and 52 are arranged symmetrically on both sides of the light spot 46 on a vertical line Y 1 -Y 1 . Thus, the light spot 46 is located in the center of a cross formed by the luminous bars 48 , 50 , 52 , and 54 .
[0025] The luminous bars 48 , 50 , 52 , and 54 can be formed on the surface of the LED 40 , e.g., by a method of photolithography from a conductive material, e.g., from aluminum or chromium. In one model of the sight of the invention tested by the applicant, the LED 40 was a custom-made homo-transition type LED based on epitaxial structures of GaAsP/GaAs. The LED 40 was made with a large surface (with a diameter of about 2 to 3 mm) on which the radiation elements are formed so that it would be possible to perform the aforementioned photolithography. Each element of the reticle, i.e., a bar or a light point, is a closed-loop contour in the form of an elongated rectangle or a circle, so that the perimeter of the closed-loop contour determines the shape of the reticle element, i.e., rectangles, lines, circles, parts of the circle, dots, etc. As shown in FIG. 3, the upper electrodes or luminous bars 48 , 50 , 52 , and 54 and the light spot 46 are connected to a positive terminal 56 a of a source of power supply 56 , e.g., a lithium battery via an electric circuit with an electric switch 58 . A negative terminal 56 b of the power source 56 is connected to the metallic LED holder 41 (FIG. 2B). Thus, a negative potential of the power source 56 is applied to the metallic holder 41 , which is in contact with the bottom of the LED 40 , while a positive potential is applied to the selected upper electrode which is represented by the selected elements of the reticle. The switch 58 can be a rotary type switch, a button-type switch, or an electronic switch. In the general view of the sight shown in FIG. 1, the control element of the switch 58 is shown as a rotary knob 59 which can be switched between four positions, i.e., a position “1”, a position “2”, a position “3”, and a position “OFF”. As shown in FIG. 3, the switch 58 has three switchable contacts SW 1 , SW 2 , and SW 3 , which can be closed or opened in various combinations determined by the aforementioned positions of the knob 59 . The light point 46 is connected to the switch 58 via a conductor 60 , a contact point 62 on the surface of the LED 40 , and a conductor 64 . The luminous bar 48 is connected to the switch 58 via a conductor 66 , a contact 68 on the surface of the LED 40 , and a conductor 70 . The luminous bars 50 , 52 , and 54 , which are connected parallel to each other via conductors 72 , 74 , and 76 , are connected to the switch 58 via a conductor 78 , a contact 80 on the surface of the LED 40 , and a conductor 82 .
[0026] At the maximum of its radiation, this LED generated red light of 650±10 nm. With the d.c. current of 20 μA, the LED 40 produced light with the brightness of not less than 150 μcd.
[0027] Operation temperature ranged from minus 60° C. to plus 70° C.
[0028] The reticle pattern shown in FIG. 3 makes it possible to select the following reticle shapes: a light point 46 , a light point 46 in the center of a cross formed by the luminous bars 48 , 50 , 52 , and 54 , a combination of the light point 46 with the luminous bars 50 , 52 , and 54 . It is understood that this simplified pattern was shown only as an example that illustrates the principle of the invention. It is understood that many other patterns and combinations of luminous elements are possible. Examples of other patterns are shown in FIGS. 4 and 5. The pattern of FIG. 4 consists of a central light spot 84 , two horizontal luminous bars 86 and 88 arranged symmetrically on both sides of the light spot 84 , and two arched elements 90 and 92 with outward radial projections. The elements 90 and 92 are also arranged symmetrically in a vertical direction with respect to the light point 84 . In the example of FIG. 5, the reticle is formed by a central light point 94 with two concentric luminous elements 96 and 98 , each consisting of arched portions separately connected to the power source via respective conductors (not shown). In this embodiment, the light point 94 can be combined with either of the circular reticles 96 and 98 , or can be combined with both of the at the same time.
[0029] Operation of the Optical Sight of the Invention
[0030] In operation, when a hunter needs to select a specific reticle combination which to the most extent satisfies his/her needs with regard to the shooting conditions, shooting habits, type of a target, etc., he/she selects one position of the switch 58 . For example, when only a light spot 46 is needed in the reticle of FIG. 3, the switch 58 is installed to a position, in which the light point 46 is electrically connected to the switch 58 via a conductor 60 , a contact point 62 on the surface of the LED 40 , and a conductor 64 . In this selection, which corresponds, e.g., to the position “1” of the knob 59 , the switchable contact SW 1 is closed and the switchable contacts SW 2 and SW 3 are open. When it is necessary to illuminate a light point 46 and the cross formed by the luminous bars 48 , 50 , 52 , and 54 , all three switchable contacts SW 1 , SW 2 , and SW 3 are closed (position “2” of the knob 59 ), and when it is necessary to select a combination of the light point 46 with the luminous bars 50 , 52 , and 54 , the switchable contacts SW 1 and SW 3 are closed, while the switchable contact SW 2 is opened (position “3” of the knob 59 ). Position “OFF” of the knob 59 corresponds to the condition when all elements of the reticle are disconnected from the source of power supply 56 . It is understood that the switchable contacts are interlocked in such a manner that switching of contacts from one position to another automatically selects right position for the switchable contacts of the selected pattern and eliminates combination of the switchable contacts corresponding to the previous pattern.
[0031] Once the reticle pattern is selected, the shooter tries to find the target in the vision field of the optical sight 20 while constantly observing the reticle 44 as seen as if it is located in the infinity or in a very remote zone. The reticle 44 is aligned with the image of the target, which is also seen by the shooter's eye.
[0032] Thus, it has been shown that the invention provides an optical sight for use in viewfinders of photocameras, or in aiming devices of fire arms, which is simple in construction, inexpensive to manufacture, has no moving reticles or reticle elements, and ensures selection of reticle types and images in a wide range in compliance with the shooting conditions. Although the invention has been shown and described with reference to specific embodiments, it is understood that these embodiments should not be construed as limiting the areas of application of the invention and that any changes and modifications are possible, provided these changes and modifications do not depart from the scope of the attached patent claims. For example, the optical sight of the invention can be used in riflescopes, camcoders, telescopes, telescopic tubes, binoculars, surveying tools, navigation instruments, microscopes, optical micropositioning devices, etc. An unlimited variety of reticle patterns are possible, such as squares, triangles, ovals, hair lines, semi circles, or their combinations. The sight itself can be an open type or enclosed in a tubular housing. The brightness of the reticle image can be adjusted by changing the current supplied to the LED. The current adjustment control can be connected via a feedback line to an automatic exposure meter for automatically adjusting the reticle brightness in compliance with the environmental lighting conditions. The LED may emit light other than red.
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An optical sight for a photocamera viewfinder or for an aiming device of a firearm comprises a combination of a light emitting diode (LED) with a plurality of reticle patterns applied onto the surface of the LED and selectively illuminated by connecting various portions of the reticle patterns to the source of electric power supply. The switching from one reticle pattern to another is carried out electrically without the use of moving parts of the reticles or reticle images. This ensures high accuracy in positioning of reticle elements with regard to each other, e.g., with regard to the front sight center of the partially transparent mirror, and hence, with regard to the ballistic trajectory of the bullet.
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BACKGROUND OF THE INVENTION
The present invention relates to an anaerobic digestor which decomposes organic material to produce a liquid fertilizer and methane gas, and in particular to an anaerobic digestor heated by solar energy.
It is well known to produce methane gas through the anaerobic decomposition of organic material or wastes containing methanogenic bacteria. The usual process is to combine the organic materials in a sealed container in which is maintained an anaerobic atmosphere and a constant temperature in the range of 90-95° F. A period of approximately 30 days is required for an initial incubation before a sufficient quantity of gas withdrawn. A continuous process can be established whereby the feedstock of organic material is continually fed into the tank, and the expired effluent, a liquid fertilizer, is continually removed from the tank. The gas collected can be compressed and used as a methane energy source.
A problem inherent in the process exists in keeping the temperature at a constant value in the range of 90-95° F., as required for the growth of the methanogenic bacteria. In mild climates some of the methane gas produced by the process can be used to heat the digestor, however in colder climates this is not efficient since a large proportion of the methane is used in the heating, leaving a low net yield of methane. Solar energy can be used to supplement the gas heating of the digestor in order to maintain an efficient operation.
Verani, in U.S. Pat. No. 3,933,328 describes an anaerobic digestor which is solar heated. The digestor is buried in the ground and covered with a liquid filled pond. The liquid, being absorptive of solar energy, is circulated through the digestor to heat the contents. A translucent roof, in the form of a dome or inflated bubble exterior of the pond, is used to establish a regulatory temperature environment.
Boblitz, in U.S. PAT. No. 4,057,401, provides a solar heated digestor which comprises a series of sealed containers surrounded with crushed stones, enclosed in a large chamber. The roof over the chamber is pivotal to be inclined at an angle to receive the sun's rays. A black wire screen covered with transparent material is positioned in the roof to absorb the solar energy, thereby heating the air in the roof which in turn is circulated around the sealed tanks.
The structures of Verani and Boblitz, although presumably efficient in using the solar radiation during the sunlight hours to heat the digestors, do not provide adequate restriction to heat loss to the outside environment during the non-sunlight hours, which in cold climates would allow the temperature within the digestor to fluctuate considerably.
SUMMARY OF THE INVENTION
In accordance with the invention there is provided a solar heated anaerobic digestor adapted to utilize a slurry of organic material capable of decomposing to produce a liquid fertilizer and methane gas, comprising: sealed digestor container means having adjoining upper and lower portions defined by upper and lower side wall segments, the lower portion of which is operative to contain the organic material and the upper portion of which is capable of containing the gas produced; means for introducing the slurry into the container means; means for draining slurry product from the container means; means in the upper portion for withdrawing gas produced; means in the lower portion for stirring the slurry; secondary heating means for heating the slurry present in the lower portion; a layer of heat absorptive material wrapped around the lower side wall segment; a plurality of abutting removable panels of insulative material enclosing the layer of heat absorptive material; a layer of insulative material wrapped around the upper side wall segment of the container means; a layer of transparent material wrapped around the panels and the upper side wall insulative material, said layer of transparent material being spaced outwardly from the insulating panels, whereby some of the panels may be temporarily removed to permit solar radiation to heat an exposed portion of the heat absorptive material, and may be replaced when the solar radiation diminishes, thereby enabling a combination of solar heat and heat obtained from the secondary heating means to be used to maintain the temperature of the contained slurry at a desirable level.
In winter daytime hours, those insulating panels facing the sun may be selectively removed, to permit solar radiation to be absorbed by the container contents. The panels are replaced after passage of the sun to reduce heat loss. By combining this feature with auxiliary heating of the container contents by way of burning some of the produced methane, a productive process is realized.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a typical farm scale operation utilizing the solar heated anaerobic digestor shown in cross-section.
FIG. 2 is a perspective view of the anaerobic digestor enclosed within the solar heated structure, with a portion of the outer transparent material removed to view the inner area.
FIG. 3 is as FIG. 2 showing panels of the insulative material removed and having additional portions removed to view the underlying material.
FIG. 4 is a sectional view of the solar heated structure showing the layers of heat absorptive, insulative and transparent materials.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention finds application in the typical farm scale operation depicted in FIG. 1 wherein organic waste is anaerobically decomposed to produce a low grade methane gas suitable for use in heating farm buildings, while the liquid fertilizer remaining after the decomposition can be used as a plant nutrient source.
With reference to FIG. 1, organic material collected from the barn 1 is combined with water in a mixer 2 to form a slurry containing approximately 7% solids. A slurry of this water composition is necessary both to enable the slurry to be pumped and to provide a suitable medium for bacterial growth. A conventional water pump 3 is used to pump the slurry through influent tubing 4 to a sealed container 5. The sealed container 5 is composed of a closed cylindrical steel tank having an upper portion 6 defined by the lower side wall segment adjoining a lower portion 7 defined by the lower side wall segment, the lower portion 7 being operative to contain slurry of organic material, and the upper portion 6 being left empty for the accumulation of the gases produced.
The organic material within the sealed container is initially allowed to digest or decompose for an incubation period of about 30 days before a sufficient quantity of gas is produced to be drawn off. The conditions essential for the decomposition include an anaerobic atmosphere, as provided by the sealed container 5, and a near constant temperature in the range of 90°-95° F., as provided by the solar heated structure 8 and the secondary gas heating means 9 which will be described later. During the decomposition, the slurry of organic material can be stirred to prevent a hard scum for forming on the surface of the slurry. A gas bubbler is used comprising a perforated hollow ring 10 submerged within the slurry and attached to hollow tubing 11 extending to a gas source such as the gas storage tank 12. A gas valve 13 inserted in the hollow tubing 11 is used to regulate the flow rate of the gas entering the container. Preferably methane gas is bubbled through the slurry; being the major gas produced during the decomposition, it is thus available and known not to alter the conditions for the decomposition.
When a sufficient quantity of gas has been produced, as indicated by a gas manometer 14, the gas is drawn off by opening gas valve 15 in the tubing 16 leading from the upper portion 6 of the sealed container. The water is removed from the gas in a water knock-out apparatus 17 prior to passing the gas through compressor 18 and into storage tank 12.
Effluent tubing 20 leads from the sealed container allowing the expired slurry product remaining in the tank to be drawn off for use as a liquid fertilizer. The effluent tubing 20 enters the upper portion 6 of the sealed container 5 and then assumes a downward incline into the slurry. In this manner the slurry is self-draining from the sealed container 5 lending the process to a continuous operation. The gas which accumulates in the upper portion 6 of the sealed container exerts a downward pressure on the slurry causing the slurry to be continually drained from the tank through the effluent tubing 20. Additional slurry can be pumped into the container through the influent tubing 4. If otherwise desired, a batch process can be assumed, draining and refilling the sealed container 5 with the use of the pump 3 at 30 day intervals.
As previously discussed, it is necessary to maintain the temperature inside the sealed container 5 at a constant value in the range of 90°-95° F. in order to keep the decomposition operative. A solar heated structure 8 is provided exterior the sealed container 5. With reference to FIGS. 2, 3 and 4, a layer of heat absorptive material 21 is first wrapped around the lower side wall segment 7 of the sealed container 5. Black plastic material is suitable for this purpose, being absorptive of the energy associated with solar radiation. A first layer of transparent material 22 such as clear plastic capable of transmitting solar energy is wrapped over the black plastic. An air space 23 is left between these two layers by placing intermediate these two layers a first frame 24 of vertical wood slats at spaced intervals around the circumference of the upper side wall segment lower side wall segment 7 of the sealed container 5, and attaching the heat absorptive material 21 and the transparent material 22 to the first frame 24. Insulative material 25 is placed over the transparent material 22. Foam insulation having an R factor of 3.7 per inch has been found effective for the purposes of the present invention. The insulative material 25 is cut into panels 26 of size such that they fit within the spaced intervals of the first frame 24 and enclose the lower portion 7 of the sealed container 5. Clips 27 attached to the first frame 24 hold the panels 25 in place, such that the panels may be removed when desired.
On the upper side wall segment 6 of the sealed container 5, the insulative material 25 is permanently attached to the first frame 24 and further wrapped with the heat absorptive material 21 also attached to the first frame 24. It is desirable to maintain the temperature in the upper portion 6 of the sealed container 5, as close as possible, in the range of 90°-95° F., however temperature control in this area is not as critical as in the lower portion 7.
A second frame 28 is constructed around the lower portion 7 of the sealed container 5 spaced outwardly from the sealed container to leave a passageway 29 of sufficient size to walk in. A second layer of transparent material 30 such as clear plastic is attached to the first frame 24 around the upper side wall segment 6 of the sealed container 5 and to the second frame 28 around the lower portion 7 thereby protecting the enclosed materials from weather elements such as rain and wind, while allowing the solar radiation to be transmitted. The air trapped in the passageway 29 is heated by the solar radiation, thereby acting as a second insulative layer. The solar heated structure is illustrated in FIG. 4 showing the layers of heat absorptive insulative and transparent materials in the particular sequence disclosed.
When it is desired to heat the contents of the container during sunlight hours the panels of insulation 26 facing the sun are removed. The removed panels 31 are placed against the sealed container in an area not facing the sun as shown in FIG. 3, allowing the heat absorptive material 21 to absorb the energy associated with the solar radiation, which is transferred to the sealed container 5. As the position of the sun changes, or if it is no longer desirable to raise the temperature of the sealed container, the removed panels 31 are replaced to insulate the sealed container against heat lost to the outside environment. Additional panels 26 can be removed as the position of the sun or temperature of the sealed container permit. When the temperature outside the solar heated structure are in excess of 95° F., the panels 26 remain fastened to the sealed container to insulate it against the excess heat.
In addition to the solar heated structure 8, secondary gas heating means 9 are provided for use in heating the slurry in the lower portion 7 as may be required when outside temperatures are very low or during non-sunlight hours. Methane gas from the storage tank 12 is burned in the gas burner 32 to heat water. The heated water is circulated through coils 33 running through the slurry within the sealed container 5 thereby heating the slurry.
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A solar heated anaerobic digestor is provided, adapted to utilize organic material capable of decomposing to produce methane gas and a liquid fertilizer. The sealed anaerobic digestor is wrapped with a layer of heat absorptive material followed by a series of abutting removable panels of insulative material. Insulative panels may be temporarily removed to expose the heat absorptive material to solar radiation and may be replaced when the solar radiation diminishes. A layer of transparent material wrapped in outwardly spaced relation around the insulatng panels is capable of transmitting solar radiation while providing protection against environmental elements. Additional heating means extending into the digestor provide auxiliary heat as required.
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This is a continuation of application Ser. No. 942,830 filed Sept. 12, 1978, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to an exposure control device for a camera, and more particularly to an exposure control device for a camera capable of controlling camera exposure by means of light measuring output obtained and stored prior to an actual exposure. Such an exposure control is necessitated in case that an optimum exposure control is desired with respect to a main object located at a particular point within an area to be photographed, e.g., at a corner of the rectangular scene area to be photographed.
2. Description of the Prior Art
In case that, for example, one desires to photograph a composition with the main object located at a corner of the rectangular scene area to be photographed, exposure control is not generally optimum with respect to the main object since an automatic exposure control camera is so designed to control exposure in response to an averaging or a center-weighted light metering output determined subsequent to the camera release operation with respect to the whole area to be photographed.
For the purpose of achieving an optimum exposure control with respect to the main object as in the above case, prior art cameras are provided with a manually operable switch for storing a light measuring output prior to the camera release operation. This is disclosed, for example, in U.S. Pat. No. 3,756,131. The method of photography using such a camera comprises: a first step to operate the manually operable switch with the camera close to the main object so that substantially the whole acceptance angle effective for light measuring may be occupied by the main object, and the value of the stored light measuring output may thereby be determined with respect to the main object only; and a second step where the camera is returned to a position for making the desired composition and the camera release operation is actually carried out so that the exposure control may be determined by the stored light measuring output.
The above method, however, is only possible in case of a camera which is designed to control exposure in response to a TTL light measuring output obtained with the aperture at its initial aperture size, e.g., a fully open aperture size.
Moreover, there is a camera of the type in which the exposure is controlled by a TTL light measuring output obtained after the initiation of the aperture stopping-down motion from its fully open aperture size. In this type of camera, the above mentioned method is not applicable since any reliable light measuring output is not obtainable until the aperture stopping-down motion actually begins subsequent to the actual camera release operation, thereby making the above mentioned first step impossible.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a camera of a type, in which the exposure is controlled by a TTL light measuring output obtained after the initiation of aperture stopping-down motion subsequent to the actual camera release operation, with a means for enabling an optimum exposure control with respect to a main object located at a particular point within a scene area to be photographed.
The present invention is characterized in that the exposure is controlled by a light measuring output obtainable after the initiation of the aperture stopping-down motion subsequent to the actual camera release operation combined with a light measuring output stored prior to the actual camera release operation with the effective light measuring acceptance angle substantially occupied by the main object.
Specifically, according to an embodiment of the present invention, a light measuring output with the effective light measuring acceptance angle substantially occupied by the main object is first stored prior to the actual camera release operation. The camera is then positioned to make a desired composition, in which the main object is located in a small portion of the effective light measuring acceptance angle, and the camera release operation is actually performed. Upon camera release operation, the difference between the logarithm of the stored light measuring output and that of a light measuring output with the camera positioned to make a desired composition is stored prior to the initiation of aperture stopping-down motion, and the aperture stopping-down motion follows thereafter. Exposure is controlled in accordance with the logarithm of a light measuring output, which is obtained after the initiation of the aperture stopping-down motion, with the stored logarithmic difference added thereto to make the exposure control optimum with respect to the main object. The reason why the exposure is optimum with respect to the main object is that the logarithmic difference with the aperture at its initial size is equal to the logarithmic difference with the aperture stopped-down to any size. Thus, by means of the addition of the logarithmic difference stored with the aperture at its initial size, the light measuring output obtained after the aperture stopping-down motion with the light measuring acceptance angle not occupied by the main object is succesfully converted into a light measuring output that would be obtained with the effective light measuring acceptance angle occupied by the main object.
Further, according to the invention, it is recommended that a spot metering device, in addition to an averaging metering device, is utilized for the purpose of obtaining the light measuring output to be stored prior to the camera release operation. The spot metering device may make it unnecessary for the camera to be close to the main object for storing the light measuring output, since the narrow light measuring acceptance angle of the spot metering device can easily be occupied by the main object if the camera is caused to slightly deviate from the composition making position, in which, for example, the main object is at the corner of the object field, so as to be directly aimed at the main object.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 represents a block diagram of an embodiment of the exposure control device according to the present invention; and
FIG. 2 represents a schematic circuit diagram of another embodiment of the exposure control device according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, which shows a block diagram of a first preferred embodiment according to the present invention, light measuring circuit 1 is designed for averaged light measuring, with photodiode PD1 disposed in a position where it obtains an output in response to the averaged scene brightness of a field to be photographed. Light measuring circuit 2 is provided for spot light measuring, with photodiode PD2 disposed in a position where it obtains an output in response to the brightness of a comparatively small given section of a field to be photographed, e.g. the central section of the field to be photographed. Light measuring circuits 1 and 2 produce voltage signals proportional to the logarithm of the brightness of scene light incident respectively on photodiodes PD1 and PD2 through diaphragm aperture D. First memory circuit 3 stores the output produced by light measuring circuit 2 for spot light measuring. Switch S2 is manually operated and usually connected to contact b and changes to contact a, while a button provided on the camera body is kept depressed when photographing by spot light measuring. Switch S6 is also manually operated for changing photography modes, and it is closed for photographing by averaged light measuring and is opened for photographing by spot light measuring. FIG. 1 shows that switch S6 is opened for photographing by spot light measuring.
With the above mentioned construction, the camera is first held so that a main object for spot light measuring is in the spot light measuring range, and switch S2 is changed to contact a. This causes the result of spot light measuring to be stored in first memory circuit 3 as an input, and is retained therein even when switch S2 is thereafter returned to its original position at contact b (since switch S6 is opened). Then, with the camera held for making a desired composition in which the main object is at a particular location deviating from the spot light measuring range and the shutter release button depressed, the outputs of light measuring circuit 1 and first memory circuit 3 immediately before diaphragm aperture D is stopped-down from its fully open aperture size, are applied to subtraction circuit 4, the subtraction result or a difference between the outputs is stored in second memory circuit 5. The signal stored in second memory circuit 5 can be written as the following formula, assuming that the output of averaged light measuring circuit 1 for a fully open aperture is Vao, and that the output of spot light measuring circuit 2 for a similarly open aperture is Vso:
Vso-Vao
Switch S7 is opened during the shutter button depression operation immediately before diaphragm aperture D is stopped-down to thereby fix the signal storage in second memory circuit 5. With the aperture D stopped-down afterward, output Va of averaged light measuring circuit 1 when the aperture was stopped-down, and a stored signal in second memory circuit 5, are input into calculation circuit 6. Calculation circuit 6 performs a calculation formulated as follows:
Va+(Vso-Vao)
The above value corresponds to the spot light measuring output with the aperture stopped-down. Exposure control circuit 7 carries out exposure control in response to an output from the above mentioned calculation circuit 6.
For normal photographing by averaged light measuring, switch S6 is kept closed. Switch S2 remains connected to contact b since it is not operated. This means that the two inputs to subtraction circuit 4 are both from light measuring circuit 1 to make the subtraction result zero. The zero subtraction result of subtraction circuit 4 is also stored as a storage signal in second memory circuit 5. Therefore, the input to calculation circuit 6 is only output Va of averaged light measuring circuit 1 produced when diaphragm aperture D is stopped-down, and output Va is input to exposure control circuit 7 for exposure control by averaged light measuring.
The first preferred embodiment shown in FIG. 1 is applicable to a variety of automatic exposure control modes, as described below.
For automatic exposure time control with a preset aperture, calculation circuit 6 receives from light measuring circuit 1 averaged light measuring output Va when diaphragm aperture D is stopped-down to a preset position, and exposure control circuit 7 provides a shutter speed appropriate to spot light measuring made for the preset aperture. With the assumption that averaged light measuring output Va for a fully open aperture is an exposure time of 1/500 second, and spot light measuring output Vso is an exposure of 1/2000 second, the difference in shutter speed between the two exposure times is two steps, and this difference is the output of second memory circuit 5. And when averaged light measuring output Va with diaphragm aperture D stopped-down to the preset position corresponds to 1/125 second, calculation circuit 6 produces an output corresponding to 1/500 second with two steps added to the averaged light measuring output Va.
The following is an explanation of an automatic aperture control mode with a predetermined exposure time using the above example. The output of 1/500 second of light measuring circuit 1 is for a fully open aperture, and this means that diaphragm aperture D should be stopped-down by two steps if the preset shutter speed is 1/125 second. The output of second memory circuit 5 is a signal for diaphragm aperture D to be stopped-down by an additional two steps, and therefore calculation circuit 6 produces an output for the aperture to be stopped-down by four steps from the fully open aperture. In response to the output from calculation circuit 6, exposure control circuit 7 operates to stop-down diaphragm aperture D by four steps from the fully open aperture. It should be understood that in this mode second memory circuit 5 may be omitted.
For automatic aperture control with a predetermined exposure time, there is another mechanism available in which an aperture stopping-down motion toward the minimum aperture is interrupted when the TTL light measuring output obtained during the aperture stopping-down motion is in a predetermined relation with the preset shutter speed. In this case, however, while the difference in output between averaged light measuring and spot light measuring for a fully open aperture is input to calculation circuit 6 from second memory circuit 5, an averaged light measuring output during the time that the aperture is stopped-down is transmitted to calculation circuit 6 from light measuring circuit 1. With the aforesaid example of light measuring output, the light measuring output during the aperture stopping-down motion is produced from calculation circuit 6, with the difference of the two steps added, and this output is compared with a signal in response to a preset shutter speed by exposure control circuit 7. The aperture stopping-down motion is interrupted at a position where the aforesaid output and signal are equal to determine an optimum aperture size.
In the embodiment shown in FIG. 2, a common light measuring circuit is used both for averaged light measuring and spot light measuring, with photodiodes PD1 and PD2 arranged to be individually connected to a reference voltage VRef. Photodiode PD1 is used for averaged light measuring and photodiode PD2 for spot light measuring. Switch S1 is usually connected to contact b, and is connected to contact a only when a special button provided on the camera body remains depressed. Therefore, switch S1 is usually set for averaged light measuring. Transistor Q1 converts the output current of photodiode PD1 or PD2 to a logarithmically compressed voltage signal. High input impedance buffer amplifier A1 receives the output of either photodiode PD1 or PD2 and potentiometer PM1 is used to set the film sensitivity. The output of high input impedance buffer amplifier A1 is the summation of the scene brightness and the film sensitivity in accordance with the APEX notation system. Potentiometers PM2 and PM3 are used to make the averaged light measuring output and spot light measuring output equivalent. The output of high input impedance buffer amplifier A1 is generally expected to be the same for an object field having uniform brightness when either photodiode PD1 or PD2 is used. In fact, however, photodiode PD1 is positioned to optimize averaged light measuring, and photodiode PD2 is positioned to optimize spot light measuring, with their respective outputs being unequal even in the above case. This causes the output of high input impedance buffer amplifier A1 to vary in accordance with the output of either photodiode PD1 or PD2. Potentiometers PM2 and PM3 are adjusted and fixed upon assembling the camera so that both light measuring outputs in the above case become equal, thereby making the two outputs equivalent. Switch S2, interlocked with switch S1, is usually connected to contact b and disconnected from slider W3 of potentiometer PM3. Slider W2 of potentiometer PM2 is always connected to operational amplifier A3. Constant-current circuit I1 supplies constant current to potentiometers PM1, PM2 and PM3.
The following description of the circuitry shown in FIG. 2 is made with photography by spot light measuring. Switches S1 and S2 are first depressed to change their respective connection to contact a. This allows photodiode PD2 to operate for spot light measuring with a fully open aperture, and spot light measuring result Vso is stored in capacitor C1 from slider W3 of potentiometer PM3 via switch S2. In this photographing mode, manual switch S6 is opened beforehand. Furthermore, switches S3 and S4, interlocked with each other, are connected to their respective contacts a, as shown in the diagram. With switches S1 and S2 then released to return to their original positions at their respective contacts b, averaged light measuring with a fully open aperture is performed by photodiode PD1, with averaged light measuring output Vao appearing at slider W2 of potentiometer PM2. Output Vao is applied as a subtrahend to a subtraction circuit corresponding to subtraction circuit 4 of FIG. 1, consisting of resistors R1 through R4 and operational amplifier A3. The minuend of the subtraction circuit is spot light measuring output Vso with a fully open aperture, which output is stored in capacitor C1 and applied to the subtraction circuit through operational amplifier A2 designed for impedance conversion. The output of the subtraction circuit is Vso-Vao, which output is inverted by an inversion circuit, including operational amplifier A4 and resistors R5 and R6 (of equal resistance), into a signal Vao-Vso which is charged and stored in capacitor C2. With the shutter button depressed, switches S3 and S4 are changed to their respective contacts b immediately before diaphragm aperture D is stopped-down, and capacitor C2 retains output Vao-Vso which is again applied via operational amplifier A2 to the plus terminal of operational amplifier A3 as a minuend to the subtraction circuit. Averaged light measuring output Va, when diaphragm aperture D is stopped-down to a preset position, is then produced from slider W2 of potentiometer PM2 and is applied to the minus terminal of operational amplifier A3 as a subtrahend to the subtraction circuit. Therefore, the output of operational amplifier A3 at this time is (Vao-Vso)-Va which is inverted by the inversion circuit including operational amplifier A4 to become Va-(Vao-Vso) which is charged and stored in capacitor C3. Switch S5 is opened immediately before the swingable mirror of an SLR camera moves, and the aforesaid output at that time is retained by capacitor C3. Exposure time control circuit 8 operates in accordance with the voltage stored in capacitor C3 to close the shutter with a delay, which is an optimum exposure time for the main object with spot light measuring, from the instant of shutter opening.
The following description is with respect to normal photography using averaged light measuring. In this mode, switch S6 remains closed, and switches S3 and S4 are at their respective contacts a. Since switch S6 is closed, the charge at capacitor C1 is zero and the input (minuend) at the plus terminal of operational amplifier A3 in the subtraction circuit is also zero. Switches S1 and S2 are not operated, remaining connected to contact b. An averaged light measuring output is produced from slider W2 of potentiometer PM2 and is applied to the minus terminal of operational amplifier A3 in the subtraction circuit as a subtrahend, and because the minuend is only zero, the averaged light measuring output is inverted and applied to operational amplifier A4 of the inversion circuit, and is inverted again to return to its original form and charged on capacitor C3. The output charged on capacitor C3 varies during aperture stopping-down motion from the initial fully open aperture to the final preset aperture. However, an averaged light measuring output with the diaphragm aperture D stopped-down to the preset position is retained by capacitor C3 by means of opening of switch S5 immediately before the mirror-up motion and in response to that stored output of capacitor C3 exposure time is controlled. It is to be noted that in this mode the output of slider W2 may be directly input to and stored by capacitor C3 without passing through operational amplifiers A3 and A4.
In the embodiment disclosed in FIG. 1, a modification is possible in which light measuring circuit 2 for spot metering is removed from the device. In this case, it is apparent that a photographer has to approach close to the main object for storing the light measuring output so that the light measuring acceptance angle of the photodiode PD1 may be occupied by the main object and first memory circuit 3 may receive a light measuring output with respect to the main object only as in the case of receiving output from light measuring circuit 2. In the above modification, switch S6 has to be modified to be constantly closed and switch S2, which normally contacts contact b and is opened to fix the contents of first memory circuit 3, has to be kept open until switch S7 is opened. The other operations are the same as those already disclosed.
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A camera exposure control device having TTL light measuring circuitry capable of spot metering and also averaged metering is disclosed, the spot metering being used for measurement with the camera directed to a main object prior to the camera release operation, and the averaged metering being used for measurement with the camera positioned for making a desired composition including the main object. The difference between the logarithm of the spot metering output and that of the averaged metering output with the aperture at its initial size is stored prior to the aperture stopping-down motion. Exposure is actually controlled by the averaged metering output, which is obtained after the initiation of the aperture stopping-down motion in response to camera release operation with the stored difference between the aforementioned outputs added thereto, to thereby effectively achieve an exposure control equivalent to a control based on a spot metering output which would be obtained after the initiation of the aperture stopping-down motion.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to centrifugally operated clutch mechanisms and more particularly to rotary clutch mechanisms in which the clutch shoes have outrigger means supporting springs at positions which allow centrifugal forces to change the direction in which the springs act. The present invention also relates to improved heat dissipation means for centrifugal clutch devices.
2. Description of the Prior Art
Prior patents disclosing centrifugal clutches and related devices are as follows:
______________________________________2,171,837 2,718,294 3,018,8642,203,862 2,722,304 3,101,6252,386,645 2,850,131 3,506,1012,610,718 2,976,9752,623,400 2,707,542______________________________________
SUMMARY OF THE INVENTION
The foregoing prior art teaches the formation of centrifugal clutches by means of circumferentially spaced clutch shoes interconnected by springs and driven by a spider having arms interposed between the circumferentially spaced clutch shoes. The present invention differs from such prior art in that the springs interconnecting the clutch shoes are so sized and mounted to the clutch shoes that the springs are able to be bowed outwardly by centrifugal forces. The outward bow of the springs is utilized beneficially in the present invention to permit the direction in which the springs act to shift from a tension pulling the clutch shoes radially inwardly to a tension pulling the clutch shoes circumferentially or, at least, not strongly pulling the clutch shoes inwardly. This result is aided in the present invention by equipping the clutch shoes with outrigger means which anchor the tension springs at positions allowing the outward bow of the springs to change the direction in which the springs act.
In further summary of the present invention, a new clutch shoe construction along with refinements in the design of the spider which drives the clutch shoes provides improved heat dissipation.
It is accordingly an object of the present invention to provide a new and improved centrifugal clutch mechanism.
A further object of this invention is to provide a new and improved clutch shoe configuration for use in centrifugal clutches.
Still another object of this invention is to provide a new and improved mounting for springs which interconnect the clutch shoes of a centrifugal clutch mechanism, the mounting allowing the springs to bow under the influence of centrifugal forces and thereby change the direction in which the spring forces act upon the clutch shoes.
Still a further object of the present invention is to provide a clutch construction with improved heat dissipation qualities.
Other objects and advantages reside in the construction of parts, the combination thereof, the method of manufacture and the mode of operation, as will become more apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view with a portion broken away illustrating a clutch mechanism embodying the present invention.
FIG. 2 is a section view taken substantially along the line of 2--2 of FIG. 1.
FIG. 3 is a fragmentary section view taken substantially along the line 3--3 of FIG. 2.
FIG. 4 is a plan view illustrating an operative mode of the present invention.
FIG. 5 is a fragmentary plan view illustrating an operative mode of a modification.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The clutch mechanism illustrated in the drawings is adapted for assembly onto the output shaft 10 of any suitable driving means such as a gasoline engine or an electric motor, not shown. The clutch mechanism includes a spider 12 received on the shaft 10 and non-rotatably secured to the shaft 10 by means of a key 14.
Journaled for rotation on the shaft 10 is a transmission member 16 adapted to be controllably driven by operation of the clutch mechanism. The transmission member 16 is axially located on the shaft 10 by means of a spring clip 18 seated in a suitable groove in the shaft 10. Fibrous washers 20 and 22 located adjacent the opposite ends of the member 16 minimize friction between the member 16 and the spring clip 18 at one end thereof and the spider 12 which has an annular opening 23 receiving the opposite end of the member 16.
For purposes of torque transmission, the member 16 has integrally formed teeth 24 forming a sprocket for engaging a suitable transmission belt or chain, not shown. Other torque transmission means such as pulleys and gears are comprehended within the present invention.
The member 16 also includes a second annular array of teeth 26 which have been cut away on the right faces thereof as they appear in FIG. 2 to provide a notched, cylindrical hub 32 adapted to interfit a similarly shaped opening located centrally in a closure means 28 for a drum member 30. Thus, as appears in FIG. 2, the central opening in the closure means 28 includes an annular array of teeth 29 which interfit the notches in the hub 32. The drum 30 is fixedly secured to the member 16 by any suitable means such as a pressed fit, staking or the like.
As thus far described, the drum member 30 is free to rotate with respect to the shaft 10 and with respect to the spider 12. A driving connection between the shaft 10 and the drum member 30 is established in accordance with the present invention by means of a centrifugally operated clutch mechanism which will now be described.
As best appears in FIG. 1, the spider 12 comprises four equiangularly spaced spokes or arms 34 which extend outwardly in a direction generally radial with respect to the rotary axis of the shaft 10. At an intermediate point on its length, the thickness of each of the spokes as they appear in FIG. 1 is rather abruptly reduced to provide each of the spokes with a shoulder 38. It will be noted that one pair of diametrically disposed spokes has their shoulders located upon the clockwise sides thereof as appears in FIG. 1 while the other pair of diametrically disposed spokes has their shoulders 38 located on the counterclockwise sides thereof.
As appears in FIG. 1, the shoulders 38 provide seats for the ends of diametrically disposed arcuate clutch shoes 40, each of the clutch shoes 40 subtending an angle of approximately 90° about the axis of the shaft 10 when seated against the shoulders 38 as shown in FIG. 1.
As will become apparent, the teachings of the present invention are not limited to spiders having four spokes. In general, a spider suitable for use in the present invention will have its spokes or arms arranged at substantially equal angles with clutch shoes subtending an appropriate angle being disposed between alternate pairs of adjacently disposed arms, provided with shoulders as shown, the empty gaps or pockets between such alternate pairs being open and unfilled except as will be described.
Each of the spokes 34 has an outer end 36 which serves as a shoe driver and is of gradually diminishing thickness from the shoulder or seat 38 to the radially outer end of the spoke. It will also be noted that each of the spokes 34 terminates in spaced apart relation to the drum member 30 whereby the spider 12 is free to rotate within the drum member 30.
The shoes 40 are preferably a metal or an alloy which has been heat treated or tempered to withstand the high temperatures that will be encountered in the operation to be described. The shoes have been milled or otherwise formed to have inwardly indented side walls 46. The outer surface 48 of each shoe is interrupted by an axially extending notch 50 which, as will be further explained, is sized to optimize friction forces that will be developed between the shoes 40 and the drum 30 during the operation of the clutch mechanism.
Secured to each end of each of the shoes 40 is a stirrup member 54 which, as seen in FIG. 3, is secured in straddling relation to the shoe by means of a single hollow or tubular rivet 58. The stirrups 54 can be seen to comprise single lengths of a wire which has been shaped to a generally "U" shape with both ends of the wire curved to form hooks 56 which partially encircle and are seized by the rivets 58. One function of the hooks 56 is to act within the indented side walls 46 to bias the side arms 55 of the stirrup into firm contact with the inner margins 57 of the indented side walls 46. The hooks 56 thus cooperate with the rivets 58 and the side arms 55 of the stirrups to firmly anchor the stirrups against pivotal motion with respect to the shoes 40.
It can be noted that each of the stirrups 54 has a base 59 spaced apart from its shoe 40 and spanning the width of the shoes between the indented walls 46. The bases are so spaced from the shoes that the clutch drivers 36 can be received within the stirrups with a considerable tolerance for a circumferential movement of the drivers 36 within the stirrups.
Each of the bases 59 has an indentation 61 adapted to seat a hook 63 formed at one end of a helically coiled tension spring 62. The opposite end of the same spring is hooked to a circumferentially adjacent stirrup of the opposite clutch shoe. The springs are stretched and thus under tension. Assuming a condition in which the spider 12 is not rotating at a high speed, the resulting arrangement is such that the two springs 62 are disposed mutually parallel on opposite sides of the shaft 10 as illustrated in FIG. 1.
FIG. 4 illustrates the condition of the clutch mechanism of FIG. 1 when the rotational speed of the spider 12 has been increased just sufficiently to cause a clutch engagement. A comparison between FIGS. 1 and 4 will show that by the time of clutch engagement, the springs 62 have swung outwardly under the influence of centrifugal forces toward the drum 30, thus substantially relieving the radially inward force which was exerted on the clutch shoes 40 when the spider was at rest. Thus, it can be noted that the springs 62 have swung outwardly to a position in which the direction of pull exerted by the springs on the clutch shoes 40 is primarily a circumferential pull and to some extent a radial outward pull.
In the preferred construction, the springs 62 are provided with a force constant, which, in reference to the mass associated with the springs 62, allows the springs to swing outwardly to contact, or at least nearly contact, the drum 30 at substantially the same rotary velocity that causes the clutch shoes 40 to contact the drum 30. While, as indicated, the springs 62 may contact the drum 30 at the time of clutch engagement, this is not required.
Those skilled in the art will appreciate that the time of clutch engagement is the time when the clutch is most sensitive to changes in rotary velocity. Thus, as the clutch engages, the inertia of the clutch and any mechanism to be driven through the clutch must be overcome before clutch engagement is complete. Some deceleration of the clutch spider can therefore be anticipated. If such deceleration is sufficient to permit the springs to retract the clutch shoes from the drum 30, the clutch will disengage until the speed of the spider can increase sufficiently to return the clutch shoes 40 to the drum 30. This condition is known in the art as clutch "chatter". It results in part from too strong a radial inward force being exerted on the clutch shoes 40.
With the present invention, wherein the springs 62 have been designed to swing outwardly under the influence of centrifugal forces and thus subtantially relieve radially inward forces, the problems with clutch "chatter" are very materially reduced.
It will be noted that as the shoes 40, and perhaps the springs 62, first engage the drum 30, a frictional slippage with respect to the drum 30 is unavoidable. Thus the drum 30 cannot rotate with the shoes 40 until the inertia of the drum and any load associated therewith has been overcome. Until the inertia is overcome, the shoes inevitably slip with respect to the drum. It is accordingly contemplated that there will be a substantial generation of heat as the shoes engage the drum 30.
It is helpful to consider some motions that occur as the shoes 40 slidlingly engage the drum 30. Due to the symmetric design of the shoes, the symmetric locations of the springs, and the symmetry of design associated with the spider 12, the shoes will tend to move oppositely outwardly from their seats 38 to engage with the drum 30. As the shoes leave their seats 38, they continue to be driven by the spider 12. Thus, as appears in FIG. 4 wherein a direction of rotation has been shown by the arrow 69, a pair of diametrically opposite spokes will be firmly abutted against trailing ends of the shoes while a relative shift in position between the spider and the shoes will have opened substantial gaps between the leading ends of the shoes and the remaining pair of spokes 34. The spokes and shoes have been carefully shaped in recognition that the described shift in the position of the shoes will occur.
Thus, it is preferred that the shapes of the clutch drivers 36 and the ends of the shoes 40 be so designed that the interface between the shoes and the clutch drivers during periods of clutch engagement is substantially radial with respect to the axis of rotation of the shaft 10, the consequence being that the spokes tend neither to lift the shoes away from the drum 30 nor unduly load the shoes so as to retard disengagement of the clutch.
FIG. 5 illustrates a modification in which the springs 62 have been weighted to lower the angular velocity at which the springs will switch from a primarily radial pull to a primarily circumferential pull exerted on the shoes 40. In this modification, a number of weights in the form of a suitably sized balls 70 are placed within the interior of the springs 62. The balls 70 closely fit the inside spring diameter and substantially fill the spring lengths when the springs are in the chordal position illustrated in FIG. 1. As the springs develop a bow, as illustrated in FIG. 5, the balls 70 seek radially outermost positions, and, accordingly concentrate near the point of contact between the springs in which they are housed and the interior wall of the drum 30. The balls 70 provide a means whereby the angular velocity at which the springs will shift from radial to circumferential pulls may be decreased with reference to the angular velocity at which the springs will permit the clutch shoes to engage the drum 30. It will be apparent to those skilled in the art that weights of other sizes and shapes disposed either internally or externally of the springs 62 can be utilized for the same purposes.
It is to be noted, that the clutch mechanism is bi-directional in the sense that the clutch mechanism operates in the same fashion whether the shaft 10 is being rotated in a clockwise or a counterclockwise direction. It is found highly desirable that the leading and trailing corners of the clutch shoes 40 are sharply formed angles, which are preferably right angles. As the clutch is repeatedly engaged and disengaged and subjected to substantial heat generation during clutch engagement, abrasively released debris can be expected to accumulate on the interior wall of the drum 30. By forming the leading and trailing corners of the clutch shoes as sharp angles, these corners become effective to scrape and dislodge the accumulated debris.
By reason of the shape of the spider disclosed in the drawings it is desirable that the clutch shoes 40 subtend approximately 90° about the axis of rotation of the shaft 10 when the clutch shoes are seated on the seats 38. For most applications, however, this will produce outer surfaces for the clutch shoes which unless reduced in area, are too large to provide an effective radially outward force per unit of shoe area. Accordingly it is found desirable to limit the area of the outer surface 48. Inasmuch as sharp corners are found desirable at the leading and trailing ends of the clutch shoes it is also found desirable to limit the area of the outer surface 48 by providing the centrally disposed notch therein, thus doubling the number of sharp corners available to scrape accumulating debris from the interior wall of drum 30.
The notches 50 provide a further advantage in that air is permitted to circulate centrally through the clutch shoes thus extracting some of the heat generated when the outer surfaces of the clutch shoes slidingly engage the drum 30. For the same purpose the rivets 58 are formed as tubular rivets so that air may circulate through the rivets.
The circulation of air about the clutch means is enhanced in the present invention by the shape of the spokes 34. Thus as appears in FIGS. 1 and 2 the spokes are in the shape of blade-like members whose thickness is substantially less than their width. Further the side edges of the spokes which confront the closure means 28 of the drum 30 are shaped or sculptured to complement the shape or sculpturing of the closure means 28.
More particularly the side edges are formed with wings 64 which agitate the air disposed within the drum 30 and located adjacent the closure means 28.
Directing particular attention to FIG. 2, it will be noted that the axial dimension of the interior wall of the drum 30 is substantially greater than the axial dimensions of the clutch shoes 40. This dimensional relationship is desired so that the drum 30 can serve as a heat sink in regions not directly contacted by the clutch shoes. In particular, it is desirable that a notable overhang exist at the free edge of the clutch drum so as to enable heat to be sinked at the free edge where the heat can be efficiently dissipated by radiation and the movement of the air currents about the free edge of the drum.
Although a preferred embodiment of this invention has been described, it will be understood that various changes may be made within the scope of the appended claims.
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A clutch assembly for controlling the transfer of rotation from a rotatable driving member to a rotatably mounted driven member comprises a spider driven within a drum having an interior wall surrounding the spider. The spider has outwardly radiating arms which receive clutch shoes between alternate pairs of adjacently disposed arms. The clutch shoes are equipped with outrigger means providing anchors for the ends of springs which interconnect circumferentially adjacent clutch shoes. The outrigger means support the ends of the springs circumferentially outwardly from the clutch shoes in a position which enables centrifugal forces to bow the springs outwardly and thus change the direction of force exerted by the springs on the clutch shoes.
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This application claims the benefit of provisional application Ser. No. 60/847,233 filed Sep. 26, 2006.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to unloaders for reciprocating gas compressors, and in particular to an unloader having a valve assembly with a valve guard and valve seat mounted for relative rotation. The rotatable member is driven by a constant torque motor or other power source which stalls or slips when the torque supplied is overcome by forces on the valve assembly caused by pressure differentials across the valve. Once pressures equalize, the rotatable member is free to resume rotation.
2. Description of the Related Art
In my earlier patent, U.S. Pat. No. 5,695,325, entitled Synchronized Unloader System and Method for a Gas Compressor, I disclosed an unloader system for a reciprocating gas compressor which includes an unloader valve assembly having a valve seat with multiple seat passages extending therethrough and arranged in a seat passage circle. A valve guard is rotatably mounted on the valve seat and includes a plurality of valve members arrayed in a valve circle and movable between open and closed positions with respect to the seat passages. An unloader actuation system includes a controller connected to a control system for the compressor and a stepper motor drivingly connected to the valve guard. In use, the valve guard is incrementally rotated in synchronization with the compressor crankshaft by increments corresponding to the spacing between the valve members and the seat passages. The closings of the valve members are delayed by varying amounts to achieve varying amounts of unloading.
SUMMARY OF THE INVENTION
The present invention is an unloader system which utilizes a valve assembly similar to those described in U.S. Pat. No. 5,695,325. Instead of being synchronized with the compressor crankshaft by means of a stepper motor and electronic control system, however, the valve guard is rotatably driven by a power source having a constant or steady torque and the ability to stall or slip when the resistance on the valve guard exceeds the torque supplied by the power source. As the valve guard rotates, the valve members will periodically come into alignment with the valve seat passages. When the pressure acting on the valve member is sufficient to resist the torque of the power source, the power source will slip, causing a delay in the rotation of the valve guard. When the pressure equalizes across the valve member, the guard will resume rotation. The speed of rotation of the valve guard may be selected to cause the valve members to next align themselves with the valve seat passages at a point in the compressor cycle wherein some amount of gas is allowed to flow backward before the valve member can close, thereby partially unloading the compressor. The amount of backflow can be adjusted by adjusting the speed of rotation of the guard. Unloading is achieved by decreasing capacity by intentionally allowing either late closure of a suction valve or a discharge valve.
In addition to unloading, the use of rotational valves, such as the valve of the present invention also improves efficiency of the compressor. Many compressors now have up to 30% of the compressor horsepower that results from just the resistance to flow through the valves at the velocities required. Efficiently operating reciprocating compressors may have as little as 5%-7% of the horsepower used to overcome the resistance to flow through the valve. The majority of the horsepower in both cases goes to getting the gas from the lower pressure to the higher pressure.
One factor in the operation of the unloader of the present invention is that efficiency is improved as the sealing element is out of the gas stream during a significant part of the intake or exhaust stroke. In some cases, it would be possible to show an improvement of as much as 15% to 20% in the operating efficiency of a compressor if any or all valves in the compressor were equipped to allow this reduced resistance to flow. This would be referred to as “active valves” as they would have an operating mechanism, and would not be dependent strictly on a pressure differential to open the valves as is the case with conventional valves.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary cross sectional view of a reciprocating gas compressor showing a constant torque unloader system according to the present invention operating as a suction valve of the compressor.
FIG. 2 is a cross section of an unloader valve which forms a part of the unloader system taken along line 2 - 2 in FIG. 1 and showing a valve guard thereof.
FIG. 3 is a cross section of the unloader system taken along line 3 - 3 in FIG. 2 and showing valve members mounted on the valve guard in an aligned orientation with valve seat openings in a valve seat.
FIG. 3( a ) is a view similar to FIG. 3 showing an alternative embodiment of the unloader system having a rotatable guard mounted in a stationary carrier.
FIG. 4 is a cross section of the unloader system taken along line 4 - 4 in FIG. 2 and showing the valve guard in an orientation wherein the valve members are not aligned with the valve seat openings.
FIG. 5 is a cross section of the unloader system taken along line 5 - 5 in FIG. 3 and showing the valve seat thereof.
FIG. 6 is a partially schematic fragmentary view of the unloader system showing an alternative embodiment of the constant torque power source for the unloader system.
FIG. 7 is a cross sectional view similar to FIG. 3 and showing the unloader system operating as a discharge valve.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
Certain terminology will be used in the following description for convenience in reference only and will not be limiting. For example, the words “upwardly,” “downwardly,” “rightwardly,” and “leftwardly” will refer to directions in the drawings to which reference is made. The words “inwardly” and “outwardly” will refer to directions toward and away from, respectively, the geometric center of the embodiment being described and designated parts thereof. Said terminology will include the words specifically mentioned, derivatives thereof and words of a similar import.
Referring to the drawings in more detail, and in particular to FIG. 1 , the reference number 1 generally designates a constant torque unloader system according to the present invention. The system 1 is for use on a reciprocating compressor 3 including a cylinder 5 slidably receiving a piston 7 connected to a crankshaft (not shown). A suction valve assembly 9 mounted in a suction of the compressor 3 selectively communicates the cylinder 5 with a suction line 11 . Similarly, a discharge valve assembly 13 selectively communicates the cylinder 5 with a discharge line 15 . The compressor 3 generally operates to moves gas from the suction line 11 to the discharge line 15 at increased pressure.
The system 1 includes a valve assembly 21 which may be installed in the compressor 3 to act as either a suction valve assembly 9 (as shown in FIGS. 1-5 ) or as a discharge valve assembly 13 (as shown in FIG. 7 ). For purposes of simplicity, the valve assembly 21 will primarily be described and depicted herein as a single deck suction valve assembly 9 selectively controlling communication between the cylinder 5 and suction line 11 of the compressor 3 . It is to be understood, however, that the current invention may be equally well applied to radial valve assemblies and multi-deck valve assemblies, which may be either suction valve assemblies 9 or discharge valve assemblies 13 . These other types of valve assemblies 21 are generally described in U.S. Pat. No. 5,695,325, the disclosure of which is hereby incorporated by reference.
Referring to FIGS. 2-5 , the valve assembly 21 includes a valve seat 23 and a valve guard 25 rotatably mounted on the valve seat 23 . The valve seat 23 includes one or more valve seat passages 27 extending therethrough. The valve guard 25 includes one or more valve members 29 movable between open and closed positions with respect to the valve seat passages 27 when the valve guard 25 rotated relative to the valve seat 23 such that the valve members 29 are in alignment with the valve seat passages 27 . The valve guard 25 further includes a plurality of bypass openings 30 around the valve members 29 . As the valve guard 25 rotates on the valve seat 23 , the valve members 29 move cyclically in and out of alignment with the valve seat passages 27 . When the valve members 29 are aligned with the valve seat passages 27 (as shown in FIG. 3 ) the valve seat 23 the valve members 29 control flow through the valve assembly 21 . When the valve members 29 are out of alignment with the valve seat passages 27 (as shown in FIG. 4 ), gas flows freely through the valve assembly 21 by way of valve seat passages 27 communicating with the bypass openings 30 .
An exemplary valve guard 25 is shown in FIG. 2 as having eight poppet type valve members 29 arranged in a circle and equally spaced apart (at 45 degree increments). A compatible valve seat 23 is shown in FIG. 5 as having eight valve seat passages also arranged in a circle and equally spaced apart (at 45 degree increments). As best seen in FIG. 3 , each poppet valve member 29 has a head 33 , a stem 35 and urged against the valve seat 23 by a valve spring 36 . It is to be understood, however, that the number of valve seat passages 27 and valve members 29 may be more or less than the eight shown and that they may be arranged in several concentric circles. Furthermore, it is to be understood that other known types of valve members 29 may be used in place of the poppet type valve members 29 shown.
Referring again to FIG. 3 , the valve assembly 21 is mounted in a suction valve pocket 10 of the compressor 3 such that, when the valve members 29 are aligned with their respective seat passages 27 , pressure in the suction line 11 acts on the heads 33 of the valve members 29 and urges them toward their open positions. After Bottom Dead Center (BDC), pressure in the cylinder 5 acts on the stems 35 of the valve members 29 through openings 37 in the valve guard 25 and urges the valve members 29 toward their closed positions. When the pressure in the cylinder 5 is less than the pressure in the suction line 11 , the valve members 29 move into their open positions. When the pressure in the cylinder 5 is greater than the pressure in the suction line 11 , the valve members 29 move into their closed positions.
A cap 39 covers the suction pocket 10 and retains the valve assembly 21 in position. A first end of an unloader drive shaft 41 is fixedly connected to the valve guard 25 in axial relation to the circle of valve members 29 . The shaft 41 extends through a shaft receiver 43 in the valve seat 23 and is rotatable relative thereto. A second end of the unloader drive shaft 41 extends outwardly from the suction pocket 10 through an opening 45 in the cap 39 .
A constant torque power source 47 is operatively connected to the second end 42 of the unloader valve drive shaft 41 and is operable to rotate the valve guard 25 relative to the valve seat 27 . As shown in FIG. 3 , the constant torque power source 47 may be, for example a motor 47 a , such as a pneumatic, hydraulic or electric motor (such as a direct current electric motor) having the ability to slip or stall when the resistance to rotation exceeds the torque being produced. The rotational speed of the power source 47 is preferably adjustable, such as through variation in the current or fluid flow supplied to the motor 47 a , so that the amount of unloading may be varied as discussed below.
FIG. 3( a ) shows an alternative embodiment 1 a of the present invention wherein the valve guard 25 is mounted in a stationary carrier 26 having a cylindrical recess sized to rotatably receive the valve guard 25 . As with the previous embodiment, the guard 25 is fixed to the shaft 41 and carries the moveable valve members 29 . The carrier 26 is fixedly clamped between the valve seat 23 and a lower shoulder of the valve pocket 10 . Mounting the guard 25 in a separate carrier 26 allows for easier rotation of the guard 25 relative to the valve seat 23 . The operation of the system 1 a is identical to the operation of the system 1 as described below.
As shown in FIG. 6 , the constant torque power source 47 may also be a flywheel 47 b acting on the unloader valve drive shaft 41 through a slip clutch 49 . The flywheel 47 b may be, for example, driven by a motor 51 . In this embodiment, the slip clutch 49 may be adjusted to vary the torque transmitted to the valve guard 25 . The slip clutch 49 will begin to slip, pausing rotation of the valve guard 25 when the set torque limits of the clutch are overcome by forces on the valve assembly 21 caused by pressure differentials across the valve members 29 . The flywheel 47 b will continue to rotate. It should be noted that FIG. 6 , which is partially schematic, shows the motor 51 acting on the flywheel 47 b through a simple belt and sheave arrangement, however it is to be understood that the flywheel could also be driven using any known drive system, including a gear drive, and that any drive system used would incorporate sufficient reduction to allow the flywheel 47 b to rotate the valve guard 25 at the proper rotational speed for the compressor.
Operating Example
The operation of the system 1 may be shown by assuming a 320 RPM Compressor operating with 50% Suction Volumetric Efficiency (“VE”) and looking at a cycle of the compressor 5 starting with the piston 7 at top dead center (“TDC”) and the valve members 29 in their closed position sealing the valve seat passages 27 . As described above, the valve assembly 21 of the system 1 is a suction valve assembly 9 having eight valve members 29 equally space apart (at 45 degree intervals) around a circle. A constant torque is applied on the suction unloader drive shaft 41 by the power source 47 . The valve guard 25 does not move initially since at TDC the cylinder pressure pushes the valve members 29 against the valve seat 23 with sufficient force to resist the torque supplied by the power source 47 . However, when the pressure equalizes across the suction valve assembly 9 (at mid-stroke with a 50% suction VE), the valve guard 25 will start to rotate (after being delayed for one quarter revolution of the compressor crankshaft 8 ). If the valve guard 25 is rotated at one half of the speed of the compressor crankshaft, the valve members 29 will line up with the valve seat passages 27 at the same time that the piston 7 hits bottom dead center (“BDC”). If the pressure rise in the cylinder 5 is fast enough, the valve members 29 will not be able to move out of the valve seat passages 27 and compression will start. Because the valve members 29 close virtually simultaneously with the piston 7 reaching BDC, there is little or no backflow from the cylinder 5 to the suction line 11 and therefore the compressor 3 is operating in a fully loaded condition.
In order to partially unload the compressor 3 , the rotational speed at which the unloader drive shaft 41 is driven by the power source 47 would be reduced. This would cause the valve guard 25 to arrive at the point where the valve members 29 realign themselves with the valve seat passages 27 at some point after BDC. This would allow some backflow from the cylinder 5 into the suction line 11 until the valve members 29 realign themselves with the valve seat passages 27 and are seated. To reduce the load even more, the speed of the unloader drive shaft 41 would be reduced even more.
If the valve assembly 21 is installed as a discharge valve assembly 13 (as shown in FIG. 7 ), the operation of the system 1 is essentially the same except that the valve members 29 are installed such that pressure in the cylinder 5 acts on the heads 33 of the valve members 29 urging them toward their open positions and pressure in the discharge line 15 acts on the stems 35 of the valve members 29 urging them toward their closed positions. As the valve guard 25 rotates on the valve seat 23 , the valve members 29 periodically align with valve seat passages 27 . If the pressure in the discharge line 15 pushes the valve members 29 closed with sufficient force to overcome the torque of the power source 47 , the valve guard 25 will cease to rotate until pressure across the valve members 29 equalizes. Once the pressure equalizes, the valve guard 25 is free to resume rotation. As before, the degree of unloading is changed by adjusting the speed of rotation of the valve guard 25 . By slowing the speed of rotation of the valve guard 25 , the valve members 29 can be made to not align with the valve seat passages 27 again until some point after the piston 7 reaches top dead center, thereby delaying closing of the discharge valve members 29 . This will allow some gas to flow back from the discharge line 15 into the cylinder 5 , thereby delayed opening of the suction valve members, resulting in less gas coming into the cylinder during the suction event and partially unloading the compressor.
It is to be understood that while certain forms of the present invention have been illustrated and described herein, it is not to be limited to the specific forms or arrangement of parts described and shown. For example, the valve assembly 21 has been described as having a valve guard 25 rotatably mounted on a stationary valve seat 23 , however it is foreseen that the valve guard 25 could be held stationary and the valve seat 23 rotated to produce the same result.
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An unloader system for a reciprocating gas compressor includes an unloader valve assembly which may be installed as the suction valve assembly or the discharge valve assembly of the compressor. The valve assembly includes a valve seat having one or more seat passages formed therethrough and a valve guard having a number of valve members movably mounted thereon equal to the number of seat passages. One of the valve guard and valve seat is rotatable relative to the other. The rotatable member is driven by a constant torque motor or other power source which stalls when a retarding force caused by pressure differentials across the valve members overcomes the torque supplied. Once pressures across the valve members equalize, the rotatable member can resume rotation. A method of unloading a compressor using the unloader system includes selecting a rotational speed for the rotating member to allow backflow.
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RELATED APPLICATION
[0001] This application claims the benefit of priority from European Patent Application No. 13 306 201.8, filed on Sep. 3, 2013, the entirety of which is incorporated by reference.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The present invention relates to a coil arrangement of at least one stripe-shaped superconductor assembly wherein the stripe-shaped superconductor assembly can be a superconductor stripe with metal substrate and superconductor layer formed onto at least one side of the metal substrate.
[0004] The superconductor stripe can be a tape or wire. According to need one or more buffer layer(s) can be provided between the substrate and the superconductor layer. as well as onto the superconductor layer.
[0005] The metal substrate can be biaxially textured, for example, by deformation process.
[0006] The superconductor material can be a high temperature superconductor (hts) material including rare earth oxide, for example REBa 2 Cu 3 O 7 -δ wherein RE is selected from the group consisting of rare earth elements and Yttrium, and δ is a number of greater than 0 and less than 1.
[0007] 2. Description of Related Art It is well known to wind superconductor tapes or wires into a coil configuration for obtaining a compact space saving design wherein a maximum length of superconductor tape or wire requires as little volume as possible
[0008] A particular application of such compact coil arrangement of superconductor stripes such as tapes or wires is in resistive fault current limiters. Superconducting fault current limiters make use of the unique transition characteristics of superconducting material. When a fault occurs in a power transmission system connected with a resistive superconductor fault current limiter, the current density in the superconductor material exceeds the critical current density of the material, and the superconductor material undergoes transition from its superconducting state into its normal resistive state thereby limiting the current flow.
[0009] Preferably in the coil arrangement the current path is designed such that in adjacent turns of the coil current flow is in opposite direction in order to minimize induction.
[0010] Such a coil arrangement wherein the current path is designed such that current flow in adjacent turns is in opposite direction is also referred to “coil arrangement of low inductance”.
[0011] In the well-known bifilar superconductor coil arrangement the superconductor tape or wire changes direction at one end of the coil, also referred to reversal point, and is returned in parallel to the first winding to the opposite end of the coil, i.e. the starting point of the coil winding, Due to the bifilar winding current flow and, as a consequence, the orientation of the magnetic field induced by the current flow is in opposite direction in adjacent turns. Since the magnetic fields are in opposite direction the “sum” of the magnetic fields is about zero and induction in the coil arrangement is minimized.
[0012] There are known helical bifilar coils and flat spiral bifilar coils, so called pancake coils. A typical example of a bifilar pancake coil is disclosed in EP 1 797 599 B1.
[0013] A typical problem in bifilar coil winding, irrespectively whether helical or pancake arrangement, is that the starting and end points of the winding, i.e. current input and output, are very close to each other, so that all of the voltage applied across the coil appears between these two points and makes provision of good electrical insulation necessary for avoiding short-circuit.
[0014] US 2011/011O198 A1 relates to a flat spiral bifilar coil arrangement with improved distance between current input and current output. For obtaining increased distance two or more superconductor tapes or wires are arranged on a common plane and are shaped to form a common coil winding, wherein each of the superconductor tapes or wires form a bifilar structure with the reversal point of each bifilar structure being located around the center of the spiral. in the result a larger distance between the starting and end point of each bifilar structure of the coil assembly can be obtained
[0015] U.S. Pat. No. 6,275,365 B1 relates to a fault current limiter composed of a plurality of bifilar pancake coils. Each pancake coil is separated by an insulation layer and is wound from the same continuous length of superconducting tape. The individual coils are stacked on top of each other along a longitudinal axis for obtaining a relatively compact superconducting fault current limiter with minimized total inductance.
[0016] Another approach for obtaining a coil arrangement with minimized inductance is disclosed in EP 2 472 532 A1. According to this approach a hts tape or wire is wound onto two adjacent longitudinal axes in a manner that adjacent turns of the first axis show current flow in opposing directions wherein at least two turns on the first axis are connected in series via at least one turn on the second axis. The resulting coil arrangement is monofilar rather than bifilar thereby avoiding change of direction at one end of the coil (i.e. the reversal point) and, further, the maximum voltage drop between adjacent turns is only a fraction of the voltage drop across the entire coil.
[0017] In the known bifilar coil winding of superconductor stripes the substrate side is oriented in the same direction and points either inwards or outwards of the coil. In such arrangement the substrate side of a first turn faces the superconductor layer side of the adjacent turn with opposite current flow.
[0018] As set out above conventional bifilar coils with substrate orientation towards the same direction are advantageous in that the inductance is only low since the overall sum of the magnetic fields is zero.
[0019] However, this situation is completely different when considering local parts of such conventional bifilar coil. In local parts significant local magnetic fields exist between adjacent turns with opposite current flow so that the substrate of a first turn which faces the superconductor layer of the adjacent turn, is in a region of magnetic field. Such an exposition of metal substrates to magnetic field is disadvantageous in particular in AC applications due to the changing magnetic field. Interaction of the magnetic field with the metal of the substrate leads to considerable AC losses due to both hysteretic and eddy current effects. These AC losses are particularly significant in cases where the metal is ferromagnetic. For example, Nickel and its alloys which are commonly used as metal substrate for superconductor stripes such as known as coated conductors, are typical ferromagnetic materials.
[0020] These power losses cause high cryogenic requirements and consequently increased costs.
[0021] AC losses due to hysteretic and eddy current effects are a problem in any superconductor coil arrangement wherein the superconductor material, irrespectively whether low or high temperature superconductor, is adjacent to a normally conductive metal, in particular ferromagnetic metal.
OBJECTS AND SUMMARY
[0022] It was the object of the present invention to provide a coil arrangement of low inductance, such as for example a bifilar coil arrangement, for superconductor stripes comprising a metal substrate and deposited thereon a superconductor layer, having reduced AC losses along the coil.
[0023] This object is solved by a coil arrangement of at least one stripe-shaped superconductor assembly with metal substrate and superconductor layer formed onto at least one side of the metal substrate wherein the at least one stripe-shaped superconductor assembly is formed into a coil arrangement wherein in adjacent turns current flow is an opposite direction in operation, and wherein in the stripe-shaped superconductor assembly the metal substrate is sandwiched between superconductor layers with same current flow direction in operation.
[0024] According to the coil arrangement of the present invention the substrate side of the stripe-shaped superconductor assembly is sandwiched between two superconductor layers.
[0025] In this arrangement the current path of the coil is formed by a sandwich structure with the metal substrate side being sandwiched between two superconductor layers.
[0026] Further, in adjacent turns of the coil arrangement with opposite direction of current flow the superconductor layer side of a first turn faces the superconductor layer side of the adjacent turns. i.e. the turn following the first turn and the turn preceding the first turn.
[0027] Due to this sandwich architecture the substrate side of each turn is positioned in a region without magnetic field, and only in the region between the superconductor layer side of adjacent turns of the coil winding a magnetic field is generated.
[0028] In principle the coil arrangement of the present invention is suitable for any coil winding wherein in adjacent turns current flows in opposite direction.
[0029] The coil arrangement can be a conventional bifilar coil winding with the stripe-shaped superconductor assembly being wound into a first coil part and is returned in parallel to the first coil part forming the second coil part.
[0030] Two or more stripe-shaped superconductor assemblies can be wound into coil configuration side by side and being returned. In this case, the two or more stripe-shaped superconductor assemblies or some of them can run together in a common reversal point and being returned from said common reversal point.
[0031] The present coil arrangement is suitable for any superconductor stripe comprising a stripe-shaped metal substrate wherein at least one side of the metal substrate is coated with a superconductor layer.
[0032] According to one embodiment of the present invention the stripe-shaped superconductor assembly can be composed of two superconductor stripes, each superconductor stripe comprising a metal substrate and a superconductor layer formed thereon. The two superconductor stripes are arranged in parallel with the substrate sides facing each other and the superconductor layer sides pointing outwards.
[0033] When such stripe-shaped superconductor assembly is formed into a coil winding of low inductance with current flow in opposite direction in adjacent turns, the superconductor layer side of a given turn faces the superconductor layer side of the adjacent turns with current flow in opposite direction and the metal substrate side being in a position of no magnetic field.
[0034] According to another embodiment of the present invention the stripe-shaped superconductor assembly can be composed of a superconductor stripe wherein on both, the top and bottom side, of the metal substrate a superconductor layer is formed.
[0035] According to need one or more buffer layers can be provided between substrate and the superconductor layer and/or onto the superconductor layer. Such superconductor stripes, materials therefore and fabrication methods are known per se.
[0036] The superconductor material can be anyone of low and high temperature superconductor materials and MgB 2 . High temperature superconductor materials are those having a critical temperature above the temperature of liquid nitrogen (77 K.). HTS materials are preferred for example in view of the use of liquid nitrogen as cooling medium which is comparatively cheaper than, e.g., liquid helium.
[0037] Examples of suitable hts materials are rare earth oxides, for example REBa 2 Cu 3 O 7-δ , wherein RE is at least one from the group consisting of rare earth elements and Yttrium, and δ is a number of greater 0 and less than 1, Bismuth-Strontium-Calcium-Copper-Oxide superconductors (BSCCO) and Thallium based superconductors,
[0038] Typical buffer layers are metal oxides such as CeO 2 , YSZ (Yttria stabilized Zirconia), Y 2 O 3 and SrTiO 3 as well as metals such as Silver. Nickel etc.
[0039] Preferably a layer of non-ferromagnetic metal is provided onto the superconductor. layer, e.g. silver, gold, copper.
[0040] The metal material for the substrate can include metal and metal alloys such as Nickel, Nickel-Tungsten, Nickel-Chromium, Nickel-Copper, Nickel-Vanadium or Hasteiloy. Stainless steel or any other suitable normally conductive metal or metal alloy.
[0041] For the fabrication of the coil arrangement of the present invention the stripe-shaped superconductor assembly can be composed of two superconductor stripes wherein a superconductor layer is provided on one side of the metal substrate.
[0042] In this case the current path is formed by two superconductor stripes wound in parallel into the coil arrangement of the present invention, wherein the substrate side of each superconductor stripe faces each other.
[0043] The superconductor layer side of each superconductor stripe points towards the adjacent turns with current flow in opposite direction in operation.
[0044] Considering the overall coil arrangement in this embodiment the current path is defined by two individual superconductor stripes each comprising a metal substrate and a superconductor layer applied onto one side of the metal substrate.
[0045] There can be a space between the two individual superconductor stripes of the stripe-shaped superconductor assembly.
[0046] A spacer of electrically insulating material can be provided in the space between the two superconductor stripes. The electrically insulating material can be plastics such as Teflon, Polyimide, Aramid etc. or any other electrically insulating material which is stable at low temperature.
[0047] According to another embodiment the two individual superconductor stripes can be jointed via their substrates, for example by soldering or gluing etc.
[0048] According to yet another embodiment the stripe-shaped superconductor assembly can be composed of a superconductor stripe wherein the substrate is provided with a superconductor layer on both the top and bottom side of the metal substrate.
[0049] Preferably, the turns of the coil arrangement of the present invention are electrically insulated by providing an electrically insulating material between the turns. The material can be one as referred to above.
[0050] In a preferred embodiment of the present invention the superconductor layer of the superconductor stripe is a rare-earth-oxide based hts material as defined above. In particular, the hts conductor stripe is one known as “coated conductor” using YBCO based hts material.
[0051] Generally, there are two main approaches for the production of superconductor stripes such as of coated conductor-type including YBCO coated conductors.
[0052] According to the first approach metal substrates are used which are untextured (random crystal orientation). In this case a buffer layer must be applied in a suitable crystal orientation for serving as a template for transferring the required crystal orientation to the superconductor layer to be grown.
[0053] According to the second approach metal substrates are used which have been treated to be textured, preferably biaxially textured i.e. in axial direction within the plane and perpendicularly to the plane.
[0054] In this case the substrate as such can serve as template. Biaxially textured metal substrates can be fabricated by rolling and heat treatment and are known as rolling assisted biaxially textured substrates (RABiTS).
[0055] The metal material for the substrate should meet a number of criteria It should be thermally and chemically stable at elevated temperatures at which the superconductor deposition and formation is carried out. Further, it should be flexible and have good yield strength in order to provide appropriate support for the final conductor. When using the RABiTS route the metal must be one in which a suitable texture can be generated by rolling and heat treatment.
[0056] For example, in the production of YBCO coated conductors Ni, Ni alloys, Ag and Ag alloys are suitable for fabricating the biaxially textured substrate via the RABiTS route since these materials allow generation of the required texture for growing the hts layer thereon in the desired crystal alignment. In view of costs Ni and Ni alloys are widely used nowadays.
[0057] However, Nickel and Nickel alloys have the drawback to be ferromagnetic with the disadvantageous consequence of significant AC losses in conventional bifilar coil winding as set out above.
[0058] According to the present invention the disadvantage in view of AC losses of substrates made of metals, in particular ferromagnetic metals such as Nickel and Nickel alloys, can be overcome.
BRIEF DESCRIPTION OF DRAWINGS
[0059] The present invention is now illustrated in more detail by reference to the accompanying figures, wherein:
[0060] FIG. 1 shows a bifilar pancake coil of prior art EP 2 041 809 81;
[0061] FIG. 2 shows schematically the substrate orientation of prior art bifilar coils such as in prior art pancake coil shown in FIG. 1 , as well as the magnetic field variation between two adjacent turns along the coil;
[0062] FIG. 3 shows schematically an embodiment of substrate orientation and winding arrangement according to the present invention as well as the magnetic field variation between adjacent turns along the coil; and
[0063] FIG. 4 shows schematically a further embodiment of substrate orientation and winding arrangement according to the present invention, as well as the magnetic field variation between adjacent turns along the coil.
DETAILED DESCRIPTION
[0064] FIG. 1 shows a prior art bifilar pancake coil winding of a hts tape of coated- conductor type 1 with Ih denoting current input, Ir current output, Wi and Wi+1 adjacent turns, as well as spacer 2 running in parallel to the hts tape 1 for separating and insulating adjacent turns.
[0065] In this coil arrangement the metal substrate side of the hts tape of coated conductor type faces outwards and the his layer insides of the arrangement. Consequently, in adjacent turns Wi and Wi+1 the hts layer of turn Wi is directed towards the substrate side of turn Wi+1.
[0066] A cross-section of the resulting coil arrangement of FIG. 1 is shown in FIG. 2 with reference no, 3 denoting the substrate, 4 the superconductor layer with current flow in first direction and 5 superconductor layer with current flow in opposite direction, the resulting magnetic fields between adjacent turns along the coil arrangement being illustrated in the diagram below.
[0067] As follows from the diagram local magnetic fields exist between adjacent turns (with alternating direction corresponding to alternating direction of current flow), Seen along the overall coil winding the sum of the local magnetic fields with alternating direction is about zero, whereas between adjacent turns local magnetic fields with alternating direction exist. Consequently, in such an arrangement the substrate sides are exposed to the magnetic field generated by the current flow. Due to the influence of the magnetic field AC losses are caused in the metal substrate due to hysteretic and eddy current effects. These AC losses are particularly considerable in cases of substrates made of ferromagnetic materials such as nickel and nickel alloys widely used in the production of superconductor stripes such as those of coated-conductor type.
[0068] A cross-section through a section of a coil winding of the present invention is shown in FIG. 3 .
[0069] In this embodiment the coil arrangement of the present invention is obtained by winding a stripe-shaped superconductor assembly composed of two superconductor stripes in parallel, wherein the substrate sides 3 of the two superconductor stripes are oriented towards each other and the superconductor layers 4 , 5 pointing in opposite directions. In this embodiment the current path is defined by the two superconductor stripes with superconductor layer 4 indicating current flow in a first direction and superconductor layer 5 in opposite direction.
[0070] Shown are four turns 6 , 7 , 8 and 9 of the coil arrangement, wherein current flow in the first and third turn 6 , 8 is in a first direction, and in the second and fourth turn 7 , 9 in opposite direction.
[0071] Within each turn 6 , 7 , 8 , 9 the substrate sides 3 are oriented towards each other and between two adjacent turns 6 , 7 ; 7 , 8 ; 8 , 9 the respective superconductor layer side 4 , 5 faces each other.
[0072] The variation of magnetic field along the coil arrangement of FIG. 3 is shown in the diagram below the cross-section. In the region between the two substrate sides 3 of each turn 6 , 7 , 8 , 9 the magnetic field is zero, whereas in the region between the superconductor layer side 4 , 5 of adjacent turns 6 , 7 ; 7 , 8 ; 8 , 9 magnetic field exists with opposite direction between consecutive turns 6 , 7 and 7 , 8 as well as 7 , 8 and 8 , 9 , respectively.
[0073] A variation of the embodiment of coil arrangement according to the present invention of FIG. 3 is shown in FIG. 4 . In this variation the distance between the substrates 3 of the individual turns 6 , 7 , 8 , 9 is closer than in the variation of FIG. 3 . The course of magnetic field of the variation of FIG. 4 is shown in the diagram of FIG. 4 .
[0074] According to a further embodiment it is also possible to join he substrate sides 3 of the two individual superconductor stripes forming the current path of the coil, Such joining can be a accomplished, for example, by soldering or gluing.
[0075] According to yet another embodiment it is also possible to use a superconductor stripe wherein a superconductor layer is provided on both the top and bottom faces of the substrate stripe.
[0076] In the coil arrangement of the present invention with opposite current flow direction in adjacent turns the substrate side of the superconductor stripe(s) wound into the coil arrangement is located in a region without magnetic field. In the result AC losses due to hysteresis effects and eddy currents caused by the influence of the changing magnetic field onto the metal material of the substrate, are prevented.
[0077] Such AC losses are particularly relevant in case of ferromagnetic metal material. The benefits of the present invention are particularly evident when YBCO coated conductors are used for forming the coil arrangement with RABiT substrates made of Nickel or Nickel alloys. Nickel and Nickel alloys are widely used in view of their good texturing capability and low costs, but are ferromagnetic.
[0078] As is evident, with current flow in opposite direction in adjacent turns, such as in bifilar winding, the present invention is advantageously applicable for any coil fabrication using superconductor stripes with metal substrates without being restricted to conventional bifilar coil winding.
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A coil arrangement formed from a stripe-shaped superconductor assembly is composed of metal substrate ( 3 ) and at least one superconductor layer ( 4, 5 ) wherein the coil arrangement is such, that in adjacent turns current flow is in opposite direction in operation, and wherein the substrate side ( 3 ) is in a region without magnetic field by sandwiching the substrate side ( 3 ) between superconductor layers ( 4, 5 ) of same current direction during operation.
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TECHNICAL FIELD OF THE INVENTION
[0001] The present invention is directed to a method for wirelessly adjusting one or more hearing devices with a central unit as well as to a system for adjusting one or more hearing devices.
BACKGROUND OF THE INVENTION
[0002] It is generally known that a person's hearing loss is not normally uniform over the entire frequency spectrum of hearing. For example, in typical noise-induced hearing loss, the hearing loss is typically greater at higher frequencies than at lower frequencies. The degree of hearing loss at various frequencies varies with individuals. The measurement of an individual's hearing ability can be illustrated by an audiogram. An audiologist, or other hearing health professionals, will measure an individual's perceptive ability for differing sound frequencies and differing sound amplitudes. A plot of the resulting information in an amplitude/frequency diagram will graphically represent the individual's hearing ability, and will thereby represent the individual's hearing loss as compared to an established range of normal hearing for individuals. In this regard, the audiogram represents graphically the particular auditory characteristics of the individual. Other types of measurements relating to hearing deficiencies may be made.
[0003] Since individuals have differing hearing abilities with respect to each other, and oftentimes have differing hearing abilities between the right and left ears, it is normal to have some form of adjustment of the hearing devices to compensate for the characteristics of the hearing of the individual.
[0004] Numerous types of adjustable hearing devices are known. As such, details of the specifics of adjusting functions will not be described in detail.
[0005] The adjustment of hearing devices can be made in several ways. First, it has been known to have the manufacturer establish a computer-based programming function at its factory or outlet centers. In this form of operation, the details of the individual's hearing readings, such as the audiogram that has been obtained by the audiologist, are forwarded to the manufacturer for use in making the adjustments. Once adjusted, the hearing device or hearing devices are then sent back to the audiologist or directly to the intended user. Such an operation clearly suffers from the disadvantage of the loss of time in the transmission of the information and the return of the adjusted hearing device. In addition, an interactive adjustment involving the audiologist and the hearing device user is usually not possible. Furthermore, such arrangements characteristically deal only with the adjustment of the particular manufacturer's hearing devices, and are not readily adaptable for adjusting various types of hearing devices.
[0006] Yet another type of prior art programming system is utilized wherein the programming system is located near the audiologist who directly adjusts the hearing device for the hearing device user. In such an arrangement, it is common for each location to have a general purpose computer especially programmed to perform the adjustment function and provide it with an interface unit hard-wired to the computer for providing the programming function to the hearing device. In this arrangement, the hearing professional enters the audiogram or other patient-related hearing information into the computer, and thereby allows the computer to calculate the auditory parameters that will be optimal for the predetermined listening situations for the individual. The computer then directly programs the hearing device. Such specific programming systems and hard-wired interrelationship to the host computer are costly and do not lend themselves to ease of altering the programming functions.
[0007] Other types of programming or adjusting systems wherein centralized host computers are used to provide programming access via telephone lines and the like are also known, and suffer from many of the problems of cost, lack of ease of usage, lack of flexibility in reprogramming, and the like.
[0008] Known methods for adjusting hearing devices are disclosed, for example, by WO 99/09 799 and by U.S. Pat. No. 5,210,803. Other types of devices having a self-identification feature for device detection are disclosed, for example, by EP-1 309 222 A2 and by US 2005/0068182.
[0009] Furthermore, US 2005/000 81 75 A1 discloses a system for programming hearing devices with a host computer that is wirelessly connectable to the hearing devices via a hearing device programmer. This known system bears the risk that the hearing device programmer connects to the wrong hearing device resulting in malfunctions due to bad or wrong adjustment of the hearing device.
[0010] It is therefore an object of the present invention to provide a method for adjusting one or more hearing devices, which method does not have the above-mentioned disadvantages.
SUMMARY OF THE INVENTION
[0011] The inventive method for wirelessly adjusting one or more hearing devices with a central unit comprises the steps of:
establishing a wireless network wirelessly connecting the central unit to hearing devices, which are responsive to said wireless network, detecting said hearing devices, identifying one or more of the detected hearing devices, selecting one or more of the identified hearing devices, establishing a wireless link from the central unit to at least one of the identified hearing devices, and adjusting the at least one identified hearing device.
[0018] Therewith, the audiologist is able to unambiguously assign one or two hearing devices in a fitting session, even if multiple hearing devices are within the range of the wireless network or wireless transmitter, respectively.
[0019] It is expressly pointed out that the term “hearing device” does not only mean a device which is inserted into a user's ear to improve the hearing ability of a hearing impaired person, but also any accessory device used in connection with the device inserted into the user's ear, as for example a remote control. In addition, the term “hearing device” may also mean a communication device or an ear protection device, which is inserted into the ear canal. Thereby, it is independent on the fact whether the hearing device is inserted into the ear canal or whether it is implanted into the inner ear, for example.
[0020] In a more specific embodiment of the present invention, the method comprises the step of displaying the detected hearing devices, preferably with additional identifier such as a model identifier or a serial number pertaining to the detected hearing device. Therewith, a list of the detected hearing devices is presented to the audiologist in order to give him or her an overview of the available hearing devices that are detected at present.
[0021] In another embodiment of the present invention, the step of identifying a detected hearing device comprises the steps of:
instructing, via the central unit, a detected hearing device to emit a signal, which preferably is an acoustic signal, and assigning the instructed hearing device to the physical hearing device that emitted said signal.
[0024] In yet another embodiment of the present invention, the step of identifying a detected hearing device comprises the steps of:
stimulating a radio frequency identification tag provided at each detected hearing device to emit a radio frequency response containing an identification code, receiving the radio frequency response, and assigning the stimulated hearing device to the corresponding physical hearing device to which the identification code belongs.
[0028] In a still further embodiment of the present invention, the step of identifying a detected hearing device comprises the steps of:
stimulating one of the detected hearing devices, monitoring the detected hearing devices in the central unit for a response of the stimulation, determining the hearing device in the central unit, for which hearing device a response has been detected, and assigning the stimulated hearing device to the determined hearing device).
[0033] Several possibilities exist how to stimulate the hearing device: provoking a feedback, operating a remote control, actuating volume control, actuating program select switch, inserting a battery, closing a battery door. A combination of two or more possibilities can be required.
[0034] In a further embodiment of the present invention, the wireless network has a limited range such that only one hearing device is detected at the same time.
[0035] In a still further embodiment of the present invention, the step of identifying a detected hearing device comprises the steps of:
displaying an additional identifier of the detected hearing devices, said additional identifier being indicated on the hearing device housings, comparing one or more displayed identifier to the ones indicated on the hearing device housings, and assigning a displayed detected hearing device to the physical hearing device having identical additional identifiers.
[0039] Furthermore, a system for wirelessly adjusting one or more hearing devices with a central unit is also provided. Such a system comprises:
a central unit, one or more hearing devices, means for establishing a wireless network wirelessly connecting the central unit to hearing devices, which are responsive to said wireless network, means for detecting said hearing devices, means for identifying one or more of the detected hearing devices, means for selecting one or more of the identified hearing devices, means for establishing a wireless link from the central unit to at least one of the identified hearing devices, and means for adjusting the at least one identified hearing device.
[0048] In an embodiment of the inventive system, means for displaying the detected hearing devices, preferably with additional identifier such as a model identifier or a serial number pertaining to the detected hearing device, are provided.
[0049] In another embodiment of the system according to the present invention, the means for identifying a detected hearing device comprise:
means for instructing, via the central unit, a detected hearing device to emit a signal, which preferably is an acoustic signal, and means for assigning the instructed hearing device to the physical hearing device that emitted said signal.
[0052] In yet another embodiment of the system according to the present invention, the means for identifying a detected hearing device comprise:
means for stimulating a radio frequency identification tag provided at each detected hearing device to emit a radio frequency response containing an identification code, means for receiving the radio frequency response, and means for assigning the stimulated hearing device to the corresponding physical hearing device to which the identification code belongs.
[0056] In still another embodiment of the present invention, the means for identifying a detected hearing device comprise:
means for stimulating one of the detected hearing devices, means for monitoring the detected hearing devices in the central unit for a response of the stimulation, means for determining the hearing device in the central unit, for which hearing device a response has been detected, and means for assigning the stimulated hearing device to the determined hearing device.
[0061] Again, several possibilities exist how to stimulate the hearing device: provoking a feedback, operating a remote control, actuating volume control, actuating program select switch, inserting a battery, closing a battery door. A combination of two or more possibilities can be required.
[0062] In a further embodiment of the system according to the present invention, the wireless network has a limited range such that only one hearing device is detectable at the same time.
[0063] In a still further embodiment of the system according to the present invention, the means for identifying a detected hearing device comprise:
means for displaying an additional identifier of the detected hearing devices, said additional identifier being indicated on the hearing device housings, means for comparing one or more displayed identifier to the ones indicated on the hearing device housings, and means for assigning a displayed detected hearing device to the physical hearing device having identical additional identifiers.
[0067] The present invention is further explained in more detail by referring to drawings illustrating exemplified embodiments of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0068] FIG. 1 schematically shows a system for adjusting one or more hearing devices,
[0069] FIG. 2 shows a first screen shot of a software application controlling the hearing devices, and
[0070] FIG. 3 shows a second screen shot of another software application controlling the hearing devices.
DETAILED DESCRIPTION OF THE INVENTION
[0071] FIG. 1 shows three hearing devices 1 , 2 and 3 , a central unit 4 —also called fitting device—and a host computer 5 , which can be a commercially available computer, e.g. a personal computer or a notebook. It is expressly pointed out that the central unit 4 and the host computer 5 can be a single unit. Therefore, whenever the term “central unit” is used in this specification, the meaning is not only limited to the intermediate unit (i.e. the fitting device) but may also include a part or the whole host computer 5 in combination with the central unit 4 (i.e. the fitting device).
[0072] As is depicted in FIG. 1 , the central unit 4 and the host computer 5 are interconnected via a connection 7 , which is either implemented as a wireless or as a wired connection. Numerous possibilities exist for implementing this connection. For example, a connection via a so called Bluetooth device, which is a wireless interconnection, a cable using a USB—(Universal Serial Bus)—interface, or—to mention another wireless network—a network implemented according to the IEEE-802.11 standard, which is also called WLAN—(Wireless Local Area Network).
[0073] In case of an inventive system with a fitting device and a host computer 5 , as it is depicted in FIG. 1 , software applications, e.g. a fitting program to adjust a hearing device 1 to 3 , are running on the host computer 5 that is standardized to a large extent (e.g. a personal computer), whereas specific hardware that is needed in some cases to adapt to specific data transmission to the hearing devices 1 to 3 , is realized in the fitting device or the central unit 4 , respectively.
[0074] According to the present invention, the hearing devices to be adjusted to the needs of an intended user are connected via a wireless connection to the central unit 4 . Therefore, a wireless network 6 is provided that is implemented to be in line with either proprietary or open standards. As open standards for wireless networks, the above-mentioned standards that have been mentioned in connection with the interconnection between the host computer 5 and the fitting device—i.e. Bluetooth, WLAN, etc.—can very well be used.
[0075] The central unit 4 is able to establish a wireless connection to the hearing devices 1 to 3 on condition that these hearing devices 1 to 3 are responsive to the wireless network 6 . Depending on the range of the network 6 , further hearing devices might be detected that are not needed for an adjustment process. After the detection of all hearing devices in a specific range of the network 6 , the hearing devices are unambiguously identified. This will be further described by several ways of implementation. By the step of identifying one or more hearing devices, the risk of adjusting a wrong hearing device 1 , 2 , 3 is eliminated. Once the hearing devices are identified, a desired hearing device is selected for the adjustment, and a wireless link can be established between the central unit 4 and the selected hearing device. In a further step, the adjustment can be made by downloading specific parameters and/or hearing programs.
[0076] It is pointed out that the term “detect a hearing device” means the awareness of the system that a hearing device is present, and the term “identify a hearing device” means the unambiguous assignment of a detected hearing device to its physical counterpart. The assignment is thereby not only unambiguous for the system but also for the audiologist carrying out the adjustment of the hearing device. In addition, the term “identify a hearing device” may also mean that further information must be provided to the inventive system in order that an unambiguous assignment can be completed. Such information can be, for example, the indication whether a hearing device will be or is inserted into the ear canal of the left ear of the user, into the ear canal of the right ear of the user, or whether a hearing device will not be inserted at all, for example in cases with detected hearing device which will not be adjusted in the current fitting session.
[0077] The step of identifying a hearing device 1 to 3 can be performed in several ways:
[0078] A first way to identify detected hearing devices is to instruct one hearing device to emit a signal, which preferably is an acoustic signal in the manner of a jingle, for example, which is very easily identifiable. The acoustic signal is generated by a loud speaker, for example the loudspeaker that is integrated into the hearing device and that is often called receiver in the technical field of hearing devices. The instruction for the hearing device to generate the signal is given by the central unit 4 , which is controlled by the audiologist during the fitting session. Once the audiologist perceives the signal, he or she can match or assign the hearing device detected by the system to the hearing device that emitted the signal. The audiologist can instruct one detected hearing device after the other to generate a signal and thereby identify all detected hearing devices, or he can stop instructing further hearing devices to emit a signal as soon as all relevant hearing devices are identified, i.e. as soon as the hearing devices are identified, which will be adjusted during the present fitting session.
[0079] A second way to identify detected hearing devices is based on a so called RFID—(Radio Frequency Identification)—technique. An unambiguous RFID-tag, which is either active or passive, is provided at each or in each of the hearing devices to be identified. By stimulating a passive RFID-tag using a specific radio frequency signal, a response signal being also a radio frequency signal containing the identification code is generated. For active RFID-tags, no stimulation is necessary because an active RFID-tag emits a response signal on its own. The response signal is detected, i.e. the identification code is received by a receiving unit (not shown in FIG. 1 ) incorporated into the central unit 4 . Therewith, the basis for assigning the stimulated hearing device to the corresponding physical hearing device is given.
[0080] In order to prevent any wrong assignment, a RFID-technique can be applied that only allows short range identification of a RFID-tag, i.e. the hearing device carrying the tag to be identified must be brought in close proximity to a RF-transmitter in order to obtain a RF-response signal carrying the identification code. Therewith, different RF-response signal may not be mixed.
[0081] A third way to identify detected hearing devices is to stimulate one of the detected hearing devices, while monitoring the detected hearing devices for a corresponding response to the stimulation in the central unit 4 at the same time. The hearing device, for which a corresponding response has been detected, is determined in the central unit 4 . Based on this information, the stimulated hearing device can be assigned to the determined hearing device, which completes the identification.
[0082] It is pointed out that one or several of the following stimulation can be used to identify the hearing devices according to the third way:
A feedback signal can be provoked in the hearing device. Operating a remote control which acts on the hearing device to be detected. Tapping on the housing of the hearing device to be identified. The tapping is captured by a microphone of the hearing device and the resulting electrical signal is transmitted to the central unit 4 , where it is monitored. Actuating a switch provided on the hearing device. This might well be a program switch which is later used to switch from one hearing program to another. Inserting a battery and thereby initiating first operation sequences might also be used as a stimulation to be monitored. Closing a battery door results in a similar behavior as the one for inserting a battery.
[0089] A fourth way to identify detected hearing devices is to limit the range of the wireless network 6 in such a way that only one hearing device can be detected at the same time. This can be accomplished by causing the central unit 4 to enter a special mode with a rather small wireless range of the network 6 , for example less than 10 cm, and the audiologist places the designated hearing device in close proximity of the central unit 4 or the transceiver contained therein, respectively, or the audiologist places the central unit 4 or the transceiver, respectively, in close proximity of the designated hearing device. The latter is appropriate in case the designated hearing device has already been inserted into the user's ear. This fourth way for identifying a hearing device is unambiguous, easy to implement and also easy to use.
[0090] A fifth way to identify the detected hearing device is by manually comparing the information automatically read out of the hearing device by the central unit 4 and the information indicated on the outside surface of the hearing device housing. The audiologist can read and compare this information to the information automatically read out of the hearing devices, thereby assigning the hearing device with identical information. For example, the serial number of the hearing device is often indicated on the outside surface of the hearing device housing and can therefore very well be used as information for the assignment. Other unique identification of the hearing devices can also be used. The assignment of the corresponding hearing devices is very reliable and technically rather easy to implement.
[0091] FIGS. 2 and 3 show screen shots of a software application controlling the adjustment during a detection and identification process. The screen shots depict a so called window 20 , 30 , as it is well known from Microsoft or Apple Computers, Inc., for example, with three hearing devices detected within the range of the network 6 . The detected hearing devices are listed with its product names (Savia), the type of the hearing device (BTE for Behind-the-Ear), a reference number (e.g. 311 ), and the serial number of the hearing devices (e.g. 123 ). In case that more than three hearing devices are detected, the window 20 , 30 will automatically enlarge to show all detected hearing devices. Alternatively, or in case there is not enough space to show all detected hearing devices, a scroll bar is provided to scroll through the detected hearing devices (not shown in FIGS. 2 and 3 ).
[0092] In FIG. 2 , a window 20 is shown which is particularly suitable for the above-described first way to identify detected hearing devices. The audiologist, to whom the window 20 according to FIG. 2 is presented, can instruct one of the listed hearing devices by pressing a button 21 , which is located to the right side of the row showing the particular hearing device. By pressing this button 21 a signal is emitted in the hearing device listed in this row of window 20 . As has already been pointed out, the signal is preferably an acoustic signal in the manner of a jingle, for example.
[0093] Once a hearing device is identified and selected for adjusting, further information is provided for this hearing device regarding its location, e.g. whether it is used on the left or on the right ear. For easy information input into the central unit 4 , a drop down menu 22 is presented to the audiologist after clicking onto the downward arrow on the same row as the hearing device information is presented (see FIG. 2 ). The drop down menu 22 preferably contains three offered selections: “Left Side”, “Right Side” and “Side not set”. As a default, the selection will be set to “Side not set”, which means that this hearing device will not be used in the subsequent adjustment. The audiologist can now change this default setting to another selection. For a binaural or bilateral hearing system, for which two hearing devices are used, the audiologist has to assign one hearing device to the right ear and another hearing device to the left ear. Once the two hearing device are identified which will be used for the binaural or bilateral hearing device, the corresponding position is indicated for each of the two hearing devices in the drop-down menu 22 as described above. Therewith, the identification is completed and the adjustment of the hearing device can begin after a wireless link has been established from the central unit 4 to the two identified hearing device belonging to the binaural or bilateral hearing system.
[0094] In FIG. 3 , a window 30 is shown which is particularly suitable for the above-described third way to identify detected hearing devices. The audiologist, to whom the window 30 according to FIG. 3 is presented, can stimulate one of the detected hearing devices by one or several of the predefined stimulating actions described in connection with this third way to identify detected hearing devices. The monitoring of a response due to the stimulation is performed by the central unit 4 and the result of this monitoring is presented in the last column 31 of the listed detected hearing devices. As can be seen from FIG. 3 , the second hearing device of the list has been stimulated in this example. This is indicated by the information “Pressed<5 sec” in the last column 31 . Accordingly, the stimulated hearing device is the one with serial number 2222. In case this hearing device is the one or one of the two hearing devices to be used for the subsequent adjustment, the audiologist again selects in the drop-down 33 on the same line as the identified hearing device and assigns the desired position, which again is “Left Side” or “Right Side”. In case of a binaural or bilateral hearing device, the audiologist stimulates—e.g. by pressing volume control or the like—the second hearing device. Again, the result is entered into the last column 31 of the list of detected hearing devices, and, as a last step, the desired side is again selected in the drop-down menu 33 by the audiologist. Therewith, both hearing devices are accurately assigned and the adjustment phase for these hearing devices can be undertaken. The fitting program guides the audiologist through the fitting or adjustment process.
[0095] Although there is no specific example for a window which is presented to the audiologist during the identification phase implemented according to the first, the fourth and the fifth way to identify detected hearing devices, it is pointed out that such windows and its content will be deducible by the skilled artisan given the information above in connection with the second and third way to identify detected hearing devices.
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A method for wirelessly adjusting one or more hearing devices ( 1, . . . , 3 ) with a central unit ( 4 ) is presented, the method comprising the steps of:
establishing a wireless network ( 6 ) wirelessly connecting the central unit ( 4 ) to hearing devices ( 1, . . . , 3 ), which are responsive to said wireless network ( 6 ), detecting said hearing devices ( 1, . . . , 3 ), identifying one or more of the detected hearing devices ( 1, . . . , 3, selecting one or more of the identified hearing devices ( 1, . . . , 3 ), establishing a wireless link from the central unit ( 4 ) to at least one of the identified hearing devices ( 1, . . . , 3 ), and adjusting the at least one identified hearing device ( 1, . . . , 3 ).
Therewith, an audiologist is able to unambiguously assign one or two hearing devices ( 1, . . . , 3 ) in a fitting session, even if multiple hearing devices are within the range of the wireless network ( 6 ) or wireless transmitter, respectively.
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FIELD OF THE INVENTION
The present invention relates to improvements in a refrigerant compressor used, for example, for an air conditioner of a vehicle, such as the cooling apparatus of an automobile.
PRIOR ART
In this type of refrigerant compressor, since refrigerant gas leaks under pressure past the peripheral face of a piston and flows into a rotor chamber to increase the pressure inside the rotor chamber, the leaked refrigerant gas in the rotor chamber flows back to the air inlet side. Lubricating oil inside the rotor chamber is thereby stirred to lubricate each bearing portion, and the lubricating oil flows to the air inlet side with the refrigerant gas and returns to the rotor chamber. However, at the air inlet side, the oil is atomized to form drops or the lubricating oil is in ebullition condition produced by abrupt pressure decrease particularly during starting and the oil is mixed, in large quantities, in the refrigerating machine to reduce the refrigeration efficiency while the lubricating operation in the compressor is reduced due to gradual increase in the temperature of the lubricating oil inside the rotor chamber. Furthermore, the pressure inside the rotor chamber rises due to the leaked compressed refrigerant gas which makes it difficult for the lubricating oil to flow smoothly back to the rotor chamber from the air inlet side. Accordingly, the lubricating oil had to be fed positively to the rotor chamber through a special oil delivery means.
Also, noise is produced through the pulsation phenomena of the refrigerant gas caused by the reciprocating motion of the piston, thus preventing smooth operation of the compressor.
SUMMARY OF THE INVENTION
An object of the invention is to provide a compressor in which the disadvantages associated with the known compressors are overcome.
In accordance with the above and further objects of the invention, there is provided a refrigerant compressor wherein the lubricating oil, which flows to the air inlet side together with the leaked refrigerant gas blown into the rotor chamber past the peripheral face of the piston, is mixed with the incoming refrigerating gas and is sucked into the cylinder from the air inlet chamber, the mixture of compressed refrigerant gas at high pressure and lubricating oil being discharged into an exhaust silencer chamber whereat the refrigerating gas is separated by a separator plate so that only the lubricating oil is introduced into a sump chamber from which the lubricating oil flows back to the rotor chamber through a central bore in the rotor driving shaft automatically by the high pressure prevailing in the sump chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described hereinafter with reference to the drawings.
FIG. 1 is an end view of a cylinder of a compressor with the cover body removed.
FIG. 2 is a cross-sectional view taken along line A--A' in FIG. 1.
FIG. 3 is a cross-sectional view of a cylinder head taken along line B--B' in FIG. 1.
FIG. 4 is a cross-sectional view of the cylinder head taken along line B--B" in FIG. 1.
DETAILED DESCRIPTION
A casing 1 of the compressor has a cylinder block 2 therein at one end and a rotor chamber 3 is formed in the casing at its other end. A cylinder head 4 is secured to one end of the casing 1 and a suction valve 18 and a valve plate 6 are interposed between the cylinder head 4 and the top face of the cylinder block 2. The cylinder head has an air inlet chamber 7 in a central portion on the inner face of the cylinder head and an exhaust chamber 8 around the air inlet chamber. The cylinder head has an air inlet silencer chamber 9 at one lateral side portion at the outer face of the cylinder head. The cylinder head has an exhaust silencer chamber 10 in an upper portion of the other lateral side of the cylinder head and a sump chamber 12 in the lower portion. The chamber 10 is separated from chamber 12 by a separator 11. An orifice 11a is provided in separator 11. A cover body 13 is secured to the outer end of the cylinder head 4. The air inlet silencer chamber 9, the exhaust silencer chamber 10 and the sump chamber 12 are formed between the inner face of the cover body and the outer face of the cylinder head 4.
A nipple 14 serves for inlet of the refrigerant gas, the nipple 14 being at the top end portion of the air inlet silencer chamber 9. The nipple 14 communicates with the air inlet chamber 7 through an air inlet hole 15 in the side wall of head 4, the air inlet silencer chamber 9 and a passage 16 formed in the top wall of head 4. An air inlet port 17 formed in valve plate 6 communicates with the air inlet chamber 7. The air inlet port 17 communicates with a cylinder bore 19 in the cylinder block 2 through an air inlet valve 18. A nipple 20 for discharge of the refrigerant gas is mounted on the top end of the exhaust silencer chamber 10. The nipple 20 communicates with the exhaust chamber 8 through an exhaust hole 21 formed in the side wall of cylinder 4, the exhaust silencer chamber 10 and a multiplicity of orifices 22 formed in the top wall of cylinder 4. The chamber 8 communicates with the cylinder bore 19 through an exhaust valve 23 and an exhaust port 24.
A cover 25 is secured to the other end of the casing 1. The cover supports a rotor driving shaft 27 rotatably through a bearing 26. A rotor body 28 is fixed to shaft 27 inside the rotor chamber 3. An inclined oscillating plate 31 is supported, through a bearing 30, on an inclined flange face 29 of the body 28 and is adapted to oscillatingly move the inclined oscillating plate 31 as the shaft 27 rotates. The inclined oscillating plate 31 is coupled to a piston 33, which is slidably engaged in the cylinder bore 19, by a universal joint 32.
A mechanical seal 34 is provided in the cover body 25 to seal one end of the rotor driving shaft 27. The rotor driving shaft 27 is supported at its other end by the cylinder block 2 through a bearing 35. A central blind bore 36 is drilled in the shaft 27 and communicates with an expansion chamber 38, which is formed in the center of the cylinder head 4, through an orifice 37 provided in the end portion of the cylinder block 2. The expansion chamber 38 communicates with the sump chamber 12 through orifices 39 and 40 in the wall in the cylinder head 4 separating chamber 9 from chamber 10 and 12. Numeral 41 is an axial pressing plate for the rotor body 28. The pressing plate cooperates with a seat plate 42 through the intermediary of a leaf spring 43 and a clamping nut body 44 engaged against the cylinder block 2 to bring the rotor body 28 into pressure contact with the cover body 25 through a bearing 45 whereby the rotor body 28 is prevented from moving axially. The rotor body is brought into pressure contact against the inclined oscillating plate 31 through the intermediary of leaf spring 46, thrust plate 47 and bush 48. The inclined oscillating plate 31 is then rotatably supported through the bush 48 and the bearing 30 with respect to the rotor body 28.
An oil sump 49 is provided at the lower end of the rotor chamber 3. A trunnion block 50 is mounted at the lower end of the inclined oscillating plate 31, and undergoes rocking movement in the sump as the plate 31 oscillates.
A passage 51 is provided between the wall of casing 1 and cylinder block 2 to provide communication between the rotor chamber 3 and the air inlet side, the passage 51 extending longitudinally between the inner peripheral face of the casing 1 and the outer peripheral face of the cylinder block 2 at the upper end of the casing 1.
A hole 52 is provided in the rotor body to establish communication between the central bore 36 in the rotor driving shaft 27 and the inner peripheral face of the bush 48 supporting the inclined oscillating plate 31. A hole 53 is formed in the shaft 27 to establish communication between the central bore 36 in shaft 27 and the bearing 26 for the rotor driving shaft 27 and the mechanical seal 34.
The operation of the compressor is as follows:
The inclined oscillating plate 31 is driven in oscillation through the rotor body 28 by the rotation of the rotor driving shaft 27, and piston 33 undergoes reciprocation through the universal joint 32 as is known. During the retraction (air inlet process) of the piston 33, the refrigerant gas flows through the air inlet hole 15, the air inlet silencer chamber 9 and the passage 16, into the air inlet chamber 7 from the nipple 14 and furthermore pushes the air inlet valve 18 away from the air inlet port 17 to flow into the cylinder bore 19. Then, during the advance (exhaust process) of the piston 33, the gas pushes the exhaust valve 23 away from the exhaust port 24 and the gas is discharged into the exhaust chamber 8. Then, the gas is discharged to the exhaust silencer chamber 10 through the orifices 22 and is fed under pressure through hole 21 and nipple 20 to a refrigerating apparatus (not shown) such as an evaporator, a condenser, or the like.
In this case, some of the refrigerant gas is blown as leakage gas into the rotor chamber 3 through the gap between the piston 33 and the surface of the cylinder bore 19.
Lubricating oil inside the oil sump is stirred by the trunnion block 50. The atomized oil flows, during the retraction stroke (air inlet process) of the piston 33, to the suction valve through the passage 51, together with the leaked refrigerant gas. The mixture of leaked gas and lubricating oil is mixed in atomized condition in the air inlet silencer chamber 9 with fresh incoming refrigerant gas from the nipple 14 and is sucked into the cylinder bore 19 through the air inlet chamber 7. Then, during the advance stroke (exhaust process) of the piston 33, the atomized oil, together with the compressed refrigerant gas, which has been discharged into the exhaust silencer chamber 10 from the exhaust chamber 8 collides against the inner face of the cover body 13 due to inertia force and is separated from the refrigerant gas. The drops of oil fall by gravity and the gas is further separated by the separator 11. The drops of oil flow into the sump chamber 12 through orifice 11a. The sump chamber 12 increases in pressure due to the compressed refrigerant gas. The lubricating oil collected inside the sump chamber 12 flows through orifice 40 and is discharged as a jet into the expansion chamber 38 through orifice 39. At this time, the temperature of the lubricating oil decreases through the sudden expansion of a very small amount of refrigerant gas mixed with the lubricating oil and the cooled lubricating oil passes into the central bore 36 of the rotor driving shaft 27. Some of the cooled lubricating oil flows onto the inner face of the bush 48 via hole 52 to lubricate the bush 48, the bearing 30, etc. Another portion of the cooled lubricating oil flows from the hole 53 to lubricate the bearings 26,45, the mechanical seal 34, etc. Still another portion of the lubricating oil lubricates the bearing 35, the thrust plate 44, etc. by flowing around the outer periphery of the rotor shaft 27 to return to the oil sump 49.
As described hereinabove, according to the present invention, in the compressor which effects a compression operation through the reciprocating movement of the piston under the driving operation of the inclined oscillating plate, the rotor chamber is caused to communicate with the air inlet side of the compressor and with the air inlet chamber through the air inlet silencer chamber provided on the air inlet side, the exhaust chamber communicating with the exhaust silencer chamber, the exhaust silencer chamber communicating with the lower sump chamber through the separator, the lubricating oil inside the sump chamber flowing back to the rotor chamber through the central bore in the rotor driving shaft communicating with the sump chamber through the orifice 39. Accordingly, the lubricating oil which has been mixed with the leaked refrigerant gas and has flowed into the air inlet side is separated, at the exhaust side, from the gas and flows into the sump chamber and then back to the rotor chamber. However, at this time, as the sump chamber is high in pressure due to the compressed refrigerant gas, the lubricating oil will flow back automatically to the rotor chamber without the need for any special oil delivery means. Since the refrigerant gas mixed in the sump chamber cools the lubricating oil due to the sudden expansion caused in the jet discharge through the orifice 39, the lubricating oil inside the oil sump can be normally kept at low temperature to improve the lubricating performance. Sufficient lubricating operation can be effected by a small amount of sealed lubricating oil. Also, since the sump chamber is provided on the exhaust side, the lubricating oil inside the sump chamber has no possibility of assuming an ebullition phenomenon due to abrupt decrease in pressure on the air inlet side during the starting operation. Also, even during a severe low speed operating condition at high exhaust pressures, the pressure of the sump chamber rises with increase in the exhaust pressure, thus resulting in increased delivery in the amount of the lubricating oil. A sufficient lubricating operation is performed, ensuring longer periods of service of the compressor.
In addition, since the small-sized air inlet silencer chamber and exhaust silencer chamber are incorporated respectively on the air inlet side and the exhaust side to prevent noise caused by the pulsation of the compressor, the present invention has various effects in that the apparatus is compact in construction and low in cost without the need for a special silencer.
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A refrigerant compressor for effecting successive compression and exhaust strokes by the reciprocating action of a piston driven by an inclined oscillating plate. A rotor chamber communicates with an air inlet chamber through an air inlet silencer chamber while an exhaust chamber communicates with an outlet via an exhaust silencer chamber. The exhaust silencer chamber communicates with a lower sump chamber through a separator so that lubricating oil can be separated in the exhaust chamber and can flow to the sump chamber wherefrom the lubricating oil can flow back to the rotor chamber through a bore in a rotor drive shaft which communicates with the sump chamber through an orifice.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Application No. 60/027,993, filed on Oct. 9, 1996, the disclosure of which is incorporated by reference herein.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
BACKGROUND OF THE INVENTION
Typical log structures are constructed of logs stacked vertically to form a wall. The lower and upper surfaces of the logs are planed to abut closely against the adjacent logs. Chinking is applied between the horizontal joints of the logs. At the corners, the logs are notched to receive logs from the adjacent wall, with the ends of each log protruding somewhat beyond the notch. Such log structures have an attractive appearance, but are time consuming and expensive to build in the traditional manner. The logs themselves are extremely heavy and frequently require a crane or other large piece of equipment to lift into place. Also, the availability of full size logs has decreased, particularly in light of increased concern for the growth of large trees and the habitat they provide.
BRIEF SUMMARY OF THE INVENTION
The present invention provides a building structure which simulates the appearance of a traditional log structure while incorporating modern wood framing construction techniques. More specifically, the invention provides a number of log heads which form the corner of the structure. Each log head is notched to receive an abutting log head from the adjacent wall to form an interlocking joint. Each log head also abuts against a stud or post to which it is appropriately fastened. A number of different types of log heads are provided by the present invention.
Spaced away from the corners, the structure's walls are framed with studs or posts and top and bottom plates, the placement of which is determined by the dimensions of the walls and the location of features such as windows and doors. Insulation is placed between the studs, and sheathing is placed over the studs on both the inside and the outside of the walls.
Wall boards are affixed to extend horizontally over the inner and outer sheathing with small spaces between vertically adjacent wall boards. The small spaces are filled with a chinking element, which can be a wood strip covered with a suitable surface material to simulate actual chinking.
The joints between the log heads and the wall boards can be angled or mitered or otherwise formed to minimize the appearance of a joint. Screws and nails can be countersunk and disguised with simulated knot holes. In this manner, the log heads and wall boards present the appearance of continuous logs as in a traditional log structure. However, the log heads and wall boards of the present invention weigh considerably less than full size logs. Construction of the structure is thereby simplified and less costly.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1 is an exploded perspective view of a log structure according to the present invention;
FIG. 2 is a further exploded perspective view of the log structure according to the present invention;
FIG. 3 is a perspective view of a male configuration of a log head according to the present invention;
FIG. 4 is a perspective view of a further male configuration of a log head according to the present invention;
FIG. 5 is a perspective view of a female configuration of a log head according to the present invention;
FIG. 6 is a perspective view of a further female configuration of a log head according to the present invention; and
FIG. 7 is a perspective view of a still further female configuration of a log head according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 and 2, the log structure according to the present invention is formed of a number of components comprising log heads 1, exterior wall boards 2, interior wall boards 3, and chinking 5. The log heads form an interlocking joint at the corner of the log structure with log heads from one wall alternating with log heads from the adjacent wall. The exterior and interior wall boards 2,3 encase or surround studs or posts 9, 10, 12, 21 which form the walls of the structure, as in traditional construction. The chinking 5 is provided between vertically adjacent wall boards 2,3.
The log structure is supported on a traditional foundation wall 14 in any suitable manner. However, unlike traditional construction, the present invention does not use a corner post, i.e., a post situated directly over the corner of the wall. Rather, the log heads 1, which form the corner, are attached to starter studs 10, 12 which are spaced inwardly from the corner a suitable distance. If a new building is constructed, the corner post of traditional wood frame construction is merely omitted. If an existing building is remodeled, the existing corner post is removed. As with traditional construction, insulation 16 is placed between the studs, and sheathing 15 is fastened over the studs. The sheathing lies between the studs and the log wall boards.
The log heads are appropriately notched on upper and lower surfaces to form a suitable joint. For example, every other one of the log heads may include a dove tail 7 and alternating log heads may include appropriate notches 8 to receive the dove tails 7. Other joints, such as a half lap joint, can be used. A starter log head 23 at the bottom of the wall is notched on the top surface only. The log heads are fastened to each other in a suitable manner, such as with countersunk screws 4 and glue.
The exterior and interior wall boards 2,3 are fastened to the studs in a suitable manner, such as with countersunk screws and glue. The ends 18 of the interior and exterior wall boards are angled to join to correspondingly angled ends 19 of the log heads and ends 18 other wall boards. A post, such as a 4×4 post 9 or stud, is placed wherever log heads join wall boards, wall boards join adjacent wall boards, or at joints with a window jam or door jam.
The log heads 1 can be formed in a male configuration (FIGS. 3 and 4) or a female configuration (FIGS. 5, 6, and 7) for attachment to the starter studs. In the female configuration (see also FIGS. 1 and 2), the log end includes two opposed interior and exterior wall extensions 25 which surround or encase the starter stud. The length of the extensions is sufficient to attach to the next adjacent stud or post as with countersunk screws 4 and glue. The ends 19 of the wall extensions are angled for joining to the angled ends 18 of the interior and exterior wall boards, as discussed above. The length of the extensions can vary from log head to log head to stagger the joints, if desired.
In the male configuration (shown in FIGS. 3 and 4), the log head includes a extension 27 which butts against the starter stud 12. The log head is angled at a location 26 spaced from the stud to receive ends 18 of interior and exterior wall boards 2,3, which thereby extend past the starter stud 12 and are fastened to the starter stud and log head 1 in any suitable manner, as with countersunk screws and glue. By combining both male and female configurations, a staggering of the joints can be achieved. The male configuration illustrated in FIG. 4 is similar to that in FIG. 3, but includes an outwardly angled cut 31 which is located closer to the notch 8 and allows for minimal joint exposure when viewed. The female configuration illustrated in FIG. 7 is similar to that in FIG. 6, but includes a bi-angle or double dovetail joint 28 which allows this log head to seat and fit properly with the double notched leg head of FIG. 5 and provide a more aesthetic appearance.
The ends 29 of the log heads can be shaped in various ways if desired. For example, they could be square or flat, octagonal, semi round, with rounded corners, or scalloped or hewed.
The chinking 5 is placed between vertically adjacent wall boards 2, 3. The chinking is formed of a wood strip covered with a suitable surface material, such as insulated tin roofing, paint (generally white to best simulate actual chinking), stucco, or a mesh material. The chinking is fastened to the studs in any suitable manner, as with chinking nails 6.
Inlaid knot holes 13 are provided to disguise the joints. For example, a knot hole is placed in the countersunk opening over the screws used to fastened the log heads and boards to the studs. The knot hole may be fastened in any suitable manner, as with glue. The inlaid knot holes add to the realistic appearance of the log structure.
The exterior and interior boards 2,3 can be formed from standard sized 2×12, 2×10, or 2×8 boards. The log heads can be formed from a solid block of wood adapted to these standard sizes. Any suitable wood can be used for the log heads, interior and exterior boards, and chinking. Southern pine is a suitable wood which is also desirable for economical reasons. The exterior wood is preferably treated for exterior use to make it resistant to moisture, mildew, and insects. The use of other materials, preferably materials which simulate the behavior and appearance of wood, can also be used in the present invention.
The log structure of the present invention is advantageous in that it adapts well to remodeling of existing structures. It is readily constructed, since the components are easy to handle without a crane or lift. The heaviest component is approximately 70 pounds, whereas a solid log can weigh between 250 and 500 pounds. Its lighter weight provides for safer construction as well. In addition, the components conserve wood, using from 50 to 60% less wood than in a traditional log structure. The materials used for the log heads and wall boards are readily available throughout the United States and many parts of the world. The log structure is more energy efficient, since the structure can be insulated with state-of-the-art insulation materials.
The invention is not to be limited by what has been particularly shown and described, except as indicated by the appended claims.
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A building structure which simulates the appearance of a traditional log structure while incorporating modern wood framing construction techniques is disclosed. A number of interlocking log heads form the corner of the structure. Each log head abuts against a stud or post displaced a distance from the corner. Wall boards are affixed to extend horizontally over sheathing attached to studs and abut each log head. Small spaces between the wall boards are filled with a chinking element, which may be a wood strip covered with a suitable surface material to simulate actual chinking.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of Provisional 60/993,559 filed Sep. 13, 2007 and applicants co-pending U.S. application Ser. No. 11/282,274 filed Nov. 18, 2005 the entire contents of which is hereby expressly incorporated by reference herein.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not Applicable
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
[0004] Not Applicable
BACKGROUND OF THE INVENTION
[0005] 1. Field of the Invention
[0006] The present invention relates generally to industrial and high bay lighting fixture using one or more inductive light elements. More specifically the invention is designed to replace a high-bay, low-bay warehouse or similar lighting fixture. The invention may include a hanging system that allows the entire assembly to be wired into a new or existing building and supply self ballasting lights, or ballast box and the dome or reflector. This fixture uses one or more high efficiency inductive lighting in similar 2 ft by 2 foot or 2 foot by 4 foot housing. A ballast box is secured to the reflector or dome retainer making the fixture a direct replacement for similar size and shape inductive fixtures.
[0007] 2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 1.98
[0008] Lighting is used to provide light when it is dark or to provide supplemental lighting for a dark area. Often in large buildings, overhead lighting is provided from lights placed near the ceiling of the building and the light is directed downward. Most light bulbs used in these lighting installations are inefficient, and a portion of the energy used in these lights is expended in heat. In the summer, the heat must be cooled with the building air conditioning system. The maintenance cost of these bulbs is also high due to the cost of government imposed lamp disposal fee, the short lifespan and the rapid degradation of 30 to 40% after a year. What is needed is a new lighting fixture that includes the ballast and may further include the dome that can easily be replaced with existing fixtures simply by having a new energy efficient fixture. The ballast is provided with multiple high efficiency fluorescent or inductive lighting bulbs that provide equivalent or superior illumination with improved efficiency and a reduction in the amount of heat that is generated. The invention proposed provides a solution to all the listed requirements.
[0009] U.S. Pat. No. 5,497,048 issued to Burd is for a fluorescent bulb that has multiple fluorescent elements located within the light bulb. This invention provides the equivalent energy efficiency and an equivalent amount of light, but the bulb is a custom light bulb, and the light bulb is not manufactured in high volume. The invention does not provide multiple efficient light bulbs that are cost effective and readily available.
[0010] U.S. Pat. No. 5,541,477 issued to Maya et al. is for a single fluorescent bulb that also has multiple fluorescent bulb elements that are connected into a single screw-in base. This invention provides the equivalent energy efficiency and the equivalent amount of light, but the bulb is a custom light bulb, and the light bulb is not manufactured in high volume. The invention does not provide multiple efficient light bulbs that are cost effective and readily available.
[0011] U.S. Pat. No. 4,664,465 issued to Johnson et al. is for a bulb with a clip attached that allows the bulb to be attached to a metal strip. The patent covers the clip connected to a hollow tube that can extend from a vertical or horizontal surface. This invention uses a single bulb connected to an elongated metal tube or neck. The invention is intended for wiring to an electrical power source. The invention does not include multiple light sockets that connect into a base that can be screwed into a lamp base.
[0012] U.S. Pat. No. 6,964,502 issued to Neal R. Verfuerth on Nov. 15, 2005 discloses a retrofit fluorescent light tube fixture apparatus. While this retrofit apparatus that fits into older fluorescent fixtures it simply replaces one fluorescent lighting fixture with another fluorescent lighting fixture that is prone to the same efficiencies and life expectancy of that it replaces.
[0013] U.S. Pat. No. 7,070,303 issued to Charles E. Kassey et al. on Jul. 4, 2006 discloses a fluorescent lighting fixture with improved up lighting the bulb receiving portion of the fixture is curved so the outer bulbs have a reflector that is not parallel with the ground. While this configuration provide for more up lighting the illumination elements are still fluorescent bulbs.
[0014] The ideal product would be used where high or low bay lighting would be used that might require a ballast or self ballast energy efficient lighting solution for operation. Standard high efficiency light bulbs could be inserted into the multiple sockets to provide equivalent light intensity at a significant reduction in the energy being used. A single or multiple inductive light elements also provides improved illumination with a longer life expectancy of 500%. The integration of the fixture with the dome as one piece further reduces the components and the cost of manufacturing.
BRIEF SUMMARY OF THE INVENTION
[0015] It is an objective of the present invention to provide an energy efficient lighting system that replaces standard 2 foot by 2 foot and 2 foot by 4 foot with similarly sized and shaped inductive lighting fixtures. The fixture may also include a dome or other reflector or fixture design to focus the light downward. A standard 100-watt incandescent bulb uses 100 watts of energy, a fluorescent light (or inductive light) bulb that provides the same amount of light only requires about 20 to 25 watts of energy. Fluorescent light consume 45 to 50% less energy than a standard incandescent light bulb. The light from fluorescent light is similar or superior to the light from an incandescent light, and can be tinted to provide different shades to simulate other lighting sources. The fixture requires the installation onto the rafters or ceiling of the building where it is installed to produce light that is emitted above and below the lighting fixture as well as out the sides of the lighting fixture. A reflector dome or cover located in the lighting fixture helps to focus the lighting down to where the light is needed. An inductive light source provides an improved lighting source 20 to 30% brighter than standard fluorescent bulbs with increased efficiency and 50% longer bulb life.
[0016] A warehouse typically uses 450-465 watt incandescent, halogen or similar light bulb and ballast system. The proposed invention replaces the single 400-watt light bulb with five fluorescent or inductive self ballasting fluorescent lights providing the same or more illumination. The standard warehouse light uses 450-465 watts to produce the light. The five self ballasting fluorescent lights only require 240 to 250 watts of energy. An inductive light source only requires 200 to 220 watts of energy to produce the same amount of illumination, saving 170 to 255 watts of energy that would be spent in heat. A 400 watt metal halide light operates at 1750 degrees of heat, where a fluorescent or inductive lamp operates at 190 to 210 degrees. Inside an air conditioned building the 170 to 255 watts of heat would need to be cooled with the air conditioning system within the building. The savings come from three places, first the more efficient lights, second from air conditioning costs and third, from less maintenance costs. In addition, there can be safety benefits from less ultraviolet rays, and for less chance that the fluorescent bulbs will explode. Inductive lighting provides improved efficiency and savings where a standard warehouse light uses 450-465 watts to produce the light. One to three inductive lights may require as little as 200 watts of energy to produce more light than a standard warehouse light and will provide saving of 250 to 265 watts of energy and 1500 degrees of heat would be spent in heat. Inside an air conditioned building the 1750 degrees of heat would need to be cooled with the air conditioning system within the building. The savings come from three places, first the more efficient lights, and second from air conditioning costs, induction lamps further reduce re-lamping costs by 500%, or mounted separately to 600% reduce, and third the maintenance and government imposed hazardous waste disposal costs.
[0017] When the new lighting fixture is installed into a new or existing building the enclosure for the ballast may be eliminated. The multiple bulbs can be as little as two to as many bulbs that are required to provide equivalent light output and wattage drop for the incoming voltage. If the lighting is 120 VAC or 277 VAC, multiple 120 VAC or 277 VAC fluorescent, 120 VAC, 277 VAC inductive lighting bulbs can be used to achieve equivalent or superior light output. Other light bulbs operating at up to 480 VAC with the capability of being dimmed are contemplated.
[0018] The lighting fixture can be separated from the ballast box and mounted or hung separately where the installation calls for reducing the height by as much as 40%. This allows improved cosmetics, height without compromising the efficiency or operation of the fixture. The components of the fixture are designed to allow the parts to be connected or separated in the field without requiring additional components.
[0019] One problem with placing a torus lighting element within the dome is the shadow that exists from the light of the lighting element blocking the light emitted from the back side of the lighting element. Different light diameters and different dimensions will yield varying reflective angles that will reflect the light from behind the lighting element to the front of the lighting fixture to eliminate the shadow that can be appear under the lighting dome. The internal geometry to minimize or eliminate the shadow. The proposed lighting apparatus minimizes the blocked light by reflecting light around the torus, inductive lighting element.
[0020] One of the most common sizes of lighting is with 2 foot by 4 foot fluorescent lighting. This size lighting is found around the world to illuminate work stations, garages and factories. The proposed inducting lighting application is a simple direct replacement of these lighting fixtures that has a similar size foot print and can directly replace older fluorescent fixtures with a variety of illumination intensities.
[0021] Various objects, features, aspects, and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention, along with the accompanying drawings in which like numerals represent like components.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0022] FIG. 1 is a sectional view of a high bay lighting fixture using inductive lighting elements.
[0023] FIG. 2 is a detailed cross sectional view of the lighting fixture from FIG. 7 showing the retaining tab.
[0024] FIG. 3 is a perspective view of the lighting fixture showing the arrangement of the components.
[0025] FIG. 4 is a view showing the light transmission and reflection rays of the dome and deflector
[0026] FIG. 5 is a sectional view of a 2 foot×2 foot lighting fixture using an inductive lighting element.
[0027] FIG. 6 is a perspective view looking up into the 2 foot×2 foot inductive lighting fixture.
[0028] FIG. 7 is a perspective view looking up into a 2 foot×4 foot inductive lighting fixture with two lighting elements.
[0029] FIG. 8 is a perspective view looking up into a 2 foot×4 foot inductive lighting fixture with three lighting elements.
[0030] FIG. 9 is a perspective view looking up into a 2 foot×4 foot inductive lighting fixture with four lighting elements.
[0031] FIG. 10 is a perspective view looking up into a 2 foot×4 foot inductive lighting fixture with two horse shoe type inductive lighting elements.
[0032] FIG. 11 is a perspective view looking up into a 2 foot×4 foot inductive lighting fixture with four inductive lighting elements where the fixture provides enhanced side lighting.
[0033] FIG. 12 is a perspective view looking down onto the top of a 2 foot×4 foot inductive lighting fixture showing the electrical connections.
[0034] FIG. 13 is a perspective exploded view of a 2 foot×4 foot inductive lighting fixture showing the various components.
[0035] FIG. 14 is a perspective assembled view of a 2 foot×4 foot inductive lighting fixture showing the various components shown looking into the inward formed housing.
[0036] FIG. 15 is a perspective exploded view of a 2 foot×2 foot inductive lighting fixture showing the various components.
[0037] FIG. 16 is a perspective assembled view of a 2 foot×2 foot inductive lighting fixture showing the various components shown looking into the inward formed housing.
[0038] FIG. 17 is a perspective view of the outside of a 2 foot×4 foot inductive lighting fixture shown with up light openings.
[0039] FIG. 18 is a perspective view of the outside of a 2 foot×2 foot inductive lighting fixture shown with up light openings.
DETAILED DESCRIPTION OF THE INVENTION
[0040] FIG. 1 shows a sectional view of a bay lighting fixture using inductive lighting elements 200 . The reflective or focusing dome 10 directs light from the lighting elements 202 and 204 downward so more of the light shines where desired. This figure show two lighting elements of different size, but the size, shape and output illumination of the lighting elements can be the same or different depending upon the desired amount of light that is required. The reflective or focusing dome 10 is attached to the housing with clips or fasteners 230 . The dome rests on the dome retainer 220 , where gravity and the retaining tab 230 lock the dome in place. The shape and configuration of these clips is shown and described in more detail with FIG. 2 below. The dome retainer is connected or integrated with a connecting tube 250 that supports the lighting and dome in addition to providing a conduit for wiring. The connecting tube 250 is attached to the ballast enclosure. In some configurations contemplated, the ballast box may be empty, when the ballast is included with the lighting elements. The ballast 240 is shown housed in the ballast box 210 . One configuration of electrical connection to the ballast is with screw terminals 245 , but the wiring connection(s) could be made with wire nuts or spring clips where the wires are pushed into the terminals and retained by spring force that both retain the wires and provide electrical connection between the ballast and the external wiring. An electrical connection from the ballast extends through connecting tube 250 , into the dome retainer 220 for connection with the lighting elements 202 , 204 or lighting socket for the lighting elements. Locking bars 270 and 275 hold the inductive lighting elements in place within the dome and on the lower cover 260 that is capped with an extender 262 , and an extender cap 264 . The extender allows the placement and retention of the additional lighting element 204 that holds locking bar 275 .
[0041] A lower cover 260 encloses the lower portion of the housing to protect the electrical wiring. The ballast box 210 , dome retainer 220 , and the lower cover 260 can be fabricated using a number of different methods including but not limited to casting, machining, drawing, forming or molding. In the preferred embodiment the part are made from an injection molded process. The materials for these components can also be variety of types including but not limited to plastics, resins, ceramic, ferrous and non-ferrous materials, with the qualities of strength, heat resistance. A safety locking mechanism 285 is installed on the end of retaining cable 280 to hold the light fixture in position. While in this figure the retaining mechanism 285 is shown extended from the cable 280 , upon installation the safety device is secured against the bottom of the lighting fixture.
[0042] FIG. 2 is a detailed cross-sectional view of the lighting fixture from FIG. 1 showing the retaining tab 230 . The reflective or focusing dome 10 is shown resting upon a portion of the dome retainer 220 . For installation, the dome is brought over the dome retainer 220 , the retaining tabs 230 will flex inward from the hinge area 234 allowing the dome 10 to pass by the clip, and then spring back into position locking the dome 10 under the tab at point 232 . Once the dome is in position, gravity, in addition to the clips 230 will keep the dome resting on the dome retainer at location 236 and all around the dome retainer. The lower housing 260 is shown in position under the dome retainer protecting the wiring connections. Vent 29 is shown in this view as it passes through the dome retainer. The vents are a critical part of the design because they allow heat from the room and from the lights to vent out of the fixture.
[0043] FIG. 3 is a perspective view of the lighting fixture showing the arrangement of the components. A retaining cable 280 passes through the entire lighting fixture and is secured with a safety line 285 located at the end of the cable. The top portion of the cable 280 is attached to a hook 290 that can be secured to the ceiling or joists of a building. The bottom portion 297 of the hanging hook 290 is secured to the ballast box with a nut 292 that is threaded onto the end of the hook at 297 from inside the ballast box. In an alternate mounting embodiment the hook 294 is connected to the top of the dome retainer 220 . The dome 10 is shown below the dome retainer 220 . A seams 221 , 223 , 227 are shown in this figure. The seam allows the dome retainer to be fabricated in multiple sections that can be connected. In the embodiment shown, the dome retainer is made from four pieces. In another contemplated embodiment, the dome retainer and at least a portion of the ballast box is made from a single component. The enclosure for a ballast is shown located above the lighting fixture with a top housing 212 , of the ballast box 210 and an access cover 217 . In this embodiment the top and bottom housings are connected with a hinged arrangement with a closure. In yet another contemplated embodiment, the ballast box dome retainer and connecting pipe are made in two halves. This view shows the dome retainer essentially as a dish shape but other similar shapes can be used. The lower cover 260 is shown under the dome and it is attached to the dome retainer. The design of the lower cover is critical to the transmission of light around the lighting element(s). A description of the design requirement to reflect light around the lighting elements is shown and described with FIG. 4 . The extender 262 is shown below the lower cover and attaches to the lower cover. The extender cap 264 is shown below the extender and closes the opening in the bottom of the extender 262 .
[0044] The disk shape is ideal because it allows for any heat to be channeled up through the lighting fixture. Vents 29 are shown around the dome retainer. In the embodiment shown the vents are essentially rectangular in shape, but other shapes are contemplated to include but not be limited to rectangular, circular, elliptical vents or combination thereof.
[0045] FIG. 4 is an isometric view of a one piece light dome 10 with a separate ballast box 210 . In this embodiment the dome is cast from a clear, multi-colored, translucent, or opaque material and is then internally coated or painted with an aluminum or chrome to provide a reflective surface. The dome is made from a polycarbonate abs or other similar material as opposed to being cast or spun out of aluminum or other metal. The ballast box 210 is shown mounted separately from the lighting dome, and prototypes have been made with a separation of 15 feet between the ballast and the lighting elements. The wiring from the buildings electrical system 6 enters into the ballast box 210 and, after the voltage is converted, a separate set of wiring 5 connects to the lighting fixture 10 . This entire lighting system is attached to the ceiling or joist 28 of the building from hooks 35 , chain 40 and or hooks integrated into the lighting or ballast enclosure 290 .
[0046] FIG. 5 is a sectional view of a 2 foot×2 foot lighting fixture 200 using an inductive lighting element. While the majority of fluorescent fixtures are configured in a 2 foot by four foot configuration a number of fluorescent fixtures is 2 foot by 2 foot in size. In this embodiment the reflector is a bent reflector 100 is formed from sheet metal. The inside surface of this reflector is preferably painted white or other similar reflective color or a silver color to reflect the light. The inductive lighting element 202 is attached to the bent reflector with clips or fasteners. It is also contemplated that the lighting fixture is clamped through the bent reflector 100 using the cover and the ballast box.
[0047] The connecting tube 250 is attached to the ballast enclosure. In some configurations contemplated, the ballast box may be empty, when the ballast is included with the lighting elements. The ballast 240 is shown housed in the ballast box 210 . One configuration of electrical connection to the ballast is with screw terminals 245 , but the wiring connection(s) could be made with wire nuts or spring clips where the wires are pushed into the terminals and retained by spring force that both retain the wires and provide electrical connection between the ballast and the external wiring. An electrical connection from the ballast extends through connecting tube 250 , into the dome retainer 220 for connection with the lighting elements 202 or lighting socket for the lighting elements. Locking bars 270 hold the inductive lighting elements in place within the dome and on the lower cover 260 that is capped with an extender 262 .
[0048] A lower cover 260 encloses the lower portion of the housing to protect the electrical wiring. The materials for these components can also be variety of types including but not limited to plastics, resins, ceramic, ferrous and non-ferrous materials, with the qualities of strength, heat resistance. A safety locking mechanism 285 is installed on the end of retaining cable 280 to hold the light fixture in position. While in this figure the retaining mechanism 285 is shown extended from the cable 280 , upon installation the safety device is secured against the bottom of the lighting fixture.
[0049] FIG. 6 is a perspective view looking up into the 2 foot×2 foot inductive lighting fixture. The fixture is constructed with a bent metal reflector 100 . While a bent metal reflector is shown and described, because it is the most common and cost effective, other materials are contemplated including but not limited to glass, paper and plastics. The sides of the reflector 100 are bent to ensure more of the light shines downward. Inside the reflector the top of the fixture has an inside bend 110 to spread the light from the top of the inductive lighting element 202 . This figure shows the electromagnet(s) 160 that encircle a portion of the illumination torus. The end of the extender 262 can be seen extending through the inductive lighting element 202 . Locking bar(s) 270 hold the inductive lightning element 202 in the fixture and provide some protection from vibration and shock.
[0050] FIG'S. 7 - 9 are perspective views looking up into a 2 foot×4 foot lighting fixture with two, three and four elliptical lighting elements. While a 2 foot×4 foot is described other sizes are contemplated as previously described or needed based upon the design requirement including longer, wider or narrower designs. This is the most common size fluorescent lamp and this application provides for a variety of different inductive lamp configurations and lighting intensities in the same footprint. The inductive lights can be the same intensity or different intensities depending upon the desired amount of light. The fixture is constructed with a bent metal reflector 100 . While a bent metal reflector is shown and described, because it is the most common and cost effective, other materials are contemplated including but not limited to glass, paper and plastics. The sides of the reflector 100 are bent to ensure more of the light shines downward. While only one bend angle is shown in the figures other bend angles are contemplated that optimize the light for a particular installation. Inside the reflector the top of the fixture has an inside bend 110 to spread the light from the top of the elliptical lighting element 140 . This figure shows the electromagnet(s) 160 that encircle a portion of the elliptical lighting element 140 . A portion of the ballast 170 is shown mounted to the top of the bent reflector 100 . In the embodiments shown one ballast is used with each inductive lamp, but it is contemplated that a single ballast can operate multiple lamps.
[0051] FIG. 10 is a perspective view looking up into a 2 foot×4 foot lighting fixture with two horse shoe type inductive lighting elements 150 . These inductive illumination elements 150 are shaped like a horse shoe and have the electromagnet 160 located in the middle of the horse shoe. The bent reflector 100 is a similar construction as shown and described in FIGS. 7-9 where with an inside bend 110 for reflecting light from the underside of the inductive lighting elements 150 . A portion of the ballast 170 is shown mounted to the top of the bent reflector 100 . In the embodiments shown one ballast is used with each inductive lamp, but it is contemplated that a single ballast can operate multiple lamps.
[0052] FIG. 11 is a perspective view looking up into a 2 foot×4 foot lighting fixture with four lighting elements where the fixture provides enhanced side lighting. The outside dimensions of the bent reflector 100 are similar to the size described in FIGS. 7-10 but because the outside of the fixture is bent up 120 the light can spread upward while the majority of the light is reflected downward. The bottom of the reflector 130 is shown as an essentially flat surface, but other embodiments are contemplated wither the bottom reflector 130 is corrugated, bent or has a lamp conforming configuration. Four elliptical lighting element(s) 140 are shown in this figure but it is contemplated that as few as one to more than four can be used based upon the amount of light that is required. This figure shows the electromagnet(s) 160 that encircle a portion of the elliptical lighting element 140 .
[0053] FIG. 12 is a perspective view looking down onto the top of a 2 foot×4 foot inductive lighting fixture showing the electrical connections. All of the lighting fixtures require some form of electrical connection the incoming power 6 . In the embodiment shown a junction box 180 exists across the top of the bent reflector 100 . The fixture has two inductive lamps (not shown) and two ballasts 170 are shown mounted to the top of the bent reflector 100 . Conduit 181 connects the ballasts to the junction box 180 and each of the inductive lamps. This figure shows chains 40 for connecting the fixture to a ceiling or joists. While chain is shown in this figure other connection methods are contemplated including but not limited to pipe, cable, rods T-bar or drop ceiling connections.
[0054] FIG. 13 is a perspective exploded view of a 2 foot×4 foot inductive lighting fixture showing the various components and FIG. 14 is a perspective assembled view of a 2 foot×4 foot inductive lighting fixture showing the various components shown looking into the inward formed housing. FIG. 15 is a perspective exploded view of a 2 foot×2 foot inductive lighting fixture showing the various components and FIG. 16 is a perspective assembled view of a 2 foot×2 foot inductive lighting fixture showing the various components shown looking into the inward formed housing. These four figures show an inductive two foot by two foot lighting fixture and a two foot by four foot inductive lighting fixture. The housing is an inward formed housing 125 having an essentially square or rectangular outer periphery formed as a new or replacement fixture where a fluorescent lighting would be used. In the preferred embodiment the fixture housing and various other components are formed from sheet metal.
[0055] The inward formed housing 125 has a reflector 105 formed from two separate halves secured within the inward formed housing 125 . The reflector(s) are bent 110 at an angle of between 13 and 15 degrees to focus the majority of the illumination downward and out of the housing 125 . A ballast cover 115 is mounted on the inward formed housing 125 . At least one ballast 210 is secured between the ballast cover 115 and the inward formed housing 125 . In one preferred embodiment the ballast 210 is located between the reflector 115 and the inward formed housing 125 . In another preferred embodiment the ballast cover 115 or covers and the ballast or ballasts is located on an outer surface of the inward formed housing 125 . The ballast(s) 210 is secured with screws or other similar fasteners such as but not limited to clips or springs 214 . The ballast cover 115 is secured with screws or other similar fasteners such as but not limited to clips or springs 118 . The inductive lighting lamp(s) 140 or 145 is electrically connected to the ballast(s) 210 and mechanically secured 142 to the reflector(s) 105 such that when sufficient electrical power is applied to the ballast(s) 210 , the ballast(s) 210 will provide electrical power to the inductive lamp(s) 140 or 145 to provide illumination.
[0056] One ballast can be used to operate more than one inductive lighting lamp, but in the embodiment where more than one ballast and more than one inductive lighting lamp is used, each ballast and each associated inductive lighting lamp is separately controllable for illumination intensity to reduce power consumption. Inductive lamps are individually or collectively controllable to vary the illumination intensity from each inductive lamp using a dimmer.
[0057] FIG. 17 is a perspective view of the outside of a 2 foot×4 foot inductive lighting fixture shown with up light openings 126 and FIG. 18 is a perspective view of the outside of a 2 foot×2 foot inductive lighting fixture shown with up light openings 126 . These figures also show hanging loops 128 for securing the fixtures by chain, drop ceiling or other similar methods. These outside views of the inductive lighting fixture 125 shows at least one opening 126 in the inward formed housing 125 as a means for the function of providing side and or up lighting from the fixture. In FIG. 18 a portion of the circular inductive lighting element 145 is visible. Various hanging methods and apparatus are contemplated to secure the fixture to a ceiling. These methods include but are not limited to hooks 128 , tabs, flanges or eye holes to hang the fixture or suspend the fixture in a drop or suspended manner.
[0058] Thus, specific embodiments and applications of a lighting and replacement light fixture have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims.
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A lighting fixture where the lighting fixture uses inductive lighting technology or self ballasting lighting elements with one or a plethora of efficient light elements. The lighting fixture is used where high bay or low bay lighting may be used, but incorporates multiple light sources to provide an equivalent light intensity. The invention may include a hanging system that allows the entire assembly to be wired into a new or existing building and supply self ballasting lights, or ballast box and the dome or reflector. This fixture uses one or more high efficiency inductive lighting in similar 2 ft by 2 foot or 2 foot by 4 foot housing. A ballast box is secured to the reflector or dome retainer making the fixture a direct replacement for similar size and shape inductive fixtures.
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FIELD OF THE INVENTION
The present invention relates to a clip for securing workpieces to a bath bar in electrolytic processes and more particularly to such a clip adapted for use in anodizing baths together with a method for forming the clip and a method for using the clip.
BACKGROUND OF THE INVENTION
A number of different constructions of clips or the like for securing workpieces in place upon bath bars or other frameworks have been disclosed in the prior art.
Generally, anodizing operations are similar to other electrolytic processes in that workpieces or parts to be anodized or electrolytically treated, must be secured and suspended in various corrosive baths. For example, in conventional anodizing operations, the workpieces are first suspended in a caustic bath for cleaning their surfaces and conditioning them for the anodizing operation. The workpieces are then suspended in an acid tank employed for anodizing. In the acid tank, electrolytic conditions are developed within the bath commonly by employing the walls of the tank as a cathode and an overhead I-beam for coupling the workpiece as an anode. A framework including bath bars extending downwardly into the tank are connected to the overhead beam and are adapted for supporting the workpieces. The workpieces must of course be in conductive engagement with the overhead beam through the bath bars in order for the process to be carried out.
With the above arrangement and with the workpiece for example being aluminum, a current is then caused to pass through the bath for converting the surface of the workpieces to an aluminum oxide coating. The current employed per square foot of workpiece surface area, the time for the process and selection of coloring agents, etc., are of course well known in the electrolytic art.
In any event, the acid tank employed for the anodizing operation is particularly corrosive to all parts of the supporting framework that are suspended within the bath. These parts of course include any means for securing the workpieces to the bath bars.
In the prior art, it was common to employ C-clamps which were conventionally used for clamping the work pieces against the bath bar and thus suspending them within the bath. Although these clamps worked satisfactorily for the purpose, they were found to be very time consuming.
Other clamping arrangements are disclosed for example in U.S. Pat. No. 3,108,058 issued Oct. 22, 1963 to Mines et al and U.S. Pat. No. 3,013,959 issued to Ventre on Dec. 19, 1961.
In the first noted patent, a relatively complex resilient rocker assembly was employed to form a clamp for mounting workpieces on a bath bar and assuring conductive engagement of the workpieces with the bath bars.
The second patent noted above disclosed the use of angled members formed on the bath bars with wedging members being resiliently urged toward the angled members in order to secure workpieces against the bath bar.
Both of these references provided certain improvements over by both of these patents also exhibited certain shortcomings. For example, they were either secured by bolts to the bath bars or included elements on the bath bars so that they could only function in one position. In addition, the clamping mechanisms provided by both of these patents were also relatively complex, requiring substantial time either for installation or mounting of the workpieces. At the same time, since both combinations included parts which were subject to corrosion within the bath, they also exhibited a relatively limited operating life.
In any event, there has been found to remain a need for an improved clamp or device for securing workpieces to a bath bar in anodizing or other electrolytic operations.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide an improved clip suitable for use in applications such as those outlined above while overcoming numerous problems of the type also described above.
It is more particularly an object of the invention to provide such a clip having an elongated body with first and second engagement means formed at each end thereof, the clip being urged against a bath bar by a resilient band wrapped around the bar for causing the clip body to maintain one or more workpieces in conductive engagement with the bath bar.
It is a further related object of the invention to provide such a clip wherein the first and second engagement means project outwardly relative to a central portion of the clip body so that each of the first and second engagement means is capable of being withdrawn from engagement with the bar for receiving a workpiece therebetween, interaction of the resilient band between the clip and bar thereafter urging the workpiece into conductive engagement with the bar.
Preferably, the clip is formed with a plurality of tapered teeth forming each of the first and second engagement means, the means formed centrally on the body for engagement with the flexible band comprising a transverse bore adapted for receiving a bolt and nut for engagement with opposite ends of the resilient band.
It is further preferred that the clip be relatively massive in order to resist corrosion in the bath. At the same time, it is also preferred that the clip have a uniform cross-sectional configuration adapting it for formation by extrusion. For this purpose, the bore formed at the center of the clip body is formed by an open slot along one surface of the body. In this manner, the bore can be formed by extrusion along with other features of the clip body. Thereafter, it is contemplated that an extruded member having a cross-sectional configuration as described above may be simply cut or sliced transversely into sections, the sections forming respective clips according to the present invention.
A clip constructed in accordance with the present invention has a number of important advantages. Initially, the clip is of particularly simple design having only an integral clip body together with the resilient band and means for securing the band to the clip body. It has also been found that the clip of the present invention has a surprisingly long life, particularly within the harsh environment of the electrolytic or anodizing baths. For example, it has been found that the clip of the present invention may be used in as many as one hundred cycles or anodizing operations contrasted with the five to ten cycles noted above for the prior art. In addition, the clip of the present invention is self-adjusting because of the resilient band in that workpieces of widely varying thicknesses may be secured by the clip. For example, one size of clip contemplated within the invention may be employed with workpieces as thin as one eighth inch for example and as thick as two and one half to three inches for example. At the same time, the clip is extremely versatile in that it may be positioned anywhere along the length of the bath bar and may be used for securing workpieces under both ends of the clip. Furthermore, each clip can be used for securing workpieces of widely varying thicknesses under its opposite ends.
Further related objects of the invention include a method for forming such a clip by extrusion and a method for using the clip in accordance with the advantages set forth above.
Additional objects and advantages of the invention will be apparent from the following description and drawings which are provided only by way of example and are not intended to limit the scope of the invention.
A BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial schematic side view in elevation of an anodizing tank wherein the clip of the present invention is employed.
FIG. 2 is a side view in elevation of the clip of the present invention, a bath bar and a resilient band adapted for engaging the clip with the bath bar being shown in phantom.
FIG. 3 is a view taken from the left side of FIG. 2 with the bath bar, the resilient band and means for securing the band to the clip also being shown in phantom.
FIG. 4 is a view of a single extruded member having a cross-sectional configuration corresponding to the clip of the present invention and illustrating the manner in which a plurality of clips may be formed from the single extruded member by simple transverse cuts.
FIG. 5 is a side view of a clip mounted on one bath bar.
FIG. 6 is a cross-sectional view taken along section line 6--6 of FIG. 5.
FIGS. 7 and 8 together with FIG. 5 illustrate in sequence the manner in which the clip of the present invention may be employed to secure a workpiece under one end thereof and optionally a second workpiece under the other end of the clip.
FIG. 9 illustrates a tool novelly adapted for use with the clip of the present invention to force its opposite ends away from the bath bar for receiving a workpiece therebetween.
FIG. 10 illustrates another embodiment of the clip of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and particularly to FIG. 1, the present invention relates to a clip for securing workpieces to be anodized or otherwise electrolytically processed in an anodizing assembly of the type generally indicated at 11 in FIG. 1. Multiple clips constructed and employed within the assembly 11 and in accordance with the present invention are both generally indicated at 12. Although anodizing processes employing acid tank baths of the type indicated at 11 in FIG. 1 are well known in the art, the system is briefly described below in order to assure an understanding of the present invention.
In the processing system 11 of FIG. 1, a suitable acid for carrying out an anodizing operation is indicated at 14 in a tank 16 in further accordance with the prior art, an overhead I-beam 18 and the walls of the tank 16 itself form opposing electrodes for carrying out the electrolytic anodizing process and are accordingly interconnected by a source 20 of electrical potential.
Further details of the electrolytic assembly and parameters for its operation are not believed necessary herein since they are well known in the prior art. In any event, the overhead beam 18 includes a conductive framework comprising bath bars 22 extending downwardly from the overhead beam 18 into the acid bath 14.
Workpieces of different configurations such as the extruded bar 24 and the flat sheet 26 are suspended within the acid bath 14 in conductive contact with the overhead beam 18 through the bath bars 22. The processing assembly ten is thus adapted for anodizing or otherwise electrolytically processing the workpieces 24 and 26 by imposing a suitable electrical potential between the overhead beam 18 and the tank 16 for causing a current to flow through the acid bath 14 between the tank 16 and the workpieces 24 and 26 since they are conductively engaged with the bath bars 22 and the overhead beam 18.
The clip 12 of the present invention is described in greater detail below followed by a description of a preferred method for forming the clip and a novel method of using the clip within the anodizing assembly 11.
Turning now to FIGS. 2 and 3 together with FIGS. 5 and 6, the clip 12 of the present invention comprises a unitary elongated body 28 having engagement means or teeth 30 and 32 respectively formed at opposite ends 34 and 36 of the elongated body 28. The engagement teeth 30 and 32 are arranged on one side of the body so that they can both be positioned against one of the bath bars 22.
As may be best seen in FIGS. 2 and 5, the engagement means 30 and 32 are formed as tapered sets of teeth with outer teeth 38 and 40 in the respective engagement means 30 and 32 projecting outwardly the furtherest from the elongated body 28 so that they always tend to be in engagement with the bar 22 or with a workpiece as described in greater detail below.
Attachment means 42 are arranged at a central portion of the elongated body 28 for connection with a resilient flexible band 44 adapted to be engaged with the clip body 28 and wrapped around the bath bar 22 for holding the clip in place relative to the bar 22 and for urging the engagement teeth 30 and 32 against the bar 22.
Preferably, the resilient band 44 is formed as an elongated member having slits 46 cut into each end thereof. At the same time, the attachment means 42 preferably comprises a nut and bolt assembly 48 and 50 adapted to penetrate a bore 52 formed transversely in the body 28. The bolt 50 also penetrates the slits 46 in the opposite end of the band 44 so that the band is held in place relative to the bar 22 and the clip body 28 as illustrated in the above noted figures.
All portions of the clip 12 together with the nut and bolt combination 48, 50 and the resilient band 44 are immersed in the acid bath 14 and accordingly must be capable of withstanding that harsh environment. For that purpose, the clip body 28 is preferably formed from a similar metal as the bath bars 22 or a plastic such as polypropylene. In the assembly 11 of FIG. 1, both the bath bars 22 and the clip bodies 12 are preferably formed from conventionally known aluminum alloys. The nut 48 and bolt 50 are preferably formed from nylon for the same reason while the resilient band 44 is formed from a rubber selected for maintaining its resiliency under both the corrosive conditions of the bath 14 and relatively high temperatures often developed therein. The resilient band 44 is also formed of a predetermined length so that when it is wrapped around the bath bar 22 as illustrated in the above noted figures, it applied substantial force in tension to the clip body 28.
Because of the notch effect formed in the clip body 12 by the bore 52, an opposite portion of the elongated body is formed as a protruding or rounded reinforcement area 54 providing generally constant cross-sectional mass along the length of the body 28. The rounded reinforcement area 54 is preferably formed with a radius as best seen in FIG. 2 so that it falls approximately in line with the inner teeth 56 and 58 respectively of the engagement means 30 and 32.
The clip body 28 is also formed with notches 60 and 62 between the rounded reinforcement area 54 and the inner teeth 56 and 58 respectively. The notches 60 and 62 are formed generally on opposite ends of the elongated body 28 in order to adapt the body 28 for use with a tool 64 described in greater detail below and shown in FIG. 9. As will be described in greater detail below, the tool 64 of FIG. 9 is employed for pulling either or both ends of the clip body 28 away from the bar 22 for inserting workpieces therebetween.
In accordance with the preceding description, the various means formed on the clip body 28 are arranged on exposed surfaces of the body. At the same time, an elongated member 68 is illustrated having a cross-sectional configuration corresponding to that described above for the clip body 28. Because of the design of the clip body 28 and particularly because of the slot 66 in communication with the bore 52, the entire clip body 28 can be formed by extrusion. Accordingly, after the elongated member 68 is formed by extrusion, it is cut or sliced as indicated in numerous positions at 70 to form a plurality of sections or individual clip bodies in accordance with the present invention. At the same time, the transverse dimension of the sections or clip bodies may readily be adjusted simply by repositioning the cuts in the elongated member 68. Also, through the formation of the clip body 28 in this manner, it is formed as a relatively massive structure better adapted for resisting corrosion within an acid bath such as that indicated at 14 in FIG. 1.
The manner in which the clip 12 of the present invention is used in conjunction with the nut and bolt 48, 50 and the resilient band 44 is believed obvious from the preceding description. However, its method of use is described in greater detail below particularly to demonstrate the manner of use for the tool 64 and to assure a complete understanding of the invention.
Referring now to FIGS. 5-8, the clip body 28 is initially positioned adjacent one of the bath bars 22 and held in that position by the resilient band 44. Thus, the position of the clip 12 on the bath bar can be readily adjusted and any number of clips can be positioned along each of the bath bars.
In order to employ the clip 12 for positioning a workpiece on the bath bar, one end of the clip body 28 is engaged by the tool 64, for example as illustrated in FIG. 7. Referring to FIG. 7, a notch 72 is formed in the tool 64 to conform to the cross-sectional configuration of the clip body 28 adjacent either of the notches 60 and 62. Referring again to FIG. 7, the tool 64 is thus engaged for example with the notch 60. The tool 64 is then forced downwardly as indicated by the arrow 74 to provide leverage force on the elongated body 28 for urging its upper end 34 and especially the outer tooth 38 away from the bar 22.
With the clip body 28 maintained in this position, one workpiece, for example that also indicated at 24 in FIG. 1 can readily be inserted between the bath bar 22 and the engagement means 30 including the outer tooth 38 on the upper end 34 of the clip body 28. With the clip body 28 then being released by the tool 64, the engagement means 30 and particularly the outer tooth 38 is forced against the workpiece 24 by the resilient band 44 in order to maintain the workpiece 24 in position and in conductive engagement with the bath bar 22.
Thereafter, a second workpiece corresponding for example with that illustrated at 26 in FIG. 1 may then be held in place on the bath bar 22 by the other end of the same clip 12. For that purpose, the tool 64 is then similarly engaged in the notch 62 toward the other end 36 of the clip body 28. With upward force then being applied to the tool 64 as illustrated by the arrow 76, the lower end 36 of the body 28 and particularly the outer tooth 40 is forced away from the bar 22 in order to permit the workpiece 26 to be inserted therebetween. With the workpiece 26 in that position, the clip body 28 is again released by the tool 64 so that the resilient strap 44 applies force through both ends of the clip body 28 for positioning both of the workpieces 24 and 26 while maintaining them in conductive engagement with the bath bar 22. At the same time, it may be best seen in Figure 8 that the clip 12 is adapted for securing workpieces of substantially different dimension upon the bath bar 22. In addition to the substantial differences in thicknesses illustrated for the workpieces 24 and 26, they may also be of widely varying configurations for example if desired.
Another embodiment of a clip constructed according to the invention is illustrated at 12' in FIG. 10. Elements of the clip 12' in FIG. 10 corresponding to similar elements of the clip 12 in FIGS. 2-8 are indicated with similar primed numerical labels.
The clip 12' of FIG. 10 has a slightly different shape body 28'. In particular, the outer teeth 38' and 40' are relatively large with the remaining teeth tapering in size as well as position. These changes in the clip 12' are believed to provide for an even longer operating life because of the larger outer teeth 38' and 40' and the increased transverse distance between the teeth 38' and 40' and the bolt 50.
Accordingly, there has been described above a novel clip for use in anodizing or other electrolytic processing baths together with a novel method of forming the clip body by extrusion and a novel method for use of the clip in such an electrolytic bath assembly. Numerous modifications are believed apparent in addition to those indicated above. Accordingly, the scope of the present invention is defined only by the following appended claims.
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A clip is disclosed of a type for securing workpieces to a bar forming part of a framework for suspending the workpieces in a bath suitable for anodizing or other electrolytic treatment of the workpieces. The clip has an elongated body with tapered engagement teeth at both ends thereof for arrangement adjacent the bath bar. A central portion of the clip body is adapted for engagement with a flexible band which is wrapped around the bar for resiliently urging the clip against the bar. In use, either end of the clip may be moved away from the bar, preferably by using a tool fitting into slots on the clip body for positioning a workpiece between either end of the clip and the bar. The clip is of a uniform cross-sectional configuration adapted for extrusion whereby a plurality of the clips may be formed by transversely cutting an extruded member conforming with the cross-section of the clip.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an optical analysis system, particularly but not exclusively suited to automated analysis of large numbers of samples, and further, to a positioning apparatus for the samples of such a system.
2. Description of the Related Art
For many clinical, forensic or other applications, it is required to perform fluorescence/polarization (FPIA) or other optical analyses on large quantities of samples, which may individually be very small "microspots".
The microspots may be typically a few tens of micrometres in diameter, and may need to be aligned with a fluorescent probe, and focussed to similar tolerances. While it is feasible to align and bring into focus a small number of samples manually, (e.g. using an adjustable stage viewed through a microscope) there is a need for a rapid method of achieving this automatically.
SUMMARY OF THE INVENTION
One object of the present invention is to provide an optical analysis system and positioning apparatus which facilitates such multiple sample analysis.
According to the present invention positioning apparatus for indexing a stage to align selectively a plurality of locations on the substrate with a focus of optical test or processing means, comprises a mounting arrangement for the substrate permitting at least two degrees of freedom of the substrate in its own plane, the substrate having on its surface an optical location, orientation and focusing pattern with at least part of which the locations have a predetermined spatial relationship, the mounting arrangement further permitting movement of the substrate in a direction transverse to its own plane, the positioning apparatus further including means so arranged in relation to the optical test or processing means as to have a common focus with the test or processing means, the imaging means having image storage means for storing at least part of an image of the location, orientation and focusing pattern and focus assessment means for assessing the position relative to the common focus of at least part of the location, orientation and focusing pattern, the apparatus further comprising control means for controlling the mounting arrangement in response to the relative disposition of live and stored images of the substrate and in response to the focus assessment means.
The imaging means preferably includes a digital data processor responsive to the disposition of a live image of the optical pattern to control the mounting arrangement to move the substrate to a position in which a selected location lies at the common focus.
The optical pattern may comprise a location and orientation reference pattern and a separate focusing pattern.
The processor may control the mounting arrangement to index the substrate through the locations successively.
The processor is preferably responsive to the imaging means to control the mounting arrangement to maximise the contrast between different parts of the image of the focusing pattern.
The optical reference pattern may identify both position and orientation on the substrate.
According to a feature of the invention, an optical analysis system may comprise positioning apparatus as aforesaid, the substrate being adapted to carry test samples at each of the locations.
BRIEF DESCRIPTION OF THE DRAWINGS
One embodiment of an optical analysis system and positioning apparatus for such a system will now be described, by way of example only, with reference to the accompanying drawings, of which:
FIG. 1 is a diagram of the overall system; and
FIGS. 2 and 3 are plan views of alternative sample carrying substrates.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a substrate 1 is carried by a mounting arrangement 3. The substrate 1 will be described subsequently but basically consists of a disc, plate or platform on which, in one application, samples for analysis are deposited. It will become clear that the nature and thickness of the substrate are not relevant to the invention and the term "substrate" is to be interpreted in this broad sense. In other applications the substrate 1 might be a platform having a plurality of point locations at each of which some process was required.
In the present case the samples are analysed by an optical analysis unit 5 which may, for example, be such as is employed in known fluorescence polarization immunoassay (FPIA) testing. In this system a material to be detected (e.g. a drug) is labelled with a fluorescent dye which effects the polarization plane of an incident light beam; the `tracer-drug` thus produced is made to compete with the suspect material (suspected of being the same drug) for locking engagement with an antibody material. A beam of polarized light incident on combination of reagents has its polarization plane rotated to a degree dependent on the proportions of suspect material and tracer drug that have locked to the antibody. Such analysis systems are known and do not form part of the present invention. The important point is that a very narrow beam from the unit 5 is required to be focused on to a substantially point location on the substrate carrying a microspot of the the reagent combination in the above drug detection case . It is assumed that the optical unit 5 has a fixed focus on its axis 7 and it is therefore required to position each deposit selectively or in sequence at this focus.
A video camera 9 having an optical axis 11 is set with a fixed focus arranged to coincide with the plane of the substrate 1 when the substrate 1 is properly positioned for the optical unit 5. The substrate is then illuminated by a light source 13 by way of a partially transparent mirror 15.
The video camera produces a live image which is applied to a combined video and digital data processor 17 which controls the mounting 3 of the sample substrate as will be explained.
A monitor 19 may also be coupled to the video camera output for manual operation of the system or for pure monitoring of the automated process.
The actual individual sample test results from the unit 5 are stored in a data logger 21, correlated with information from the processor 17 as to the identity of the sample.
Operation of the system requires the sample substrate to be indexed from one sample to the next, either in sequence or by selection, and, at each location the sample has to be brought accurately to the focus of the optical unit 5. For this purpose the mounting arrangement 3 has to have at least two degrees of freedom for moving the substrate in its own plane. These may be `X` and `Y` translational movements or angle (rotational) and radius (translational) movements, or a combination of both. There is then a further requirement for movement of the substrate with at least a component along the axis 7 of the optical unit.
Referring now to FIG. 2, this shows one example of a substrate carrying samples for analysis. The samples 23 are regularly spaced around the periphery of the substrate, ie concentrically with the circular substrate 1. The substrate, which may consist of a polystyrene or ceramic disc, carries an optical reference pattern 25 which uniquely identifies a particular radius 24 of the disc. In the example shown, the reference pattern 25 is a chevron but any pattern is suitable which provides the unique radius identification, for example two (different) peripheral marks at each end of a diameter. It is necessary of course that in this case the ends of a diameter are distinguishable one from the other. It is also desirable that the reference pattern extends over a considerable part of a diameter for greaser accuracy in positioning.
In addition to the reference pattern 25 the substrate carries a focusing pattern 27. This consists of a row of bars which are imaged by the video camera 9 and passed to the control processor 17 for maximisation of the contrast in the image. The bar pattern 27 has a bar width and spacing which are large enough to be easily resolvable by the camera so that the imaging system and processor 17 can distinguish each bar from the next. The bars are also sufficiently close that when the substrate is out of the camera focal plane to the maximum likely extent the image of one bar touches or overlaps the next. The control processor includes means for assessing the contrast of the focusing pattern. This may be done by scanning across a stored image of the bars in the processor and detecting the peak/trough signal ratio. This signal will of course be a maximum when there is at least some `all-white` image between the bars and if the bars are sufficiently close this condition will obtain for a very limited axial range of the camera.
The focus indication from the processor 17 then controls the axial movement of the substrate, ie movement along the axis 11, until focus is achieved. Lateral alignment of an individual sample with the axis 7 is achieved from stored information as to the location of the sample referred to the chevron 25 and the substrate periphery. Thus the radius and/or distance-from-the-substrate-edge of a sample is known, together with the angle offset from the chevron radius. The substrate is thus moved, either by angle and radius or in X and Y coordinates, until the video camera image of the chevron 25 and substrate periphery accord with the stored information.
With the focal bar pattern (27) shown, it will generally be more convenient to orient the substrate to accord with the stored image before performing the focus assessment. In an alternative focus pattern the bars may be concentric rings, around the periphery for convenience. The scan of the processor store, for contrast assessment, may then be performed at a fixed store location.
The substrate may be one of a large number and it is convenient to include a serial number code 29 as part of the overall markings. This code may be a decimal number requiring decoding by the processor, or a binary or other code. It may be convenient to incorporate this serial number block as part of (or all of) the lateral reference pattern otherwise provided by the chevron 25. It is only necessary to arrange it in such a position as to indicate a unique radius.
It would also be possible to combine the functions of the lateral reference pattern 25 and the focus (axial) pattern 27. For example, the bars shown could be of decreasing length from left to right, the lengths being accurately defined so that an imaginary line of symmetry through them pointed to a unique peripheral point. Again, merely by moving the bar pattern bodily to the right (say), its line of symmetry would indicate such a unique point.
The substrate itself is conveniently, as mentioned above, a polystyrene or ceramic disc and the markings may be impressed by standard photoetching, laser-marking or other appropriate techniques.
FIG. 3 shows an alternative sample substrate of rectangular form. In this case the samples are deposited in rows parallel to the long edges and symmetrically disposed about a centre line. Again, the substrate has focusing and lateral reference patterns and a serial number.
It will be clear that in the two examples shown, the form of the substrate, circular or rectangular, can be used as part of the sample location reference, ie referring the sample location to the periphery. In an alternative arrangement the peripheral form of the substrate may be ignored and a complete lateral reference provided by markings. In the substrates shown, the chevron itself could be used to indicate both position and orientation if it is sufficiently well defined. Alternatively, for example, three widely-spaced spot markings forming an isosceles triangle could be used for both position and orientation references.
For use in an immunoassay application as described above, the antibody would be deposited at the point location on the substrate in preparation for later application of the competing antigens. Both of these operations are performed using the above described machine vision system to orientate, locate and focus the substrate. The reagents are deposited preferably in a predetermined orientation relative to the chevron but otherwise in a recorded orientation. The circular nature of the substrate in FIG. 2 facilitates the mechanical operation of the system.
The substrate is placed on the mounting arrangement and initially the chevron radius aligned with a datum (say the axis 7) by the processor. The analysis sequence is then set in motion, the processor bringing each sample in turn on to the axis 7 and at each such indexing the processor makes a focus assessment and correction. After each analysis the sample data, including sample characteristics, identity, location, substrate identity, is output to the data logger.
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An optical analysis or processing system for use, for example, in the analysis of microscopic spots of material by their effect on a very fine polarized beam of light (e.g., FPIA). For multiple "spot" analysis the spot samples are disposed on a substrate in predetermined relation with an optical pattern, bars, chevrons, etc. The substrate is mounted in the path of the fixed and focused beam with three degrees of freedom of movement. A video camera records the optical pattern very accurately and controls the substrate mounting to position a selected sample spot at the beam focus. Multiple and rapid sample analysis can thus be performed.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention is generally directed toward a method and a system for creating a software program deliverable. More specifically, the present invention is directed to creating a software program deliverable that combines a configuration data file with an executable portion of the software program deliverable.
[0003] 2. Discussion of Related Art
[0004] Software programs include instructions that direct microprocessors to perform certain functions. The instructions are typically created in files that are stored on a storage medium, such as a Compact Disk or a computer hard disk drive. The instructions are compiled in a language that is readable by a microprocessor. The microprocessor accesses and executes the compiled instructions to perform in a manner as directed by the compiled instructions.
[0005] Microprocessors are tasked to perform many types of functions. An example of one such function may include controlling a Redundant Array of Independent Disk (RAID) storage system. The controlling of a RAID storage system includes directing a manner in which data is managed by the RAID storage system. Such a microprocessor would be found in a RAID controller. The RAID storage system typically stores redundant information across multiple disks under control of one or more RAID controllers within the subsystem. The information includes redundant data provided by a host system as well as redundant data generated and managed by the RAID storage system. The generation and management of the redundant information are transparent to the host system. An example of a host system includes a host operating system, such as Windows developed by Microsoft Corporation. The redundant information is used to enhance the reliability and/or performance of the storage system. For example, when information is lost on one disk of the array, the storage system may continue to operate using the redundant information managed by the storage system on other disks of the array
[0006] An example of a single disk in the array is a hard disk drive as typically found in a personal computer. Access to data on the disks is gained through input/output (I/O) operations, such as reading and writing. The RAID controllers that are usually internal to the storage subsystem process these I/O operations. A user working in a host operating system environment of a computer views the multiple disks as a single disk because the redundant information generated and utilized by the RAID storage system and the distribution of information over multiple disks is independent of, and transparent to, the host operating system that is coupled to the RAID storage system.
[0007] Occasionally, a customer who acquires a RAID storage system has specific needs of the RAID storage system. These customer needs may include varying functional aspects of the RAID storage system that can be operatively controlled by the one or more RAID controllers. These functional aspects can be implemented with software programs. However, manufacturers of RAID storage systems would quickly become overwhelmed if each software program were customized for each customer need.
[0008] One method of customizing software for a variety of customer needs includes building a single software program that includes a suite of customer-derived functions. The customer-derived functions are implemented by defining variables within the software program prior to a compilation of the software program. Thus, each customized function is initialized by variables that are pre-configured in the software program. However, this method is especially time-consuming for the manufacturer since the software program must be compiled for each customized version of software that is produced.
[0009] One known solution to this problem is to provide a configuration file that stores information regarding the proper functioning of the system. Particular user or customer needs may be expressed as variables in the configuration data file. This known technique introduces further problems in that the configuration information and associated executable portion of the software are separated. An improper placement of the configuration files on the system can occur by human error. In fact, the configuration files may not be placed on the system at all.
[0010] As evident from the above discussion, a need exists for improved structures and methods for creating customized software programs.
SUMMARY OF THE INVENTION
[0011] The present invention solves the above and other problems and advances the state of the useful arts by providing structure and methods of encapsulating an executable portion of a software program deliverable with custom configuration information into a single software program deliverable. The custom configuration information describing the needs of a particular customer is included and provided in a separate configuration data file. The executable portion software program includes functionality that is common to all customers. The executable also includes a sub-set of functionality that is customized for particular customers. The encapsulated, customized software product deliverable is then provided to the customer so as to reduce potential human errors in implementing the customized functionality.
[0012] An example of the customized functionality is found in customers who are resellers of the RAID storage system. A reseller of the RAID storage system may embed the customer's, or reseller's, brand name information within the software of the RAID storage system. Other examples of customized functionality could include a power-up delay function for a disk drive of a redundancy group of a RAID storage system, a unit test function that determines a manner in which the software should reply if a volume of the RAID storage system has failed, an inquiry function that determines a manner in which the software should reply if a volume of the RAID storage system does not exist, and a subsystem component polling interval function that assists in detecting faults of a volume of a RAID storage system. The customer related variables could be used to implement these customized functions. The customer related variables could, thus, include at least one of a power-up delay indicator, a unit test indicator, an inquiry indicator, and a polling interval indicator. A configuration data file is generated and maintained as an individual file that includes customer related variables. In accordance with the present invention, the configuration data file is included in a software program deliverable but is separate from an executable portion of the software program deliverable. The executable portion of the software program deliverable accesses the configuration data file to retrieve the customer related variables. Once retrieved, the customer related variables activate functions within the executable portion of the software program deliverable that are relevant to the customer. These activated functions can direct a RAID controller to operate in a manner as desired by the customer.
[0013] In one exemplary preferred embodiment of the invention a system creates a software program deliverable. The system includes a configuration data generator configured for generating a configuration data file that includes variables for implementing customizable features within the software program deliverable. The system also includes a compiler configured for generating an executable portion of the software program deliverable. The system also includes an encapsulator communicatively connected to the compiler and to the configuration data generator for encapsulating the configuration data file and the executable portion of the software program deliverable to create a single customized software program deliverable.
[0014] In another aspect of the invention, the system includes a database communicatively connected to the configuration data generator for providing the variables.
[0015] In another aspect of the invention, the encapsulator includes an encoder configured for receiving the configuration data file and concealing the configuration data file from a user of the single customized software program deliverable.
[0016] In another aspect of the invention, the variables include at least one of a power-up delay indicator, a unit test indicator, an inquiry indicator, and a polling interval indicator.
[0017] In another aspect of the invention, the set of the software functions includes a sub-set of customized software functions.
[0018] Advantages of the invention include an improved maintenance of customer-defined variables by separating the customer-defined variables from executable portions of software program deliverables and filing the customer-defined variables in customer dependent configuration data files. Other advantages include a compiler time savings as a single software program deliverable can be developed and maintained that activates pre-compiled user-defined functions by accessing a relevant customer dependent configuration data files to retrieve customer-defined variables.
BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] [0019]FIG. 1 is a block diagram illustrating an exemplary preferred embodiment of the invention.
[0020] [0020]FIG. 2 is a flow chart diagram illustrating an exemplary preferred operation of the invention.
[0021] [0021]FIG. 3 is a block diagram illustrating another exemplary preferred embodiment operation of the invention.
[0022] [0022]FIG. 4 is a flow chart diagram illustrating a first step of the exemplary preferred operation of the invention.
[0023] [0023]FIG. 5 is a flow chart diagram illustrating a second step of the exemplary preferred operation of the invention.
[0024] [0024]FIG. 6 is a flow chart diagram illustrating a third step of the exemplary preferred operation of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] While the invention is susceptible to various modifications and alternative forms, a specific embodiment thereof has been shown by way of example in the drawings and will herein be described in detail. Those skilled in the art will appreciate that the features described below can be combined in various ways to form multiple variations of the invention. As a result, the invention is not limited to the specific examples described below, but only by the claims and their equivalents.
[0026] With reference now to the figures and in particular with reference to FIG. 1, an exemplary preferred embodiment of the invention is shown in system 100 . System 100 is configured to create a software program deliverable. System 100 includes configuration data generator 102 configured to generate a configuration data file that includes, variables for implementing customizable features within the software program deliverable. The variables may indicate functions to be activated within an executable portion of the software program deliverable.
[0027] System 100 includes compiler 104 configured for generating the executable portion of the software program deliverable. System 100 includes encapsulator 106 communicatively connected to compiler 104 and to configuration data generator 102 for encapsulating the configuration data file and the executable portion of the software program deliverable to create a single customized software program deliverable 108 .
[0028] [0028]FIG. 2 shows operation 200 of system 100 in one embodiment of the invention. Operation 200 commences in step 202 . Configuration data generator 102 provides the configuration data file that includes the variables for implementing customizable features within the software program deliverable in step 204 . Compiler 104 provides the executable portion of the software program deliverable in step 206 . Encapsulator 106 encapsulates the configuration data file with the executable portion of the software program deliverable to create the single customized software program deliverable 108 in step 208 . Operation 200 ends in step 210 .
[0029] [0029]FIG. 3 illustrates a block diagram of system 300 in an exemplary preferred embodiment of the invention. System 300 is configured for creating a software program deliverable. The software program deliverable may be used to operatively control a Redundant Array of Independent Disks (RAID) storage system. System 300 includes configuration data generator 302 , compiler 304 , encapsulator 306 , and database 312 . Configuration data generator 302 is configured for generating a configuration data file that includes variables for implementing customizable features within the software program deliverable. Configuration data generator 302 is communicatively connected to database 312 for retrieving the variables. The variables typically include information from a customer of the RAID storage system. For example, a customer may be a reseller of the RAID storage system who may wish to embed the customer's brand name information within the software of the RAID storage system. Other information may include customized functions within the software program deliverable that are relevant to the customer. Examples of the customized functions could include a power-up delay function for a disk drive of a redundancy group of a RAID storage system, a unit test function that determines a manner in which the software should reply if a volume of the RAID storage system has failed, an inquiry function that determines a manner in which the software should reply if a volume of the RAID storage system does not exist, and a subsystem component polling interval function that assists in detecting faults of a volume of a RAID storage system. The variables of the configuration data file could be used to implement these customized functions. The variables could, thus, include indicators for a disk drive of a redundancy group of a Redundant Array of Independent Disks (RAID) storage system, such as a power-up delay indicator, a unit test indicator, an inquiry indicator, and a polling interval indicator. Information that is relevant to the customer can be stored on database 312 to derive the customer variables that activate the customized functions.
[0030] Compiler 304 is configured for generating an executable portion of the software program deliverable. Encapsulator 306 is communicatively connected to configuration data generator 302 and compiler 304 . Encapsulator 306 is configured for encapsulating the configuration data file and the executable portion of the software program deliverable to create a single customized software program deliverable 308 . Encapsulator 306 includes encoder 310 configured for receiving the configuration data file. Encapsulator 306 includes encoder 310 configured for concealing the configuration data file from a user of the single customized software program deliverable 308 . Encapsulation of the configuration data file with the executable portion of the software program deliverable can improve customization and maintenance of software program deliverables, such as single customized software program deliverable 308 . The encapsulation can improve maintenance by maintaining individual configuration data files that include variables for implementing customized functions for each customer of the RAID) storage system. The encapsulation can improve the development and maintenance of the software program deliverable by maintaining a single software program deliverable that includes a plurality of functions relevant to specific customers. The plurality of functions are initialized and/or activated with respect to customer-derived variables of the configuration data file.
[0031] [0031]FIG. 4 is a flow chart diagram illustrating step 204 of exemplary preferred operation 200 of the invention. Step 204 enters through entry point 401 . Configuration data generator 302 provides the configuration data file that includes the variables for implementing customizable features within the software program deliverable. Customer-derived variables are retrieved from database 312 in step 402 . Step 204 then exits through exit point 403 .
[0032] [0032]FIG. 5 is a flow chart diagram illustrating step 206 of exemplary preferred operation 200 of the invention. Step 206 enters through entry point 501 . Compiler 304 provides the executable portion of the software program deliverable. Compiler 304 pre-compiles a set of software functions in step 502 . The set of software functions can include a sub-set of customized software functions. Step 206 then exits through exit point 503 .
[0033] [0033]FIG. 6 is a flow chart diagram illustrating step 208 of exemplary preferred operation 200 of the invention. Step 208 enters through entry point 601 . Encapsulator 306 encapsulates the configuration data file and the executable portion of the software program deliverable to create the single customized software program deliverable 308 . Encoder 310 encodes the configuration data file to conceal the configuration data file from a user of the single customized software program deliverable 308 in step 602 . Step 208 then exits through exit point 603 .
[0034] Instructions that perform the above operation can be stored on storage media. The instructions can be retrieved and executed by a microprocessor. Some examples of instructions are software, program code, and firmware. Some examples of storage media are memory devices, tapes, disks, integrated circuits, and servers. The instructions are operational when executed by the microprocessor to direct the microprocessor to operate in accord with the invention. Those skilled in the art are familiar with instructions and storage media.
[0035] Advantages of the above embodiments of the invention include an improved maintenance of customer-defined variables by separating the customer-defined variables from executable portions of software program deliverables and filing the customer-defined variables in customer dependent configuration data files. Other advantages include a compiler time savings as a single software program deliverable can be developed and maintained that activates pre-compiled user-defined functions by accessing a relevant customer dependent configuration data files to retrieve customer-defined variables.
[0036] While the invention has been illustrated and described in the drawings and foregoing description, such illustration and description is to be considered as exemplary and not restrictive in character. One embodiment of the invention and minor variants thereof have been shown and described. Protection is desired for all changes and modifications that come within the spirit of the invention. Those skilled in the art will appreciate variations of the above-described embodiments that fall within the scope of the invention. As a result, the invention is not limited to the specific examples and illustrations discussed above, but only by the following claims and their equivalents.
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The invention includes a method and system of encapsulating an executable portion of a software program deliverable with custom configuration information into a single software program deliverable. The custom configuration information describing the needs of a particular customer is included and provided in a separate configuration data file. The executable portion software program includes functionality that is common to all customers. The executable also includes a sub-set of functionality that is customized for particular customers. The encapsulated, customized software product deliverable is then provided to the customer so as to reduce potential human errors in implementing the customized functionality.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a boom assembly of an operating machine such as a front loader.
2. Description of the Related Art
A boom assembly of a front loader includes a boom assembly formed by joining a front boom sub assembly on the front of the center in a longitudinal direction of the boom assembly, and a rear boom sub assembly on the rear of the center in the longitudinal direction of the boom assembly (for example, see Japanese Patent Application “kokai” No. 11-158907).
A boom assembly of a front loader also includes a round boom assembly bent at the center in a longitudinal direction so as to form a round shape protruding upward when seen from the side (for example, see Japanese Patent Application “kokai” No. 11-158907 and Japanese Patent Application “kokai” No. 6-313325).
A boom assembly of a front loader further includes a boom assembly in which a body portion is formed into an angle protruding upward when seen from the side by bending a flat sheet material into a Π-shape in section opening downward and then further bending the flat sheet material at the center in a longitudinal direction of the boom assembly (for example, see Japanese Patent Publication No. 7-108410).
SUMMARY OF THE INVENTION
The round boom assembly bent at the center in the longitudinal direction so as to form the round shape protruding upward when seen from the side has good appearance. However, it is difficult to form the round boom assembly from one member from a front end to a rear end.
Thus, it is considered that the round boom assembly bent at the center in the longitudinal direction so as to form the round shape protruding upward when seen from the side is fabricated to include a front boom sub assembly on the front of the center in a longitudinal direction, and a rear boom sub assembly on the rear of the center in the longitudinal direction. For forming body portions of the front and rear boom sub assembly, for example, a boom forming member cut out of a flat sheet material is bent into an inverted u-shape constituted by right and left side walls and an upper wall connecting upper edges of the right and left side walls and then bent into a round shape protruding upward.
When a body of each of the front and rear boom sub assemblies is formed into a round shape protruding upward from one end to the other end in the longitudinal direction, and plural types of boom assemblies having different lengths are fabricated, plural types of boom sub assemblies having different lengths can be fabricated by one press die with the bodies of the front and rear boom sub assemblies having the same radius of curvature. However, in a front loader in which a bucket cylinder for swinging a bucket provided swingably at a tip of the boom assembly is placed in an upper front of the boom, expanding and contracting the bucket cylinder for swinging the bucket vertically swings the bucket cylinder, and causes the bucket cylinder to be moved close to or away from an upper surface of the boom. Thus, considering avoiding interference between the bucket cylinder and the boom, it is difficult in design to fabricate plural types of boom sub assemblies in each of which a front boom sub assembly is formed into a round shape protruding upward from one end to the other end in a longitudinal direction, and that have arcs with the same radius of curvature and different lengths.
Thus, the boom sub assemblies of the round boom assembly are formed to have radii of curvature corresponding to the lengths, thereby solving the problem. In this case, however, press dies corresponding to the boom sub assemblies having different lengths need to be made to increase costs, and a die changing step is required in fabrication of the boom assemblies having different lengths, thereby reducing productivity and increasing labor costs.
Therefore, the present invention has an object to provide a boom assembly that solves the problem.
In order to solve the technical problem, the following technical means are taken.
Specifically, there is provided a boom assembly bent at the center in a longitudinal direction so as to form a round shape protruding upward when seen from the side, comprising;
a front boom sub assembly, the front boom sub assembly constituting the front of the center in the longitudinal direction of the boom assembly; and
a rear boom sub assembly, the rear boom sub assembly constituting the rear of the center in the longitudinal direction of the boom assembly,
wherein the front boom sub assembly and the rear boom sub assembly are symmetric when seen from the side, and portions from the midway positions in the longitudinal direction of the front boom sub assembly and the rear boom sub assembly to the center in the longitudinal direction of the boom assembly have upper surfaces of arc shape protruding upward when seen from the side, and portions from the middles in the longitudinal direction of the front boom sub assembly and the rear boom sub assembly to ends in the longitudinal direction of the boom assembly have upper surfaces of linear shape when seen from the side.
Bodies of the front boom sub assembly and the rear boom sub assembly may be formed into an inverted u-shape in section by right and left side walls and an upper wall connecting upper edges of the right and left side walls.
The boom assembly includes an operating tool swingably at a front end of the boom assembly, and is suitably adopted in a loader in which a hydraulic cylinder that swings the operating tool is placed in an upper front of the boom assembly.
When a round boom assembly comprising a front boom sub assembly and a rear boom sub assembly, and bent at the center in a longitudinal direction so as to form a round shape protruding upward when seen from the side is adopted in a front loader in which a hydraulic cylinder that swings an operating tool swingably provided at a front end of the boom assembly is placed in an upper front of the boom assembly, the front boom sub assembly that constitutes the front of the boom assembly being formed into an arc shape protruding upward from one end to the other end, it is difficult in design in forming boom assemblies having different lengths to form front boom sub assemblies having the same radius of curvature in view of avoiding interference with the hydraulic cylinder. Thus, the front boom sub assemblies have to be formed into arc shapes with different radii of curvature, which requires a plurality of press dies.
On the other hand, according to the present invention, the boom assembly is formed so that the portion from the middles in the longitudinal direction to the center in the longitudinal direction of the boom assembly has the upper surface of arc shape protruding upward when seen from the side, and the portions from the middles in the longitudinal direction to the ends in the longitudinal direction of the boom assembly have the upper surfaces of linear shape when seen from the side. Thus, even if the boom sub assemblies are formed to have linear portions with different lengths to form arc portions with the same radius of curvature in fabricating boom assemblies having different lengths, the problem can be easily addressed of avoiding interference between the hydraulic cylinder and the boom assembly in each of the boom assemblies having different lengths.
Thus, the boom sub assemblies having different lengths can be formed to have arc portions with the same radius of curvature, and the front and rear boom sub assemblies are symmetric in the front and rear when seen from the side, thereby minimizing fabrication of press dies for forming the arc portions to reduce costs, and reduce a die changing time, increase productivity, and reduce labor costs in fabrication of the boom assemblies having different lengths.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a front loader;
FIG. 2 is a side view of a tractor to which the front loader is mounted;
FIG. 3 is an exploded side view of a boom assembly;
FIG. 4 is a side view of boom assemblies having different lengths;
FIG. 5 is a side view of boom sub assemblies having different lengths;
FIG. 6 is a rear sectional view of a pivot connecting portion of a boom cylinder of the boom assembly;
FIG. 7 is a side view of the pivot connecting portion of the boom cylinder of the boom assembly; and
FIG. 8 is a side sectional view of the center in the longitudinal direction of the boom assembly.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Now, an embodiment of the present invention will be described with reference to the drawings.
In FIG. 2 , reference numeral 1 denotes a tractor (running vehicle), and reference numeral 2 denotes a front loader (loader) removably mounted to the front of the tractor 1 . A vehicle body 3 of the tractor 1 mainly includes an engine 4 in the front, a flywheel housing connected to the rear of the engine 4 , and a transmission case 5 connected to the rear of the flywheel housing, and the transmission case 5 includes a front clutch housing 5 A and a rear transmission case 5 B.
The engine 4 is covered with a hood 6 , and a front axle frame 7 is mounted and secured to a lower portion of the engine 4 so as to protrude forward from the engine 4 . A pair of right and left front wheels 8 are supported by the front axle frame 7 , and a pair of right and left rear wheels 9 are supported in the rear of the transmission case 5 . The vehicle body 3 of the tractor 1 is drivably supported by the pairs of right and left front and rear wheels 8 and 9 . Also as shown in FIG. 1 , the front loader 2 includes a pair of right and left side frames 11 , a pair of right and left boom assemblies 12 , a pair of right and left boom cylinders 13 , a pair of right and left bucket cylinders 14 , and one bucket 15 (operating tool).
Each of the right and left side frames 11 mainly includes a pair of right and left side plates 16 , and a connection plate 17 connecting the right and left side plates 16 , and an engagement pin 18 provided across the right and left side plates 16 is provided in a lower end. The right and left boom assemblies 12 are connected at bases (rear ends) to upper portions of the side frames 11 on the same lateral sides pivotably around a lateral shaft by a pivot 19 , and the right and left boom assemblies 12 are connected at the front by a connecting member 20 made of a cylindrical pipe material.
The boom cylinders 13 include hydraulic cylinders, and the right and left boom cylinders 13 are placed in lower rear portions of the boom assemblies 12 on the same lateral side (below a rear boom sub assembly 48 described later), one ends of the boom cylinders 13 (rear ends, tips of piston rods) are connected to the middles in a vertical direction of the fronts of the side frames 11 on the same lateral side pivotably around a lateral shaft by a pivot 21 , and the other ends of the boom cylinders 13 (front ends, bottom ends of the cylinders) are connected to cylinder pivot portions 60 in lower ends of the rears of the pair of right and left bracket plates 22 provided in the middles in the longitudinal direction of the boom assemblies 12 pivotably around a lateral shaft by a pivot 23 , and the boom cylinders 13 are expanded and contracted (the piston rods are protruded and retracted) to vertically swing the boom assemblies 12 around the pivot 19 .
The bucket 15 is connected at a lower back portion to tips (front ends) of the right and left boom assemblies 12 pivotably around a lateral shaft by a pivot 24 , one ends of first links 25 are connected to a back side of the bucket 15 pivotably around a lateral shaft by a pivot 27 , and the other ends of the first links 25 are connected to the other ends of second links 26 pivotably around a lateral shaft by a pivot 29 , the second links 26 having one ends connected to the tips of the boom assemblies 12 pivotably around a lateral shaft by a pivot 28 .
The bucket cylinders 14 include hydraulic cylinders, and placed above the fronts of the boom assemblies 12 on the same lateral side (above a front boom sub assembly 47 described later), one ends of the bucket cylinders 14 (rear ends, bottom ends of the cylinders) are connected to cylinder pivot portions 59 in the fronts of upper ends of the bracket plates 22 pivotably around a lateral shaft by a pivot 31 , the other ends of the bucket cylinders 14 (front ends, tips of piston rods) are connected to connecting portions between the first links 25 and the second links 26 pivotably around a lateral shaft by the pivot 29 , the bucket cylinders 14 are expanded and contracted (the piston rods are protruded and retracted) to vertically swing the bucket 15 (scooping and dumping operation). At this time, the boom cylinders 14 vertically swing around the pivot 31 to be moved close to and away from the boom assemblies 12 .
In the front loader 2 , a stand 33 is provided that supports the boom assemblies 12 with the bucket 15 being grounded when the front loader 2 is removed from the tractor 1 . The stand 33 includes a front end 33 a connected to lower sides of the boom assemblies 12 pivotably around a lateral shaft, and a grounded portion 33 b in a rear end removably locked to the lower sides of the boom assemblies 12 , and is changeable in position between a non-use position along the boom assemblies 12 and a use position swung downward from the non-use position. On the other hand, in the tractor 1 , a loader mounting frame 36 for removably mounting the front loader 2 is provided.
The loader mounting frame 36 includes, as shown in FIG. 1 , a pair of right and left mounting plates 37 mounted and secured to the vehicle body 3 of the tractor 1 , a pair of right and left support bases 38 provided to protrude laterally outward from the vehicle body 3 of the tractor 1 , and a pair of right and left main frames 39 standing on the support bases 38 , and the mounting plates 37 , the support bases 38 , and the main frames 39 are placed on the right and left of the vehicle body 3 of the tractor 1 . Each mounting plate 37 is formed of one steel sheet, placed in a lower rear portion of the engine 4 and the side in a lower portion of the flywheel housing, the front is secured by bolts to an outer surface of the front axle frame 7 , and upper and lower portions of the rear are secured by bolts to an outer surface of the flywheel housing.
Each support base 38 is formed of a cylindrical pipe material having a lateral axis, and a lateral inner end thereof is joined by welding to the rear of the mounting plate 37 . Each main frame 39 is formed of one cast steel sheet, and joined by welding at a lower portion to a lateral outer end of the support base 38 . In the middle in a vertical direction of the front of the main frame 39 , a receiving portion 41 is provided into which the engagement pin 18 provided in the lower portion of the side frame 11 is fitted from above to be received.
An upper portion of the main frame 39 is connected to the side frame 11 by a connection pin 42 inserted through the main frame 39 and the middle in the vertical direction of the rear of the side frame 11 . In the front loader 2 having the above described configuration, the engagement pin 18 of the side frame 11 fits into the receiving portion 41 of the main frame 39 from above with an upper front portion of the main frame 39 being inserted between the right and left side plates 16 of the side frame 11 . The connection pin 42 is inserted through the upper portion of the main frame 39 and the middle in the vertical direction of the rear of the side frame 11 with the engagement pin 18 being received in the receiving portion 41 , thus the side frame 11 is mounted to the main frame 39 , and the front loader 2 is supported by the loader mounting frame 36 .
For removing the front loader 2 from the tractor 1 , for example, first, the connection pin 42 is removed with the tip of the bottom of the bucket 15 being grounded and the stand 33 being lowered from the non-use position to the use position, then the bucket cylinder 14 is contracted in this state to lower the boom assembly 12 and cause the stand 33 to be grounded. After the stand 33 is grounded, the boom assembly 12 swings around the grounded portion of the stand 33 so as to raise the side frame 11 , and the engagement pin 18 of the side frame 11 is removed upward from the receiving portion 41 of the main frame 39 , and thus the front loader 2 enters a standing state where the boom assembly 12 is supported by the stand 33 with the bottom of the bucket 15 being grounded.
A bracket 44 extending downward from the lower end of the main frame 39 is integrally formed with the lower end of the main frame 39 , and a front end of a sub frame 45 is secured to the bracket 44 by bolts, the sub frame 45 extends rearward along the vehicle body 3 of the tractor 1 , and the rear end is connected to a member secured to the transmission case 5 B.
As shown in FIGS. 1 and 3 , the right and left boom assemblies 12 are bent into a curve at the center in the longitudinal direction so as to form a round shape protruding upward when seen from the side, and have gradually increasing vertical widths from the front and rear ends toward the center in the longitudinal direction.
The boom assembly 12 mainly includes a front boom sub assembly 47 on the front of the center in the longitudinal direction of the boom assembly 12 , a rear boom sub assembly 48 on the rear of the center in the longitudinal direction of the boom assembly 12 , and a center connection plate 49 connecting the front and rear boom sub assemblies 47 and 48 at the center in the longitudinal direction of the boom assembly 12 . The front and rear boom sub assemblies 47 and 48 are each constituted by a body 51 and a bottom plate 52 , and the bodies 51 of the front and rear boom sub assemblies 47 and 48 have the same shape (symmetric in the front and rear when seen from the side), thereby achieving sharing of members.
The body 51 of each of the boom sub assemblies 47 and 48 is formed into an inverted u-shape in section opening downward by a pair of right and left side walls 53 and an upper wall 54 connecting upper edges of the right and left side walls 53 .
In the body 51 of each of the front and rear boom sub assemblies 47 and 48 , a portion of each of the front and rear boom sub assemblies 47 and 48 from the middle in the longitudinal direction to the end at the center in the longitudinal direction of the boom assembly 12 is a round portion 51 a having an upper surface of arc shape protruding upward when seen from the side, and a portion of each of the boom sub assemblies 47 and 48 from the middle in the longitudinal direction to the end in the longitudinal direction of the boom assembly 12 is a linear portion 51 b having an upper surface of linear shape when seen from the side.
The body 51 of each of the front and rear boom sub assemblies 47 and 48 are formed into an inverted u-shape in section by bending (pressing) one boom forming sheet material cut out of a flat sheet material into a predetermined shape to form the right and left side walls 53 and the upper wall 54 , the walls are bent into an inverted u-shape, then the boom sub assemblies 47 and 48 are bent (pressed) into a curve protruding upward at the centers in the longitudinal direction of the boom assembly 12 to form the round portions 51 a , and the linear portions 51 b are not bent into a curve. For forming the round portions 51 a into an arc shape, for example, a press die is provided constituted by a female mold having a concave surface and placed above the boom sub assemblies 47 and 48 so that the concave surface faces upper surfaces of the boom sub assemblies 47 and 48 , and a male mold having a convex surface and placed below the boom sub assemblies 47 and 48 so that the convex surface faces lower edges 53 a of the side walls of the boom sub assemblies 47 and 48 , and the boom sub assemblies 47 and 48 are press molded between the female mold and the male mold to form the round portions 51 a.
Thus, in the round portion 51 a , the lower edge 53 a of the side wall 53 is also formed into an arc shape protruding upward, and in the linear portion 51 b , the lower edge 53 a of the side wall is also formed into a linear shape when seen from the side. The shape seen from the side of the lower edge 53 a of the side wall 53 is determined in a cutting-out stage, and thus not limited to the arc shape or the linear shape. The bodies 51 of the front and rear boom sub assemblies 47 and 48 thus formed are abutted and joined by welding at ends of the side walls 53 at the center in the longitudinal direction of the boom assembly 12 .
For the boom assembly 12 having the above described configuration, in fabrication of boom assemblies 12 having different lengths, the round portions 51 a of the bodies 51 of the boom sub assemblies 47 and 48 are formed by one press die with the radii of curvature of arcs thereof being the same, and the lengths of linear portions 51 b are made different to form the boom sub assemblies 47 and 48 having different lengths. The lengths of the boom sub assemblies 47 and 48 are determined in the stage of cutting out the flat sheet material. In the front end of the front boom sub assembly 47 , a front pivot portion 56 is provided made of a cylinder, passing through the right and left side walls 53 , and secured to the side walls 53 by welding, and a bucket 15 is connected to the front pivot portion 56 pivotably around a lateral shaft by the pivot 24 .
In the rear end of the rear boom sub assembly 48 , a rear pivot portion 57 is provided made of a cylinder, passing through the right and left side walls 53 , and secured to the side walls 53 by welding, and the side frames 11 are connected to the rear pivot portion 57 rotatably around a lateral shafts by the pivot 19 . The middles of the right and left side walls 53 of the right and left front boom sub assemblies 47 are connected by the connecting member 20 . The bottom plate 52 is formed of a flat sheet, placed below the upper wall 54 and between the right and left side walls 53 , and provided so as to extend from the ends of the front and rear boom sub assemblies 47 and 48 at the center in the longitudinal direction of the boom assembly 12 to the front and rear pivot portions 56 and 57 .
In the embodiment, the bottom plate 52 of the front and rear boom sub assemblies 47 and 48 is integrally formed of one sheet, and secured to the bodies 51 by welding when (or after) the bodies 51 of the front and rear boom sub assemblies 47 and 48 are joined together. Bottom plates 52 of the front and rear boom sub assemblies 47 and 48 may be formed separately. A rear end of the bottom plate 52 of the rear boom sub assembly 48 is secured to the rear pivot portion 57 by welding. A front end of the bottom plate 52 of the front boom sub assembly 47 may be also secured to the front pivot portion 56 by welding. On the other hand, on a bottom side of one of the right and left boom assemblies 12 , hydraulic pipes for the boom cylinder 13 and the bucket cylinder 14 are provided along the bottom plate 52 from the rear to the connecting member 20 , the hydraulic pipes are provided below and along the connecting member 20 to the other of the right and left boom assemblies 12 , the middles of the hydraulic pipes or the ends thereof on the side of the other boom assembly 12 are connected to the boom cylinder 13 and the bucket cylinder 14 via hydraulic hoses, and rear ends of the hydraulic pipes are connected to a control valve provided in the main frame 39 or the like via the hydraulic hoses.
For the bottom plate 52 of the front and rear boom sub assemblies 47 and 48 , the bottom plate 52 at the end in the longitudinal direction of the boom assembly 12 is close to the lower edge 53 a of the side wall 53 of the body 51 , the bottom plate 52 at the center in the longitudinal direction of the boom assembly 12 is positioned in the middle in a vertical width direction at the center in the longitudinal direction of the boom assembly 12 (a middle in the vertical direction of an edge of the side wall 53 at the center in the longitudinal direction of the boom assembly 12 ).
Thus, a distance from the bottom plate 52 to the lower edge 53 a of the side wall 53 is long at the center in the longitudinal direction of the boom assembly 12 , and a housing space for the hydraulic pipes is large at the center in the longitudinal direction of the boom assembly 12 .
The distance from the bottom plate 52 to the lower edge 53 a of the side wall 53 is long at the center in the longitudinal direction of the boom assembly 12 , and a width between the right and left side walls 53 is narrow, thus in welding the bottom plate 52 to the side walls 53 , a welding torch is hard to be placed between the side walls 53 at the center in the longitudinal direction of the boom assembly 12 , and welding of the bottom plate 52 to the side walls 53 is difficult at the center in the longitudinal direction of the boom assembly 12 . Thus, notches 58 are formed in upper portions of the bodies 51 of the front and rear boom sub assemblies 47 and 48 at the center in the longitudinal direction of the boom assembly 12 , the bottom plate 52 is welded to the side walls 53 from below from the front and rear ends of the boom assembly 12 to the middles in the longitudinal direction of the boom sub assemblies 47 and 48 , and the bottom plate 52 is welded to the side walls 53 from above via the notches 58 at the center in the longitudinal direction of the boom assembly 12 .
The notches 58 are formed in the upper walls 54 by cutting a predetermined range in the longitudinal direction of the boom from the ends of the upper walls 54 at the center in the longitudinal direction of the boom assembly 12 , and formed so as to extend from the notch portions in the upper walls to the right and left side walls 53 .
The center connection plate 49 is formed by bending a flat sheet into a curve protruding upward, and provided across the upper walls 54 of the front and rear boom sub assemblies 47 and 48 so as to close the notches 58 from above. The bracket plates 22 are placed on the right and left of the boom assembly 12 at the center in the longitudinal direction of the boom assembly 12 , provided across the side walls 53 of the front and rear boom sub assemblies 47 and 48 , and placed on outer surfaces of the side walls 53 of the front and rear boom sub assemblies 47 and 48 and secured by welding. Thus, the bracket plates 22 also serve as reinforcing plates.
FIG. 4 shows three types of round boom assemblies 12 of the embodiment having different lengths, and FIG. 5 shows boom sub assemblies 47 and 48 of the three types of boom assemblies 12 in FIG. 4 . The boom sub assemblies 47 and 48 of the three types of boom assemblies 12 having different lengths are formed so that radii of curvature of arcs of upper walls 54 at round portions 51 a are the same, lengths A in a longitudinal direction of the upper walls 54 are the same, and radii of curvature of lower edges 53 a of side walls 53 at the round portions 51 a are the same, and the round portions 51 a of the boom sub assemblies 47 and 48 of the three types of boom assemblies 12 are formed by the same press die.
Arc portions of the boom sub assemblies 47 and 48 of plural types of boom assemblies 12 having different length are formed by the same press die, and the front and rear boom sub assemblies 47 and 48 are made symmetric in the front and rear, thereby minimizing press dies for forming the round portions 51 a of the boom sub assemblies 47 and 48 to reduce costs, and eliminating a press die changing step in production of plural types of boom assemblies 12 having different lengths to increase productivity and reduce labor costs. In the boom sub assemblies 47 and 48 of the three types of boom assemblies 12 having different lengths, lengths B in the longitudinal direction of the upper walls 54 at the linear portions 51 b are relatively significantly different, and the lengths of the linear portions 51 b are made different to form the three types of boom assemblies 12 having different lengths.
Forming portions of the notches 58 at the round portions 51 a of the three types of boom sub assemblies 47 and 48 in FIGS. 4 and 5 have slightly different lengths, but if the arc portions have the same radius of curvature with different lengths, the round portions 51 a can be formed by the same press die. Thus, the lengths A of the arc portions of the upper walls 54 may be slightly different.
Two types or four or more types of boom assemblies 12 having different lengths may be formed in the same manner.
As shown in FIGS. 6 to 8 , the cylinder pivot portion 60 of each of the right and left bracket plates 22 to which the end of the boom cylinder 13 is pivotably connected is provided with a cylindrical boss 61 that supports the pivot 23 for supporting the boom cylinder 13 , and formed with a boss insertion hole 62 through which the boss 61 is inserted.
One end in an axial direction of the boss 61 (a lateral inner end) is inserted through the boss insertion hole 62 from a lateral outer surface of the bracket plate 22 , and the boss 61 is joined to the cylinder pivot portion 60 by fillet welding between an outer peripheral surface of the boss 61 and the outer surface of the bracket plate 22 . The front end of the boom cylinder 13 is placed between the right and left cylinder pivot portions 60 , and the front end of the boom cylinder 13 is pivotably connected to the right and left cylinder pivot portions 60 by the pivot 23 inserted through the right and left bosses 61 and passing through the front end of the boom cylinder 13 . According to the above described configuration, the inner end of the boss 61 is inserted from the outer surface of the bracket plate 22 through the boss insertion hole 62 formed in the cylinder pivot portion 60 of the bracket plate 22 to join the outer surface of the cylinder pivot portion 60 and the outer peripheral surface of the boss 61 by welding. Thus, an external force acting on the boss 61 can be received by a welding bead 63 around the boss 61 and the bracket plate 22 (the inner surface of the boss insertion hole 62 ), thereby reducing load on the welding bead 63 around the boss 61 .
An upper portion of an end surface 61 a at the lateral inner end of the boss 61 laterally overlaps the lower end of the side wall 53 of the rear boom sub assembly 48 , the upper portion of the end surface 61 a at the lateral inner end of the boss 61 abuts against the lower end of the side wall 53 of the rear boom sub assembly 48 , and the end surface 61 a at the lateral inner end of the boss 61 and the lower edge 53 a of the side wall 53 of the rear boom sub assembly 48 are joined by fillet welding so as not to close an inner hole 61 b of the boss 61 . The lateral inner surface of the bracket plate 22 and the lower edge 53 a of the side wall 53 of each of the front and rear boom sub assemblies 47 and 48 are joined by fillet welding from the front end to the rear end of the bracket plate 22 . A welding bead 64 that joins the lateral inner surface of the bracket plate 22 and the lower edge 53 a of the side wall 53 of each of the front and rear boom sub assemblies 47 and 48 , and a welding bead 65 that joins the end surface 61 a at the lateral inner end of the boss 61 and the lower edge 53 a of the side wall 53 of the rear boom sub assembly 48 are continuous.
A portion of the lower edge 53 a of the side wall 53 of the rear boom sub assembly 48 , welded to the end surface 61 a at the lateral inner end of the boss 61 is formed with an arc-shaped notch 66 along the inner hole 61 b of the boss 61 , and the side wall edge 53 a of the boom assembly 12 of the portion against which the end surface 61 a at the lateral inner end of the boss 61 abuts is formed along the inner hole 61 b of the boss 61 . The inner end of the boss 61 is configured to be inserted through the boss insertion hole 62 from the outer surface of the bracket plate 22 , and thus the end surface 61 a at the inner end of the boss 61 and the side wall edge 53 a of the boom assembly 12 can be joined by welding, and the end surface 61 a at the inner end of the boss 61 and the side wall edge 53 a of the boom assembly 12 are joined by welding to significantly reduce stress around the boss 61 .
As described above, the boss insertion hole 62 is formed through the cylinder pivot portion 60 of the bracket plate 22 , one end in the axial direction of the cylindrical boss 61 is inserted through the boss insertion hole 62 from the outer surface of the bracket plate 22 , the outer surface of the cylinder pivot portion 60 and the outer peripheral surface of the boss 61 are joined by welding, and the end surface 61 a of one end in the axial direction of the boss and the side wall edge 53 a of the boom assembly 12 are joined by welding so as not to close the inner hole of the boss 61 .
The end surface 61 a of one end in the axial direction of the boss 61 of the portion welded to the side wall edge 53 a of the boom assembly 12 abuts against the outer surface of the side wall 53 of the boom assembly 12 , and the side wall edge 53 a of the boom assembly 12 of the portion against which the end surface 61 a of one end in the axial direction of the boss 61 abuts is formed along the inner hole 61 b of the boss 61 .
According to the present invention, one end in the axial direction of the boss 61 is inserted through the boss insertion hole 62 formed in the cylinder pivot portion 60 of the bracket plate 22 from the outer surface of the bracket plate 22 to join the outer surface of the cylinder pivot portion 60 and the outer peripheral surface of the boss 61 by welding, and thus an external force acting on the boss can be received by the welding bead around the boss and the bracket plate. This reduces load on the welding bead around the boss 61 . One end in the axial direction of the boss 61 is inserted through the boss insertion hole 62 from the outer surface of the bracket plate 22 , and thus the end surface 61 a of one end in the axial direction of the boss 61 and the side wall edge 53 a of the boom assembly 12 can be joined by welding. Then, the end surface 61 a of one end in the axial direction of the boss 61 and the side wall edge 53 a of the boom assembly 12 are joined by welding to significantly reduce stress around the boss 61 . This ensures strength against the external force acting on the boss 61 , eliminates the need for increasing an outer diameter of the boss 61 or providing a reinforcing plate for ensuring the strength of the boss 61 , reduces costs, and improves design.
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There is provided a boom assembly bent at the center in a longitudinal direction so as to form a round shape protruding upward when seen from the side, comprising; a front boom sub assembly ( 47 ), the front boom sub assembly constituting the front of the center in the longitudinal direction of said boom assembly; and a rear boom sub assembly ( 48 ), the rear boom sub assembly constituting the rear of the center in the longitudinal direction of the boom assembly, wherein the front boom sub assembly ( 47 ) and the rear boom sub assembly ( 48 ) are symmetric when seen from the side, and portions from the midway positions in the longitudinal direction of the front boom sub assembly ( 47 ) and the rear boom sub assembly ( 48 ) to the center in the longitudinal direction of the boom assembly ( 12 ) have upper surfaces of arc shape protruding upward when seen from the side, and portions from the middles in the longitudinal direction of the front boom sub assembly ( 47 ) and the rear boom sub assembly ( 48 ) to ends in the longitudinal direction of the boom assembly ( 12 ) have upper surfaces of linear shape when seen from the side.
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TECHNICAL FIELD
This invention pertains to monitoring the operation and durability of mechanical actuators fabricated of generally linear shape memory alloy members. More particularly the invention pertains to estimating the expected remaining life of a shape memory alloy actuator using resistance or resistivity measurements made during electrical heating of the alloy members.
BACKGROUND OF THE INVENTION
Shape memory alloys (SMAs) may exist as two phases, a lower modulus, lower temperature, crystalline martensite phase and a higher modulus, higher temperature, austenite phase of a different crystal structure. The transition from one phase to the other may, by appropriate choice of alloy system, alloy composition, heat treatment or applied stress, be selected to occur over a temperature span of from −100° C. up to about +150° C. or so. But many useful SMA alloys exist in their martensite form at, or slightly above, about 25° C. or so, and transform to their austenite form at temperatures ranging from about 60° C.-80° C. or so. These characteristics substantially assure that the SMA will be in its martensitic phase at essentially any ambient temperature experienced by a motor vehicle but may be readily transformed to austenite with only modest heating.
Shape memory alloys may be used as mechanical actuators. Commonly alloys for actuator applications are prepared as generally linear members. These members are commonly wires, but other suitable shapes include tapes, chains or cables. For brevity only, and without limitation, the term wire will be used in future sections. The wires, after shaping to a desired ‘remembered’ length or shape in their austenite phase are cooled to ambient temperature. On cooling the wires will revert to their martensite crystal structure. The wires may then be stretched and deformed to some predetermined length. The deformation exceeds the maximum allowable elastic strain which may be imposed on the actuator and is often termed pseudo-plastic deformation. These pseudo-plastically-deformed martensitic wires are in the appropriate starting condition for the actuator.
Generally the stretch or strain, that is, the change in length of the wire divided by its original or base length, applied during such pseudo-plastic deformation does not exceed 7% and more commonly may be 5% or less. Importantly, the base length, to which all length changes are referred, is the length of the wire in its high temperature, austenite, phase.
Deformed martensitic shape memory alloys may, when heated and transformed to austenite, revert to their original undeformed shape and are capable of exerting appreciable force as they do so. In changing shape, the wire will shorten by an amount substantially equal to the pseudo-plastic strain previously applied when it was in its martensitic form. So, by suitable choice of wire length, any desired displacement may be achieved. As an example, a 10 inch or so length of wire, prestrained to 5% strain, may enable a displacement of about one-half inch or so.
This change in length, in combination with the ability of the SMA to apply a significant force as it changes length, are the characteristics which make SMAs suitable for use as actuators in mechanical devices. In one common actuator design, a pseudo-plastically stretched martensite SMA wire of a length suitable for an intended displacement, is heated along its entire length and transformed to austenite. The transformation to austenite causing the wire to contract so that it may linearly displace an attached moving element.
In an exemplary application the attached moving elements may be an air dam which may be deployed, on-demand, by action of the SMA actuator. Of course, other linear motion devices such as latches may also be operated by SMA actuators. Also, by addition of pulleys and similar mechanical contrivances, an SMA actuator may be readily adapted to enable rotary motion. Any heat source may be used to elevate the SMA wire temperature and promote its transition to austenite. But, preferably, the wire should be heated uniformly along its length and throughout its cross-section so that substantially the entire volume may be heated and transformed, the transformation being effected generally simultaneously in the wire volume.
One convenient approach which assures generally uniform heating of the entire wire length is electric resistance heating. Electrical connections may be made to the SMA wire ends for attachment to a suitable power source, commonly a nominally 12 volt battery in the case of a motor vehicle, and a controlled current passed along the length of the wire. The applied current may be initially small and increased during the duration of the heating cycle using a ramp, sine, step or arbitrary variation of current with time or a fixed battery voltage may be applied and its heating power adjusted using pulse width modulation (PWM). Generally operation of the actuator occurs over a relatively short time period, typically on the order of 1 or 2 seconds. Application of power is generally under the control of a controller which may be independent of, or integrated with, other on-vehicle electronics. Many SMA-actuated devices are intended to operate over a fixed displacement. Thus, when the SMA device achieves its design displacement, the applied current is reduced to a value sufficient to maintain it at its design stroke. This end-of-stroke current may be termed a terminal current. Any suitable method may be used to signal the controller that end-of-stroke has been reached, including, for example, a contacting or non-contacting micro-switch. Once end-of-stroke is signaled, application of a continuing current sufficient to maintain the wire temperature is required. Suitable controllers and control strategies for accomplishing this are well known to those skilled in the art.
Actuator action may be reversed by stopping passage of the electric heating current and allowing the wire to cool to about ambient temperature and revert to its martensitic crystal structure. Generally forced cooling is neither required nor employed. During cooling, the SMA wire will not spontaneously change its length to its initial deformed length but, in its martensitic phase, it may be readily stretched again to its initial predetermined length. Any suitable approach, including deadweights, may be employed to stretch the wire, but often a spring positioned in series with the SMA wire is used. Stretching may be continued until the wire ends are positioned against preset stops which establish the predetermined wire length.
These changes in length result from the transition in crystal structure resulting from the imposed temperature changes. Provided the transition in crystal structure is fully reversible this cycle of extending and contracting the wire by application of suitable thermal stimulus may continue indefinitely.
In practice however, the phase transitions and the accompanying cyclic transitions from extended length to retracted length and back again to extended length, are not completely reversible. This irreversibility may lead to changes in the operating characteristics of the SMA wire with continuing use and even to fatigue of the SMA wire after extensive use. The occurrence of such fatigue may be promoted by overdriving or otherwise exceeding the design parameters or capabilities of the SMA wire
There is therefore a need to monitor SMA wire performance. In particular there is need for a method of detecting any change or deterioration in device capability. Preferably such change may be detected before it has increased to a level where a device may be rendered inoperative. More preferably the extent of any change may be interpreted to signal the remaining life of the device.
SUMMARY OF THE INVENTION
This invention provides an electrical resistance-based method of monitoring the condition of an SMA actuator in a device and of estimating its remaining useful life.
Since heating is commonly accomplished using electrical resistance heating, the wire resistance may be determined as it is being heated during an actuation cycle without interruption to the process. The resistance is simply the ratio of the instantaneous voltage to instantaneous current and, with repeated sampling, a near-continuous record of the SMA element resistance may be obtained. Generally resistance measurements are satisfactory, but, if necessary, the resistance, R, may be used to compute the resistivity, ρ, which is material dependent but geometry-independent. Specifically:
ρ=( A/L )× R
where A=element area; L=element length; and R=element resistance It will be appreciated that resistivity has the dimensions of resistance×length, for example ohm-meters. As will be discussed in greater detail subsequently, the length of the SMA may be readily assessed, enabling the area to be computed since the wire volume remains constant.
Both the resistance and resistivity vary in a systematic and similar manner during the heating time of the SMA. By extracting some characteristic features from the resistance or resistivity versus heating time curves and monitoring changes over repeated cycling of the SMA, the state of the SMA and its remaining life may be estimated. A typical heating cycle or deployment cycle may be as short as one or two seconds. So developing sufficient detail in the resistivity record to extract the characteristic features may require a sampling frequency for voltage and current on the order of 500-1000 Hz.
A curve representative of the change in resistivity with time during actuation and deployment of a fixed displacement SMA-actuated device is shown in FIG. 3 , in conjunction with a curve showing the associated changes in strain plotted against a common time scale. Initially, the SMA will be at ambient temperature or about 25° C. At this temperature the SMA will be in its martensite phase and will have undergone a strain ε 1 , relative to its austenitic state, and exhibit a resistivity ρ 1 . On heating, the SMA will attain its transformation temperature and its resistivity will initially increase, reach a maximum (ρ 2 ) at a strain ε 2 and then rapidly decrease to a minimum value (ρ 3 ) at a strain ε 3 . Continued heating will induce a terminal value of resistivity ρ 4 in the wire and a corresponding terminal, non-zero, strain of ε 4 . Under conservative device operation, ρ 4 may be equal to ρ 3 . An analogous curve results if resistance, R, is plotted rather than resistivity, ρ.
The inventors have determined that the magnitude of the difference in resistivity between the minimum resistivity (ρ 3 ) and the terminal resistivity (ρ 4 ), that is (ρ 4 −ρ 3 ), increases systematically with increasing degradation of the SMA element over multiple cycles. A similar result holds for the analogous difference in resistance (R 4 −R 3 ). When this resistivity (or resistance) difference attains a critical value, device failure may be imminent. Thus with knowledge of the critical value and the current value of the resistivity or resistance difference the remaining life of the SMA may be estimated.
Suitably such life estimation may be performed by an on-vehicle controller capable of: accepting and interpreting electrical signals representative of the instantaneous current and voltage; identifying the significant features of the resistivity versus time curve; and performing some simple calculations to assess the instantaneous performance of the SMA element and to estimate its remaining useful life.
Further the controller may, based on some pre-established criteria, initiate one or more of the following actions: provide a warning or alert to the vehicle operator; restrict further use of the device; or limit the power supplied to the device so that device operates at less than its full capacity.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows, in section, an SMA device for deployment of a vehicle air dam. The air dam is shown in its stowed or retracted configuration out of the vehicle airflow.
FIG. 2 shows the air dam in its deployed configuration in which it is inserted in to the vehicle airflow.
FIG. 3 shows two curves, drawn to a common time scale, showing changes in the resistivity (ρ) and strain (ε) versus elapsed time t (in seconds) of an SMA wire during actuation. For the small strains shown, the strain will be substantially equal to the elongation undergone by the wire. Note that the unstrained (ε=0) state of the wire is the austenitic state.
FIG. 4 shows a graph of the maximum SMA wire temperature versus (ρ 4 −ρ 3 ) illustrating the linear variation in (ρ 4 −ρ 3 ) with temperature for maximum temperatures of 140° C. and greater. The results represent the evolution of (ρ 4 −ρ 3 ) and maximum temperature as a wire is repeatedly cycled, over thousands of cycles, to develop a fixed displacement.
FIGS. 5A and 5B are curves showing the changes in resistivity (ρ) of an SMA wire during passage of an electric current to heat and transform the SMA. FIG. 5A is representative of a wire very early in the life of the device, typically less than 10% of expected life, while FIG. 5B is representative of the behavior of the wire much later in life say at about 90% of expected life.
FIGS. 6A-C illustrates the variation of SMA wire lifetime with applied current under several different static loads.
FIG. 7 is a graph of the logarithm of the SMA wire life (N F ), expressed in cycles and the logarithm of the change in resistivity, (ρ 4 −ρ 3 ).
FIG. 8 schematically illustrates the integration and inter-relationships between an SMA device, an SMA device controller and an SMA element diagnostic module.
DESCRIPTION OF PREFERRED EMBODIMENTS
The following description of the embodiment(s) is merely exemplary in nature and is not intended to limit the invention, its application, or uses.
Shape memory alloys (SMAs) are particular alloys which undergo substantially reversible transformation between two crystal phases—a low temperature phase known as martensite and a high temperature phase known as austenite. The particular phase transformation temperature varies with alloy system, but generally ranges from between about −100° C. to about +150° C. or so. Shape memory behavior has been observed in a large number of alloy systems including Ni—Ti, Cu—Zn—Al, Cu—Al—Ni, Ti—Nb, Au—Cu—Zn, Cu—Zn—Sn, Cu—Zn—Si, Ag—Cd Cu—Sn, Cu—Zn—Ga, Ni—Al, Fe—Pt, Ti—Pd—Ni, Fe—Mn—Si, Au—Zd, and Cu—Zn but only a few of these alloys are commercially available. Nitinol, an alloy of nickel and titanium in substantially equiatomic proportion, enjoys the widest use.
Associated with the change in crystal structure is a change in shape. In most applications the SMA is preformed into a wire or similar elongated form such as a tape or strip, and the change in crystal structure is manifested by a change in the length of the wire or other SMA element. This change in length is characteristic of the specific alloy system and may range up to about 7% or so in some systems such as the Ni—Ti system. As the SMA element seeks to change its length it may apply appreciable force, sufficient to overcome any mechanical drag or opposition. With appropriate design, mechanical devices may be fabricated to harness and utilize the force resulting from transformation to operate or actuate mechanisms or similar mechanical devices.
FIGS. 1 and 2 show a representative example of a fixed-displacement linear mechanical device. FIGS. 1 and 2 are representative of an automotive application of an SMA-actuated device, an SMA-deployed air dam, a device generally fitted beneath the front bumper of an automobile and extending into the under-vehicle airflow. Air dams are most effective at high speeds and may improve the handling and control of the motor vehicle, increase fuel economy, and also improve the routing of air flow for cooling/heat exchange in the vehicle engine compartment. The effectiveness of air dams is greatest when they extend almost to the roadway but this configuration renders them most vulnerable to impact with roadway obstacles. Thus the geometry of fixed air dams necessarily represents a compromise between aerodynamic effectiveness and avoiding collision of the air dam with obstacles or road hazards. A better compromise may be made by using a retractable air dam. Such a retractable air dam offers opportunity of deploying the air dam only at high speed and retracting the air dam to a stowed position at low speeds to minimize the likelihood of a damaging air dam collision when the air dam is least effective.
In the sectional view of FIG. 1 the air dam system 10 includes air dam 22 , housing 12 and an SMA actuation system comprising SMA wire 30 . The air dam is shown in its stowed position located out of airflow 38 . Air dam 22 is generally L-shaped with a longer portion 24 intended for insertion into air flow 38 . The shorter section 26 of air dam 22 has opposing surfaces 23 , 25 and is mechanically attached to the SMA wire and responsive to its movement. Surface 23 is secured to an end of SMA wire 30 and surface 25 to an end of tension spring 28 . The opposing end of spring 28 is attached to the underside of cover 14 . SMA wire 30 is secured at its other end at mount 32 and routed around pulleys 34 to enable a more compact device. The device is contained within housing 12 , formed of opposing, generally vertical walls 18 , generally horizontal cover 14 and opposing closure 16 . Closure 16 includes a slotted opening 20 with compliant flap seals 21 which sealingly engage to deny access of road splash and debris to housing 12 when air dam 22 is retracted and stowed.
In FIG. 2 , SMA wire 30 has been actuated, preferably by utilizing the mechanical connectors on the wire ends as electrical connectors and passing an electric current along the length of the wire (details not shown). Wire 30 , prior to heating of the wire by the electric current, or other applicable means, was in its low temperature, lower strength martensitic state. In its low modulus, martensite state, spring 28 may deform and elongate wire 30 retracting air dam 22 into housing 12 as shown in FIG. 1 . Heating SMA wire 30 results in its transformation into its higher strength austenitic state, shown as wire 30 ′ in FIG. 2 . Associated with its transformation to higher strength austenite, wire 30 seeks to shrink to a length appropriate to austenitic wire 30 ′. As it does so it applies sufficient force to overcome the force exerted by spring 28 , causing spring 28 to extend and forcing portion 24 of air dam 22 through opening 20 where it extends into airflow 38 . Seals 21 are deflected into contact with the opposing surfaces of portion 24 of the air dam, so that they may continue to exclude moisture and debris from housing 12 .
On cessation of heating, wire 30 ′ will cool and transform to martensitic wire 30 . The lower strength martensitic wire 30 may be deformed by spring 28 , enabling spring 28 to contract and, because of its connection to surface 25 of air dam 22 , retract air dam 22 within housing 12 as shown at FIG. 1 .
In this application, the SMA actuator mechanism is intended to operate in fixed displacement mode so that the air dam will extend beyond the housing by some predetermined extension. This, relatively simple, operating scheme may be implemented, for example, by progressively increasing the applied current passed through the wire until the design displacement is achieved and then continuing to apply the terminal current necessary to maintain the desired deployment.
For this example, and other automotive applications, resistance heating may result from passage of direct current (DC) electricity stored in a vehicle battery. Non-automotive applications may also employ alternating current (AC). Improved control of the heating may result from using pulse width modulated (PWM) direct current. Thus any subsequent description of an electric current in this application may encompass both the instantaneous DC current and an equivalent AC or PWM current. Similar considerations apply to voltage. It will be appreciated that since the average current is varied over the duration of the heating cycle, which may be as short as a second or so, that any determination of average current should be based on an appropriately-short time window.
The just-described mechanism is, of course, specific to its intended use. However the general approach, using a spring capable of deforming an SMA element in its martensitic state but incapable of resisting the force applied by the SMA element as it transforms to austenite is widely used in fixed displacement, linear device applications. Similar devices may be used for rotary applications.
The data and results reported herein were developed using a 0.006 inch diameter. 115 millimeter long NiTi-based wire sold by Dynalloy (Tustin, Calif. 92780) under the trade name Flexinol® and tested under an ambient temperature of about 22° C. This wire, when under no stress, transforms from austenite to martensite over the temperature range 45° C. to 55° C., and from martensite to austenite over the temperature range of 70° C. to 75° C. All samples were subjected to at least 100 heating-cooling cycles with some samples undergoing up to 300,000 cycles. Heating was by electric resistance heating, employing a voltage of around 4 volts and a current of 500 mA or so, with natural cooling. The wire was heated, in about 1-2 seconds, to a maximum temperature of between 100° C. and 200° C., typically to about 130° C., and cooled, in between 0.5 to 2.0 seconds, to a temperature suitable for transforming to martensite.
During operation of the SMA device the resistance R may be determined provided the voltage (V) and current (I) are known using the relation V=I·R or, R=V/I. In most practices of this invention it will be sufficient to track changes in resistance as described more fully below. However, the value of resistance, in addition to the wire composition, temperature and phase, depends on the wire geometry, its length and cross-sectional area. The influence of these geometrical factors may be compensated by using resistivity (ρ), rather than resistance, where ρ=A/L·R with A=wire cross-sectional area and L=wire length. The resistivity data reported here employ the instantaneous values of wire area and length as the wire dimensions change during actuation, but because the maximum change in wire length is usually less than 7% the general form of the curves would be maintained if resistance rather than resistivity were plotted. The wire length may be inferred from the measured change in resistance and the area computed using the length and subject to the requirement that the wire volume remains essentially constant.
Changes in the strain and resistivity of the SMA wire during actuation of the device are represented by the curves shown in FIG. 3 , which were developed for the Flexinol® wire described above. While the numerical values are specific to the tested wire, the form of these curves is generally reflective of the transformation of any SMA element from martensite to austenite to produce the transition from the device configuration of FIG. 1 to the configuration of FIG. 2 . In FIG. 3 , plots of SMA element resistivity (ρ) and SMA element strain (ε) are shown plotted against a common time scale corresponding to the application of an electric current to heat and transform the wire. The initial temperature of the SMA is less than its transformation temperature so the wire is initially in its martensite phase.
At the onset of transformation, and before any cycling has occurred, the SMA will have a strain of ε 1 , referred to the wire in its original austenite phase. This strain, approximately equal to the wire elongation, represents the maximum strain or elongation undergone by the SMA. In its initial state the SMA has a resistivity of ρ 1 .
After heating is initiated, the resistivity increases to a peak value ρ 2 with a corresponding decrease in strain to ε 2 . As the temperature continues to increase, and the transformation of the pre-existing martensite phase to austenite becomes more extensive, the resistivity decreases to a minimum value ρ 3 corresponding to a marked reduction in strain to ε 3 . Further heating results in a further minor reduction in strain to ε 4 with a modest increase in resistivity to a terminal resistivity ρ 4 .
The inventors have determined that the remaining life of the SMA actuator may be determined from consideration of certain of these various features of the resistivity versus time curve, particularly the difference between the terminal resistivity ρ 4 , and the minimum resistivity, ρ 3 .
The minimum resistivity, ρ 3 , indicates the residual strain level in the actuator after the bulk of the transformation has taken place. Additional transformation may result from continued heating, reducing the strain to ε 4 and increasing the resistivity to the terminal resistivity, ρ 4 . However as shown at FIG. 4 , this continued heating results in an overtemperature condition and the resistivity difference (ρ 4 −ρ 3 ) is linearly related to the maximum temperature when the maximum temperature exceeds 140° C.
The utility of the resistivity values and their differences may best be appreciated by consideration of the evolution in the resistivity versus actuation or heating time curves for a particular SMA actuator as shown in FIGS. 5A and 5B . For convenience, the actuator may be selected to be typical of that employed as the actuator in a linear mechanism such as shown in FIGS. 1 and 2 . In this application the actuator is intended to position a device at one of two positions. These positions correspond to a first position when power is applied and a second position when power is removed, and may, in different devices, be variously described as a deployed or an advanced or a powered-on position and a stowed or a retracted or a powered-off position among others. Whatever the terminology the actuator is intended to deliver a fixed stroke or displacement over some design lifetime, generally expressed in terms of a number of cycles, with each cycle corresponding to one progression of the actuator from the first position to the second position and back to the first position.
Commonly such SMA actuators are designed conservatively so that initially the intended displacement is obtained without fully transforming the SMA. In such a fixed displacement device, the resistance of the SMA element during heating evolves in a consistent and reproducible manner from the curve of FIG. 5A to the curve of FIG. 5B . Early in its intended life the resistance will follow the pattern of FIG. 5A . Typically the device will be at ambient or near-ambient temperature initially and the resistance will modestly increase until the temperature at which the martensite begins to transform to austenite is reached. The resistance will then adopt its maximum value R 2 as the phenomena described in connection with FIG. 2 occur and the strain in the SMA element progressively reduces. When the SMA achieves a strain corresponding to the desired device displacement, the current may be maintained at its current value resulting in a constant resistance (R 3 ). Because of the conservative design of the actuator, generally only some portion of the SMA will have transformed, and the measured resistivity value (R 3 ) will not be representative of a fully austenitic wire.
After some cycling, cycle-to-cycle irreversibility will begin to permanently degrade the SMA element. Typically the SMA element will accumulate some plastic strain, manifested as a permanent extension of the wire, which will lead to a reduction in the available stroke. In a fixed displacement device, this will require that the element contract to a greater extent to compensate for the permanent extension. This will require additional heating so that the SMA may achieve a more elevated temperature to promote additional transformation of martensite to austenite. As this occurs, the value of the term (R 4 −R 3 ) will, analogously to the term (ρ 4 −ρ 3 ) of FIG. 4 , attain a non-zero value and the resistance versus heating time curve will evolve, near end-of life, to that shown in FIG. 5B , the form previously shown in FIG. 3 . Now, the rapid decrease in resistance ‘bottoms out’ at minimum resistance R 3 and the resistance then increases gradually before reaching its terminal value R 4 .
The development of such a minimum in the resistance or resistivity is a clear indication of irreversible changes in the SMA wire and serves as an indication that the SMA wire is approaching the end of its useful life. Thus any non-zero value of (R 4 −R 3 ) or (ρ 4 −ρ 3 ) will signal approach to device ‘end-of-life’.
The difference in resistance (R 4 −R 3 ), like the difference in resistivity (ρ 4 −ρ 3 ) of FIG. 4 , is proportional to the overtemperature or temperature in excess of 140° C. for the SMA alloy investigated. It is these overtemperature excursions which promote yet further irreversible extension of the SMA wire and lead to its eventual failure.
The inventors have determined that the magnitude of the resistivity difference (ρ 4 −ρ 3 ) is inversely related to the remaining life of the SMA wire. Each of FIGS. 6A-C shows a series of curves developed using an SMA wire to repeatedly raise and lower a weight of a specific mass. A series of fixed electrical currents is applied to the SMA wire for a period of 1 second and the value of (ρ 4 −ρ 3 ) is plotted versus the number of the test cycle until the wire fails by fracture. The terminal (failure) cycles for each current are described by a failure curve. Because the test is conducted under a fixed stress and without any attempt to control displacement, the value of (ρ 4 −ρ 3 ) changes very little over the life of the wire. The clear relationship between (ρ 4 −ρ 3 ) and life is evident and a similar relationship obtains under alternate operating schemes, such as that employed on the air dam of FIGS. 1 and 2 .
Thus the magnitude of the parameter (ρ 4 −ρ 3 ), or equivalently of (R 4 −R 3 ), may be employed to provide two pieces of information on the state of the SMA wire. First, since the device is initially intended to operate at a terminal resistivity of ρ 3 , in the early stages of life, the initial value of (ρ 4 −ρ 3 ) will be zero. As is clear from the data of any of FIGS. 6A-C , the measured resistivity change, (ρ 4 −ρ 3 ), may exhibit noise which may, in some circumstances, be comparable to the signal. Hence suitable data smoothing or data averaging techniques, such as a multi-sample running average may be employed to enable systematic changes to be more reliably detected. But the onset of a statistically-reliable, that is, not noise-generated, positive non-zero value of (ρ 4 −ρ 3 ) may serve as an early indication that an SMA wire is approaching its end of life and that wire fracture may be anticipated.
In FIG. 7 , the logarithm of the cycles to failure is shown plotted against the logarithm of the resistivity. A generally straight line relationship is observed, but in common with many fatigue processes there is some variability in the life of the SMA wire, even under a constant applied current. The scatter tends to be greater at long lifetimes and under small resistivity changes which may be more difficult to measure due to the presence of electrical noise as addressed above. This relationship may be exploited to estimate the remaining useful lifetime (in cycles) of the SMA. A suitable relation for estimating the remaining life of a actuator is:
N REM =N (ρ 43F /ρ 43 −1) Equation 1
where:
N REM =Remaining number of cycles
N=Current number of cycles
ρ 43F =Value of (ρ 4 −ρ 3 ) at failure; a suitable value for the alloy used in this study is 1.8×10 −9 ohm-meters.
ρ 43 =Current value of (ρ 4 −ρ 3 )
The above relationship, using the suggested fixed value of ρ 43F of 1.8×10 −9 ohm-meters, has been found to be accurate, to within a factor of two, over the last 70% or so of life, and over lifetimes spanning 4 decades. This level of accuracy, which may be enhanced by ‘tuning’ or customizing the factor ρ 43F for individual devices and SMA compositions, is satisfactory since the estimates are conservative, underestimating the remaining life. Thus, continued device operation, provided some additional life is predicted by the model, should not lead to unanticipated device failure. Also errors in the remaining life prediction lessen as end of life is approached so that the prediction is generally most accurate when failure is imminent.
More generally, given the analogous behavior of resistance and resistivity, the above relationship may be represented as:
N REM =N ( RR 43F /RR 43 −1) Equation 2
where:
N REM =Remaining number of cycles; N=Current number of cycles; RR 43F =Value of (terminal resistance−minimum resistance) or (terminal resistivity−minimum resistivity) at failure; and RR 43 =Current value of (terminal resistance−minimum resistance) or (terminal resistivity−minimum resistivity).
Of course, a value of RR 43F , like ρ 43F appropriate to a specific actuator and SMA wire may be determined experimentally or in any other suitable manner.
Knowledge of the variation in resistivity of an SMA device may be incorporated into a control and monitoring scheme as schematically illustrated in FIG. 8 . As depicted in FIG. 8 , control and monitoring is effected by a series of interconnected modules, each capable of executing one or more operations, with appropriate communication links between them. Those skilled in the art will appreciate that the operations ascribed to each of the modules may be implemented in a like number of separate and distinct devices, as shown, or integrated into a single dedicated device. Also the operations may be implemented in hardware, firmware or software and, if implemented in software, may be implemented in a dedicated computer or implemented in a generalized computing device, such as an Engine Control Module (ECM). Similarly communication links may be internal or external to the devices and may be representative of physical connections of either electrical or optical transmission lines or reflect wireless communication between suitably matched transmitters and receivers.
As shown, an SMA device such as air dam 10 with SMA element 30 ′ is exercised under the control of controller 50 responsive to inputs from either a vehicle operator or an on-board computing device or similar (not shown). An on-board computing device may command controller 50 , for example, to actuate device 10 under some predetermined vehicle operating conditions such as exceeding a predetermined vehicle speed. During device actuation a resistance measurement system 52 may repeatedly determine the resistance (R) or, the resistivity (ρ) of the SMA element to develop a curve of resistance or resistivity versus heating time like those shown in FIGS. 5A and 5B and FIG. 3 . For convenience, future discussion will refer only to resistivity, but analogous procedures apply to resistance measurements also. From the resistivity versus heating time curve, an analysis module 54 may extract values of ρ 1 , ρ 2 , ρ 3 and ρ 4 from the curve. The values of ρ 3 and ρ 4 , and, optionally, of ρ 1 and ρ 2 also, pass to data bank or data repository 56 where at least some number of the most recent values of these parameters may be stored, for example in a push-down stack.
These values of ρ 3 and ρ 4 may be passed to a comparator 58 where they may be compared with prior values of these parameters ρ 3 ′ and ρ 4 ′ obtained from data bank 56 . Comparator 58 may include some computing and logic capability to enable comparison of the current (ρ 3 and ρ 4 ) and prior (ρ 3 ′ and ρ 4 ′) resistivity values, or any combination of these values such as (ρ 4 −ρ 3 ) and (ρ 4 ′−ρ 3 ′).
If such comparison yields an unexpected or problematical result, comparator 58 may pass that result to controller 50 by two routes. In a first approach comparator 58 may first pass the result, via link 72 , to operator alert module 60 which in turn will communicate the result to controller 50 via link 66 . In a second approach the comparator may pass the result directly to controller 50 via link 68 .
The use of both links enables controller 50 to respond appropriately without alerting an operator when a sensed condition calls for no action from the operator. Operator alert 60 may employ auditory signals as depicted but visual and haptic alerts, or any combination of these, may be used. But it is preferred that any visual indication employ messaging so that the operator may be informed of the specifics of any problem and provided some indication of its severity. Color coding of the message characters or the message background may also be employed to communicate the severity of any operational concerns. Thus red-colored characters or a red-colored background might be employed to indicate an issue requiring immediate operator attention, while a yellow-colored character of background may serve to alert the operator to an impending future issue or concern.
Comparator 58 may also pass information to the Remaining Life Prediction module 62 , but typically only when a non-zero value of (ρ 4 −ρ 3 ) is recorded. The Remaining Life Prediction module may then execute one of Equation 1 or Equation 2 without concern for ‘divide by zero’ errors or ‘negative divisor’ issues. When the estimated remaining life (N F −N) is less than a preselected threshold the Remaining Life Prediction module 62 may communicate with the Operator Alert module over communication link 64 .
As is clear by inspection of FIGS. 6A-C , there can be appreciable cycle-to-cycle variation, or noise, in the instantaneous determined values of ρ 3 , ρ 4 and (ρ 4 −ρ 3 ). It is important that the influence of such noise be minimized so that the progressive and systematic variation in (ρ 4 −ρ 3 ) which may be related to remaining life may be confidently detected. Approaches to reducing noise in digital data are well known to those skilled in the art. Since the noise has a high frequency while the variation in (ρ 4 −ρ 3 ) occurs at a much lower frequency, the evolution of (ρ 4 −ρ 3 ) over time may be extracted by filtering. The individual values of ρ 3 and ρ 4 may be filtered before computing (ρ 4 −ρ 3 ) or (ρ 4 −ρ 3 ) may be determined from the unsmoothed values of ρ 3 and ρ 4 and the resulting values of (ρ 4 −ρ 3 ) may be filtered. As an example, a running average may be used to filter the data since a running average is a simple filter in which all terms are weighted equally. Of course more sophisticated filtering schemes which assign variable weights to the data may also be employed.
The Remaining Life Prediction Module may continue to update its estimate of remaining life with continued use of the device, whether or not an alert has been issued. Preferably a continuing series of increasingly urgent alerts would be provided to the operator as the estimated life continues to decline. Representative examples of increasingly urgent alerts may include auditory alerts of increasing loudness, flashing visual alerts of increasing brightness and/or frequency and haptic alerts of increasing intensity. The Operator Alert module may communicate with Controller 50 over link 66 so that the Controller may modify or amend the actuation scheme to minimize degradation if appropriate. For example, as end-of-life approaches, the Controller may revert to a ‘limp-home’mode, and communicate this to a vehicle operator, to enable reduced device capability. Communication link 70 enables direct communication between Remaining Life Prediction module 62 and Controller 50 , bypassing the Operator Alert module when operator alert is unnecessary, typically when the life threshold has not been crossed.
Examples of limp-home modes may include disabling the SMA function, and hence device operation entirely. Alternatively, for devices, such as the air dam, which actuate automatically under predetermined conditions, the frequency of deployments may be reduced. This may be accomplished, for example, by imposing more restrictive conditions on deployment, say by changing from deploying a speeds in excess of 50 miles per hour to deploying at speeds in excess of 65 miles per hour. A further alternative suitable for some devices, again such as an air dam, which function, albeit at reduced effectiveness, when less than fully deployed, the stroke of the SMA actuator may be reduced by reducing the maximum applied current.
While preferred embodiments of the invention have been described as illustrations, these illustrations are not intended to limit the scope of the invention.
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Mechanical devices powered by Shape Memory Alloy (SMA) wires or other linear elements offer advantages in automotive applications. Such SMA-powered devices are commonly reliable and long-lived but have a finite lifetime. Measurements of the electrical resistivity of an SMA element during operation of the element may be related to the remaining lifetime of the element. Because operation of SMA elements is promoted by heating the element, usually by passage of an electric current, the resistivity measurements, and hence assessment of SMA element operation, may be made without interruption to the operation of the SMA-powered device and without addition of dedicated sensors.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This Application claims priority to German Application Number 102011115142.0 filed Sep. 27, 2011 to Ewald Rimmel entitled “Complete-Cut Station and Method for Separating Packages,” currently pending, the entire disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates to a complete-cut station and to a method for separating several packages from a coherent film.
BACKGROUND OF THE INVENTION
[0003] A complete-cut station and a method for separating packages that are produced in one common coherent film are currently used in packaging machines. Frequently, complete-cut stations are used in packaging machines in which packages are produced from or with a plastic sheet, e.g. in deep-drawing machines For reasons of efficiency, packages may be frequently produced using several tracks and several rows, i.e. an array of packages is produced in one work cycle, with several packages being provided one behind the other as well as side by side in the direction of production. These packages may be joined together in one common coherent film, as at least one film (i.e. the lower film and/or the upper film) that extends continuously across all packages, connecting these packages to one another. If deep-drawing machines are used, it is often the lower film in which package troughs are deep-drawn, and the upper film is sealed simultaneously onto a plurality of package troughs or trays.
[0004] On principle, there are two different possibilities to separate such packages joined by a coherent film. In the first alternative, a longitudinal cutting device and a cross-cutting device are provided one behind the other, i.e. separated from each other, in the direction of transport. First, the cross-cutting devices are usually set between adjacent rows of packages, i.e. the coherent film is cut through between adjacent rows. Subsequently, the longitudinal cutting device may then separate the packages of the respective tracks.
[0005] In the second alternative, on which the present invention is based, packages may be cut out or punched out of the coherent film in one work step.
SUMMARY OF THE INVENTION
[0006] It is the object of the present invention to improve a complete-cut station and a method for separating packages using a complete-cut station to obtain higher-quality packaging.
[0007] This object is achieved by a complete-cut station comprising several cutting tools. Each cutting tool may, in turn, be provided with one or more cutting knives either for separating an individual package or for separating several packages. For example, the cutting knives of a cutting tool may be adapted to cut all packages out of the coherent film of a complete track or row of an array of packages, thereby separating them. At least one of these cutting tools may be adjustable with respect to its position relative to another cutting tool. This feature has the effect that the cutting contour produced by the complete-cut station as a whole is variable without exchanging or changing the cutting knives. This configuration has the enormous advantage that the cutting contour can be varied if a variation, e.g. with respect to the position of the sealed seams of the packages to be separated, is present. Such a variation can occur, for example, if a different packaging material is used or if the environmental conditions and, thus, the properties of the packaging material change. In particular, this may result in a different warpage of the packaging film as the coherent film is fed forward. This warpage can now be compensated in whole or in part by varying the position of the cutting tools in the complete-cut station. Thus, the cutting contour produced by the complete-cut station as a whole can be optimized with respect to the position and the course of the sealed seams of the packages. This increases the quality of the packages and may result in an excess width of a sealed seam, which had frequently been necessary in former times for reasons of safety, being reduced or even totally omitted, thereby saving material and, ultimately reducing the packaging costs.
[0008] Another great advantage of the invention may be achieved by providing one common lifting gear for all cutting tools despite the relative adjustability of positions. Thus, not only the drive of the cutting tools remains simple, but it also ensures, in a constructively simple manner, that all packages are cut out of the coherent film at the same time or approximately at the same time.
[0009] In particular, an adjustment of the cutting contour to a changing position of the sealed seams of the packages may be easily possible when the at least one adjustable cutting tool is adjustable with respect to its position in a horizontal direction relative to another cutting tool.
[0010] In general, an optimum adjustment of the cutting contour to the sealed seams of the packages can be achieved if the at least one adjustable cutting tool is adjustable with respect to its position in a direction parallel to a direction of production of the complete-cut station and/or transversely to this direction of production. In particular, an optimum adjustment of the cutting contour to the sealed seams may be obtained if no sealed seams are affected by the cutting contour of the complete-cut station, so that all sealed seams are preserved in terms of their original width and strength.
[0011] It would be conceivable that more than one cutting tool is adjustable relative to one another with respect to their positions. For example, a separate cutting tool could be provided for each row or each track of packages in an array of packages of more than two rows or three rows (or two or three tracks, respectively). Also, several separate cutting tools could be provided per row or track of packages. In an extreme case even a separate cutting tool would be provided for each single package, which is adjustable with respect to its position relative to the other cutting tools or a stationary cutting tool. The finer the subdivision of the complete-cut station into several separate cutting tools, i.e. the more cutting tools adjustable relative to one another are provided, the more effective the cutting contour may be varied and optimized with respect to the position of the sealed seams.
[0012] One embodiment includes a stop or an oblong hole guide to limit the adjustability of at least one of the adjustable cutting tools. This defines and limits the adjustment travel distance of the cutting tool and can thus facilitate the adjustment of a desired cutting contour.
[0013] In another embodiment, a conveyor belt or other conveying means for separated packages is provided underneath the cutting tools. As a result of gravity, or otherwise assisted by another appropriate guidance mechanism, the packages cut out of the coherent film by means of the complete-cut station may be transferred to the conveying means or onto outer packaging conveyed on the conveyor belt or other conveying means. The conveyor belt or other conveying means can then remove the separated packages from the complete-cut station.
[0014] According to another embodiment of the invention, a measuring device for detecting the position of sealed seams on packages is provided. This measuring device can comprise, for example, a sensor for detecting the position of the sealed seam. The detected position can be transmitted to and processed by a controller, and can be used for an optimum alignment of the cutting tools. The advantage thereof is that this may be accomplished automatically, without the interference by the user, even during the operation.
[0015] The invention further relates to the embodiments of a packaging machine comprising a complete-cut station of the above-described type, and to a method for separating packages from a coherent film using the complete-cut station of the present invention. The method provides for the production of sealed seams on several packages joined together in a coherent film, e.g. in a sealing station of a packaging machine.
[0016] Furthermore, the packaging machine or the complete-cut station may make a correlation between the position of the sealed seams and the position of the cuts in the coherent film producible or already produced by one or more cutting tools of a complete-cut station. Different possibilities are feasible for this method step. In one alternative embodiment, sealed seams are produced and the packages are then separated by the cutting tools of the complete-cut station. Subsequently, an automatic or manual or visual inspection of the correlation between the produced cuts and the position of the sealed seams takes place. It could be checked, for example, whether the cutting contour of the complete-cut station has contacted the sealed seams or cut through the sealed seams somewhere. Depending on the correlation checked in this way the position of one or more cutting tools of the complete-cut station can now be varied relative to the position of another cutting tool so as to optimize the position of the cutting contour with respect to the position of the sealed seams. In another alternative embodiment, the position of the sealed seams is detected before the packages are separated in the complete-cut station. Depending on this detected position of the sealed seams, the position of one or more cutting tools of the complete-cut station can be varied still before the packages are separated. In this case, too, the position of the cutting contour may be optimized with respect to the position of the sealed seams. Each cutting tool may be associated with a tray receptacle for receiving one or more trays.
[0017] In the method according to the invention it may be provided that a lifting motion of all tray receptacles of the complete-cut station is driven by a common lifting gear for all tray receptacles so as to move by this lifting motion all packages to the cutting tools, which, if necessary, are driven in the opposite sense, thereby separating them from the coherent film. Despite the possibility to adjust the position of the cutting tools, this step renders the method particularly simple.
[0018] According to an embodiment of the present method, the position of a sealed seam on one or more packages may be detected, and the adjustment of the position of one or more cutting tools is carried out in dependence on the detected position of the sealed seam. As was already described above, the sealed seam can be detected visually by an operator, or automatically by means of measuring device suited for this purpose. This measuring device could be, for example, a camera having a suited image evaluation software capable of detecting the position of the sealed seams from the recorded image of an array of packages.
[0019] In addition, or alternatively, correlating the position of the sealed seams with the position of the cuts producible by one or more cutting tools of the complete-cut station could also be realized by measuring a feed length of the coherent film, e.g. by a vision system detecting the position of sealed seams and/or markings on the packaging film. Changes in the feed length could then correspondingly be converted into changes of the relative positional relationship between the cutting tools of the complete-cut station so as to align the cutting tools, and specifically their cutting knives, optimally with respect to the position of the sealed seams.
[0020] Also, it was already explained that a particularly favorable adjustment of the cutting contour is ensured if the adjustment of the adjustable cutting tool(s) is accomplished in a horizontal direction.
[0021] The quality of the cuts made to separate the packages from the coherent film can additionally be improved through another embodiment of the present invention wherein the coherent film is clamped in a clamping frame prior to the separation of the packages. In particular, the clamping frame could clamp horizontal flanges or edges of the packages on which usually also the sealed seams of the packages are provided.
[0022] Other and further objects of the invention, together with the features of novelty appurtenant thereto, will appear in the course of the following description.
DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0023] In the accompanying drawings, which form a part of the specification and are to be read in conjunction therewith, in which like reference numerals are used to indicate like or similar parts in the various views:
[0024] FIG. 1 is a side view of a deep-drawing packaging machine including a complete-cut station in accordance with one embodiment of the present invention;
[0025] FIG. 2 is a top view of an array of packages having three tracks and four rows to be separated by a complete-cut station in accordance with one embodiment of the present invention;
[0026] FIG. 3 is a side view of a complete-cut station according to one embodiment of the present invention;
[0027] FIG. 4 is a top view of a complete-cut station having two cutting tools according to one embodiment of the present invention;
[0028] FIG. 5 is a side view of view of a complete-cut station according to another embodiment of the present invention;
[0029] FIG. 6 is a side view of view of a complete-cut station according to one embodiment of the present invention during the separation of packages; and
[0030] FIG. 7 is a side view of view of a complete-cut station according to one embodiment of the present invention after the separation of packages.
[0031] Like components are provided with like reference numbers throughout the figures.
DETAILED DESCRIPTION OF THE INVENTION
[0032] The invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. For purposes of clarity in illustrating the characteristics of the present invention, proportional relationships of the elements have not necessarily been maintained in the drawing figures.
[0033] The following detailed description of the invention references specific embodiments in which the invention can be practiced. The embodiments are intended to describe aspects of the invention in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments can be utilized and changes can be made without departing from the scope of the present invention. The present invention is defined by the appended claims and the description is, therefore, not to be taken in a limiting sense and shall not limit the scope of equivalents to which such claims are entitled.
[0034] FIG. 1 shows a schematic view of a packaging machine 1 according to the invention in the form of a deep-drawing machine. This deep-drawing machine 1 comprises a forming station 2 , a sealing station 3 and a complete-cut station 4 according to the invention, which are arranged in this order in a working direction R on a machine frame 6 . On the input side a feed roller 7 is mounted on the machine frame 6 , from which a film 8 is withdrawn. In the region of the sealing station 3 a material storage 9 is provided from which a cover film 10 is withdrawn. The packaging machine 1 further comprises a non-illustrated feed device, which grips the film 8 and conveys it further in the working direction R per main work cycle. The feed device can be, for example, conveyor chains arranged on both sides of the film 8
[0035] In the represented embodiment the forming station 2 is realized as a deep-drawing station, in which troughs 14 are formed into the film 8 by deep-drawing. The forming station 2 may be configured such that several troughs are formed side by side in the direction perpendicular to the working direction R. A charging section 15 is provided in the working direction R behind the forming station 2 , in which troughs 14 formed in the film 8 are manually or automatically filled with a product 16 .
[0036] The sealing station 3 has a closable chamber 17 in which the atmosphere in the package troughs 14 can be replaced prior to the sealing, e.g. by gas-flushing with a replacement gas or a gas mixture. Alternatively, the package troughs 14 may be evacuated in the closable chamber 17 .
[0037] In the complete-cut station 4 the packages produced together in one work cycle of the packaging machine 1 are separated at the same time, i.e. they are cut out of the coherent film 5 simultaneously. This coherent film 5 is made of the lower film 8 and the cover film 10 , through which all packages of the group of packages are joined together. In the complete-cut station each package is cut out or punched out of the coherent film 5 in one single operation.
[0038] The packaging machine 1 further comprises a controller 18 . The controller 18 has the task of controlling and monitoring the processes executed in the packaging machine 1 . A display device 19 with operating elements 20 serves to visualize and influence the process operations in the packaging machine 1 for or by an operator, respectively.
[0039] The general operating mode of the packaging machine 1 will be briefly described below.
[0040] The lower film 8 is withdrawn from the feed roller 7 and conveyed by a feed device into the forming station 2 . In the forming station 2 troughs 14 are formed in the film 8 by means of deep-drawing. The troughs 14 and the surrounding region of the film 8 are conveyed in one main work cycle further to the charging section 15 , in which they are filled with a product 16 .
[0041] Subsequently, in another main work cycle, the filled troughs 14 and the region of the film 8 surrounding them are conveyed further by the feed device into the sealing station 3 . After the covering film 10 has been sealed to the film 8 it is conveyed further by a feed motion of the film 8 , whereby the cover film 10 is withdrawn from the material storage 9 . By sealing the covering film 10 onto the package troughs 14 sealed packages 21 are created, which are initially still joined together in one common coherent film 5 . As explained, this coherent film is formed of the lower film 8 and the cover film 10 . In the complete-cut station 4 the packages 21 are eventually separated.
[0042] Outer packagings 22 , e.g. cartons, may be provided in the region of the complete-cut station 4 to receive separated packages 21 . FIG. 1 shows an alternative in which outer packagings 22 are conveyed by means of a conveying member, e.g. a conveyor belt 23 , to a position underneath the complete-cut station 4 . There, each outer packaging 22 can be filled from above by means of one or more groups of simultaneously produced and separated packages 21 . Once an outer packaging 22 is completely filled, it is removed by the conveyor belt 23 and replaced by a new outer packaging 22 . Alternatively, the conveyor belt or conveying means 23 could also directly remove the separated packages 21 , i.e. without outer packagings 22 . As shown in FIG. 1 , the conveying means 23 could be aligned transversely to the production direction R of the packaging machine 1 as well as in the production direction R or parallel to the production direction R.
[0043] FIG. 2 shows a group 24 of twelve packages 21 simultaneously produced in one work cycle of the packaging machine 1 . These twelve packages 21 are arranged in an array of three tracks and four rows. Each track extends in the production direction R of the coherent film 5 , and each row extends transversely to the production direction R.
[0044] In the sealing station 3 each package 21 is provided with a sealed seam 25 , which is located in the shape of a ring on the surrounding edge of the package 21 . In the complete-cut station 4 the packages 21 are to be separated by cutting each package 21 out of the coherent film 5 along a cutting contour 26 which is supposed to be outside of the sealed seam 25 . It would be optimal if the cutting contour 26 extended around the package 21 equidistantly with respect to the sealed seam 25 , preferably with a smallest possible space from the sealed seam 25 .
[0045] FIG. 3 shows in a schematic lateral view a first alternative of the complete-cut station 4 according to the invention. The complete-cut station has two separate cutting tools 30 . Each of these cutting tools 30 comprises cutting knives 31 at their lower sides. The cutting knives 31 produce such a cutting contour 26 that two rows of packages 21 can be cut out of the coherent film 5 Consequently, the two cutting tools 30 are capable of cutting out four rows of packages 21 and, thus, the whole group 24 represented in FIG. 2 with 3×4 packages 21 .
[0046] Two tray receptacles 32 are located underneath the cutting tools 30 and are each associated with one of the two cutting tools 30 . Each tray receptacle 32 is provided to receive exactly the number of packages 21 that can be cut out by the associated cutting tool 30 . The tray receptacles 32 have annular bearing surfaces 33 on which the edges of the packages 21 can rest during the separation. Drop shafts 34 are located between the bearing surfaces 33 , through which the separated packages 21 can drop onto the conveying means 23 situated underneath the tray receptacles 32 .
[0047] A clamping frame 35 capable of clamping the edges of a group 24 of packages 21 against the bearing surfaces 33 during the separation is provided between the cutting tools 30 and the associated tray receptacles 32 . In the opened state of the complete-cut station 4 as shown in FIG. 3 the coherent film 5 with the packages 21 is conveyed between the clamping frames 35 and the bearing surfaces 33 into the complete-cut station 4 in production direction R.
[0048] A lifting gear 36 is provided as a common lifting drive for all cutting tools 30 and for all tray receptacles 32 of the complete-cut station 4 . In the embodiment of FIG. 3 the lifting gear 36 is a lifting table which may be driven, for example, electromotively or pneumatically. Arrow P shows that the whole lifting table 36 carrying the cutting tools 30 and the tray receptacles 32 can be shifted in a direction along or opposite to the production direction R so as to allow an easy adjustment of the complete-cut station 4 to the position of the packages 21 or the desired position of the cutting line 26 . This applies, in particular, to the position of the cutting tool 30 illustrated on the right and the associated tray receptacles 32 on the right, which are fixedly mounted on the lifting table 36 in a horizontal direction. They are aligned relative to one another to allow the cutting knives 31 of the cutting tool 30 to move into openings in the clamping frame 35 as well as into the drop shafts 34 of the tray receptacles 32 .
[0049] The group of the cutting tool 30 and the associated tray receptacle 32 shown on the left is adjustable relative to the right cutting tool 30 in the horizontal direction, which is indicated by arrow A. During this horizontal adjustment of the position of the cutting tool the tray receptacle 32 always moves along, so that in this case, too, the cutting knives 31 are always capable of moving into the drop shafts 34 of the tray receptacle 32 if the cutting tool 30 is moved vertically to the tray receptacle 32 . The horizontal adjustability of the cutting tool 30 shown on the left in direction A is limited by a stop 37 between the two tray receptacles 32 . This stop 37 may be adjustable, e.g. in the form of a stop screw.
[0050] Vertical guides 38 , e.g. guide rods, make sure that the cutting tools 30 and the clamping frames 35 are always aligned to the associated tray receptacles 32 , even if the tray receptacles 32 and the cutting tools 30 move towards one another in a vertical direction.
[0051] FIG. 4 shows a top view of the tray receptacles 32 of the complete-cut station 4 as illustrated in FIG. 3 . Each tray receptacle 32 comprises four drop shafts 34 each having an oval contour. The drop shafts 34 are surrounded by a horizontal bearing surface 33 . Each of the four corners of each tray receptacle 32 is penetrated by a vertical guide 38 .
[0052] As described above, the right tray receptacle 32 is fixedly mounted on the lifting table 36 , while the left tray receptacle 32 is adjustable with respect to its position in direction A, i.e. in the production direction R, together with the associated cutting tool 30 provided above the same. Two oblong hole guides 39 serve to guide and limit the horizontal adjustability of the tray receptacle 32 and the cutting tool 30 . These oblong hole guides 39 are each comprised of an oblong hole 40 , which is formed in the tray receptacle 32 , and a bolt 41 penetrating through this oblong hole 40 and being fixedly mounted on the lifting table 36 .
[0053] FIG. 5 shows a second embodiment of a complete-cut station 4 . This embodiment merely differs from the embodiment shown in FIG. 3 by the two separate cutting tools 30 now being adjustable relative to one another and also relative to the lifting gear or lifting table 36 , respectively, in the horizontal direction A. Horizontal guides 42 guide and limit the adjustability of the tray receptacles 32 and the associated cutting tools 30 . In all embodiments it is conceivable that the cutting tools 30 can be adjusted not only in the production direction R, but, alternatively, or additionally, also transversely to the production direction R so as to allow an adjustment of the cutting contour 26 to the position of the sealed seams 25 .
[0054] FIG. 6 shows the complete-cut station 4 illustrated in FIGS. 3 and 5 during the separation of the packages 21 from the coherent film 5 Proceeding from the opened states ( FIGS. 3 and 5 ), initially the tray receptacles 32 and the clamping frames 35 were moved towards one another along the vertical guides 38 until the coherent film 5 is clamped between them. Subsequently, the cutting tools 30 move downwardly in the vertical direction along the guides 38 until the cutting knives 31 have cut through the coherent film 5 and, thus, separated the packages 21 . A mechanism ensures that the lifting motion of the lifting gear 36 is transferred in a suitable fashion to the tray receptacles 32 for these working steps to be carried out. The lifting gear 36 thus serves as a common drive for all tray receptacles 32 of the complete-cut station 4 . All cutting tools 30 and all clamping frames 35 may be driven by another common lifting drive H.
[0055] FIG. 7 shows the complete-cut station 4 at a time after the separation of the packages 21 . The separated packages 21 have fallen through the drop shafts 34 and are now located on the conveying means 23 , which can convey the packages 21 out of the complete-cut station 4 and thus out of the packaging machine 1 .
[0056] In order to detect the position of the sealed seams 25 of the group 24 of packages 21 a measuring device 44 may be provided between the sealing station 3 and the complete-cut station 4 , see FIG. 1 . Such a measuring device 44 could be, for example, a camera having a suited image evaluation software, which detects the position of the sealed seams 25 and transmits it to the machine controller 18 . The machine controller 18 can then adjust the position of the cutting tools 30 of the complete-cut station 4 so that the cutting contour 26 is optimally aligned relative to the position of the sealed seams 25 .
[0057] Based on the described embodiment it is possible to modify the inventive complete-cut station and the inventive method in many ways. In particular, the complete-cut station 4 may be configured to separate any optional number of n×m packages 21 . Moreover, the number of the cutting tools 30 of the complete-cut station is not limited to two, but there may also be provided three, four, five or more separately adjustable cutting tools 30 .
[0058] The constructions and methods described above and illustrated in the drawings are presented by way of example only and are not intended to limit the concepts and principles of the present invention. Thus, there has been shown and described several embodiments of a novel invention. As is evident from the foregoing description, certain aspects of the present invention are not limited by the particular details of the examples illustrated herein, and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. The terms “having” and “including” and similar terms as used in the foregoing specification are used in the sense of “optional” or “may include” and not as “required”. Many changes, modifications, variations and other uses and applications of the present construction will, however, become apparent to those skilled in the art after considering the specification and the accompanying drawings. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention which is limited only by the claims which follow.
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A complete-cut station for separating several packages from a coherent film. The complete-cut station may comprise several cutting tools, each cutting tool having cutting knives for separating one or more packages from the coherent film. At least one of the cutting tools may be adjustable with respect to its position relative to another cutting tool. In addition, a common lifting gear for all cutting tools may be provided to lift the coherent film to engage the cutting tools. The invention further relates to a corresponding method for separating packages from a coherent film using the complete-cut station of the present invention.
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BACKGROUND OF THE INVENTION
In the manufacture of printed circuit boards, printed circuit elements and like goods, and in processes in connection with the same, it has become commonplace to deliver the articles, such as printed circuit boards, through a chamber in a continuous manner, while the articles are being treated by the spray of a suitable treatment fluid, such as an etchant onto them. Generally, the etchant is of a corrosive nature, such as ammonium hydroxide and ammonium chloride, with a suitable chelating or complexing agent, although other etchants or treatment fluids may also be utilized. See, for example, U.S. Pat. No. 4,233,106, the disclosure of which is herein incorporated by reference.
Most particularly, when the treatment fluids are corrosive in nature, and are dangerous to personnel handling the apparatus, particularly to the skin, eyes, etc., of such personnel, and particularly to nearby equipment as well, it is desirable to prevent access by such personnel to such treatment fluid.
In the course of preventing such access, it has been known to perform the various treatments in chambers, with limited, slit-like access at the inlets and outlets thereof to the treatment chambers. See, for example, U.S. Pat. Nos. 3,776,800 and 4,015,706, the entire disclosures of which are herein incorporated by reference.
In many such operations, it is desirable to provide access to the interior of the chamber by personnel, which access may readily be obtainable upon opening or removing a door or the like, for purposes of repair, cleaning, correcting some malfunction, or for any myriad of reasons that may dictate the desirability of access to the interior of the chamber.
PRESENT INVENTION
The present invention is directly toward effecting the treatment of articles, in such a manner that the same may be done in sealed-off arrangement relative to the exterior of the chamber (except as to inlet and outlet access for articles entering and leaving the chamber), and principally in such a manner as to effect a seal of the access door to the wall of the chamber in which such door exists, and especially to do so in such a manner that the seal is fluid-tight and can prevent fluid from the interior of the chamber from contaminating the working environment outside the chamber through the closed access door.
SUMMARY OF THE INVENTION
The present invention is therefore directed toward the chemical treatment of articles in a substantially closed chamber, in which access to the chamber by means of a door through a wall, may be securely provided, but may be released when desired to facilitate access to the interior of the chamber.
Accordingly, it is a primary object of this invention to provide a method of treating articles under conditions of novel controlled access to the interior of the chamber in which the articles are being treated.
It is a further object of this invention to accomplish the above object, in which an access door to the interior of the chamber may be effectively sealed by means of a fluid-pressure-operative seal, but which may be releasably de-actuated, for access to the interior of the chamber.
It is a further object of this invention to provide an apparatus for treating articles in a substantially closed chamber, but wherein the chamber is provided with an access door that may be selectively sealed or unsealed, depending upon whether or not access is desired to the chamber.
It is a further object of this invention to accomplish the above object, wherein the door is provided with an expansible fluid-operative seal that may be selectively actuated or de-actuated, depending upon the restriction of access to, or desired access to, the interior of the chamber.
Other objects and advantages of the present invention will be readily apparent to those skilled in the art, from a reading of the following brief descriptions of the drawing figures, detailed description of the preferred embodiment, and the appended claims.
IN THE DRAWINGS
FIG. 1 is a vertical sectional view, taken transverse of a chamber that is designed to practice the method of this invention, wherein the path of flow of articles through the chamber is indicated as being into the plane of the paper, and wherein the various functional components of the operation in the chamber are principally illustrated.
FIG. 2 is an enlarged fragmentary elevational view of a portion of the openable door in a wall of the chamber, and wherein the general design of the door is illustrated, with the view being taken generally along the line of II--II of FIG. 1.
FIG. 3 is a more highly enlarged, fragmentary, vertical sectional view, taken through the door and wall of FIG. 2, generally along the line III--III of FIG. 2, and wherein the expansible seal is more clearly illustrated.
FIG. 4 is a fragmentary vertical elevational view, of the wall of the chamber of the apparatus of this invention, taken generally along the line of IV--IV of FIG. 1, wherein the arrangment of the door and the wall of the chamber is illustrated.
FIG. 5 is an enlarged fragmentary cross-sectional view, partially in schematic, of the juncture of a portion of the door of the chamber with the wall of the chamber, as well as the apparatus and technique for expanding the door seal by means of fluid.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings in detail, reference is first made to FIG. 1, wherein there is illustrated a chamber generally designated by the numeral 10, having an interior 11, defined by front and back walls 12 and 13, respectively, upper and lower walls 14 and 15, respectively, and opposed end walls, only one of which is indicated by the numeral 17.
Printed circuit boards PCB or other articles being treated, pass through the chamber 10, in a direction into the plane of the paper, as illustrated, being driven through the chamber 10 by means of a drive mechanism similar to that set forth in U.S. Pat. No. 4,015,706, the disclosure of which is herein incorporated by reference. For purposes of brevity, the articles are driven by means of wheels 18 carried by rods 20, which rods 20 are rotatably driven at their ends by a suitable gear drive 21, with the gear drive 21 being driven by a suitable motor (not shown) that does not form a specific part of this invention.
The etchant or other treatment fluid is delivered from a suitable interior line 28, to preferably upper and lower spray headers 22 and 23, to deliver the treatment fluid through a plurality of spray nozzles or the like 24, to upper and lower ends of the articles being treated, as illustrated in FIG. 1. Suffice it to say, as the articles being treated move from one end to the other, 17 of the apparatus, as is described more fully in U.S. Pat. No. 4,015,706, they will generally be subjected to a number of similar spray treatments to that illustrated in FIG. 1. The treatment fluid is collected at the lower end of the chamber 11, at 25, for reuse, and such may be effected by delivering the same, preferably through a filter 26, to a pump 27, to be returned to the spray headers 22 and 23 via line 28, as illustrated, for recirculation of the fluid in that manner.
As aforesaid, the treatment fluid will generally be an etching fluid or an oxidation/reduction fluid, or a treatment fluid related to such an etching or like chemical treatment operation, and, it will therefore be desired that a treatment fluid be restrained, during the treatment operation, from passing outwardly of the chamber, through walls thereof, so as not to contaminate the exterior environment and/or personnel outside the chamber.
The upper portion of the wall 30 is provided with a removable door 31 therein. The door 31 is provided with a preferably transparent rectangular plate 32, situated in, and sealingly secured to a notched opening 33 in a frame portion 34 by means of a suitable bonding means. The frame portion 34 is defined by flattened peripheral portions 35, 36, connected by arcuate portions 37, which, aggregatively define the periphery 38 of the door. The frame portion 34 carries a flange plate 40 secured thereto, such that, when the door 31 is applied to the wall 30, from the exterior of the chamber 10, the protruding lip 41 of the flange portion engages against an adjacent surface 42 of the wall portion 30, as illustrated in FIG. 5. It will thus be apparent that the peripheral surface 38 of the door 31 faces a complementally configured surface 45 of the wall portion 30, which comprises means facilitating the closing of the door, as does the flange plate 40.
The surface 38 of the door has an arcuate, generally semispherical (in transverse section) groove 46 therein, which receives a hollow tubular seal 50 therein, to be carried by the door 31. The seal 50 is continuous around the periphery of the door, preferably bonded in place on each side of the groove 46, on surface 38 thereof at 49 as shown in FIG. 3, and forms a closed fluid-containing loop therein, with opposite ends of the hose-like structure brought together and sealed (not shown) to complete the loop. The seal 50 is adapted to receive a compressed fluid, such as compressed gas therein, to effectively expand the seal 50 radially outwardly as viewed in FIGS. 3 and 5, to tightly, frictionally engage against surface 45 in the wall portion 30, to sealingly engage the removable door 31, relative to the wall portion 30.
It will be noted that the seal 50 is constructed of a corrosion-resistant material, such as a suitable plastic or the like, hose-like material, suitable for the environment in which it is operating, and being generally flexible and expansible upon receipts of air or other fluid applied to the interior 53 thereof. Similarly, the other structural components of the chamber, such as the walls thereof, will preferably be constructed of a polypropylene, stainless steel, or other suitable materials that are able to withstand a corrosive environment.
The seal 50 will preferably be provided a suitable inlet port, in the form of a protruding nipple 54 that extends into a blind bore 55 for accommodating the same, from the bottom of the arcuate groove or recess 46 in peripheral wall 38 of the door, and this blind bore 55 communicates with a transverse bore 56, extending through door frame 34, as illustrated in FIG. 5, into the flange portion 40 carried thereby, to, in turn, meet with a communicating, longitudinal bore 57 therein, which, in turn, communicates with another transverse bore 58 in the frame number 40. A transverse bore 60 is disposed in wall portion 30, as illustrated in FIG. 5, and this communicates with a mounting block 61, inwardly of the wall portion 60, to carry a fluid fitting 62, coupling 63, and fluid inlet hose 64, as illustrated.
A sealing grommet 65 is provided, recessed in the outer surface of wall portion 30, as illustrated in FIG. 5, carried thereby, but with an opening therethrough, as illustrated, to form a part of the conduit 60, such that, upon placement of the door 31 in the opening in the wall portion 30, such that the flange portion 40 is disposed against the wall portion 30, as illustrated in FIG. 5, the transverse conduit 58 in the flange portion will register with, and communicate with the conduit portion 60 in the wall portion 30, in such a way that the sealing grommet 65 will seal the meeting surfaces against escape of fluid from the conduit portions 60 and 58, but will permit communication of fluid between the conduit portions 58 and 60, from one to the other.
In operating in accordance with the present invention, the door 31 will be provided in the wall portion 30 of the chamber, with the closed flexible and hollow seal 50 therein, as aforesaid. Then, seal-expanding fluid, such as compressed gas or the like, will be delivered by means not shown to line 70, through a preferably manual ball valve or the like 71, suitably actuated by preferably manual handle 74 to open and permit passage of the fluid from line 70, through valve 71, through manually operable pressure regulator 79, through constructing orifice 72, into line 75, when the valve handle 74 is in the full line operation shown in FIG. 5, to be delivered to flexible hose or the like 64, and eventually through the conduits 60, 57, 56, 55, into the inlet port 54 of the seal, and then into the interior 53 of the seal, to expand the same into tight frictional engagement against the surface 45 of the wall portion 30, to be in sufficiently tight engagement thereagainst as to prevent manual removal of the door, until release of pressure within the seal 50 is effected. A pressure sensor 73, preferably of the transducer type, is provided to sense a reduction of pressure in the line 75 (which reflects an insufficiently tight sealing of the door 31), and actuates a control device 76 which is connected via line 77 to shut down the pump 27, and to discontinue the treatment operation in the chamber, until the door seal is properly pressurized or the malfunction properly corrected. Accordingly, the pressure to the seal 50 will be maintained during the application of treatment fluid to the articles being treated within the chamber.
When it is desired to open the door, the manual activator or handle 74 may be engaged and moved in the direction of arrow 78 to assume the approximate position illustrated in phantom in FIG. 5, to close the ball valve 71, whereby pressure will no longer be provided therethrough to line 75, and whereby pressure that is within the seal 50 may be released, as, in the case of air being the fluid, to discharge to atmosphere (not shown) through bleed type regulator 79. It will also be apparent that, in times of emergency or the like, wherever access to the interior of the chamber 10 is desired, the control mechanism may be activated by means of the lever arm 74 or the like, to release fluid from the seal, in the manner just described.
It will be apparent from the foregoing that various modifications may be made in the details of construction, as well as in the use and operation of the preferred invention, all within the spirit and scope of the invention as defined in the appended claims. While the door of the apparatus of this invention is thus described, it will be apparent that the same terminology aptly describes a window or any other access panel or other structure where a sealed-closed arrangement is desired.
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A method and apparatus is provided for chemically treating articles, generally in a corrosive environment by etching or the like, where a corrosive substance is applied to the articles being delivered through a substantially closed chamber. The chamber is provided with access through an openable door, and a seal is provided between the door and the wall of the chamber. The seal is flexible and is inflatable, to prevent a treatment fluid with which articles are being treated within the chamber, from being dispersed from inside the chamber to outside the chamber at the juncture of the door with the wall of the chamber in which the door is located. The seal is expanded by means of a fluid pressure, and is releasable upon desired access to the chamber.
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PRIOR RELATED APPLICATIONS
This application is a U.S. 371 National Phase Patent Application and claims priority to PCT Patent Application PCT/CU2010/000004, Filed Oct. 8, 2010, Published on Apr. 14, 2011 as Publication No. WO 2011/041989; PCT Patent Application PCT/CU2009/000172, Filed Oct. 9, 2009, which applications are incorporated herein in their entireties by reference thereto.
OBJECT OF THE INVENTION
This invention is related to chemistry and pharmacy and, in particular, to the production of novel molecular entities: tricyclic and tetracyclic derivatives of the benzodiazepine, pyridodiazepine, and pyrimidodiazepine type fused with 1,4-dihydropyridine derivatives, acting upon the Vascular and Central Nervous Systems. From derivatives containing a dihydropyridine ring reacting with compounds of the ortho-phenyldiamine, ortho-diaminopyridine, and ortho-diaminopyrimidine type, as well as some subsequent transformations thereof, tricyclic and tetracyclic derivatives of the I-XII general formula can be obtained, with a diazepine or diazepinone nucleus fused to a 1,4-dihydropyridine nucleus, wherein cycle A is a substituted or unsubstituted ring of benzene, pyridine or pyrimidine.
Such molecular entities have a GABAergic and modulating action on calcium channels that can be used to treat cardiovascular, cerebrovascular, neurodegenerative, neuropsychiatric, and neurologic diseases.
BACKGROUND OF THE INVENTION
This invention is related to the chemical and pharmaceutical branches, and more specifically with obtaining new molecular entities, synthetic variants of diazepine fused dihydropyridines of a general formula:
DESCRIPTION OF THE INVENTION
For compounds of general formula I, II, III, IV, V, VI, VII, VIII, IX, X, XI, and XII, R represents H, alkyl group (preferable straight or branched chain alkyl groups having up to 8 carbon atoms such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, and octyl and all chain isomers thereof; as well as cyclic alkyl and alkyl-substituted compounds, preferably substituted with halogens; vinyl and vinyl-substituted compounds; and cycloalkyl chains, preferably the cyclohexyl group.
For compounds of general formula I, II, III, IV, V, VI, VII, VIII, IX, X, XI, and XII, R also represents an aryl group (benzyl, naphtyl, and substituted naphtyl or antracyl). The aryl and aryl-substituted group, represent, preferably, unsubstituted phenyl or phenyl substituted by one and up to five substituents independently selected from —NO 2 , —NH 2 , —OH, F, Cl, Br, I, —CN —OCH 3 , —N(CH 3 ) 2 ), —CH 3 , —OCOCH 3 , —COOCH 3 , —OCF 3 , —SH, —NH(C═O)—CH 3 , —CHO, —C═NH, —C═NH—NH 2 , —C═NH—OH.
For compounds of general formula I, II, III, IV, V, VI, VII, VIII, IX, X, XI, and XII, R also represents heteroaryl, and heteroaryl substituted, wherein heteroaryl and heteroaryl substituted refer preferably to furfuryl, furfuryl substituted, pyrrolidyl, pyrrolidyl substituted, thiophenyl, thiophenyl substituted, pyridyl, (2-pyridyl, 3-pyridyl, and 4-pyridyl), pyridyl substituted, quinoline (2-quinoline, 3-quinoline, and 4-quinoline), pyrazolyl.
For compounds of general formula I, II, III, IV, V, VI, VII, VIII, IX, X, XI, and XII, R also represents an heteroaryl, preferably pyrrol, thiophen, and phenyl-substituted furan, wherein the phenyl group can be substituted in turn by one or more substituents selected from —CN, —C(C═O)—CH 3 , F, Cl, Br, NH 2 , NO 2 .
For compounds of general formula I, II, and III, R 1 represents H, straight or branched chain alkyl group, and alicyclics, preferably having 1 to 16 carbon atoms.
For compounds of general formula I, II, and III, R 1 also represents OR′, wherein R′ can represent H or its Sodium (Na) and Potassium (K) salts; straight or branched chain alkyl groups having 1 to 24 carbon atoms, such as methyl, ethyl, propyl, isopropyl, butyl, isobutyl, sec-butyl, tert-butyl, pentyl, isopentyl, sec-pentyl, tent-pentyl, neopentyl, hexyl, isohexyl, sec-hexyl, tert-hexyl, heptyl, octyl, nonyl, decyl, undecyl, duodecyl, and all straight or branched chain position isomers thereof: —(CH 2 )n-O—(CH 2 )n-CH 3 ; —(CH 2 )n-O—(CH 2 )n-O—(CH 2 )n-CH 3 ) wherein n is equal to 1 and less than 8, —(CH 2 )n-CN, wherein n is a number between 1 and 8.
R′ also represents lipid chains derived from mono or polyunsaturated fatty acids having up to 24 carbon atoms.
R 1 also represents —NHR″, wherein R″ independently represents H, straight or branched alkyl groups of carbonate chains having from 1 to 24 carbon atoms; —(CH 2 )n-O—(CH 2 )n-CH 3 ; —(CH 2 )n-O—(CH 2 )n-O—(CH 2 )n-CH 3 ) wherein n is a number between 1 and 8, —(CH 2 )n-CN, wherein n=1-8; R″ also represents lipid chains derived from mono and polyunsaturated fatty acids having up to 24 carbon atoms.
R 1 also represents —NHR′″, wherein R′″ independently represents —(CH 2 )n-NH 2 , wherein n is a number between 1 and 10, like for example (and preferably) —NH—(CH 2 ) 6 —NH 2 , —NH—(CH 2 ) 3 —NH 2 ; R 1 also represents chains of the —NH—(CH 2 )n-NH(C═O)—R 3 type, wherein n is a number between 1 and 10 and R 3 represents straight or branched alkyl groups; unsaturated alkylate remnants of the —(CH 2 )n-C═C—(CH 2 )n-CH 3 type, preferably long chains having up to 18 carbon atoms. For example (and preferably) —NH—(CH 2 ) 6 —NH(C═O)—C 11 H 23 , —NH—(CH 2 ) 6 —NH(C═O)—C 7 H 14 —CH═CH—C 8 H 17 .
For compounds of general formula I, II and III, R 1 also represents amino acid remnants of the —NH—CH(R 4 )—COOH type, wherein R 4 is amino acid remnants, preferably from valine, phenylalanine, alanine, histidine, lysine, tryptophan, cysteine, leucine, tyrosine, isoleucine, proline, and methionine; R1 also represents small peptide chains having 2 and up to 12 amino acids, obtained by combining some of them, independently selected.
R 1 also represents —NH—OH; —NH—NH 2 ; —NH—NH—(C═O)—NH 2 ; —NH—NH—(C═S)—NH 2 .
R 1 also represents —NHR 5 , wherein R 5 is a thiazole or thiazole-substituted ring, 4-phenylthiazole or 4- phenylthiazole substituted; R 5 also represents a phenyl or a phenyl-substituted substituent.
For compounds of general formula I, II, and III, R 2 represents an alkyl or cycloalkyl group; alkyl groups can be straight or branched chained having 1 to 16 carbon atoms; —(CH 2 )n-NH 2 groups, and —(CH 2 )n-OH groups, wherein n is 1 to 8.
For compounds of general formula I, II, III, IV, V, VI, VII, VIII, IX, X, XI, and XII, cycle A is a 6-membered aromatic ring fused to the diazepine ring and represents a benzene or benzene-substituted ring, conforming a benzodiazepine, fused in such a way that it implies a structure and all its position isomers and all possible tautomers.
Benzene fused diazepine, represented as Ring A, is in turn substituted by one and up to four substituents independently selected from OH, COOH, CH 3 , NO 2 , NH 2 , CHO (formyl group), halogens and combinations thereof.
The benzene group fused diazepine, represented by A, can also be replaced with carboxylic acid derivatives —C(C═O)—R 6 , wherein R 6 represents O-alkyl, —O-aryl, NH 2 , —NH-alkyl, —NH-aryl.
The benzene group fused diazepine, represented by A, can also be replaced by a —NH—C(C═O,S)—N(R 7 ) 2 group, wherein R 7 is an H, or a small straight or branched chain alkyl group having 1 to 6 carbon atoms.
The benzene group fused diazepine, represented by A, can also be replaced by a —NH—(C═O,S)—OR 7 group, wherein R 7 is an H or small straight or branched chain alkyl group having 1 to 8 carbon atoms.
For compounds of general formula I, II, III, IV, V, VI, VII, VIII IX, X, XI, and XII, cycle A is also a 6-membered heterocyclic ring fused to the diazepine ring and represents a pyridine and pyridine-substituted ring, preferably with halogens. The pyridine ring can be fused to the diazepine ring in such a way that it will imply a structure and all possible position isomers and possible tautomers thereof.
For compounds of general formula I, II, III, IV, V, VI, VII, VIII IX, X, XI, and XII, cycle A is also a 6-membered heterocyclic ring fused to the diazepine ring and represents a pyrimidine substituted or unsubstituted ring, wherein one or both nitrogen atoms of the pyrimidine can be substituted by H, CH 3 , OH, SH y NH 2 and combinations thereof, independently selected; the carbon atoms of the pyrimidine can be independently substituted by one or more substituents selected from H or CH 3 as well as OH, SH, NH 2 , —C═O, —C═S, —C═NH, in such a manner that it implies a structure and all tautomeric forms, and position isomers and all tautomeric forms derived thereof.
For compounds of general formula I, II, III, IV, V, VI, VII, VIII, IX, X, XI, and XII, wherein cycle A is a pyrimidine-substituted ring, such pyrimidine ring can also be substituted in the carbon positions of the cycle by a R 8 substituent, wherein R 8 represents a straight or branched chain alkyl group having 1 to 6 carbon atoms, and preferably by an unsubstituted phenyl group or a phenyl group substituted by one and up to 5 substituents, independently selected from —NO 2 , —NH 2 , —OH, F, Cl, Br, I, —CN—OCH 3 , —N(CH 3 ) 2 ), —CH 3 , —OCOCH 3 , —COOCH 3 , —OCF 3 , —SH, —NH(C═O)—CH 3 , —CHO, —C═NH, —C═NH—NH 2 , —C═NH—OH, in such a manner that it implies a structure and all its possible position isomers and all tautomeric forms derived thereof.
These novel compounds can serve as a basis for therapeutic drugs to treat anxiety, ischemia, epilepsy, hypertension and other cardiovascular, cerebrovascular, neurodegenerative, neuropsychiatric, and neurological disorders, as well as other disorders related to the cardiovascular system.
Compounds of the I, II, III, X, XI, and XII type are obtained by fusing a 1,4-dihydropyridine derivative adequately substituted with a ortho-diamine disubstituted compound, ortho-phenylenediamine, ortho-diaminepyridines, ortho-diaminepyrimidines, to generate tricyclic (I, II, III) and tetracyclic (X, XI, and XII) compounds derived from diazepines or diazepinones fused with the 1,4-dihydropyridine derivative.
Transformation of compounds of general formula I, II, and III, can lead to the formation of tetracyclic structures of the IV, V, VI, VII, XIII, and IX type.
Due to the presence of a chiral carbon, new derivatives are obtained as a racemic modification, based on the racemic derivatives of 1,4-dihydropyridines, obtained in turn through their synthetic precursors, also obtained in a racemic form.
Enantiomers can be resolved and obtained separately, with an enantiomeric excess above 90% and is done by enantiomeric resolution of any of the baseline intermediaries or by enantiomeric resolution directly on the final product, preferably through enzymatic resolution, with previous chemical transformation (not always required) to facilitate the resolution process, and its subsequent transformation into the original resolved structure. All separated enantiomers were additionally characterized by measuring their specific rotation.
Benzodiazepines were the first pharmacological entities denominated privileged structures. Generally, most benzodiazepines act as depressant agents of the Central Nervous System by inhibiting the GABA A receptor, which is part of a bidirectional inhibiting system connected between several areas of the Central Nervous System. These derivatives have hypnotic, anxiolytic, anticonvulsant, amnesic, and muscle relaxant effects. They also have a vasodilator action and can be used in treating heart failure.
The 1,4-DHPs have been characterized as having a vasodilator and antihypertensive action. These structures have an antioxidant and neuro-protective activity.
In our molecular system, the presence of a fragment of 1,4-dihydropyridine that can interact as a calcium channel blocker, fused with a diazepine derivative, provides de possibility of using this new chemical entity as a potential therapeutic agent for treating cardiovascular, cerebrovascular, neurodegenerative, neuropsychiatric and neurological diseases.
After an analysis of the structure of the molecules tested and the exploratory behavior in rodents as an indicator of their interaction with the GABA A receptor, the use of synthetic variants of diazepines fused with DHPs for treating cerebrovascular, neurodegenerative, neuropsychiatric and neurological diseases is justified.
The novelty in this invention is obtaining a tricyclic or tetracyclic molecular system with a diazepine derivative fused DHP ring for potential application in the treatment of cardiovascular, cerebrovascular, neurodegenerative, neuropsychiatric and neurological diseases, as well as the possibility of obtaining these tricyclic or tetracyclic systems using 1,4-dihydropyridine derivatives as a starting material.
BACKGROUND OF THE INVENTION
There are several patents describing benzodiazepine or dihydropyridine derivatives for treating Central Nervous System diseases. In such cases, however, no description is made of the fusion of these nucleuses to form a new pharmacologic entity. Patents using different substituents of the benzodiazepine nucleus, having no relation with the subject matter of our invention are listed below:
Patents EP1593683 and EP1157992 describe the process of obtaining molecules derived from dihydro-2,3-benzodiazepine as potential anticonvulsants, but use hydrogen-type substituents, alkyl chains, and aromatic rings of the phenyl, thienyl, furyl, pyridyl, imidazolinyl, benzimidazolyl, benzothiazole, and pthalazinyl type. Patent EP-349949 describes benzodiazepine-substituted derivatives with heterocyclic groups substituted in turn with aryl, hydroxyl, and carboxyl groups. Patent US20040157833, describes pharmaceutical compounds based on 1-(3,4-dimethoxyphenyl)-4-methyl-5-ethyl-7-methoxy-8-hidroxy-5H-2,3-benzodiazepine.
Patent US20020103371 describes benzodiazepine derivatives modulating the GABA receptor, but does not mention the dihydropyridines.
Patent EP-733634 describes new molecular entities derived from thieno(2,3-B)(1,5) benzodiazepine.
Other patents disclosing benzodiazepine derivatives are the following: U.S. Pat. No. 5,658,901 (yielding 2,3-dihydro-1-(2,2,2-trifluoroethyl)-2-oxo-5-phenyl-1H-1,4 benzodiazepines); U.S. Pat. No. 5,610,158 (yielding 4-oxo- and 4H-imidazo(5,1-c)(1,4)benzoxazines); EP-558104 and GB9201180 (1,5-Benzodiazepine derivatives); EP-491218 (benzodiazepinone derivatives).
Diazepine synthetic variants fused with dihydropyridines, the subject matter of our invention, showed some kind of action upon the Vascular and Central Nervous Systems. However, the degree of the action depends on the nature of the R substituent at the 4-position of the 1,4-DHP and the nature of R 1 substituent.
General experimental conditions: NMR- 1 H and NMR- 13 C spectra, were registered at 25° C. in a Bruker DPX300 spectrometer (300 MHz- 1 H, 75.4 MHz- 13 C) in DMSO-d 6 . Mass spectra were obtained with a Hewlett Packard 5989 A purity study was done using a CAMAG TLC-SCNNER II densitometer (Switzerland) (λ=254 nm).
EXAMPLES OF PROCEDURE
Example 1
Synthesis of the 4-aryl-5-carbonyloxy-6-methyl-2-oxo-1,2,3,4-tetrahydropyridine Synthetic Intermediary Useful for Preparing Compounds of the I, II, III, IV, V, VI, VII, XIII, AND IX Type
The 4-aryl-5-carbonyloxy-6-methyl-2-oxo-1,2,3,4-tetrahydropyridines derivatives are part of the synthetic intermediaries required to obtain the final products. In a 100 mL flask provided with a reflux condenser, 5.76 g (40 mmol) of Meldrum acid are dissolved in 40 mL of glacial acetic acid, acetonitrile or ethanol. Then, 40 mmol of the corresponding aromatic aldehyde are added, together with 40 mmol of the given dicarbonyl compound that can be acetyl-acetone, methyl-acetoacetate, ethyl-acetoacetate or any other commercial or previously prepared dicarbonyl compound, and 3.46 g (45 mmol) ammonium acetate. The reaction mixture is heated to reflux for about 8 to 16 hours. Then it is poured into cold water and the precipitated solid is vacuum filtered and recrystallized with ethanol.
Example 2
Synthesis of the Synthetic Intermediary Derived From 4-aryl-5-carbonylacohoxy-6-methyl-2-oxo-1,2,3,4-tetrahydropyridine, Useful for Preparing Compounds of the X, XI, AND XII, Type
Method 1
1.44 g (10 mmol) of Meldrum acid are dissolved in 10 mL of glacial acetic acid and 10 mmol of the corresponding aromatic aldehyde are added together with 1.40 g (10 mmol) of another dicarbonyl cyclic compound that could be Dimedone, and 0.7 g (10 mmol) of ammonium acetate. The reaction mixture is heated to reflux for 20 to 35 hours. Once the reaction ends, the mixture is poured into cold water and the precipitated solid is filtered and recrystallized with the proper solvent.
Method 2.
The technique described in EXAMPLE 1, METHOD 1, is used by adding to the mixture of reaction 0.8 mmol, 0.14 g of p-toluensulfonic acid between 4 and 10 hours. The isolation procedure and purification is the same one that for the METHOD 1.
Method 2.
10 mmoles of 5-X-ariliden-derived were dissolved such as 2,2-dimethyl-1,3-dioxane-4,6-dione in 10 mL of glacial acetic acid. To the mixture they are added 1.40 g (10 mmol) of the other necessary dicarbonilic compound (acetilacetone, dimedone, or other) and 0.7 g of ammonium acetate and is refluxed during 2-10 hours. After that, the reaction mixture is added on cold water, and the precipitated solid is filtered and recrystallized with an appropriate solvent.
Example 3
Synthesis of 4-aryl-3-carbonylalcohoxy-2-alkyl-6-chloro-5-formyl-1,4-dihydropyridine Synthetic Intermediary
The 4-aryl-3-carbonylalcohoxy-2-alkyl (or aryl)-6-chlorine-5-formyl-1,4-dihydropyridine derivatives are also synthesis intermediaries. To an N,N-dimethylformamide solution in anhydrous chloroform, an equimolar quantity of phosphorus oxychloride is added at room temperature. After a while, a solution of the corresponding 4-aryl-5-carbonylacohoxi-6-alkyl-2-oxo-1,2,3,4-tetrahydropyridine derivative is added. It is then stirred at room temperature for approximately 10-20 hours. Then, a sodium acetate aqueous solution is added and it is stirred for 10 to 30 minutes. The organic phase is separated and the solvent is vacuum-filtered. The solid obtained is recrystallized with ethanol.
Example 4
Synthesis of the Synthetic Intermediary of aryl-3-carboxy-2-methyl-6-chloro-5-formyl-1,4-dihydropyridine (Method A).
In a flask were dissolved in an appropriate organic solvent the derived corresponding of 4-aril-3-carbonilalcohoxi-2-metil-6-chlorine-5-formil-1,4-dihidropiridine, then is added in excess an iorhidrico acid dissolution previously treated with sodium thiosulfate in order to eliminate any impurity. The mixture is refluxed between 8 and 24 hours. After that, the reaction mixture is added in water and the reaction is neutralized with carbonate of sodium or potassium. The precipitated solid is vacuum filtered and washed with small portions of an ethanol/water. Yields 40-75%.
Example 5
Synthesis of the Derived Synthetic Middleman of 4-aryl-3-carboxy-2-methyl-6-chlorine-5-formyl-1,4-dihydropyridine (METHOD B)
The saponification of those derived of 4-aryl-5-carbonylamethoxy-6-methyl-2-oxo-1,2,3,4-tetrahydropyridine is carried out using NaOH, in methanol and water, to those derived of 4-aryl-5-carbanylacarboxy-6-methyl-2-oxo-1,2,3,4-tetrahydropyridine, and following transformation to those derived of 4-aryl-3-carboxy-2-methyl-6-chlorine-5-formyl-1,4-dihydropyridine, by the procedure explained in the Example 3.
Example 6
Synthesis of the Tricyclic and Tetracyclic Systems Derived from Diazepines Fused Dihydropyridines (Compounds Ia II, III, X, XI and XII).
In a flask equipped with magnetic stirring, the corresponding 1,4-dihydropyridiine derivative obtained is dissolved in. The corresponding 1,2 diamine derivative is then added to the resulting solution. The reaction mixture is stirred at temperatures between 10-78° C. for several hours, till a precipitate appears. This precipitate is filtered and washed with ethanol. For some compounds, isolation of the final products using the column chromatography technique is required.
It is then dried in a desiccator. Yield: 35-80%. Reaction is followed by thin-layer chromatography (ethanol: cyclohexane: chloroform). Compounds are characterized by NMR-H 1 , NMR-C 13 and mass spectrometry.
Example 7
Effect of Different Diazepine Fused Dihydropyridines Synthetic Variants on Exploratory Behavior in Mice
The open field test has been a widely used test to evaluate drugs with a sedative effect. In this test, the number of rearing and/or crossings of animals in the central area of the open field are quantified. These behaviors are indicative of the exploratory behavior of rodents. Sedative drugs reduce the exploratory behavior of rodents.
The effect of different diazepine fused dihydropyridines synthetic variants on the exploratory behavior was evaluated on Swiss albino rats with 18-22 g of body mass. Animals were administered a 4 mg/Kg dose. After 30 minutes, animals were individually placed in an exploratory activity box for 6 minutes, during which time the number of erections and crossing through the center of the box were recorded.
SUMMARY OF THE INVENTION
The findings of the evaluation of the different molecules tested show a neuro-sedative behavior, though the decrease in the exploratory behavior was not the same in all cases. The difference is due to the structural variations made to the nucleus of the polyheterocyclic system tested. This behavior fits the neuro-pharmachological profile of sedative drugs. The structural nature of the molecules evaluated may justify the resulting effect, due to their potential interaction with the GABAergic receptor.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 Global structure of tricyclic and tetracyclic derivates; and
FIG. 2 General formulas of different synthetic variants of diazepine fused dihydropyridines.
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The present invention relates to chemistry and pharmacy and, in particular, to the production of novel molecular entities, tricyclic and tetracyclic derivatives of benzodiazepine, pyridodiazepine and pyrimidodiazepine type fused with 1,4-dihydropyridine derivatives, having an effect on the central-nervous and vascular systems. Derivatives containing a dihydropyridine ring are used, by means of reactions with compounds of the ortho-phenylenediamine, ortho-diaminopyridine and ortho-diaminopyrimidine type, and also subsequent conversions to some thereof, to obtain tricyclic and tetracyclic derivatives of general formula I-XII that contain a diazepine or diazepinone nucleus fused to a 1,4-dihydropyridine nucleus, in which the A ring is a substituted or unsubstituted benzene, pyridine or pyrimidine ring. These molecular entities exhibit GABAergica and modulating action in the case of calcium channels which can be used in the treatment of cardiovascular, cerebrovascular, neurodegenerative, neuropsychiatric and neurological disorders.
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CROSS REFERENCE
This application claims the benefit of a U.S. Provisional Application Ser. No. 60/157,289, entitled “Network Access Arbitrator” which was filed on Oct. 1, 1999.
BACKGROUND OF THE INVENTION
The present invention relates generally to communication network access technologies, and more particularly, to a system and method for providing transparent and automatic switching between different network access technologies without interrupting active network applications or sessions.
The advent of computer networks has brought a revolutionary change to the world about how people work with computers in their daily activities. Networked computers allow users to share various computer resources and provide significant conveniences to users. Various network access technologies (NATs) are co-existing today that provide users with different network design alternatives. For example, Token Ring, Ethernet, and Wireless Local Area Network are all well known network access technologies that are widely used. Therefore, it is very likely that multiple networks using different network access technologies are located side by side in a larger network that services, for example, a large company.
This co-existence of different network access technologies brings problems and undesired delays when a user switches from one part of a network to another if each part uses different access technologies. For example, it is possible that a user's laptop is equipped with one Ethernet card and one wireless LAN PCMCIA card for providing two alternate network accesses to a corporate network. For example, consider a user in the middle of an active network session, such as downloading a lengthy file via Ethernet access in the user's office, and the user must go to a meeting with his colleagues in another building and must bring the file with him. If he has to wait for the file to be completely downloaded, he may be late for the meeting. Alternatively, the user can terminate the downloading session and download the same file all over again at the meeting where he reestablishes a network connection (either through another Ethernet connection in the meeting room or through the wireless LAN PCMCIA connection on his laptop). Both choices are not desirable because either the user is delayed or he has to waste whatever has been downloaded before he leaves his office.
When a user has to disconnect from a network while using a particular NAT and reestablish another network connection through a different NAT, certain processes must happen. In any network that is in conformance with the standard Open Systems Interconnection (OSI)- 7 Layer model, all activities in different layers must be terminated.
Referring now to FIG. 1 , an overall schematic for the standard OSI-7 Layer Protocol Stack 10 is shown. The concept of layering is generally known in the art and the OSI standard is the only internationally accepted framework of standards for communication between different system made by different vendors. The OSI-7 Layer Protocol Stack 10 typically has seven different layers: a Physical Layer (L 1 ) 12 , a Data Link Layer (L 2 ) 14 , a Network Layer (L 3 ) 16 , a Transport Layer (L 4 ) 18 , a Session Layer (L 5 ) 20 , a Presentation Layer (L 6 ) 22 and an Application Layer (L 7 ) 24 . As shown in FIG. 1 , L 1 deals with the physical means of transmitting data over communication lines, and in a network environment, usually refers to various Network Interface Cards (NICs) 26 designed for different NATs. L 2 is concerned with procedures and protocols for operating the communication lines, and in this example, is the corresponding Adapter Driver Software 28 for various NICs. In order to identify each NIC, usually a Data Link Layer address or an L 2 address is assigned to the NIC. L 3 provides information 30 about how data packet routing and relaying can be accomplished. This information may include network or Internet Protocol addresses for communication nodes such as a file server or other computers. L 4 defines the rules for information exchange, e.g., information about various network protocols 32 such as TCP/IP protocols, UDP, or ICMP, L 5 , L 6 and L 7 are dedicated more to network applications 34 . All these layers are working together on a computer hardware platform 36 such as a host computer server.
Now referring to FIG. 2 , a flow diagram 40 is shown for terminating a first network access with a first NAT and switching to a second network access with a second NAT, all while active network applications are in progress. When terminating the first network access, the active network applications are interrupted. From the perspective of layering, the active network applications relating to L 5 , L 6 and L 7 are first shut down in step 42 . Then the corresponding network connections (relating to L 4 and L 3 ) are destroyed in step 44 . Eventually network software and hardware in L 2 , L 1 and the computer platform are reconfigured in step 46 . Using the new NAT, network connections must be initiated in step 48 , and the network applications must be restarted again in step 50 . In summary, the conventional techniques for switching from the first NAT to the second NAT tears down all processes from L 7 downward to L 1 , and then re-establishes the applications back from L 1 upward to L 7 . This lengthy process incurs extra delays and expenses for network computing and greatly reduces the efficiency of network applications.
What is needed is a method and system to switch between different network access technologies without interrupting active network applications or sessions.
SUMMARY OF THE INVENTION
A system and method is provided for seamlessly switching between different network access technologies without interrupting active network applications or sessions.
Using as an example the standard OSI-7 Layer Protocol Stack to implement network communications, one embodiment of the present invention provides a Network Access Arbitrator (NAA). The NAA is a virtual network device driver situated between the Data Link Layer (L 2 ) and the Network Layer (L 3 ) of the OSI-7 Layer Protocol Stack for controlling necessary switching between different network access technologies. Since all computer network applications are controlled by layers residing on or above L 3 , all applications using network services provided by L 3 (connection or connectionless) will continue their active network sessions without disruption, as the NAA switches between network access technologies.
In addition to providing switching between different network access technologies, the NAA also works in conjunction with Mobile Internet Protocol functions such as IP-in-IP encapsulation/de-capsulation, proxy ARP, gratuitous ARP, etc.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an overview of the standard OSI-7 Layer Protocol Stack.
FIG. 2 illustrates a process flow for switching between two different network access technologies.
FIG. 3 is a graphical representation of how a Network Access Arbitrator interacts with different Layers of the OSI-7 Layer Protocol Stack in accordance with one embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 3 , a Network Access Arbitrator (NAA) 60 is shown in the environment of an OSI-7 Layer Protocol Stack 10 according to one embodiment of the present invention. The NAA 60 is a virtual adapter driver located between L 2 and L 3 for providing seamless network hand-offs between two different network access technologies (NATs). With the implementation of the NAA 60 , various active network applications are uninterrupted as the NAA 60 stops exchanging information through an existing NAT and moves over to use a new NAT.
On a computer hardware platform 36 such as a host computer server on L 2 , there are multiple NATs available, e.g., multiple network interface cards (NICs) 62 along with their corresponding adaptive driver software (NIC 0 to NIC N). The NAA 60 is inserted in between L 2 and L 3 . The NAA 60 insures that L 3 detects only a virtual Anchor Adapter driver (Anchor) even though there are multiple NICs 62 and adapter drivers installed on the computer platform 36 . Therefore, all the processes on and above L 3 are not aware of different NICs 62 and adapter drivers 64 .
Out of all the available adapters or NICs 62 on the computer platform, one particular NIC can be initially set as a primary adapter. Its driver thus is the primary adapter driver. All the other adapters and their corresponding drivers are considered non-primary or secondary. Initially, the primary adapter driver is the Anchor.
When executing a network application, the primary adapter is usually the one for providing the network access. At any moment, only one of the adapters or NICs is active. However, due to the availability of multiple NATs, the active network adapter may or may not be the primary adapter. The active adapter receives and transmits all Internet Protocol (IP) data packets including those in unicast, multicast, and broadcast format. However, inactive adapters will receive only multicast and broadcast packets. Moreover, the NAA 60 monitors all the adapters 62 , and receives and transmits data packets only through the active adapter. Since the NAA 60 is situated between L 2 and L 3 , all network applications or communications using L 3 network protocols deal exclusively with the NAA 60 without directly involving any L 2 network components. In other words, without letting L 3 know which adapter driver in L 2 and its associated active adapter in L 1 is actually used, the NAA 60 supplies/retrieves data packets to/from the active adapter, whether it is the primary adapter or any other one connected to the same host computer hardware platform. Therefore, an active network application that works with L 3 network protocols observes a constant data stream coming from the NAA 60 and sends back to the NAA 60 another data stream for outgoing information without noticing a transition between two NATs.
The NAA 60 treats outgoing data packets and incoming data packets differently. For an outgoing data packet, if the active adapter is the primary adapter, the data packet is sent unmodified from the NAA 60 to the primary adapter except when there is a special need for encapsulation. If the active adapter is an adapter other than the primary adapter, a hardware frame of the data packet is modified by the NAA so that a source hardware address in the frame is set to the L 2 address of the active adapter before data packet is sent to that active adapter.
For an incoming packet, if the receiving adapter is the primary adapter, the data packet is “passed up” unmodified to the NAA 60 , except when there is a special need for decapsulation. If the receiving adapter is not the primary adapter, a hardware frame of the data packet is modified so the destination hardware address is set to the L 2 address of the primary adapter before the data packet is passed through the NAA 60 . This ensures that L 3 sees no change in the Anchor (that it detects at all time).
In addition, Address Resolution Protocol (ARP) must be blocked or handled appropriately so that an ARP module of the protocol stack is not confused about a single IP address in L 3 with multiple L 2 addresses. For instance, in response to an ARP request message sent by a router, a message can be broadcasted to publish the L 2 address of the active adapter.
Furthermore, it is important for the NAA 60 to determine which network adapter or NIC is active at any moment. Some NICs and their associated adapter drivers are capable of indicating a connection and disconnection status. Typically, the time required to detect a disconnection detection is around one second and around six seconds to detect connection. These time thresholds are good indicators of the activity status of the NICs. The NAA 60 is thus capable of making use of these hardware status indications to obtain information about which adapter is active.
Also, according to one embodiment of the present invention, the NAA 60 is equipped with a timer that times out on a one-second basis. This timed event is used to detect the existence of incoming data packets. If the NAA 60 detects a data packet for the primary adapter, the primary adapter is deemed the active adapter. If the NAA 60 detects that there is no data packet going through the primary adapter in a period of two seconds, but there is at least one data packet received on a non-primary or a secondary adapter, the secondary adapter is used as the active adapter. An active adapter is viewed by the NAA 60 as active until another active adapter replaces it.
With the implementation of the NAA 60 , a user can freely switch from one NAT to another without worrying about disrupting any active network applications. For example, as mentioned above, if a user's laptop is equipped with one Ethernet card and one wireless LAN PCMCIA card, thereby providing for two alternate network access to a corporate network, network application will not be interrupted when the network access is switched from the Ethernet card to the PCMCIA card. The NAA 60 may initially set the Ethernet card as the primary adapter and the PCMCIA adapter as a secondary adapter. While in the middle of downloading a file through the active primary adapter, if the user must go to a meeting in another building, he can simply unplug the Ethernet connection and start on the wireless PCMCIA card. The user is then free to go to the meeting while his laptop continues the downloading session using the wireless LAN connection. The user will be on time at the meeting and be able to finish downloading without any delay.
Further, the NAA 60 can be used in conjunction with Mobile Internet Protocol to allow a mobile device to roam seamlessly between different subnets having different NATs. Similarly, the present invention also applies to networks using various packet based wireless access technologies. As long as there are at least two different NATs, the present invention preserves the integrity of active network applications while providing smooth transition from one NAT to another.
It is noted that in addition to providing switching between different network access technologies, as mentioned above, the NAA 60 also works in conjunction with other Mobile Internet Protocol functions such as IP-in-IP encapsulation/de-capsulation, proxy ARP, gratuitous ARP, etc.
The above disclosure provides many different embodiments, or examples, for implementing different features of the invention. Also, specific examples of components, and processes are described to help clarify the invention. These are, of course, merely examples and are not intended to limit the invention.
While the invention has been particularly shown and described with reference to the preferred embodiment thereof, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention.
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A system and method is provided for seamlessly switching between different network access technologies without interrupting active network applications or sessions. A Network Access Arbitrator (NAA), which contains a virtual network adapter driver, resides between a Data Link Layer and a Network Layer of the standard OSI-7 Layer Protocol Stack for controlling necessary switching between different network access technologies. Since all network applications are controlled by layers residing on or above the Network Layer, all applications using network services provided by the Network Layer will continue their active network sessions or applications without disruption, as the NAA switches between different network access technologies.
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FIELD OF THE INVENTION
[0001] The present invention relates to an environmentally friendly dipping material composition, which forms an interphase between the synthetic fiber that is used in the production of cord fabric and rubber and thus bonds the said two structures to each other.
BACKGROUND OF THE INVENTION
[0002] Cord fabric is used as tire reinforcement material. Since the chemical structures of synthetic fibers used in cord fabric production and rubber are considerably different from each other, the said materials are incompatible with each other in terms of their chemical and physical structures. Synthetic fibers have high strength and low elongation whereas rubbers are polymeric materials which have high elongation and low strength. The polar groups (amide, hydroxyl and carbonyl groups) present in the structure of the synthetic fibers are incompatible with the non-polar structures of the rubber. This incompatibility present in the state of the art is eliminated with water-based Resorcinol-Formaldehyde-Latex (RFL) adhesive solutions which form a phase between the cord and the rubber and enable the rubber and the fiber to be attached to each other.
[0003] Main function of RFL is to serve as an adhesive bonding two incompatible structures by forming a phase between fiber and rubber. RF functional group in RFL is attached to the polar groups of fiber while Latex (L) group is attached to the fiber by vulcanization, and thus the rubber-fiber composite structure is formed. The vehicle tire application is amongst the most significant product examples wherein the said composite structure is used. The water based RFL adhesives are applied on cord fabric during “dipping” process which is the final step of cord fabric production. The strength of the bonds formed between the rubber and the cord is examined with adhesion tests. Adhesion is a very important parameter in high tenacity cord reinforced rubber products. This is because cord-rubber adhesion is a factor which directly effects the tire life and performance.
[0004] RFL adhesive formulation has been used as an adhesive material in all synthetic fiber reinforced materials for over half a century because of its stable structural features and low cost. However, both resorcinol and formaldehyde are the chemicals which possess high risk for human and environmental health, and therefore their use is limited. Regarding this subject, significant feedbacks have come from international organizations, manufacturers and end users. It is known that the resorcinol causes itching and rash when it contacts the skin, irritates the eye and shows toxic properties in liver and cardiovascular systems.
[0005] Formaldehyde is riskier than resorcinol for human health and safety. In 2004, formaldehyde was classified as group 2A chemical (probably carcinogenic to humans) by a group of scientists in International Agency for Research on Cancer (IARC) of World Health Organization, and later as group 1 (carcinogenic for humans). In 2009, formaldehyde was included in the list of chemicals causing leukemia by IARC. In line with this, formaldehyde was claimed to be a gene mutagen. Even low level of formaldehyde (1 ppm) can cause eye, nose and throat irritation.
[0006] Although formaldehyde-based resins are advantageous in terms of cost, both producers and consumers search for alternatives because of the reasons stated above. Therefore, especially in recent years, researchers have been working on the development of resorcinol and formaldehyde-free cord fabric dip solutions. The preparation of formaldehyde-free dip solutions have been reported in various studies.
[0007] United States Patent document no US20120041113, an application known in the state of the art, discloses preparing a composition comprising an epoxy, a blocked isocyanate, an epoxy curing agent and vinyl pyridine latex.
[0008] International Patent document no WO9600749, another application known in the state of the art, discloses the application of dipping solutions formulated with three functional-epoxy resins, styrene-butadiene-vinyl pyridine and styrene-butadiene-acrylonitrile-acrylic acid latex to polyethylene terephthalate (PET) cord fabric and its strength of adhesion with rubber.
[0009] U.S. Pat. No. 5,118,545, another application known in the state of the art, discloses the synthesis of an aramide comprising multiple double bonds. It is stated that the synthesized resin is applied on the aramide-based cord fabric and that the double bonds in the aramide resin are vulcanized with the double bonds in rubber while the amide groups provide physical adhesion to the aramide fiber.
[0010] U.S. Pat. No. 4,472,463 discloses dipping non-adhesive activated PET fibers with two-step dipping process. The first dipping step comprises aromatic glycidyl ester epoxy and blocked isocyanate, while the second dipping step comprises two different latexes. The first latex is styrene-butadiene-vinyl pyridine copolymer, and the other one is acrylic acid-methyl methacrylate-styrene copolymer. It is stated that the H-adhesion values are higher than that of RFL dipped fibers.
[0011] United States Patent document no US20040249053, another application in the state of the art wherein an environmentally friendly dipping material is disclosed, discloses that the maleinized-polybutadiene is rendered water-soluble by reacting with polyethylene glycol. The PET cords modified with epoxy are first coated with this resin and then with styrene-butadiene-vinyl pyridine latex. The said resin exhibited lower adhesion strength relative to the fabrics treated with RFL.
SUMMARY OF THE INVENTION
[0012] The objective of the present invention is to provide a dipping material, which comprises more environmentally benign chemicals and provides high performance for cord fabrics, instead of the chemicals used in the state of the art.
[0013] Another objective of the present invention is to provide a dipping material production method, which enables the cord fabrics to give the desired effect by being processed for a shorter period of time relative to the method known in the state of the art and provides high performance for cord fabrics.
[0014] A further objective of the present invention is to provide a dipping material providing high performance for cord fabrics which has pale yellow color and thus makes it possible to produce cords in desired colors.
DETAILED DESCRIPTION OF THE INVENTION
[0015] In an inventive dipping material composition providing high performance for cord fabrics, there are functional acrylic resin (polymer) involving carboxylic acid, epoxy resin, blocked polyisocyanate, styrene-butadiene and styrene-butadiene-vinyl pyridine latexes. In the polymers comprising carboxylic acid, at least one of the monomers such as acrylic acid, methacrylic acid, itaconic acid, crotonic acid, cinnamic acid, maleic acid is employed in order to provide functionality to the acrylic resin. In the preferred embodiment of the invention, the amount of carboxylic acid within the acrylic polymer is between 10-100% by mole. In one embodiment of the invention this ratio is preferably kept between 30-70 mol %. Then, pH value of this composition comprising water and acrylic polymer is adjusted. In the preferred embodiment of the invention, ammonium is added to the composition to reach a pH value of 7-12, preferably 7-10. After pH is adjusted to the desired level, epoxy is added into the composition. In the preferred embodiment of the invention, the epoxy which is used is either a water soluble epoxy or a water-based dispersion. As the epoxy, at least one of glycidyl-based glycerol, sorbitol epoxy, diethylene glycol diglycidyl ether, polyethylene glycol diglycidyl ether, polypropylene glycol diglycidyl ether, 1,6-hexanediol glycidyl ether, trimethylol propane polyglycidyl ether, polyglycerol polyglycidyl ether, pentaerithiole polyglycidyl ether, diglycerol polyglycidyl ether, phenol novalac epoxy, cresol novalac epoxy, cresol novalac and bisphenol A epoxy resins is used. However their use is not limited to these. Any epoxy which is water soluble or can be prepared as dispersion in water can be used in this invention.
[0016] In the preferred embodiment of the invention, water-based blocked isocyanate or water-based polyurethane prepolymer comprising blocked polyisocyanate groups is used. As polyisocyanate, at least one of tetramethylene diisocyanate, hexamethylene diisocyanate (1,6-diisocyanatohexane), octamethylene diisocyanate, decamethylene diisocyanate, dodecamethylene diisocyanate, aromatic isocyanates 2,4- or 2,6-tolylenediisocyanate, tetramethylxylene diisocyanate, p-xylene diisocyanate, 2,4′- or 4-4′-diisocyanatediphenylmethane, 1,3- or 1,4-phenylene diisocyanate is used alone or in the form of functional group attached to the polymers. At least one of phenol, thiophenol, chlorophenol, cresol resorcinol, p-sec-butylphenol, p-tert-butylphenol, p-sec-amylphenol, p-octylphenol, p-nonylphenol, tert-butyl alcohol, diphenylamine, dimethylaniline, phthalic imide, δ-valerolactam, ε-caprolactam, malonic acid dialkylester, acetylacetone, acetoacetic acid alkylester, acetoxime, methylethylketoxime, cyclohexanone oxime, 3-hydroxypyridine and acidic sodium sulfite can be used as free isocyanate blocking agent, but their use is not limited to these. In the preferred embodiment of the invention, the molecular weight of the waterborne polyurethane prepolymer comprising blocked isocyanate groups is in the range of 1000-10000 g/mol, in one embodiment of the invention this value is between 1500-3000 g/mol.
[0017] In the invention, vinylpyridine-styrene-butadiene, vinylpyridine-styrene-butadiene modified with carboxylic acid, styrene-butadiene, styrene-butadiene modified with carboxylic acid, natural latex, chloroprene latex and the like can be used. In the invention, a composition comprising 2 different latexes is used. The first latex is styrene-butadiene copolymer and the second is styrene-butadiene-vinyl pyridine terpolymer. 1,3-butadiene and 2-methyl-1,3-butadiene can be used as butadiene component, but its use cannot be limited to these. Styrene, α-methylstyrene, 2-methylstyrene, 3-methylstyrene, 4-methylstyrene, 2,4-diisopropilstyrene, 2,4-dimethylstyrene, 4-t-butylstyrene and hydroxymethylstyrene can be used as styrene component, but its use cannot be limited to these. 2-vinylpyridine, 3-vinylpyridine, 4-vinylpyridine, 2-methyl-5-vinylpyridine, 5-ethyl-2-vinylpyridine can be used as vinyl pyridine monomer, but the use is not limited to these. In the preferred embodiment of the invention, the solid amount inside the latex is between 35-45% by weight. The ratio of the solid of the 1 st latex to that of the 2 nd is in the range of 0.05-1 by weight; however preferably the said ratio should be in the range of 0.13-0.30.
[0018] The dipping material is obtained by adding all the materials mentioned in the previous steps into the water at room temperature and stirring it.
[0019] The compositions were prepared by using acrylic functional polymer, epoxies and polyisocyanates in different ratios. The said compositions were made ready for rubber by being dried in different drying and curing temperatures.
[0020] In the preferred embodiment of the invention, the acrylic resin is used in ratio of 0.5-10%, preferably 1.5-5% by weight; the epoxy is 2-10%, preferably 4.5-7% by weight, polyisocyanate is 5-17%, preferably 9-14% by weight; styrene-butadiene latex is 5-17%, preferably 10-13% by weight; styrene-butadiene-vinyl pyridine latex is 50-80%, preferably 65-75% by weight.
[0021] The invention is a composition which can be used in dipping of cords such as nylon 6.6, nylon 6, polyethylene terephthalate, polyethylene naphthalate, rayon, aramide, and its use is not limited to these. After the said cords are prepared in certain constructions (ply number and twist), it is dipped with the inventive dipping material and dried at between 100-210° C. first. Subsequently, they are cured at between 200-240° C. The dipped cords are made ready to be cured with rubber compound, and it is pressed to the unvulcanized rubber compound. The said composite material is generally cured at 170° C. under press for about 20 minutes, and the final cord reinforced composite is obtained.
[0022] The said dipping material composition is prepared using more environmentally friendly chemicals relative to RFL. Furthermore, the said method is advantageous in terms of both cost and short preparation time. The final product being pale yellowish does not create any visual pollution and also enables the preparation of cord fabrics in various colors by the addition of colorants.
EXAMPLES
[0023] The chemicals used in the said invention are acrylic resin, epoxy, polyisocyanate, latex, water and ammonium. Adding and stirring processes were performed via mechanical stirrer under room conditions. The ratios of chemicals used in the preparation of the aqueous composition are given in FIG. 1 by weight.
[0024] The amount of solids of the mixtures in the present invention was determined as 15%, and pH was adjusted to 9-10 range. The indexed peel adhesion strength values are given in FIG. 1. The adhesion of cords dipped with RFL to the rubber was taken as reference, and this value was considered as 100. The dipping solution shown as RFL in the invention is the D-5 dipping whose intellectual property rights belong to General Tire Company (USA). Two layered 1400 dtex nylon 6.6 yarns were twisted as 396×396, and the twisted cord was dipped into the inventive dipping solutions. The cord treated with control (RFL) dipping solution was first dried for 60 seconds at 130 ° C., and then cured for 60 seconds at 235 and 230° C., respectively. The dipping solutions in the invention were passed through 3 ovens at different temperatures. The temperature of the 1 st oven is kept between 110-210° C., preferably between 150-200° C.; the temperature of the 2 nd furnace is between 220-245° C., preferably between 225-240° C.; the temperature of the 3 rd furnace is kept between 210-235° C., preferably between 220-230° C.
[0025] Five cords were placed parallel to each other on the rubber mixture for the adhesion test. The said mixture was cured at 170° C. under pres, and then tested by pulling in Instron device. Here, the detachment value of the cord from the cured rubber was measured as kg.
[0026] As the acrylic functional polymer (resin) waterborne polymeric materials having 50% solid content and carboxylic acid and polybasic alcohol groups are used.
[0027] Glycerol based glycidyl resin was used as the epoxy. The said resin is 100% water soluble.
[0028] Water based, caprolactam blocked 1,4-phenylene diisocyanate with 60% solid content was used as the blocked polyisocyanate.
[0029] Styrene-butadiene latex is a material with a solid content of 41% and a pH of 10.4.
[0030] Styrene-butadiene-vinyl pyridine is a material with a solid content of 41% and a pH of 10.5.
[0000]
Acrylic
SBR
VP
Peel
resin
Epoxy
Isocyanate
latex
latex
adhesion
Composition
(%)
(%)
(%)
(%)
(%)
*
1
2.4
6.6
11.1
12.0
68.0
107.9
2
1.8
5.1
13.0
12.0
68.0
103.1
3
4.3
5.5
10.2
12.0
68.0
101.4
Control
100.0
(RFL)
*indexed
|
The present invention relates to a dipping material composition that is environmentally friendly and used in production of cord fabric and the rubber to be attached to each other by providing a phase between the said two structures. The objective of the present invention is to provide a dipping solution comprising more environmentally friendly chemicals (an acrylic resin containing a carboxylic acid group, an epoxy resin, a blocked polyisocyanate, a styrene butadiene latex and a styrene butadiene vinylpyridine latex) relative to the chemicals used in the state of the art, providing the desired effect by treating cord fabrics for shorter period of time, and enabling the cords to be produced in desired colors owing to their pale yellowish color.
| 3
|
RELATED APPLICATIONS
[0001] This patent application is a divisional of U.S. patent application Ser. No. 11/089,157, filed Mar. 24, 2005, which claims the benefit of priority from U.S. provisional patent application Ser. No. 60/557,087, filed Mar. 26, 2004; both of which are hereby incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to compounds for use in the treatment of AIDS and other viral diseases and HIV+related infections and compositions containing such compounds. The present invention also provides methods for the treatment of such diseases and infections and methods of making such compounds and compositions.
BACKGROUND OF THE INVENTION
[0003] Diseases of the immune systems pose a major threat owing to the potentially devastating effects that such diseases can have on humanity. An example of a disease of the immune system is Acquired Immunodeficiency Syndrome (AIDS). A retrovirus designated human immunodeficiency virus (HIV) is the etiological agent of AIDS, a complex disease that includes the progressive destruction of the immune system and degeneration of the central and peripheral nervous system. AIDS is one of the deadliest diseases to have struck humans in recent times, and it has reached epidemic proportions. It is estimated that over eighteen million people are infected with HIV worldwide. AIDS has been reported in more than one hundred and twenty-three countries.
[0004] Currently, a number of drugs and drug combinations are available to treat and control AIDS. There is an ongoing search in to identify potent compounds that are effective against AIDS and HIV+ related infections. Representative examples of methods and compounds for treating and controlling AIDS are disclosed in, e.g., U.S. Pat. Nos. 6,180,634; 6,120,772; 6,040,434; 6,015,796; 5,905,077; 5,888,511; 5,846,978; 5,811,462; 5,747,540; 5,744,906; 5,631,088; 5,504,065; 5,491,166; 5,475,136; 5,430,064; 5,413,999; 5,229,368; 5,162,499; 5,108,993; 5,059,592 and 5,028,995.
[0005] Diseases of the immune system pose a major problem to society. Epidemiological statistics relating to AIDS and other viral diseases show an ever increasing prevalence of such diseases, with global and regional health organizations predicting catastrophic consequences on a mass scale unless effective and easily applicable means are provided and implemented for the control of such diseases.
[0006] Accordingly there is a need in the art to develop potent compounds that are effective in the treatment, prevention and control of AIDS and other viral diseases and HIV+ related infections.
SUMMARY OF THE INVENTION
[0007] The present invention provides improvements in or relating to compounds for use in the treatment of AIDS and other viral diseases and HIV+ related infections and the like and compositions comprising such compounds. The present invention also provides methods for making such compounds and compositions and methods of treating or controlling such diseases or infections.
[0008] According to one aspect of the present invention therefore there is provided a method of treating, preventing or controlling a viral disorder by administering to a patient in need thereof a compound represented by the structure of formula I:
[0009] wherein:
[0010] the dotted line represents a single or a double bond.
[0011] In some embodiments, R 1 and R 2 may be the same or different and independently of each other may represent —CH 2 OH, —CH 2 OR 4 , —CH(OH)CH 3 , —CH(OR 4 )CH 3 or a group represented by the formula:
[0012] where R 4 is a linear or branched C 1 -C 4 alkyl; R 5 is H, OH or OR 6 (where R 6 is a linear or branched C 1 -C 4 alkyl); and
[0013] A-B is a group represented by the formula:
[0014] In some embodiments, m may be an integer of 0 or 1, n may be an integer of 1-500, and X may be O, —CH 2 O, —CH 2 CH 2 O, —CH(CH 3 )CH 2 O or —CH 2 CH(CH 3 )O.
[0015] Alternatively, m may be 1, n may be an integer of 0 to 500, and X may be —CH 2 O, —CH 2 CH 2 O, —CH(CH 3 )CH 2 O or —CH 2 CH(CH 3 )O.
[0016] Z may be —CH 2 CH 2 O, —CH(CH 3 )CH 2 O or —CH 2 CH(CH 3 )O.
[0017] In some embodiments, n may be an integer of from 1-200, particularly 1-100.
[0018] Thus, in particular, X may be O, —CH 2 O, —CH 2 CH 2 O, —CH(CH 3 )CH 2 O or —CH 2 CH(CH 3 )O, Z may be —CH 2 CH 2 O, —CH(CH 3 )CH 2 O or —CH 2 CH(CH 3 )O, m may be 0 or 1 and n may be 0-50, but preferably m and n may not both be 0. More preferably, n may be an integer of from 1-50.
[0019] In some embodiments, n may be an integer of from 5-75. For example, n may be 5, 6, 7, 8, 10, 11, 12, 13, 15, 16, 17, 18, 20, 25, 30, 33, 34, 35, 40,45, 50, 60, 65, 68, 69, 70, or 75. Preferably, n is 7, 12, 17, 34 or 69.
[0020] In some embodiments, R 1 may be —CH 2 OH, —CH 2 OR 4 , —CH(OH)CH 3 or —CH(OR 4 )CH 3 .
[0021] Alternatively, R 1 may be:
[0022] wherein R 5 is H or OH. Thus, in some embodiments, R 1 may be phenyl or:
[0023] In some embodiments, R 2 may be —CH 2 OH, —CH 2 OR 4 , —CH(OH)CH 3 or —H(OR 4 )CH 3 .
[0024] Alternatively, R 2 may be:
[0025] wherein R 5 is H or OH. Thus, in some embodiments, R 2 may be phenyl or
[0026] In a further aspect of the present invention there is therefore provided a method of treating, preventing or controlling a viral disorder by administering to a patient in need thereof a compound represented by the structure of formula II:
[0027] wherein:
[0028] the dotted line represents a single or a double bond; and
[0029] R 5 and R 5 ′, independently of each other, are H, OH or OR 6 (where R 6 is a linear or branched C 1 -C 4 alkyl).
[0030] As before, m may be an integer of 0 or 1, n may be an integer of 1-500, and X may be O, —CH 2 O, —CH 2 CH 2 O, —CH(CH 3 )CH 2 O or —CH 2 CH(CH 3 )O.
[0031] Or m may be 1, n may be an integer of 0 to 500, and X may be —CH 2 O, —CH 2 CH 2 O, —CH(CH 3 )CH 2 O or —CH 2 CH(CH 3 )O.
[0032] Z may be —CH 2 CH 2 O, —CH(CH 3 )CH 2 O or —CH 2 CH(CH 3 )O.
[0033] In some embodiments, n may be an integer of from 1-200, particularly 1-100.
[0034] Thus, in particular, X may be O, —CH 2 O, —CH 2 CH 2 O, —CH(CH 3 )CH 2 O or —CH 2 CH(CH 3 )O, Z may be —CH 2 CH 2 O, —CH(CH 3 )CH 2 O or —CH 2 CH(CH 3 )O, m may be 0 or 1 and n may be 0-50, but preferably m and n may not both be 0. More preferably, n may be an integer of from 1-50.
[0035] In some embodiments, n may be an integer of from 5-75. For example, n may be 5, 6, 7, 8, 10, 11, 12, 13, 15, 16, 17, 18, 20, 25, 30, 33, 34, 35, 40, 45, 50, 60, 65, 68, 69, 70, or 75. Preferably, n is 7, 12, 17, 34 or 69.
[0036] In some embodiments, m may be 0. Alternatively, X may be —CH 2 O, and m may be 1.
[0037] Thus, the present invention comprehends methods of treating, preventing or controlling a viral disorder by administering to a patient in need thereof a compound represented by the structure of formula III:
[0038] wherein the dotted line, R 5 , R 5 ′, Z and n have the same meanings as recited above in relation to formula I and II.
[0039] In some embodiments, Z may be —CH(CH 3 )CH 2 O, and accordingly the present invention embraces methods of treating, preventing or controlling a viral disorder by administering to a patient in need thereof a compound represented by the structure of formula IV:
[0040] wherein the dotted line, R 5 , R 5 ′ and n have the meanings as ascribed to them above in relation to formula I and II.
[0041] In some embodiments, R 5 is H. In some embodiments, R 5 is OH.
[0042] In some embodiments, R 5 ′ is H. In some embodiments, R 5 ′ is OH.
[0043] In some embodiments, n is an integer of 1-20. In some embodiments, n is an integer of 10-20. In some embodiments, n is 17. Alternatively, n may be an integer of 1-10, preferably 5-10, e.g. n=7.
[0044] The present invention also includes salts or hydrates of the compounds represented by the structures of formula I, II, III and IV.
[0045] In a particular aspect of the present invention, there is provided a method of treating, preventing or controlling a viral disorder by administering to a patient in need thereof a compound of formula A:
[0046] wherein R is a polyalkylene glycol polymer having p units, where p is an integer from 1-100.
[0047] In some embodiments, the polyalkylene glycol polymer may be polyisopropylene glycol.
[0048] p may be an integer of from 5-75. For example, p can be 5, 6, 7, 8, 10, 11, 12, 13, 15, 16, 17, 18, 20, 25, 30, 33, 34, 35, 40, 45, 50, 60, 65, 68, 69, 70 or 75. Preferably, p is 7, 12, 17, 34 or 69.
[0049] Further, the present invention provides methods of treating, preventing or controlling a viral disorder by administering to a patient in need thereof compounds of formulae B, C, D, E or F:
[0050] wherein R and p have the same respective meanings as given in relation to formula A.
[0051] In a different aspect of the present invention there is provided a composition for treating, preventing or controlling a viral disorder comprising one or more compounds of formulae I, II, III, IV, A, B, C, D, E or F. Thus, in some embodiments, the present invention provides a pharmaceutical composition for treating, preventing or controlling a viral disorder comprising as an active ingredient one or more compounds of formula I, II, III, IV, A, B, C, D, E or F, together with one or more pharmaceutically acceptable excipients or adjuvants. In some embodiments, the pharmaceutical composition of the invention may comprise one or more compounds of formulae I or II.
[0052] In another aspect of the present invention there is provided a method for the treatment, prevention or control of AIDS and other viral diseases and HIV+ related infections, which method comprises administering one or more compounds of formula I, II, III, IV, A, B, C, D, E or F and/or a pharmaceutical composition comprising one or more compounds of formula I, II, III, IV, A, B, C, D, E or F to a patient in need thereof. Typically, one or more compounds of formula I or II may be used.
[0053] In yet another aspect, the present invention comprehends the use of one or more compounds of formula I, II, III, IV, A, B, C, D, E or F as hereinbefore defined in the manufacture of a medicament for the treatment, prevention or control of AIDS and other viral diseases and HIV+ related infections.
[0054] In yet another aspect of the present invention there are provided methods for inducing AICD, inducing apoptosis, inhibiting a chemokine receptor, inhibiting malignant metastasis or inhibiting fibrosis or aberrant fibroblast proliferation, which methods each comprise administering one or more compounds of formula I, II, III, IV, A, B, C, D, E or F and/or a pharmaceutical composition comprising one or more compounds of formula I, II, III, IV, A, B, C, D, E or F to a patient in need thereof. In some embodiments, one or more compounds of formulae I or II are used. Said compounds of the invention may suitably be administered in a carrier which minimises micellar formation or van der Waals attraction of molecules of the compounds; an example of such a carrier is DMSO.
[0055] In some embodiments, the compounds of the present invention may exclude N-cinnamoyl-D,L-phenylalaninol, N-[1-hydroxymethyl-2-(1H-indol-3-yl)-ethyl]-3-phenyl-propionamide, N-[1-hydroxymethyl-2-phenyl-ethyl]-3-(4-hydroxy-phenyl)-propionamide, N-(1-hydroxymethyl-2-phenyl-ethyl)-3-(1H-indol-3-yl)-propionamide, N-(1-hydroxymethyl-2-phenyl-ethyl)-3-phenyl-propionamide, N-[1-hydroxymethyl-2-(4-hydroxyphenyl)-ethyl]-3-phenyl-propionamide, or N-[1-hydroxymethyl-2-(1H-imidazol-4-yl)-ethyl]-3-(4-hydroxyphenyl)-propionamide.
[0056] In accordance with a different aspect of the present invention, the S-enantiomeric forms of the compounds of formula A to F may be particularly advantageous in that embodiments thereof have been found to exhibit useful cell division inhibitory properties whilst at the same time demonstrating little or no toxicity to animal cells at the concentration levels required to achieve such cell inhibition.
[0057] Accordingly, in a particular aspect of the present invention there is provided a compound of formula A′, B′, C′, D′, E′ or F′ as follows:
[0058] wherein the chiral centre indicated by * is in the S-enantiomeric conformation, and R represents a polyalkylene glycol polymer having p units, in which p is an integer from 1-100. Preferably R is polyethylene glycol or polypropylene glycol and p is an integer in the range 1 to 20. Particularly preferred are compounds where p is 7 or 17.
[0059] In a particular aspect of the present invention are provided (S) 2-N(3-O-polypropyleneglycol)propylbenzene)-3-(4-hydroxyphenyl)propylamide (AV 61S, p=7) and (S)2-N(3-O-(polypropyleneglycol)-1-propyl-4-hydroxybenzene)-3-phenylpropylamide (AV 74S, p=7).
[0060] Said compounds of formula A′, B′, C′, D′, E′ or F′ as hereinbefore defined may be used in methods of treatment of the human or animal body by therapy, for example for the treatment, prevention or control of AIDS and other viral diseases and HIV+ related infections as described above or for the treatment or prophylaxis of immuno-allergical or autoimmune diseases or for the treatment, prevention or control of organ or tissue transplantation rejection in humans or animals as described in copending PCT/IB2003/04993, the contents of which are incorporated herein by reference.
[0061] In a different aspect of the present invention is provided a method for making a compound of formula A′, D′ or E′ as defined above which comprises:
[0062] (i) providing a compound of formula V:
[0063] wherein the chiral centre indicated by * is the S-enantiomer, said compound of formula V comprising at least one hydroxy phenyl group;
[0064] (ii) reacting said compound of formula V with a protecting agent adapted to protect the phenylic hydroxyl group(s) on said compound;
[0065] (iii) forming an alkali metal salt of the alkyl hydroxyl group;
[0066] (iv) reacting said alkali metal salt with a polyalkylene glycol comprising a leaving group; and
[0067] (v) thereafter deprotecting said phenylic hydroxyl group(s) to obtain said compound of formula A′, D′ or E′.
[0068] Preferably said compound of formula V comprises a phenyl group and an hydroxy phenyl group, such as a 4-hydroxy phenyl group.
[0069] Said polyalkylene glycol may be polyethylene glycol or polypropylene glycol.
[0070] A preferred protecting agent in step (ii) is di-tert-butyl dicarbonate, but any other protecting group known to those skilled in the art for use in peptide synthesis may be used.
[0071] The alkali metal salt formed in step (iii) may be the potassium or sodium salt which may be obtained, for example, by reacting the (protected) compound of formula V with sodium or potassium ethoxide.
[0072] A preferred leaving group in step (iv) is mesyl (methane sulfonyl), but other suitable leaving groups are known to those skilled in the art.
[0073] Said compound of formula V may be formed by coupling a compound of formula X:
[0074] with a compound of formula Y:
[0075] wherein at least one of X and Y comprises an hydroxy phenyl group.
[0076] In some embodiments, N-hydroxybenzotriazole (HOBt) and dicyclohexylcarbodiimide (DCC) may be employed as coupling agents, but other suitable coupling agents are known and available to those skilled in the art of peptide synthesis.
[0077] Said compound of formula X may be selected from 3-(4-hydroxyphenyl)-propionic acid and hydrocinnamic acid. Said compound of formula Y may be selected from L-tyrosinol hydrochloride and 3-(4-hydroxyphenyl)-propionic acid.
[0078] It has been found that the method for making a compound of formula A′, D′ or E′ in accordance with the present invention gives surprisingly high yields as compared with other possible methods such, for example, as those described in copending PCT/IB2003/004993. In particular, the yield of said compound of formula A′, D′ or E′ may be at least 20% wt. or 30% wt., with the majority of any other product(s) or residue being composed substantially of unreacted polyalkylene oxide. In some embodiments, yields of 40% wt. or more may be obtained. Generally it has been discovered that the yield of the desired compound may be greater for lower values of p. A particularly preferred value of p is 7. Another preferred value is 17.
[0079] In accordance with yet another aspect of the present invention therefore there is provided a composition comprising at least 20% wt. of a compound of formula A′, D′ or E′, wherein R and p are as defined above. Said composition may further comprise unreacted polyalkylene glycol as a side product. In some embodiments, said composition may comprise more than about 30% wt. or 40% wt. of said compound, preferably more than 50% wt., and more preferably more than 75% wt., e.g. about 80% wt. or about 85% wt.
[0080] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods and materials are described below by way of example only. All publications, patent applications, patents and other references mentioned herein are incorporated herein in their entirety by reference. In the case of conflict, the present specification, including definitions, will control. In addition, the materials, methods and examples are illustrative only and are not intended to be limiting.
[0081] The above description sets forth rather broadly important features of the present invention in order that the detailed description thereof that follows may be better understood and that the present contributions to the art may be better appreciated. Other objects and features of the present invention will be apparent from the following detailed description considered in conjunction with the accompanying drawings. It is to be understood that the drawings are designed solely for the purposes of illustration and not as a definition of the limits of the invention, for which reference should be made to the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0082] FIGS. 1-15 illustrate the data obtained from the experiments described in Examples 5-13 below.
DETAILED DESCRIPTION OF THE INVENTION
[0083] As contemplated herein, an “alkyl” group refers to a saturated aliphatic hydrocarbon, including straight-chain, branched-chain and cyclic alkyl groups. In some embodiments of the present invention, the alkyl group may have 1-4 carbons. For example, the alkyl group may be a methyl group. Alternatively, the alkyl group may be an ethyl group. Alternatively, the alkyl group may be a propyl group. Alternatively, the alkyl group may be a butyl group. The alkyl group may be unsubstituted or substituted by one or more groups selected from halogen, hydroxy, alkoxy carbonyl, amido, alkylamido, dialkylamido, nitro, amino, alkylamino, dialkylamino, carboxyl, thio and thioalkyl.
[0084] Synthetic methodologies for obtaining the compounds of the present invention are disclosed in detail in the Examples section below. However, it should be apparent to those skilled in the art that the compounds of the present invention may be prepared by any feasible synthetic method and that, except where stated otherwise, the syntheses set forth in the Experimental Details Section are in no way limiting. Compounds of the invention may be further modified as allowed by the rules of chemistry. Such modifications include the addition of various substituents (e.g., hydroxylation, carboxylation, methylation, etc.), generation of enantiomers, creation of acid- or base-addition salts or the like. Other modifications include adding polyalkylene glycol polymers.
[0085] In accordance with the present invention the compounds of the invention may be synthesised as polyalkylene glycol (PAG) conjugates. Typical polymers used for conjugation include poly(ethylene glycol) (PEG)—also known as or poly(ethylene oxide) (PEO)—and polypropylene glycol (including poly isopropylene glycol). Such conjugates may be used to enhance solubility and stability and to prolong the blood circulation half-life of molecules.
[0086] In its most common form, a polyalkylene glycol (PAG), such as PEG, is a linear polymer terminated at each end with hydroxyl groups:
HO—CH 2 CH 2 O—(CH 2 CH 2 O) q —CH 2 CH 2 —OH.
[0087] The above polymer, alpha-, omega-dihydroxylpoly(ethylene glycol), can also be represented as HO-PEG-OH, where it is understood that the -PEG-symbol represents the following structural unit:
—CH 2 CH 2 O—(CH 2 CH 2 O) q —CH 2 CH 2 —
[0088] where q typically ranges from about 4 to about 10,000. PEG is commonly used as methoxy-PEG-OH, or mPEG, in which one terminus is the relatively inert methoxy group, while the other terminus is a hydroxyl group that is subject to ready chemical modification. Additionally, random or block copolymers of different alkylene oxides (e.g., ethylene oxide and propylene oxide) that are closely related to PEG in their chemistry can be substituted for PEG in many of its applications.
[0089] PAGs are polymers which typically have the properties of solubility in water and in many organic solvents, lack of toxicity and lack of immunogenicity. One use of PAGs is to attach covalently the polymer to insoluble molecules to make the resulting PAG-molecule “conjugate” soluble. For example, it has been shown that the water-insoluble drug paclitaxel, when coupled to PEG, becomes water-soluble. Greenwald, et al., J. Org. Chem., 60:331-336 (1995).
[0090] Polyalkylated compounds of the invention may typically contain between 1 and 500 monomeric units. Other PAG compounds of the invention may contain between 1 and 200 monomeric units. Still other PAG compounds of the invention may contain between 1 and 100 monomeric units. For example, the polymer may contain 1, 10, 20, 30, 40, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 100 monomeric units. Some compounds of the invention may contain polymers which include between 5 and 75 or between 1 and 50 monomeric units. For example, the polymer may contain 2, 3, 5, 6, 7, 8, 10, 11, 12, 13, 15, 16, 17, 18, 20, 25, 30, 33, 34, 35, 40, 45, 50, 60, 65, 68, 69, 70, or 75 monomeric units. Preferably, m or n is 7, 12, 17, 34 or 69. The polymers may be linear or branched.
[0091] It is to be understood that compounds which have been modified by the addition of a PAG moiety may include a mixture of polymers which have a varying number of monomeric units. Typically, the synthesis of a PAG-modified compound (e.g., a PAG-conjugate) will produce a population of molecules with a Poisson distribution of the number of monomeric units per polymer in the conjugate. Thus, a compound described as having a polymer of N=7 monomeric units refers not only to the actual polymers in that population being described as having N=7 monomeric units, but also to a population of molecules with the peak of the distribution being 7. The distribution of monomeric units in a given population can be determined, e.g., by nuclear magnetic resonance (NMR) or by mass spectrometry (MS).
[0092] Throughout this application, conventional terminology is used to designate the isomers as described below and in appropriate text books known to those of ordinary skill in the art. (See, e.g., “Principles in Biochemistry”, Lehninger (ed.), page 99-100, Worth Publishers, Inc. (1982) New York, N.Y.; “Organic Chemistry”, Morrison and Boyd, 3rd Edition, Chap. 4, Allyn and Bacon, Inc., Boston, Mass. (1978)).
[0093] As described above, certain compounds of the present invention may exist in particular geometric or stereoisomeric forms. Except where specified to the contrary, the present invention comprehends all such compounds, including cis- and trans-isomers, R— and S-enantiomers, diastereomers, ( D )-isomers, ( L )-isomers, racemic mixtures thereof and other mixtures thereof as falling within the scope of the invention. Additional asymmetric carbon atoms may be present in a substituent such as an alkyl group. All such isomers, as well as mixtures thereof, are included in this invention.
[0094] A carbon atom which contains four different substituents is referred to as a chiral centre. A chiral centre can occur in two different isomeric forms. These forms are identical in all physical properties with one exception, the direction in which they can cause the rotation of plane-polarized light. These compounds are referred to as being “optically active,” i.e., the compounds can rotate the plane-polarized light in one direction or the other.
[0095] The four different substituent groups attached to a carbon can occupy two different arrangements in space. These arrangements are not superimposable mirror images of each other and are referred to as optical isomers, enantiomers or stereoisomers. A solution of one stereoisomer of a given compound will rotate plane polarized light to the left and is called the levorotatory isomer [designated (−)]; the other stereoisomer for the compound will rotate plane polarized light to the same extent but to the right and is called dextrorotatory isomer [designated (+)].
[0096] The R S system was invented to avoid ambiguities when a compound contains two or more chiral centres. In general, the system is designed to rank the four different substituent atoms around an asymmetric carbon atom in order of decreasing atomic number or in order of decreasing valance density when the smallest or lowest-rank group is pointing directly away from the viewer. The different rankings are well known in the art and are described on page 99 of Lehninger. If the decreasing rank order is seen to be clock-wise, the configuration around the chiral centre is referred to as R; if the decreasing rank order is counter-clockwise, the configuration is referred to as S. Each chiral centre is named accordingly using this system.
[0097] If, for instance, a particular enantiomer of a compound of the present invention is desired, for example the S enantiomer, then it may be prepared by asymmetric synthesis or by derivation with a chiral auxiliary where the resulting diastereomeric mixture is separated and the auxiliary group cleaved to provide the pure desired enantiomers. Alternatively, where the molecule contains a basic functional group, such as an amino or acidic functional group, such as carboxyl, diastereomeric salts are formed with an appropriate optically-active acid or base, followed by resolution of the diastereomers thus formed by fractional crystallisation or chromatographic means well known in the art and subsequent recovery of the pure enantiomers.
[0098] The compositions and pharmaceutical compositions of the present invention may comprise one or more of the compounds of the present invention either in a pure form or a partially pure form. Similarly, the methods of the present invention comprise using one or more compounds, wherein the compounds are in a pure form or a partially pure form.
[0099] In some embodiments, a composition of the invention may comprise at least one of the compounds of the present invention, i.e. one or more of the compounds represented by the structures of formula I, II, III, IV, A, B, C, D, E, F, A′, B′, C′, D′, E′ and F′. In some embodiments, a composition of the invention may comprise a mixture of at least two of the compounds represented by the structures of formulae I, II, III, IV, A, B, C, D, E, F, A′, B′, C′, D′, E′ and F′. In some embodiments, a composition of the invention may comprises a mixture of at least five of the compounds represented by the structures of formula I, II, III, IV, A, B, C, D, E, F, A′, B′, C′, D′, E′ or F′. In some embodiments, a composition of the invention may comprise a mixture of at least ten of the compounds represented by the structures of formula I, II, III, IV, A, B, C, D, E, F, A′, B′, C′, D′, E′ and F′.
[0100] It has been surprisingly found that one or more compounds represented by the structures of formulae I, II, III, IV, A, B, C, D, E, F, A′, B′, C′, D′, E′ and F′ are effective against AIDS and other viral diseases and against HIV+ related infections. Thus, in some embodiments, the present invention provides a method for the treatment, prevention or control of AIDS and other viral diseases and HIV+ related infections in human as well as in veterinary applications. In some embodiments, said method may comprise administering to a subject one or more compounds represented by the structures of formulae I, II, III, IV, A, B, C, D, E, F, A′, B′, C′, D′, E′ and F′. In some embodiments, the method may comprise administering to a subject a pharmaceutical composition comprising one or more compounds represented by the structures of formulae I, II, III, IV, A, B, C, D, E, F, A′, B′, C′, D′, E′ and F′.
[0101] It has also been found that compounds of the invention should be useful for treating AIDS and HIV+ related infections. In experiments described in the Examples below, compounds of the invention have shown activity in vitro. In binding experiments which involved the chemokine receptor CXCR4, compounds of the invention showed activity by preventing the function of this receptor, which is the most important receptor for the entrance of the HIV-1 T tropic into its target cell. Treatment of other conditions in which chemokine receptor inhibition is important or desirable are also contemplated. For example, control and/or prevention of malignant metastasis is highly important and desirable in cancer treatment. Since the chemokine receptor CXCR4 (and to an extent CXCR3) is involved in cell migration and is possibly the most prominent and important receptor in the movement of the malignant cells, compounds of the invention, which prevent the function of this receptor, may contribute to control/prevent the movement of such cells.
[0102] Compounds of the invention are also intended for inducing apoptosis and/or inducing AICD. The inventors have found that compounds of the invention exert an inhibitory effect under certain conditions against apoptosis, as described in PCT/IB03/04993 cited above. According to PCT/IB03/04993, however, the compounds are administered in a more hydrophilic carrier, e.g., a water-containing carrier. It has now been surprisingly found that the compounds of the invention, when dissolved in even a small amount of a carrier which minimizes micellar formation or van der Waals attraction of molecules of the compounds, like DMSO, appear to enhance the development of an immune response, as evidenced by enhanced lymphocyte proliferation and apoptotic effect which are characteristic of activation-induced cell death (AICD.) Without wishing to be bound by theory, it is believed that the effect of the DMSO (or other agent which would interfere with micellar formation) is to allow the compounds to behave differently (i.e., proliferation followed by apoptosis) than when the compounds are in ‘AV micelle’ wherein proliferation is inhibited.
[0103] Methods of inhibiting fibrosis or aberrant fibroblast proliferation are also within the scope of the invention. Preventing fibrosis or aberrant fibroblast proliferation is important in treating or preventing liver cirrhosis, for example, and compounds of the invention may exert an inhibitory effect on fibroblast proliferation as shown in the Examples. As such, the compounds of the invention will have usefulness in this regard.
[0104] Methods of administration are well known to a person skilled in the art. Methods of administration include, but are not limited to, parenterally, transdermally, intramuscularly, intravenously, intradermally, intranasally, subcutaneously, intraperitoneally or intraventricularly or rectally. Methods and means of administration are known to those skilled in the art from, for example, U.S. Pat. Nos. 5,693,622; 5,589,466; 5,580,859; and 5,566,064, which are hereby incorporated by reference in their entirety.
[0105] In addition, the present invention provides a pharmaceutical composition comprising as an active ingredient one or more compounds of the present invention, together with one or more pharmaceutically acceptable excipients. As used herein, “pharmaceutical composition” means a therapeutically effective amount of one or more compounds of the present invention together with suitable excipients and/or carriers useful for the treatment of immuno-allergical diseases, autoimmune diseases and organ or tissue transplantation rejection. A “therapeutically effective amount” as used herein refers to that amount that provides a therapeutic effect for a given condition and administration regimen. Such compositions can be administered by any one of the methods listed hereinabove.
[0106] A further aspect of the invention comprehends a compound of the invention in combination with other compounds of the invention. A compound of the invention may also be administered in combination with an anti-inflammatory agent, an immunosuppressant, an antiviral agent or the like. Furthermore, the compounds of the invention may be administered in combination with a chemotherapeutic agent such as an alkylating agent, anti-metabolite, mitotic inhibitor or cytotoxic antibiotic as described above. In general, currently available dosage forms of the known therapeutic agents for use in such combinations will be suitable.
[0107] Combination therapy” (or “co-therapy”) includes the administration of a compound of the invention and at least a second agent as part of a specific treatment regimen intended to provide the beneficial effect from the co-action of these therapeutic agents. The beneficial effect of the combination includes, but is not limited to, pharmacokinetic or pharmacodynamic co-action resulting from the combination of therapeutic agents. Administration of these therapeutic agents in combination is typically carried out over a defined time period (usually minutes, hours, days or weeks depending upon the combination selected). “Combination therapy” may, but generally is not, intended to encompass the administration of two or more of these therapeutic agents as part of separate monotherapy regimens that incidentally and arbitrarily result in the combinations of the present invention.
[0108] “Combination therapy” is intended to embrace administration of these therapeutic agents in a sequential manner; that is wherein each therapeutic agent is administered at a different time, as well as administration of these therapeutic agents, or at least two of the therapeutic agents, in a substantially simultaneous manner. Substantially simultaneous administration can be accomplished, for example, by administering to the subject a single capsule having a fixed ratio of each therapeutic agent or in multiple, single capsules for each of the therapeutic agents.
[0109] Sequential or substantially simultaneous administration of each therapeutic agent can be effected by any appropriate route including, but not limited to, oral routes, intravenous routes, intramuscular routes and direct absorption through mucous membrane tissues. The therapeutic agents can be administered by the same route or by different routes. For example, a first therapeutic agent of the combination selected may be administered by intravenous injection while the other therapeutic agents of the combination may be administered orally. Alternatively, for example, all therapeutic agents may be administered orally or all therapeutic agents may be administered by intravenous injection. The sequence in which the therapeutic agents are administered is not narrowly critical.
[0110] “Combination therapy” also can embrace the administration of the therapeutic agents as described above in further combination with other biologically active ingredients and non-drug therapies (e.g., surgery or radiation treatment.) Where the combination therapy further comprises a non-drug treatment, the non-drug treatment may be conducted at any suitable time so long as a beneficial effect from the co-action of the combination of the therapeutic agents and non-drug treatment is achieved. For example, in appropriate cases, the beneficial effect is still achieved when the non-drug treatment is temporally removed from the administration of the therapeutic agents, perhaps by days or even weeks.
[0111] The compounds of the invention and the other pharmacologically active agent may be administered to a patient simultaneously, sequentially or in combination. It will be appreciated that when using a combination of the invention, the compound of the invention and the other pharmacologically active agent may be in the same pharmaceutically acceptable carrier and therefore administered simultaneously. They may be in separate pharmaceutical carriers such as conventional oral dosage forms which are taken simultaneously. The term “combination” further refers to the case where the compounds are provided in separate dosage forms and are administered sequentially.
[0112] The compositions and combination therapies of the invention may be administered in combination with a variety of pharmaceutical excipients, including stabilising agents, carriers and/or encapsulation formulations as described herein.
[0113] In some embodiments, the compositions of the present invention are formulated as oral or parenteral dosage forms, such as uncoated tablets, coated tablets, pills, capsules, powders, granulates, dispersions or suspensions. In some embodiments, the compositions of the present invention are formulated for intravenous administration. In some embodiments, the compounds of the present invention are formulated in ointment, cream or gel form for transdermal administration. In some embodiments, the compounds of the present invention are formulated as an aerosol or spray for nasal application. In some embodiments, the compositions of the present invention are formulated in a liquid dosage form. Examples of suitable liquid dosage forms include solutions or suspensions in water, pharmaceutically acceptable fats and oils, alcohols or other organic solvents, including esters, emulsions, syrups or elixirs, solutions and/or suspensions.
[0114] Suitable excipients and carriers can be solid or liquid and the type is generally chosen based on the type of administration being used. Liposomes may also be used to deliver the composition. Examples of suitable solid carriers include lactose, sucrose, gelatin and agar. Oral dosage forms may contain suitable binders, lubricants, diluents, disintegrating agents, colouring agents, flavouring agents, flow-inducing agents, and melting agents. Liquid dosage forms may contain, for example, suitable solvents, preservatives, emulsifying agents, suspending agents, diluents, sweeteners, thickeners, and melting agents Parenteral and intravenous forms should also include minerals and other materials to make them compatible with the type of injection or delivery system chosen.
[0115] This invention is further illustrated in the Examples section which follows. This section is set forth to aid in an understanding of the invention but is not intended to, and should not be construed to, limit in any way the invention as set forth in the claims that follow thereafter.
EXAMPLES
Example 1
Synthesis of compounds
[0116] Compounds of the present invention were synthesised and characterized as described below.
AV 23
[0117] 0.66g 4 mM 4-hydroxy hydrocinnamic acid and 4 ml thionyl chloride in 30 ml cyclohexane were refluxed for 2 hours. Evaporation gave a yellow solid to which were added 0.9g 4 mM, phenyl alanine ethyl ester HCl, 30 ml dichloromethane and 1 ml triethyl amine. After stirring 2 hours at room temperature, water and KOH were added to neutral pH and the reaction extracted with dichloromethane Evaporation gave a light yellow viscous oil, which was triturated and recrystallized with ethanol to give 0.25 g 18%, white solid,mp-213.
[0118] NMR CDCl 3 7.30-6.9(9H,m),4.20(2H,q,J=7.0 Hz),3.30(1H,m) 3.10(2H,t,J=7.2 Hz) 2.90 (2H,m),2.60(2H,t,J=7.2 Hz),1.35(3H,t,J=7.0 Hz).
[0119] MS-341 M + ,10%),277(15),194(20),165(M-phenethyl ester,100%),149(65) m/e.
AV24
[0120] 0.66 g 4 mM 4-hydroxy hydrocinnamic acid and 4 ml thionyl chloride in 30 ml cyclohexane were refluxed for 2 hours. Evaporation gave light yellow solid to which were added 0.5 g 4.1 mM, phenethyl amine, 30 ml dichloromethane and 0.6 ml triethyl amine. After stirring for 2 hours at room temperature, water and KOH were added to neutral pH and the reaction was extracted with dichloromethane. Evaporation gave a viscous oil which was recrystallized with ethanol to give 0.3 g white solid, 28%, mp-165.
[0121] NMR acetone d 6 7.35-6.75(9H,m),3.40(2H,q,J=7.1 Hz),2.90(2H,t,J=7.2 Hz) 2.75 (2H,t,J=7.2 Hz),2.42(2H,t,J=7.1 Hz). Phenethyl amine-NMR acetone d 6 7.2(5H,m),2.96(2H,t,J=7.2 Hz) 2.75 (2H,t,J=7.2 Hz).
[0122] MS-269(M + ,100%),178(M-benzyl) m/e.
AV 26
[0123] 0.66 g 4 mM 4-hydroxy hydrocinnamic acid and 4 ml thionyl chloride in 30 ml cyclohexane were refluxed for 1.5 hours. Evaporation gave a light yellow solid to which were added 0.5 g 4.1 mM, histidine amine, 30 ml dichloromethane and 0.5 ml triethyl amine. After stirring 2 hours at room temperature, water and KOH were added to neutral pH and the reaction was extracted with dichloromethane. Evaporation gave a viscous oil which was recrystallized with ethanol to give 0.15 g white solid, 15%, mp-245.
[0124] NMR acetone d 6 7.35-(6H,m),3.42(2H,q,J=7.1 Hz),2.93(2H,t,J=7.2 Hz), 2.73 (2H,t,J=7.2 Hz),2.45(2H,t,J=7.1 Hz).
[0125] MS-259(M + ,17%),239(25),213(18),194(100%),185(37) m/e
AV 27
[0126] 3.2 g DL phenyl alanine, 20 ml ethylene glycol and 7 ml thionyl chloride were refluxed for 2 hours. Workup as above gave 1.3 g oil which was used in the synthesis of AV 28.
[0127] NMR acetone d 6 7.35-(5H,m),4.50,3.27,2.90 (3H,12 line ABX), 4.32 (2H,t,J=7.0 Hz), 3.76 (2H,t,J=7.0 Hz).
AV 28
[0128] 1 g 6 mM 4-hydroxy hydrocinnamic acid and 5 ml thionyl chloride in 30 ml cyclohexane were refluxed for 1.5 hours. Evaporation gave a light yellow solid to which were added 1.2 g AV 27 in 30 ml dichloromethane and 1 ml triethyl amine. After stirring 2 hours at room temperature, water and KOH were added to neutral pH and the reaction was extracted with dichloromethane. Evaporation gave a viscous oil which was recrystallized with ethanol to give 0.18 g white solid,8%,mp-224.
[0129] NMR acetone d 6 7.35-6.8(9H,m),3.73-2.50(12H,m).
AV 29
[0130] 0.22 g 1.3 mM, 4-hydroxy hydrocinnamic acid and 2 ml thionyl chloride in 30 ml cyclohexane were refluxed for 1.5 hours. Evaporation gave a light yellow solid to which were added 0.2 g 1.4 mM, tryptamine in 30 ml dichloromethane and 0.3 ml triethyl amine. After stirring 1.5 hours at room temperature, water and KOH were added to neutral pH and the reaction was extracted with dichloromethane. Evaporation gave a viscous oil which was recrystallized with ethanol to give 0.11 g white solid,27%,mp-136.
[0131] NMR acetone d 6 7.36(2H,d,J=7.8 Hz),7.0(8H,m),3.48(2H,q,J=7.1 Hz),3.05(2H,t,J=7.1 Hz),2.88 (2H,t,J=7.1 Hz),2.52(2H,t,J=7.1 Hz).
AV 30
[0132] 0.22 g 1.3 mM, 4-hydroxy hydrocinnamic acid and 2 ml thionyl chloride in 30 ml cyclohexane were refluxed for 1.5 hours. Evaporation gave light yellow solid to which were added 0.2 g 1.5 mM, tyramine, 30 ml dichloromethane and 0.3 ml triethyl amine. After stirring for 2 hours at room temperature, water and KOH were added to neutral pH and the reaction was extracted with dichloromethane. Evaporation gave a viscous oil which was recrystallized with ethanol to give 85 mg white solid,23%.
[0133] NMR acetone d 6 7.36(4H,ABq,J=8.8 Hz), 7.20 (4H,Abq,J=8.6 Hz), 3.48(2H,q,J=7.1 Hz), 3.05(2H,t,J=7.1 Hz),2.88 (2H,t,J=7.1 Hz), 2.52(2H,t,J=7.1 Hz).
AV32
[0134] A. 0.8 g 4-hydroxy cinnamic acid in 40 ml methanol and 10 drops HCl were refluxed for 12 hours. Workup as above gave 0.6 g oil,68% yield.
[0135] NMR CDCl 3 7.02,6.75 (4H,Abq,J=8.6 Hz),3.66(3H,s),2.86(2H,t,J=7.4 Hz), 2.60 (2H, t,J=7.4 Hz).
[0136] B. 0.6 g 3.3 mM, ester from step A and 0.26 g 4.2 mM, ethanol amine were heated at 100 for 3 hours in an open vessel. Chromatography gave 0.3 g recovered ester followed by amide. The viscous oil was triturated with acetone-methylene chloride and filtered to give 160 mg white solid, 23% yield, mp-102.
[0137] NMR acetone d 6 8.10(1H,s,OH),7.03,6.74(4H,Abq,J=8.8 Hz),3.90(1H,t,J=5.2 Hz, NH),3.54(2H,q,J=7.1 Hz),3.28(2H,t,J=7.1 Hz), 2.80(2H,t,J=8.2 Hz),2.41(2H,t,J=8.2 Hz).
AV 33
[0138] 0.9g, 6 mM, hydrocinnamic acid and 0.6g 6 equivalents, triphosgen in 30 ml dichloromethane and 1.5 ml triethyl amine were stirred 10 minutes at room temperature and 0.7 g phenethyl amine were added. After 2 hours at room temperature, workup (HCl) gave a viscous oil which was recrystallized with hexane-methylene chloride to give 166 mg white solid, 11%, mp-91.
[0139] NMR acetone d 6 7.35(10H,m), 3.40(2H,q,J=7.2 Hz), 2.90(2H,t,J=7.4 Hz), 2.74 (2H,t,J=7.2 Hz), 2.46(2H,t,J=7.4 Hz).
AV 34
[0140] Prepared as AV 33, in the same amount but with tyramine instead of phenethyl amine. Chromatography and trituration with benzene-hexane gave 220 mg white solid, 14%, mp-98.
[0141] NMR acetone d 6 7.25(5H,m),6.96,6.75(4H,Abq,J=8.4 Hz),3.43(2H,q,J=6.8 Hz),2.94(2H,t,J=7.6 Hz),2.65 (2H,t,J=6.8 Hz),2.42(2H,t,J=7.6 Hz).
AV 35
[0142] Prepared as AV 33, 3 mM, from indole propionic acid and tryptamine. Chromatography and trituration with ethanol gave 162 mg white solid, 16%, mp-142.
[0143] NMR acetone d 6 7.57(2H,d,J=7.8 Hz), 7.36(2H,d,J=7.8 Hz), 7.0(8H,m), 3.48(2H,q,J=7.1 Hz), 3.05(2H,t,J=7.1 Hz),2.88 (2H,t,J=7.1 Hz), 2.52(2H,t,J=7.1 Hz).
AV 38
[0144] Prepared as AV 33, 2 mM, from indole propionic acid and phenethyl amine. Chromatography and trituration with ethanol gave 220 mg white viscous oily solid, 37%.
[0145] NMR acetone d 6 7.57(2H,d,J=7.8 Hz)),7.25-6.97(9H,m),3.44(2H,q,J=7.1 Hz), 3.10(2H,t,J=7.1 Hz),2.66(2H,t,J=7.1 Hz),2.51(2H,t,J=7.1 Hz).
AV 43
[0146] 0.9 g 6 mM hydrocinnamic acid and 0.6 g 6 equivalents, triphosgen in 30 ml dichloromethane and 1 ml triethyl amine were stirred for 10 minutes at room temperature and 0.6 g ethanol amine were added. After 2 hours at room temperature, workup (HCl) gave a viscous oil which was recrystallized with hexane to give 124 mg white solid, 11%, mp-91.
[0147] NMR acetone d 6 7.30 (5H,m), 3.63(2H,t,J=5.2 Hz), 3.36(2H,q,J=5.2 Hz), 2.97(2H,t,J=7.3 Hz), 2.50(2H,t,J=7.3 Hz).
AV 45
[0148] Prepared similar to AV 28, but with the triphosgen method, from 6 mM indole propionic acid, AV 27. Chromatography gave 0.35 g viscous oil, 13% yield.
[0149] NMR CDCl 3 7.95(1H(br.s), 7.57(2H,d,J=8.0 Hz),7.36-6.90(9H,m), 4.36(2H,t,J=7.1 Hz), 4.17(2H,q,J=7.0 Hz), 3.5-2.8 (7H,m).
[0150] 0.65 g 3.9 mM, 4-hydroxy hydrocinnamic acid, 15 ml ethylene glycol and 5 ml thionyl chloride were refluxed 3 hours. Workup gave 0.5 g 61%, oil.
[0151] NMR acetone d 6 7.02,6.76(4H,ABq,J=8.6 Hz), 4.28(2H,t,J=7.1 Hz), 3.63(2H,t,J=7.1 Hz), 2.85,2.63(4H,m).
AV 48
[0152] Prepared as AV 33, 3 mM, from indole propionic acid and tyramine. Chromatography and trituration with ethanol-hexane gave 120 mg pink-white solid, 13%.
[0153] NMR acetone d 6 7.57(2H,d,J=7.8 Hz)),7.25-6.97(8H,m),3.44(2H,q,J=7.1 Hz), 3.10(2H,t,J=7.1 Hz),2.66(2H,t,J=7.1 Hz),2.51(2H,t,J=7.1 Hz).
AV 49
[0154] To 0.7 g 5 mM, hydrocinnamic aldehyde and 0.7 g 5 mM, tyramine in 20 ml ethanol was added 0.4 g NaBH 4 and the reaction refluxed 1 hour. Workup gave 0.7 g viscous oil, 55% yield.
[0155] NMR acetone d 6 7.35(5H,m), 7.15,6.85(4H,ABq,J=8.6 Hz), 2.85(2H,t,J=6.7 Hz), 2.70(6H,m),1.80(2H,quin.,J=7.2 Hz).
Example 2
Synthesis of Polyalkylene Glycol Compounds
[0156] Polyalkylene glycol compounds were generally synthesised by preparation of the appropriate alcohol compound (e.g., one of the compounds described in Example 1, or a hydroxylated derivative thereof) and then conjugation of the alcohol with a polyalkylene glycol (PAG) polymer (e.g., polyethylene glycol (PEG) or polypropylene glycol (PPG)) of the desired length.
[0000] Compound 1, Phenyl Alaninol
[0157] 1.2 g 32 mM, of LiAlH 4 were added to 2.3 g 10 mM, phenyl alanine ethyl ester HCl in 50 ml dry ether. After stirring for 2 hours at room temperature, water and KOH were added and the reaction product was extracted with ethyl acetate. After evaporation, 0.8 g of compound 1, a light yellow oil, was obtained.
[0158] Compound 1 crystallized on standing. Mp-70.
[0159] NMR CDCl 3 7.30(5H,m),3.64(1H,dd,J=10.5,3.8 Hz) 3.40(1H,dd,J=10.5,7.2 Hz) 3.12 (1H,m),2.81(1H,dd,J=13.2,5.2 Hz),2.52(1H,dd,J=13.2,8.6 Hz)
[0160] NMR acetone d 6 7.30(5H,m),3.76(1H,dt) 3.60(1H,m) 3.30 (1H,t),2.85(2H,m).
[0161] Helv. Chim. Acta, 31, 1617(1948). Biels. -E3,Vol. 13,p 1757.
Compound 2, Tyrosinol
[0162] To 3 g 12 mM, L-tyrosine ethyl ester HCl in 50 ml dry ether was added 1.2 g 32 mM LiAIH 4 . After stirring 3 hours at room temperature, water and KOH were added and the reaction was extracted with ethyl acetate. Evaporation gave 1.1 g of a light yellow oil, 54% yield, which on standing crystallized. mp-85.
[0163] NMR CDCl 3 7.20(4H,AB q,J=8.6 Hz), 3.50(2H,m) 3.20(1H,m), 2.81(2H,m).
[0164] NMR tyrosine ethyl ester free base CDCl 3 7.0,6.56(4H,AB q,J=8.8 Hz), 4.20(2H,q,J=7,0 Hz), 3.70,3.0,2.80(3H,12 line ABXm),1.28.(3H,t,J=7.0 Hz).
[0165] JACS, 71,305(1949). Biels. -E3,Vol. 13, p 2263.
[0166] Compound 3, Tryptophanol
[0167] To 3 g 12.9 mM, L-tryptophan methyl ester HCl in 50 ml dry ether was added 1.2 gr, 32 mM LiAlH 4 . After stirring 6 hours at room temperature water and KOH were added and the reaction extracted with ethyl acetate. Evaporation gave 1.23 g light yellow oil, 50% yield. On standing crystallized. Mp-65.
[0168] NMR CDCl 3 7.30(5H,m),3.64(1H,dd,J=10.5,3.8 Hz) 3.40(1H,dd,J=10.5,7.2 Hz) 3.12 (1H,m),2.81(1H,dd,J=13.2,5.2 Hz),2.52(1H,dd,J=13.2,8.6 Hz)
[0169] J. Het. Chem, 13, 777(1976). Biels. -E5, 22 Vol. 12, p 90.
[0000] Compound 4, AV 22
[0170] 0.66 g 4-hydroxy hydrocinnamic acid and 4 ml thionyl chloride in 30 ml cyclohexane were refluxed for 2 hours. After evaporation, a white solid was obtained, to which 0.65 g oil of Compound 1 (4.3 mM) in 30 ml dichloromethane and 0.4 ml triethyl amine were is added. After stirring for 2 hours at room temperature, water and KOH were added in order to neutralize the pH. The reaction product was extracted with dichloromethane. Evaporation gave 0.8 g of compound 4, light yellow viscous oil. Part of this product was triturated and recrystallized with ethanol to give a white solid. Mp-149.
[0171] NMR CDCl 3 7.30-6.9(9H,m),3.50(2H,m) 3.30(2H,t,J=7.2 Hz) 2.90 (3H,m),2.60(2H,t,J=7.2 Hz).
Compound 5, AV 57
[0172] 0.75 g 5 mM, hydrocinnamic acid and 4 ml thionyl chloride in 30 ml cyclohexane were refluxed for 2 hours. Evaporation gave a white solid to which were added 0.83 g 5.5 mM, phenyl alaninol in 30 ml dichloromethane and 0.5 ml triethyl amine. After stirring 3 hours at room temperature, water and KOH were added to neutral pH and the reaction was extracted with dichloromethane. Evaporation gave 0.57 g of a yellow viscous oil, 40% yield.
[0173] NMR CDCl 3 7.40-7.10(10H,m),3.60(2H,m) 3.35(2H,t,J=7.2 Hz) 2.95 (3H,m), 2.50(2H,t,J=7.2 Hz).
Compound 6, AV 58
[0174] 0.66 g 4 mM, 4-hydroxy hydrocinnamic acid and 4 ml thionyl chloride in 30 ml cyclohexane were refluxed 3 hours. Evaporation gave a light yellow solid to which were added 0.72 g 4.3 mM, tyrosinol in 30 ml dichloromethane and 0.5 ml triethyl amine. After stirring 3 hours at room temperature water and KOH were added to neutral pH and the reaction was extracted with dichloromethane. Evaporation gave 0.53 g light yellow viscous oil, 42% yield.
[0175] NMR CDCl 3 7.30,7.20 (8H,2 ABq,J=8.6 Hz),3.40(2H,m) 3.30(2H,t,J=7.2 Hz) 2.90 (3H,m),2.60(2H,t,J=7.2 Hz).
Compound 7 AV 59
[0176] 0.45 g 3 mM, hydrocinnamic acid and 3 ml thionyl chloride in 30 ml cyclohexane were refluxed for 2 hours. Evaporation gave a light yellow solid to which were added 0.66 g 3.5 mM, tryptophanol in 30 ml dichloromethane and 0.4 ml triethyl amine. After stirring 3 hours at room temperature, water and KOH were added to neutral pH and the reaction was extracted with dichloromethane. Evaporation gave 0.61 g viscous oil, 63% yield.
[0177] NMR CDCl 3 7.50-7.05(10H,m),3.65(2H,m) 3.32(2H,t,J=7.3 Hz) 2.92 (3H,m) 2.53(2H,t,J=7.3 Hz).
Compound 8, AV 72
[0178] 0.45g 3mM, hydrocinnamic acid and 3 ml thionyl chloride in 30 ml cyclohexane were refluxed for 2 hours. Evaporation gave a light yellow solid to which were added 0.58 g 3.5 mM, tyrosinol in 30 ml dichloromethane and 0.4 ml triethyl amine. After stirring for 2.5 hours at room temperature, water and KOH were added to attain neutral pH and the reaction was extracted with dichloromethane. Evaporation gave 0.57 g light yellow viscous oil, 63% yield.
[0179] NMR CDCl 3 7.40-7.10(9H,m),3.60(2H,m) 3.35(2H,t,J=7.2 Hz) 2.95 (3H,m),2.50(2H,t,J=7.2 Hz).
Compound 9, AV 73
[0180] 0.38 g 2 mM, 3-indole propionic acid and 2 ml thionyl chloride in 30 ml cyclohexane were refluxed for 2 hours. Evaporation gave light yellow solid to which were added 0.4 g 2.6 mM, phenyl alaninol in 30 ml dichloromethane and 0.3 ml triethyl amine. After stirring 2.5 hours at room temperature, water and KOH were added to neutral pH and the reaction was extracted with dichloromethane. Evaporation gave 0.47 g pink solid,75% yield.
[0181] NMR CDCl 3 7.58(1H,d,J=8.0 Hz), 7.40(1H,d,J=8.0 Hz), 7.30-6.9(8H,m), 3.50(2H, m) 3.30(2H,t,J=7.5 Hz), 2.95 (3H,m),2.70(2H,t,J=7.5 Hz).
[0000] Compound 10
[0182] 0.3 g of Compound 4 (AV 22), 0.8 g triphenyl phosphine and 0.55 g ethyl diazo carboxylate were added to 1 g of poly(propylene glycol), (average molecular weight ca 1000), in 60 ml dichloromethane. Stirring for 2 hours at room temperature, evaporation and chromatography gave 0.65 g of Compound 10, Formula VII, as a viscous oil.
Additional Compounds Synthesised from Phenyl Alaninol
[0183] These compounds include those represented by the following formula:
[0184] This compound can also be represented as Formula A, where R is a polypropylene glycol polymer and n is the total number of polypropylene monomers in the polymer:
AV61:
[0185] R=PPG (polypropylene glycol) n=7 MW-706
[0186] 0.3 g AV 22 (1 mM), 0.8 g 3 mM, triphenyl phosphine and 0.55 g 3.2 mM, ethyl diazo carboxylate were added to 1 g of poly(propylene glycol) (average mol. weight 424, n=7) in 60 ml dichloromethane. After stirring for 4 hours at room temperature, evaporation and chromatography gave 0.55 g viscous oil, a 73% yield.
[0187] NMR CDCl 3 7.30-6.9(9H,m),4.1-3.0(m),2.60(2H,t,J=7.2 Hz), 1.2-1.1(m)
[0000] AV 62
[0188] R=PPG n=12 MW-996
[0189] Was prepared as above from 0.2 g AV 22 to give 0.3 g 46% yield.
[0000] AV 60
[0190] R=PPG n=17 MW-1286
[0191] Was prepared as above from 0.1 g AV 22 to give 0.2 g 48% yield.
[0000] AV 63
[0192] R=PPG n=34 MW-2274
[0193] Was prepared as above from 0.1 g AV 22 to give 0.25 g 34% yield.
AV 132
[0194] Was prepared as the procedure for AV 72, substituting L(−) tyrosinol for the (racemic) tyrosinol to give the above compound, and an undetermined amount of impurity. Use of an adequate protecting scheme to protect the open phenol ring from attack by the propylene glycol should reduce the amount of impurity.
AV 133
[0195] Was prepared as the procedure for AV 22, substituting D(+)phenyl alaninol for the (racemic) phenyl alaninol to give the above compound, and an undetermined amount of impurity. Use of an adequate protecting scheme to protect the open phenol ring from attack by the propylene glycol should reduce the amount of impurity.
AV 134
[0196] Was prepared as the procedure for AV 22, substituting L(+)phenyl alaninol for the (racemic) phenyl alaninol to give the above compound, and an undetermined amount of impurity. Use of an adequate protecting scheme to protect the open phenol ring from attack by the propylene glycol should reduce the amount of impurity.
AV 136
[0197] R=PPG n=1
[0198] Was prepared as above from AV 22 and from AV 133, to give the compound or its isomer, and an undetermined amount of impurity. Use of an adequate protecting scheme to protect the open phenol ring from attack by the propylene glycol should reduce the amount of impurity.
AV 137
[0199] R=PPG n=1
[0200] Was prepared as above from AV 22 and from AV 134, to give the compound or its isomer, and an undetermined amount of impurity. Use of an adequate protecting scheme to protect the open phenol ring from attack by the propylene glycol should reduce the amount of impurity.
Compounds Synthesised from Compound 5, AV 57
AV 86
[0201] R=PPG n=7 MW-690
[0202] Was prepared as above from 0.22 g AV 57 to give 0.25 g,47% yield.
[0000] AV 87
[0203] R=PPG n=17 MW-1270
[0204] Was prepared as above from 0.2 g AV 57 to give 0.33 g,33% yield.
Compounds Synthesised from Compound 9, AV 73
AV76
[0205] R=PPG n=7 MW-729
[0206] Was prepared similar to AV 61 above from 0.22 g AV 73 to give 0.23 g,47% yield.
[0000] AV 77
[0207] R=PPG n=34 MW-2297
[0208] Was prepared as above from 0.2 g AV 73 to give 0.35 g,25% yield.
[0000] Compounds Synthesised from Tyrosinol
[0209] Compounds Synthesised from Compound 6, AV 58
AV 64
[0210] R=PPG n=7 MW-722
[0211] Was prepared as above from 0.2 g AV 58 to give 0.21 g,46% yield.
[0000] AV 65
[0212] R=PPG n=17 MW-1302
[0213] Was prepared as above from 0.23 g AV 58 to give 0.28 g,29% yield.
Compounds Synthesised from Compound 8, AV 72
AV 74
[0214] R=PPG n=7 MW-706
[0215] Was prepared similar to AV 61, above, from 0.22 g AV 72 to give 0.26 g 50% yield.
[0000] AV 75
[0216] R=PPG n=34 MW-2274
[0217] Was prepared as above from 0.2 g AV 72 to give 0.35 gr,23% yield.
[0000] AV 131
[0218] R=PPG n=69 MW-4307
[0219] Was prepared as above from AV 72 and poly(propylene glycol (average mol. weight 4,000).
AV 135
[0220] R=PPGn=1
[0221] Was prepared similar to AV 74, above, from AV 72 and from AV 132, to give the compound or its isomer, and an undetermined amount of impurity. Use of an adequate protecting scheme to protect the open phenol ring from attack by the propylene glycol should reduce the amount of impurity.
[0000] Compounds Synthesised from Tryptophanol
[0222] Compounds Synthesised from Compound 7, AV 59
[0223] R=PPG n=7 MW-729
[0224] Was prepared similar to AV 61, above, from 0.22 g AV 59 to give 0.26 g 53% yield.
[0000] AV 82
[0225] R=PPG n=34 MW-2297
[0226] Was prepared as above from 0.2 g AV 59 to give 0.35 g 41% yield.
Example 3
Synthesis of (S)2-N(3-O-polypropyleneglycol)propylbenzene)-3-(4-hydroxyphenyl)propylamide (AV 61S, n=7)
[0227] Reagents and Instrumentation
[0228] 1-Hydroxybenzotriazole hydrate (HOBt), Aldrich cat.# 15,726-0; N,N′-dicyclohexylcarbodiimide (DCC), Aldrich cat.# D8-000-2; potassium carbonate, Aldrich cat.# 46,781-2; L-phenylalanynol, Fluka cat.# 78100; 3-(4-hydroxyphenyl)propionic acid, Fluka cat.# 56190; L-tyrosinol hydrochloride, Aldrich, cat.# 46,999-8; hydrocinnamic acid, Aldrich, cat. # 13,523-2; methanesulfonyl chloride, Aldrich cat.# 47,125-9; poly(propylene glycol) M n =425, Aldrich cat.# 20,230-4; poly(propylene glycol) M n =1000, Aldrich cat.# 20,232-0. THF and acetonitrile were dried over KOH pellets for at least 48 hours prior to use. methanesulfonyl chloride (mesyl chloride) and pyridine were distilled prior to use. TLC tests were carried out with Merck's 60F 254 silica-gel on aluminium plates. Column chromatographic separations were made with Merck's Kieselgel 60 silica gel. UV lamp (λ=254 nm) was used to detect UV absorbing spots on the TLC plates. Proton NMR tests were made on Bruker's Avance 500 and Avance 200 instruments. Mass-spectral analyses of small molecular weight molecules were made on Bruker's Esquire 3000 plus mass-spectrometer and of the PPG-containing molecules on Bruker's MALDI-TOF (reflex IV) mass-spectrometer. Using a chromatotron is recommended for a better controlled chromatographic separations.
Synthesis of 1 (S isomer)
[0229] 3-(4-Hydroxyphenyl)-propionic acid (0.2 g, 1.2 mmol), L-phenylalaninol (0.18 g, 1.2 mmol), N-hydroxybenzotriazole (HOBt) (0.16 g, 1.2 mmol) and THF (5 mL) were put into a round-bottom flask equipped with a magnetic stirrer. The flask was cooled in an ice-water bath and a pre-cooled solution of dicyclohexylcarbodiimide (DCC) (0.26 g, 1.26 mmol) in 3 mL THF was introduced dropwise into the reaction mixture. The reaction mixture was allowed to stir for additional 1 hour at low temperature and then for another 2 hours at room temperature. The white precipitate formed was filtered out and the filtrate was evaporated to dryness. The residue was dissolved in 10 mL ethyl acetate and the organic phase washed twice with 1M HCl, then twice with a saturated solution of sodium bicarbonate solution and then once with water. The organic phase was dried over anhydrous magnesium sulfate, paper filtered and evaporated to about a quarter of its original volume. The remaining solution was allowed to cool and the crystalline precipitate formed was recovered by vacuum filtration to yield 0.24 g of 1 (67%).
Synthesis of 2 (S isomer)
[0230] 1 (0.1 g, 0.33 mmol), potassium carbonate (0.069 g, 0.5 mmol, thinly crushed) and THF (3 mL, dried over KOH pellets) were put in a round-bottom flask equipped with a magnetic stirrer and a CaCl 2 drying tube. The mixture was cooled over an ice-salt bath (−10° C.) and a pre-cooled solution of di-tert-butyldicarbonate (0.066 g, 0.30 mmole) in 2 mL THF (dried) was introduced dropwise. The mixture was allowed to stir at ice temperature for 1 hour and then for 2 days at room temperature. The reaction mixture was then evaporated, water (5 mL) introduced and the product was extracted with two 10 mL portions of ethyl acetate. The combined extracts were dried over anhydrous magnesium sulfate, paper-filtered and the solvent removed. The oily residue was triturated with a small amount of n-hexane and the solid formed recovered by vacuum filtration (Yield 0.12 g, 90.1%). Alternatively, the oily residue can be dissolved in an 1:1 mixture of ethyl acetate and hexane and the product recrystallized.
Synthesis of 3 (S isomer)
[0231] a. Mesylation of PPG.
[0232] 106 mg of PPG 425 (0.25 mmol) was reacted with 90 mole-percent of mesyl chloride (26 mg, 2 drops) and 0.4 mmol pyridine (31.6 mg, 2 drops) to afford the mono-mesylated PPG (A). After combining PPG, mesyl chloride and pyridine, the mesylation reaction was carried out at 0° C. during 30 minutes, while stirring, and then continued for another 60 minutes at room temperature. During mixing the reaction mixture turned from colorless to milky-white. The mixture was then dissolved in 5 mL methylene chloride and the organic phase washed twice with 1M HCl solution, then twice with 1M NaOH solution and once with water. The organic phase was dried over anhydrous sodium sulphate, filtered and the solvent removed.
[0233] b. Sodium activation of 2.
[0234] 0.1 g of 2 (0.25 mmol) was dissolved in 5 mL of absolute ethanol and then reacted with an equi-molar amount of sodium-ethoxide in absolute ethanol (previously prepared by reacting 0.25 mg-atom of sodium with an access of absolute ethanol). The ethanol of the combined solutions was evaporated to total dryness to yield the sodium salt of 2 (B).
[0235] c. Reacting A and B
[0236] A was dissolved in 5 mL of a potassium hydroxide-dried acetonitrile and the solution introduced into a round-bottom flask containing a magnetic stirrer. 5 mL of dried acetonitrile solution of B was introduced into the flask, followed by a catalytic amount (few crystals) of potassium iodide. A reflux condenser and a gas bubbler adjusted on top of it were connected to the reaction vessel and the reaction mixture was allowed to reflux under nitrogen atmosphere, while stirring, during 24 hrs. The reaction mixture was then paper-filtered and the solvent removed. The residue was dissolved in 2 mL of ethyl acetate and then passed through a silica-gel column, using ethyl acetate for elution. The TLC (elution with ethyl acetate) UV-absorbing spot at R f =0.55 turned out to contain the desired product 3 (a mixture of molecules containing different PPG sub-unit lengths), however, containing also some unreacted PPG. Other fractions contained unreacted mesylated PPG and doubly-mesylated PPG.
Synthesis of 4 (AV 61S)
[0237] 40 mg of 3 were dissolved in 3 mL of methylene chloride and 10 drops of tri-fluoroacetic acid (TFA) were added. The mixture was gently heated on a hot plate, while at the same time removing the solvent and TFA by directing a stream of nitrogen gas at the reaction mixture. The remaining is an oil-like product, containing target product 4 (a mixture of molecules containing different lengths of the PPG sub-units and also unreacted PPG chains).
Example 4
Synthesis of (S)2-N(3-O-(polypropyleneglycol)-1-propyl-4-hydroxybenzene)-3-phenylpropylamide (AV 74S, n=7)
[0238] Synthesis of 5 (S isomer)
[0239] Hydrocinnamic acid (36.8 mg, 0.24 mmol), L-tyrosinol hydrochloride (0.05 g, 0.24 mmol), N-hydroxybenzotriazole (HOBt) (0.033 g, 0.24mmol), sodium bicarbonate (84 mg, 1 mmol) and THF (5 mL) were put into a round-bottom flask equipped with a magnetic stirrer. The flask was cooled in an ice-water bath and a pre-cooled solution of dicyclohexylcarbodiimide (DCC) (53 mg, 0.26 mmol) in 3 mL THF was introduced dropwise into the reaction mixture. The reaction mixture was allowed to stir for another 1 hour at low temperature and then 2 hours at room temperature. The white precipitate formed was paper-filtered and the filtrate evaporated to dryness. The residue was dissolved in 10 mL ethyl acetate. (Some precipitate that may occur at this stage must be filtered out). The clear organic filtrate was twice washed with 1M HCl, then twice with a saturated aqueous solution of sodium bicarbonate and then once with water. The organic phase was dried over anhydrous magnesium sulfate and paper filtered. TLC showed three UV-absorbing spots (eluant ethyl acetate), one at R f =0.55, the second at R f =0.35 and the third at R f =0.05. Proton NMR (methyl sulfoxide) indicated that the spot at R f =0.35 is of compound 5. This component was separated on a silica-gel column (elution with ethyl acetate), yielding 25 mg of 5 (yield: 35%). Alternatively, a quite pure compound 5 (yield 85%) can be obtained by recrystallysing the reaction mixture from methylene chloride.
Synthesis of 6 (S isomer)
[0240] Same as synthesis of compound 2. (Yield: 73%).
Synthesis of 7 (S isomer)
[0241] Same as synthesis of compound 3. The reaction mixture was chromatographed on a silica-gel column (eluant: ethyl acetate) and a fraction containing UV-absorbing spot (R f =0.43, eluant ethyl acetate) proved by MALDI-TOF mass-spectrometer to contain 7 (a mixture of molecules containing PPG chains of different size), along with unreacted PPG chains and some unreacted mesylated PPG chains.
Synthesis of 8 (AV 74S)
[0242] Same as synthesis of compound 4.
[0243] Analogues of compounds 4 (AV 61S) and 8 (AV 74S) containing PPG 1000 chains (n=17) (AV60 S and AV 78S, respectively) were prepared using the same synthetic route as given for the PPG 425 -containing counterparts.
[0244] TLC data of the PPG 1000 analogues:
[0245] PPG 1000 analogue of AV61S (AV60S): spot at R f =0.40 (eluant: ethyl acetate).
[0246] PPG 1000 analogue of AV74S (AV78S): spot at R f =0.43 (eluant: ethyl acetate).
Example 5
Effect of AV Compounds on Inhibiting CXCR4 and CXCR3
[0247] Shearflow experiments. Soluble, affinity purified seven-domain human VCAM-1, sVCAM-1 together with the chemokine SDF-1 (ligand for CXCR4) or Mig (Ligand for CXCR3) were mixed in coating media (PBS buffered with 20 mM sodium bicarbonate pH8.5) and adsorbed as 10 μl drops on a polystyrene plate (60×15 mm Petri dish, Becton Dickinson, Lincoln Park N.J.) over night at 4° C. The plate was then washed and blocked with human serum albumin, HSA (20 mg/ml PBS) for 2 hr at 4° C. To co-immobilize SDF-1 and Mig with the adhesive substrates, the ligands (VCAM-1) were coated in the presence of active (2 μg/ml) or heat denatured SDF-1 or Mig and HSA (2 mg/ml) and washed and quenched as above. A polystyrene plate with coated adhesive substrates was assembled as the lower wall in a parallel plate flow chamber (260 μm gap) mounted on the stage of an inverted phase contrast microscope (Diaphot 300, Nikon) and extensively washed with binding medium. All experiments were conducted at 37° C. Treated (1 hr incubation with 0.1, 1, 10 μg/ml of AV 61, 63, 75, 77) and untreated T cells were diluted with binding medium and perfused into the chamber at 10 6 cells/ml by an automated syringe pump (Harvard Apparatus, Natick, Mass.). All experiments were recorded on videotape by a long integration camera LIS-700 CCD (Applitech, Holon Israel) and a SVHS time lapse video recorder (AG-6730 Panasonic). The human T cells were allowed to accumulate for 1 min on the substrate and then the flow rate was increased to 22 dyn/cm 2 . All recorded images of cells interacting with the adhesive substrates were analyzed and quantified by computer tracking individual cells. The results obtained for each experiment were normalized according to the total number of videotaped cells.
[0248] As can be seen from the results of the experiments, shown in FIGS. 1A-1C (CXCR4) and FIGS. 2A-2D (CXCR3), compounds of the invention are effective in inhibiting these cytokine receptors, and as such should be useful in treating HIV and AIDS via preventing the function of this receptor, which is the most important receptor for the entrance of the HIV-1 T tropic into its target cell.
Example 6
Effect of AV Compounds on AICD
[0249] T cells were isolated from buffy coats (BC) of consenting normal human donors (Hadassah Hospital Blood Bank). The BC preparations were diluted 1:4 with phosphate-buffered saline (PBS) that contained 10 U/mL heparin. Peripheral blood mononuclear cells were separated by Ficoll/Paque density centrifugation. Monocytes and B cells were depleted by plastic adherence and passage through nylon wool columns, respectively. Small T lymphocytes were harvested from the pellet of a discontinuous Percoll gradient. The cells were found to be >80% CD3+ by FACS analysis. Cells were cultured in the presence of various concentrations of compound and/or phytohemaglutinin (PHA) (1 μg/ml) T cell mitogen. Proliferation was measured by culturing 1×10 5 cells in each well of a 96-well flat-bottomed microtiter plates. 48 hrs and 7 days following addition of compound, 1 μCi 3 [H] thymidine was added to each well and the cultures were incubated for an additional 24 hrs. Samples were harvested and incorporated radioactivity was measured. A 7 day incubation with compounds led to a significant increase in the proliferation of PHA-stimulated T cells versus PHA alone.
[0250] The effect of AV 63, AV 75, AV 77, AV 131, and polypropylene glycol (“PPG-34”, MW 2000, as a control) on PHA (phytohemagglutinin)-treated human peripheral blood mononuclear cells (PMBCs), using DMSO as a carrier, was investigated. Data from the AV 63 experiment is shown in FIGS. 5B and 6A . Data from the AV 75 experiment is shown in FIGS. 3A, 4A and 6 B. Data from the AV 77 experiment is shown in FIGS. 5A and 6C . Data from the PPG-34 experiment is shown in FIGS. 3C and 4B . Data from the AV 131 experiment is shown in FIGS. 3B, 3D , 4 C and 7 A. Data from the AV 77 experiment is shown in FIGS. 5A and 6C .
[0251] As can be seen from the results of the experiments, shown in the above-mentioned figures, compounds of the invention surprisingly show the enhanced lymphocyte proliferation and apoptotic effect which is characteristic of activation-induced cell death (AICD.)
Example 7
Effect of AV Compounds on Inhibiting Fibrosis
[0252] The effect of AV compounds on fibroblast proliferation was investigated. A thymidine (TdR) incorporation experiment was conducted to determine the effect of combined AV molecules on human foreskin fibroblast cells (HFF).
[0253] Method: Quantitation of [3H]thymidine (TdR) incorporation
[0254] Control: Cell culture medium
[0255] Inhibitor: >50% decrease of cpm relative to control (drug Doxorubicin)
[0000] Procedure:
[0256] HFF are cultured in DMEM medium +1% Na-Pyruvate, 1% Pen/Srep, 1% L-Glu, 1% none-essential amino acid and 10% FBS. The cells were plated at 5×10 3 /well in a 96 well plate. Extracts were added one day after seeding cells. The cells were incubated for 4 days. 2 days before the end of the experiment, [3H]-thymidine (1 mCi/well) was added. TdR—1:50 (20 ml in 1 ml) (NET-027 Thymidine [methyl-3H] from NEN 6.7 Ci/mmol Batch 3106446) Cells were harvested by adding denaturated agent and scintillation liquid and then counted for 1 min/sample.
[0257] Compounds used (AV 61, AV 63 AV 74, AV 75, AV 76, AV 77, AV 81, and AV 82) were resuspended in medium, and diluted to the concentrations indicated in the Figures. Controls were: 1) negative-medium 2) Positive-10ˆ-5M Doxorubicin.
[0258] Data from the experiments are shown in FIGS. 8 and 9 . As can be seen from the results of the experiments, compounds of the invention are effective inhibitors of fibroblast proliferation.
Example 8
AV Compound Selectivity Index
[0259] Anti-HIV-1 results obtained with AV 61 show activity against HIV-1 (III B strain) with an EC 50 and CC 50 of as low as 15.6 μg/ml and 125 μg/ml, of pure substance, resulting in a selectivity index of greater than 8, and a % PR of as high as 100%, as was determined by an MTT-assay.
[0260] The following experimental procedures were employed. MT-4 cells were grown in RPMI 1640 medium (Life Technologies, Merelbeke, Belgium), supplemented with 10% (v/v) heat-inactivated fetal calf scrum (FCS), 2 mM L-glutamine, 0.1% sodium bicarbonate and 20 μg /ml gentamicin (Life Technologies, Merelbeke, Belgium). The cells were maintained at 37° C. in a humidified atmosphere of 5% CO 2 in air. Every 3-4 days, cells were seeded at 3×10 5 cells/ml.
[0261] Stocks of HIV-1 IIIB strain were obtained from the culture supernatant of 4×10 5 MT-4 cells/ml infected with HIV at 400 CCID 50 immediately after complete cytopathic effect (CPE) has appeared. The virus titre of the supernatant was determined in MT-4 cells using the Reed and Muench end-point dilution method. The virus stocks were aliquoted and stored at −70° C. until used.
[0262] Flat-bottom, 96-well plastic microtiter trays (Nunc, Roskilde, Denmark) were filled with 100 ml of complete medium using a Titertek Multidrop dispenser (ICN Biomedicals—Flow Laboratories). Stock solution (10× final test concentration) of AV 61, were added in 25 μl volumes to two series of triplicate wells to allow simultaneous evaluations of their effects on HIV- and mock-infected cells. Serial five-fold dilutions were made directly in the microtiter trays using a Biomek 2000 robot (Beckman, Fullerton, Calif.). Untreated control and mock-infected cell samples were included. 50 μl of HIV at 100 CCID 50 or medium was added to either HIV-infected or mock-infected part of a microtiter tray. Exponentially growing MT-4 cells were centrifuged for 5 min at 140×g, and the supernatants were discarded. The MT4 cells were resuspended at 6×10 5 cells/ml in a flask connected with an autoclavable dispensing cassette of a Titertek Multidrop dispenser. Under slight magnetic stirring, 50 μl volumes were then transferred to the microtiter tray wells. The outer row wells were filled with 200 μl of medium. The cell cultures were incubated at 37° C. in a humidified atmosphere of 5% CO 2 in air. The cells remained in contact with the test compounds during the whole incubation period. Five days after infection, the viability of mock and HIV-infected cells was examined spectrophotometrically by the MTT method as described hereinbelow.
[0263] The MTT assay is based on the reduction of the yellow coloured 3-(4,5-dimethylthiazol-2-yl)-2,5-diphenyltetrazolium bromide (MTT) (Sigma Chemical Co., St. Louis, Mo.) by mitochondrial dehydrogenase of metabolically active cells to a blue formazan which can be measured spectrophotometrically.
[0264] To each microtiter well, 20 μl of a solution of MTT (7.5 mg/ml) in phosphate-buffered saline was added using the Titertek Multidrop. The trays were further incubated at 37° C. in a 5% CO 2 incubator for 1 hr. A fixed volume of medium (150 μl) was then removed from each cup using the Biomek 2000 robot without disturbing the MT-4 cell clusters containing the formazan crystals. Solubilization of the formazan crystals was achieved by adding 100 μl of 10% (v/v) Triton X-100 in acidified isopropanol (2 ml concentrated HCl per 500 ml solvent) using the Biomek 2000 robot. Complete dissolution of the formazan crystals could be obtained after the trays had been placed on a plate shaker for 10 min (ICN Biomedicals Flow Laboratories). Finally, the absorbances were read in an eight-channel computer controlled Titertek Microplate reader and stacker (Multiskan MCC, ICN Biomedicals—Flow Laboratories) at two wavelengths (540 and 690 nm). The absorbance measured at 690 nm was automatically subtracted from the absorbance at 540 nm, to eliminate the effects of non-specific absorption. Blanking was carried out directly on the microtiter trays with the first column wells which contained all reagents except MT-4 cells, virus and compounds. All data represent the average values for a minimum of three wells. The 50% cytotoxic concentration (CC 50 ) was defined as the concentration of compound that reduced the absorbance (OD 540 ) of the mock-infected control sample by 50%. The percent protection achieved by the compounds in HIV-infected cells was calculated by the following formula:
( OD T ) HIV - ( OD C ) HIV ( OD C ) mock - ( OD C ) HIV expressed in %
[0265] wherein (OD T )HIV is the optical density measured with a given concentration of the test compound in HIV-infected cells; (OD C )HIV is the optical density measured for the control untreated HIV-infected cells; (OD C )mock is the optical density measured for the control untreated mock-infected cells; and all O.D. values were determined at 540 nm. The concentration achieving 50% protection according to the above formula was defined as the 50% effective concentration (EC 50 ).
[0266] The results showed that AV 61 has activity against HIV-1 (III B strain) with an EC 50 and CC 50 of as low as 15.6 μg/ml and 125 μg/ml, of pure substance, resulting in a selectivity index of greater than 8, and a % PR of as high as 100%, as was determined by an MTT-assay.
Example 9
Effect of AV 61S and PPG7 on PHA-Activated PBMCs
[0267] FIG. 10 shows the results of an experiment to investigate the inhibitory effect of AV 61S on PHA-activated PBMCs. Human PBMCs were prepared from a blood bank and plated out at a concentration of 10 5 cells per well in a standard 96-well plate. PHA was added to each well at a concentration of 10 μg/ml together with AV 61S or PPG-7 (both in PBS) at concentrations of 50 μg/ml, 1 μg/ml, 100 ng/ml, 1 ng/ml and 100 pg/ml respectively for AV 61S and 50 μg/ml, 1 μg/ml and 10 ng/ml for PPG-7. The cells were then incubated for 7 days. [3H]-thymidine (NET-027 Thymidine [methyl-3H] from NEN 6.7 Ci/mmol Batch 3106446) was added to each well 48 hours after plating at a concentration of 1 mCi/well; a second dose was added to each well 18 hours before the end of the experiment. The cells were then harvested and counted for 1 min./sample.
[0268] The controls were medium alone and CsA (1 mg in 1 ml ethanol).
[0269] As can be seen in FIG. 10 , 60% inhibition relative to the controls was shown at a concentration of AV 61S of 50 μg/ml.
Example 10
Effect of AV 61S, AV 61 R, AV 74S and AV 74 R on PHA-Activated PBMCs
[0270] Example 9 was repeated using separately compounds AV 61S, AV 61R and AV 74S and AV 74R. In each case the test compound was diluted in DMSO to a final concentration of 0.25%. A single dose of [3H]-thymidine (NET-027 Thymidine [methyl-3H] from NEN 6.7 Ci/mmol Batch 3106446) was added to each well 18 hours before the end of the experiment.
[0271] FIGS. 11A and 11B show the results for AV 61S and AV 61R and FIGS. 12A and 12B show the corresponding results for AV 74S and AV 74R. As may be seen, AV 61S shows an inhibitory effect of about 97% relative to the controls at a concentration of 100 μg/ml and about 49% at 50 μg/ml. AV 61R shows a significantly reduced activity, namely 74% inhibition at 100 μg/ml and 42% at 50 μg/ml.
[0272] The results for AV 74S and AV 74R show an even more marked difference between the S and R enantiomers of the compound. As may be seen from FIG. 12A , at 100 μg/ml AV 74S shows 100% inhibition relation to the controls and 81% at 50 μg/ml. AV 74R, as shown in FIG. 12B , shows no inhibition of activated PBMCs. at 100 μg/ml or less.
Example 11
Toxicity of AV Compounds Against PBMC Cells by Alamar Blue Reagent
[0273] It has been established in Examples 9 and 10 above that the molecules AV 61S and AV 74S have an inhibitory effect on PBMCs (AV 74R had no effect whereas AV 61R had only a marginal effect) when tested in the concentrations of 100 μg/ml and 50 μg/ml (61S) and 100 μg/ml; 50 μg/ml and 25 μg/ml (74S). A preliminary experiment with Alamar Blue showed that the inhibitory effect was due to an anti-proliferative activity of the molecules rather than to a “killing” effect. In order to check this in more detail, the present experiment was performed:
[0274] Human PBMC cells were obtained from a blood bank and plated out on a standard 96-well plate at a concentration of 10 5 cells/well. PHA (10 μg/ml) and AV 61S (or AV 74S) at different dilutions in DMSO of 100 μg/ml, 50 μg/ml, 25 pg/ml, 10 μg/ml and 1 μg/ml were added simultaneously to each well. The cells were incubated for 24 hours.
[0275] After 24 hours, Alamar Blue reagent was added up to 10% of the total well volume.
[0276] The controls were medium only and CsA (1 mg/1 ml EtOH).
[0277] The contents of each well were then assayed 1 hour, 3 hours and 6 hours after addition of Alamar Blue by fluorescence in the manner known to those skilled in the art to determine the viability of the PBMCs. The results are shown in FIGS. 13A-13C .
Example 12
Toxicity of AV Compounds Against PBMC Cells by Alamar Blue Reagent
[0278] Example 9 was repeated, except that the cells were incubated for 48 hours prior to dyeing with Alamar Blue. The results are shown in FIGS. 14A-14C .
[0279] As shown in FIGS. 13A-13C and FIGS. 14A-14C , Alamar Blue dyeing confirmed the non-toxic effect of the molecules, except for AV 74S at 100 μg/ml which has the same activity and toxicity pattern as Cyclosporine (CsA). All other concentrations with AV 61S and AV 74S showed an anti-proliferative effect.
Example 13
Toxicity of AV Compounds Against PBMC Cells by Trypan Blue Reagent
[0280] Examples 11 and 12 were repeated using, in each case, Trypan Blue reagent instead of Alamar Blue. The results, which confirm those obtained using Alamar Blue, are shown in FIGS. 15A and 15B respectively.
[0000] Equivalents
[0281] Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, numerous equivalents to the specific procedures described herein. Such equivalents are considered to be within the scope of the invention. Various substitutions, alterations, and modifications may be made to the invention without departing from the spirit and scope of the invention. Other aspects, advantages, and modifications are within the scope of the invention. The contents of all references, issued patents, and published patent applications cited throughout this application are hereby incorporated by reference. The appropriate components, processes, and methods of those patents, applications and other documents may be selected for the invention and embodiments thereof.
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The present invention provides methods for treating Acquired Immunodeficiency Syndrome (AIDS) and other viral diseases and Human Immunodeficiency Virus (HIV) related infections by administering one or more compounds of formula I:
wherein: the dotted line represents a single or a double bond; and
R 1 and R 2 are the same or different and independently of each other represent —CH 2 OH, —CH 2 OR 4 , —CH(OH)CH 3 , —CH(OR 4 )CH 3 or a group represented by the formula:
or salts or hydrates thereof in a carrier which minimizes micellar formation or van der Waals attraction of molecules of said compound. The invention also provides S enantiomeric forms of such compounds which possess the ability to inhibit cell growth whilst being of low toxicity to such cells and methods of making such compounds.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of provisional patent application 61/173,664 filed Apr. 29, 2009 by the present inventor and the application is hereto incorporated by reference in its entirety.
[0002] STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0003] Not Applicable
NAMES OF PARTIES TO JOINT RESEARCH AGREEMENT
[0004] Not Applicable
REFERENCE TO SEQUENCE LISTING
[0005] Not Applicable
DESCRIPTION OF ATTACHED APPENDIX
[0006] Not Applicable
BACKGROUND OF THE INVENTION
[0007] 1. Field of the Invention
[0008] This invention relates generally to devices for the elimination of human urine while outdoors and specifically outdoor urinal systems that minimize urine scent.
[0009] 2. Description of Related Art
[0010] Hunters, photographers and videographers commonly use tree stands or elevated hunting blinds as a vantage point from which to view and hunt game. The nature of these activities requires patience, quiet and concealment by the operator, in order to avoid scaring away the game. Hunters go to extremes to ensure their concealment, including camouflaging themselves and the hunting blind, spraying clothing down with scent retardant, and attempting to be quiet and still. Often they must spend many hours in this low profile state, either on the ground or elevated, in order to view or take aim at their game.
[0011] One of the constant frustrations with the aforementioned activities is the inability to use the bathroom. Leaving the tree stand, hunting blind, elevated platform or even ground level area to urinate on the ground invokes multiple problems. The noise and activity associated with climbing up and down, walking to a desired spot and commencing urination can, of itself, scare nearby animals away. The strong scent associated with human urine is yet another strong animal deterrent. The scent can carry a significant distance and can linger for many days, effectively destroying the concealment of the hunter and often scaring off the prey.
[0012] Frequently, these outdoor pursuits involve long hours and weather that is inclemently cold or hot. Such conditions invite the need for beverages. Many hunters unfortunately, must deign to drink anything at all, in order to avoid the disruption that the need to urinate causes.
[0013] Various methods to solve the problems associated with urination during hunting have been attempted; however none have effectively solved all the problems. The primary problems are the noise and activity associated with having to leave the camouflaged area to urinate on the ground; the odor associated with urinating on the ground or in a device, and the disposal of the urine.
[0014] A few patents and marketed products for this problem exist yet none offer a true scent minimization system. Few hunters wish to urinate in a bottle or packet which they then must carry with them. Nor do hunters wish to transport and install a bulky large urinal container in the stand or blind. Yet another proposed solution is a scent minimizing slurry packet to pour over urine that is excreted onto the ground, yet this solution requires the user to continually repurchase and carry packets on their persons.
[0015] There is a need for a urination system that is small and lightweight, easy to transport, set up and use, and inexpensive. There is a need for such a system to effectively and quietly eliminate the urine as well as effectively minimize the urine scent.
NOTATION AND NOMENCLATURE
[0016] Certain terms are used throughout the following description to refer to particular method components. As one skilled in the art will appreciate, design and manufacturing companies may refer to a component by different names. This document does not intend to distinguish between components that differ in name but not function.
[0017] In the following discussion, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . .” Also, the term “couple” or “couples” is intended to mean either an indirect or direct connection. Thus, if a first device couples to a second device, that connection may be through a direct connection or through an indirect connection via other intermediate devices and connections. Moreover, the term “method” means “one or more components” combined together. Thus, a method can comprise an “entire method” or “sub methods” within the method.
[0018] “Filtration medium” may comprise charcoal, coal, zeolyte or any readily obtainable, low cost substance that minimizes odor and assists in filtration, effective for the purposes described herein.
[0019] “Scent minimizing substance” may comprise any odor minimizing substance effective for the purposes described herein.
SUMMARY OF THE INVENTION
[0020] The disadvantages shown in the prior art are solved by a method and device for outdoor urination and minimization of human urine scent while in a tree stand, elevated hunting blind, ground blind or other outdoor area where traditional bathroom facilities are unavailable, yet disposal of urine and minimization of urine scent is important.
[0021] The scent minimizing outdoor urinal of the disclosed invention includes a urine collection container having a top end with a closeable lid and a bottom end with a closeable spout. The urinal includes a hose extending from the urinal to a buried disposal bucket, having one end that fits over the bottom end of the urine collection container and an opposite end that lodges inside the buried bucket. The buried bucket has a closed lid and may have a hole with a slightly larger diameter than the hose so the hose can protrude into the bucket, which also has a filtration medium in it. The bucket further has drainage holes such that the urine enters the bucket via the hose, is dispersed through the filtration medium and then exits the bucket into the ground via the drainage holes in the bucket.
[0022] An objective of the disclosed invention is to provide urinal facilities to a hunter in close proximity of where he is waiting for the game.
[0023] A further objective of the disclosed invention is to minimize urine odor after voiding.
[0024] A further objective of the disclosed invention is to cleanly and permanently dispose of the urine without the need for transporting the urine to a designated location.
[0025] A further objective of the disclosed invention is to minimize sound when the user needs to void.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The application makes no claim for the structure of the objects depicted in the photos and drawings, such as drawings of hunting blinds, tree stands or funnels, and they are considered prior art.
[0027] The drawings contained herein represent preferred embodiments of the invention and are not intended to limit the scope. For a detailed description of various embodiments, reference will now be made to the accompanying illustrative drawings in which:
[0028] FIG. 1 illustrates a preferred embodiment of the system.
[0029] FIG. 2 illustrates a preferred embodiment of the urine collection container.
[0030] FIG. 3 illustrates a preferred embodiment of the underground urine disposal container.
[0031] FIG. 4 illustrates a preferred embodiment of the disclosed invention in flowchart format.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0032] Although tree stands or elevated hunting blinds are the most obvious embodiment, even ground level blinds, camping spots, construction sites or any outdoor areas where bathroom facilities are unavailable may prove useful sites for the disclosed invention. The disclosed invention presents a low cost, easy to assemble and easy to transport system for outdoor urination with scent minimization.
[0033] A preferred embodiment of the urine collection container of the system includes a generally funnel shaped container with a wide top end and a narrow bottom end. The top end may be closed with a plastic snap on lid or other type of lid and the bottom end may be closed with a twisting on/off valve or spout to seal out urine scent after elimination. A flexible tubing or hose of small diameter clamps onto the bottom end of the urinal container and is of sufficient length to allow the opposite end to be buried into the center of an underground urine disposal device. The underground urine disposal device contains a perforated bottom end and layers of carbon medium in specific size and placement to encourage the efficient disbursement of urine into the ground and the elimination of associated urine scent. In an additional embodiment, the urine scent can be effectively flushed from the apparatus by a flushing scent minimizing rinse. In one embodiment, fine charcoal mixed with water may be used as the scent minimizing rinse by pouring the mixture into the urinal container after urination.
[0034] In an alternative embodiment, the urine collection container may be a bag, a bottle or any other liquid impermeable hollow container effective for voiding into.
[0035] Carbon and zeolyte are effective means of scent removal and are relatively inexpensive and easy to obtain.
[0036] FIG. 1 illustrates the disclosed preferred embodiment for the eradication of human urine and human urine scent when on an elevated hunting blind 10 or tree stand. The urine collection container 12 , is depicted as generally funnel shaped and is attached to a corner or side of the interior of the blind 10 .
[0037] In the preferred embodiment, a hose 14 is connected to the base end of the urine collection container 12 , with the opposite end of the hose 14 terminating midway into an underground urine disposal device (UUDD) 16 . The hose 14 is of a length sufficient to reach from the end of the urine collection container 12 to the midway point of the UUDD 16 . The hose 14 used in the preferred embodiment is a black UV resistant flexible vinyl tubing of approximately 17 feet in length and 1/2 inch in diameter, however, one skilled in the art will appreciate that any tubing, conduit or a hose of any reasonable diameter, sufficient to allow the passage of fluid, may be used, and the length used will vary with the height of the tree stand, elevated platform, or ground structure. The hose 14 may be attached to the leg 18 of the elevated hunting blind 10 or, in the case of a tree stand, the tree trunk itself, by any reasonable attachment means 20 such as zip ties, rope, plastic straps, wire or other means. The attachment prevents unwanted movement of the hose 14 by wind or other disturbances.
[0038] In a preferred embodiment, the UUDD 16 , is buried a few inches underground near the leg 18 of the elevated platform 10 or near the tree trunk and can be easily removed when blind location is changed.
[0039] In FIG. 2 a preferred embodiment of the urine collection container 12 is depicted. The urine collection container 12 may be generally a funnel shape although other shapes may be used and the drawings and descriptions herein are not intended to limit the shape. In the preferred embodiment, the urine collection container 12 has a twist on/off valve 22 at the base of the container 12 to further seal out scent after elimination has occurred. The urine collection container 12 may have a snap on or screw on lid 24 which may or may not be used as desired. In the preferred embodiment, the urine collection container 12 has a handle 26 for ease of use, although this is not a necessary element. The urine collection container 12 depicted in FIG. 2 is preferable due to the handle 26 and twist valve 22 which make the container easier to use and more effectively eliminates any possible residual urine scent.
[0040] In the preferred embodiment the urine collection container 12 may be simply hung on a nail driven into the tree or the wall of the elevated platform 10 . In an alternative embodiment it may also be hung by a strap, though one skilled in the art will appreciate that any reasonable fastening means may be used to hang the urine collection container in the elevated platform or blind, including straps, wire, hooks, clips, Velcro™, ties, zip tie or other available means.
[0041] In the preferred embodiment, and as depicted in FIG. 3 , the UUDD 16 comprises a two gallon bucket 26 that has a lid 28 and a sufficiently perforated bottom 30 , to allow drainage of the urine into the surrounding underground. The bucket 26 may be three gallons or any other size desired although two gallons provides sufficient space for the filtration medium and is small enough for easy storage and transportation. In the preferred embodiment, the bucket 26 has a hole 32 in the middle of the lid 28 that is just slightly larger diameter than the hose 14 .
[0042] In the preferred embodiment, the UUDD 12 is buried underground with, in a preferred embodiment, at least a couple of inches of dirt over the lid 28 . The bucket 26 contains a filtration medium 34 which will typically be activated carbon and zeolyte. The carbon medium allows for disbursement and drainage of the urine while eliminating the urine scent.
[0043] As a preferred embodiment of final disposal of the human urine and elimination of the human urine scent, a final step may be taken as illustrated in FIG. 4 . The user performs the following steps: First step 40 : void into urine collection container; Second step 42 : mix a packet of carbon medium with water; Third step 44 : rinse urine collection container by pouring packet mixture in urine collection container; Fourth step 46 : twist valve or spout at base of urine collection container to off, or if no valve, place lid on container; Fifth step 48 : urine and urine scent is eradicated. These steps minimize if not eliminate the presence of odor in the stand or blind. The user can pour the packet of scent minimizing filtration medium into a bottle of water and shake up the mixture for ease of use. The packet may contain fine pieces and particles of activated carbon and zeolyte or activated carbon only. The packet may also contain charcoal plus an activating acid if desired. A premixed solution of carbon and water or carbon and acid are alternative embodiments of the rinsing and flushing process.
[0044] The method and device disclosed herein effectively disposes of human urine, while minimizing noise, odor and movement for a user who does not have traditional urinal facilities available. The disclosed method and device eliminates the need to climb up and down the elevated platform or tree or leave the ground level site, which can scare away the wildlife.
[0045] The system is uniquely designed such that all of the elements of the system (hose, attachment straps or ties, urine collection container, carbon filtration packet and carbon filtration medium) all fit in the bucket for ease in packaging, marketing and transportation. The bottled water may be purchased separately by the end user or may be sold with the system.
[0046] Packets of the carbon medium used for rinsing the urine collection container and tubing may also be packaged and sold separately for replacement purchase by the end user.
[0047] The method and device disclosed herein achieve significant advantages over the prior art in that it is easy to set up, small and portable enough to carry out to the tree stand or elevated blind, blends in well with the environment, is quiet to use, is quick and easy to use, and eliminates the need to carry one's urine or to climb up and down the stand, or leave a ground blind. The method and device disclosed herein depict a far superior attainment of urine disposal with urine scent minimization, while also minimizing noise and movement, than the prior art methods.
[0048] While the disclosed method and apparatus has been described in conjunction with the preferred embodiments thereof, many changes, modifications, alterations and variations will be apparent to those skilled in the art. The invention should therefore not be limited to the particular preferred embodiment disclosed but should include all embodiments that could fall within the scope of the claims.
[0049] Accordingly, the preferred embodiments of the invention shown in the drawings and described in detail above are intended to be illustrative, not limiting, and various changes may be made without departing from the spirit and scope of the invention as defined by the claims set forth below.
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A method and device for a scent minimizing outdoor urinal having a urine collection container, a hose connected to the urine collection container and extending down through the closeable lid of a disposal bucket buried in the ground and containing a filtration medium and having drainage holes.
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RELATED APPLICATION
[0001] This application is a divisional application of U.S. patent application Ser. No. 12/769,525 filed Apr. 28, 2010 and entitled “Apparatus For Separating Recycled Materials Using Air,” which claims priority to U.S. Provisional Patent Application No. 61/214,794 filed Apr. 28, 2009 and entitled “Apparatus For Separating Recycled Materials Using Air.” The complete disclosure of each of the above-identified applications is hereby fully incorporated herein by reference.
TECHNICAL FIELD
[0002] This invention relates to an apparatus for sorting materials. More particularly, the invention relates to an apparatus that employs closed-system air separation to sort and recover materials from recyclable materials.
BACKGROUND
[0003] Recycling of waste materials is highly desirable from many viewpoints, not the least of which are financial and ecological. Properly sorted recyclable materials often can be sold for significant revenue. Many of the more valuable recyclable materials do not biodegrade within a short period. Therefore, recycling such materials significantly reduces the strain on local landfills and ultimately the environment.
[0004] Typically, waste streams are composed of a variety of types of waste materials. One such waste stream is generated from the recovery and recycling of automobiles or other large machinery and appliances. For example, at the end of its useful life, an automobile will be shredded. This shredded material can be processed to recover ferrous metals. The remaining materials, referred to as automobile shredder residue (ASR) typically would be disposed in a landfill. Recently, efforts have been made to recover additional materials from ASR, such as plastics and non-ferrous metals. Similar efforts have been made to recover materials from whitegood shredder residue (WSR), which are the waste materials left over after recovering ferrous metals from shredded machinery or large appliances. Other waste streams may include electronic components, building components, retrieved landfill material, or other industrial waste streams. These materials generally are of value only when they have been separated into like-type materials. However, in many instances, cost-effective methods are not available to effectively sort waste streams that contain diverse materials. This deficiency has been particularly true for non-ferrous materials, and particularly for non-metallic materials, such as high density plastics, and non-ferrous metals, including copper wiring. For example, one approach to recycling plastics has been to station a number of laborers along a sorting line, each of whom manually sorts through shredded waste and manually selects the desired recyclables from the sorting line. This approach is not sustainable in most economies because the labor cost component is too high. Also, while ferrous recycling has been automated for some time, mainly through the use of magnets, this technique is ineffective for sorting non-ferrous materials. Again, labor-intensive manual processing has been employed to recover wiring and other non-ferrous metal materials. Because of the cost of labor, many of these manual processes are conducted in other countries and transporting the materials to and from these countries adds to the cost.
[0005] Copper wiring and other valuable non-ferrous metals can be recovered and recycled. However, waste materials, including ASR and WSR, must be separated from a concentrated mass of recoverable materials. Typically, the waste materials will include wood, rubber, plastics, glass, fabric, and copper wiring and other non-ferrous metals. The fabric includes carpet materials from the shredded automobiles. Often, the fabric includes embedded ferrous materials accumulated during the shredding process. Methods are known for separating the non-ferrous metals from these other materials. These methods may include a “pre-concentration” process that roughly separates the materials for further processing. However, these methods typically involve density separation processes. These processes typically involve expensive chemicals or other separation media and are almost always a “wet” process. These wet processes are inefficient for a number of reasons. After separation, often the separation medium must be collected to be reused. Also, these wet processes typically are batch processes, and they cannot process a continuous flow of material.
[0006] Another known system uses an air aspirator, or separator, to separate a light fraction of materials, which typically contains the waste materials that are not worth recovering (that is, the wood, rubber, and fabric), from a heavy fraction of materials, which typically includes the metals to be recovered. These types of separators are known in other industries as well, such as the agricultural industry, which uses air separators to separate materials of differing densities.
[0007] However, these known systems usually employ open systems, where air is moved through the system and then released to the atmosphere. One problem with these systems is that they need air permits to operate, which adds cost to the system.
[0008] Conventional systems also force air directly up from a bottom of the plenum, and the material being separated falls on top of a screen at the bottom of the plenum. Accordingly, such systems cannot process heavy materials because the heavy materials will damage the screen when those materials fall on top of the screen.
[0009] Accordingly, a need exists in the art for a system and method that processes materials to be separated while recycling air in a closed system. Additionally, a need exists for a system and method that can separate heavier materials without damaging the system.
SUMMARY
[0010] The invention relates to a closed air system for separating materials. A fan directs air into a plenum in which the materials are separated. A heavier fraction of the materials falls through the air in the plenum to the bottom of the plenum. A stream of air carrying a lighter fraction of the materials exits the plenum and is directed to an expansion chamber. In the expansion chamber, the lighter fraction of the materials falls to the bottom as the velocity of the air slows. The air then flows from the expansion chamber to a centrifugal filter, which removes remaining material from the air. The air then returns to the fan where it is re-circulated through the system.
[0011] The separated materials can be removed from the system at the bottom of the plenum, the bottom of the expansion chamber, and the bottom of the centrifugal filter. Rotary Valves (“Air Locks”) at these locations prevent air from flowing therethrough while allowing the materials to pass.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIGS. 1 , 2 , and 3 are perspective, side, and top views, respectively, of an air separation classifier according to an exemplary embodiment.
[0013] FIG. 4 is a perspective view of certain components of the classifier illustrated in FIGS. 1-3 .
[0014] FIG. 5 is a cross sectional view of an air reducer according to an exemplary embodiment.
[0015] FIG. 6 is a side view of an expansion chamber according to an exemplary embodiment.
[0016] FIG. 7 is a side view of a lower air plenum according to an exemplary embodiment.
[0017] FIG. 8 is a perspective view of a rotary valve according to an exemplary embodiment.
[0018] FIGS. 9 and 10 are perspective and end views, respectively, of an exemplary vane of the rotary valve depicted in FIG. 8 .
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0019] Referring to the drawings, in which like numerals represent like elements, aspects of the exemplary embodiments will be described.
[0020] With reference to FIGS. 1-4 , an exemplary air separation classifier system 100 will be described. FIGS. 1 , 2 , and 3 are perspective, side, and top views, respectively, of an air separation classifier system 100 according to an exemplary embodiment. FIG. 4 is a perspective view of certain components of the system 100 illustrated in FIGS. 1-3 . The system 100 implements a closed air system to process solid materials.
[0021] An air flow producing device 102 produces air flow in the system 100 in the direction of the arrows illustrated in FIGS. 1-3 by drawing air from a return side of the air flow producing device 102 and pushing air through a supply side of the air flow producing device 102 . The size of the air flow producing device can be adjusted to provide the desired air flow and pressures throughout the system 100 . In an exemplary embodiment, the air flow producing device 102 is a 50-75 horsepower fan. The air flow producing device 102 can have a variable speed control to control the air flow created by the air flow producing device 102 .
[0022] The air flow producing device 102 pushes air into the air intake 104 . The air then flows from the air intake 104 through a lower transition 106 , through an air reducer 107 , and into a plenum 108 . The air reducer 107 comprises a butterfly valve 502 ( FIG. 5 ) that can be rotated around a shaft 504 ( FIG. 5 ) to obstruct or unobstruct air flow through the air reducer 107 , thereby controlling the air flow and velocity through the air reducer 107 and into the plenum 108 .
[0023] The plenum 108 includes two sections, a lower plenum 108 a and an upper plenum 108 b . The air enters the lower plenum 108 a via a lower entrance 108 c in the lower plenum 108 a.
[0024] Material to be separated is introduced into the system 100 at location A via an intake feeder (not shown). The material to be separated is fed into a first rotary valve 110 (A), which allows the material to fall into the upper plenum 108 b via an upper entrance 108 d in the upper plenum 108 b . The first rotary valve 110 (A) also prevents all or a substantial amount of air from exiting the system 100 via the upper entrance 108 d in the upper plenum 108 b . The rotary valve 110 (A) prevents a sufficient amount of, in some cases all, air from exiting the system 100 to maintain the desired static pressures and air flows therein.
[0025] The air flows through the air intake 104 , into the plenum 108 , and up the plenum 108 , where it interacts with the material to be separated as the material to be separated falls through the plenum 108 via the force of gravity.
[0026] The movement of air through the material to be separated causes lighter material to be entrained in the air flow while heavier material falls through the plenum 108 . The heavier material falls through a lower exit 108 f in the lower plenum 108 a and exits the system 100 at location B via a second rotary valve 110 (B) attached to the lower exit 108 f in the lower plenum 108 a . The second rotary valve 110 (B) also prevents air from exiting the system 100 via the lower exit 108 f in the lower plenum 108 a , similarly to the operation of the first rotary valve 110 (A).
[0027] Some light material could remain with the heavy material, as the light material is physically entwined with the heavy material and the force of the air is insufficient to entrain the light material. The system 100 can minimize the amount of light material that is not entrained in the air by optimizing the residence time of the material to be separated in the plenum 108 . By optimizing the residence time, the chances are increased that the air flow will separate the heavy and light fractions of material and that the light fractions will be entrained in the air. This optimization allows for the separation of materials that have relatively close densities.
[0028] Residence time of the material to be separated in the plenum 108 can be optimized in a number of ways. This optimization allows for highly efficient separation of the materials—the residence time is such that the material to be separated that falls through the plenum 108 under gravity is mixed with the moving air to maximize the amount of light materials that are entrained in the air as it moves up through the plenum 108 . This process, in turn, maximizes the amount of heavy material, including, for example, copper wire, that falls out of the plenum 108 . In other words, this increased residence time allows for a more complete separation of the light and heavy fractions of materials.
[0029] The material to be separated can be sized, such as in a granulator or other size reducing equipment, prior to entering the plenum 108 . In exemplary embodiments, this step can be omitted, and the system 100 can process the material to be separated directly from a shredder or other process equipment without sizing.
[0030] In one exemplary embodiment, the residence time in the plenum 108 is increased by matching the required air flow with the size of the material to be separated. An air diffuser plate 602 ( FIG. 6 ) is added between the location where the air flow leaves the air flow producing device 102 and the location where the air flow enters the plenum 108 . As illustrated in the exemplary embodiment of FIG. 7 , the diffuser plate is disposed at the lower inlet in the plenum 108 . The diffuser plate 602 creates minor back pressure and distributes the air flow evenly throughout the width of the plenum 108 . The diffuser plate 602 can be a perforated metal plate and can have openings sized to maximize the residence time of the material to be separated based on the size of the material to be separated and the size of the air flow producing device 102 . Examples for configurations for this plate range from a plate with one-half inch holes to a mesh screen, with many fine holes. For example, for material to be separated with a nominal size of 0-4 millimeters, the diffuser plate can have one-quarter inch holes. For larger size particles, a plate with larger holes may be used.
[0031] In the exemplary embodiment illustrated in FIGS. 1 , 2 , 4 , and 7 , the lower inlet in the plenum 108 is angled with respect to a vertical pathway through which the mixture and the heavy fraction of materials pass. In this manner, the heavy fraction of materials can fall through the plenum 108 to the lower exit 108 f of the plenum 108 without falling onto and/or damaging the screen 602 , which is positioned at the lower inlet in the plenum 108 .
[0032] Alternatively or additionally, a depth of the plenum chamber can be optimized to achieve the maximum residence time for the waste material to be separated in the chamber. For example, the depth can be between 10 inches and 16 inches. The smaller depth can be used for smaller particle sizes. For example, the 10 inch depth can be matched to particles with a size range of 0-1 inch. In exemplary embodiments, a volume of the plenum 108 , including a particular depth, width, height, and shape can be selected to obtain the desired static pressures and air flows in the plenum 108 and the system 100 and to process the desired type and size/density of materials.
[0033] In one exemplary embodiment, the following static pressures and air flow volumes for different particle size ranges are used:
[0000]
Static Pressure
Air Flow
Particle Size
(in. of water)
(cubic feet per minute)
4 millimeters to ⅝ inches
8 to 12
8,000 to 12,000
⅝ inches to 1.25 inches
12
15,000 to 22,000
1.25 inches to 5 inches
9 to 13
12,000 to 15,000
[0034] The sizes of the air flow producing device 102 , the passageways and transitions through which the air flows, the plenum 108 , the air reducer 107 , the expansion chamber 114 , and other components can be selected to obtain the desired static pressures and air flows throughout the system 100 and to process the desired type and size/density of materials.
[0035] As illustrated in FIGS. 1 , 2 , and 4 , the lower plenum 108 a can comprise an access door 126 to gain entry into an interior of the plenum 108 .
[0036] The air with the entrained light fraction of materials moves up and out of the plenum 108 , through an upper transition 112 , and into an expansion chamber 114 via an entrance 114 a in the expansion chamber 114 . In the expansion chamber 114 , the air and entrained light fraction of materials contact a redirecting plate 702 ( FIG. 7 ), which redirects the path of the air and entrained light fraction of materials. As the velocity of the air slows in the expansion chamber 114 , the entrained light fraction of materials falls to the bottom of the expansion chamber 114 and exits the system 100 at location C via a third rotary valve 110 (C) attached to a lower exit 114 b in the expansion chamber 114 . The third rotary valve 110 (C) also prevents air from exiting the system 100 via the lower exit 114 f in the expansion chamber 114 , similarly to the operation of rotary valves 110 (A, B).
[0037] The air then flows from an upper exit 114 c of the expansion chamber 114 , through ducting 116 , and into a centrifugal filtering device 118 .
[0038] The air flow producing device 102 pushes the air through the expansion chamber 114 and also draws the air from the centrifugal filtering device 118 , which in turn draws air from the expansion chamber 114 . The expansion chamber 114 can comprise a make-up air vent to allow air into the expansion chamber 114 to maintain the desired air flow and static pressure throughout the system 100 . In exemplary embodiments, the make-up air vent can comprise a butterfly-type vent, a pressure actuated vent, or other suitable vent.
[0039] Referring to FIG. 7 , the plate 702 prevents the air and entrained light fraction of materials from flowing directly through the expansion chamber 114 , from the entrance 114 a to the upper exit 114 c . With the plate 702 , the air flows through the expansion chamber in the general direction of the dashed arrows illustrated in FIG. 7 , allowing time for the air flow to slow and for the light fraction of materials to fall to the bottom of the expansion chamber 114 . The exemplary plate 702 includes two sections oriented and positioned to deflect the air flow in the desired direction. However, any suitable shape and position of the plate 702 can be used to redirect the air flow in the desired direction. Additionally, the shape and position of the plate 702 can be controlled to optimize the air flow based on the materials included in the light fraction of materials entrained in the air flow.
[0040] In exemplary embodiments, a volume of the expansion chamber 114 , including a particular depth, width, height, and shape can be selected to obtain the desired static pressures and air flows in the expansion chamber 114 and the system 100 and to process the desired type and size/density of materials.
[0041] Referring back to FIGS. 1-3 , the centrifugal filtering device 118 removes additional solid material that remains entrained in the air. In operation, the centrifugal filtering device 118 directs the flow of the air in a circular (cyclone) manner, which forces the remaining material to the outside of the centrifugal filtering device 118 . The remaining material then falls to the bottom of the centrifugal filtering device 118 and exits the system 100 at location D via a fourth rotary valve 110 (D) attached to the centrifugal filtering device 118 . The fourth rotary valve 110 (D) prevents air from entering the system 100 via the centrifugal filtering device 118 so air can only be drawn from the expansion chamber 114 , similarly to the operation of rotary valves 110 (A, B, C) which prevent air from exiting the system 100 .
[0042] Additionally or alternatively, other devices can be used to filter the air and/or recover materials from the air that is flowing through the system 100 . For example, an inline filter can be used in the ducting 116 . Any suitable device that further cleans the air returning to the fan while maintaining the desired air flow and static pressures in the system 100 can be used.
[0043] Alternatively, in a non-closed loop system embodiment, the filter can filter the air as it exits the expansion chamber 114 into the atmosphere.
[0044] In the exemplary embodiment illustrated in FIGS. 1-3 , transitions 120 direct the air flow from the ducting 116 into the centrifugal filtering device 118 and from the centrifugal filtering device 118 into the ducting 116 .
[0045] The air is then cycled back to the air intake 104 . More specifically, the air flows from the centrifugal filtering device 118 through ducting 116 and returns to the air flow producing device 102 . The air flow producing device 102 draws the air from the ducting 116 and pushes the air towards the plenum 108 , thereby reusing the air throughout the system 100 .
[0046] In this way, the process air loops through the system 100 and is not released to the atmosphere. The air path from the fan to the plenum 108 to the expansion chamber 114 to the centrifugal filter device 118 and back to the fan is closed. Valves (such as the rotary valves 110 ) and duct connections prevent the bleeding of air into the atmosphere.
[0047] The system 100 can comprise brackets 122 at various external locations to attach the system 100 to a support structure 124 that holds the components of the system 100 in place.
[0048] Materials separated via the system 100 can be usable materials or waste materials. In one exemplary embodiment, all of the materials can be waste materials that are separated and removed from the system 100 at locations A-D for proper disposal. In another exemplary embodiment, all of the materials can be recyclable materials that are separated and removed from the system 100 at locations A-D for recycling. In yet another exemplary embodiment, the materials can comprise both waste materials and recyclable materials that are separated and removed from the system 100 at locations A-D for proper disposal and recycling, respectively.
[0049] The rotary valves 110 described with reference to FIGS. 1-3 are exemplary “airlocks,” which maintain a suitable air seal while allowing materials to enter or exit the system 100 . However, other suitable types of airlocks can be used which maintain a suitable air seal while allowing materials to enter or exit the system 100 .
[0050] An exemplary rotary valve 110 will now be described with reference to FIGS. 8-10 . FIG. 8 is a perspective view of a rotary valve 110 according to an exemplary embodiment. FIGS. 9 and 10 are perspective and end views, respectively, of an exemplary vane of the rotary valve 110 depicted in FIG. 8 .
[0051] The rotary valve 110 comprises in inlet 801 through which material enters the rotary valve 110 and an exit 803 through which material exits the rotary valve 110 . An interior of the rotary valve 110 houses multiple vanes 804 supported on a shaft 806 . The vanes 804 are sizes to contact the interior of the rotary valve 110 during operation such that air does not pass through the rotary valve 110 . In operation, a motor 802 turns the shaft 806 , thereby turning the vanes 804 . As the vanes 804 turn, material disposed between the vanes 804 is transferred from the inlet 801 to the exit 803 .
[0052] The vanes 804 can comprise a material that creates a suitable seal with the interior of the rotary valve 110 to prevent air flow through the rotary valve 110 .
[0053] FIG. 10 illustrates an exemplary embodiment comprising five vanes 804 disposed seventy-two degrees apart. Other configurations utilizing more or less vanes that prevent an air path through the rotary valve 110 are within the scope of the invention.
[0054] The description above uses the terms heavy fraction and light fraction to describe the two streams of material to be separated. One of ordinary skill in the art would understand that these terms are relative. In one exemplary embodiment, the light fraction can include fabric, rubber, and insulated wire, and the heavy fraction can include wet wood and heavier metals, such as non-ferrous metals including aluminum, zinc, and brass. In another exemplary embodiment, the light fraction can include fabric (“fluff”), and the heavy fraction can include insulated wire. Indeed, the apparatus of the present invention can be optimized to separate material within a narrow range of densities. As such, the processed material can range from raw shredder residue to a light fraction that was separated by a different separator technology, such as a Z-box air separator or sink/float separator.
[0055] One of ordinary skill in the art also would understand that the separator described above may be one step in a multi-step process that concentrates and recovers recyclable materials, such as copper wire from ASR and WSR.
[0056] Although specific embodiments of the present invention have been described in this application in detail, the description is merely for purposes of illustration. It should be appreciated, therefore, that many aspects of the invention were described above by way of example only and are not intended as required or essential elements of the invention unless explicitly stated otherwise. Certain steps and components in the exemplary processing methods and systems described herein may be omitted, performed and a different order, and/or combined with other steps or components. Various modifications of, and equivalent components corresponding to, the disclosed aspects of the exemplary embodiments, in addition to those described herein, can be made by those having ordinary skill in the art without departing from the scope and spirit of the present invention described herein and defined in the following claims, the scope of which is to be accorded the broadest interpretation so as to encompass such modifications and equivalent structures.
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Separating a mixture comprising at least two solid materials comprises transporting the mixture into a plenum, introducing air into the plenum, removing a heavier fraction of the solid materials from the plenum, removing air having a lighter fraction of the solid materials entrained therein from the plenum, removing the lighter fraction of the solid materials from the air that is removed from the plenum, filtering the remaining air, and re-circulating the air back to the plenum. Valves at the locations where material is introduced to and removed from the system can prevent air flow therethrough while allowing the materials to pass. The air can be introduced into the plenum at an angle with respect to the pathway in which the heavier fraction of the materials falls through the plenum, thereby avoiding damage to a screen that diffuses the air being introduced into the plenum.
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TECHNICAL FIELD
[0001] The present invention relates to a device for holding and positioning construction materials. More specifically, the present invention relates to a device that is suitable for holding and positioning construction materials, such as drywall.
BACKGROUND OF THE INVENTION
[0002] Drywall (also commonly referred to as or wallboard or sheetrock) is commonly installed on studs to form the basis for finished interior walls of residential and commercial buildings. While drywall is produced in many sizes, the typical sizes for installation are in sheets four feet wide and eight or twelve feet in length.
[0003] Standard pieces or sheets of drywall are heavy and difficult to install by one person alone. Accordingly, at least two people are commonly needed to hold and install these drywall sheets. In construction, time is of the essence as it relates to profitability. Use of multiple people reduces efficiency and, therefore, adds to the cost of construction.
[0004] A particular problem associated with drywall or wallboard installation relates to hanging the drywall on upper portions of a stud wall. It is particularly difficult to hold drywall at elevated positions on the stud wall for installation. It is also difficult to hold the drywall so that it remains properly aligned with the stud wall, the ceiling, etc. before being secured in place.
[0005] A variety of installation devices exhibiting different levels of complexity are known in the art. For example, the following patents and patent applications describe lifters that generally resemble the letter “T”, with the drywall or other construction material placed at the top and hoisted into position either through a cranking mechanism, screwing device, spring or telescopic means that are arranged on the vertical portion of the device: U.S. Pat. No. 3,930,645 (Anderson); U.S. Pat. No. 4,120,484 (Zimmer); U.S. Pat. No. 4,695,028 (Hunter); U.S. Pat. No. 4,733,844 (Molloy); U.S. Pat. No. 4,928,916 (Molloy); U.S. Pat. No. 5,129,774 (Balseiro et al); U.S. Pat. No. 5,979,854 (Lundgren et al); U.S. Pat. No. 6,082,945 (Jeffries et al); U.S. Pat. No. 6,508,448 (Stewart); U.S. Pat. No. 6,663,084 (Butler); International Patent Application No. PCT/AU95/00382 (WO 96/01353); and UK Patent Application GB 2,260,559. These devices, while useful for their intended purpose, can be bulky and in many cases do not lend themselves to use by a single person.
[0006] The following patents describe lifting or positioning devices that rely on the use of a foot to hoist construction materials a few inches from ground level: U.S. Pat. No. 2,692,753 (Masterson); U.S. Pat. No. 2,989,286 (Gillespie); U.S. Pat. No. 3,268,209 (Humbyrd); U.S. Pat. No. 4,712,771 (Donnelly et al); U.S. Pat. No. 5,501,561 (Wulff); U.S. Pat. No. 5,814,842 (Muldoon et al); and U.S. Pat. No. 6,497,399 (Nelson). While suitable for certain types of construction projects, these devices do not permit materials to be positioned at the higher reaches of a wall.
[0007] Some of the more complicated devices for lifting drywall and other construction materials are represented by the following patents: U.S. Pat. No. 3,828,942 (Young); U.S. Pat. No. 4,339,219 (Lay); U.S. Pat. No. 4,375,934 (Elliott); U.S. Pat. No. 4,600,348 (Pettit); U.S. Pat. No. 5,640,826 (Hurilla); U.S. Pat. No. 6,010,299 (Jesswein); U.S. Pat. No. 6,176,063 (Warin); U.S. Pat. No. 6,244,810 (Reyes); and U.S. Pat. No. 6,527,492 (Kerns, III et al). In many cases, these devices require assembly before use. In addition, these devices can be bulky and heavy, including such features as tripods and scaffolding. They are consequently better suited for use in commercial construction projects than in home renovations, for example.
[0008] An example of a more current lifting device is described in United States Patent Application Publication Number US 2001/0029715 A1 (Bradley et al). This publication describes a drywall installation apparatus that includes a support for holding the drywall to be installed, an extension to adjust the length of the drywall installation apparatus, and a base to which a lifting mechanism may be coupled to raise the drywall installation apparatus holding the drywall into a desired position for installation on a stud wall. The drywall installation apparatus includes an alignment member to assist in orienting the piece of drywall to be installed on the stud wall. This alignment member (or “stud guide”) is U-shaped and serves to maintain the drywall installation apparatus in a desired position when a sheet of drywall is being raised or lowered relative to a stud wall. This installation apparatus, while suitable for certain types of walls, such as the stud walls having metal brackets that are favored in many parts of North America, is less convenient for use on other types of wall surfaces.
[0009] There is a need, therefore, for a device for holding and positioning construction materials that is simple to use and lightweight, yet sturdy enough to support the weight charge of most construction materials. There is a further need to provide an installation device and method that will allow a single person to hold and install a construction material on a wall, such as drywall, particularly at upper reaches of the wall.
[0010] The present invention seeks to meet these needs.
SUMMARY OF THE INVENTION
[0011] The present invention relates to an adjustable support device for holding drywall or gypsum wallboard in place as it is being installed at ceiling level. The device includes an extension section comprising an elongate tubular member and a shaft member telescopically disposed in the elongate tubular member. The extension section is coupled at one end to a support which can receive and hold a piece of drywall during installation. The extension section is further coupled to a base portion at the end opposite to the support. The base includes a pivot feature that serves to lift the drywall once it has been positioned on the support. The extension is adjustable to install drywall on a stud wall at various heights.
[0012] Advantageously, this device is lightweight, easy to transport and does not require assembly once on site. It may thus be used immediately upon reaching a construction site, saving on construction time and therefore money. The simplicity of the design should appeal not only to experts in the construction field, but also to novices who engage in home renovation and repair, for example.
[0013] Moreover, the device is secure and allows a sheet of drywall to be readily installed by a single person.
[0014] The device has the following characteristics:
It can stand alone without support; It is balanced towards the front in order to permit a vertical lift along a wall; It is suitable for lifting or hoisting a variety of construction materials, including gypsum drywall, rigid insulation panels, decorative wall panels, as well as any other flat material that is to be positioned onto a wall; It possesses a useful charge of approximately 500 lbs; It lifts construction materials through the use of single, light foot pressure performed in an effortless manner by the end user; It adjusts easily to the desired height; and It is very resistant.
[0022] The device may be made of iron, steel or any other metallic alloy that has the capacity to support the weight of construction materials.
BRIEF DESCRIPTION OF THE FIGURES
[0023] An embodiment of the invention will now be described by way of example only with reference to the accompanying drawings, in which:
[0024] FIG. 1 is a perspective view of the device of the present invention showing it in use, supporting a drywall panel so that it may be attached by nails, screws and the like to a stud wall.
[0025] FIG. 2 is another perspective view of the device illustrating its features.
[0026] FIG. 3 is a lateral view of the device shown in FIG. 2 .
[0027] FIG. 4 is a lateral view of the device shown in FIG. 2 , illustrating the foot pivot when in use.
[0028] FIG. 5 is a rear sectional view of the pivot or pedal portion of the device taken along line 5 - 5 of FIG. 3 .
[0029] FIG. 6 is a lateral sectional view of the pivot or pedal portion of the device taken along line 6 - 6 of FIG. 2 .
DETAILED DESCRIPTION
[0030] FIG. 1 shows the principal features of a particular embodiment of the device of the present invention. The device 10 includes an adjustable extension section 12 allowing the installation of drywall on a stud wall at various heights. It is coupled at one end to a support 30 which can receive and hold a piece of drywall 100 during installation, as illustrated in FIG. 1 . The extension section 12 is further coupled to a base portion 50 at the end opposite to the support. The base portion 50 includes a pivot feature 55 that serves to lift the drywall once it has been positioned on the support.
[0031] Turning now to FIG. 2 , beginning from the top of the device one can see the features of the support 30 in greater detail. The support 30 includes a horizontally projecting support bearing flange 34 and a vertically projecting pusher flange 32 for pushing against the back face of the construction material. As illustrated in FIG. 2 , the horizontally projecting support bearing flange 34 is located at an approximately right angle relative to the vertically projecting pusher flange 32 . Advantageously, the support bearing flange's flat shape and extended length prevent breakage of the construction material that is to be lifted.
[0032] Still in FIG. 2 , the extension section 12 comprises an elongate tubular member 14 and a shaft member 16 telescopically disposed in the elongate tubular member 14 . The shaft member 16 must be capable of ready movement within the tubular member 14 , so that the device may be manually adjusted to the desired height. As illustrated here, the shaft member 16 includes orifices 18 that allow the extension section 12 of the device to be secured at a variety of different heights through the use of a locking mechanism 20 which engages with a chosen orifice 18 when this orifice is aligned with a corresponding orifice 19 (shown in shadow in FIG. 4 ) in the elongate tubular member 14 . The orifices shown here are circular in shape but may assume any convenient geometry for engagement with a chosen locking mechanism: square, hexagonal, octagonal, etc.
[0033] As shown at the bottom of FIG. 2 , the base portion 50 includes a pivot feature 55 that serves to lift the drywall once it has been placed on the support for positioning against a wall. The design of the base portion 50 , while simple, allows for the simultaneous support of the drywall when placed on the device 10 and for an end user to lift the drywall through the use of one foot placed on the pivot feature 55 . As may be appreciated from the illustration, the base portion 50 includes a support plaque 74 oriented at an approximate right angle relative to the pivot feature. This support plaque 74 is flat and extends a few inches on either side of the pivot feature 55 . Underneath the pivot feature 55 an elevation element 70 is disposed at a distance that is approximately ⅓ rd the distance from the extension section 12 and approximately ⅔ rd the distance from the proximal end 57 of the pivot feature 55 . The elevation element 70 is shown as a rectangular block but may assume a variety of different configurations. Its purpose is to keep the pivot feature 55 at a slight elevation until the end user is ready to place his or her foot on the pivot feature to lift the drywall to the desired height and position. The pivot feature 55 includes two elongate side members 58 disposed at an approximately right angle relative to an upper member 56 suitable to support the end user's foot when the device is in use. The elongate members 58 have a basic rectangular geometry but are tapered as they reach the proximal end 57 of the pivot feature 55 . The pivot feature 55 further includes a curved portion 60 which engages with the extension section 12 of the device and serves to secure in place. As illustrated in the figures, a spring 65 or other retention means may be included on the device so as to join the outer surfaces of the curved portion 60 and the elongate tubular member 14 of the extension section 12 , in order to prevent the extension section 12 from rocking about.
[0034] As may be seen more particularly in FIG. 4 , the extension section 12 has two orifices at its base through which fastening means 63 may be inserted and positioned against side plates 62 located at the distal ends of the two elongate members 58 . These fastening means 63 serve to lock the elongate tubular member 14 in place, preventing its lateral motion when the device 10 is in use.
[0035] FIGS. 3 and 4 illustrate the device 10 of the present invention from a lateral perspective. FIG. 3 shows the device at rest while FIG. 4 reveals the device when in use.
[0036] The details of the base portion 50 of the device are illustrated in FIGS. 5 and 6 . FIG. 5 is a rear sectional view of the base portion 50 taken along line 5 - 5 of FIG. 3 , while FIG. 6 is a lateral sectional view of the same element taken along line 6 - 6 of FIG. 2 . As may be seen from these figures, the bottom end of the elongate tubular member 14 is curved and rests within a cavity carved in a metal block 80 . As better shown in FIG. 6 , this cavity is also curved, allowing the elongate tubular member 14 to rock back and forth, but not laterally since the fastening means 63 prevent any sideways motion. In order to restrict this back and forth rocking, a spring 65 or other retention means may be included on the device so as to join the outer surfaces of the curved portion 60 and the elongate tubular member 14 of the extension section 12 . As shown in FIG. 6 , the ends of the spring may be attached to the curved portion 60 and the elongate tubular member 14 via rings 66 , or any other suitable means.
[0037] A method for using the device 10 is shown in FIG. 4 . To use the device, the end user first adjusts the extension section 12 of the device to the desired height by manually pulling the shaft member 16 within the tubular member 14 , and then securing the extension section 12 by inserting a locking mechanism 20 (which can be a pin, screw, or the like) through the orifice 19 in the elongate tubular member 14 which has been aligned with a chosen orifice 18 . Next, the user places the construction material on the support 30 of the device, and then positions the device with its load close to where the construction material is to be installed. With the device in position, the end user simply places one foot near the proximal end 57 of the pivot feature 55 of the base portion 50 and pushes downward. This causes the construction material to be elevated approximately 1-3 inches. The device will maintain and support the drywall at the chosen position and height, enabling the end user to attach it to the wall by permanent means.
EXAMPLE 1
Description of the Features of One Particular Embodiment, Including Approximate Dimensions
[0038] In one particular embodiment, the height of the support in the device can be adjusted from a height of approximately 42″ to a height of approximately 60″. As will be appreciated by those of skill in the art, the extension section may be manufactured so that it can accommodate a variety of convenient height positions.
[0039] The support 30 is made of iron. The horizontally projecting support bearing flange 34 has the following dimensions: 3″×8″×¼″. The vertically projecting pusher flange 32 for pushing against the front face of the construction material has the following dimensions: 1″×8″×⅛″.
[0040] The extension section 12 is made of iron or steel components that are capable of supporting the weight of conventional drywall panels or other construction materials. Any metallic alloy may be selected, as long as it is sturdy enough to support the load of construction materials. The elongate tubular member 14 is 42″ in length and has a diameter of ¾″. The shaft member 16 telescopically disposed in the elongate tubular member 14 is 32″ in length and has a diameter of ⅝″. The shaft member 16 includes orifices 18 that are ¼″ in size and are spaced apart at a distance of ⅛″. The locking mechanism 20 which engages with a chosen orifice 18 when this orifice is aligned with a corresponding orifice 19 is circular, has a length of 1½″ and a diameter of ¼″.
[0041] The base portion 50 includes a support plaque 74 that has the following dimensions: 1″×8″×⅛″. Underneath the pivot feature 55 , the elevation element 70 is made of iron and has the following dimensions: 2″×2″×¾″. The pivot feature 55 itself includes two elongate side members 58 that are approximately 16″ in length and ½″ in width disposed at an approximately right angle relative to an upper member 56 that is also approximately 16″ in length and 2″ in width. The elongate side members 58 and the upper member 56 are made of iron and have a thickness of approximately 3/16″. Together, the elongate side members 58 and the upper member 56 , which comprise the lever portion of the pivot feature 55 , create a “U”-type bar. The pivot feature 55 further includes a curved portion 60 which engages with the extension section 12 of the device and serves to secure into place. The curved portion 60 is made of iron and has the following dimensions: 8″×2″×¼″. With reference to FIG. 4 , it will be recalled that the extension section 12 has two orifices at its base through which fastening means 63 may be inserted and positioned against side plates 62 located at the distal ends of the two elongate members 58 . These fastening means 63 are approximately ⅜″×2½″, while the side plates have the following dimensions: 2″×3″×¼″.
[0042] Although the present invention has been described by way of particular embodiments and examples thereof, it should be noted that it will be apparent to persons skilled in the art that modifications may be applied to the present particular embodiment without departing from the scope of the present invention.
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The present invention discloses a device and method that allows the installation of construction materials, such as drywall, by a single person. The device comprises an extension (or hoist) section coupled at one end to a support which can receive and support a piece of drywall during installation. The extension section is further coupled to a base portion at the end opposite to the support. The base portion includes a pivot feature that serves to lift the drywall once it has been positioned on the support. The extension is adjustable to install drywall on a stud wall at various heights. Advantageously, the device is lightweight, easily transportable and easy to use. The device's convenient design enables its utilization immediately upon reaching a construction site.
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[0001] This application claims priority to U.S. Provisional Patent Application No. 61/089,664, filed Aug. 18, 2008, which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] This invention relates to gloves that are cut resistant and chemical resistant, where chemical resistance is maintained even when an outer surface of the glove is damaged. The outer surface provides wet and dry grip properties without accumulating liquid.
BACKGROUND
[0003] Polymeric shells, including unsupported medical, surgical, and other gloves, are typically made of latex. These polymeric shells are produced in an assembly line fashion by dipping a coagulant-coated former of desired shape into an aqueous latex emulsion, thereby coagulating the latex. The coagulated layer is subsequently cured to form the unsupported polymeric shell. The aqueous latex emulsion may comprise additives, including viscosity modifiers, waxes, surfactants, stabilizers, cross-linking agents and the like, to produce a cured latex product having specific characteristics, such as thickness, tensile strength, tear and penetration resistance, flexibility, etc., in a controlled manner. Aqueous latexes of different compositions are known in the art, and they include natural rubber latexes, synthetic polyisoprenes, and other synthetic latexes, including polychloroprene (i.e., neoprene), nitrile compositions, and the like. Examples of polymeric shells made from a typical aqueous dipping process are described in U.S. Pat. No. 3,268,647 to Hayes et al., which discloses the manufacture of rubber gloves. Nitrile latex gloves are commonly used to provide chemical resistance. Likewise, chemical resistant polymeric shells are commonly made from nitrile latex. The gloves can be provided with skin comfort features such as an open-celled foam lining as described in U.S. Pat. No. 7,048,884 (Woodford), or lined with a flock lining as described in U.S. Pat. No. 7,037,579 (Hassan). Skin-generated moisture is absorbed the open celled foam or flock lining to provide a comfortable feel on the hand of the user.
[0004] Supported polymeric shells with a liner are known in the art and are commonly used in industrial environments, such as in the form of gloves for protecting hands, where use of a strong latex product is needed. A number of patents disclose coating the liner with a latex composition. For example, U.S. Pat. No. 2,083,684 to Burke discloses rubber-coated gloves and a method of making the same. U.S. Pat. Nos. 4,514,460; 4,515,851; 4,555,813; and 4,589,940 to Johnson disclose slip-resistant gloves and a method for their manufacture.
[0005] Cut resistant liners are also known in the prior art. U.S. Pat. No. 4,526,828 to Fogt, et al. discloses protective apparel material and method for producing same. The protective material comprises a base layer of textile material, an intermediate layer of relatively cut-resistant fiber material, and an outer layer of solid, elastomeric material. The intermediate layer is formed from intermeshing strands of cut resistant materials such as aramid or wire. The intermeshing strands define pores sufficiently large to permit the passage of a dipped elastomeric material while the base layer is sufficiently non-porous to prevent the passage of the dipped elastomeric material. The outer layer of elastomeric material retards penetration by liquid. A cut through the elastomeric layer from a blade tip may penetrate the pores which will result in liquid permeability through the protective glove. Cotton may be a predominant component of the skin-contacting base layer.
[0006] U.S. Pat. Nos. 4,779,290 and 4,833,733 to Welch et al. disclose cut resistant surgical glove and the method of making the same. This surgical glove has a ventral side and a dorsal side that are integrally connected by a thin stretchable material layer that is impermeable to air and water. The dorsal side includes a layer of flexible armor embedded in the thin stretchable material. The armor is made from interwoven aramid and nylon fibers. A cut to the thin stretchable layer results in leakage of any liquid contacting the glove and the integrity of the surgical glove is compromised.
[0007] U.S. Pat. No. 5,070,540 to Bettcher discloses protective garment having a cover, a fabric liner, and a coating of elastomeric material permeating the cover and adhering the liner and cover together. The fabric liner is in a skin-contacting region. The cover is cut resistant with wire strands. The cover can be knit from yarn that has a core having 2 to 6 strands of stainless steel wire and a parallel synthetic polymer fiber strand, and the core can be wrapped with strands of non-aramid fiber in opposite directions one on top of the other. The elastomeric material can be formed from nitrile latex, which is said to infiltrate the cut resistant cover, but does not infiltrate through the fabric liner, yet infiltrates sufficiently to adhere the liner to the cover. Such precision of latex dipping, however, is not readily realized in industrial practice. Grip on an outer surface of the glove surface is provided by adding pumice to the nitrile latex, which also decreases its impregnating capability into the cut resistant cover. This type of nitrile impregnation is only possible if the cover has knits that are widely spaced, which according to Bettcher, is indicated to be 0.05 inches based on the overall yarn dimension including the core and its wraps. A blade can easily penetrate this wide space between the knits of the cover creating a cut that compromises the impermeability of the elastomeric layer and that permits liquid accumulation. Thus, the protective glove is not damage tolerant.
[0008] U.S. Pat. No. 5,581,812 to Krocheski discloses a leak-proof textile glove. The inner surface of a cut-resistant textile layer is bonded to a leak-proof, petroleum-resistant, polymeric material, such as PVC, and the skin contacting side of the leak-proof liner is coated with cotton flock. Any damage to the leak-proof polymeric layer by a sharp object results in leakage of a liquid contacting the glove.
[0009] U.S. Pat. No. 5,822,791 to Baris discloses a protective material and a method wherein a base layer comprises cut resistant yarn, an intermediate layer comprises natural fiber, and an outer layer comprises a flexible, elastomeric material impervious to liquid. The intermediate layer is bonded to the elastomeric material, while the cut resistant yarn in the base layer remains substantially free of encapsulation by the elastomeric material. The intermediate layer is joined to the base layer at one or more locations, preferably by selective strike through of limited amounts of the elastomeric material to encapsulate yarn in the base layer. The cut resistant yarn forms the innermost layer of the glove contacting and protecting the hand. However, any damage to the outer elastomeric material results in liquid permeation and thus the material according to Baris does not sustain damage and still protect the user.
[0010] U.S. Pat. No. 6,021,524 to Wu et al. discloses cut resistant polymeric films. The cut resistant polymeric films are used for manufacturing medical or industrial gloves and comprises at least three elastomeric layers wherein the middle layer has a three-dimensional network of cut resistant fibers selected from glass fibers, steel fibers, aramid fibers, polyethylene fibers, particle filled polymeric fibers, and their mixtures. The integrity of the cut resistant layer is entirely determined by the character of the network of the cut resistant fibers. Chopped, loose fibers can be moved around especially when encapsulated in a polymeric material such as synthetic or natural rubber and the liquid leak-proof quality of the polymeric film can be easily compromised by a small cut.
[0011] U.S. Pat. Nos. 6,543,059 and 6,596,345 to Szczesuil et al. disclose a protective glove and a method for making same. This protective glove for a human hand includes an inner glove of polyester, non-woven, needle-punched material and a melt-sprayed polyurethane coating. This non-woven needle-punched material has no mechanical integrity, unlike a woven or knitted fabric and the hot melt-sprayed polyurethane adhesive holds the configuration together forming a glove. The melt-sprayed glove is heated to a temperature of 300 to 325° F. to allow the remelted polyurethane to penetrate the inner glove to a depth short of penetrating to the inner surface of the inner glove. The polyurethane coating on the outer surface of the inner glove cures in approximately 24 hours by reaction with ambient moisture. The inner glove is further coated with a rubberized material to produce an inner glove held together by the rubber, which is then cut to pieces and sewn, to form a glove with internal sewn seams. Such a glove is not liquid-impervious, since these sewn seams are not bonded and leak. Such a glove is, therefore, not chemically resistant. The protective glove is said to protect from puncture, but the polyester non-woven inner glove will not provide cut resistance. The glove is only leak-proof as long as the polyurethane adhesive layer is not cut and due to the shallow penetration of the polyurethane adhesive coating, it is easy to cut the polyurethane layer.
[0012] U.S. Pat. Nos. 6,782,720 and 6,782,721 to Vero et al. disclose unilayer fabric with reinforcing parts. This unilayer flexible textile performance fabric has a base fabric of a predetermined design of a pattern continuously formed by a step of selectively manipulating and chain-stitching on a programmed knitting machine into the base fabric at least one dissimilar high performance fiber into the base fabric in the same layer using a preselected single needle. This selectively reinforced fabric which may have a glove shape has no liquid-impervious latex layer and is therefore not leak-proof.
[0013] U.S. Pat. No. 6,918,241 to Zhu discloses cut resistant yarns and process for making the same, fabric and glove. The glove is made by knitting or weaving of a cut resistant yarn comprising polyurethane filament or rubber and a plurality of bulked continuous cut resistant filaments, wherein the plurality of bulked continuous cut resistant filaments have a random entangled loon structure in the yarn. The glove is heat set and a coating of polyurethane or a polynitrile is applied to the glove and cured. The leak-proof quality of the glove relies on the integrity of the polyurethane or polynitrile layer and any damage to this layer results in liquid leakage.
[0014] U.S. Pat. No. 7,007,308 to Howland et al. discloses protective garment and glove construction and method for making same. The garment or glove has a cut and puncture resistant protective liner or multiple liners affixed to the inside shell or outside shell of the garment or glove by means of adhesives or stitching. The cut resistant protective liner may be attached to the outer surface of the inside shell by an adhesive layer. Alternatively, the cut resistant liner may be attached to the inside surface of the outside shell by an adhesive layer. When both inside shell and outside shell are present, the cut resistant liner is only attached to the inside shell by an adhesive layer. The liner or the adhesive is not indicated to be leak-proof. The cut resistant liner is not integrally attached to either the inside shell or the outside shell, thus any damage to the outer shell results in liquids leakage. The outer shell does not provide grip properties.
[0015] U.S. Pat. Appln. Pub. No. 2006/0068140 to Flather et al. discloses a polymeric shell adherently supported by a liner and a method of manufacture. This glove article has a cured, liquid-impervious polymeric shell that is substantially free from defects, a liner, and a non-tacky, thermoplastic adhesive layer between the shell and the liner. The adhesive layer is melted and solidified to create a non-tacky bond between the shell and the liner. The liner can be moisture-absorbing or cut-resistant and the liner supports and limits stretch ability of the shell, thereby preventing adhesive delamination between the adhesive layer and either of the shell and/or the liner. In one embodiment, the cut resistant liner is outside the liquid-impervious polymeric shell and is bonded by melted and solidified non-tacky polyurethane adhesive. The bond between the shell and the cut resistant liner is generally superficial, that is, the adhesive does not readily penetrate the cut resistant liner. Also, the adhesive used is non-tacky and solid at room temperature, creating a rigid bond between the liner and the liquid-impervious polymeric shell. As a result, upon impact from a blade or the like, there can be free space between the cut resistant liner and the liquid-impervious shell, which can lead to liquid accumulation. This liquid accumulation can reduce the grip properties of the glove since the accumulated liquid acts as a lubricant.
[0016] WO Int'l Pub. No. WO2007/024127 to Aaron et al. discloses a method and article of manufacturing a waterborne polyurethane coated glove liner. The process for producing a waterborne polyurethane coated glove liner comprises the compounding of the waterborne polyurethane that is coated on a glove liner using the conventional dipping process of a supported glove. The glove liner to support the glove includes nylon or other synthetic polyamides, polyester, cotton, rayon, Dyneema, Kevlar, Lycra, spandex, acrylic and blended yarns. The polyurethane coating is free of DMF solvent. The waterborne polyurethane coated glove liner is designed to give excellent grip for safe and secure handling. The polyurethane coating is subject to damage by oils and petroleum and is affected by solvents. The contact of polyurethane coating against the hand in a cut resistant fiber may expose sharp ends of the cut resistant liner, thus irritating the skin of the user.
[0017] Therefore, there is a need in the art for damage tolerant chemically resistant cut resistant flexible latex glove article that has superior dry and wet grip properties. While handling oily or wet articles, liquid should not accumulate on the surface of the glove compromising glove grip properties. There is a need in the art for a manufacturing process that reliably produces high quality damage tolerant chemically resistant cut resistant gloves on a routine basis at a low cost. These and other objects and advantages, as well as additional inventive features, will be apparent from the detailed description provided herein.
SUMMARY
[0018] Provided are damage tolerant cut resistant chemical handling flexible latex gloves and methods of making and using the same. These gloves are flexible and lightweight. A knitted cut resistant liner with cotton fibers in combination with cut resistant fibers is applied to a cured, liquid-impervious polymeric latex shell. Preferably, the polymeric shell is a nitrile shell and is provided with skin moisture management skin-contacting surface treatments including a foamed layer and/or a flock lined layer, preferably a flock lined layer deposited by an electrostatic deposition method. The cut resistant liner that is applied to the polymeric shell can have a slightly smaller glove size so that the knit spaces are opened out when a polymeric bonding layer formed by a water-based soft nitrile or polyurethane is applied. The cut resistant liner is bonded to the shell by these polymer materials. For example, a cured water-based polyurethane latex emulsion penetrates the liner due to the soaking characteristics of the cotton fibers present in the liner. A thin coating of nitrile latex emulsion is applied over the polyurethane layer in a wet state prior to curing. The nitrile protects the polyurethane-coated surface from oil or chemical damage during use. In another example, a soft nitrile bond layer is provided between the cut resistant liner and the liquid impervious polymeric shell, which itself is resistant to oil exposure and would not need the nitrile overcoat used with the polyurethane layer. The flexibility of the glove is a result of the combination of the liquid-impervious polymeric shell, bonded to a stretched cut resistant liner by polymer materials that exhibits high elongation (typically 600% to failure). The cured soft nitrile layer or the polyurethane layer and the protective nitrile layer cured together replicate the texture of the knitted liner, whose plurality of cut resistant and cotton yarns cross each other, thereby creating a rough, controlled, predictable glove external grip surface that provides superior grip properties in wet as well as dry conditions. The soft nitrile layer or the polyurethane and nitrile layers seal the interstices between the yarns of the liner and also bond the liner to the polymeric shell, such that no liquid accumulates between the liner and the shell upon damage to the outer layers. Moreover, the grip properties of the glove are not compromised by lubrication due to an accumulated liquid lubricant layer. When the glove is cut by a sharp object such as a blade or a knife, there are multiple polymer layers including the soft nitrile layer or the nitrile-protected polyurethane layer, which infiltrates the cut resistant liner, and the liquid-impervious polymeric shell. When the soft nitrile layer or the nitrile-protected polyurethane layer is cut, the liquid-impervious shell prevents entry of the liquid onto the user's hand. Even if the soft nitrile or the polyurethane layer is entirely cut, the shell still prevents entry of the liquid. And, the cut resistant liner in its own right prevents the blade tip from cutting the liquid-impervious polymeric shell.
[0019] The process for the manufacture of the glove includes creating a liquid-impervious cured latex shell by conventional techniques including providing a former in the shape of a human hand, dipping the former in a coagulant solution such as calcium nitrate solution with several additives, drying the coagulant-coated former, dipping the coagulant-coated former in a latex liquid emulsion, destabilizing the latex at the boundary layer between the coagulant coated former and latex emulsion creating a gelled/coagulated latex layer, and washing the gelled latex layer. The external surface of the gelled/coagulated latex layer may be coated with a foam lining or a flock lining such as an electrostatically deposited cotton flock lining. The glove on the former is then cured in an oven to create a liquid-impervious polymeric shell. When the cured polymeric liquid-impervious shell is inverted upon removal from the former, the surface having the skin moisture management features becomes the skin-contacting side. The moisture management system may be applied in a separate step on the polymeric liquid-impervious shell. The liquid-impervious polymeric shell is then applied to a former with the moisture management features contacting the external surface of the former.
[0020] A cut resistant liner is produced by knitting cut resistant yarns that contain some content of cotton fibers. The cut resistant yarns can comprise steel fibers, aramid fibers, glass fibers, liquid crystal fibers such as Spectra™, Dyneema™ and high hardness (>3 moh hardness) particle filled fibers and combinations thereof. The cut resistant fibers may be optionally wrapped with non-performance fibers including cotton, nylon, polyester, and combinations thereof. The knitted cut resistant liner is preferably of a slightly smaller dimension so that when the cut resistant knitted liner is slipped over the polymeric shell on the former, the knits of the liner are slightly stretched enabling infiltration of the water-based polyurethane latex emulsion between the interstices, that is, the spaces between the knitted liner yarns.
[0021] Next, the cured liquid impervious shell is applied to a former. The former may be a solid former, which can be difficult to dress with the liquid impervious polymeric shell, especially if the latex thickness is of the order of 13 mils. The former may be a wire form former or an inflatable former which is easy the dress even with a 13 mil thick liquid impervious shell. A cut resistant knitted liner with yarns that include cotton fibers is dressed over the outer surface of the liquid impervious glove shell on the former. The former with the liquid-impervious polymeric shell with the cut resistant liner is dipped in a water-based soft nitrile or polyurethane latex emulsion. Due to the low viscosity of the water-based soft nitrile or polyurethane latex emulsion and the soaking characteristics of the cotton fibers in the cut resistant liner, the soft nitrile latex emulsion or polyurethane latex emulsion enters interstices between the knits in the cut resistant liner and soaks through all the cotton fibers in the cut resistant liner creating a soft nitrile or polyurethane layer that replicates the knitted cut resistant liner surface features, yet creating a seal between each of the knits. The water-based soft nitrile or polyurethane latex emulsion creates an adhesive bond between the liquid-impervious polymeric shell and the cut resistant liner.
[0022] In one embodiment, the water-based soft nitrile coated polymeric shell with the cut resistant liner is taken out from the water-based soft nitrile latex emulsion bath and is rotated from the vertical dipping position to a horizontal position and gently rotated. This operation prevents the dripping of the low viscosity soft nitrile latex emulsion and covers the yarns of the cut resistant liner, while the interspaces in between the knits remain not filled up and hence depressed. This texture is frozen in place by dipping the soft latex covered polymeric liquid impervious shell with the cut resistant liner in a coagulant such as a calcium nitrate solution. The coagulating action freezes the soft nitrile layer outer surface texture even though underlying soft nitrile latex emulsion below the surface may still be uncoagulated. The former with the liquid impervious shell, cut resistant liner that is coated with soft nitrile layer is taken to a curing furnace, which cross-links the coagulated and uncoagulated soft nitrile latex layer equally creating a bond between the cut resistant liner and the polymeric liquid impervious shell.
[0023] In another embodiment, the water-based polyurethane coated polymeric shell with the cut resistant liner is taken out from the water-based polyurethane latex emulsion bath and is rotated from the vertical dipping position to a horizontal position and gently rotated. This operation prevents the dripping of the low viscosity polyurethane latex emulsion and covers the yarns of the cut resistant liner, while the interspaces in between the knits remain not filled up and hence depressed. This texture is frozen in place by dipping the soft latex covered polymeric liquid impervious shell with the cut resistant liner in a coagulant such as a calcium nitrate solution. The coagulating action freezes the polyurethane outer surface texture even though underlying polyurethane latex emulsion below the surface may still be uncoagulated. The external surface of the glove with the polyurethane coating is then sprayed with a thin layer of nitrile latex coating in the uncured wet state. The viscosity of the sprayed nitrile latex should be low so that the nitrile layer covers the entire polyurethane external surface of the glove and the low viscosity of the nitrile latex assures that the surface features of the knit surface replicated by the water-based polyurethane on the cut resistant liner outer surface are preserved providing an external surface that has excellent grip properties. This thin nitrile layer may be optionally applied by a dipping procedure using a thin nitrile latex emulsion with low nitrile polymer solid content. The former with the liquid impervious shell, cut resistant liner that is coated with polyurethane and nitrile layers is taken to a curing furnace, which cross links the coagulated and uncoagulated polyurethane and nitrile layers equally creating a bond between the cut resistant liner and the polymeric liquid impervious shell. Since the polyurethane layer cures at the same time as the nitrile layer, an intimate bond is established between the liquid-impervious polymeric shell, the polyurethane layer, and the nitrile layer forming a high strength, yet flexible glove.
[0024] The glove article created covers the entire front, back and wrist of the user. High level of flexibility of the glove article is due to use of thin liquid-impervious polymeric shell, typically soft nitrile that has low modulus, a cut resistant liner that is stretched and held in place by low modulus high elongation soft nitrile or nitrile-protected polyurethane layer that adhesively bonds the cut resistant liner to the liquid-impervious polymeric shell resistant to chemical or oil damage. The wet and dry grip character of the glove arises from the soft nitrile or nitrile-protected polyurethane layer replicating the knit structure that appears like a rough textured surface that replicates series of sealed knit squares that are not filled up to form a smooth flat surface. Thus, any liquid applied to the external surface of the glove upon damage to the glove is prevented from getting into the space between the cut resistant knitted liner and the liquid-impervious polymeric shell. If this were to happen, the accumulated liquid in between the cut resistant liner and the liquid-impervious polymeric shell will result in a lubricious liquid boundary layer providing very little or no glove gripping capability. If the glove were to be damaged during use, for example by a blade cut, the glove leak-proof qualities are protected first by the soft nitrile or nitrile-protected polyurethane layer. The cut resistant liner prevents the liquid-impervious polymeric shell from being damaged, so that the user is protected from exposure to liquid even when the glove surface is damaged.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 illustrates a fragmentary cross-sectional view of the damage tolerant cut resistant chemical resistant flexible latex glove article according to subject invention having a liquid-impervious chemical resistant polymeric shell of, for example, nitrile or polychloroprene latex, with a cotton fiber containing cut resistant liner that has been infiltrated and anchored with a water-based soft nitrile or nitrile-protected polyurethane layer resistant to degradation by oils and chemicals;
[0026] FIG. 2 illustrates a fragmentary cross-sectional view of the latex article of FIG. 1 placed on a compliant substrate such as a hand with the interior surface of the liquid-impervious chemical resistant polymeric shell contracting the hand and a knife contacting the soft nitrile or nitrile-protected polymeric coating resulting in cutting of both the soft nitrile layer or the nitrile-protected polyurethane layer with the cut resistant liner preventing damage to the liquid-impervious polymeric shell at the knife edge;
[0027] FIG. 3 illustrates the steps involved in producing a liquid-impervious chemical resistant polymeric shell;
[0028] FIG. 4 illustrates the steps involved in dressing a former with a liquid-impervious polymeric shell at step A; applying a cotton-containing cut resistant liner over the outer surface of the impervious chemical resistant polymeric shell at step B; encapsulating the cotton-containing cut resistant liner with a soft nitrile latex layer that replicates the surface texture of the cut resistant liner at step C; and sealing the spaces in the cut resistant liner and integrally attaching the cut resistant liner with the liquid-impervious polymeric shell by the soft nitrile layer.
[0029] FIG. 5 illustrates the steps involved in dressing a former with a liquid-impervious polymeric shell at step A; applying a cotton-containing cut resistant liner over the outer surface of the impervious chemical resistant polymeric shell at step B; encapsulating the cotton-containing cut resistant liner with a polyurethane latex layer that replicates the surface texture of the cut resistant liner at step C; and sealing the spaces in the cut resistant liner and integrally attaching the cut resistant liner with the liquid-impervious polymeric shell by the polyurethane layer, followed by the application of nitrile-protective layer by spraying on the coating at step D.
DETAILED DESCRIPTION
[0030] Provided are cut resistant chemical handling latex gloves and methods of making and using the same. Generally, provided are gloves having a liquid-impervious polymeric shell, a cut resistant, cotton-containing liner that has been encased in a polyurethane coating, and an outer coating of nitrile. In one or more detailed embodiments, provided is a latex glove comprising a cured, liquid-impervious chemical resistant polymeric shell substantially free from defects, an optional electrostatic flock coating on the surface of the polymeric shell on the skin-contacting surface, a cut resistant, cotton-containing liner that has been encased in a polyurethane coating integrally connecting the cut resistant liner with the liquid-impervious chemical resistant polymeric shell and replicating the surface texture of the knitted cut resistant liner. FIG. 1 provides a geometrical arrangement of the glove 10 , which represents a cross-section of the glove. A hand of the user is located at H inside the interior of the glove. An optional moisture management liner 11 on the skin-contacting surface can be an open-celled foam, or an electrostatically applied flock, such as cotton flock. The liquid-impervious polymeric shell 12 is typically 9 to 13 mil thick. A knitted cut resistant liner with cut resistant fibers and cotton fibers 13 is attached to the liquid-impervious polymeric shell by the infiltration of water-based soft nitrile or polyurethane latex 14 . The water-based soft nitrile or polyurethane impregnates the cut resistant liner containing cotton fibers and cut resistant fibers 13 , soaks through the liner and creates a bond between the cut resistant liner and the polymeric shell. The water-based soft nitrile or polyurethane seals the individual fibers within the yarn and seals the spaces between the fibers of the cut resistant liner forming a leak-proof seal against the liquid-impervious polymeric shell. The soft nitrile or polyurethane layer replicates the surface texture of the liner providing a rough surface texture that is capable of providing dry and wet grip when the glove is cured. Since a polyurethane layer is susceptible to attack by chemicals and oil, a thin overcoat of nitrile latex layer 15 protects the polyurethane layer 14 . A soft nitrile layer 14 does not need this nitrile coating 15 since it is already degradation resistant by chemicals or oil.
[0031] FIG. 2 at 20 depicts the interaction between a blade tip/a knife-edge 21 with an embodiment of a glove made according to the subject invention. The blade tip cuts through the nitrile layer 15 and partially cuts through the polyurethane layer 14 . The blade may similarly cut through the soft nitrile layer 14 . The cutting action stops as it encounters the cut resistant fibers of the knitted cut resistant liner 13 . Since the cut resistant liner is completely wetted and sealed by the soft nitrile layer 14 or the polyurethane layer 14 and the nitrile layer 15 , no liquid can accumulate, that is no liquid can enter through and occupy the interstices of the cut resistant liner 13 and the outer portion of the liquid-impermeable polymeric shell 12 . Liquid accumulation could create a liquid pocket that lubricates a gripped object severely reducing grip provided by the glove, but does not because there is no accumulation. No liquid enters the glove or touches the hand since the liquid-impermeable polymeric shell remains intact directly below the cut resistant liner, thus the glove of the subject invention is damage tolerant.
[0032] The polymeric shell needs to be liquid-impermeable so that the resultant article is liquid resistant. For chemical resistance, the shell needs to be an elastomer that is chemically resistant. The polymeric shell generally comprises a synthetic latex, such as nitrile latex or polychloroprene latex, and is highly flexible due to its high degree of soft feel. Nitrile latex has a low modulus and therefore feels soft on the hand and larger thickness gloves can be made with a comfortable feel. The thickness of polymeric shell, made of, for example, nitrile latex or polychloroprene latex that covers the user's hand is typically in the range of 9 mil to 13 mil.
[0033] FIG. 3 provides a schematic diagram 30 representing the manufacturing process for the liquid-impervious latex polymeric shell. In step 31 , a suitable former 35 , such as a ceramic or metallic former, in the shape of a human hand and forearm is dipped in a coagulant solution 36 , which is typically calcium nitrate and forms a film 37 . In step 32 , the coagulant-coated former is dipped into an aqueous latex emulsion tank 38 , containing an aqueous nitrile latex for example, and the coagulant locally destabilizes the latex emulsion forming a gelled latex layer 12 on the former 35 . A nitrile latex emulsion typically is water-based and contains a base nitrile latex in an amount of approximately 100 phr, a cross-linking agent such as sulfur in an amount of approximately 0.5 phr, an accelerator such as zinc oxide in an amount of approximately 3.0 phr, an accelerator such as ZMBT in an amount of approximately 0.7 phr, and surfactants such as sodium or calcium dodecylbenzenesulphonate, emulsion stabilizers, and viscosity moderators. This process may be repeated until a sufficient latex layer is built up on the former 35 . The former 35 with the gelled latex layer 12 is washed in step 33 , and cured in step 34 to cross link the latex 12 . The inner surface of the polymeric shell may be coated with latex foam or electrostatically applied cotton flock to produce a soft sweat-absorbing surface that contacts the hand of the user using known methods.
[0034] FIG. 4 provides a schematic diagram 40 for the process of creating the damage tolerant cut resistance surface on the liquid-impervious polymeric shell 12 . The cured polymeric shell made from, for example, nitrile latex or polychloroprene latex is mounted over a glazed or polished former, a wire former or an inflatable former 35 of the desired shape and size, shown as configuration A at step 41 . The interior hand-contacting surface of the polymeric shell, which can have the optional skin moisture controlling cotton flock (not shown) contacts the former 35 . A cut resistant knitted liner 13 is slipped over the external surface of he liquid-impervious polymeric shell 12 in step 42 and the resulting configuration is shown as configuration B. It is desirable that the knitted cut resistant liner is slightly of a smaller glove size so that the knits of the liner are well spread out for the next process step. The preferred cut resistant liner comprises 20 micron steel yarns knitted with a cotton carrier with a three dimensional knit patterns preferably tailored to match the anatomical shape of a human hand and forearm as exemplified in U.S. Pat. No. 7,213,419 (Hardee) and U.S. Pat. No. 7,246,509 (Hardee). The cut resistant liner 13 generally has a thickness in the range of 15 to 30 mils. The former 35 with the liquid-impervious polymeric shell 12 and the cut resistant liner 13 is dipped in to a water-based soft nitrile latex emulsion bath marked ‘SOFT NITRILE’ in step 43 and removed in step 44 creating a configuration shown at C. The former with the soft nitrile coated glove is withdrawn and turned into a horizontal orientation and rotated to uniformly coat the yarns of the cut resistant liner while leaving the interstices between knits depressed as shown in configuration D, step 45 . The former with the soft nitrile coated glove is dipped in or sprayed with a coagulant solution (not shown since the texture is preserved) to freeze the surface texture of the soft nitrile layer. The former with the soft nitrile layer coated glove is heated in step 46 to cure and bond the applied coating.
[0035] FIG. 5 provides a schematic diagram 50 for the process of creating the damage tolerant cut resistance surface on the liquid-impervious polymeric shell 12 . The cured polymeric shell made from, for example, nitrile latex or polychloroprene latex is mounted over a glazed or polished former a wire former or an inflatable former 35 of the desired shape and size, shown as configuration A at step 51 . The interior hand-contacting surface of the polymeric shell, which can have the optional skin moisture controlling cotton flock (not shown) contacts the former 35 . A cut resistant knitted liner 13 is slipped over the external surface of he liquid-impervious polymeric shell 12 in step 52 and the resulting configuration is shown as configuration B. It is desirable that the knitted cut resistant liner is slightly of a smaller glove size so that the knits of the liner are well spread out for the next process step. The preferred cut resistant liner comprises 20 micron steel yarns knitted with a cotton carrier with a three dimensional knit patterns preferably tailored to match the anatomical shape of a human hand and forearm as exemplified in U.S. Pat. No. 7,213,419 (Hardee) and U.S. Pat. No. 7,246,509 (Hardee). The cut resistant liner 13 generally has a thickness in the range of 15 to 30 mils. The former 35 with the liquid-impervious polymeric shell 12 and the cut resistant liner 13 is dipped in to a water-based polyurethane latex emulsion bath marked ‘PU’ in step 53 and removed in step 54 creating a configuration shown at C. The former with the polyurethane coated glove is withdrawn from the water-based polyurethane latex emulsion bath and turned into a horizontal orientation and rotated to uniformly coat the yarns of the cut resistant liner while leaving the interstices between knits depressed as shown in configuration D, step 55 . The former with the polyurethane coated glove is sprayed with a thin nitrile latex emulsion as shown in configuration E at step 56 covering the polyurethane external surface of the glove. The former with the polyurethane and nitrile coated glove is heated in step 57 to cure and bond the applied coating.
[0036] The performance of the cut resistant latex glove article is evaluated by cut resistance ASTM tests. A 4-inch long strip is cut from the cut resistant latex glove article and is mounted using a double sided tape securing the hand-contacting side of the glove to a cylindrical steel mandrel with the axis of the cylinder oriented along the knife movement. The curvature of the mandrel prevents binding of the knife and the generation of frictional forces. A cutting blade is mounted on a rotatable arm and was loaded with a selected weight. The arm with the cutting blade is rotated exerting a cutting force on the cut resistant latex glove article strip on the polymeric coating surface. The knife progressively cuts and eventually cuts through the glove strip. The length of the cut is recorded. Next, the glove strip is displaced and the knife is loaded with an increased weight and the test is repeated. The cut length as a function of the knife-selected load is determined. Clearly, as the load increases, the cut length decreases since the knife readily cuts through the glove strip. The cut resistance is found to be satisfactory.
[0037] All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
[0038] The use of the terms “a,” “an,” “the,” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
[0039] It should be understood that the illustrated embodiments are exemplary only, and should not be taken as limiting the scope of the invention.
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A damage tolerant cut resistant chemical handling glove that is flexible and lightweight comprises a cured, liquid-impervious polymeric latex shell, a knitted cut resistant liner comprising a cotton yarn and at least one cut resistant yarn, the liner being infiltrated with a soft nitrile or polyurethane layer such that the liner bonds to the shell. The soft nitrile or polyurethane layer seals interstices of the cut resistant liner and replicates its rough texture on the external surface of the glove, providing enhanced grip properties. A thin nitrile latex layer applied to and cured together with the polyurethane layer to protect the polyurethane layer from oil or chemical degradation. The intimate seal thus created between the shell and the liner prevents accumulation of liquid there between, which prevents formation of a liquid boundary layer and interference with grip properties of the glove.
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PRIORITY CLAIM
The present application claims benefit of U.S. provisional patent application No. 61/379,579 filed on Sep. 2, 2010.
BACKGROUND OF THE INVENTION
The present invention relates to installation of foam roof insulation sheets and, particularly to a method of installation for these insulation sheets using reinforced membrane covering in lieu of glue or screws.
Insulation for commercial roofs is generally in sheets about ½″ to 3″ thick or more. As usual, thicker insulation installed in a roof or wall of a building improves energy efficiency. The foam sheets of insulation used in a common commercial building roof are installed by laying the sheets on top of a roof deck, which may be comprised of concrete, steel or wood. In recent history the roofing industry has transitioned from using asphalt on flat roofs to using TPO membranes for commercial buildings. Thermoplastic Olefin or Polyolefin (TPO) membranes are single-ply roof membranes constructed from ethylene propylene rubber. They are designed to combine the durability of rubber with the proven weather-proofing and durable performance of seams that are welded using hot air. These membranes are often installed over the insulation sheets of commercial roofs.
In previous construction techniques, the insulation sheets installed in commercial roof decks are usually secured to the roof deck first to avoid shifting when wind blows under the overlying membrane roof covering material. Wind uplift is a major problem in roofing with respect to both the roof covering and the underlying insulation. The insulation is installed before applying the membrane roofing to the roof. The insulation generally comprises sheets that are 4′×8′ in size. The insulation sheets are installed by laying them side by side on the roof deck with the lap joints staggered. The joints of the insulation sheets are usually attached with screws and plates to the roof deck. Alternatively, it is common to glue the insulation sheets to a roof deck, or use hot asphalt where glue is unacceptable because of environmental hazards.
Existing means for securing insulation discussed above are both expensive and inefficient. For example, in the most common method of attaching insulation sheeting with screws and plates, the plates must be manually set and multiple screws must be installed in a multitude of plates. These screws and plates are difficult to remove in the case the roof needs the roof needs to be replaced. Hot asphalt is expensive, installation is energy-intensive, and it can be difficult to deliver to roof decks. Further, hot asphalt is not approved for installation of insulation directly to steel decks.
SUMMARY OF THE INVENTION
It would be advantageous to attached insulation sheets without the need to use expensive screws, glue or hot asphalt. A method is also needed to fasten insulation to a roof deck using the membrane structure that will be installed over the insulation sheets. Another method is needed to attach insulation separately to a roof deck without the need for screws, glue or asphalt.
The present invention provides for holding a roof system down from the top without the use of screws, or at least very few compared to traditional methods for installing roof installation sheets. In this regard, additional methods for attaching cables to retain roofing membranes together with insulation sheets are provided by the invention. The system provides for installation of insulation sheets from above using a cable fastening system, as opposed to attachment of the insulation sheets with screws attached below the sheets.
In particular, cables are laid selectively over the insulation sheets or roofing membrane. The cable or reinforced elongate member comprising the cable may be fastened to the membrane covering the insulation or fasted directly to the insulation sheets. In addition the roofing membrane may be attached to the insulation sheets by an adhering means such as hook and loop fastener, snap-locking members, or adhesive substance. Once the membrane is stuck onto the insulation sheets, wind cannot get under the roofing materials and blow the insulation around once the membrane or insulation sheets are secured using a cable system. Attaching the membrane to the insulation sheets will be advantageous to prevent shifting of the insulation when the cable system secures the membrane.
An object of the present invention is to improve efficiency of installation for foam insulation sheets.
Another object of the invention reduces the need for attaching foam insulation sheets form to a structure below the sheets with screens, adhesive or hot asphalt.
Still another object improves efficiency for removal of foam insulation sheets.
Still another object improves efficiency of installation of roof systems through combination of installing foam insulation sheets with the step of installing thermoplastic membrane material.
Yet another object provides an improved method for securing foam insulation sheets to a roof substrate in a manner that exceeds requirements for wind and weatherproofing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an insulation sheet modified with adherent hook and loop material in accordance with an embodiment of the invention.
FIG. 2 a is a perspective view of a membrane material modified with an adherent hook and loop material in accordance with an embodiment of the invention.
FIG. 2 b is a perspective view of a membrane material modified with an adherent hook and loop material in an alternative embodiment of the invention.
FIG. 3 is a perspective view of an insulation sheet modified with adherent material in an alternative embodiment of the invention.
FIG. 4 is a perspective view of a method for installation of roof insulation in accordance with an embodiment of the invention.
FIG. 5 is a perspective view illustrating an alternative method for installing roof insulation according to the invention.
FIG. 6 is a perspective view illustrating an alternative method for installing roof insulation according to the invention.
FIG. 7 is a side plan view illustrating installation of roof insulation according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
A new method of attaching insulation sheets 2 to membrane material 4 for securing the system with cable 6 is provided in the several embodiments depicted herein. Beginning now with FIG. 1 , the preferred embodiments of the method include putting an adherent material 8 , such as hook and loop fastener or heat activated glue on the top side of insulation sheets 2 like that shown in FIG. 1 for engaging and attaching to the membrane material 4 that is laid over the insulation sheets 2 .
For example, a hook and loop fastening material may be applied to the top side of the insulation sheets 2 in sections as shown in FIG. 1 or as a unitary layer of material as shown in FIG. 3 , and, then, sectional strips 10 of hook and loop attaching material may be manufactured into the rolls of membrane material 4 or as a unitary solid backing. Whereby, when the membrane material 4 is rolled out over the insulation sheets 2 , as depicted in FIGS. 2 a and 2 b , and the membrane material will attach itself to the insulation sheets 2 . The provision of adherent material on surfaces of both the membrane material and the insulation sheets is a first step toward providing a secure installation of the insulation sheets without the need for attaching the bottom side of the insulation sheets to a roof substrate with screws, adhesive or asphalt.
After the membrane material is attached to the insulation by contact of the adherent top surface of the insulation surface with adherent bottom surface of the membrane material, cable is used in a further step of the process to securing the membrane and insulation sheets. Elongate cable 6 may comprise any elongate cord or material of sufficient strength for stretching across membrane material 4 on a roof deck and securing the cable to the roof deck with sufficient force to retain the membrane material and resist wind and other weather or elements. In particular, the cable 6 may comprise an elongate member of membrane material, which may be reinforced by layering, fiber, or integrated cord or cable. It is further recognized that adherent material may only be required on either the top surface of the insulation sheet or bottom surface of the membrane material should heat activated glue or other adherent be used that only requires one surface contain adherent material. Whereas, when the preferred hook and loop fastener is used, it will be desirable for both the insulation sheet surface and membrane material surface to be treated with adhering material of the hook and loop nature.
Once the membrane is secured with cable 6 , the insulation sheets 2 would be unable to shift when exposed to windy conditions. Thus in one embodiment, the hook and loop fastening material is applied to the top side of the insulation sheets 2 in strips 12 , and the membrane material 4 is manufactured with a solid hook and loop backing 14 as shown in FIG. 2 a that attaches to these strips. In yet another embodiment, both the adherent material 8 applied to the top side of the insulation sheets 2 and the adherent material applied to the membrane backing are arranged in strips 10 , 12 that are aligned for attachment of each to the other.
Alternatively, these strips 10 , 12 may be crisscrossed for easier alignment, and, whereby the strips save material as compared with manufacturing a solid surface or backing of adherent material. A suitable material that will adhere the insulation sheets 2 to the membrane material 4 may be substituted for hook and loop fastener, such as snap-lock material, adhesive with pull off covering, or adhesive activated at the time of installation for securing the membrane material to the insulation sheets 2 .
The membrane material is secured using several sections of elongate cable 6 crossing the membrane 4 and also the underlying foam insulation sheets 2 . As the foam insulation sheets 2 are secured by the membrane material 4 layered thereon or the insulation sheets are secured from above by cross-bars 16 , 18 or tracks 22 as discussed below, the several sections of cable 6 that cross the insulation sheets will secure both the insulation sheets and the membrane material. In particular, once the membrane material is secured to the roof deck by any means, the insulations sheets when attached to the membrane material will in turn be secured and tolerant to wind and other weather conditions. In one preferred embodiment, the membrane material over the insulation sheets is attached by cable 6 , which will be fastened at or near to a perimeter edge of the building and then run in a direction perpendicular to the direction of the perimeter edge to which it is fastened. Several of these cables 6 will be a regular distance apart to secure the membrane, while crossing several insulation sheets as well.
In another embodiment depicted in FIG. 4 , the insulation sheets 2 are held in place on the roof deck 102 by plates or cross-bars 16 , 18 that fit over top of each or several insulation sheets 2 and hold each insulation sheet in place by grabbing onto a cross-bar on the bottom of the sheet. A pair of cross-bar plates may be arranged to overlap on the top and bottom with the top cross-bar 16 grabbing the bottom cross-bar 18 to secure them together. The cross-bars fit between the insulation sheets 2 . One or more of the cross-bars may include adhesive for holding the insulation sheets 2 . The top cross-bar may include eyelets 20 , buckles, bracket or attachment means for the cable 6 or straps to engage or pass through to hold the top plate and thereby secure the plates and insulation sheets 2 in place. The system may be integrated with fitted pieces to provide a synergistic method for installation of insulation sheets 2 .
In another embodiment shown in FIG. 5 , H-shaped tracks 22 are provided within the roof deck for insertion of the insulation sheets 2 . The H-tracks hold the insulation sheets 2 in their general position so that the sheets can be secured by a cable 6 or strap system from above. Cables or straps 24 are run across the top of the tracks to secure the insulation sheets 2 . In a related embodiment of FIG. 6 , H-joints 26 are provided to secure the insulation sheets 2 , and the insulation sheets are attached to the joints, such as by screws 28 . The joints are attached to the bottom the membrane sheets to secure the position of the insulation sheets 2 within the roof deck. The membrane is then attached by cables, which secures the underlying joints and insulation sheets 2 .
In another embodiment cable 6 may be used to as an attachment point or used to secure membrane. Straps 24 cross the insulation sheets 2 to secure them in place and attach to a secure member 30 or to the cables 6 . Said cables may comprise reinforced members that act as cable structure, such as reinforced membrane sections. The straps 24 may wrap-around the cables and adhere to themselves. A system of straps provides a low profile structure for holding the insulation sheets 2 that will not cause water build-up on the roof.
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A method for installing roof insulation includes adhering the insulation to a covering membrane material or retaining the insulation by an overlapping cross-bar, track or joint. Elongate cables stretch across the insulation and membrane material to secure the insulation and membrane material to roof deck.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of application Ser. No. 08/435,361 filed May 5, 1995 (now abandoned), and the benefit of this earlier filing date is hereby claimed under 35 U.S.C. §120.
FIELD OF THE INVENTION
The present invention relates generally to a machine alignment compensation actuator system, and particularly to an alignment compensation actuator system that may be disposed between the tool head and the framework of a machine tool to maintain accurate alignment of the tool head.
BACKGROUND OF THE INVENTION
In many machines, such as machine tools, a tool for performing certain operations is movably attached to a rigid framework. To accurately perform certain operations, such as the cutting of a workpiece, it is often necessary to maintain the orientation of the tool as consistently as possible. However, the wearing of machine components, the force exerted against the tool by the workpiece, forces due to shifting masses, and the expansion or contraction of components due to either localized or environmental changes in temperature are examples of influences that effect the orientation or alignment of the tool. This is a particular problem in maintaining accurate alignment of the tool head and cutter in a typical machine tool.
Existing methods or systems for maintaining machine component alignment include accurate machining of guide mounting surfaces, such as ways, hand scraping of guide mounting surfaces, applying assembly fixtures and non-shrink epoxy to align guide surfaces, and incorporating redundant structural mounts into the structure to distort the overall structure in an effort to achieve the desired alignments. These alignment methods and systems, however, are permanent and cannot easily be changed once initially established. Thus, changes caused by loads or wear of components still have very undesirable effects on the alignment of the tool. This has detrimental effects on the overall performance of the machine.
Furthermore, the manufacturing costs associated with these methods can be difficult to predict. The costs tend to increase rapidly as tighter tolerances are required, due to the necessary precision with which the various machine components must be constructed. It would be advantageous to have a system that did not require such precise construction of machine components.
Other attempts have been made to alleviate the problems of alignment. In some devices, corrections in alignment of the tool are made by adjusting the machine slides or ways. In at least one device, corrections are made by deforming the machine structure via thermal expansion and contraction. The latter device uses a plurality of cooling jackets and heaters mounted about the base of the machine. Thus, different portions of the machine base may be heated or cooled to provide twisting of the structure and realignment of the tool. This approach may be problematic, because the response times are relatively long. Additionally, the alignment control works through the structure of the machine rather than acting directly against the tool head, thus complicating the correction of alignment.
It would be advantageous to provide a machine alignment compensation actuator system that acts directly against the machine tool head assembly to quickly readjust the orientation of the tool.
SUMMARY OF THE INVENTION
The present invention features a machine alignment compensation actuator system for use with a machine tool of the type that moves a tool to perform an operation on a workpiece. The actuator system is designed to maintain precise alignment of the tool and comprises a framework and a machine slide assembly configured to hold the tool along a given axis set in space. An actuator assembly is disposed between the machine slide assembly and the framework. The actuator assembly has a plurality of actuators with each actuator being disposed at a unique location. By adjusting each actuator independently, the machine slide assembly and tool can be reoriented.
According to more detailed aspects of the invention, the plurality of actuators may comprise piezoelectric ceramics. Alternatively, the actuators may comprise diaphragms cooperating with the tool holder to form cavities for receiving pressurized fluid. By selectively pressurizing the cavities, the diaphragms are forced to flex and thereby readjust the orientation of the tool holder assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements, and:
FIG. 1 is a schematic representation and perspective view of the machine alignment compensation actuator system according to a one embodiment of the invention;
FIG. 2 is a detailed front view of a preferred embodiment of the machine alignment actuator system incorporating diaphragms according to one embodiment of the invention;
FIG. 3 is a partial cross-sectional top view of the embodiment illustrated in FIG. 2;
FIG. 4 is a partial cross-sectional top view showing one of the diaphragms connected to the machine slide assembly; and
FIG. 5 is an internal view of a diaphragm used in conjunction with one embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring generally to FIG. 1, a machine tool alignment system 10, according to a preferred embodiment of the present invention, is illustrated as including a machine tool 12 of the type designed to move a tool 14 for performing an operation on a workpiece 16. In the illustrated embodiment, workpiece 16 is mounted on a workpiece pallet 18, and tool 14 is oriented along a preferred or desired axis 20 fixed in space. The illustrated tool 14 is for forming workpiece 16, but a wide variety of tools are encompassed within the scope of the present invention. For example, tool 14 may comprise shearing cutters, rotary cutters, such as end mills or drills, and probes for sensing certain parameters of workpiece 16.
Machine tool 12 includes a framework 22, and framework 22 may include at least one reference surface or way 24. Preferably, framework 22 includes a pair of ways 24.
A machine slide assembly 26 is movably mounted to framework 22, and in the illustrated embodiment, is slidably mounted along ways 24. However, machine slide assembly 26 and ways 24 could be mounted in a variety of orientations along various axes. Machine slide assembly 26 may include a tool holder 28, such as the illustrated cantilevered beam or a rotatable spindle, or machine slide assembly 26 may be configured to receive workpiece 16 or workpiece pallet 18 mounted thereon. Machine slide assembly 26 may further include a support or headstock 30 mounted to tool holder 28.
An actuator assembly 32 includes a plurality of actuators 34, each disposed between machine slide assembly 26 and framework 22, e.g., between ways 24 and support 30. Each actuator 34 is placed at a unique location and can be independently adjusted to reorient machine slide assembly 26, and thus tool 14, with respect to the desired axis 20 and workpiece 16. Actuators 34 and machine slide assembly 26 could also be connected between the framework and the workpiece 16 to adjust the workpiece with respect to axis 20 and tool 14.
Actuators 34 may be constructed in a variety of forms that are able to produce lateral movements with respect to framework 22. Exemplary actuators include piezo-electric ceramics, such as those manufactured by EDO Corporation, diaphragm assemblies 36 as illustrated in the remaining figures, or various other actuator devices.
The actuators 34 are preferably controlled by a computer numerical controller 38 of the machine tool 12 that may be programmed for adjusting actuators 34 to compensate for a variety of angular errors produced by external effects, such as component wear, thermal distortion, and forces acting against tool 14. Other controllers, known to those of ordinary skill in the art, could also be used.
Depending on the types of errors the machine tool alignment system 10 is designed to correct, controller 38 can be programmed with appropriate control algorithms to compensate the alignment errors as would be known to one of ordinary skill in the art. For example, controller 38 could be programmed to command actuators 34 based on previously measured machine alignment conditions for a given tool location, or with appropriate sensors (not shown), an in-process closed loop alignment system could be achieved. The present invention is not limited to any particular control algorithm, and controller 38 could be programmed with a variety of control algorithms depending on the desired error correction for a particular type of machine or usage of tool 14.
In the illustrated embodiment in which actuators 34 comprise diaphragm assemblies 36, at least one pressure reducing valve 40, such as the DRE4K, manufactured by Rexroth Corp., is connected in fluid communication with diaphragm assemblies 36. Preferably, one pressure reducing valve 40 is connected to each corresponding diaphragm assembly 36. Valves 40 are also connected to a valve driver 42, such as the MDSD1 valve driver, manufactured by Rexroth Corp. In the preferred embodiment, there are four actuators 34 connected to four corresponding valves 40, which, in turn, are each connected to a valve driver 42. Valve drivers 42 are controlled by controller 38.
Referring generally to FIGS. 2-5, a specific embodiment of the invention incorporating diaphragm assemblies 36 is illustrated in greater detail. In this embodiment, support 30 comprises a plate 44 having recessed portions 46 in a back surface 48 (see FIGS. 3 and 4). Each diaphragm assembly 36 includes a diaphragm 50 having an internal cavity 52. Each diaphragm 50 is attached to back surface 48 within a corresponding recessed portion 46 to effectively enclose cavity 52 between back surface 48 and diaphragm 50 as illustrated in FIG. 4.
Preferably, diaphragm 50 is attached to plate 44 by a plurality of fasteners 54, such as bolts, that extend through plate 44 and are threaded into corresponding threaded openings 56 of diaphragm 50. A seal (not shown), such as an elastomeric o-ring, is disposed between diaphragm 50 and back surface 48 to ensure an airtight seal of cavity 52 therebetween. As shown in FIG. 5, diaphragm 50 may include a groove 57 configured to retain the elastomeric o-ring in its proper position. Additionally, each diaphragm 50 may be further secured in place by a retainer plate 58 bolted to the sides of plate 44 as illustrated in FIGS. 3 and 4.
As illustrated best in FIGS. 4 and 5, the preferred form of diaphragm 50 includes a cavity plate 60, in which cavity 52 is formed, and an attachment plate 62 opposite cavity 52. Cavity plate 60 and attachment plate 62 are connected by a region of reduced cross sectional area 64. Cavity 52 comprises recessed channels 66 formed in cavity plate 60 and stops 67 disposed between channels 66 to abut back surface 48 and effectively stop any further compression of cavity 52 resulting from impact loading of machine slide assembly 26.
Attachment plate 62, on the other hand, is designed for rigid attachment to a way truck 68 that is slidably mounted to framework 22 and specifically to a corresponding way 24. Attachment plate 62 and way truck 68 are rigidly connected by an appropriate fastening mechanism, such as bolts or other fastening means.
Because diaphragms 50 are the links between way trucks 68 and headstock 30 (plate 44 in FIG. 4), they must be formed from a stiff material. Preferably, diaphragms 50 are made from a steel, such as 4140HR steel.
In the illustrated embodiment, there are two ways 24, each having a pair of grooves 70 formed in the sides thereof. Two way trucks 68 are slidably mounted on each way via a pair of flanges 72 that matingly engage grooves 70 as illustrated in FIG. 4. Thus, way trucks 68 and the attached machine slide assembly 26 may be moved along ways 24 by a mechanism 74, such as the ball screw drive illustrated in FIG. 3.
In the preferred embodiment, each valve 40 is mounted on plate 44 and communicates with its corresponding cavity 52 via a fluid passage 76 having an inlet orifice 77. Inlet orifice 77 may be fixed or adjustable to provide appropriate damping by restricting fluid flow therethrough when machine slide assembly 26 is placed under load. Valves 40 and diaphragm assemblies 36 could be designed for use with a variety of fluids, including liquids or gases, but are typically designed for use with pressurized oil. Each valve 40 includes a fluid inlet 78 and a fluid exit 80. Fluid inlets 78 are connected to a high pressure oil source (not shown) and the ingress and egress of fluid is controlled by controller 38 and valve drivers 42.
Appropriate measurement devices 82, such as linear encoders, may be used to measure the movement of machine slide assembly 26 along ways 24. It should also be noted that FIGS. 2 and 3 illustrate a tool holder mount 84, but do not actually show the tool holder 28.
Thus, support 30 of machine tool 12 may be selectively oriented to maintain proper alignment of tool 14 along a predetermined desired axis, such as axis 20. This alignment is accomplished by mounting actuator assembly 32 between framework 22 and machine slide assembly 26. The individual actuators 34 are disposed at unique locations between the framework and the support 30. Therefore, by selectively controlling the pressure, and therefore the extension, of individual actuators, (e.g., by flexing selected diaphragms 50) the machine slide assembly can be reoriented with respect to the framework 22. Consequently, tool 14 is properly reoriented with respect to desired axis 20 and/or workpiece 16. Preferably, four actuators are placed at four unique locations, but this number could be decreased or increased depending on the specific application.
It will be understood that the foregoing description is of a preferred exemplary embodiment of this invention, and this invention is not limited to the specific forms shown. For example, the system could be incorporated into a variety of machines, with or without ways, a variety of actuators could be used as long as the extension and contraction of each actuator may be independently controlled, a variety of control systems and control algorithms may be used with the invention, a variety of tools and tool holder assemblies may be used, and a variety of materials may be incorporated into the diaphragms. These and other modifications may be made in the design and arrangement of the elements without departing from the scope of the invention as expressed in the appended claims.
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A machine alignment compensation actuator system is disclosed. The system is designed to selectively orient the tool head of a machine tool to maintain the tool along a desirable axis of alignment. The system includes a framework and a machine slide assembly configured to hold the tool. An actuator assembly having a plurality of actuators is disposed between the machine slide assembly and the framework. Each actuator is disposed at a unique location to permit selective reorientation of the machine slide assembly and tool with respect to the framework.
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RELATED APPLICATIONS
This application is a divisional of U.S. patent application Ser. No. 10/572,762, filed on Mar. 21, 2006, which is a 371 of PCT/SE04/01370 filed Sep. 24, 2004, which claims priority to Swedish Application No. 0302550.9 filed Sep. 25, 2003, which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
This invention relates to washing of gas turbines and particularly to a nozzle for washing a gas turbine unit during operation. Further the invention relates to a method for washing of said gas turbine unit under operation.
DESCRIPTION OF PRIOR ART
The invention relates to the general art of washing gas turbine equipped with axial compressors or radial compressors. Gas turbines comprise of a compressor for compressing air, a combustor for combusting fuel together with the compressed air and a turbine driving the compressor. The compressor comprises in turn multiple compression stages, where a compression stage comprises of a rotor disc and subsequent stator disc with vanes.
Gas turbines in operation consumes large quantities of air. The air contains contaminants in form of small particles, called aerosols, that enters the compressor with the air stream. A majority of these particles will follow the air stream and exit the gas turbine with the exhaust. However, there are particles with the properties of sticking on to components in the engine's gas path. These particles build up a coating on the components, reducing the aerodynamic properties. The coating result, in an increase in the surface roughness which result in a decrease in the pressure gain as well as a reduction of the air flow that the compressor compresses. For the gas turbine unit it results in a decrease in efficiency, a reduced mass flow and a reduced pressure ratio. To reduce the contamination modern gas turbines are equipped with filters for filtering of the air to the compressor. These filters can only capture a portion of the particles. To maintain an economic operation of the gas turbine, it is found necessary to regularly clean the compressor gas path components to maintain the good aerodynamic properties.
Different methods for cleaning gas turbine compressors are previously known. To inject crushed nut shells into the air stream is shown to be practical. The disadvantage with the method is that nut shell material may find its way into the internal air system of the gas turbine with the consequence of clogging of channels and valves. Another method for cleaning is based on wetting of the compressor components with detergent. The detergent is injected with nozzles spraying it into the air stream of the compressor.
Stationary gas turbines vary much in size. The largest gas turbines on the market have a rotor diameter in excess of two meters. This means that the air duct upstream of the compressor will thereby also have large geometries. For a gas turbine with a two meter diameter rotor may have more than two meter distance to the opposite duct wall. With these large geometries there may be difficulties in injecting washing fluid into the part of the duct with the core air stream. If the liquid follows the core air stream the surface of the rotor blades and stator vanes will essentially be wetted whereby a good wash will be obtained. If the liquid on the contrary will follow close to the duct wall, the liquid will in an unsatisfactory way wet the blades and vanes. Further, a portion of the liquid will be caught by the boundary layer air stream by the duct wall and will there form a liquid film which is transported into the compressor by the air stream. This liquid will not participate in washing of the compressor and can cause damage of, for example, the liquid fills the gap between the rotor tip and compressor casing.
In contrary to large gas turbines with large geometries there are small gas turbines with moderate dimensions on the inlet air duct. For smaller gas turbines the spray can more easily penetrate in to the core air stream. Experience from actual wash installations on gas turbines show that the spray from conventional nozzles penetrated the air stream some tens of a centimeter. For most small and medium size gas turbines this is sufficient for satisfactory wetting of the rotor blades and stator vanes. One problem is that conventional nozzles can not penetrate the air stream of large gas turbines.
A preferred cleaning method is based on wetting the compressor components with a washing fluid. The fluid is injected through a nozzle that atomizes the liquid into a spray in the air stream entering the compressor. The washing fluid may consist of water or a mixture of water and chemicals. During injection of the wash liquid the gas turbine rotor is cranked with its starter motor. This method is called “crank wash” or “off-line” wash and is characterized by that the gas turbine does not fire fuel during washing. The spray is created by the washing liquid being pumped through the nozzles which then atomizes the fluid. The nozzles are installed on the duct walls upstream of the compressor's inlet or on a frame temporarily installed in the duct.
The method is characterized by the compressor components soaked with cleaning fluid where contamination is released by act of the chemicals together with mechanical forces from the rotation of the shaft. The method is considered efficient and fruitful. The rotor speed at crank wash is a fraction of the speed prevailing at normal operation. One important property with crank washing is that the rotor is rotating at low velocity whereby there is little risk for mechanical damage. While practicing this method the gas turbine must be taken out of service which may cause production loss and costs.
U.S. Pat. No. 5,011,540 discloses a method for wetting of compressor components while the gas turbine is in operation. This method is known as “on-line” washing and is characterized by fuel is being fired in the gas turbine combustor during washing. The method has in common with the crank wash method in that liquid is injected up stream of the compressor. This method is not as efficient as the crank wash method. The lower efficiency relates to poor washing mechanisms prevailing at high rotor speeds when the gas turbine is in operation. For example, a correct dose of liquid must be injected as a too high dose may cause mechanical damage to the compressor and a too low dose may cause poor wetting of the compressor components. Further, the droplets must be small else large droplets may cause erosion damage from the collision of the droplets with the rotor and stator blades.
A gas turbine compressor is designed to compress the incoming air. In the rotor the rotor energy is transformed into kinetic energy by the rotor blade. In the subsequent stator vane the kinetic energy is transformed into a pressure rise by a velocity reduction. To enable the compression process high velocities are required. For example, it is common that the rotor tip of modern gas turbines exceeds the velocity of sound. This means that the axial velocity in the compressor inlet is very high, typically 0.3-0.6 Mach or 100-200 m/s.
According to state of the art technology, wash liquid is pumped at high pressure in a conduit to a nozzle on the duct wall upstream of the compressor inlet. In the nozzle the liquid reaches high velocity whereof atomization takes place and a spray of droplets are formed. The spray is caught by the air stream and the droplets carried with the air stream into the compressor. By the choice of nozzle design small or large droplets can be formed. Alternatively, a nozzle for small droplets can be used. With small droplets in this context means droplets with a diameter of less than 150 μm. The disadvantage with small droplets is that have a small mass and thereby low inertia when leaving the nozzle. The droplets velocity is quickly reduced by the air resistance and the range is therefore limited. Alternatively can a nozzle for large droplets be selected. With large droplets in this context means droplets with a size greater than 150 μm. Large droplets have the advantage of a high inertia when leaving the nozzle. The relationship between the droplet size and its mass is that the mass is proportional to the radius cubed. For example, a 200 μm droplet is twice the size of a 100 μm droplet but has eight times its mass. Through the greater mass follows a greater range compared to the smaller droplet. The disadvantage with the larger droplet is that when the droplets are caught by the air stream they also achieve high velocity towards the compressor. At impact with the blade surface large energies are transferred whereof there may be damage on the blade surface. The damages will appear as erosion damages.
To achieve a good washing effect the spray must penetrate into the core of the air stream. A difficulty with the on-line wash method, e.g. as shown in U.S. Pat. No. 5,011,540 is to get the liquid into the core of the air duct. As previously mentioned there are very high velocities in the air duct which drags the wash liquid before it has penetrated into the core of the air stream. Thereby, the droplets must be small as to avoid erosion damage. However, small droplets show a disadvantage in this respect. Small droplets has low inertia, as off its low mass, and quickly loose velocity when the atomization is completed. In contrary to large droplets which has a good ability to maintain initial velocity over a longer range. A spray of small droplets has therefore an impaired ability to penetrate into the core of the air stream. This problem is especially evident for large gas turbines with large air duct geometries where the distance from the nozzle to the centre of the air duct is long.
In summary, the washing of gas turbines, especially during gas turbine operation, is associated with a number of problems.
SUMMARY OF THE INVENTION
One objective with the invention is to provide a nozzle and a method for washing of a gas turbine during operation in an efficient and safe way.
This and other objectives are achieved by this invention with a nozzle and a method which have the characteristics defined by the independent claims. The preferred embodiments are defined in the dependent claims.
For the purpose of clarification the use of “angle against shaft centre” or “angle against centre axis” means the angle between the direction of a liquid stream from a nozzle and a reference surface parallel with the centre axis through the nozzle body.
According to the first aspect of the invention, a nozzle is disclosed for washing of a gas turbine unit. The nozzle is arranged for atomizing a washing fluid in the air stream of an air inlet duct to said gas turbine unit including a nozzle barrel which, in turn, includes an inlet end for inlet of said washing fluid and an outlet end for outlet of said washing fluid. The nozzle includes further multiple orifices at the outlet end where the orifice is arranged at a defined distance from the nozzle barrel shaft axis.
According to a second aspect of the invention, a method is disclosed for washing of a gas turbine unit comprising of atomizing a wash fluid in an air intake of said gas turbine unit comprising of an inlet end for entering wash liquid and an exit end for releasing said wash fluid. The method is characterized by the formation of said atomized wash fluid by feeding said wash fluid to said orifice at nozzle exit end, whereof each orifice is arranged at suitable distance from the nozzle body centre axis.
The invention is based on the idea of increasing the local density of the atomized wash fluid in a specified volume by feeding the wash fluid through multiple orifices of the nozzle barrel arranged at suitable distances from the nozzle barrel centre axis. This arrangement will allow an improved penetration of the spray into the air stream with maintained droplet size, or even with decreased droplet size, i.e. the nozzle according to the invention will allow wash fluid to be injected into the core of the air stream in the air duct without increasing the droplet size. Thereby will the risk for erosion damage on gas turbine components be reduced while a high efficiency wash will be obtained compared to conventional solutions.
Another advantage is that the nozzle may be equally applied to gas turbines with small geometries as well as gas turbines with large geometries.
Yet another advantage is that washing of components in the gas turbine unit can be practiced during gas turbine operation with significant cost savings. Another advantage is that the nozzle according to the invention can be used for crank washing.
According to preferred embodiment of the invention each orifice is pointing at an angle towards the nozzle centre axis so that the liquid will exit the orifice towards the centre axis. Thereby will the liquid jet from an orifice be within an angle range of 0-80° and preferred within an angle range 10-70°.
By directing the orifice in a suitable angle towards the nozzle centre axis a preferred coverage can be obtained which means that the spray shall have a spray angle as to satisfactory wet the rotor blades and stator vanes within the segment of the compressor inlet where the spray will act. The condition for coverage is thereby fulfilled by selecting a nozzle with the appropriate spray angle. By directing the orifice in a suitable angle towards the centre axis an increased spray density can locally be obtained and a better penetration of the fluid into the air stream can be obtained.
The advantage by the invention is further enhanced by the spray shape shows a smaller projected area against the air stream compared to the spray from a conventional nozzle. By the smaller projected area the spray will not that easy be caught by the air stream but instead penetrate better into the air stream.
According to the preferred embodiment of the invention each of the said orifices is positioned at essentially the same distance from said centre axis and at essentially the same angle towards the centre axis. This design is found to be advantageous in increasing the local density of the spray in the desired area and thereby reduce the risk for erosion damage on the gas turbine components while maintaining a high washing efficiency.
According to an exemplified embodiment of the invention are the orifice arranged as to point towards the centre axis and have a common conjunction point in the range 5-30 cm from said orifice.
Preferably shall the liquid pressure be in the range 35-175 bar.
Preferably are the orifices arranged as to bring the liquid through the orifice at a velocity in the range 70-250 m/s.
According to the preferred embodiment of the invention are the orifices of essentially the same design.
According to a preferred embodiment of the invention is the orifice designed to form a spray with an essentially circular spray pattern, i.e. a spray with a essentially circular cross section. Alternatively may the orifice be arranged to form a spray of an essentially elliptical shape or an essentially rectangular shape.
According to a preferred embodiment of the invention there are two orifices in connection to said outlet end of the nozzle barrel. By using two orifices somewhat apart from each other and allowing the sprays to converge at a point after completion of the atomization, the core of the air stream is reached. Within the volume where the two sprays merge, the density of the spray will double and increasing the impact force on the surrounding air, followed by a better penetration into the air stream, followed by a more efficient wash and a reduced risk for erosion damaged on the compressor components as the droplets are allowed to remain small, i.e. with a diameter less than 150 μm.
Additional advantages with the invention will be obvious by the following detailed descriptions in the preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The preferred embodiments of the invention will now be described in detail with reference to the attached drawings where:
FIG. 1 shows a part of a gas turbine and positioning of nozzles for injecting wash fluid into the air stream.
FIG. 2 shows atomization of wash fluid in a nozzle.
FIG. 3 shows a conventional nozzle for injection of wash liquid into a gas turbine inlet
FIG. 4 . shows the nozzle according to the invention and a first exemplary embodiment of the invention.
FIG. 5 shows the nozzle according to the first exemplary embodiment of the invention.
FIG. 6 shows the nozzle according to the invention and a second exemplary embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 1 , a section of a gas turbine 1 and the positioning of nozzles for injecting of wash liquid into a compressor inlet are shown. The gas turbine comprises of an air intake 2 which is rotationally symmetric to axis 3 . The air flow is indicated by arrows. Air enters radially to be rerouted and flow parallel to the machine shaft through compressor 14 . Compressor 14 has an inlet 4 at the leading edge of the first disc of stator vanes. After disc 5 with stator vanes follows a disc 6 with rotor blades, followed by a disk 7 with stator vanes, and so on. The air intake has an inner duct wall 8 and an outer duct wall 9 . A nozzle 10 is installed on the inner duct wall. A conduit 11 connects the nozzle with a pump (not shown) which supplies the nozzle with wash fluid. After passing nozzle 10 the liquid atomizes and forms a spray 12 . The droplets are carried with the air stream to compressor inlet 4 . Alternatively, nozzle 13 is installed on the outer air duct wall 9 .
FIG. 2 shows atomization of a fluid from a nozzle. A nozzle 20 with an axis 24 has an inlet 21 for the wash fluid and an orifice 22 where the liquid exit the nozzle. The orifice area and liquid pressure is adapted for a specific flow rate. Orifice 23 has a hole where the wash fluid flows. A nozzle for gas turbine compressor washing has an orifice area and a liquid pressure such as that the liquid velocity through the orifice is high, in the order of 100 m/s.
The direction of flow will be direction of which the orifice is pointing. If the orifice is circular a spray with a circular cross section will form. The spray will propagate with one component in the hole's axial direction and another component in the direction perpendicular to the axial direction. According to FIG. 2 , the geometry of the spray can be described as a cone with base C and height B and where C is the cone's diameter.
After the liquid has left the orifice the atomization takes place implying that the liquid first is fragmentized followed by a breakdown into small particles. The particles finally take the shape of a sphere governed by that the surface tension is minimized. At a distance A from the orifice 22 according to FIG. 2 , the atomization is essentially completed. A spray consisting of droplets of varying size is then formed. For a nozzle in this gas turbine application, operating at a liquid pressure of 70-140 bar, the distance A is typically 5-20 cm. At an additional distance B the droplets have continued to propagate but it is now greater distances between the droplets. When the distances between the droplets become bigger, this means that the spray density is reduced. If the was fluid is assumed to be water, the density before atomization takes place is 1000 kg/m 3 . At distance B the spray is characterized as having a less density than at distance A where density is defined as the number of particles by volume air locally. For a nozzle in this gas turbine application operating at a liquid pressure of 50-140 bars, the density at A is typically 20 kg/m 3 .
Ii is evident that when the droplets collide with the air molecules the velocity is reduced. In the context of this invention, a key issue is how far the spray penetrates the air before the air stream has reached the compressor inlet. A single droplet with a certain initial velocity will quickly loose its initial velocity and asymptotically reach zero velocity. The man skilled in the art can estimate the droplets velocity as a function of the distance from the orifice by the use of the balance for the aerodynamic drag force and the force by inertia. For the spray as a whole, it shall displace the air in its way. This can be seen as it has an impinging force on the air characterized by its density, volume flow and velocity. The impact force can be estimated as:
F=dens*Q*V*Cd (equation. 1)
where
F=impact force
dens=density
Q=volume flow
V=velocity
Cd=de-acceleration coefficient
The de-acceleration coefficient is estimated from the balance between the droplet aerodynamic drag force and the force of inertia.
For the wash procedure according to the invention it is important that the spray well penetrates the air stream. This will occur with a high impinging force as per the definition above. Further, for a good wash result it is required that the spray has a good coverage. By coverage means that the spray shall have a spray angle to satisfactory cover rotor blades and stator vanes within the segment that the spray is acting. The condition for coverage is satisfied by a nozzle with a defined spray angle.
The spray as per above is characterized by its impingement force being highest at the nozzle orifice and the decrease with the distance from the orifice. If the wash fluid is assumed to be water, the density is 1000 kg/m 3 . The area is estimated from the hole diameter. At each distance from the nozzle orifice the impingement force can then be estimated from equation 1. The increased area with the increased distance result in that the impingement force will asymptotically be zero.
FIG. 3 show the same spray as shown in FIG. 2 , where identical parts have the same reference numerals as in FIG. 2 . FIG. 3 shows a conventional nozzle. Distance D is the distance the spray has penetrated the air stream before the air stream has transported the droplets to the compressor inlet. The condition for coverage is fulfilled by choice of nozzle with spray angle 34 resulting in coverage E at distance D.
In the description above a spray with a circular projection is assumed. By selecting a nozzle with appropriate orifice geometry, an elliptic or rectangular spray is formed. In the art of gas turbine compressor washing non-circular sprays are used.
With reference to FIG. 4 and FIG. 5 , a first preferred embodiment of the invention is shown. The invention relates to a nozzle performing a spray with an increased impaction force. With the increased impaction force will the distance D according to FIG. 3 , increase and thereby will the earlier identified problem of penetration into the core of the air stream, be eliminated or partly eliminated. FIG. 4 shows a nozzle according to the invention. A nozzle 54 includes a nozzle barrel 40 with a centre axis 49 with an opening 41 for entering a washing fluid and a first orifice 42 at the outlet end 55 and orifice 42 has an opening 43 where washing fluid exits the nozzle. The first orifice 42 is positioned off side the centre axis 49 and with an angle pointing towards the centre axis so that the formed spray is directed to the centre axis. The spray that is formed is circular. The spray geometry can be described as a cone with a base line with one end 44 and another end 45 and tip 43 . Nozzle 54 has a second orifice 46 at the outlet end 55 and orifice 46 has an opening 47 where fluid exits the nozzle. Orifice 46 is positioned off side the centre axis 49 and with an angle pointing towards the centre axis so that the formed spray is directed to the centre axis. The spray that is formed is circular. The spray geometry can be described as a cone with a base line in between one end 45 and another end 48 and tip 47 . According to the preferred embodiment of the invention the orifices are directed at angles towards the centre axis so that the fluid from one orifice is preferably within the angle range 0-80° and additionally preferably within the angle range 10-70°.
The two orifice openings have the same hole area and the alike geometry whereby the incoming liquid is equally distributed between the two orifice 42 and 46 . The two orifice openings are directed-towards the centre axis at a junction point 57 at distance J from the orifice openings. Distance J is within the range 5-20 cm.
The liquid is atomized when exiting the orifice openings 43 and 47 . At a distance F from the orifice openings the atomization is in general completed. The two sprays will now merge whereby a zone 53 is formed with increased density by merging of the two sprays. Zone 53 is limited by points 50 , 52 , 45 , 51 and 50 . With the increased density follows an increased impingement force according to equation 1. It is the purpose of the invention to increase the impingement force. By a suitable nozzle spray angle and spray direction the requirements of coverage H at distance G is fulfilled.
FIG. 5 shows the nozzle in the perspective X-X, where like parts are indicated with the same reference numerals as in FIG. 4 . FIG. 5 shows the orientation of the orifices 42 and 46 with respect to the direction of the air stream. The direction of the air stream is indicated with arrows.
The effect of the invention is further improved by the fact that the spray in accordance with FIG. 4 discloses a projected area against the air stream that is smaller in comparison with the spray from a conventional nozzle. With the direction of stream in accordance with FIG. 5 the projected area against the air stream the area between the points 47 , 50 , 43 , 52 , 48 , 45 , 44 , 51 and 47 in FIG. 4 . This area should be compared with the projected area that results at use of a conventional nozzle in accordance with FIG. 3 , where this area constitutes the area between the points 22 , 31 , 32 and 22 . The area in FIG. 3 is larger than corresponding area in FIG. 4 . Due to the smaller projected area, the spray is not caught by the air stream that easy and thereby the spray is able to penetrate the air stream in a more effective manner.
With reference now to FIG. 6 , a nozzle in accordance with the present invention that exemplifies a second embodiment of the invention will be shown. FIG. 6 shows the nozzle in the perspective X-X, where like parts are indicated with the same reference numerals as in FIG. 4 . As the function of this embodiment of the nozzle in accordance with the present invention is substantially the same as the function of the above-described embodiment such a description of the function is omitted here. FIG. 6 shows the orientation of the orifices 42 , 46 and 60 with respect to the direction of the air stream. The orifice 60 has, as the orifices 42 and 46 , an opening 61 where the fluid leaves the nozzle. The direction of the air stream is indicated with arrows. The third orifice 60 is mounted at the side of the axis centre at the same distance from the axis centre 49 and at the same angle as the orifices 42 and 46 such that the formed spray is directed against the axis centre in a corresponding manner as in the above-discussed embodiment.
Even if the presently preferred embodiments of the invention has been described, it is from the above description obvious for the man skilled within the art that variations of the present embodiments can be realized without departing from the scope of the principles of the invention.
Thus, the intention is not that the invention should be limited only to the structural and functional elements described with reference to the embodiments but only by the appended patent claims.
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A method for cleaning a gas turbine unit. The invention further relates to a nozzle for use in washing the gas turbine unit. The nozzle is arranged to atomize a wash liquid in the air stream in an air intake of the gas turbine unit and comprises a nozzle body comprising an intake end for intake of said wash liquid and outlet end for exit of said wash liquid. The nozzle further comprises a number of orifices that are connected to the outlet end and respective orifice is arranged at a suitable distance from a center axis of said nozzle body, whereby the local density of the injected wash liquid in a desired area can be increased with preserved droplet size and thereby the efficiency of the cleaning process can be significantly improved at the same time as the risk for damaging the components in the gas turbine unit is significantly reduced.
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This application is a division of Ser. No. 09/912,190 filed Jul. 24, 2001.
REFERENCE TO RELATED PATENTS
This Application is related to the subject matter described in the following U.S. patents: U.S. Pat. No. 5,578,813, fitled Mar. 2, 1995, issued Nov. 26, 1996, and entitled FREEHAND IMAGE SCANNING DEVICE WHICH COMPENSATES FOR NON-LINEAR MOVEMENT; U.S. Pat. No. 5,644,139, filed Aug. 14, 1996, issued Jul. 1, 1997, and entitled NAVIGATION TECHNIQUE FOR DETECTING MOVEMENT OF NAVIGATION SENSORS RELATIVE TO AN OBJECT; and U.S. Pat. No. 5,786,804, filed Oct. 6, 1995, issued Jul. 28, 1998, and entitled METHOD AND SYSTEM FOR TRACKING ATTITUDE. These three patents describe techniques of tracking position movement. Those techniques are a component in a preferred embodiment described below. Accordingly, U.S. Pat. Nos. 5,578,813, 5,644,139, and 5,786,804 are hereby incorporated herein by reference.
This application is also related to the subject matter descnbed in U.S. Pat. No. 6,057,540, filed Apr. 30, 1998, issued May 2, 2000, and entitled MOUSELESS OPTICAL AND POSITION TRANSLATION TYPE SCREEN POINTER CONTROL FOR A COMPUTER SYSTEM; U.S. Pat. No. 6,151,015, filed Apr. 27, 1998, issued Nov. 21, 2000, and entitled PEN LIKE COMPUTER POINTING DEVICE; and U.S. patent application Ser. No. 09/052,046, filed Mar. 30, 1998, entitled SEEING EYE MOUSE FOR A COMPUTER SYSTEM. These two related patents and patent application describe screen pointing devices based on the techniques described in U.S. Pat. Nos. 5,578,813, 5,644,139, and 5,786,804. Therefore, U.S. Pat. Nos. 6,057,540 and 6,151,015, and U.S. patent application Ser. No. 09/052,046, filed Mar. 30, 1998, entitled SEEING EYE MOUSE FOR A COMPUTER SYSTEM, are hereby incorporated herein by reference.
THE FIELD OF THE INVENTION
This invention relates generally to devices for controlling a cursor on a display screen, also known as pointing devices. This invention relates more particularly to a system and method for reducing power consumption in an optical pointing device.
BACKGROUND OF THE INVENTION
The use of a hand operated pointing device for use with a computer and its display has become almost universal. By far the most popular of the various devices is the conventional (mechanical) mouse, used in conjunction with a cooperating mouse pad. Centrally located within the bottom surface of the mouse is a hole through which a portion of the underside of a rubber-surfaced steel ball extends. The mouse pad is typically a closed cell foam rubber pad covered with a suitable fabric. Low friction pads on the bottom surface of the mouse slide easily over the fabric, but the rubber ball does not skid. Rather, the rubber ball rolls over the fabric as the mouse is moved. Interior to the mouse are rollers, or wheels, that contact the ball at its equator and convert its rotation into electrical signals representing orthogonal components of mouse motion. These electrical signals are coupled to a computer, where software responds to the signals to change by a ΔX and a ΔY the displayed position of a pointer (cursor) in accordance with movement of the mouse. The user moves the mouse as necessary to get the displayed pointer to a desired location or position. Once the pointer on the screen points at an object or location of interest, a button on the mouse is activated with the fingers of the hand holding the mouse. The activation serves as an instruction to take some action, the nature of which is defined by software in the computer.
In addition to mechanical types of pointing devices like a conventional mouse, optical pointing devices have also been developed, such as those described in the incorporated patents and patent application. In one form of an optical pointing device, rather than using a moving mechanical element like a ball in a conventional mouse, relative movement between an imaging surface, such as a finger or a desktop, and photo detectors within the optical pointing device, is optically sensed and converted into movement information.
It would be desirable to reduce the power typically consumed by an optical pointing device. Limiting power consumption is particularly important for portable electronic devices, such as portable computers, cellular telephones, personal digital assistants (PDAs), digital cameras, portable game devices, pagers, portable music players (e.g., MP3 players), and other similar devices that might incorporate an optical pointing device.
Some optical motion sensors for optical pointing devices include a low-power mode that is automatically entered if no motion is detected for a period of time. In low power mode, power savings is achieved by turning off a light source of the optical pointing device. The light source is a major contributor to power consumption. The light source is turned back on if the optical motion sensor detects any movement, or the light source is periodically turned back on to facilitate motion detection. In some existing optical motion sensors, an undesirable switch from the low power mode to a full power mode can be caused by noise. If the optical motion sensor is on a border between pixels, the optical motion sensor may report oscillations in motion as it attempts to determine whether it is positioned just over or just under the next pixel step threshold, which causes the optical motion sensor to leave the low power mode. In addition, reasonably slow drift motions, such as those caused by vibrations around an optical mouse, or those caused by placing an optical mouse on a surface with a slight incline, can cause an optical motion sensor to undesirably exit the low power mode.
In the low power mode in some optical motion sensors, images are captured, but at a significantly reduced rate compared to the rate at which images are captured in the full power mode. Some optical motion sensors provide 1500 “frame periods” per second. An image may or may not be captured during a frame period. For example, in full power mode, an image may be captured during each frame period, resulting in 1500 images per second. In low power mode, an image may only be captured every 10 or 12 frame periods, resulting in 125-150 images per second. In full power mode, the light source typically remains on for all frame periods, and is not turned off during a frame period or between frame periods. In low power mode, the light source is typically turned on only during frame periods when images are captured, but remains on for the duration of those frame periods. Turning the light source on for only one frame period out of every 10 frame periods results in a reduction of the power used for illumination of about 90 percent. It would be desirable to provide further power savings in the low power mode, as well as a reduction in power consumption in the full power mode.
Regardless of which mode an optical motion sensor is in, the light source remains on for the entire frame period when an image is captured. However, light is only needed for a small portion of a frame period. A frame period includes three phases—an integration phase, an analog to digital conversion phase, and an image processing phase. Light is only needed during a portion of the integration phase when an “electronic shutter” is open, allowing light to be collected. Power is unnecessarily consumed by leaving the light source on for the entire frame period.
It would be desirable to provide an optical screen pointing device with reduced power consumption.
SUMMARY OF THE INVENTION
One form of the present invention provides an apparatus for controlling the position of a screen pointer for an electronic device having a display screen. The apparatus includes a light source for illuminating an imaging surface, thereby generating reflected images. The apparatus includes a motion transducer. A lens receives the reflected images and directs the reflected images onto the motion transducer. The motion transducer includes an electronic shutter for controlling the amount of time that light is collected for image frames. The motion transducer is configured to generate digital representations of the reflected images. The motion transducer is configured to generate movement data based on the digital representations of the reflected images. The movement data is indicative of relative motion between the imaging surface and the motion transducer. A controller coupled to the light source turns the light source on only during the time that light is being collected for an image frame.
Another form of the present invention provides a method of controlling the position of a screen pointer for an electronic device having a display screen. Light is directed from a light source onto an imaging surface, thereby generating reflected images. The reflected images are focusd onto an array of photo detectors. Output values of the photo detectors are digitized, thereby generating digital representations of the reflected images. At least one version of a first one of the digital representations is correlated with at least one version of a second one of the digital representations to generate motion data indicative of relative motion between the imaging surface and the array of photo detectors. The light source is turned off during the digitizing and correlating steps. The position of the screen pointer is adjusted in accordance with the motion data.
Another form of the present invention provides an apparatus for controlling the position of a screen pointer for an electronic device having a display screen. The apparatus includes a light source for illuminating an imaging surface, thereby generating reflected images. The apparatus includes a motion transducer. A lens receives the reflected images and directs the reflected images onto the motion transducer. The motion transducer includes an electronic shutter for controlling the amount of time that light is collected for image frames. The motion transducer is configured to generate digital representations of the reflected images. The motion transducer is configured to generate movement data based on the digital representations of the reflected images. The movement data is indicative of relative motion between the imaging surface and the motion transducer. A controller calculates a time average of the movement data. The controller is configured to determine whether to switch the apparatus from a low power mode to a full power mode based on the calculated time average.
Another form of the present invention provides a method of switching an optical screen pointing device from a low power mode to a full power mode. A first movement is detected with the optical screen pointing device. A first value representing an amount of the first movement is calculated. An accumulated movement value representing an accumulation of previously detected movements is stored. The accumulated movement value is updated by adding the first value. The updated accumulated movement value is compared to a threshold value. It is determined whether to switch to the full power mode based on the comparison of the updated accumulated movement value and the threshold value.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictographic side view illustrating the main components of an optical, motion translation type screen pointer device according to one embodiment of the present invention.
FIG. 2 is an electrical block diagram illustrating major components of one embodiment of a screen pointing device according to the present invention.
FIG. 3 is a timing diagram illustrating phases of a frame period according to one embodiment of the present invention.
FIG. 4 is a flow diagram illustrating a process for reducing power consumption in an optical motion sensor according to one embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims.
FIG. 1 shows a simplified representation of a side view of a motion detection device 1 suitable for tracking the movement of a human finger 7 pressed against a surface 5 of a transparent stud 3 . A motion detection device like that shown in FIG. 1 is described in detail in the above-incorporated U.S. Pat. No. 6,057,540 (the '540 patent). The operation of motion detection device 1 is also summarized below.
When the tip 6 of finger 7 is pressed against surface 5 , the ridges of skin and any other micro texture features are visible in the plane of surface 5 , just as if they were a part of surface 5 . Lens 8 focuses light from those features onto an array of photo detectors, which is part of movement sensor 9 . Movement sensor 9 automatically acquires and tracks any suitable image. When tracking an image, movement sensor 9 produces incremental (X, Y) signals.
Lifting fingertip 6 away from surface 5 produces a loss of tracking. This condition is detected within motion detector 9 , and in one embodiment, the production of incremental (X, Y) signals ceases. This has the effect of leaving the position of the screen pointer unchanged at whatever location it currently occupies, and is exactly the same as when a user of a mouse removes his hand from the mouse. When fingertip 6 is subsequently replaced on surface 5 , motion detector 9 appreciates that an image has been acquired, and, in one embodiment, treats that acquisition as though a reset has been performed. That is, until there has been new motion subsequent to the new acquisition, the incremental coordinates (X, Y) will have the value (0, 0). This leaves the existing position of the screen pointer undisturbed until such time as it is deliberately moved by the motion of fingertip 6 , and corresponds exactly to a mouse user's placement of his hand back on the mouse without moving it.
An LED 2 , which is an IR LED in one embodiment, emits light that is projected by lens 4 onto a region 5 that is part of a work surface 6 to be imaged for navigation. In one embodiment, motion sensor 9 is an integrated circuit (IC) having an array of photo detectors, memory, and arithmetic circuits arranged to implement image correlation and tracking functions described herein and in the incorporated patents. An image of the illuminated region 6 is projected through an optical window (which may be transparent stud 3 itself) to a package (not shown) of integrated circuit 9 and onto the array of photo detectors. Lens 8 aids in the projection of the image onto the photo detectors.
One preferred optical navigation technique used by motion detection device 1 involves optically detecting motion by directly imaging as an array of pixels the various particular optical features visible at surface 5 , much as human vision is believed to do. IR light reflected from a textured work surface pressed against surface 5 is focused onto a suitable array (e.g., 16×16 or 24×24) of photo detectors. The responses of the individual photo detectors are digitized to a suitable resolution and stored as a frame into corresponding locations within an array of memory.
FIG. 2 shows an electrical block diagram illustrating major components of motion detection device 1 . Motion detection device 1 includes light source 2 , lenses 4 and 8 , and motion sensor 9 . Motion sensor 9 includes light sensitive current sources 148 A- 148 C (collectively referred to as current sources 148 ), electronic shutter 150 having a first plurality of switches 151 A- 151 C (collectively referred to as switches 151 ) and a second plurality of switches 153 A- 153 C (collectively referred to as switches 153 ). Motion sensor 9 also includes a plurality of sense capacitors 154 A- 154 C (collectively referred to as sense capacitors 154 ), multiplexer 156 , amplifier 157 , analog to digital (A/D) converter 158 , correlator 160 , system controller 162 , shutter controller 164 , and light controller 166 . In an alternative embodiment, only a single lens 8 is used, rather than two lenses 4 and 8 .
The operation of motion sensor 9 is primarily controlled by system controller 162 , which is coupled to multiplexer 156 , A/D converter 158 , correlator 160 , shutter controller 164 , and light controller 166 . In operation, according to one embodiment, light source 2 emits light that is projected by lens 4 onto surface 6 , which is a fingertip in one form of the invention. In an alternative embodiment, screen pointer device 1 takes the form of an optical mouse, and surface 6 is a suitable surface for an optical mouse, such as a desktop. Light source 2 is controlled by signals from light controller 166 . Reflected light from surface 6 is directed by lens 8 to light sensitive current sources 148 . Current sources 148 represent an array of photo detectors, and are also referred to as photo detectors 148 . Photo detectors 148 each provide a current that varies in magnitude based upon the intensity of light incident on the photo detectors 148 .
Shutter switches 151 and 153 are controlled by a shutter signal from shutter controller 164 . Electronic shutter 150 is “open” when switches 151 are open and switches 153 are closed, and electronic shutter 150 is “closed” when switches 153 are open. When shutter switches 151 are open and shutter switches 153 are closed (i.e., electronic shutter 150 is open), charge accumulates on sense capacitors 154 , creating a voltage that is related to the intensity of light incident on photo detectors 148 . When shutter switches 153 are opened (i.e., electronic shutter 150 is closed), no further charge accumulates or is lost from sense capacitors 154 . Multiplexer 156 connects each sense capacitor 154 in turn to amplifier 157 and A/D converter 158 , to amplify and convert the voltage from each sense capacitor 154 to a digital value. Sense capacitors 154 are then discharged by closing switches 151 and 153 . After discharging sense capacitors 154 , switches 151 are opened so that the charging process can be repeated.
Based on the level of voltage from sense capacitors 154 , A/D converter 158 generates a digital value of a suitable resolution (e.g., one to eight bits) indicative of the level of voltage. The digital values for the array of photo detectors 148 represent a digital image or digital representation of the portion of fingertip 6 positioned over surface 5 of optical pointing device 1 . The digital values are stored as a frame into corresponding locations within an array of memory within correlator 160 . In one embodiment, each pixel in a frame corresponds to one of the photo detectors 148 .
The overall size of the array of photo detectors 148 is preferably large enough to receive an image having several features (e.g., ridges in the whorls of skin). In this way, images of such spatial features produce translated patterns of pixel information as fingertip 6 moves. The number of photo detectors 148 in the array and the frame rate at which their contents are digitized and captured cooperate to influence how fast fingertip 6 can be moved across photo detectors 148 and still be tracked. Tracking is accomplished by correlator 160 by comparing a newly captured sample frame with a previously captured reference frame to ascertain the direction and amount of movement.
In one embodiment, the entire content of one of the frames is shifted by correlator 160 by a distance of one pixel successively in each of the eight directions allowed by a one pixel offset trial shift (one over, one over and one down, one down, one up, one up and one over, one over in the other direction, etc.). That adds up to eight trials. Also, since there might not have been any motion, a ninth trial “null shift” is also used. After each trial shift, those portions of the frames that overlap each other are subtracted by correlator 160 on a pixel by pixel basis, and the resulting differences are preferably squared and then summed to form a measure of similarity (correlation) within that region of overlap. Larger trial shifts are possible, of course (e.g., two over and one down), but at some point the attendant complexity ruins the advantage, and it is preferable to simply have a sufficiently high frame rate with small trial shifts. The trial shift with the least difference (greatest correlation) can be taken as an indication of the motion between the two frames. That is, it provides raw movement information that may be scaled and or accumulated to provide display pointer movement information (ΔX and ΔY) of a convenient granularity and at a suitable rate of information exchange. Correlator 160 automatically detects when fingertip 6 has been removed from surface 5 , by sensing that all or a majority of the pixels in the image have become essentially uniform.
In addition to providing digital images to correlator 160 , A/D converter 158 also outputs digital image data to shutter controller 164 . Shutter controller 164 helps to ensure that successive images have a similar exposure, and helps to prevent the digital values from becoming saturated to one value. Controller 164 checks the values of digital image data and determines whether there are too many minimum values or too many maximum values. If there are too many minimum values, controller 164 increases the charge accumulation time of electronic shutter 150 . If there are too many maximum values, controller 164 decreases the charge accumulation time of electronic shutter 150 .
In operation, images should be acquired at a rate sufficient that successive images differ in distance by no more that perhaps a quarter of the width of the array, or 4 pixels for a 16×16 array of photo detectors 148 . Experiments show that a finger speed of 50 mm/sec is not unreasonable, which corresponds to a speed at the array of 800 pixels per second. To meet a requirement of not moving more than four pixels per cycle, a measurement rate of 200 samples per second is needed. This rate is quite practical, and it may be desirable to operate at several times this rate.
FIG. 3 is a timing diagram illustrating phases of a frame period 300 according to one embodiment of the present invention. A frame period represents the time provided for capturing an entire frame of image data, and for analyzing the image data to determine movement information. Image data need not be captured every frame period. For example, when motion sensor 9 is in a low power mode, an image may only be captured every 10 or 12 frame periods. In one embodiment, when motion sensor 9 is in a full power mode, an image is captured every frame period.
Frame period 300 includes three phases—an integration phase 302 , an analog to digital (A/D) conversion phase 304 , and an image processing phase 306 . During integration phase 302 , light is “collected” by photo detectors 148 , and charge accumulates on sense capacitors 154 as described above. During A/D conversion phase 304 , the collected charge from sense capacitors 154 is converted into digital data by A/D converter 304 as described above. During image processing phase 306 , correlator 160 processes the digital image data and generates incremental movement signals (ΔX, ΔY) as described above.
In previous image sensors, in high power mode, the light source 2 typically remained on for all frame periods, and in low power mode, the light source 2 was typically turned on only during frame periods when images were captured. Regardless of which mode the sensor was in, for each frame period that an image was captured, the light source remained on for that entire frame period. However, light is only needed for a small portion of frame period 300 . Light is only needed during a portion of integration phase 302 when electronic shutter 150 is open, allowing light to be collected. Power is unnecessarily consumed by leaving light source 2 on for an entire frame period 300 .
In one embodiment of motion sensor 9 , light source 2 is controlled by shutter signal 308 from shutter controller 164 . Shutter signal 308 is shown in FIG. 3 below frame period 300 . As shown in FIG. 2, shutter controller 164 is coupled to electronic shutter 150 and light controller 166 . When shutter signal 308 goes high, the high signal causes light controller 166 to turn on light source 2 . The high shutter signal 308 also causes electronic shutter 150 to open, thereby allowing charge to accumulate on sense capacitors 154 . When shutter signal 308 goes low, the low signal causes light controller 166 to turn off light source 2 , and causes electronic shutter 150 to close. Therefore, light source 2 is only on during a portion of integration period 302 , rather than during the entire frame period 300 as in previous motion sensors. As described above, the time that electronic shutter 150 is open is varied based on how bright or dark the captured images are. Likewise, the time that light source 2 is on is varied to be on as long as the electronic shutter 150 is open. The time that electronic shutter 150 is open and light source 2 is on is based on the length of time that shutter signal 308 remains high. During the period of time in integration period 302 prior to shutter signal 308 going high, sense capacitors 154 are reset or pre-charged to a desired starting value.
The time that electronic shutter 150 is open is typically substantially less than the time it takes to setup and process one image frame (i.e., a frame period). In one embodiment, a frame period 300 is over 10,000 clock cycles, whereas the electronic shutter 150 may only be open for 1 or 2 clock cycles of a frame period 300 . Thus, a 10,000 to 1 reduction in the amount of current used for illumination may be obtained for each frame period 300 by only turning light source 2 on during the time electronic shutter 150 is open. Power is saved regardless of whether motion sensor 9 is in a full power mode, or a low power mode.
As described above in the Background of the Invention section, in some existing optical motion sensors, an undesirable switch from the low power mode to a full power mode can be caused by noise or reasonably slow drift motions. In one form of the invention, motion sensor 9 implements a process for avoiding this undesirable switch to full power mode, which includes time averaging motion values. FIG. 4 is a flow diagram illustrating one embodiment of a process 400 implemented by motion sensor 9 for reducing power consumption by avoiding such an undesirable switch to full power mode. To simplify the explanation, process 400 is described in the context of one-dimensional movement (i.e., movement in an X direction).
Process 400 begins with motion sensor 9 in a low power mode. In step 402 , a frame of image data is captured by motion sensor 9 . In step 404 , the captured frame is correlated with a previous frame by correlator 160 . Based on the correlation, correlator 160 determines ΔX in step 406 , which represents the amount of the movement. In step 408 , motion sensor 9 updates a stored current accumulated ΔX value by adding the ΔX determined in step 406 to the stored current accumulated ΔX value. Motion sensor 9 then stores the updated value. In step 410 , motion sensor 9 determines whether the current accumulated ΔX value (as updated in step 408 ) is greater than a threshold value. In one embodiment, the threshold value is 1, representing a one pixel movement per frame. If the current accumulated ΔX value is not greater than the threshold value, motion sensor 9 reduces the current accumulated ΔX by a decay factor in step 412 and stores the reduced value. In one embodiment, the decay factor is 0.5. In alternative embodiments, other decay factors are used. After reducing the current accumulated ΔX by the decay factor, motion sensor 9 remains in a low power mode, and jumps to step 402 to repeat the process. If the current accumulated ΔX value is greater than the threshold value in step 410 , the ΔX motion data determined in step 406 is reported in step 414 . In step 416 , motion sensor 9 enters a full power mode.
To further explain process 400 , an example with movement values will described. Assume that there has been no motion detected for a long period, and then a first movement occurs that is a one-half pixel movement. Thus, in step 406 , correlator 160 determines that ΔX=0.5. In step 408 , 0.5 is added to the current accumulated ΔX value (which is about 0 since there has been no movement for a while). Thus, the updated current accumulated ΔX value is 0.5. Since the current accumulated ΔX value is not greater than 1 (step 410 ), motion sensor 9 reduces the current accumulated ΔX to 0.25 (0.5× decay factor of 0.5) in step 412 , and motion sensor 9 remains in a low power mode. Process 400 is then repeated, beginning at step 402 .
Assuming that the next ΔX calculated in step 406 is also 0.5, the current accumulated ΔX as updated in step 408 will be 0.75 (0.25+ the new ΔX value of 0.5). Since the current accumulated ΔX value (0.75) is not greater than 1 (step 410 ), motion sensor 9 reduces the current accumulated ΔX value to 0.375 (0.75× decay factor of 0.5) in step 412 , and motion sensor 9 remains in a low power mode. Process 400 is again repeated.
Assuming that the next ΔX calculated in step 406 is 1.0, the current accumulated ΔX as updated in step 408 will be 1.375 (0.375+ the new ΔX value of 1.0). Since the current accumulated ΔX value (1.375) is greater than 1 (step 410 ), motion sensor 9 reports the motion (step 414 ) and enters a full power mode (step 416 ).
Process 400 maintains the motion accuracy of motion sensor 9 , but effectively reduces the sensitivity of motion sensor 9 to go into a full power mode when small amounts of motion are reported. Power savings are obtained by remaining in low power mode in the presence of noise, vibrations, or slow drift motions that caused previous motion sensors to switch to full power mode. By time averaging motion reports, motions far in the past are “forgotten”, and only current motions have a significant effect in determining whether motion sensor 9 will enter full power mode. When motion stops, the current accumulated ΔX value continues to decay each frame period to zero. If motion reports are oscillating back and forth, for example, between +1 and −1 pixels, the time averaging feature works to cancel out this type of noise.
Although the power savings techniques described herein are described in the context of a finger pointing device, the techniques are also applicable to an optical desktop mouse implementation.
It will be understood by a person of ordinary skill in the art that functions performed by motion sensor 9 may be implemented in hardware, software, firmware, or any combination thereof. The implementation may be via a microprocessor, programmable logic device, or state machine. Components of the present invention may reside in software on one or more computer-readable mediums. The term computer-readable medium as used herein is defined to include any kind of memory, volatile or non-volatile, such as floppy disks, hard disks, CD-ROMs, flash memory, read-only memory (ROM), and random access memory.
Although specific embodiments have been illustrated and described herein for purposes of description of the preferred embodiment, it will be appreciated by those of ordinary skill in the art that a wide variety of alternate and/or equivalent implementations may be substituted for the specific embodiments shown and described without departing from the scope of the present invention. Those with skill in the chemical, mechanical, electro-mechanical, electrical, and computer arts will readily appreciate that the present invention may be implemented in a very wide variety of embodiments. This application is intended to cover any adaptations or variations of the preferred embodiments discussed herein. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof.
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An apparatus for controlling the position of a screen pointer for an electronic device having a display screen includes a light source for illuminating an imaging surface, thereby generating reflected images. The apparatus includes a motion transducer. A lens receives the reflected images and directs the reflected images onto the motion transducer. The motion transducer includes an electronic shutter for controlling the amount of time that light is collected for image frames. The motion transducer is configured to generate digital representations of the reflected images. The motion transducer is configured to generate movement data based on the digital representations of the reflected images. The movement data is indicative of relative motion between the imaging surface and the motion transducer. A controller coupled to the light source turns the light source on only during the time that light is being collected for an image frame.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a corner waveguide-integrated electric circuit case, a waveguide/strip line converter, a circuit serving both as an oscillator and a mixer (hereafter referred to as an oscillator mixer), a circuit serving both as a multiplier and a mixer (a multiplier mixer), and an arrangement of a frequency-modulated continuous-wave (hereafter, FM-CW) radar. In particular, this invention is concerned with a corner waveguide-integrated electric circuit case and a waveguide/strip line converter, which are preferred as structures for connecting between antennas and a sensor unit in an FM-CW radar, an oscillator mixer and a multiplier mixer, which are preferred as circuits for a sensor unit in an FM-CW radar, and a new arrangement of an FM-CW radar.
2. Description of the Related Art
An FM-CW radar transmits an electric wave that is frequency-modulated by a triangular wave to an object via a transmission antenna, receives an electric wave reflected from the object via a reception antenna, generates a beat signal by mixing the received wave with the transmission wave in a mixer, and then analyzes the frequency of the beat signal in order to measure a relative distance and a relative velocity with respect to the object simultaneously. The FM-CW radar is mounted on the outer surface of an automobile, helicopter, or other vehicle because of its purpose of use. The FM-CW radar is, therefore, requested to be compact in terms of appearance and ease of installation. A millimeter wave band is usually used as the output frequency. Therefore, if a large number of circuit components is required, many expensive millimeter wave devices are employed, and an increase in cost ensues.
In an on-vehicle FM-CW radar, both a transmission antenna and a reception antenna are composed of a waveguide in which holes through which electromagnetic waves leak out or invade are bored at specified intervals, and a parabolic reflector lying behind the waveguide. The transmission and reception waveguides are stood up in a V-shaped form so that wave fronts from the waveguides cross. A sensor unit containing the circuits of a transmitter and a receiver is placed below the antennas. The whole radar section including the transmission and reception antennas and the sensor unit is shaped like a letter Y.
The radar is mounted on a front grille. The size, or especially, height of the radar must be as small as possible in terms of limited installation space and appearance.
As an attempt to cope with this demand, a bent waveguide or a corner waveguide is used. Specifically, a waveguide linked with the sensor unit is positioned horizontally in order to reduce the height of a radar.
This structure requires a bent waveguide or a corner waveguide, which poses the first problem that the number of parts increases and the height can be reduced only on a limited basis.
As described previously, each of the transmission and reception antennas is connected to a sensor unit via a hollow waveguide. The circuitry in the sensor unit is constituted by a microstrip lines made up of a dielectric board, a grounded conductor formed on the bottom of the dielectric board, and strip lines formed on the top of the dielectric board. At a junction between the transmission or reception antenna and the sensor unit, therefore, a waveguide/strip line converter must be provided to convert the transmission mode between the hollow waveguide and the strip line.
The waveguide/strip line converter usually has such a structure that a strip line board, which is realized with a dielectric board having a grounded conductor on part of its back and strip lines on its surface, projects into a hollow determined by the inner wall of a hollow waveguide from a side opening in a stationary fashion. The strip line board is secured by attaching the entire grounded conductor to the inner wall of the side opening of the hollow using conductive adhesive or solder.
When an equipment in which the waveguide/strip line converter having the aforementioned structure is incorporated is manufactured according to a mass production system, some products may be provided with excessive conductive adhesive or solder which will ooze out duly. In addition, although a strip line board must be fixed at a precise position, the above structure may cause a variation in the length of a projecting portion among products.
The shape of the line pattern in the projecting portion of a waveguide/strip line converter is designed to provide a maximum conversion characteristic (VSWR) for a product that has no oozing of conductive adhesive and is aligned precisely. If conductive adhesive oozes out or a fixing position deviates, the VSWR (voltage standing wave ratio) deteriorates. This results in the second problem that a desired conversion characteristic is unavailable.
In a basic configuration of an FM-CW radar, a sensor unit consists of a voltage-controlled oscillator, a directional coupler, and a mixer. The voltage-controlled oscillator inputs a modulating signal of a triangular wave, and outputs a millimeter wave signal that is frequency-modulated by a triangular wave. The millimeter wave signal is transmitted to a transmission antenna. Part of the millimeter wave signal is branched by the directional coupler, and mixed with a received millimeter wave signal coming from a reception antenna by the mixer. A baseband signal whose frequency corresponds to a difference in frequency between the transmitted wave and received wave is then fetched. A device used for a millimeter wave oscillator is, generally, expensive. Alternatively, the voltage-controlled oscillator generates a frequency-modulated signal whose frequency is a divisor of the transmission frequency, and then a multiplier multiplies the frequency-modulated signal.
The voltage-controlled oscillator, mixer, and multiplier have been constructed independently using different active elements. This poses the third problem that a sensor unit must be realized as a large circuitry made up of numerous expensive millimeter wave devices.
When two systems of FM-CW radars each having the aforesaid configuration are mounted on a vehicle, one of the FM-CW radars uses transmission and reception antennas, which are installed on the front frame of the vehicle, to measure a relative distance and a relative speed with respect to a vehicle running ahead, while the other FM-CW radar uses a transmission antenna placed to face the oblique forward ground and a reception antenna which is installed so as to receive part of electric waves reflected irregularly from the ground, to perform almost the same processing as one FM-CW radar. This permits measurement of a speed of a vehicle as well as a relative speed. If the speed of a vehicle can be measured, an absolute speed of a vehicle running ahead can be calculated and displayed, and, in conjunction with a measured value of a rotating speed of a wheel, a slip occurring on a tire can be detected and the degree of the slip can be measured. Thus, the range of use of an FM-CW radar further expands.
An FM-CW radar having the aforesaid configuration has a characteristic that the output signal of a voltage-controlled oscillator is changed not only in frequency but also in amplitude relative to a variation in amplitude of a control signal. Therefore, an amplitude-modulated (hereafter, AM) component whose frequency is the same as the frequency of a modulating signal (FM-AM conversion noise) is superimposed on the output signal. This frequency is very close to the frequency of a signal resulting from FM detection of a reflected signal. As a result, the signal-to-noise ratio deteriorates. A switching radar has been proposed as a solution to the above problem.
The switching radar comprises a rectangular wave generator that generates a rectangular wave whose frequency is sufficiently lower than the frequency of a carrier and at least twice as large as a frequency corresponding to a sum or difference between beat frequencies generated by a mixer, and a switch that is driven with the rectangular wave and outputs a frequency-modulated wave as a signal whose amplitude is modulated with an on/off signal. When the rectangular wave signal is mixed with an output of the mixer, the FM-AM conversion noise occurring in the voltage-controlled oscillator is eliminated effectively. Consequently, a signal with a high signal-to-noise ratio results.
As described previously, two systems of electric circuits are needed to enable measurement of a speed of a vehicle. This contradicts a demand for downsizing and price cutting. As for the switching radar, it does not effectively utilize power when switched off.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a corner waveguide-integrated electric circuit case permitting further downsizing and price cutting of an FM-CW radar.
Another object of the present invention is to provide a waveguide/strip line converter that makes it possible to reduce influence of the oozing of conducting adhesive (solder) resulting in deteriorated characteristics and is preferable for an FM-CW radar.
Another object of the present invention is to provide a waveguide/strip line converter that makes it easy to align a stripline board with a waveguide and is preferable for an FM-CW radar.
Another object of the present invention is to provide an oscillator mixer and a multiplier mixer each of which is realized by a millimeter wave device having two or more functions and contributes to materialization of a compact and low-price FM-CW radar.
Another object of the present invention is to provide a compact and low-price radar capable of measuring not only a relative distance and a relative speed with respect to an object but also an absolute self-speed.
Another object of the present invention is to provide a radar capable of effectively eliminating FM-AM conversion noise and utilizing power in a switching radar placed in the off state.
In accordance with the present invention, there is provided a corner waveguide-integrated electric circuit case, comprising:
a first conductor member including a first outer surface having a board mounting section on which an electric circuit board is mounted, a second outer surface opposed to the first outer surface, and an inner surface determining a first elongated space that penetrates from the first outer surface to the second outer surface;
a second conductor member including a third outer surface that is in close contact with the second outer surface of the first conductor member, the third outer surface having a linear groove that determines a second elongated space extending from one end of the first elongated space in the direction crossing the first elongated space together with the corresponding portion of the second outer surface; and
a third conductor member attached to the first conductor member so as to shield the electric circuit board mounted on the board mounting section of the first outer surface;
the inner surface, the linear groove, and the corresponding portion of the second outer surface making up an inner wall of a corner waveguide that is coupled with electric circuits formed on the electric circuit board.
In accordance with the present invention, there is also provided a waveguide/strip line converter, comprising:
a hollow waveguide having a side opening;
a strip line board including a dielectric board, a grounded conductor formed on one surface of the dielectric board, and a line conductor formed on the other surface of the dielectric board, the grounded conductor being fixed to an inner wall of the side opening so that an end of the line conductor projects into the hollow of the hollow waveguide; and
an anti-oozing means for eliminating influence of an excessively oozing portion of conductive adhesive that attaches and electrically connects the grounded conductor to the inner wall of the side opening.
In accordance with the present invention, there is also provided a waveguide/strip line converter, comprising:
a hollow waveguide having a side opening;
a strip line board including a dielectric board, a grounded conductor formed on one surface of the dielectric board, and a line conductor formed on the other surface of the dielectric board, the grounded conductor being fixed to an inner wall of the side opening so that an end of the line conductor projects into the hollow of the hollow waveguide; and
projection length restricting means for restricting a length of a projecting portion of the line conductor into the hollow of the hollow waveguide.
In accordance with the present invention, there is also provided an oscillator mixer for providing an output signal having a specified frequency modulated in accordance with a modulating signal and for outputting a baseband signal having a frequency corresponding to a difference in frequency between an input signal and the output signal, comprising:
a voltage-controlled oscillator including an element having a non-linear characteristic, and providing an output signal having the specified frequency which varies in accordance with the voltage of the modulating signal;
a coupling member inserted into the voltage-controlled oscillator so as to couple the input signal with a line on which the output signal resides; and
a baseband signal output port connected to the voltage-controlled oscillator via a member for blocking a signal having the specified frequency and through which the baseband signal is fetched.
In accordance with the present invention, there is also provided a multiplier mixer for providing an output signal obtained by multiplying a first input signal, and for outputting a baseband signal whose frequency corresponds to a difference in frequency between a second input signal and the output signal, comprising:
a multiplier including an element having a non-linear characteristic, inputting the first input signal, and outputting a multiplied signal as the output signal;
a coupling member inserted in the multiplier so as to couple the second input signal with a line on which the output signal resides; and
a baseband signal output port connected to the multiplier via a member for blocking a signal having the same frequency as the output signal and through which the baseband signal is fetched.
In accordance with the present invention, there is provided a radar, comprising:
a modulating circuit for generating a frequency modulated transmission wave;
a first transmission antenna for transmitting the transmission wave-generated by the modulating circuit toward a first object in a first direction;
a second transmission antenna for transmitting the transmission wave generated by the modulating circuit toward a second object in a second direction different from the first direction;
a switching circuit for supplying the transmission wave generated by the modulating circuit selectively to the first transmission antenna or the second transmission antenna;
a first reception antenna for receiving a wave reflected from the first object;
a second reception antenna for receiving a wave reflected from the second object;
a demodulating circuit for generating a demodulated signal by demodulating a wave received with the first and second reception antenna; and
a signal processing circuit for calculating a relative distance and a relative speed with respect to the first object, and a relative speed with respect to the second object, from the demodulation signal.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a front view of a radar section of an FM-CW radar according to an embodiment of the present invention;
FIG. 1B is a cross-sectional view of the radar section of the FM-CW radar;
FIG. 2 is an enlarged cross-sectional view of the radar section of the FM-CW radar;
FIG. 3A is a front view of a radar section of an FM-CW radar according to another embodiment of the present invention;
FIG. 3B is a cross-sectional view of the radar section of the FM-CW radar;
FIG. 4A is a transverse sectional view of a conventional waveguide/strip line converter;
FIG. 4B is a longitudinal sectional view of the conventional waveguide/strip line converter;
FIG. 5 is a longitudinal sectional view of a waveguide/strip line converter according to another embodiment of the present invention;
FIG. 6 is a longitudinal sectional view of a waveguide/strip line converter according to another embodiment of the present invention;
FIG. 7 is a longitudinal sectional view of a waveguide/strip line converter according to another embodiment of the present invention;
FIG. 8A is a transverse sectional view of a waveguide/strip line converter according to another embodiment of the present invention;
FIG. 8B is a longitudinal sectional view of the waveguide/strip line converter of FIG. 8A;
FIG. 9A is a transverse sectional view of a waveguide/strip line converter according to another embodiment of the present invention;
FIG. 9B is a longitudinal sectional view of the waveguide/strip line converter of FIG. 9A;
FIG. 10A is a transverse sectional view of a waveguide/strip line converter according to another embodiment of the present invention;
FIG. 10B is a longitudinal sectional view of the waveguide/strip line converter of FIG. 10A;
FIG. 11A is a transverse sectional view of a waveguide/strip line converter according to another embodiment of the present invention;
FIG. 11B is a longitudinal sectional view of the waveguide/strip line converter of FIG. 11A;
FIGS. 12 and 13 are cross-sectional views explaining a ditch machined in a corner of a stopper in FIGS. 9A and 9B or a recess in FIGS. 10A and 10B;
FIG. 14 is a block diagram showing a basic circuitry of a sensor unit for an FM-CW radar;
FIG. 15 is a circuit diagram showing an example of a conventional voltage-controlled oscillator;
FIG. 16 is a circuit diagram showing an example of a conventional mixer;
FIG. 17 is a block diagram showing a basic circuitry of a sensor unit using a multiplier;
FIG. 18 is a circuit diagram showing an example of a conventional multiplier;
FIG. 19 is a circuit diagram showing an oscillator mixer according to another embodiment of the present invention;
FIG. 20 is a circuit diagram showing another example of the oscillator mixer according to another embodiment of the present invention;
FIG. 21 is a circuit diagram showing another example of the oscillator mixer according to another embodiment of the present invention;
FIG. 22 is a circuit diagram showing another example of the oscillator mixer according to another embodiment of the present invention;
FIG. 23 is a circuit diagram showing an example of a multiplier mixer according to another embodiment of the present invention;
FIG. 24 is a circuit diagram showing another example of the multiplier mixer according to another embodiment of present invention;
FIG. 25 is a block diagram showing a basic configuration of an FM-CW radar;
FIG. 26 is a diagram showing two systems of FM-CW radars for detecting absolute speeds of vehicles;
FIG. 27 is a block diagram showing a configuration of a conventional switching radar;
FIG. 28 is a block diagram showing an FM-CW radar system according to another embodiment of the present invention;
FIG. 29 is a block diagram showing an FM-CW radar system according to another embodiment of the present invention;
FIG. 30 is a block diagram showing an FM-CW radar system according to another embodiment of the present invention;
FIG. 31 is a block diagram showing an FM-CW radar system according to another embodiment of the present invention;
FIG. 32 is a block diagram showing an FM-CW radar system according to another embodiment of the present invention; and
FIG. 33 is a block diagram showing an FM-CW radar system according to another embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1A and 1B show a radar section of an on-vehicle FM-CW radar according to an embodiment of the present invention. FIG. 1A is a front view, while FIG. 1B is an X-X cross-sectional diagram. FIG. 2 is an enlarged view of a portion indicated with Y in FIG. 1B. Referring to FIGS. 1A and 1B, and 2, a construction of the first embodiment of the present invention will be described.
A sensor unit 10 contains electric circuits: such as, a transmitter that transmits an fm modulating wave, and a receiver that receives a wave reflected from an object, detects the wave by performing homodyne reception, and sends a baseband signal to a signal processor which is not shown. A waveguide 12, in which holes for leaking out electromagnetic waves are bored at regular intervals, and a parabolic reflector 16 provided on the surface of a radar housing 14 make up a parabolic reflector antenna using the waveguide 12 as a linear wave source. A reception parabolic reflector antenna is composed of a waveguide 18 and a parabolic reflector 20.
A metallic member 24 has a through hole 26 that fits the cross section of the waveguide 12. A corner waveguide is made up of the through hole 26 and a linear groove 30 that is dug in a metallic member 28 and fits the cross actin of the waveguide 12. The waveguide 12 is connected to the corner waveguide via a flange 11. The other end of the corner waveguide is terminated with a metallic member 32. Part of a circuit board 34 mounted on the metallic member 24 is projecting into the terminal portion of the corner waveguide. The terminal portion forms a waveguide/strip line converter in cooperation with a strip line on the circuit board 34. The striplines on the circuit board 34 provide electric circuits such as a modulator and a demodulator. A metallic member 36 protects and shields the electric circuits entirely. In short, the corner waveguide is integrated with a metallic case made up of the metallic members 24, 28 and 36.
The metallic member 24 extends upward. The parabolic reflector 16 is formed on the surface of the metallic member 24. That is to say, the radar housing 14 and the case of the sensor unit 10 are integrated. This structure realizes downsizing and price cutting.
FIGS. 3A and 3B show another embodiment of the present invention. In this embodiment, the circuit board 34 is mounted on the back of the parabolic reflector 16. This structure realizes further downsizing. The reflector 16 also plays a role of a heat sinking plate for the circuit board 34.
This structure of the present invention is not limited to an FM-CW radar, but, needless to say, can apply to a general device that requires a bent waveguide or a corner waveguide, and a case containing electric circuits connected to the waveguide.
In FIG. 1B or 3B, the waveguide/strip line converter is formed at the terminal portion of the waveguide formed with the through hole 26 bored on the metallic member 24. FIGS. 4A and 4B show a structure of a conventional waveguide/strip line converter. FIG. 4A is a cross-sectional diagram, viewing the structure along the axis of a waveguide. FIG. 4B is a cross-sectional diagram, viewing the structure from the side of the waveguide. As illustrated, the waveguide/strip line converter usually has a structure that a strip line board 48 realized with a dielectric board 42 having a grounded conductor 44 on part of the back thereof and a strip line 46 on the surface thereof is projecting from a side opening into a hollow 40 determined by the inner wall of a hollow waveguide in a stationary fashion. The strip line board 48 is secured by attaching the entire grounded conductor 44 to the inner wall of the side opening 50 of the hollow 40 using conductive adhesive or solder.
When an equipment in which a waveguide/strip line converter having the above structure is incorporated is manufactured according to a mass production system, some products may be provided with excessive conductive adhesive or solder. The excessive conductive adhesive or solder then may ooze out (52) as shown in FIG. 4B. In addition, although the strip line board 48 must be fixed at a precise position, the above structure may cause a variation in length of the projecting section among products.
FIG. 5 is a cross-sectional diagram showing another embodiment of the present invention, which corresponds to FIG. 4B. In this embodiment, a groove 54 is dug in the inner wall of the opening 50 in the vicinity of the hollow 40. A majority of excessive conductive adhesive (solder) oozes out to the groove 54. A quantity of conductive adhesive oozing out to the hollow 40 is reduced. Therefore, even if excessive conductive adhesive (solder) is used, the conversion characteristic does not deteriorate very much.
FIG. 6 shows another embodiment of the present invention. The groove 54 joins the hollow 40. In FIG. 6, even if excessive conductive adhesive (solder) is used and partly oozes out, the oozing area is located outside the hollow 40 and below the grounded conductor 44. Therefore, influence of oozy adhesive on the conversion characteristic is limited.
FIG. 7 shows another embodiment of the present invention. In this embodiment, the grounded conductor 44 is installed so as to partly project into the hollow 40. The shape of, for example, the strip lines 46 is designed to provide an optimal conversion characteristic for the above structure. Even if excessive conductive adhesive (solder) oozes out to the hollow 40, since the oozing area is located below the grounded conductor 44, influence on the conversion characteristic is limited.
FIGS. 8A and 8B show another embodiment of the present invention, which correspond to FIGS. 4A and 4B. In this embodiment, for precise alignment of the line conductor 46, the dielectric board 42 is long enough to abut on the wall of the waveguide. Precise alignment is achieved by abutting the end of the dielectric board 42 on the wall.
FIGS. 9A and 9B show another embodiment of the present invention. In this embodiment, the other end of the dielectric board 42 is abutted on a stopper 56 for alignment.
FIGS. 10A and 10B show another embodiment of the present invention. This embodiment is based on the embodiment described in conjunction with FIGS. 8A and 8B. A recess 58 is formed on the wall of the waveguide, which receives and supports the distal end of the dielectric board 42. The recess 58 also permits alignment of the dielectric board 42. This structure supports the dielectric board 42 in a stable manner. When multiple adjustment patterns 70 are formed as shown in FIGS. 11A and 11B, for example, thermo-compression bonding can be performed for adjustment after assembling; that is, a gold ribbon can be attached to a gap between the adjustment patterns 70.
The stopper 56 in FIGS. 9A and 9B, or the recess 58 in FIGS. 10A and 10B must have a corner for receiving the corner of the dielectric board 42. For this purpose, machining is performed. The machining, however, tends to create a round as shown in FIG. 12. This makes it impossible for the end 62 of the dielectric board 42 to abut on the wall perfectly. When a ditch 64 is dug as shown in FIG. 13, the above problem is solved. The ditch 64 also serves as a receptor of conducting adhesive (solder).
FIG. 14 shows a basic circuitry of a sensor unit 10 (FIGS. 1A and 1B) for an FM-CW radar.
In FIG. 14, on receipt of a modulating signal, a voltage-controlled oscillator 70 generates a frequency-modulated wave. The frequency-modulated wave is transmitted to an object via a transmission antenna. For an FM-CW radar, a millimeter wave with a frequency of, for example, 60 gigahertz is employed. A triangular wave is used as the modulating signal. A signal reflected from the object and received with a reception antenna is mixed in a mixer 72 with part of a transmission signal that is separated in a directional coupler 74. Then, a baseband signal having a frequency corresponding to a difference in frequency between the transmitted wave and received wave is fetched. Based on the frequency of the baseband signal, a relative distance and a relative speed with respect to the object are calculated.
FIG. 15 is a circuit diagram showing an example of a conventional voltage-controlled oscillator 70 operating in a millimeter wave frequency band. A strip line resonator 77 is connected to a gate of a field-effect transistor (hereafter, FET) 76 that is a gallium arsenide (GaAs) FET or a heterojunction FET. A variable-capacitance diode 78 is connected in parallel with the strip line resonator 77. A modulating signal is applied to the variable-capacitance diode 78 through an inductive element 79 via a modulation terminal. The drain terminal of the FET 76 has a stub 80. The stub 80 controls the size of reflected power indicated with an arrow X at the right of a dot-dash line in FIG. 15. By adjusting the length of the stub 80 and the distance of the stub 80 from the drain terminal of the FET, the reflected power indicated with the arrow X is controlled to become larger than the power loss in the resonator 77 for a 60-gigahertz signal. This allows the resonator 77 to continue stable oscillation at a resonance frequency.
The source terminal of the FET 76 is grounded. A dc bias is supplied from a power supply -Vcc to the gate and drain terminals of the FET 76 via resistors 84 and 86. Stubs 81 and 82 are installed to have a distance μg/4 from the gate and drain terminals of the FET 76 respectively and have a length μg/4 at a frequency of 60 gigahertz. The stubs 81 and 82 serve as band-rejected filters. In other words, since stubs are installed at the above distance and with the above length, when a frequency is 60 gigahertz, seen from the FET 76 side, the gate and drain terminals are seen to be open, the roots of the stubs are seen to be short-circuited, and the tips of the stubs are seen to be open. Thus, the power supply is separated from the oscillation circuit of respect to the signal of 60 gigahertz.
In the voltage-controlled oscillator having the circuitry shown in FIG. 15, when a triangular wave is applied via the modulation terminal on the left of FIG. 15, a frequency-modulated triangular wave signal of 60 gigahertz is generated.
FIG. 16 shows an example of a conventional mixer 72 operating in a millimeter wave frequency band. A local oscillator signal LO and a radio-frequency signal (RF) are added in a hybrid 88, and then applied to a gate terminal of a FET 90. A source terminal of the FET 90 is grounded. Due to the non-linear characteristic of an FET, an intermediate-frequency signal whose frequency corresponds to a difference in frequency between two signals develops at the drain terminal. Stubs 92 and 94 of the input and output terminals perform impedance matching on the input and output signals, thus maximizing the power transfer efficiency. Direct-current power supplies 96 and 98 provide the gate and drain terminals with specified negative and positive dc biases. Stubs 100 and 102 are, as described above, provided to separate the power supplies.
In general, devices employed for a millimeter wave oscillator are expensive. Alternatively, a frequency-modulated signal whose frequency corresponds to a divisor of the transmission frequency may be generated, and multiplied for use. FIG. 17 show a basic circuitry for materializing this procedure. In FIG. 17, a voltage-controlled oscillator 104 operating at 30 gigahertz generates a frequency-modulated signal, and the frequency-modulated signal is multiplied by a multiplier 106. Thus, a signal with 60 gigahertz is produced.
FIG. 18 is a circuit diagram showing an example of a conventional multiplier 106. A 30-gigahertz signal is applied to a gate terminal of an FET 108. A source terminal of the FET 108 is grounded, and in a drain terminal thereof harmonics that are derived from a 30 gigahertz input signal and that include a 60-gigahertz signal are obtained. The harmonics pass through a bandpass filter 110 that is made up of strip lines and is designed to pass 60-gigahertz components, thus producing a 60-gigahertz doubled signal. A stub 112 performs impedance matching on an input signal. The gate and drain terminals of the FET are provided with negative and positive bias voltages from dc power supplies 114 and 116. A stub 118 separates the power supply with respect to 30-gigahertz in an input side, while a stub 120 separates the power supply with respect to 60-gigahertz in an output side.
To realize the sensor unit 10 for an FM-CW radar having the basic configuration shown in FIG. 14, an oscillator circuit having the circuitry shown in FIG. 15 and a mixer having the circuitry shown in FIG. 16 must be employed according to the aforesaid prior art. To realize an FM-CW radar having the basic configuration shown in FIG. 17, an multiplier shown in FIG. 18 and a mixer shown in FIG. 16 must be employed. In either case, a large-scale circuitry made up of expensive millimeter wave devices ensues.
FIG. 19 is a circuit diagram showing an oscillator mixer according to another embodiment of the present invention.
An FET 76 that is a GaAs FET or a heterojunction FET, a resonator 77, a variable-capacitance diode 78, an inductive element 79, stubs 80, 81, and 82, and resistors 84 and 86 constitute a voltage-controlled oscillator described in conjunction with FIG. 15. Specifically, a signal whose frequency is the same as the resonance frequency of the resonator 77 is output as a signal transmitted by the radar. When a modulating signal is applied to one end of the inductive element 79, a frequency-modulated signal is output.
A signal reflected from an object and received with a reception antenna is coupled with the gate terminal of the FET 76 by a directional coupler 122. Due to the non-linear characteristic of the FET 76, a signal whose frequency corresponds to a difference in frequency between the transmitted and received signals develops at a drain terminal (and a gate terminal) of the FET 76. The signal is fetched as a baseband signal via the stub 82 for blocking transmitted and received signals. The resistor 86 has an impedance that is high enough to block a signal having the same frequency as the baseband signal. The baseband signal is, therefore, separated from the power supply by the resistor 86.
FIG. 20 is a circuit diagram showing another example of an oscillator mixer of the present invention. As shown in FIG. 20, a received signal can be coupled with a drain of the FET 76 via a directional coupler 124. The baseband signal can be fetched at the gate terminal of the FET 76. In this case, the impedance of the resistor 84 separates the baseband signal from the power supply.
FIG. 21 shows another example of an oscillator mixer of the present invention. In FIG. 21, since an FET capable of directly oscillating a signal in a millimeter wave frequency band or with a frequency of 60 gigahertz is expensive, the signal is oscillated with a frequency that is a divisor of an intended frequency, and then a harmonic is fetched using a highpass filter. Thus, this oscillator mixer shown in FIG. 21 is based on an oscillator multiplication technique.
Assuming that the intended frequency is 60 gigahertz, the resonance frequency of a strip line resonator 126 is half of the intended frequency; that is, 30 gigahertz. An FET 128 forms a 30-gigahertz oscillator. The stubs 81 and 82 function as band-reject filters that do not pass 60-gigahertz. Stubs 130 and 132 function as band-reject filters that do not pass 30 gigahertz. The bends of the stubs 130 and 132 have no significant meanings. The output of the oscillator passes through a waveguide-stripline converter 134 and goes to a 60-gigahertz waveguide 136. That is to say, although the waveguide 136 is originally designed to guide a signal to a transmission antenna, the waveguide 136 also functions as a broadband filter for blocking a 30-gigahertz signal and extracting only a 60-gigahertz signal.
A directional coupler 122 for coupling a received signal may be connected to the gate terminal of the FET 128 as shown in FIG. 21, or to the drain terminal of the FET 128 similarly to those in FIGS. 19 and 20. The baseband signal may be fetched from a port connected to the drain terminal as shown in FIG. 21, or from a port connected to the gate terminal as shown in FIG. 20.
FIG. 22 shows an example using a gunn diode as a non-linear element for use in oscillation and mixing. A bias circuit for supplying bias voltage to a gunn diode 138 is composed of a dc power supply 140, an inductive element 142, a resistor 144, and a capacitor 146. A modulating signal is superimposed on the voltage of the dc power supply 140, thus producing a frequency-modulated signal. A stub 148 is used to separate the gunn diode 138 from the bias circuit at an oscillator frequency.
A received signal is coupled with a transmitted signal by a directional coupler 150. A baseband signal is fetched via a stub 148.
FIG. 23 is a circuit diagram showing an example of a multiplier mixer according to the present invention.
An FET 108, stubs 112, 118 and 120, bias power supplies 114 and 116, and a bandpass filter 110 make up a multiplier described in conjunction with FIG. 18.
A received signal is added to a 30-gigahertz frequency-modulated signal by a hybrid 152, and fed to a gate terminal of the FET 108 after passing through the stub 112.
Due to the non-linear characteristic of the FET 108, a baseband signal developed at the drain terminal is fetched via the stub 120. A choke coil 154 is designed to separate the baseband signal from the power supply 116.
The received signal may be coupled with the gate or drain terminal of the FET 108 using a directional coupler as described in conjunction with FIGS. 19 and 20. As described in FIG. 21, the bandpass filter 110 may not be installed but the waveguide may substitute for the function of the bandpass filter 110.
FIG. 24 is a circuit diagram showing another example of a multiplier mixer of the present invention. The multiplier mixer is based on a multiplier using the non-linear characteristic of a Schottky diode.
The Schottky diode-based multiplier is composed of a Schottky diode 156, a bandpass filter 158, stubs 160 and 162, and a resistor 164. A received signal is added to a 30-gigahertz frequency-modulated signal by a hybrid 166 and supplied to an anode of the Schottky diode 156. A bias for the Schottky diode is a self-bias occurring across the resistor 164 due to a dc voltage drop in a signal. A baseband signal is fetched from a port between the stub 162 and resistor 164.
FIG. 25 shows a basic configuration of an entire FM-CW radar. A triangular wave generated by a triangular wave generator 170 is fed to a voltage-controlled oscillator 172, and transmitted as a triangular-wave frequency-modulated transmission wave via a transmission antenna 174. An electric wave reflected from an object is received via a reception antenna 176, and mixed in a mixer 178 with part of the transmission wave separated in a directional coupler 180. This results in a beat signal. Spectrum analysis is performed to measure the frequency of the beat signal, whereby a relative distance and a relative speed with respect to an object are calculated simultaneously.
As shown in FIG. 26, two systems of FM-CW radars 182 and 184 each having the aforesaid configuration are installed in a vehicle 186. The FM-CW radar 182 uses a transmission antenna 196 and a reception antenna 198 mounted on the front frame of the vehicle to measure a relative distance and a relative speed with respect to a vehicle running ahead. The FM-CW radar 184 uses a transmission antenna 200 facing the oblique forward ground and a reception antenna 202 placed to receive part of electric waves irregularly reflected from the ground 204, which perform almost the same procedure as the FM-CW radar 182 in order to measure the speed of an own vehicle. If the speed of an own vehicle can be measured, the absolute speed of the vehicle running ahead can also be calculated and displayed. If these data are analyzed in conjunction with a measured value of a rotating speed of a wheel, a slip occurring on the tire of the wheel can be detected and the degree of the slip can be measured. Thus, the range of use of the FM-CW radar expands.
FIG. 27 shows a configuration of a conventional switching radar. In FIG. 27, a rectangular wave generator 188 generates a rectangular wave whose frequency is sufficiently lower than that of a carrier and is at least twice as large as a frequency corresponding to a difference or sum between beat frequencies generated by the mixer 178 in FIG. 25. A switch 190 is driven with the rectangular wave and amplitude-modulates the frequency-modulated wave with an on/off signal. A bandpass filter 192 is characteristic of passing only those components having the same frequency as the rectangular wave. The passed signal is mixed with a rectangular wave signal by the mixer 194. This configuration efficiently eliminates an FM-AM conversion noise occurring in the voltage-controlled oscillator 172 and provides a signal with a high signal-to-noise ratio.
However, the configuration shown in FIG. 26 requires two systems of electric circuits in order to enable measurement of the speed of a vehicle to which the radar is attached and contradicts a demand for downsizing and price cutting. The switching radar shown in FIG. 27 does not effectively utilize power when switched off.
FIG. 28 shows another embodiment of the present invention. In FIG. 28 and subsequent FIGS. 29 to 33, components identical to those in FIGS. 25 to 27 will bear the same numerals, and the description will be omitted.
A switch 204 can be manipulated to select either a transmission antenna oriented ahead of a vehicle or a transmission antenna 200 oriented to the oblique forward road surface.
When the switch 204 has selected the transmission antenna 196, a transmission signal sent from a directional coupler 180 is supplied to the antenna 196. Part of an electric wave that has emerged from the antenna 196 and been reflected from a vehicle running ahead is received via a reception antenna 198, and supplied to a mixer 178 via a hybrid 208. The distance and speed calculated by a signal processing circuit at this time are a relative distance and a relative speed with respect to the vehicle running ahead.
When the switch 204 has selected the transmission antenna 200, a transmission signal sent from the directional coupler is supplied to the antenna 200. Part of an electric wave that has emerged from the antenna 200 and been reflected irregularly from the oblique forward road surface is received by a reception antenna 202, and fed to the mixer 178 via the hybrid 208. The speed calculated by the signal processing circuit corresponds to the speed of the vehicle to which the radar is attached. The calculated speed is, however, a speed component in the direction in which an electric wave is transmitted. The speed value must, therefore, be corrected from this viewpoint.
FIG. 29 shows another embodiment of the present invention. A switching circuit 206 is driven with a rectangular wave signal supplied by a rectangular wave signal generator 210, and selects an antenna 196 or an antenna 200 according to the level of the rectangular signal. The rectangular wave signal is also supplied to a signal processing circuit. Synchronously with the signal, the signal processing circuit calculates a relative distance and a relative speed with respect to a forward vehicle, and the speed of the vehicle to which the radar is attached.
FIG. 30 shows another example of the present invention. A rectangular wave signal generator 188 is identical to that used in the switching radar described in conjunction with FIG. 27. A switching circuit 206 is driven with a rectangular wave generated by the rectangular wave signal generator 188. Two signals, each of which corresponds to a signal produced by modulating the amplitude of a frequency-modulated wave with a rectangular wave as used in the switching radar, are obtained in outputs of the switching circuit 206, and they are supplied to antennas 196 and 200.
A signal reflected from a forward vehicle and received with a reception antenna 198 is amplified by a low-noise amplifier 212, and supplied to a mixer 214. On the other hand, a signal reflected from the forward road surface and received with a reception antenna 202 is supplied to a mixer 216. Part of a transmission signal separated by a directional coupler 180 and distributed by a hybrid 218 is supplied to the other input terminals of the mixers 214 and 216. The mixers 214 and 216 function in the same way as the mixer 178 in FIGS. 25 and 27. Bandpass filters 220 and 222 pass, similarly to the bandpass filter 192 in FIG. 27, the components of outputs of the mixers 214 and 216 having the same frequency as the rectangular wave fed by the rectangular wave signal generator 188. Mixers 224 and 226 mix, similarly to the mixer 194 in FIG. 27, the signals passing through the bandpass filters 220 and 222 with the rectangular wave, and send the mixed signals to a signal processing circuit.
As described above, in the embodiment shown in FIG. 30, an output of the voltage-controlled oscillator 172 is used to generate a transmission signal for two systems of switching radars. Even when a rectangular wave signal is turned off, power is utilized effectively. The low-noise amplifier 212 is used to amplify a signal reflected from a forward vehicle. A signal reflected from a road surface and received with the antenna 202 is so intense that a low-noise amplifier need not be installed for this signal.
FIG. 31 shows another embodiment of the present invention. What differs from the embodiment in FIG. 30 is that the hybrid 58 is not used to distribute part of a transmission signal separated by the directional coupler 180 to two systems. A signal is fetched from a port of a directional coupler, which is connected to a dummy load in FIG. 27, and supplied to a system for measuring the speed of a vehicle to which the radar is attached. Although a quantity of leakage power to this port is small, since a power loss from the transmission antenna 200 to the reception antenna 202 is small, the quantity is sufficient.
FIG. 32 shows another embodiment of the present invention. What differs from the embodiment in FIG. 30 is that two antennas or the transmission and reception antennas 200 and 202 are replaced with a transmission/reception antenna 228. A hybrid 230 is used as a duplexer circuit. An antenna for detecting the speed of a vehicle to which the radar is attached is not required to have such an excellent orientation characteristic or sensitivity as an antenna for detecting a relative distance and a relative speed with respect to another vehicle. That is why the replacement is possible. This idea can apply to the embodiments shown in FIGS. 28, 29 and 31.
FIG. 33 shows another embodiment of the present invention. Instead of switching the switch 206 according to the level of a rectangular signal as is in the circuitry in FIG. 30, the center frequency of the voltage-controlled oscillator 172 is switched according to the level of the rectangular signal, and a branching circuit 232 is used to separate two signals having different center frequencies. This idea can apply to the circuits shown in FIGS. 28, 29, 31 and 32.
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In a structure adopted for an FM-CW radar, a corner waveguide for connecting each of transmission and reception antennas to a sensor unit is integrated with a sensor unit case. In a waveguide/strip line converter for converting the transmission mode between the waveguide and the strip lines in the circuits of the sensor unit, a ditch is dug in the inner wall of an opening of the waveguide in order to prevent oozing of conductive adhesive. The strip line board is abutted on the inner wall of the waveguide in order to restrict a length of a projecting portion of a line conductor on the strip line board. By employing an oscillator mixer or a multiplier mixer, the circuitry in the sensor unit can be simplified without using lots of expensive millimeter wave devices. Furthermore, power can be utilized effectively even when a switching radar is off, which enables measurement of an absolute speed. Moreover, cost reduction can be achieved.
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GOVERNMENT RIGHTS
The United States Government has acquired certain rights in the invention pursuant to Contract No. DTRA01-03-D-0018-0006 with the Defense Threat Reduction Agency.
RELATED APPLICATION
The present application is related to U.S. patent application Ser. No. 11/415,703, filed May 2, 2006, entitled “Method of Forming a Body-Tie” which is assigned to the assignee of the present invention and incorporated by reference herein, in its entirety.
FIELD OF THE INVENTION
The present invention relates to Field Effect Transistor (FET) fabrication processes, and more particularly, to a process flow providing direct contact to the body tie silicon.
BACKGROUND
One issue that FETs fabricated in a Silicon on Insulator (SOI) substrate may experience is a floating body effect. In such FETs, floating body effects are a result of having a body region that is electrically isolated from a bulk substrate. In order to supply a voltage potential to the body, and therefore mitigate floating body effects, an applied bias is often supplied from a body-contact to the body. When a body-contact receives an applied bias, which may be a ground or a positive or negative potential, it carries it to the body via a body tie. Often, the body-tie is formed in device layer silicon and runs beneath an oxide, and in general, the body tie allows the body region and the body-contact to be in remote locations in an SOI substrate.
Conventional SOI devices without body ties are susceptible to hysteresis and transient upset effects. Body tie contacts can help control the hysteresis and transient upset effects, but the layout density of current area efficient body tie fabrication process flows is limited by the n or p masking layer alignment and critical dimension control in order to contact the body tie. As such, a fabrication process flow that eliminates the critical alignment and dimension control requirements to improve the layout density, while mitigating body effects, is desired.
SUMMARY
In an exemplary embodiment, a process flow for fabricating a shallow trench isolation (STI) device with direct body tie contact is provided. The process flow follows steps similar to standard STI fabrication methods except that in one of the etching steps, an opening is etched through the nitride mask and STI oxide layer, directly to the body tie silicon. This adjustment in the process flow allows contacts to be directly landed on the body tie, thus addressing the issues related to floating body effects by providing a direct body contact that eliminates hysteresis and transient upset effects common in non body contact configurations, without the critical alignment requirements and critical dimension control of the layout as in previous body contact configurations.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial diagram illustrating a top view of the layout configuration with direct body tie contact, according to an embodiment of the present invention.
FIG. 2 a is a pictorial diagram of a cross-section cut through the top view of FIG. 1 , according to an embodiment of the present invention.
FIG. 2 b is a pictorial diagram of a cross-section cut through the top view of FIG. 1 during an n+ implant step, according to an embodiment of the present invention.
FIG. 3 is a flow diagram of an STI scheme, according to an embodiment of the present invention.
DETAILED DESCRIPTION
FIG. 1 is a pictorial diagram illustrating a top view of the layout configuration of a Shallow Trench Isolation (STI) device 100 . The STI device 100 comprises a buried oxide layer 102 , over which an n+ drain 106 , n+ source 108 and p+ tap 112 are formed with a body tie layer 104 in between. A gate 110 a,b is formed between the n+ drain 106 and n+ source 108 regions. Each of the n+ drain 106 , n+ source 108 , gate 110 and p+ tap 112 are accessed via contacts 114 , 116 , 118 , and 120 respectively.
Note that the layout configuration of the STI device 100 has a body contact in a separate active area 112 from the source and drain. Unless the body tie silicon 104 is electrically connected by the standard contact 120 through the p+ tap 112 or the direct body tie contact 122 , the STI device 100 may be susceptible to hysteresis and transient upset effects. However, a direct body tie contact 122 provides a direct connection to the body tie 104 eliminating the need for critical alignment and dimension control requirements in the n+/p+ lithography processes as well as the elimination of the p+ tap 112 feature. This improves the layout density while reducing the cost of the n+/p+ lithography steps.
FIG. 3 is a flow diagram of an STI scheme 300 , according to an embodiment of the present invention. The fabrication process flow of the STI device 100 begins with the step of providing an SOI wafer with a top silicon layer 302 , followed by the step of patterning the top silicon with a photoresist mask 304 . Once the hardmask is formed, two separate silicon etching steps 306 are performed to form the multi-tiered body tie 104 structure. After the structures are formed, the steps of oxide deposition 308 and oxide planarization 310 are performed, after which the forming of a gate oxide and polysilicon gate layer 312 step takes place. After the formation of the gate layer, doping levels of the n+ drain 106 and n+ source 108 are established 314 by a series of implants. This series of implants requires separate masks for n+ doping and p+ doping. After the establishment of the source and drain doping levels 314 , the formation of contacts 316 takes place. A drain contact 114 , a source contact 116 , a gate contact 118 and a p+ tap contact 120 are formed at the drain region 106 , the source 108 region, the gate region 110 and the p+ tap region 112 , respectively.
At this point, an additional step of etching through to the body tie silicon 318 is included. An opening is etched through the nitride etch-stop layer down to the body tie silicon 104 , after which a direct contact 122 to the body-tie 104 is formed 320 . This adjustment to the process flow removes the requirement that a body tie contact must occur in a normal active area, which is a feature that must be lithographically designated in the active area masking and etch steps, the n+ and p+ masking and doping steps, and the implantation step.
FIG. 2 a is a pictorial diagram of the cross-section cut through along the X-X′ plane of the STI device configuration shown in FIG. 1 . Buried oxide layer 202 isolates the device silicon areas 204 , 208 , 212 and 214 from the silicon substrate 201 . A deposited and subsequently CMP planarized oxide 206 comprises the STI oxide isolation. The n+ source 208 , p+ tap 212 and multi-tiered body tie 204 structures correspond to the n+ source 108 region, p+ tap 112 region, and body tie 104 region in FIG. 1 , respectively. The multi-tiered body tie structure 204 is formed by two separate silicon etches as described above. A layer of silicon 214 remains after the silicon etches. A nitride layer 210 provides a hard mask etch stop for potential subsequent processing steps and the STI oxide layer 206 blocks the n+ and p+ source and drain implants from doping the underlying body tie silicon layer 214 .
P+ contact 220 , n+ source contact 216 , and direct body tie contact 222 correspond to p+ tap contact 120 , n+ source contact 116 and direct body tie contact 122 in FIG. 1 , respectively. As shown, p+ tap contact 220 and n+ source contact 216 connects to the p+ tap 212 and n+ source 208 respectively by etching through the nitride layer 210 . The direct body tie contact 222 connects to the body tie 204 by etching through the nitride layer as well as the STI oxide layer. The direct body tie contact 222 is oriented vertically and of unitary construction. The interface of where the direct contact occurs is such that a least a portion of the direct body tie contact 222 overlays at least a portion of the body tie structure 204 . In an alternative embodiment, if the selectivity to the source, drain, or gate contact areas are not sufficient to etch to the body tie, then the body tie contact lithography etch can be done before the source, drain and gate contacts are formed.
In another alternative embodiment, the p+ tap feature can be eliminated in this direct body tie contact configuration, since it is no longer needed. Eliminating the p+ tap feature also eliminates the need for a photoresist mask feature at a minimum design rule distance from the n-channel transistor during the n+ implant. FIG. 2 b is a pictorial diagram of the cross-section cut through along the X-X′ plane of the STI device configuration shown in FIG. 1 , during an n+ implant step. For reference, the columns 220 ′, 216 ′, and 222 ′ are where contacts 220 , 216 and 222 will be formed in a later step, as shown in FIG. 2 a . The photoresist 224 is necessary when a p+ tap feature is implemented, but can be left out in this alternative embodiment. As such, eliminating the p+ tap feature can improve the density as well as reduce the lithography costs of the device.
Further, an additional lithography and implant step can be performed after the direct body tie contact has been formed to increase the doping in the direct body tie contact to reduce contact resistance. In this case, the direct body tie contact implants only go into the contact areas so n+ and p+ spacing requirements are still relaxed. Note that dopant activation to improve performance can optionally occur in a typical contact TiN liner anneal step. In view of the various embodiments of the present invention, the best case scenario requires no additional processing, and the worst case scenario requires one additional contact mask and etch step, and two reuses of well masks during two additional implants.
Although the presented method has been described with reference to an STI scheme in an SOI process, it may, however, be carried out at other points of an SOI process. The presented direct body-tie contact may be particularly advantageous in radiation hardened circuits. However, it is also contemplated that such a body-tie may also be used where appropriate in a non-radiation hardened circuit. It should be understood, therefore, that the illustrated examples are examples only and should not be taken as limiting the scope of the present invention. Also, the claims presented below should not be read as limited to the described order or elements unless stated to that effect. Therefore, all examples that come within the scope and spirit of the following claims and equivalents thereto are claimed as the invention.
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A process flow for fabricating shallow trench isolation (STI) devices with direct body tie contacts is provided. The process flow follows steps similar to standard STI fabrication methods except that in one of the etching steps, body tie contacts are etched through the nitride layer and STI oxide layer, directly to the body tie. This process flow provides a direct body tie contact to mitigate floating body effects but also eliminates hysteresis and transient upset effects common in non-direct body tie contact configurations, without the critical alignment requirements and critical dimension control of the layout.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a wireless tag system adapted to communications between a plurality of wireless tags (to be also referred to as IC tags hereinafter) and a read/write device and also to a wireless tag access control device, a wireless tag access control method, a wireless tag access control program and a tag that can be used for such a wireless tag system.
2. Description of Related Art
As a result of the rapid development of IC technologies in recent years, wireless tag systems using ICs have become very popular and are currently spreading very fast (see, inter alia, Patent Document 1: Jpn. Pat. Appln. Laid-Open Publication No. 2003-196360).
With such a wireless tag system, a plurality of wireless tags are attached to respective objects that have to be held under control so that any of the tags can be accessed by way of a read/write device in order to read information from and/or write information to it, thereby systematizing and facilitating the operation of controlling the objects of control.
When accessing a wireless tag (to be referred to simply as tag hereinafter), the read/write device firstly operates for an anti-collision process and acquires the unique IDs (to be referred to as UIDs hereinafter) of the tags of the system. Subsequently, it accesses the tag by using the acquired UID of the tag.
FIG. 21 of the accompanying drawings is a flow chart of the operation of the read/write device for an anti-collision process.
Referring to FIG. 21 , the read/write device firstly transmits a group select command to the tags and waits for acknowledgements from the tags (Step S 1 ). Then, it determines if it has properly received acknowledgements from the tags and acquired the UIDs of the tags (Step S 2 ). If it is determined that the read/write device has properly acquired the UIDs (Step S 2 , Yes), the device transmits a read command (READ) to the tags and receives an acknowledgement from the tags (Step S 3 ). Thereafter, the tags do not respond to any Fail command nor to any Success command from the read/write device.
Then, the read/write device determines if it has received acknowledgements consecutively for not less than a predetermined number of times (Step S 4 ). If it is determined that it has not received acknowledgements for a predetermined number of times (Step S 4 , Yes), the read/write device terminates the process. If, on the other hand, it is determined that it has received acknowledgements for the predetermined number of times (Step S 4 , No), the read/write device transmits a Success command and receives an acknowledgement from the tags (Step S 5 ).
On the other hand, if it is determined that the read/write device has not properly acquired the UIDs (Step S 2 , No), the read/write device determines if it has not received acknowledgements because there were collisions of acknowledgements from the tags (Step S 6 ). If, on the other hand, it is determined that the read/write device has received acknowledgements (Step S 6 , Yes), it transmits a Fail command to the tags and receives an acknowledgement from the tags (Step S 7 ).
If it is determined that the read/write device has not received acknowledgements because there were collisions of acknowledgements from the tags (Step S 6 , No), it determines if it has not received an acknowledgement from any of the tags or not (Step S 8 ). If it is determined that the read/write device has not received an acknowledgement from any of the tags (Step S 8 , No), it terminates the process. However, if the read/write device has received at least an acknowledgement (Step S 8 , Yes), it proceeds to the above described processing operation of Step S 4 and that of Step S 5 .
FIG. 22 of the accompanying drawings is a flow chart of the operation of a tag for an anti-collision process from the start of power supply.
Firstly, as power is supplied, the tag turns its mode of operation to a ready mode (Step S 21 ). Then, it determines if it has received a command from the read/write device (Step S 22 ). If it is determined that the tag has not received any command (Step S 22 , No), it repeats the processing operation of Step S 22 . If, on the other hand, it is determined that the tag has received a command (Step S 22 , Yes), the tag determines if it has received a group select command or not (Step S 23 ).
If it is determined that the tag has received a group select command (Step S 23 , Yes), it turns its mode of operation to an ID mode (Step S 24 ) and then returns to the ready mode. If, on the other hand, it is determined that the tag has not received a group select command (Step S 23 , No), the tag determines if its mode of operation is an ID mode or not (Step S 25 ). If it is determined that the mode of operation is an ID mode (Step S 25 , Yes), the tag further determines if it has received a fail command or not (Step S 26 ).
If it is determined that the tag has not received a fail command (Step S 26 , No), it determines if it has received a success command or not (Step S 27 ). If it is determined that the tag has received a success command (Step S 27 , Yes), it updates the reading of the counter in the tag by decrementing the reading by −1 (Step S 28 ) and determines if the reading of the counter in the tag is 0 or not (Step S 29 ). If it is determined that the reading of the counter in the tag is 0 (Step S 29 , Yes), the tag transmits its own UID (unique ID) to the read/write device (Step S 30 ).
If, on the other hand, it is determined that the tag has received a fail command (Step S 26 , Yes) as a result of the operation of determining if it has received a fail command or not (Step S 26 ), it determines if the reading of the counter in the tag is 0 or not (Step S 31 ) and, if it is determined that the reading of the counter in the tag is 0 (Step S 31 , Yes), the tag updates the reading of the counter by incrementing it by +1 (Step S 32 ). If, on the other hand, it is determined in Step S 31 that the reading of the counter in the tag is not 0 (Step S 31 , No), the tag generates a random number of 1 or 0 (Step S 33 ) and determines if the generated random number is −0 or not (Step S 34 ). If it is determined that the generated random number is −0 (Step S 34 , Y), the tag transmits its own UID to the read/write device (Step S 35 ).
Thus, with an anti-collision process as described above, it is possible for the read/write device to acquire the UID of each tag, while preventing mutual interferences of a plurality of tags.
In order to prevent collisions, an anti-collision process as described above is conducted while restricting the transmission of tag UIDs for part of the tags and the process is repeated until the read/write device receives the UIDs of all the tags. Therefore, the processing operation proceeds fast when the number of tags is small because the probability of collisions is low. However, as the number tags increases, the number of times of repeating the process has to be raised in order to prevent collisions and hence the process is accompanied by a problem that a considerably long time is required before acquiring the UIDs of all the tag.
SUMMARY OF THE INVENTION
In view of the above identified problem hitherto known, it is therefore an object of the present invention to provide a wireless tag system that does not require any anti-collision process or, if an anti-collision process is required, can reduce the number of tags that need to participate in the anti-collision process to make the anti-collision process proceeds fast along with a wireless tag access control device, a wireless tag access control method, a wireless tag access control program and a tag that can be used for such a wireless tag system.
In an aspect of the present invention, the above object is achieved by providing a wireless tag system comprising: a plurality of wireless slave tags which have respective unique IDs; a plurality of wireless master tags arranged for the slave tags and storing the unique IDs of the slave tags; and a wireless tag access control device which accesses the master tags to acquire the unique IDs of the slave tags from the master tags and subsequently accessing the slave tags by using the acquired unique IDs of the slave tags.
Preferably, in a wireless tag system according to the present invention, dedicated commands are defined respectively for the master tags and the slave tags and the wireless tag access control device selectively accesses either the master tags or the slave tags by using the corresponding one of the dedicated commands.
Preferably, in a wireless tag system according to the present invention, group addresses are defined respectively for the master tags and the slave tags and the wireless tag access control device selectively accesses either the master tags or the slave tags by specifying the corresponding one of the group addresses.
Preferably, in a wireless tag system according to the present invention, a plurality of combinations of a master tag and slave tags are provided and at least a super master tag storing the unique IDs of the plurality of master tags is provided for the plurality of master tags, the wireless tag access control device being adapted to access the super master tag in order to acquire the unique IDs of the plurality of master tags and access the master tags by using the acquired unique IDs of the master tags.
Preferably, in a wireless tag system according to the present invention, at least one of the master tags and at least one of the slave tags are combined to operate as a single tag and the unique IDs of the slave tags stored in the master tags include its own unique Ids.
Preferably, in a wireless tag system according to the present invention, the master tag is facsimiled in numbers and the facsimiled master tags are identifiable.
Preferably, in a wireless tag system according to the present invention, the master tags store positional information of the slave tags in correspondence to the unique IDs of the slave tags stored in the master tags.
In another aspect of the present invention, there is provided a wireless tag access control device which accesses wireless tags comprising: a unique ID acquiring section which accesses at least a master tag provided for a plurality of slave tags and acquiring the unique IDs of the slave tags stored in the master tag; and a slave tag accessing section which accesses the slave tags by using the unique IDs of the slave tags acquired by the unique ID acquiring section.
Preferably, in a wireless tag access control device according to the present invention, dedicated commands are defined respectively for the master tags and the slave tags so that accesses either the master tags or the slave tags are selectively accessed by using the corresponding one of the dedicated commands.
Preferably, in a wireless tag access control device according to the present invention, group addresses are defined respectively for the master tags and the slave tags so that either the master tags or the slave tags are selectively accessed by specifying the corresponding one of the group addresses.
Preferably, a wireless tag access control device according to the present invention further comprises a positional information acquiring section for acquires positional information of the slave tags corresponding to the acquired unique IDs of the slave tags, the device being adapted to access the slave tags according to the unique IDs and the positional information.
In still another aspect of the present invention, there is provided a wireless tag access control method which accesses a plurality of wireless tags, the method being adapted to provide at least a master tag storing the unique IDs of a plurality of slave tags which have respective unique IDs, the method comprising: a slave tag UID acquiring step which accesses the master tag and acquiring the unique IDs of the plurality of slave tags stored in the master tag; and a slave tag accessing step which accesses the slave tags by using the acquired unique IDs of the slave tags.
Preferably, in a wireless tag access control method according to the present invention, dedicated commands are defined respectively for the master tags and the slave tags so that either the master tags or the slave tags are selectively accessed by using the corresponding one of the dedicated commands.
Preferably, in a wireless tag access control method according to the present invention, group addresses are defined respectively for the master tags and the slave tags so that either the master tags or the slave tags are selectively accessed by specifying the corresponding one of the group addresses.
Preferably, in a wireless tag access control method according to the present invention, a plurality of combinations of a master tag and slave tags are provided and at least a super master tag storing the unique IDs of the plurality of master tags is provided for the plurality of master tags, the wireless tag access control method being adapted to access the super master tag in order to acquire the unique IDs of the plurality of master tags and access the master tags by using the acquired unique IDs of the master tags.
Preferably, in a wireless tag access control method according to the present invention, at least a master tag is facsimiled in numbers from the master tags and slave tags and the facsimiled master tags are identifiable so that each tag is identified and selectively accessed.
Preferably, in a wireless tag access control method according to the present invention, an identifying section is provided for each tag to indicate the tag to be in use or not in use so that, when an unusable state is detected for at least one of the facsimiled master tags, the information stored in the master tag detected as unusable and the other facsimiled master tags is written in the facsimiled master tags not in use and the tags in which the information is written are indicated to be in use by the identifying section so as to make the other master tags and the master tag facsimiled master tags.
In still another aspect of the present invention, there is provided a wireless tag access control program which causes a computer to execute a wireless tag access control method which accesses a plurality of wireless tags, the program being adapted to provide at least a master tag storing the unique IDs of a plurality of slave tags which have respective unique IDs, the program comprising: a slave tag UID acquiring step which accesses the master tag and acquiring the unique IDs of the plurality of slave tags stored in the master tag; and a slave tag accessing step which accesses the slave tags by using the acquired unique IDs of the slave tags.
Preferably, in a wireless tag access control computer program according to the present invention, dedicated commands are defined respectively for the master tags and the slave tags so as to cause a computer to selectively access either the master tags or the slave tags by using the corresponding one of the dedicated commands.
In still another aspect of the present invention, there is provided a wireless tag comprising a wireless antenna and a memory section and adapted to be accessed by a read/write device by means of a wireless signal; the wireless tag storing unique IDs of wireless tags other than itself in the memory section so that they may be accessed by the read/write device by means of the unique IDs.
Thus, the invention provides an advantage that no anti-collision process is required or, if an anti-collision process is required, the number of tags that need to participate in the anti-collision process can be remarkably reduced to make the anti-collision process proceeds fast. This advantage becomes even more remarkable particularly in a situation where a large number of slave tags, or thousands to tens of thousands of slave tags, have to be processed because it is not necessary for a read/write device to collectively store the UIDs of such large number of slave tags.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic block diagram of a first embodiment of wireless tag system according to the invention, illustrating the overall configuration thereof;
FIG. 2 is a schematic block diagram of a master tag and a slave tag, showing the configuration thereof;
FIG. 3 is a flow chart of the operation of the first embodiment;
FIG. 4 is a conceptual illustration of a second embodiment;
FIG. 5 is a flow chart of the operation of the second embodiment;
FIG. 6 is a conceptual illustration of a third embodiment;
FIG. 7 is flow charts of the operation of the third embodiment;
FIG. 8 is a conceptual illustration of a fourth embodiment;
FIG. 9 is a flow chart of the operation of the fourth embodiment;
FIG. 10 is an illustration of the command format of a fifth embodiment;
FIG. 11 is a conceptual illustration of a sixth embodiment;
FIG. 12 is a flow chart of the operation of the sixth embodiment;
FIG. 13 is a conceptual illustration of a seventh embodiment;
FIG. 14 is a conceptual illustration of an eighth embodiment;
FIG. 15 is a conceptual illustration of a ninth embodiment;
FIG. 16 is a flow chart of the operation of the ninth embodiment;
FIG. 17 is a conceptual illustration of a tenth embodiment;
FIG. 18 is a flow chart of the operation of the tenth embodiment;
FIG. 19 is a conceptual illustration of the processing operation for updating the data on the slave tags registered in a master tag;
FIG. 20 is a conceptual illustration of the processing operation for initializing slave tags and master tags;
FIG. 21 is a flow chart of the operation of a read/write device in a conventional anti-collision process; and
FIG. 22 is a flow chart of the operation of a tag in a conventional anti-collision process.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now, the present invention will be described in greater detail by referring to the accompanying drawings that illustrate preferred embodiments of the invention.
[First Embodiment]
FIG. 1 is a schematic block diagram of the first embodiment of wireless tag system according to the invention, illustrating the overall configuration thereof. Referring to FIG. 1 , the wireless tag system comprises a plurality of slave tags 1 , at least a master tag 2 arranged for the plurality of slave tags 1 , a read/write device (R/W) 3 adapted to access the master tag 2 and the slave tags 1 and communicate with any of them, a PC 4 that controls the read/write device 3 and a server 5 connected to the PC 4 and adapted to provide the PC 4 with necessary information.
The plurality of slave tags 1 respectively have their own UIDs (UID 1 A through UID 6 A). The master tag 2 stores the UIDs (UID 1 A through UID 6 A) of the slave tags 1 and is adapted to transmit the UIDs of all the slave tags 1 in response to a request from the read/write device 3 . The read/write device 3 can receive the transmitted UIDs and transfer them to the PC 4 . The master tag 2 can delete or replace any of the stored UIDs and add one or more than one new UID in response to a request from the read/write device 3 .
Each of the slave tags 1 stores predetermined management information on the objects of management (e.g., wears, books, building components, packages) (not shown) so as to be readable/writable to the read/write device 3 in addition to its own UID. Preferably, the slave tags 1 are arranged within the communicable area of the read/write device 3 with the master tag 2 and attached respectively to objects of management, for example.
The PC 4 , the read/write device 3 or the PC 4 and the read/write device 3 in combination operate as a wireless tag access control device according to the invention that can access the wireless tags (slave tags 1 , master tag 2 ). While a plurality of slave tags 1 are provided in this embodiment, the present invention is applicable to a a system that comprises a single slave tag 1 .
FIG. 2 is a schematic block diagram of a master tag and a slave tag, showing the configuration thereof.
Each of the tags 1 , 2 comprises a tag chip (IC chip) 6 and a loop antenna 7 . The tag chip 6 in turn comprises an analog/digital converter 8 for converting an analog signal such as a radio signal, into a digital signal for internal processing, a command analyzing/processing section 9 for analyzing a command and carrying out a predetermined processing operation and a memory section 10 . In the master tag 2 , the memory section 10 stores the UID of the tag, the above described UIDs (UID 1 A through UID 6 A) of the slave tags 1 and other necessary pieces of information. The slave tag 1 stores predetermined management information in addition to its own UID. The memory section 10 also stores address information on the each of the tags.
Now, the operation of the first embodiment will be described by referring to the flow chart of FIG. 3 in terms of the processing operation that is carried out by the tag access control device (the read/write device and the PC) to access the slave tags 1 .
Firstly, the tag access control device transmits a data read command to the master tag 2 , using the UID of the master tag 2 (Step S 101 ). After receiving data from the master tag 2 (Step S 102 , Yes), it acquires the UIDs of all the slave tags 1 stored in the memory section 10 of the master tag 2 (Step S 103 ). Then, it transmits a data read/write command to the slave tags 1 , using the acquired UIDs of the slave tags 1 , (Step S 104 ). When the read/write operation relating to all the slave tags 1 is completed (Step S 105 , No), it ends the processing operation.
Thus, with the above-described first embodiment, it is possible to acquire the UIDs of the slave tags without carrying out an anti-collision processing operation relative to the slave tags by acquiring the UIDs of the slave tags from the master tag 2 and accesses the slave tags 1 to remarkably improve the efficiency of the management. Note that, in a wireless tag access control device according to the invention, a UID acquiring section is responsible for Step S 101 through Step S 103 , whereas a slave tag accessing section is responsible for Step S 104 .
When a single master tag 2 is provided, it is accessed by using its own UID. If there are a plurality of master tags 2 , either an anti-collision processing operation is carried out or a group address is used as will be described hereinafter. However, according to the invention, it is possible to dramatically reduce the number of necessary tags if compared with an arrangement where an anti-collision processing operation needs to be carried out for all the slave tags. Therefore, it may be clear that the present invention can carry out the anti-collision processing operation remarkably quickly.
[Second Embodiment]
In the second embodiment, dedicated commands are provided in order to discriminate the access to the master tag and the access to the slave tags.
FIG. 4 is a conceptual illustration of the second embodiment. In FIG. 4 , (a) shows a situation where a single master tag 2 and a plurality of slave tags 1 exist. It is necessary to firstly access the master tag 2 in order to acquire the UIDs of the slave tags stored in the master tag 2 . The master tag 2 can be accessed efficiently by separately preparing an access command which accesses the master tag 2 and an access command which accesses the slave tags. This arrangement provides an additional managemental advantage that, when the slave tags need to be accessed, they can be accessed without involving the master tag.
In FIG. 4 , (b) shows an example of command format. With this format, the master tag 2 is selected when the command code is “0x00” so that all the subsequent commands are regarded as those solely for the master tag 2 . On the other hand, the slave tags 1 are selected when the command code is “0x01” so that all the subsequent commands are regarded as those solely for the slave tags 1 .
Referring to FIG. 5 illustrating a flow chart of the operation of the second embodiment, as a processing operation for selecting a command is started, it is determined if the coming communication is to be held with the master tag or not (Step S 111 ). If the coming communication is to be held with the master tag (Step S 111 , Yes), the command for the master tag is selected (Step S 112 ) and the selected command is transmitted (Step S 113 ). If, on the other hand, the coming communication is to be held not with the master tag but with the slave tags (Step S 111 , No), the command for the slave tags is selected (Step S 114 ) and the selected command is transmitted (Step S 113 ).
[Third Embodiment]
In the third embodiment, group addresses are provided so as to be able to identify the master tag and the slave tags which are accessed.
FIG. 6 is a conceptual illustration of the third embodiment. FIG. 6( a ) shows an example of command format. If the command code is “0x00” and the group address is “10” while the data is “0x80”, it is clearly seen from (b) of FIG. 6 that the data “0x80 ” stored at address “10” is carried by tag B. Thus, it is possible to tell if a given command is for the master tag or for the slave tags by using group addresses as described above to a great advantage of improving the efficiency of management.
FIGS. 7( a ) and 7 ( b ) show flow charts of the operation of the third embodiment. FIG. 7( a ) shows a flow chart for the access control device, whereas FIG. 7( b ) shows a flow chart for the tags.
As shown in FIG. 7( a ,) when a processing operation is started, the wireless tag access control device determines if the coming communication is for the master tag or not (Step S 121 ). If it is determined that the coming communication is for the master tag (Step S 121 , Yes), the wireless tag access control device selects the group address for identifying the master tag (Step S 122 ) and then selects and transmits the command (Step S 123 ). If, on the other hand, it is determined that the coming communication is not for the master tag (Step S 121 , No), the wireless tag access control device selects the group address for identifying the slave tags (Step S 124 ) and proceeds to Step S 123 .
Now, referring to FIG. 7( b ) showing a flow chart for the tags, firstly it is determined if the group address is for its own group or not (Step S 131 ). If it is determined that the group address is for its own group (Step S 131 , Yes), the tag or each of the tags analyzes the command and carries out a corresponding processing operation (Step S 132 ). If, on the other hand, it is determined that the group address is not for its own group (Step S 131 , No), it simply terminates the operation.
[Fourth Embodiment]
The fourth embodiment is adapted to an arrangement where there are more than one group of a master tag and slave tags. In the fourth embodiment, a dedicated command is provided so that only the master tag of each group may participate in the anti-collision processing operation.
FIGS. 8( a ) and 8 ( b ) show a conceptual illustration of a fourth embodiment. FIG. 8( a ) shows that there are more than one group (two in the illustrated instance), or groups G 1 , G 2 , of a master tag and slave tags. In this case, it is necessary to firstly carry out an anti-collision processing operation for the master tags 2 in order to acquire the UIDs of the master tags for the purpose of acquiring the UIDs of the slave tags. When carrying out the anti-collision processing operation, the UIDs of the master tags can be acquired with ease if it is possible to discriminate the tags (master tags) that need to participate in the anti-collision processing operation from the slave tags. Therefore, it is desirable to provide a command which causes only the master tags to participate in the anti-collision processing operation.
FIG. 8( b ) shows an example of a command format. Only the master tags are put into a mode for participating in the anti-collision processing operation when the command is “0x00”. On the other hand, only the slave tags are put into a mode for participating in the anti-collision processing operation when the command is “0x01”.
FIG. 9 is a flow chart of the operation of the fourth embodiment. Firstly, because the anti-collision processing operation is started only for the master tags, the command for specifying the master tags for the anti-collision processing operation is selected (Step S 141 ) and the selected command is transmitted (Step S 142 ) to end the processing operation.
[Fifth Embodiment]
The fifth embodiment corresponds to the third embodiment in the sense that, where there are a plurality of groups of a master tag and slave tags, a group address is used to specify the master tag of a groups as shown in (a) of FIG. 8 .
FIG. 10 is an illustration of the command format of the fifth embodiment. Referring to FIG. 10 , if the command code, the group address and the data for the group are respectively “0x00”, “10” and “0x80”, only the tag whose group address and data are respectively “10” and “0x80” can be selected as master tag. In the wireless tag access control device, as the processing operation of the step of specifying the master tag is carried, that of the step of selecting the group address of the master tag and that of the step of transmitting the command which have the group address are carried out sequentially.
[Sixth Embodiment]
The sixth embodiment is adapted to accommodate a situation where there are a plurality of master tags as in the case of a plurality of groups of a master tag and slave tags by providing a super master tag that stores the UIDs of the master tags.
Assume that there are groups G 1 , G 2 of a master tag and slave tags as shown in FIG. 11 . Then, a super master tag 11 is provided to store the UIDs of the master tags 2 . Then, referring to FIG. 12 , the wireless tag access control device firstly accesses the super master tag 11 and acquires the UIDs (UID( 0 ), UID( 1 )) of the plurality of master tags 2 (Step S 151 ) and subsequently accesses the master tags by using the acquired UIDs of the master tags to acquire the UIDs of the slave tags stored in each master tag (Step S 152 ).
Thus, with the sixth embodiment, it is not necessary to carry out an anti-collision processing operation if there are a plurality of master tags so that the processing operation proceeds fast to a great advantage of management.
[Seventh Embodiment]
In the seventh embodiment, one of the slave tags is used as master tag. In other words, one of the slave tags operates both as master tag and slave tag.
FIG. 13 is a conceptual illustration of the seventh embodiment. Referring to FIG. 13 , the master tag stores the UIDs of a plurality of slave tags and one of the UIDs is the UID of the master tag. With this arrangement, the master tag registers its own UID both as that of a slave tag and as that of the master tag so that it can operate as slave tag.
[Eighth Embodiment]
In the eighth embodiment, the master tag is facsimiled in numbers (e.g., duplicated) to raise the reliability of the system.
FIG. 14 is a conceptual illustration of the eighth embodiment. Referring to FIG. 14 , two master tags 2 A, 2 B that store the UIDs of the same slave tags are provided to control the UIDs of the slave tags. If the wireless tag access control device cannot read the UIDs of the slave tags from the master tag 2 A, it reads the UIDs of the slave tags from the master tag 2 B. With this arrangement, the system shows an enhanced degree of reliability because, if one of the master tags fails or shows some other trouble, the other master tag can provide the UIDs of the slave tags. It is also possible to facsimile the slave tags to further enhance the reliability of information management.
[Ninth Embodiment]
In the ninth embodiment, the master tag is facsimiled in numbers (e.g., duplicated) to raise the reliability of the system in terms of UID management of the slave tags as in the case of the eighth embodiment and, at the same time, the facsimiled master tags are made identifiable so that the system can be restored if it fails.
FIG. 15 is a conceptual illustration of the ninth embodiment. FIG. 16 is a flow chart of the operation of the ninth embodiment.
Referring to the drawings, each tag is provided with a restoration flag area (identifying section for identifying if the tag is in use or not in use) 13 and restoration flag “0” is written to each tag that is in use. Restoration flag “1” is written to each unused tag that is to be used for restoration. If one of the facsimiled master tags (tag 2 A) fails (Step S 161 , Yes), an unused tag (tag 2 C) is searched for by searching for the tag with restoration flag “1” out of the master tags in the communication area and, if an unused tag is found (Step S 162 , Yes), the data (the UIDs of the slave tags) of the master tag 2 B that is the duplicate of the failed master tag are transferred (copied) to the tag 2 C (Step S 163 ) and the flag of the master tag is set to “1” (Step S 164 ). Thereafter, the master tag 2 B and the master tag 2 C are used as facsimiled (duplicated) master tags.
[Tenth Embodiment]
In the tenth embodiment, positional information of the slave tags are stored in the master tag along with the UIDs of the slave tags.
FIG. 17 is a conceptual illustration of the tenth embodiment. Referring to FIG. 17 , positional information of the slave tags 1 A, 1 B is stored in the master tag 2 D so that, when the slave tags are applied to large product such as a building component (not shown), it is possible to access either of the tags and modify the information stored in the tag depending on the positions of the tags.
More specifically, as shown in FIG. 17 , positional information 21 b on the applied (bonded) position of each slave tag is added to the UID information 21 a as slave tag information 21 that is stored in the master tag 2 D. In the case of a large product such as a building component, it may be desired to write different pieces of information respectively to different parts of the products. For example, a lower part of the product is to be painted in a step of the building operation, the data on the time and date of the painting operation may have to be written to the tag applied to the lower part of the product. Then, it is possible to read the slave tag information 21 in the master tag 2 D and write the necessary data (management information) only to the tag for the lower part of the product.
FIG. 18 is a flow chart of the operation of the tenth embodiment when writing information in a slave tag.
Referring to FIG. 18 , firstly, the wireless tag access control device accesses the master tag 2 D and acquires the UID 21 a and the positional information 21 b of each of the slave tags 1 A, 1 B from the slave information 21 (Step S 171 ). Then, it selects and acquires the UID of the slave tag that has the right positional information (Step S 172 ). As it acquires the UID of the slave tag which have the right positional information, it accesses the slave tag, using the UID and operates for writing the necessary data (Step S 173 ). Note that the positional information acquiring section is responsible for the operation of Step S 171 .
The present invention is described above by way of preferred embodiments. Now, the processing operation for updating the data (UIDs) of the slave tags registered in the master tag(s) will be described below. While the data updating processing operation will be described in terms of the first embodiment below, it is similarly applicable to the other embodiments including the second embodiment through tenth embodiment.
Referring to FIG. 19 , the data updating processing operation may be repeated at regular time intervals (or at a predetermined clock time or predetermined clock times). The PC of the wireless tag access control device acquires the UIDs of the slave tags from the master tag by way of the read/write device (P 1 ) and sequentially reads the data of the slave tags, using the UIDs (P 2 through P 4 ). If a slave tag (UID 3 in the illustrated instance) goes out of control, no acknowledgement can be received from the slave tag with the UID (P 4 ). Therefore, the PC decides that the slave tag has gone out of control of the PC (the commodity carrying the slave tag may have been moved to the outside) and issues an order to the master tag for erasing the UID. Upon receiving the order, the master tag deletes the UID of the slave tag (P 5 ). Then, the processing operation described above for the preferred embodiments is carried out for the remaining slave tags (P 6 ). Note that the relationship between the super master tag and the master tags in the sixth embodiment is similar to the above-described relationship between the master tag and the slave tags. So is the relationship between the master tag and the slave tags in the seventh embodiment where one of the slave tags is used as master tag. In the seventh embodiment, if it is judged that the slave tag that is operating as master tag has gone out of control, some other slave tag may be registered as master tag.
Now, the processing operation of initializing the slave tags and the master tag(s) will be described below by referring to FIG. 20 . The PC carries out an anti-collision processing operation by way of the read/write device and acquires the UIDs of all the tags including the slave tags and the master tag(s) (P 11 ). As the PC identifies the UID of the master tag (assuming that the master tag is provided with a UID that can be discriminated from the UIDs of the other tags), it handles all the tags with the UIDs other than the UID of the master tag as slave tags and writes and stores the UIDs in the master tag (P 12 ). In the case where some slave tags operate also as so many master tags as in the eighth embodiment, the PC may assign a master tag to any UID group and store the UIDs of the slave tags of the group in the master tag.
After the initialization, the information in the master tag can be updated in a similar manner when a slave tag is added. More specifically, an anti-collision processing operation is carried out for the slave tags and, if it is determined that there is a UID of a slave tag that is not registered in the master tag, it is written to the master tag appropriately.
The present invention is described above in detail by way of preferred embodiments. Thus, the present invention provides a wireless tag access control program which causes the computer of a wireless tag access control device according to the invention to execute the processing operation of any of the flow charts described above and illustrated in the accompanying drawings. More specifically, such a program can be executed by the computer of a wireless tag access control device according to the invention when it is stored in a computer-readable recording medium. Computer-readable recording mediums that can be used for the purpose of the present invention include transportable recording mediums such as CD-ROMs, flexible disks, DVD disks, magnetic optical disks and IC cards along with data bases that retain computer programs, other computers, their data bases and transmission mediums on communication lines.
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A wireless tag system which does not require any anti-collision process or, if an anti-collision process is required, can reduce the number of tags that need to participate in the anti-collision process to make the anti-collision process proceeds fast. The wireless tag system comprises a plurality of wireless slave tags which have respective unique IDs, a plurality of wireless master tags arranged for the slave tags and storing the unique IDs of the slave tags and a wireless tag access control device which accesses the master tags to acquire the unique IDs of the slave tags from the master tags and subsequently accessing the slave tags by using the acquired unique IDs of the slave tags.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to methods and devices to ensure the safe storage of food and, specifically, to a method and device to display the identity and storage time of food items in a refrigerator.
2. Description of Related Art
Most people have discovered mold growing on food in a refrigerator. The common response is a slight shudder of revulsion followed by quick disposal of the offending item. Sometimes one does not discover the problem until the food is being prepared for consumption or is actually about to be eaten. If the spoilage is not readily visible, the tainted item may actually be eaten, with mild to severe medical consequences. Although the problem is most apparent with readily perishable food in a refrigerator, food in a freezer, and even dried or canned food in a cupboard also deteriorate, albeit at a slower pace. The prior art solution to this pervasive problem has ranged from periodic disposal of all stored items to various lists attached to the front of the refrigerator or cupboard and manually maintained.
The problem with manual lists is that it is difficult to unambiguously identify the stored items. If one stored a piece of cheese in a refrigerator and wrote "cheese" on a list on the refrigerator door, confusion would result if there were more than one piece of cheese in the refrigerator. An attempt could be made to track the age of the particular item by also writing the date of storage on the list. Unfortunately, it is very difficult to look at such a list and immediately spot the item which is approaching the end of its useful life. When faced with a list of dates, the human mind does a poor job of instantly computing the current age of the item based on its date of storage. Also, most people do not have a clear idea of how long a given leftover should be stored. Furthermore, even if a leftover on the list is identified as approaching the end of its useful life, it is often difficult to easily locate the leftover in the refrigerator. Many perishable items cleverly hide on upper shelves or behind other items.
It is an object of the present invention to solve these common problems of food storage management;
It is another object to provide a method and device to furnish a ready display of the names of the stored food items, an indication of how long such an item should be stored, and a display of how long each item has actually been stored; and
It is a further object of the present invention to provide a quick and simple way to locate a food item stored inside a crowded refrigerator.
SUMMARY OF THE INVENTION
The invention is comprised of a base unit that is designed to maintain both a list of the stored food items, including the recommended maximum storage period for each item, and a display of how long each item has been in storage. Additionally, the invention may comprise an assortment of food storage containers made of plastic or some other suitable material. The storage containers are keyed to the list on the base unit. The base unit is a substantially flat device. It is more or less rectangular in shape and would normally be about the size of a standard sheet of paper. It is designed to be removably attached to or placed near the food storage location. The base unit performs three main tasks: a cataloging task, an associating task, and a timing task.
The cataloging task can be thought of as a flexible form of list-keeping. The base unit has a number of item slots, each of which serves as a position for the entry of a potential item on a list. For example, a typical base unit might have 14 item slots. This means that the unit could simultaneously track 14 food items: the item list could be up to 14 items in length. The important thing is that the base unit allows the item slots to be reversibly filled so that a list of stored items can be flexibly maintained. In the very simplest embodiment an item slot would be a rectangular region on the smooth surface of the base unit. To add a newly-stored item of food to the list one would simply write the name of the item onto the slot with a dry-erasable felt marker pen. To delete an item (when the leftover has been removed from storage), the slot would simply be wiped with a paper towel or cloth to erase the name.
A slightly more advanced version of the invention provides preprinted food names which are printed on or laminated onto thin magnetic tabs. The base unit surface is constructed of a magnetic material, and the preprinted names can be removably attached to fill a slot. The unused names can be stored in alphabetical order on the face of the refrigerator with other refrigerator magnets. Custom items for which no preprinted tabs existed can be created by either writing directly on the base unit with an erasable pen, as already explained, or by writing on a blank magnetic tab. After the item is consumed, the tab can be erased so that another item name can be written onto it. Alternately, the tab can be detached from the item slot and placed with the preprinted tabs so that the handwritten entry can be used again in the future.
In the most advanced version of the invention, a microprocessor provides the names of the stored items and controls their display. A portion of the face of the base unit, including the item slots, is a display screen such as a liquid crystal display (LCD). An input device such as a keyboard is also provided. By manipulating the input device, the name of the item of food to be stored is displayed in one of the empty item slots on the face of the base unit.
It will be appreciated that the cataloging task explained thus far is much more flexible than list-keeping methods that are known in the prior art. Moreover, the cataloging task also encompasses a lifetime function. The lifetime function comprises a method of providing storage lifetimes for the perishable items to be stored. In the simplest embodiment it would be a printed list of the lifetimes. For example, green beans might have a storage life of five days. If the cataloging task were implemented by writing with an erasable pen on the front surface of the base unit, this lifetime "5" would be entered beside the name on the blank item slot. In the case of preprinted magnetic tabs, the recommended lifetime would come preprinted next to the name of the food item. Finally, the microprocessor implementation would automatically provide the lifetime along with the item name, and display both on an item slot.
If the user disagrees with a provided lifetime, the user could alter it by using the erasable pen with the magnetic tab version or by a simple key stroke with the microprocessor version. Finally, many products such as yogurt or milk come from the store already marked with a preprinted expiration date. In that case, the user would write the date, in a numerical month/date format (i.e. 7/29 for Jul. 29), on the base unit item slot (on a tab or directly on the surface, depending on the version of the invention) or enter it with the microprocessor input device.
The second task is the association task. As explained above, a problem with keeping lists of stored items has been the difficulty of readily finding the item if it is in a closed container and of differentiating items if more than one example of a given item-type is stored at the same time. The association task is an integral part of the present invention that solves this nagging problem. As already explained, the face of the base unit contains a column of item slots which are used to create a list of the stored items and display their storage lifetimes. Next to each item slot is an identifier swatch. The identifier swatch is preferably a small patch of color or pattern. Ideally there would be between four and six different colors or patterns. Red, green, blue, and yellow would be a preferred choice of four colors.
The invention also comprises a series of food storage containers in a number of different sizes. These are ordinary, reusable containers of plastic or other suitable materials for storage purposes. However, each container prominently displays an identifier that matches one of the identifier swatches on the base unit. For example, the lids of the containers might match the color or pattern of a given identifier swatch. Reusable bands or disposable tapes that match identifier swatches can also be provided to mark prepackaged perishables such as yogurt or milk.
One begins the association task by choosing a storage container sized to fit the food item or an appropriate marking band and puts the item in the container or marks it with the band before putting the item into the refrigerator. Next, one chooses an empty item slot on the base unit whose identifier swatch matches that on the already chosen container or marking band. As already explained, each item slot is associated with an identifier. The user enters the name and lifetime into the slot. Now the entry on the list is associated with an item in the refrigerator or other storage location. Because the identifiers are of a bright color or pattern, one can easily locate the item within the refrigerator. As each stored item is consumed, its item slot is reclaimed by either erasing the handwritten label, removing the preprinted magnetic tab, or by operating the microprocessor input device to clear the entry.
There is a tension between the number of different identifiers and the ease of locating an item. If there are a large number of different identifiers, it will be easy to locate a stored item, since there will only be one container in the refrigerator with that identifier. If there is a relatively small number of different identifiers, there is a good chance that there will be more than one container with a given identifier in the refrigerator at one time. However, a large number of different identifiers would require a prohibitively large number of food storage containers if there is to be a variety of sizes for each identifier. A choice of between four and six different identifiers results in a good balance between ease of locating an item and an excessive number of food containers.
The way that the cataloging task creates a list of stored items along with their storage lifetime and how the association task links the list entry with a particular stored item has now been explained. The timing task completes the present invention. The timing task displays the time that has elapsed since the item was placed into storage. When the elapsed time exceeds the lifetime shown on the item slot, the item is no longer fit to eat.
The timing task is executed by a series of electronic timing circuits, preferably with an electronic display for each item slot. Associated with each display is one or more buttons or switches that activate, inactivate, or otherwise control that particular display. Preferably, the buttons or switches are immediately adjacent to each display, but for economy they might be grouped on a keypad at a single location on the base unit, and a single button might be used to control multiple slots (i.e., a given item slot could be selected by punching in its number, and its display then activated by pushing a single activation button). In the microprocessor version of the invention, the timing display is actually part of the same screen that displays the item slots with their names.
After the cataloging task and the association task have been completed (i.e., the item slot is filled in and the item is stored in an identifying container), the timing task is performed: the timing display associated with the item slot is activated. This is accomplished by pressing the appropriate button. When the item is removed from storage and the item slot is cleared, the timing function is deactivated either by pressing the button a second time or, depending on the exact embodiment of the invention, pressing a special "stop" button. With the microprocessor version of the invention, the timing function is automatically activated by the process of invoking the cataloging task to put a name into an item slot. When the item is removed from storage, the slot is selected and a button is pressed to delete both the item name and the timing display.
The display shows elapsed time in appropriate timing intervals that match the lifetimes entered in the item slot. When the invention is used to track leftovers in a refrigerator, these increments are days. For the tracking of frozen or dried food, the increments are weeks or months. A particular base unit might display only one of the possible timing increments. Alternatively, a switch or switches could be provided that would alter the timing increments of individual or of all the displays on a base unit. The microprocessor version is most flexible and can automatically select and display the appropriate timing interval by selecting an appropriate storage location button.
Items such as milk or yogurt that have a month/day expiration date are treated slightly differently. In that case, one of the control buttons causes the timing display to show the month/day rather than just elapsed time. For example, in the elapsed time mode (day increments), the timing display will show "0" when it is first activated. Preferably, this display would be next to the lifetime on the item slot. Thus, if the item were salad with a three-day lifetime, the item slot and timing display would look like this: "SALAD 3 0." Each day the timing display is automatically incremented by one day. After 24 hours, the slot and display will read: "SALAD 3 1." After three days, the display will match the lifetime number, indicating that the salad is at the end of its useful lifetime. The goal is to consume the salad before the timing display exceeds the lifetime. In the case of yogurt the timing display is placed in the month/day mode. In that mode the display shows the month/day either by flashing the digits alternately, or by showing them simultaneously, depending on the version of the invention. Thus, upon activation, the item slot and display would read: "YOGURT 7/15 7/12." The next day the line would read: "YOGURT 7/15 7/13." When the display exceeds the lifetime, the product is no longer useable. The microprocessor version handles the process the most elegantly: the unit can display the lifetimes as explained above, or it can display in a countdown mode which shows how many useful days of life are left. Furthermore, the microprocessor has an alert mode that flashes the item slot entry on and off as that item approaches or exceeds its useful lifetime.
The present invention helps to minimize loss of leftover, perishable, or dated foods through spoilage, thereby saving money. It also speeds meal planing and preparation by eliminating the need to open multiple containers to determine refrigerator inventory. Furthermore, the inventory maintained through the cataloging task is a ready source of data for manual or automated production of shopping lists.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects and features of the present invention, which are believed to be novel, are set forth with particularity in the appended claims. The present invention, both as to its organization and manner of operation, together with further objects and advantages, may best be understood by reference to the following description, taken in connection with the accompanying drawings.
FIG. 1 is a perspective view of the magnetic tab version of the invention shown on a refrigerator;
FIG. 2 is a diagram of the front surface of the base unit of the magnetic tab embodiment of the present invention;
FIG. 3 is a diagram of the back surface of the magnetic tab embodiment of the present invention;
FIG. 4 is a representation of a single preprinted magnetic tab;
FIG. 5 shows a number of the identifier marked food storage containers; and
FIG. 6 is a diagram of the front surface of the base unit of the microprocessor embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows the present invention in use. A base unit 10 is detachably mounted to the face of a refrigerator 16 by magnetic strips 13 located on the back surface 15 of the unit (see FIG. 3). Also shown on the front of the refrigerator are a number of magnetic tabs 12, one of which can be seen in FIG. 4, which are used in the cataloging task which is explained below. FIG. 5 shows several food container 14 marked with identifiers 22 and suitable for use in the present invention.
FIG. 2 shows a view of the front surface 11 of the base unit 10 in the magnetic tab embodiment of the present invention, also shown in FIG. 1. The workings of the invention can be explained by reference to FIG. 2. There is a holder 21 for a dry-erasable pen 23. There is a vertical column 14 of empty item slots 24. The surface of the item slot 24 is of painted or enameled steel or other magnetic material marked with an identifier 22. A preprinted magnetic tab 12 (see FIG. 4) can be removably attached to create a filled item slot 20.
The identifier 22 is preferably a color or a pattern and can be seen most readily in an empty item slot 24. A portion of the identifier 22 is also visible in the filled item slot 20 as an identifier swatch 26 because the tab 12 is not as long as the slot 24. As explained above, the optimal number of identifiers is between four and six. This will provide relative ease in locating a stored food item and still not require an excessive number of food storage containers. Ideally, there will be a choice of several different container sizes marked with each identifier.
Next to the identifier swatch 26 at the end of the item slot 20 is a timing display 28. The timing displays 28 form a vertical column 27, one for each filled item slot 20 and each empty item slot 24. Next to each timing display 28 is a start button 30 and a stop button 32. Like the timing displays 28, the buttons 30, 32 are arranged in vertical columns, with one start button 30 and one stop button 32 for each timing display 28. The timing displays 28 are attached to electronic circuits (not shown) within the base unit 10, and the buttons adjacent to each timing display control that particular display. Pressing the start button 30 activates the adjacent display 28, causing it to display "0." Twenty-four hours later the display will increment to show "1." Pressing the start button 30 a second time invokes the expiration date mode. This is used for products like milk that have a month/day expiration date. When the expiration mode is activated, the display will show the month and day by alternately flashing the appropriate numbers. For example, if the current date were July 15, the display would flash "7," followed by "/" and then by "15"; then the display would blank for a moment and then repeat the sequence. Pressing the start button 30 a third time would invoke the countdown mode. This is indicated by the display showing a flashing "1" rather than the date. In this mode the display decrements one day each 24 hours, rather than incrementing one day. Finally, pressing the stop button 32 stops the clock and causes the display to show "-- ". The clock can be restarred by pressing the start button. Pressing the stop button 32 a second time resets the clock and deactivates the display, causing it to be entirely blank.
The details of the base unit 10 now having been explained, one can readily understand the functioning of the entire method. For example, suppose that one had a portion of baked beans that one wished to inventory and place into the refrigerator. One would first select an appropriately-sized food container 14 for the item to be stored, place the item into the container, and place the container into the refrigerator. One would then look at the base unit 10 to discover if there were an empty item slot 24 whose identifier swatch 26 matched the identifier 22 of the selected storage container 14. Assuming that there were an empty slot 24, one would then inspect the preprinted magnetic tabs 12 which are stored in alphabetical order on the front surface of the refrigerator 16 and select the tab 12 for baked beans. Alternately, if there were no preprinted tab 12 for baked beans, one would take the pen 23 and write "Baked Beans" on a blank magnetic tab 12 (or directly on the surface of the empty item slot 24). One would then place the magnetic tab 12 for "Baked Beans" onto the empty item slot 24, where it would adhere magnetically. The tab 12 is shorter than the empty item slot 24 so that a portion of the item slot identifier 22 shows as the identifier swatch 26 to the right of the magnetic tab 12. If, for some reason, one had decided not to use one of the identifier-coded food containers 14, this would be indicated by placing the magnetic tab 12 so that the identifier swatch 26 appears to the left of the tab 12.
At the right-hand end of the magnetic tab 12 is printed the item lifetime (e.g. "4" for Baked Beans); farther to the right is the timing display 28 for that filled item slot 20. One activates the display 28 by pressing the start button 30. The display 28 will increment each day. When the display 28 number exceeds the lifetime number, the baked beans are no longer safe to eat. If one selects the countdown mode, one would then press the start button 30 repeatedly until the display 28 shows the item lifetime ("4" in this case). The display 28 will decrement each day and flash to indicate the countdown mode is in operation. When a negative number is displayed, the baked beans are no longer fit to eat. The advantage of the countdown mode is that it is easy to see at a glance how many days of life are left for an item. If the expiration mode is selected, the item is safe to consume until the date flashed on the display 28 exceeds the expiration date written on the tab 12.
FIG. 6 shows the microprocessor version of the current invention. Much of the front surface area 11' of the base unit 10' is covered by an LCD screen 40. In this embodiment of the invention the screen displays fourteen lines allowing fourteen item slots 44. Each item slot 44 is numbered at its left-hand end (the top slot is number 1, while the bottom slot is number 14). The right-hand end of the screen is set off by a vertical line to form a column of timing displays 48. To the right of the timing displays is a vertical column of identifier swatches 46. At the bottom of the unit is a keyboard input 42, location keys 47, and a directional input key 50. The base unit 10' is fabricated as a single-board microcomputer. A low-power CMOS (complementary metal oxide semiconductor) microprocessor with integral EPROM (erasable programmable read only memory) is employed. A small lithium battery provides backup for a clock/calendar RAM (random access memory) chip. The LCD screen 40 is mounted directly to the circuit board, as is the membrane-switch keyboard 42, the location keys 47, and the directional input keys 50. A molded plastic case 52 with cutouts for the screen 40 and keyboard input 42, location keys 47, and directional input keys 50 encloses the circuit board. Power is provided by batteries or, alternately, by a cordset transformer (not shown), which delivers approximately 15 volts AC to the unit through a relatively slender power cord (not shown) which can be looped around the hinge side of the refrigerator.
All the functions of the manual/magnetic tab version 10 of the invention are implemented through software in the microprocessor version 10'. The overall method of using the unit 10' is essentially unchanged. After the food item is placed in a container 14, the cataloging task inputs the item name and lifetime. To accomplish this, one simply presses the first letter of items named on the keyboard 42. The unit's ROM (read only memory) contains more than 100 items. For example, if one pressed "A," the first ROM item starting with "A" would appear in the topmost empty item slot. In this example, that would be "APPLE." If that is not the desired item, then the second letter of the name can be pressed, and the first item that has those two letters will appear. This is continued until the desired name appears.
If the name is not found, it can be entered by typing out the entire name on the keyboard 42. If the item is in the ROM, the lifetime automatically appears in the timing display 48. If the item is a newly-entered custom item, "?" flashes in the timing display, indicating that the operator must enter a lifetime. The suggested lifetime may be increased or decreased by pushing the "up" or "down" arrow keys of the directional input 50. Custom entries can be permanently saved in an onboard nonvolatile memory. Because the computer is always aware of the product lifetime, the unit always operates in the countdown mode wherein the lifetime numbers decrease day by day until they become negative. At that point the entire name flashes to indicate that the item is no longer fit to eat. The product expiration date also works in countdown mode. The computer is aware of the calendar date, so when a month/day is input, it is immediately converted to a lifetime in days for the countdown mode.
The memory actually maintains three separate lists: one for the refrigerator (R), one for the freezer (F), and one for the pantry (P). When the operator presses a location key 47, the appropriate list is displayed and may then be accessed.
The association task works with the identifier swatches 46 in much the same manner as with the manual version 10 of the invention: after the item is placed in a food storage container 14, an item slot 44 is selected whose identifier swatch 46 matches the identifier 22 of that container 14. The directional input keys 50 allow one to move the recently-inputted item from the topmost empty item slot to a lower slot so one can have some choice of identifiers. If an identifier-marked container 14, 22 is not used, a special symbol can be placed on the screen 40 to so indicate.
Any item slot 44 can be selected with the directional input keys 50 or by slot number so that it is easy to modify the line or to clear the slot 44 when the stored item is consumed. The battery-backed clock/calendar records the identity and timing status of each item so that power interruptions will not cause a loss of data.
Those skilled in the art will appreciate that various adaptations and modifications of the just-described preferred embodiment can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein.
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A method and device for ensuring the consumption of perishable food items before the safe storage lifetime of the items has elapsed. A base unit which is mounted near or removably attached to a food storage location such as a refrigerator and allows identification and timing of the stored food items. When an item is placed into the storage location, its name and storage lifetime are recorded on the base unit. This recording may be accomplished manually by writing directly onto the base unit or by use of handwritten or preprinted labels, or recording may be accomplished electronically through a microprocessor-controlled base unit. For ease of later location the item may be optionally stored inside of food storage containers that are color coded to the base unit. The base unit also provides an electronic timing display for each stored item. This display can be activated when an item is stored so that the length of time an item has been stored can be readily determined and compared with the safe storage lifetime that is also provided for each food item.
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BACKGROUND OF THE INVENTION
The present invention relates to chest compression devices and in particular to a high frequency chest wall oscillator device.
Manual percussion techniques of chest physiotherapy have been used for a variety of diseases, such as cystic fibrosis, emphysema, asthma and chronic bronchitis, to remove excess mucus that collects in the lungs. To bypass dependency on a caregiver to provide this therapy, chest compression devices have been developed to produce High Frequency Chest Wall Oscillation (HFCWO), a very successful method of airway clearance.
The device most widely used to produce HFCWO is THE VEST™ airway clearance system by Advanced Respiratory, Inc. (f/k/a American Biosystems, Inc.), the assignee of the present application. A description of the pneumatically driven system is found in the Van Brunt et al. Patent, U.S. Pat. No. 6,036,662, which is assigned to Advanced Respiratory, Inc. Additional information regarding HFCWO and THE VEST™ system is found on the Internet at www.thevest.com. Other pneumatic chest compression devices have been described by Warwick in U.S. Pat. No. 4,838,263 and by Hansen in U.S. Pat. Nos. 5,543,081 and 6,254,556 and Int. Pub. No. WO 02/06673.
These HFCWO systems may be used in the home, however, successful use in the home is dependent on regular use of the device by the patient. Patient compliance is also important to obtain insurance reimbursement. Ease of use is an important factor in gaining acceptable patient compliance.
BRIEF SUMMARY OF THE INVENTION
The present invention is an improved method of providing high frequency chest wall oscillations to a patient. The method includes generating oscillating pneumatic pressure having a steady state pressure component and an oscillating pressure component and applying an oscillating compressive force to the patient's chest that includes a steady state force component corresponding to the steady state pressure component and an oscillating force component corresponding to the oscillating pressure component. The frequency of the oscillations change according to a predetermined pattern while maintaining the steady state pressure and force components.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective of the HFCWO system of the present invention.
FIG. 2 is a perspective view of the air pulse generator of the present invention.
FIG. 3 is a front view of the user interface.
FIG. 4 is a table summarizing STEP and SWEEP modes.
FIG. 5 is a table summarizing modes of the air pulse generator.
FIG. 6 is a perspective view of one embodiment of the control switch.
FIG. 7 is a perspective view of a second embodiment of the control switch.
FIG. 8 is a perspective view of the inside of the air pulse generator with a front portion of the shell removed.
FIG. 9 is an exploded view of the inside of the front portion of the shell.
FIG. 10 is a perspective view of the inside of the back portion of the shell.
FIG. 11 is a perspective view of the air pulse module.
FIG. 12 is a perspective view of the back side of the air pulse module.
FIG. 13 is a perspective view of the air chamber shell.
FIG. 14 is a perspective view of the crankshaft assembly within the air pulse module.
FIG. 15 is an exploded view of the crankshaft assembly.
FIG. 16 is a perspective view of the heatsink on the control board.
FIG. 17 is a perspective view of the electronic circuitry on the control board.
FIG. 18 is a block diagram of a control system of the present invention.
FIG. 19 is an electrical schematic diagram of the AC Mains circuit.
FIG. 20 is an electrical schematic diagram of the Switching Power Supply circuitry.
FIG. 21 is an electrical schematic diagram of the Power Up Clear & Fault Reset circuitry.
FIG. 22 is an electrical schematic diagram of the Diaphragm Motor controller.
FIG. 23 is an electrical schematic diagram of the Blower Motor controller.
FIG. 24 is a graph illustrating the performance of the present invention using an adult large vest for HFCWO.
FIG. 25 is a graph illustrating the performance of the present invention using an adult medium vest for HFCWO.
FIG. 26 is a graph illustrating the performance of the present invention using an adult small vest for HFCWO.
FIG. 27 is a graph illustrating the performance of the present invention using a child large vest for HFCWO.
FIG. 28 is a graph illustrating the performance of the present invention using a child medium vest for HFCWO.
DETAILED DESCRIPTION
FIG. 1 shows a pneumatic HFCWO system of the present invention. FIG. 1 shows patient P having chest C and system 10 which includes inflatable vest 12 , hoses 14 , and air pulse generator 16 . Vest 12 is positioned on chest C of patient P. Hoses 14 are fluidly connected to vest 12 and air pulse generator 16 .
In operation, air pulse generator 16 provides air pulses and a bias pressure to vest 12 . The air pulses oscillate vest 12 , while the bias pressure keeps vest 12 inflated. Vest 12 applies an oscillating compressive force to chest C of patient P. Thus, system 10 produces HFCWO to clear mucous or induce deep sputum from the lungs of patient P.
Air pulse generator 16 produces a pressure having a steady state air pressure component (or “bias line pressure”) and an oscillating air pressure component. The pressure is a resulting composite waveform of the oscillating air pressure component and the steady state air pressure component. The oscillating air pressure component is substantially comprised of air pulses, while the steady state air pressure component is substantially comprised of bias line pressure.
The force generated on the chest C by vest 12 has an oscillatory force component and a steady state force component. The steady state force component corresponds to the steady state air pressure component, and the oscillating force component corresponds to the oscillating air pressure component. In a preferred embodiment, the steady state air pressure is greater than atmospheric pressure with the oscillatory air pressure riding on the steady state air pressure. With this embodiment, the resulting composite waveform provides an entire oscillation cycle of vest 12 that is effective at moving chest C of patient P, because there is no point at which pressure applied to chest C by vest 12 is below atmospheric pressure. Chest movement can only be induced while vest 12 has an effective pressure (i.e. greater than atmospheric pressure) on chest C.
FIG. 2 shows the preferred embodiment of air pulse generator 16 . Air pulse generator 16 includes shell or housing 18 having back portion 20 with handle 22 , front portion 24 and seam 26 . Front portion 24 further includes user interface 28 , air openings 30 , switch port 32 and control switch 34 having connection plug 36 , tube 38 and control bulb 40 . Handle 22 is connected on back portion 20 of shell 18 . Front portion 24 is removably connected to back portion 20 along seam 26 . Connection plug 36 connects to front portion 24 via switch port 32 , and connection plug 36 fluidly connects to control bulb 40 via tube 38 .
Enclosure or shell 18 is composed of molded plastic such as polyvinyl chloride (PVC). Shell 18 is preferably about 13.5 in. wide, about 9.2 in. high and about 9.2 in. deep and provides the outer covering for air pulse generator 16 . Air pulse generator 16 preferably has a volume of about 1,200 in. 3 , a foot print of about 125 in. 2 and weighs about 17 lbs., which is significantly smaller and lighter than prior art HFCWO air pulse generators. These dimensions easily meet airline carry-on restrictions. Most airlines require that a carry-on weigh less than 40 lbs. and have a total length, width and height of less than 45 in., but restrictions vary from airline to airline. Typically, airlines also require that a carry-on have dimensions less than 9 in.×14 in.×22 in.
In comparison, THE VEST™ system, as previously described, is about 22 in. high, 14.5 in. wide and 10.2 in. deep. THE VEST™ system, has a volume of about 3,300 in. 3 , a footprint of about 150 in. 2 and weighs about 34 lbs.
Another HFCWO device, the Medpulse 2000™, from Electromed of New Prague, Minn. (various versions of which are depicted in U.S. Pat. No. 6,254,556 and Int. Pub. No. WO 02/06673) is about 20.5 in. wide, 16.75 in. deep and 9 in. high. The Medpulse 2000™ has a volume of about 3,100 in. 3 , a footprint of about 345 in. 2 and also weighs about 34 lbs.
In operation, user interface 28 allows patient P to control air pulse generator 16 . Air openings 30 connect hoses 14 to generator 16 . Switch port 32 allows connection plug 36 to connect to air pulse generator 16 . Patient P controls activation/deactivation of air pulse generator 16 through control switch 34 .
User interface 28 is shown in more detail in FIG. 3 . User interface 28 includes display panel 110 and keypad 112 having the following buttons: ON button 114 , OFF button 116 , UL (Upper Left) 118 , LL (Lower Left) 120 , UM (Upper Middle) 122 , LM (Lower Middle) 124 , UR (Upper Right) 126 and LR (Lower Right) 128 .
Display panel 110 is preferably an LCD panel display, although other displays, such as LED, could also be used. Display panel 110 shows the status of air pulse generator 16 and options available for usage. A single line of up to 24 characters is displayed. The characters are in a 5×8 pixel arrangement with each character measuring about 6 mm (0.24 in.)×14.54 mm (0.57 in.). A standard set of alphanumeric characters plus special symbols are used, and special characters that use any of the 40 (5×8) pixels are programmable. Display panel 110 is backlit for better character definition for all or some modes.
Keypad 112 is preferably an elastomeric or rubber eight button keypad that surrounds display panel 110 . ON button 114 is located on the left side of display panel 110 , and OFF button 116 is located on the right side of display panel 110 . UL 118 , UM 122 and UR 126 are located along the top of display panel 110 , and LL 120 , LM 124 and LR 128 are located along the bottom of display panel 110 .
Patient P may modify operation of air pulse generator 16 . Air pulse generator 16 also provides feed back to patient P as to its status. The messages are displayed as text on display panel 110 .
Buttons 114 - 128 on user interface 28 are programmed based on the particular operating mode that is presently active. In particular, in showing operating mode choices, the arrow buttons are programmed to wrap around. When showing time selection, frequency selection and pressure selection, the arrow buttons are programmed to not wrap around.
The function of UL 118 , LL 120 , UM 122 , LM 124 , UR 126 and LR 128 varies depending on the current mode of air pulse generator 16 . Each button is programmed to control various functions including the frequency of the oscillating air pressure component, or air pulses, the steady state air pressure component, or bias line pressure, and a timer, which deactivates air pulse generator 16 and will be more fully described below.
User interface 28 also allows operation of air pulse generator 16 in several different modes, such as MANUAL, SWEEP or STEP. Any one of which is programmable as a default mode that automatically operates when ON button 114 is activated.
MANUAL mode allows air pulse generator 16 to be manually programmed to set the oscillation frequency, bias line pressure and treatment time. MANUAL mode is similar to operation of the control knobs on THE VEST™ system. The oscillation frequency is set to a value ranging from 5 Hz to 20 Hz with a default frequency of 12 Hz. Likewise, the pressure control is set to a value ranging from 0 to 10 with a default pressure of 3. Treatment time is also set to a value ranging from 0 to 99 min with a default time of 10 min. Typically, treatment times are no more than 30 min.
SWEEP mode presets air pulse generator 16 to sweep over a range of oscillation frequencies while maintaining the same bias or steady state air pressure component. SWEEP mode provides three different sweep ranges, although any number or range of frequencies are programmable through user interface 28 . The table shown in FIG. 4 summarizes and illustrates the three different sweep ranges, which are: HIGH, which sweeps the oscillation frequency between 10 to 20 Hz; NORMAL, which sweeps the oscillation frequency between 7 and 17 Hz and LOW, which sweeps the oscillation frequency between 5 and 15 Hz. In each of these modes, the oscillation frequency sweeps between the two end points incrementally changing the oscillation frequency. The oscillation frequency incrementally increases until it reaches the high frequency, then incrementally decreases the oscillation frequency to the low frequency, then the oscillation frequency incrementally increases again ( FIG. 4 ). Alternatively, the oscillation frequency incrementally increases to the high frequency then returns to the low frequency and incrementally increases to the high frequency. The incremental increasing and decreasing continues throughout the treatment, or until the settings are reset. It is believed that the low frequencies are more effective at clearing small airways, and high frequencies more effective at clearing larger airways. The speed of the sweep is programmable through user interface 28 or preset. Preferably, the sweep speed is 1 cycle per 5 minutes. The default pressure setting in SWEEP mode is 3 with patient P able to modify the setting from 1 to 4 for comfort.
STEP mode presets air pulse generator 16 to step over a range of oscillation frequencies while maintaining the same bias or steady state air pressure component. STEP mode provides three different step ranges, although any number or range of frequencies is programmable through user interface 28 . Again, the table shown in FIG. 4 summarizes and illustrates the different ranges of STEP mode, which are: HIGH, which steps through the oscillation frequencies 10 Hz, 13 Hz, 16 Hz and 19 Hz; NORMAL, which steps through the oscillation frequencies 8 Hz, 11 Hz, 14 Hz and 17 Hz and LOW, which steps through the oscillation frequencies 5 Hz, 8 Hz, 11 Hz and 14 Hz. In each of these modes the oscillation frequencies step from the low frequency to the high frequency, changing the oscillation frequency a fixed amount after a fixed period of time. The oscillation frequency increases by steps until it reaches the high frequency, then decreases the oscillation frequency until the low frequency is reached. If desired, the oscillation frequency increases by steps again. The pattern of increasing and decreasing continues throughout the treatment or until the settings are reset. The fixed step amount of oscillation frequency change and the fixed period between oscillation frequency changes is programmable through user interface 28 , or the fixed step amount and the fixed period are preset. Preferably, the fixed step amount is 3 Hz, and the fixed step time period is 5 minutes. The default mode for STEP and SWEEP modes is NORMAL, and the default pressure is 3 with patient P able to modify the pressure from 1 to 4.
The table in FIG. 5 summarizes default mode settings and buttons 118 - 128 functionality in specific modes. The first column lists each mode. Columns 2 - 6 list the default settings for different parameters of HFCWO while in the various modes. Columns 7 - 9 list the function of buttons 118 - 128 while in the various modes.
The following operating modes are software supported by air pulse generator 16 : A) UNPLUGGED, B) IDLE, C) AUTO READY, D) AUTO RUN, E) AUTO PAUSED, F) PROGRAM ADJUST, G) PROGRAM RUN, H) MANUAL ADJUST, I) ERROR, J) Pulsing therapy modes including SWEEP, STEP and MANUAL and K) status and user messages including pressure adjust and frequency adjust, session run time (including pulsing and pause time) and accumulated run time (updated in memory every one minute).
In UNPLUGGED mode, display panel 110 is blank and air pulse generator 16 is disconnected from the supply mains.
In IDLE mode, air pulse generator 16 is plugged in and both blower motor 50 and diaphragm motor 64 are non-operational. Display panel 110 is not back lit, but the displayed message can be read and indicates accumulated run time (either both pulsing or pause time or only pulsing time).
The operation of control switch 34 is also programmed through user interface 28 . Control switch 34 is used in either an ON/OFF mode or a CONSTANTLY ON mode. The CONSTANTLY ON mode requires that control switch 34 be constantly depressed in order to activate air pulse generator 16 . The ON/OFF mode activates or deactivates air pulse generator 16 each time control switch 34 is pressed. The ON button 114 can also be used alternatively or to duplicate the functions of control switch 34 .
Buttons 114 - 128 and control switch 34 have the following functionality in IDLE mode: A) control switch 34 causes air pulse generator 16 to enter AUTO RUN mode using the default settings, B) ON button 114 causes air pulse generator 16 to enter AUTO READY mode, C) OFF button 116 has no effect and air pulse generator 16 remains in IDLE mode and D) buttons 118 - 128 are nonfunctional.
In AUTO READY mode, air pulse generator 16 pressurizes vest 12 for four seconds to the standby pressure level of 0.1 psi+0.05/−0.0.03 psi, and the backlit display panel 110 toggles between the default-remaining session time (e.g. “SWEEP NORMAL 20 MIN”) and status (e.g. “READY-PRESS AIR SWITCH”) messages every two seconds. Air pulse generator 16 continues alternating messages in AUTO READY mode for two minutes unless operator action occurs. After two minutes, air pulse generator 16 enters IDLE mode where vest 12 deflates, and a message displaying “INCOMPLETE XX MIN REMAIN” is displayed for five seconds.
Buttons 114 - 128 and control switch 34 have the following functionality in AUTO READY mode: A) control switch 34 causes air pulse generator 16 to enter AUTO RUN mode, B) ON button 114 causes air pulse generator 16 to enter PROGRAM ADJUST mode, C) OFF button 116 causes air pulse generator 16 to enter IDLE mode and D) buttons 118 - 128 are nonfunctional. Air pulse generator 16 returns to IDLE mode after two minutes of inactivity and displays “INCOMPLETE XX MIN REMAIN.”
In AUTO RUN mode, air pulse generator 16 inflates vest 12 for four seconds and then begins oscillation by initially performing a pressure characterization. During pressure characterization, sinusoidal pressure pulses are supplied over an average static pressure. During the initial few slow oscillation pulses of air pulse generator 16 during RUN mode, air pulse generator 16 monitors the system pressure and makes an adjustment to the average static pressure to compensate for different vest sizes and varying vest tightness. Patient P may be allowed to modify this average static pressure.
The pressure in vest 12 is comparable to the pressure in the air chamber of air pulse generator 16 at low frequencies such as 5 Hz. The correlation between the pressure in the air chamber and the pressure in vest 12 is not as comparable at high frequencies such as 15 or 20 Hz. This method allows the pressure in vest 12 to be accurately measured and maintained by taking measurements in the air chamber instead of taking measurements in vest 12 . Eliminating electronics in the vest portion increases safety. Once the average static pressure is determined, the pressure is maintained by maintaining the speed of the blower providing the bias line pressure with the tip speed of the blower fan. By using a blower with a flat pressure curve over the range of air flow, the average static pressure is maintained by simply maintaining the speed of the blower.
Oscillation proceeds using the default settings of SWEEP NORMAL for a duration of 20 minutes, while the backlit display panel 110 shows relative pressure (using vertical bars) and remaining session time. The message is displayed while air pulse generator 16 is delivering pulsed air pressure to vest 12 . The time counts down to zero in whole minute increments. When the session is complete, air pulse generator 16 reverts to IDLE mode and displays the message “SESSION COMPLETE” for five seconds.
Buttons 114 - 128 and control switch 34 have the following functionality in AUTO RUN mode: A) control switch 34 causes air pulse generator 16 to enter AUTO PAUSE mode, B) ON button 114 has no effect, C) OFF button 116 causes air pulse generator 16 to enter IDLE mode, D) UL 118 and LL 120 adjust vest pressure and E) buttons 122 - 128 are nonfunctional.
In AUTO PAUSED mode, air pulse generator 16 lowers vest pressure to the standby pressure level. Display panel 110 toggles between the default mode-remaining session time (e.g. “SWEEP NORMAL XX MIN”) and air pulse generator 16 status (e.g. “PAUSED PRESSED AIR SWITCH”) messages every two seconds. Air pulse generator 16 continues alternating messages in AUTO PAUSED mode for two minutes unless operator action occurs. After two minutes of inactivity, air pulse generator 16 enters IDLE mode causing vest 12 to deflate, and the message “INCOMPLETE XX MIN REMAIN” is displayed for five seconds.
Buttons 114 - 128 and control switch 34 have the following functionality in AUTO PAUSED mode: A) control switch 34 causes air pulse generator 16 to enter AUTO RUN mode, continuing the paused therapy session, B) ON button 114 has no effect, C) OFF button 116 causes air pulse generator 16 to enter IDLE mode and D) buttons 118 - 128 are nonfunctional.
PROGRAM ADJUST mode maintains the vest pressure established in AUTO READY mode, or lowers the vest pressure to the standby pressure level if pausing from RUN mode. If proceeding from AUTO READY mode, display panel 110 will toggle between “SWEEP NORMAL 20 MIN” and “READY-PRESS AIR SWITCH” messages every two seconds. If paused from PROGRAM RUN mode, display panel 110 toggles between the current settings of “MODE-FREQ MODIFIER-REMAINING SESSION TIME” (e.g. “SWEEP NORMAL 5 MIN”, “STEP HI 17 MIN”, OR “MANUAL ADJUST ?”) and “PAUSED-PRESS AIR SWITCH” messages every two seconds.
The different modes (SWEEP, STEP and MANUAL) are accessed using UL 118 and LL 120 . When SWEEP and STEP modes are displayed, the frequency modifiers (HIGH, LOW and NORMAL) are adjusted using UM 122 and LM 124 , and the session time (in minutes) is set using UR 126 and LR 128 . As the modes and modifiers are changed, they replace the “SWEEP NORMAL TIME” message. The mode message continues to alternate with the “READY-PRESS AIR SWITCH” or “PAUSED-PRESS AIR SWITCH” messages every two seconds. (Note: “READY” is used when PROGRAM ADJUST mode is reached from AUTO READY mode, and “PAUSED” is used when reached from RUN mode.) Pressing control switch 34 at any time causes air pulse generator 16 to proceed to PROGRAM RUN mode using the displayed settings. If time is zero when control switch 34 is pressed, air pulse generator 16 reverts to IDLE mode. Pressing UL 118 , UM 122 , LL 120 or LM 124 while in “MANUAL ADJUST?” transfers air pulse generator 16 to MANUAL ADJUST mode where frequency, pressure and session time can be adjusted. Messages continue alternating in PROGRAM ADJUST mode for two minutes unless operator action occurs. After two minutes, air pulse generator 16 reverts to IDLE mode where vest 12 deflates, and a message “INCOMPLETE XX MIN REMAIN” is displayed for five seconds.
Buttons 114 - 128 and control switch 34 have the following functionality in PROGRAM ADJUST mode: A) control switch 34 causes air pulse generator 16 to enter RUN mode (Actual RUN mode depends on setting at time of control switch 34 actuation. If control switch 34 is actuated with the session time at zero, air pulse generator 16 will reset to the IDLE mode.), B) ON button 114 has no effect, C) OFF button 116 causes air pulse generator 16 to enter IDLE mode, D) UL 118 and LL 120 toggle SWEEP, STEP and MANUAL modes, E) UM 122 and LM 124 adjust the frequency in SWEEP and STEP modes and cause transfer to MANUAL ADJUST in MANUAL mode and F) UR 126 and LR 128 adjust the time in SWEEP and STEP modes and cause transfer to MANUAL ADJUST in MANUAL mode. Air pulse generator 16 returns to IDLE mode after two minutes of inactivity displaying “INCOMPLETE XX MIN REMAIN.”
MANUAL ADJUST mode maintains vest 12 inflation at standby pressure and pulsing action remains stopped. The backlit display panel 110 shows the default or previously paused session information of frequency setting in Hertz, relative pressure and remaining session time in minutes. Adjustments to each of the parameters (frequency, pressure or time) are made by pressing the respective up or down arrow buttons.
Buttons 114 - 128 and control switch 34 have the following functionality in MANUAL ADJUST mode: A) control switch 34 causes air pulse generator 16 to enter MANUAL RUN mode (if control switch 34 is activated with the session time at zero, air pulse generator 16 will revert to IDLE mode), B) ON button 114 has no effect, C) OFF button 116 causes air pulse generator 16 to enter IDLE mode, D) UL 118 and LL 120 adjust frequency in Hertz, E) UM 122 and LM 124 adjust relative pressure and F) UR 126 and LR 128 adjust session time in minutes.
Air pulse generator 16 returns to IDLE mode after two minutes. If the session time has elapsed, air pulse generator 16 returns to PROGRAM ADJUST mode displaying “SESSION COMPLETE” for five seconds and then displaying “MANUAL ADJUST?”
In PROGRAM RUN mode, vest 12 inflates for four seconds and air pulse generator 16 begins pulsing in the selected mode: SWEEP, STEP or MANUAL. Each mode is described below in further detail.
In MANUAL RUN mode, vest 12 inflates for four seconds and air pulse generator 16 begins pulsing the selected or default parameters. No pressure characterization is required in MANUAL RUN mode. Display panel 110 is backlit and shows frequency settings in Hertz, relative pressure setting and remaining session time in minutes. The message is displayed while air pulse generator 16 is delivering pulsed air pressure to vest 12 . The time counts down to zero as whole minute increments. Adjustments to each of the parameters can be made by pressing the adjacent up or down arrow buttons.
Buttons 114 - 128 and control switch 34 have the following functionality in MANUAL RUN mode: A) control switch 34 causes air pulse generator 16 to enter PROGRAM ADJUST mode and the settings are remembered, B) ON button 114 has no effect, C) OFF button 116 causes air pulse generator 16 to enter IDLE mode, D) UL 118 and LL 120 adjust frequency in Hertz, E) UM 122 and LM 124 adjust relative vest pressure and F) UR 126 and LR 128 adjust time in minutes.
Once the session time is completed, air pulse generator 16 returns to PROGRAM ADJUST mode with initial session settings. When the session timer counts to zero, the pulsing stops, vest pressure drops to standby, and air pulse generator 16 resets to the session values previously entered. If air pulse generator 16 is further reset to IDLE mode, the session values of frequency, pressure and time are lost, and the default values are loaded.
In SWEEP RUN and STEP RUN modes, air pulse generator 16 inflates vest 12 for four seconds and then begins oscillation by initially performing the pressure characterization described above. Oscillation proceeds through the pre-selected or default sweep settings while the backlit display panel 110 shows relative pressure (using vertical bars) and remaining session time. The message on display panel 110 is displayed while air pulse generator 16 is delivering pulsed air pressure to vest 12 . The time counts down to zero in whole minute increments.
Buttons 114 - 128 and control switch 34 have the following functionality in SWEEP RUN and STEP RUN modes: A) control switch 34 causes air pulse generator 16 to enter PROGRAM ADJUST mode, B) ON button 114 has no effect, C) OFF button 116 causes air pulse generator 16 to enter IDLE mode, D) UL 118 and LL 120 adjust vest pressure and E) buttons 122 - 128 are non-functional.
Once time is completed, air pulse generator 16 returns to IDLE mode and displays “SESSION COMPLETE” for five seconds. Pulsing stops, vest 12 deflates, session settings are lost, and the default values are loaded if SWEEP RUN or STEP RUN mode is re-entered.
When an error is detected, air pulse generator 16 reverts to IDLE mode and displays the non-backlit error message “See Manual.” Only UNPLUGGED mode is allowed. If air pulse generator 16 is unplugged and replugged, the message clears, and air pulse generator 16 attempts to run again. Buttons 114 - 128 and control switch 34 have no effect. Air pulse generator 16 continues to alternate Error and Call messages.
Air pulse generator 16 provides a static pressure produced by a centrifugal blower with an electric feedback speed control loop for controlling the pressure. A pressure offset is generated during the startup period, which compensates for the different bladder sizes available in the assorted vest options. Average minimum output pressure is 0.28 psi minimum, the average maximum output pressure is 0.70 psi minimum, and the average IDLE output pressure is 0.1 psi nominal and the maximum pressure is 1.2 psi. The pressure setting and the actual operating average pressure tolerance is 0.2 psi.
The air pulse frequency is generated by a DC brushless motor driving a double linkage connected to two natural rubber diagrams, which is described in more detail below. The minimum air pulse frequency is 5 Hz, and the maximum air pulse frequency is 20 Hz. The pulse frequency delivered by air pulse generator 16 is 20% of the selected parameter. The maximum peak pressure, measured at the input port of vest 12 , does not exceed 1.2 psi at any pulse frequency (5-20 Hz), using any vest size and any pressure setting.
The pressure oscillates causing pressure fluctuations that are the result of dual diaphragm oscillations of a fixed volume displacement of 29.2 in. 3 per cycle. The pressure fluctuations at vest 12 are: A) a minimum level of 0 psi, B) a maximum level of 1.2 psi maximum, C) a maximum of 0.45 psi minimum and D) a minimum pressure delta of 0.15 psi.
FIG. 6 shows one embodiment of control switch 34 in more detail. FIG. 6 includes shell 18 with switch port 32 and control switch 34 having connection plug 36 , tube 38 and control bulb 40 . Connection plug 36 connects control switch 34 to air pulse generator 16 .
Control switch 34 is similar to control switches used on prior art devices, such as the pneumatic control switch used with THE VEST™ airway clearance system from Advance Respiratory, Inc., St. Paul, Minn. Control switch 34 is activated by compressing control bulb 40 , such as with a hand or a foot of patient P. Upon compression, control bulb 40 sends an air pulse through tube 38 to a pneumatic switch, which activates/deactivates air pulse generator 16 . Control switch 34 operates as a toggle switch when depressed and released.
FIG. 7 shows a second embodiment of control switch 34 . Here, control switch 34 includes connection plug 36 and button bulb 42 . Button bulb 42 is a small pneumatic bulb comprised of plastic, such as 60 durometer PVC, directly connected to connection plug 36 . Button bulb 42 may have a bleed hole to relieve pressure. Control switch 34 is inserted in switch port 32 of shell 18 . Button bulb 42 eliminates the need for tube 38 and provides an on/off/pause control next to user interface 28 for convenience and ease of use. Similar to the first embodiment described in FIG. 6 , control switch 34 shown in FIG. 7 sends an air pulse to a pneumatic switch, which activates/deactivates air pulse generator 16 . Again, control switch 34 operates as a toggle switch when depressed and released.
FIG. 8 shows air pulse generator 16 with front portion 24 removed. Air pulse generator 16 includes back portion 20 with handle 22 , air pulse module 44 , mounting plate 46 and main control board 60 . Air pulse module 44 further includes blower motor 50 , blower 52 , tube 54 and air chamber assembly 56 with air ports 58 , first diaphragm assembly 68 and second diaphragm assembly 70 . In the one embodiment, mounting plate 46 secures air pulse module 44 to shell 18 . Blower motor 50 is connected to blower 52 . Tube 54 fluidly connects blower 52 to air chamber assembly 56 , and first and second diaphragm assemblies 68 and 70 are positioned on opposite sides of air chamber assembly 56 . Main control board 60 is preferably secured within shell 18 opposite mounting plate 46 .
The oscillatory air pressure component is created by the pulsing action of first and second diaphragm assemblies 68 and 70 , which oscillates the air within air chamber assembly 56 at a selected frequency. The oscillatory pressure created by first and second diaphragm 68 and 70 follows a sinusoidal waveform pattern.
To create the steady state air pressure, blower motor 50 powers blower 52 to provide a bias line pressure to air chamber assembly 56 through tube 54 . Air within air chamber assembly 56 oscillates to provide the air pulses to vest 12 . Blower motor 50 and blower 52 may be, for example, an Ametek model 119319 or Torrington 1970-95-0168. Preferably, the steady state air pressure created by blower 52 is greater than atmospheric pressure, so that a whole oscillatory cycle is effective at moving chest C of patient P.
FIG. 9 shows an exploded view of front portion 24 of shell 18 . Front portion 24 includes keypad 112 , surround 113 , anchors 111 , display panel 110 , secondary control board 29 , fasteners 109 , air openings 30 and seal 62 . Keypad 112 fits into surround 113 , which fits onto the outside of front portion 24 . Anchors 111 are on the inside of front portion 24 such that display panel 110 fits between anchors 111 to secure display panel 110 in place. Secondary control board 29 is attached on the back side of display panel 110 and contains electronic circuitry for user interface 28 , which is detailed below. Fasteners 109 secure keypad 112 , surround 113 , anchors 111 and display panel 10 with secondary control board 29 together to form user interface 28 . Fasteners 109 further secure user interface 28 to front portion 24 .
Seal 62 is positioned between the front of air pulse module 44 and front portion 24 . Seal 62 is fitted around air openings 30 and air ports 58 to form an air tight connection between hoses 14 and air pulse module 44 .
When air pulse generator 16 is operating, essentially all of the pulsed air is transferred from air pulse module 44 to hoses 14 . Seal 62 is preferably comprised of an elastomer such as black nitrile having a durometer of 80 ±5. However, seal 62 may also be comprised of closed cell foam tape, or black vinyl type foam.
FIG. 10 is an inside view of back portion 20 of shell 18 . Back portion 20 includes vent 71 and support 72 . Support 72 is positioned between the back of air pulse module 44 and back portion 20 to secure air pulse module 44 within shell 18 and reduce noise and vibration produced by air pulse generator 16 . Support 72 is also designed such that air circulates around diaphragm motor 64 ( FIG. 12 ) to dissipate heat, thus preventing diaphragm motor 64 from overheating. Support 72 is preferably one piece but may be comprised of two or more individual supports. Support 72 is comprised of an elastomer such as black nitrile having a durometer of 60±5 shaped to conform to the surrounding parts but may alternatively be comprised of closed cell foam tape or black vinyl type foam.
Vent 71 is a region of back portion 20 having openings through shell 18 . Vent 71 is positioned such that heat from diaphragm motor 64 , secondary control board 29 and/or main control board 60 is released through vent 71 to prevent overheating.
FIG. 11 shows the front of air pulse module 44 with more clarity. Air pulse module 44 includes blower motor 50 , blower 52 , tube 54 and air chamber assembly 56 with air ports 58 , first diaphragm assembly 68 and second diaphragm assembly 70 . Refer to FIG. 8 for a description of the general function of air pulse module 44 .
FIG. 12 shows the back of air pulse module 44 . Air pulse module 44 includes blower motor 50 , blower 52 , tube 54 and air chamber assembly 56 having diaphragm motor 64 , air chamber shell 66 , first diaphragm assembly 68 and second diaphragm assembly 70 . First diaphragm assembly 68 further includes plate 68 a and diaphragm seal 68 b . Second diaphragm assembly 70 further includes plate 70 a (not shown) and diaphragm seal 70 b.
Diaphragm motor 64 is directly mounted on air chamber shell 66 at the back of air pulse module 44 . Diaphragm motor 64 may be an Aspen Motion Research Part No. 11702 or an equivalent motor. First diaphragm assembly 68 and second diaphragm assembly 70 are movably attached on opposite sides of air chamber shell 66 .
Diaphragm seals 68 b and 70 b have an annular U shape and are comprised of a flexible material such as natural rubber, silicon rubber, or nitrite rubber. Plates 68 a and 70 a are comprised of metal, such as aluminum, and are substantially flat. Diaphragm seals 68 b and 70 b provide a fluid type seal between plates 68 a and 70 a , respectively, and air chamber shell 66 . Air chamber shell 66 , first diaphragm assembly 68 , second diaphragm assembly 70 and diaphragm motor 64 substantially define an air chamber. In operation, diaphragm motor 64 powers movement of first diaphragm assembly 68 and second diaphragm assembly 70 to oscillate air within the air chamber, which is detailed below.
FIG. 13 is a front view of air chamber shell 66 . Air chamber shell 66 , with curvilinear walls 66 a and 66 b , is comprised of first portion 74 , second portion 76 , top joint 78 , bottom joint 80 , first diaphragm opening 82 (not shown) and second diaphragm opening 84 . First portion 74 further includes air ports 58 and blower inlet 86 . Second portion 76 further includes motor mount 90 and motor opening 92 .
First portion 74 and second portion 76 are secured together along top joint 78 and bottom joint 80 to form air chamber shell 66 . Formation of air chamber shell 66 also defines first diaphragm opening 82 and second diaphragm opening 84 on either side of air chamber shell 66 . First diaphragm assembly 68 and second diaphragm assembly 70 ( FIG. 11 ) are positioned over first diaphragm opening 82 and second diaphragm opening 84 , respectively, and are substantially parallel to each other.
Preferably, first portion 74 is comprised of plastic and second portion 76 is comprised of metal. The plastic reduces the weight of air pulse generator 16 , while the metal dissipates heat from diaphragm motor 64 to prevent overheating.
Air ports 58 discharge air from the air chamber of air chamber assembly 56 and fluidly connect with air openings 30 of shell 18 , such as by physically aligning with air openings 30 via seal 62 . Blower inlet 86 fluidly connects with the discharge of blower 52 , such as with a pipe or tube 54 ( FIG. 11 ) to transfer air pressure to the air chamber.
Air chamber shell 66 has at least one of curvilinear walls 66 a and 66 b . Curvilinear walls 66 a and 66 b smooth the air flow movement between diaphragm openings 82 and 84 . Curvilinear walls 66 a and 66 b have a substantially parabolic shape, but other curvilinear shapes, such as more circular curvilinear shapes, also smooth the air flow movement. The smoothed air flow movement reduces noise and vibration over prior art air pulse generators.
Within second portion 76 , diaphragm motor 64 is mounted to motor mount 88 . Diaphragm motor 64 fluidly seals motor opening 90 to further define the air chamber within air chamber assembly 56 .
FIG. 14 shows the crankshaft assembly within air pulse module 44 . Air pulse module 44 includes crankshaft assembly 92 , first diaphragm assembly 68 and second diaphragm assembly 70 . When in use, crankshaft assembly 92 operates, as described below in reference to FIG. 15 , to move first diaphragm assembly 68 and second diaphragm assembly 70 in a manner that oscillates air within the air chamber.
FIG. 15 is an exploded view of crankshaft assembly 92 . FIG. 15 shows crankshaft assembly 92 , diaphragm motor 64 with drive shaft 96 , air chamber shell 66 , plates 68 a and 70 a and line of motion 108 . Crankshaft assembly 92 further includes flywheel 94 having opening 94 a centered on one face and opening 94 b off-set on the opposite face, c-ring 97 , stub shaft 98 , member 100 having bearing 100 a and opening 100 b, c -ring 101 , cam 102 having openings 102 a and 102 b, c -ring 103 , member 106 having bearing 106 a and opening 106 b , stub shaft 104 and c-ring 105 .
Drive shaft 96 is attached to diaphragm motor 64 at one end and attached at the other end to opening 94 a of flywheel 94 . Stub shaft 98 is attached to flywheel 94 at opening 94 b . C-ring 97 secures stub shaft 98 within opening 94 b . Bearing 100 a is set within one end of member 100 allowing stub shaft 98 to pass through opening 100 b . Bearing 100 a allows stub shaft 98 to rotate within member 100 . C-ring 101 secures stub shaft 98 within opening 10 b . Stub shaft 98 is secured off-center through opening 102 a of cam 102 by c-ring 101 . Stub shaft 104 is secured off-center through opening 102 b to the opposite face of cam 102 by c-ring 103 such that stub shafts 98 and 104 are positioned equally but oppositely spaced from the center of cam 102 . Bearing 106 b is set within one end of member 106 allowing stub shaft 104 to pass through opening 106 a . Stub shaft 104 is secured to member 106 by c-ring 105 but is able to rotate within member 106 . Member 100 is rigidly or integrally attached to plate 70 a at an end opposite of bearing 100 a , and member 106 is similarly rigidly or integrally attached to plate 68 a at an end opposite of bearing 106 b.
In operation, diaphragm motor 64 turns drive shaft 96 which, in turn, rotates flywheel 94 causing stub shaft 98 to rotate in a circular fashion. The rotary motion generated by stub shaft 98 is converted to a generally reciprocating motion, shown by line of motion 108 , via member 100 . The reciprocating motion of member 100 in turn reciprocates plate 70 a generally along line of motion 108 .
The rotary motion of stub shaft 98 is transferred to cam 102 causing cam 102 to rotate, and, in turn, stub shaft 104 rotates in an identical circular fashion. The rotary motion generated by stub shaft 104 is converted to a generally reciprocating motion, shown by line of motion 108 , via member 106 . The reciprocating motion of member 106 in turn reciprocates plate 68 a generally along line of motion 108 .
The generally reciprocating motion exhibited by members 100 and 106 is more precisely defined as elliptical motion. The elliptical motion is transferred to plates 68 a and 70 a such that plates 68 a and 70 a “wobble” relative to line of motion 108 . When first diaphragm assembly 68 and second diaphragm assembly 70 are fully assembled, such as shown in FIG. 14 , the flexible nature of diaphragm seals 68 b and 70 b allow plates 68 a and 70 a to tip inwardly and outwardly as they reciprocate in and out of diaphragm openings 82 and 84 , respectively, relative to air chamber shell 66 . In addition, crankshaft assembly 92 operates such that plates 68 a and 70 a reciprocate in opposite directions relative to each other. The reciprocating motion of plates 68 a and 70 a create the oscillatory air pressure component for delivering HFCWO to patient P.
Using a pair of reciprocating diaphragms or plates 68 a and 70 a helps to balance the vibration forces that are created by air pulse generator 16 . The use of more than one diaphragm assembly would appear to add size and weight. However, adding a second diaphragm assembly in combination with improved motor control, as discussed above, results in a net weight savings. The reduction in vibration forces due to the balancing nature of opposed reciprocating diaphragm assemblies 68 and 70 allows for a reduced flywheel resulting in significant weight savings. Balanced motions allow for reduced peaks and variations in force which produce less noise and vibration and allow lighter and smaller mechanical components.
The air chamber defined by air chamber shell 66 , first diaphragm assembly 68 , second diaphragm assembly 70 and diaphragm motor 64 has a volume of about 130 in. 3 and an effective diaphragm area of about 56 in. 2 . The effective diaphragm area is defined as the sum of the area of diaphragm openings 82 and 84 . In comparison, THE VEST™ system has an effective diaphragm area of about 78 in. 2 and an air chamber volume of about 39 in. 3 , and the Medpulse 2000™ system has an effective diaphragm area of about 144 in. 2 and an air chamber volume of about 182 in. 3 .
The air chamber of air pulse generator 16 has a VA ratio of about 2.32. The VA ratio is defined as the air chamber volume divided by the effective diaphragm area. In comparison, THE VEST™ system has a VA ratio of about 0.5, and the Medpulse 2000™ system has a VA ratio of about 1.26.
Plates 68 a and 70 a reciprocate with a stroke length of about 0.5 in. In comparison, THE VEST™ system has a stroke length of about 0.375 in., and the Medpulse 2000™ system has a stroke length of about 0.312 in.
FIG. 16 shows main control board 60 having heatsink 129 . In the one embodiment, air pulse generator 16 includes heatsink 129 for dissipating internal heat from main control board 60 . Heatsink 129 is made of metal and absorbs and dissipates heat from circuitry ( FIG. 17 ) on the opposite side of main control board 60 .
Alternatively, air from blower 52 may be diverted to cool main control board 60 . However, the efficiency of blower 52 is compromised with this embodiment.
FIG. 17 shows the electronic circuitry of main control board 60 in more detail. Main control board 60 includes AC/DC Power module M 1 , Switching Power Supply inductor L 1 , Switching Power Supply capacitors C 3 and C 4 , Diaphragm Output Voltage capacitor C 13 , Blower Output Voltage capacitor C 14 , AC Power input J 1 , Diaphragm Motor connector J 3 , Blower Motor connector J 2 and User Interface connector J 4 .
The input power electrical system allows air pulse generator 16 to operate within specifications when the mains voltage is about 100-265 VAC, and the mains frequency is about 50 or 60 Hz±1 Hz. Air pulse generator 16 requires 3 Amps maximum. The rated running current is 2.5 Amps at 120 VAC or 1.25 Amps at 240 VAC. Typical idle current (plugged in but not running) is 30 mAmps at 120 VAC or 15 mAmps at 240 VAC. Ground Leakage current does not exceed 300 μAmps. The rated operating power is 300 watts, and the idle power is less than 4 watts.
The input power electrical system is designed to accommodate power irregularities as listed by UL 2601/EN 60601. In addition, it provides the required filtering for air pulse generator 16 to meet the requirements of EN 55011 (CISPR 11 ) Class B. The power inlet module provides filtering and fuse protection of both line and neutral, meeting the requirements of UL 2601/EN 60601.
Connection to AC mains is supplied by a 6 ft. long minimum detachable power cord meeting the appropriate agency approvals including UL 2601/EN 60601. Power cords in the United States are “Hospital Grade” power cords.
The internal circuitry, described in more detail below, utilizes the mains AC input voltage and converts it to DC power for use by the various components. The internal power supply circuitry produces 5 VDC±3%, 12 VDC ±3%,18 VDC and 80 VDC. The 18 and 80 volt supplies are variable voltages (and, therefore, have no tolerance rating) that are microprocessor controlled to provide the correct blower and diaphragm motor speeds. The low voltage 5 and 12 volt supplies are for the display and control logic, microprocessor and related circuitry. The 5 and 12 volt supplies have a relatively small current requirement and are designed to be on when air pulse generator 16 is plugged in.
Switching Power Supply inductor L 1 generates the required current to produce a of 6 VDC to 18 VDC for brushless blower motor 50 . The maximum current draw is 4 Amps. This variable voltage is controlled by a feedback loop comprised of microprocessor based Switching Power Supply, motor voltage comparater, motor controller and Hall Effect motor sensor speed.
Switching Power Supply inductor L 1 generates the required current to produce a voltage of 15 VDC to 80 VDC for diaphragm motor 64 . The maximum current draw is 2 amps. This variable voltage is controlled by a feedback loop comprised of microprocessor based Switching Power Supply, motor voltage comparater, motor controller and Hall Effect motor sensor speed.
The backlight of display panel 110 requires 5 VDC at 500 mAmps. This circuitry is on only when air pulse generator 16 is plugged in and not in IDLE mode.
Air pulse generator 16 is controlled through user interface 28 using a combination of software and hardware. Patient P controls air pulse generator 16 via buttons 114 - 128 as described above. The status, settings and user messages are displayed on display panel 110 .
FIG. 18 is a block diagram showing a control system of air pulse generator 16 . The control system includes User Interface control 200 , Power Supply control 202 , Diagram Motor control 204 , Blower Motor control 206 , Real Time clock 208 , FLASH memory 210 , and external port 212 . User Interface control 200 monitors inputs from buttons 114 - 128 and from control switch 34 and provides outputs to control the operation of display panel 110 of user interface 28 . In addition, User Interface control 200 coordinates the operation of Power Supply control 202 , Diaphragm Motor control 204 , and Blower Motor control 206 .
User Interface control 200 provides a diaphragm power request signal and a blower power request signal to Power Supply control 202 . The power request signals are analog signals which represent a desired motor drive voltage to be supplied to diaphragm motor 64 and blower motor 50 , respectively.
User Interface control 200 receives a Hall-A signal from one Hall sensor of blower motor 50 and a composite Hall pulse train from Diaphragm Motor control 204 . The Hall-A signal is used by User Interface control 200 to monitor the speed of blower motor 50 . The composite Hall pulse train, which provides pulses for each signal transition of each of three Hall sensors of diaphragm motor 64 allows User Interface control 200 to monitor instantaneous speed of diaphragm motor 64 . The composite Hall pulse train allows User Interface control 200 to monitor diaphragm instantaneous speed for every 12 degrees of rotation of diaphragm motor 64 . Since diaphragm motor 64 is rotating at a relatively low speed (up to about 20 cycles per second maximum) and is subjected to uneven loads during each cycle, there is a need for monitoring instantaneous speed of diaphragm motor 64 closely in order to insure stable operation.
Based upon the desired operating parameters which have been set by patient P through buttons 114 - 128 and the sensed motor speeds provided by the composite Hall pulse train from Diaphragm Motor control 204 and the Hall-A sensor signal from blower motor 64 , User Interface control 200 controls the rate of diaphragm power requests and the blower power requests supplied to Power Supply control 202 . This can be accomplished by direct UIC 200 control or by the UIC 200 producing a reference voltage to the motor voltage comparater.
User Interface control 200 also receives a diaphragm pressure signal from a pressure sensor connected to the air chamber. The pressure signal is used as described above to derive a relationship between air chamber and vest pressure.
Power Supply control 202 , Diaphragm Motor control 204 , and Blower Motor control 206 are located on main control board 60 shown in FIG. 17 . User Interface control 200 , Real Time clock 208 and FLASH memory 210 are located on secondary control board 29 shown in FIG. 9 .
Under normal operation, the software monitors requests from user interface 28 and control switch 34 and generates the appropriate electrical signals that operate air pulse generator 16 at the user specified parameters. In addition, the software maintains a timer to allow reporting of therapy session time and total usage time.
Control switch 34 is an input method to activate pulsing of air, alternatively ON switch 114 may be used to activate pulsing of air. The software provides user control to operate air pulse generator 16 in the various modes described above. Pausing during a therapy session to cough, remove mucus or take medication is controlled by the software via control switch 34 . Lack of input by patient P while air pulse generator 16 is paused causes the software to begin IDLE mode.
The software also operates a timer that provides the user information about the current therapy session. The remaining session time is displayed on display panel 110 . Session time consists of either both pulsing and paused time or just pause time, and the time is displayed in minutes (e.g. 17 Minutes To Go).
The software additionally operates another timer that provides cumulative operating hours. Compliance information is displayed on display panel 110 each time air pulse generator 16 is plugged in and in IDLE mode. Cumulative operating time includes both pulsing and paused time, and the time is displayed in hours and tenths of hours (e.g. Total Use 635.6 Hours).
An I/O data port is available for interfacing to air pulse generator 16 through user interface 28 . The interface is an I/O data port serial protocol accessible via a special adapter designed to connect to the main board via a stereo jack style plug. All microprocessors are selected such that they have the 110 data port bus inherent in their design. The I/O data port bus master is the User Interface control (UIC) 200 and the slaves are the Power Supply control (PSC) 202 , the Blower Motor control (BMC) 206 and the Diaphragm Motor control (DMC) 204 . See FIG. 18 .
The I/O data port allows the following functionality: A) user compliance information, specifically, a time and date stamp (cumulative operating time), is stored in memory for reading via user interface 28 or the I/O data port. Air pulse generator 16 contains memory capable of storing six months of cumulative operating time. Once the memory is full, storage of new information will overwrite the oldest data and maintain the most recent information.
B) Operating parameters are loaded in the microcontroller memory. Downloading the functional parameters (frequency, pressure and time) via this port is available to automate manufacturing final test and checkout.
C) Operational states and failures of air pulse generator 16 are transferred to user interface 28 or to the I/O data port for troubleshooting or customer feedback.
D) Software upgrades may be transferred to the microcontroller via the I/O data port.
The software is written in a Microchip PIC compatible version of the C programming language and may contain some assembly language. Executable code is generated by the HI-TECH C compiler specifically designed for the Microchip PIC controller family. The code is tested utilizing the MPLAB simulator from Microchip, a proto-type version of hardware, and a PIC-ICE (in-circuit emulator) from Phyton.
Air pulse generator 16 uses Microchip microcontrollers (or microprocessors) running with an oscillator speed of 8 MHz minimum to host the required software. These microcontrollers are selected based on the required functionality while allowing for future development. PSC 202 , BMC 206 , DMC 204 and UIC 200 are four microprocessor controllers used.
PSC 202 software delays startup for ⅓ second to allow charging of capacitors, receives requests from the DMC 204 and the BMC 206 , controls the switching of the power supply capacitors and selects the appropriate switch for the output.
BMC 206 software controls commutation for blower motor 50 , receives blower motor 50 .
DMC 204 software controls commutation for diaphragm motor 64 , and sense motor speed information such as the composite Hall pulse train to the UIC 200 .
UIC 200 software manages display panel 110 , reads button presses, times the session and stops air pulse generator 16 when finished, maintains cumulative operating time, sends pressure and frequency requests to the DMC 204 and BMC 206 , writes parameters to FLASH memory 210 (using I/O data port), reads default parameter/messages from on board memory on the UIC 200 or from FLASH memory 210 (using I/O data port), reads messages/commands from an external port (using I/O data port), reads/writes Real Time Clock 208 (using I/O data port) and analyzes diaphragm pressure measurement.
External memory, such as FLASH memory 210 or on chip memory such as on UIC 200 stores patient use information, default parameter limits and display messages. All program instructions and variables are contained in the microcontroller on chip memory.
FIG. 19 is an electrical schematic diagram of AC Mains circuit 220 , which is a portion of power supply control 202 . AC Mains circuit includes AC Power Input connector J 1 with terminals J 1 - 1 , J 1 - 2 and J 1 - 3 , Positive Phase Power circuit 222 , Negative Phase Power circuit 224 , AC/DC Converter circuit 226 and Power On circuit 228 .
AC Mains circuit 220 receives AC line power at connector J 1 and supplies power to drive diaphragm motor 64 and blower motor 50 (+PHASE — PWR and −PHASE_PWR). In addition, AC Mains circuit 220 produces +5 V and +12 V signals which are used by the circuitry of the control system shown in FIG. 18 .
Positive Phase Power circuit 222 includes resistor R 1 , diodes D 1 and D 2 , capacitors C 1 and C 3 , and fuse F 1 . Circuit 222 stores electrical power from the AC mains line power on capacitor C 1 . Approximately a 170 volt DC voltage is established at the +PHASE power output of circuit 222 .
Similarly, circuit 224 produces the −PHASE power value based upon the other half cycle of AC power. Circuit 224 includes resistor R 2 , diodes D 3 and D 4 , capacitors C 2 and C 4 , and fuse F 2 . Circuit 224 stores electrical power from the AC mains line power on capacitor C 2 . A voltage of approximately 170 volts DC is established as the −PHASE power signal.
The +PHASE power and −PHASE power are supplied alternatively based upon the +PHASE signal which is derived from terminal J 1 - 1 of connector J 1 . The +PHASE signal allows switching circuitry of Power Supply control 202 to alternately draw power from the +PHASE power and the −PHASE power in such a way that power is drawn from whichever capacitor is currently not being charged. This provides isolation between the AC line and the remaining circuitry of the control system, without the need for expensive and heavy line noise reduction circuitry.
The DC voltage levels used by the circuitry of the control system are produced by AC/DC circuit 226 , which includes AC/DC module M 1 and capacitors C 5 and C 6 . Module M 1 is a conventional AC to DC converter.
Also shown in FIG. 19 is Line Surge protector Z 1 . It is connected between terminals J 1 - 1 and J 1 - 3 of connector J 1 .
AC Mains circuit 220 also includes Power On circuit 228 which includes resistors R 3 and R 4 , relay K 1 , transistor Q 1 , and diode D 5 .
Power On circuit 228 utilizes relay K 1 in combination resistor R 3 to provide a ⅓ second delay in startup. This allows capacitors C 1 and C 2 to precharge. Allowing ⅓ second for startup delay and 5 RC time constants for capacitors to fully charge, the resistance of resistor R 3 is calculated as follows:
R =(0.33)/(5×560 μF)
R= 118 Ohms(use 100 Ohms)
Choosing 100 Ohms limits I rms to 2.65 A (at V rms =265 volts). 560 μF capacitors were sized for ± PHASE power to stay above 100 V with ripple at I max (which occurs at V min ). At 100 VAC in , VDC max =140volts. If VDC min 100 VDC, then VDC avg =120 VDC. With 300 watts max power, I c3/c4 =300watts/120volts=2.5 amps. Each capacitor will be discharging for ½ an AC cycle (60 Hz) or 8.3 msec. The size of the capacitor required is calculated as follows: C=i(t)/V=(2.5)(0.0083)/40=519 μF (V=Vmax−Vmin=140−100=40). Diode D 5 protects transistor Q 1 from flyback current induced from relay K 1 .
FIG. 20 shows Switching Power Supply circuitry 230 , which uses the +PHASE power and −PHASE power received from AC Mains circuit 220 to produce variable voltages used to control the speed of diaphragm motor 64 and blower motor 50 . Switching Power Supply circuitry 230 reduces electrical noise and allows several dynamically variable voltages to be produced by a single switching structure. The variable voltage used to control diaphragm motor 64 is labeled DIAPH_PWR, and the variable voltage used to control blower motor 50 is labeled BLOWER_PWR.
Switching Power Supply circuit 230 includes +PHASE Switching circuit 232 , −PHASE Switching circuit 234 , Switching Power Supply inductor L 1 , Phase Detection Input circuit 236 , microprocessor IC 8 , Diaphragm Power Storage capacitor C 13 , Blower Power Storage capacitor C 14 , Diaphragm Power Charging circuit 238 , Blower Power Charging circuit 240 , Voltage Fault Sensing circuit 242 , 5V/12V convertors M 2 , M 3 , and M 4 , and crystal oscillator X 1 .
Switching circuits 232 and 234 produce 10 Amp pulses which are supplied through inductor L 1 . When the +PHASE signal received by Phase Detection Input circuit 236 indicates that the −PHASE capacitors are being charged, circuit 232 supplies the 10 amp pulses. Conversely, when the +PHASE signal supplied from circuit 236 to the RAO input of microprocessor ICS indicates that the +PHASE power storage capacitors are being charged, microprocessor IC 8 activates circuit 234 to supply the current pulses using the −PHASE power. In this way, current is drawn from the +PHASE and −PHASE storage capacitors only during the times when they are not being charged.
+Phase Switching circuit 232 includes diode D 6 , transistor Q 2 , Current Sensing driver IC 3 , resistors R 5 and R 111 , capacitors C 40 and C 8 and Current Sensing resistor R 7 .
The +PHASE power is supplied through diode D 6 to transistor Q 2 . IC 3 is a high voltage, high speed power driver which supplies a control plus to a gate of Q 2 to allow current from +PHASE power to flow through diode D 6 , transistor Q 2 and Sensing resistor R 7 to inductor L 1 . Microprocessor IC 8 activates IC 3 based upon the +PHASE sense signal by supplying an input signal to the input terminal IN of IC 3 . Q 2 is turned on by IC 3 for a time duration to produce a 10 amp pulse. IC 3 senses the current through Sensing resistor R 7 to control the current pulses.
−Phase Switching circuit 234 is similar to +Phase Switching circuit 232 . It includes diode D 7 , transistor Q 3 , Current Sensing driver IC 4 , resistors R 6 and R 112 , capacitor C 41 , and Current Sensing resistor R 8 .
When IC 4 is turned on by microprocessor IC 8 , it switches transistor Q 3 on and off to produce 10 amp pulses, which are sensed by IC 4 using Sensing resistor R 8 . The 10 amp pulses are supplied through R 8 to inductor L 1 .
Phase Detection Input circuit 236 includes resistors R 9 and R 10 , capacitor C 100 and diodes D 101 and D 102 . The +PHASE signal is received from AC Mains circuit 220 and is supplied to the RAO input of microprocessor ICS.
Microprocessor IC 8 controls the charging of capacitor C 13 by Charging circuit 238 depending upon whether the diaphragm power request, DIAPH_PWR_REQ, signal at input RB 4 is high or low. If the signal is high, circuit 238 is activated so that current pulses supplied through inductor L 1 are used to charge capacitor C 13 .
Similarly, charging of capacitor C 14 is controlled by microcontroller IC 8 through Charging circuit 238 as a function of the BLOWER_PWR_REQ signal input at RB 5 . When circuit 240 is activated, current from inductor L 1 is supplied to capacitor C 14 to increase the BLOWER_PWR voltage.
Diaphragm Power Charging circuit 238 includes resistor R 1 , Optoisolator driver IC 6 , diode D 8 , resistors R 13 and R 14 , and transistor Q 4 . When the output of IC 8 at RBO goes high, IC 6 is activated to turn on transistor Q 4 . That allows current pulses from L 1 to pass through Q 4 and charge Diaphragm Power Storage capacitor C 13 . As the pulses are received, the voltage on capacitor C 13 will tend to increase. When the diaphragm power request signal supplied to IC 8 goes low, circuit 238 turns off and charging of capacitor C 13 ceases.
Blower Power Charging circuit 240 is similar to Diaphragm Power Charging circuit 238 . It includes resistor R 12 , optoisolator driver IC 7 , diode D 9 , resistors R 15 and R 16 , and transistor Q 5 . Microprocessor IC 8 turns on IC 7 and Q 5 in response to the BLOWER_PWR_REQ signal being high. As long as that signal stays high, transistor Q 5 is turned on and current pulses from L 1 are used to charge capacitor C 14 .
Voltage Fault Sensing circuit 242 senses over voltage conditions on either capacitor C 13 or C 14 . Voltage Fault Sensing circuit 242 includes zener diodes D 13 and Dl 4 , resistors R 17 , R 18 , and R 19 , capacitor C 15 , and transistor Q 29 . The output of circuit 242 is a /V fault signal which is high as long as the voltage on C 13 does not exceed the break down voltage of zener diode D 13 , or the lower power voltage on capacitor C 14 does not exceed the break down voltage of zener diode D 14 .
FIG. 21 shows additional components of the Power Supply control 202 .
Power Up Clear & Fault Reset circuit 250 provides a fault reset signal to microprocessor IC 8 during power up conditions and in the event of a fault. Circuit 250 includes diode D 28 , resistors R 53 , R 54 , R 55 , and R 56 , capacitor C 22 , transistor Q 30 , and gates U 15 -Ul 8 and power on Reset Pulse generator U 19 . The two fault conditions sensed by circuit 250 based upon the L 1 _LOW_SIDE signal drive from the low voltage side of inductor L 1 (see FIG. 20 ) and the /V FAULT signal produced by circuit 242 of FIG. 20 .
Also shown in FIG. 21 is connector J 4 , which provides electrical connections between User Interface control 200 and Power Supply control 202 , Diaphragm Motor control 204 and Blower Motor control 206 . User Interface control 200 is on a separate circuit board, such as secondary control board 29 , from controls 202 , 204 , and 206 , which may be located on main control board 60 . FIG. 21 also shows Diaphragm Power Comparater circuit 252 and Blower Power Comparater circuit 254 .
As shown in FIG. 21 , circuit 252 includes resistors R 61 -R 64 , R 67 , and R 68 and comparator U 21 . Diaphragm Power Comparator circuit 252 produces the DIAPH_PWR_REQ input to microprocessor IC 8 as a function of a DIAPHRAGM_PWR_REQ voltage supplied by User Interface control 200 through connector J 4 , and the DIAPH_PWR voltage stored on capacitor C 13 .
User Interface control 200 generates the DIAPHRAGM_PWR_REQ signal as a function of the desired oscillation frequency set by patient P (or automatically determined) and the sensed diaphragm motor speed based upon the composite Hall pulse train. The DIAPHRAGM_PWR_REQ signal is a speed command voltage which is compared to the stored voltage DIAP_PWR on capacitor C 13 . As long as DIAPH_PWR is less then the DIAPHRAGM_PWR_REQ level, the output DIAPH_PWR_REQ is high. As long as that signal is high, microprocessor IC 8 turns Charging circuit 238 on to allow current pulses to be supplied to capacitor C 13 . When DIAPH_PWR exceeds the speed command signal DIAPHRAGM_PWR_REQ, the output of circuit 252 goes low, which causes microprocessor ICS to turn off Charging circuit 238 .
Blower Power Comparator circuit 254 is generally similar to Diaphragm Power comparator 252 . It includes resistors R 57 -R 60 , R 65 , and R 66 and comparator U 20 .
The speed command signal for blower motor 50 is BLOWER_REQ which is produced by User Interface control 200 as a function of the bias line pressure setting selected by patient P and the blower speeds as indicated by the Hall-A feed back signal from blower motor 50 . That speed command signal is compared to the voltage on capacitor C 14 , BLOWER_PWR. As long as BLOWER_PWR is less than the BLOWER_REQ command, the output of circuit 242 , BLOWER_PWR_REQ is high. That causes microprocessor IC 8 to turn on Charging circuit 240 to charge capacitor C 14 . When the command voltage BLOWER_REQ is reached or exceeded by BLOWER_PWR, the output of Comparator circuit 254 goes low, which causes microprocessor ICS to turn off Charging circuit 240 .
FIG. 22 shows Diaphragm Motor control 204 , which includes microprocessor IC 10 , crystal oscillator X 3 , connector J 3 (which includes terminals J 3 - 1 through J 3 - 8 ), Phase A Drive circuit 250 A, Phase B Drive circuit 250 B, and Phase C Drive circuit 250 C, and Hall Effect Sensor Interface circuit 260 .
Diaphragm Motor control 204 receives the variable voltage DIAPH_PWR from Power Supply control 202 . That variable voltage has supplied each of the three Phase Drive circuits 250 A, 250 B, 250 C. Microprocessor IC 10 acts as a sequencer or commutator to selectively turn on and off transistors of Drive circuits 250 A, 250 B, and 250 C to cause rotation of diaphragm motor 64 . The commutation is based upon on the Hall Effect sensor signals S A , S B and S C which are received from the three Hall Effect sensors of the BC diaphragm motor. The Hall Effect sensor signals are supplied through terminals J 3 - 6 through J 3 - 8 to inputs of microprocessor IC 10
In addition, microprocessor IC 10 supplies the HALL_TRANSITION signal which is the composite Hall pulse train supplied to User Interface control 200 , so that User Interface control 200 can determine the speed of diaphragm motor 64 .
Drive circuit 250 A is controlled by RB 1 and RB 2 outputs of microprocessor IC 10 . It includes resistors R 39 , R 42 , R 45 and R 48 , diodes D 22 and D 25 , capacitor C 19 , ferrite chip L 10 , transistor Q 22 , and Power Switching transistors Q 16 and Q 17 .
Phase B Drive circuit 250 B is controlled by RB 4 and RB 5 outputs of microprocessor IC 10 . It includes resistors R 40 , R 43 , R 46 , and R 49 , diodes D 23 and D 26 , capacitor C 20 , ferrite chip L 11 , transistor Q 23 and Power Switching transistors Q 18 and Q 19 .
Similarly, Phase C Drive circuit 250 C is controlled by RB 6 and RB 7 outputs of microprocessor IC 10 . It includes resistors R 41 , R 44 , R 47 , and R 50 , diodes D 24 and D 27 , capacitor C 21 , ferrite chip L 12 , transistor Q 24 , and Power Switching transistors Q 20 and Q 21 .
Hall Effect Sensor Interface circuit 260 includes ferrite chips L 13 -L 17 and Pull Up resistors R 106 -R 108 .
FIG. 23 is a schematic diagram of Blower Motor control 206 . It includes microprocessor IC 9 , Phase A Drive circuit 270 A, Phase B Drive circuit 270 B, and Phase C Drive circuit 270 C, and Hall Effect Sensor Interface circuit 280 and crystal oscillator X 2 .
Microprocessor IC 9 controls Phase A, B, and C Drive circuits 270 A- 270 C as a sequencer or commutator based upon the Hall Effect sensor signals S A , S B and S C . Drive circuits 270 A- 270 C selectively supply the variable voltage BLOWER-PWR through the phase A, phase B, and phase C windings of blower motor 50 . The operation of Blower Motor control 206 is similar to that of Diaphragm Motor control 204 with one exception. Because blower motor 50 runs at a much higher speed than diaphragm motor 64 , a single Hall Effect sensor signal Blower_Hall_A can be supplied to User Interface control 202 as the speed feedback signal.
Drive circuit 270 A is controlled by RB 1 and RB 2 outputs of microprocessor IC 9 . Drive circuit 270 A includes resistors R 27 , R 30 , R 33 and RR 36 , diodes D 16 and D 19 , capacitor C 16 , ferrite chip L 2 , transistor Q 13 and Power Switching resistors Q 7 A and Q 7 B.
Drive circuit 270 B is controlled by RB 4 and RB 5 outputs of microprocessor IC 9 . Drive circuit 270 B includes resistors R 28 , R 31 , R 34 and R 37 , diodes D 17 and D 20 , capacitor C 17 , ferrite chip L 3 , transistor Q 14 and Power Switching transistors Q 9 A and Q 9 B.
Similarly, Phase C Drive circuit 270 C is controlled by RB 6 and RB 7 outputs of microprocessor IC 9 . It includes resistors R 29 , R 32 , R 35 , and R 38 , diodes D 18 and D 21 , capacitor C 18 , ferrite chip L 4 , transistor Q 15 , and Power Switching transistors Q 11 A and Q 11 B.
FIGS. 24-28 are graphs illustrating the performance of air pulse generator 16 with and without internal heat dissipation compared to prior art air pulse generators. A prior art air pulse generator, 103 ; air pulse generator 16 with air from blower 52 diverted to cool main control board 60 , 104 cool; and air pulse generator 16 without diversion of air from blower 52 , 104 were performance tested at 5 Hz, 10 Hz, 15 Hz and 20 Hz. The testing consists of measuring pressure inside a vest's air reserve (bladder) with a Viatron pressure transducer attached to the vest's connector port, and the output of the transducer is connected to an oscilloscope. A vest is connected to each of the air pulse generators and the observed pulse maximum (PMAX) and pulse minimum (PMIN) are recorded at each frequency, with the exception that 104 cool was not tested at 5 Hz. The delta, or pressure stroke, is calculated by subtracting the PMIN from PMAX.
FIG. 24 shows the results using an adult large vest, FIG. 25 is the results using an adult medium vest, FIG. 26 is the results using an adult small vest, FIG. 27 is the results using a child large vest and FIG. 28 is the results using a child medium vest. As depicted in each of the graphs, 104 and 104 cool exhibit pressure consistent with the prior art air pulse generator.
Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.
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An improved method of producing high frequency chest wall oscillations (HFCWO) includes generating oscillating pneumatic pressure and applying an oscillating force to a patient's chest that corresponds to the oscillating pneumatic pressure. The frequency of oscillations changes according to a prescribed treatment regimen.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of the filing date of U.S. provisional patent application Ser. No. 60/455,718, attorney docket no. 25791.262, filed on Mar. 18, 2003, the disclosure of which is incorporated herein by reference.
[0002] This application is related to the following co-pending applications: (1) U.S. Pat. No. 6,497,289, which was filed as U.S. patent application Ser. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999, which claims priority from provisional application 60/111,293, filed on Dec. 7, 1998, (2) U.S. patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claims priority from provisional application 60/121,702, filed on Feb. 25, 1999, (3) U.S. patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claims priority from provisional application 60/119,611, filed on Feb. 11, 1999, (4) U.S. Pat. No. 6,328,113, which was filed as U.S. patent application Ser. No. 09/440,338, attorney docket number 25791.9.02, filed on Nov. 15, 1999, which claims priority from provisional application 60/108,558, filed on Nov. 16, 1998, (5) U.S. patent application Ser. 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No. 09/811,734, filed on Mar. 19, 2001, (114) U.S. patent application Ser. No. 10/436,467, attorney docket no. 25791.268, filed on May 12, 2003, which is a continuation of U.S. Pat. No. 6,604,763, which was filed as application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claims priority from provisional application 60/131,106, filed on Apr. 26, 1999, (115) U.S. provisional patent application Ser. No. 60/459,776, attorney docket no. 25791.270, filed on Apr. 2, 2003, (116) U.S. provisional patent application Ser. No. 60/461,094, attorney docket no. 25791.272, filed on Apr. 8, 2003, (117) U.S. provisional patent application Ser. No. 60/461,038, attorney docket no. 25791.273, filed on Apr. 7, 2003, (118) U.S. provisional patent application Ser. No. 60/463,586, attorney docket no. 25791.277, filed on Apr. 17, 2003, (119) U.S. provisional patent application Ser. No. 60/472,240, attorney docket no. 25791.286, filed on May 20, 2003, (120) U.S. patent application Ser. No. 10/619,285, attorney docket no. 25791.292, filed on Jul. 14, 2003, which is a continuation-in-part of U.S. utility patent application Ser. No. 09/969,922, attorney docket no. 25791.69, filed on Oct. 3, 2001, which is a continuation-in-part application of U.S. Pat. No. 6,328,113, which was filed as U.S. patent application Ser. No. 09/440,338, attorney docket number 25791.9.02, filed on Nov. 15, 1999, which claims priority from provisional application 60/108,558, filed on Nov. 16, 1998, (121) U.S. utility patent application Ser. No. 10/418,688, attorney docket no. 25791.257, which was filed on Apr. 18, 2003, as a division of U.S. utility patent application Ser. No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claims priority from provisional application 60/124,042, filed on Mar. 11, 1999, (122) U.S. utility patent application Ser. No. ______, attorney docket no. 25791.238.02, which was filed on Feb. 26, 2004, which claims the benefit of the filing date of U.S. provisional patent application Ser. No. 60/450,504, attorney docket no. 25791.238, filed on Feb. 26, 2003, (123) U.S. utility patent application Ser. No. ______, attorney docket no. 25791.253.02, which was filed on Mar. 11, 2004, which claims the benefit of the filing date of U.S. provisional patent application Ser. No. 60/453,678, attorney docket number 25791.253, filed on Mar. 11, 2003, (124) U.S. utility patent application Ser. No. ______, attorney docket no. 25791.40.02, which was filed on Mar. 15, 2003, which claims the benefit of the filing date of U.S. provisional patent application Ser. No. 60/455,051, attorney docket number 25791.40, filed on Mar. 14, 2003, and (125) U.S. utility patent application Ser. No. ______, attorney docket no. 25791.236.02, which was filed on Mar. 15, 2004, which claims the benefit of the filing date of U.S. provisional patent application Ser. No. 60/454,896, attorney docket number 25791.236, filed on Mar. 14, 2003, the disclosures of which are incorporated herein by reference.
BACKGROUND
[0003] This invention relates generally to oil and gas exploration, and in particular to forming and repairing well bore casings to facilitate oil and gas exploration.
[0004] Expandable tubing may be used in, among other applications, the forming and repairing of well bore casings. Typically, an expandable tubing string is lowered into and down a well bore by an expansion apparatus positioned at the bottom of the string. The expansion apparatus is lowered down the well bore via another tubing string that is disposed through the expandable tubing string and connected to the expansion apparatus. Because the expansion apparatus supports the weight of the expandable tubing string, the string is in compression while being carried down the well bore. If the expandable tubing string is comprised of a series of interconnected joints, this compressive state can result in damage to the various joint connections along the expandable tubing string. Also, if the expandable tubing string is long enough, the overall weight of the string may cause the string to compress to such a degree that an unwanted and/or uncontrolled expansion of the string occurs.
[0005] Therefore, what is needed is an apparatus and method for carrying an expandable tubing string in a well bore that overcomes the above-described problems, among others.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a partial elevational/partial sectional/partial schematic view, not necessarily to scale, depicting a system according to one embodiment, the system including a tool 20 , a slip joint 24 , a safety sub 28 , an expansion apparatus 30 and an expandable member 34 wherein the expansion apparatus 30 , among other components, is being lowered.
[0007] FIG. 1 a is a partial sectional view, not necessarily to scale, depicting the tool 20 of FIG. 1 .
[0008] FIG. 1 b is a partial sectional view, not necessarily to scale, depicting the slip joint 24 of FIG. 1 .
[0009] FIG. 1 c is a partial elevational/partial sectional view, not necessarily to scale, depicting the sub 28 and the expansion apparatus 30 of FIG. 1 .
[0010] FIG. 2 a is a partial sectional view, not necessarily to scale, depicting the tool 20 of FIG. 1 but showing another operational mode.
[0011] FIG. 2 b is a partial sectional view, not necessarily to scale, depicting the slip joint 24 of FIG. 1 but showing another operational mode.
[0012] FIG. 3 a is a partial sectional view, not necessarily to scale, depicting the tool 20 of FIG. 1 but showing yet another operational mode.
[0013] FIG. 3 b is a partial sectional view, not necessarily to scale, depicting the slip joint 24 of FIG. 1 but showing yet another operational mode.
DETAILED DESCRIPTION
[0014] Referring to FIG. 1 of the drawings, the reference numeral 10 refers to a well bore penetrating a subterranean ground formation F for the purpose of recovering hydrocarbon fluids from the formation, the well bore having a bottom 12 . A series of components 14 is lowered into the well bore 10 by a tubular string 16 , in the form of coiled tubing, jointed tubing, or the like which is connected to the upper end of the series. The components in the series 14 will be described.
[0015] The string 16 extends from a rig 18 that is located above ground and extends over the well bore 10 . The rig 18 is conventional and, as such, includes support structure, a motor driven winch, or the like, and other associated equipment for receiving and supporting the series 14 and lowering it into the well bore 10 by unwinding the string 16 from the winch. The upper portion of the well bore 10 can be lined with a casing 19 in any conventional manner.
[0016] The series 14 includes a tool 20 to which the string 16 is connected. A tubular string 22 , in the form of coiled tubing, jointed tubing, or the like, is connected to and extends downward from the tool 20 . A slip joint 24 is connected to the lower end of the string 22 , and a tubular string 26 , in the form of coiled tubing, jointed tubing, or the like, is connected to and extends downward from the slip joint 24 and its lower end is connected to a safety sub 28 . An expansion apparatus 30 is connected to the sub 28 . The expansion apparatus 30 includes a float shoe 32 .
[0017] An expandable tubular member 34 is connected to, and extends downward from, the lower end of the tool 20 to the shoe 32 so that the slip joint 24 , the string 26 , the sub 28 , and the expansion apparatus 30 are all disposed within the member 34 . The expansion apparatus 30 is slidably engaged with the internal wall of the member 34 . The member 34 is comprised of a plurality of joints (not shown) that are each interconnected via a left hand thread engagement configuration. Thus, the series of components 14 includes the tool 20 , the string 22 , the slip joint 24 , the string 26 , the sub 28 , the expansion apparatus 30 which includes the shoe 32 , and the member 34 .
[0018] The lower end portion of the member 34 that extends around the apparatus 30 has an increased diameter, and a variable-dimension annulus 35 is defined by the internal wall of the member 34 and the external walls of the string 22 , the slip joint 24 and the string 26 . A variable-dimension annulus 36 is also defined between the inner wall of the well bore 10 and the external wall of the member 34 .
[0019] Referring to FIG. 1 a , an embodiment of the tool 20 is shown and includes an elongated tubular member or coupling 37 to which the string 16 is connected via a conventional drillpipe box thread connection 38 . The coupling 37 includes an o-ring 40 , a pair of openings 42 a and 42 b , and an internal straight thread connection 44 . Also, the coupling 37 defines a passage 45 .
[0020] A mandrel extension 46 , in the form of an elongated tubular body member, is connected to the coupling 37 via the thread connection 44 , and the o-ring 40 seals against the mandrel extension 46 immediately above this connection. The mandrel extension 46 includes a pair of openings 48 a and 48 b that are aligned with the openings 42 a and 42 b of the coupling 37 , and the aligned openings receive two torque pins 50 a and 50 b , respectively. The mandrel extension 46 further includes an o-ring 52 , a pair of openings 54 a and 54 b , and an internal straight thread connection 55 .
[0021] A mandrel 56 , also in the form of an elongated tubular body member, is connected to the mandrel extension 46 via the thread connection 55 , and the o-ring 52 seals against the mandrel immediately above this connection. The mandrel 56 includes a pair of openings 58 a and 58 b that are aligned with the openings 54 a and 54 b , respectively, of the mandrel extension 46 . Two torque pins 60 a and 60 b extend through the aligned openings 54 a and 60 a , and the aligned openings 54 b and 60 b , respectively. The mandrel 56 further includes a plurality of external splines 62 a and 62 b extending downwardly a predetermined distance along the mandrel 56 . Each external spline 62 a and 62 b includes at least one chamfer 64 .
[0022] An external shoulder 66 is formed on the mandrel 56 below the external splines 62 a and 62 b , and a plurality of downward-extending grooves 68 are formed in the shoulder 66 (a side wall of one groove 68 is shown in FIG. 1a ). The mandrel 56 further includes a conventional drillpipe pin thread connection 70 to which the string 22 is connected.
[0023] A tubular cap 72 extends around the mandrel 56 and has a plurality of internal splines 74 a and 74 b formed therein which are engaged with the external splines 62 a and 62 b , respectively, of the mandrel 56 . Each of the splines 74 a and 74 b has at least one chamfer 76 (not shown) which is adapted to engage a corresponding chamfer 64 of the mandrel 56 . The cap 72 further includes a radial surface 78 that is engaged with the shoulder 66 of the mandrel 56 , and a pair of fluid ports 80 a and 80 b are formed in the cap 72 at a predetermined distance below the surface 78 . An annular recess 82 is formed in the cap 72 at a predetermined distance below the fluid ports 80 a and 80 b , and receives an anti-torque ring 84 , which is made of a conventional low-friction material. The cap 72 further includes an internal right hand straight thread connection 86 .
[0024] A casing adapter 88 , in the form of an elongated tubular member, is connected to the cap 72 via the connection 86 and the anti-torque ring 84 is adapted to allow the cap 72 to be removably connected to the casing adapter 88 . Since the anti-torque ring 84 is conventional, it will not be described in further detail. The casing adapter 88 extends downwardly and includes an internal left hand thread connection 90 to which the member 34 is connected. It is understood that the connection 86 may be tightened until the casing adapter 88 firmly shoulders against the anti-torque ring 84 and the recess 82 in the cap 72 , and then the casing adapter 88 may be backed off of at least a portion of the threads in the connection 86 so as to prevent any inadvertent right hand torque from being applied to the top of the member 34 and thereby loosen the aforementioned left hand threaded joint interconnections of the member 34 .
[0025] Referring to FIG. 1 b , an embodiment of the slip joint 24 is shown within the expandable tubular member 34 and includes a tubular member 92 having a conventional drillpipe box thread connection 94 to which the string 22 is connected. The bore of the member 92 is stepped to define three concentric inner passages 96 , 98 and 100 of increasing diameter in a downwardly direction, as viewed in FIG. 1 b . An o-ring 101 is retained in an annular channel extending circumferentially about the passage 98 .
[0026] The upper end portion of a tubular member 102 is connected to the lower end portion of the tubular member 92 via a threaded connection 103 and a pair of torque pins 104 a and 104 b . The tubular member 102 defines a passage 106 and includes a pair of protrusions 108 a and 108 b extending upwardly from the connection 103 . A pair of channels 110 a and 110 b are formed in the bottom portion of the tubular member 102 (one inner side wall of each channel 110 a and 110 b are shown in FIG. 1 b ).
[0027] The slip joint 24 also includes an elongated tubular member 112 which is disposed in the passages 98 , 100 and 106 . The tubular member 112 includes an upper portion 114 that is slidably engaged with a portion of the internal wall of the passage 98 of the tubular member 92 , with the o-ring 101 sealing against the upper portion 114 . A integral flange or ring 116 extends radially outward from the tubular member 112 and a pair of channels 118 a and 118 b are formed therein (one inner side wall of each channel 118 a and 118 b are shown in FIG. 1 b ). The channels 118 a and 118 b are configured to couple with the protrusions 108 a and 108 b , respectively, of the tubular member 102 .
[0028] A tubular member 120 also forms part of the slip joint 24 , defines an internal passage 121 , and is connected to the tubular member 112 via a threaded connection 122 and a pair of torque pins 124 a and 124 b . The tubular member 120 has a pair of protrusions 126 a and 126 b extending upwardly from the connection 122 and configured to couple with the channels 110 a and 110 b , respectively, of the tubular member 102 . The tubular member 120 further includes an o-ring 127 which is sealed against a bottom portion of the tubular member 112 , and a conventional drillpipe pin thread connection 128 to which the string 26 is connected.
[0029] Referring to FIG. 1 c , an embodiment of the expansion apparatus 30 is shown within the tubular member 34 . The upper end of the apparatus 30 is connected to the sub 28 in any conventional manner, and the sub 28 is connected to the string 26 via a conventional drillpipe box thread connection 130 .
[0030] The expansion apparatus 30 includes an expansion cone portion 132 that engages the inner wall of the member 34 . The shoe 32 of the expansion apparatus 30 is connected to the member 34 via a threaded connection 134 and a pair of radially-extending threaded fasteners 136 a and 136 b are disposed through the member 34 and into the shoe 32 . The sub 28 and the expansion apparatus 30 are designed so that torque may be transmitted from the string 26 to the member 34 via the shoe 32 . To this end, the expansion apparatus 30 may be in the form of one of several existing expansion apparatuses, such as, for example, the expansion apparatus disclosed in detail in co-pending U.S. patent application Ser. No. ______ (attorney's docket no. 25791.238.02), which claims the benefit of the filing date of U.S. provisional patent application Ser. No. 60/450,504, attorney docket no. 25791.238, filed on Feb. 26, 2003, the disclosure of which is incorporated herein by reference.
[0031] The operation will be described in connection with the general goal of placing the expandable apparatus 30 at the bottom 12 of the well bore 10 and conditioning it for expansion in a manner to be described. To this end, the string 16 and the series of components 14 are lowered in the well bore 10 .
[0032] During this lowering, the external splines 62 a and 62 b of the mandrel 56 are engaged with the internal splines 74 a and 74 b of the cap 72 , and the surface 78 of the cap 72 is in contact with the shoulder 66 , as described above. Also, the tubular member 34 is in tension since its weight is primarily carried by the shoulder 66 of the mandrel 56 of the tool 20 and neither the above-described joints nor the joint interconnections of the member 34 undergo compression due to the weight of the expandable tubular member. Further, the fluid ports 80 a and 80 b allow fluid to flow from the well bore 10 and into the annulus 35 , or vice versa, and the o-rings 40 and 52 provide a fluid seal between the well bore 10 and the passage 45 of the tool 20 . Moreover, the o-ring 101 provides a fluid seal between the passage 100 and the passage 98 of the slip joint 24 , and the o-ring 127 provides a fluid seal between the annulus 35 and the passage 121 .
[0033] The lowering continues until the shoe 32 of the expansion apparatus 30 reaches the bottom 12 of the well bore 10 . However, during this movement, a relatively high predetermined displacement resistance may be encountered as a result of (1) the shoe 32 reaching a relatively narrow or collapsed section of the well bore 10 , (2) the shoe 32 or the member 34 becoming jammed or stuck in the well bore, (3) the friction between the member 34 and the well bore 10 being too high, or (4) any similar resistance.
[0034] If a resistance is encountered, the string 16 is further lowered into the well bore 10 which also lowers the mandrel extension 46 , the mandrel 56 , the string 22 , the member 92 and the member 102 relative to the expansion apparatus 30 , the shoe 32 , the sub 28 , the member 34 , the cap 72 , the members 112 and 120 and the string 26 which are prevented from further movement by the resistance. This causes the external splines 62 a and 62 b of the mandrel 56 to disengage from the internal splines 74 a and 74 b of the cap 72 , respectively, and the shoulder 66 of the mandrel 56 to disengage from the surface 78 of the cap 72 , as shown in FIG. 2a . Also, since the tubular member 120 is stationary in the well bore 10 , the above lowering of the tubular member 102 causes the channels 110 a and 110 b of the member 102 to engage the protrusions 126 a and 126 b , respectively, of the tubular member 120 and thus connect the member 102 to the member 120 as shown in FIG. 2 b , and therefore to the string 26 , the expansion apparatus 30 , and the tubular member 34 . It is noted that the grooves 68 allow fluid to flow between the annulus 35 and the ports 80 a and 80 b.
[0035] In this position, a torque from the rig 18 is applied to the string 16 in any conventional manner, to rotate the string 16 clockwise, as viewed downwardly towards the bottom 12 of the well bore 10 , to apply a right hand torque that is transmitted from the string 16 through the coupling 37 , the mandrel extension 46 , the mandrel 56 , the string 22 , the tubular member 92 , the tubular member 102 , the tubular member 120 , the string 26 , the sub 28 , the expansion apparatus 30 , the shoe 32 and the member 34 , due to the above-described connections between these components. However, it is noted that even thought the cap 72 will rotate due to its connection with the member 34 , torque is not directly transferred between the mandrel 56 and the cap 72 since the external splines 62 a and 62 b of the mandrel 56 are spaced, and therefore disengaged, from the internal splines 74 a and 74 b , respectively, of the cap 72 .
[0036] This torque thus causes the shoe 32 and the member 34 to rotate in a clockwise direction, as defined above and hopefully free them from the above-described resistance, thus allowing the string 16 and the series of components 14 to be lowered further until the shoe 32 reaches the bottom 12 of the well bore 10 . Due to the above-described left hand thread engagement configuration of the various joint interconnections of the member 34 , the interconnections are not loosened due to this rotation.
[0037] Assuming that the shoe 32 reaches the bottom 12 of the well bore 10 either directly by the lowering operation described above, or as a result of the shoe 32 and/or the member 34 being freed up as described above, and further lowered as necessary, the expansion apparatus 30 can be conditioned for expansion in the following manner.
[0038] In particular, the string 16 , and therefore the coupling 37 , the mandrel extension 46 and the mandrel 56 , are raised as necessary in order to directly connect the mandrel 56 with the cap 72 by engaging the external splines 62 a and 62 b of the mandrel with the internal splines 74 a and 74 b , respectively, of the cap, and by engaging the shoulder 66 of the mandrel 56 with the surface 78 of the cap 72 . This also raises the string 22 and the tubular members 92 and 102 of the slip joint 24 , thereby disengaging the channels 110 a and 1 10 b from the protrusions 126 a and 126 b , respectively and thus disconnecting the member 102 from the member 120 .
[0039] Left hand torque is then applied to the string 16 , thereby rotating the string 16 in a counterclockwise direction towards the bottom 12 of the well bore 10 . This torque is transmitted from the string 16 , through the coupling 37 , the mandrel extension 46 , the mandrel 56 , and to the string 22 . The mandrel 56 also transmits the torque directly to the cap 72 , via the engagement of the splines 62 a and 74 a , and 62 b and 74 b . Thus, the cap 72 is rotated counterclockwise until it disengages from the threaded connection 86 and therefore the casing adapter 88 . It is understood that, during this rotation, the anti-torque ring 84 functions in a conventional manner, allowing the cap 72 to be removed from the casing adapter 88 . However, during this rotation, the torque is not transmitted from the string 22 to the string 26 since there is no engagement between the members 102 and 112 , nor between the members 102 and 120 , as described above and as shown in FIG. 1 b.
[0040] Once the cap 72 is disengaged from the casing adapter 88 in the above manner as shown in FIG. 3 a , the string 16 is raised further, thereby raising the coupling 37 , the mandrel extension 46 , the mandrel 56 , the cap 72 (via the shoulder 66 of the mandrel 56 ) and the string 22 . As the string 22 is raised, the tubular members 92 and 102 are also raised until the protrusions 108 a and 108 b of the member 102 engage the channels 118 a and 118 b of the member 112 , as shown in FIG. 3 b . This places the components in condition for an expansion procedure in which the expansion apparatus 30 expands the tubular member 34 . In this context, one of several existing expansion procedures may be employed to expand the member 34 such as, for example, the methods disclosed in detail in co-pending U.S. patent application Ser. No. ______ (attorney's docket no. 25791.238.02), which claims the benefit of the filing date of U.S. provisional patent application Ser. No. 60/450,504, attorney docket no. 25791.238, filed on Feb. 26, 2003, the disclosure of which is incorporated herein by reference.
[0041] It is understood that the above-mentioned right hand torque can be applied to the string 16 to rotate the shoe 32 and the member 34 for reasons other than those discussed above. For example, before the cap 72 is disengaged from the adapter 88 , and therefore the member 34 in the above manner, it is sometimes desired to introduce a hardenable fluidic sealing material into at least a lower region of the annulus 36 between the member 34 and the wall of the well bore 10 . To this end, the sealing material would be introduced from the rig 18 into the string 16 and pass through the tool 20 , the string 22 , the slip joint 24 , the string 26 and the expansion apparatus 30 and flow into at least a lower region of the annulus 36 between the member 34 and the wall of the well bore 10 . In this situation, the application of right hand torque in the above manner to rotate the member 34 would more evenly distribute the sealing material in the lower region of the annulus 36 . In this context, examples of methods for employing the sealing material in the above manner are disclosed in detail in co-pending U.S. patent application Ser. No. ______ (attorney's docket no. 25791.238.02), which claims the benefit of the filing date of U.S. provisional patent application Ser. No. 60/450,504, attorney docket no. 25791.238, filed on Feb. 26, 2003, the disclosure of which is incorporated herein by reference. Also, it is understood that the above-mentioned right hand torque can be applied in known casing drilling applications.
[0042] It is also noted that when the above components are in condition for an expansion procedure, the series of components 14 may be entirely positioned below the casing 19 , or the series may be entirely positioned within the casing, or a portion of the series may be within the casing 19 and another portion of the series may be below the casing 19 , such as, for example, the tool 20 being positioned within the casing 19 and the majority of the member 34 being positioned below the casing 19 .
[0000] Variations
[0043] It is understood that variations may be made in the foregoing without departing from the scope of the invention. For example, the teachings of the present illustrative embodiments may be used to provide a well bore casing, a pipeline, or a structural support. Furthermore, the elements and teachings of the various illustrative embodiments may be combined in whole or in part in some or all of the illustrative embodiments. Further examples of variations are as follows:
[0044] 1. The mandrel extension 46 may be combined with the mandrel 56 to form an integral component.
[0045] 2. Additional external splines may be added to the mandrel 56 , and additional corresponding internal splines may be added to the cap 72 .
[0046] 3. Additional grooves and fluid ports for fluid flow may be formed in the shoulder 66 and the cap 72 , respectively.
[0047] 4. Conventional supporting structures such as, for example, solid centralizers or standoffs, may be added in any conventional manner in order to decrease the possibility of the member 34 buckling during the above-described operation.
[0048] 5. Instead of or in addition to torque pins, other conventional mechanisms may be used to rotatably lock the above-described rotatably-locked connections.
[0049] 6. Additional channels may be formed in the tubular member 112 of the slip joint 24 and these additional channels may be coupled to additional protrusions that may be added to the tubular member 102 .
[0050] 7. Additional channels may be formed in the tubular member 102 of the slip joint 24 and these additional channels may be coupled to additional protrusions that may be added to the tubular member 120 .
[0051] 8. Instead of or in addition to using the above-described channels and protrusions of the tubular member 102 , the channels of the tubular member 112 , and the protrusions of the tubular member 120 , it is understood that other conventional torque transmission mechanisms may be used to selectively transmit torque between the tubular member 102 and the tubular member 112 , and to selectively transmit torque between the tubular member 102 and the tubular member 120 .
[0052] 9. It is understood that the foregoing disclosure may be employed in many different applications, including cased hole applications or openhole applications and all types and variations thereof.
[0053] 10. In addition to a vertical well bore as shown in FIGS. 1 and 2 , it is understood that the foregoing disclosure may be applied to horizontal well bores and multilateral wells, including main well bores and all branches thereof.
[0054] Spatial references, such as “upper”, “lower”, “above”, “below”, “between”, “vertical”, “bottom”, “angular”, etc., are for the purpose of illustration only and do not limit the specific orientation or location of the structure described above.
[0055] Although illustrative embodiments of the invention have been shown and described, a wide range of modifications, changes and substitutions is contemplated in the foregoing disclosure. In some instances, some features of the present invention may be employed without a corresponding use of the other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures.
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A tubular apparatus and method, according to which a first tubular member is adapted to be lowered into a well bore and a second tubular member is connected to the first tubular member. A third tubular member is normally connected to the first tubular member and disconnected from the second tubular member, and is adapted for movement relative to the first and second tubular members to disconnect from the first tubular member and connect to the second tubular member.
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BACKGROUND OF THE INVENTION
This invention relates to multi-vitamin and mineral supplements. In particular, this invention relates to multi-vitamin and mineral supplements for improving health by insuring adequate intake of micronutrients needed for disease prevention and protection against nutritional losses and deficiencies due to such factors as lifestyle patterns and common inadequate dietary patterns. More particularly, this invention related to multi-vitamin and mineral supplements for men and post-menopausal women.
Vitamin and mineral preparations are commonly administered to treat specific medical conditions or as general nutritional supplements. Micronutrients are elements or compounds which are present in foods in small or trace amounts and includes vitamins, minerals, or other elements, and compounds found in foods for which a Recommended Daily Allowance (RDA) has not yet been determined. The macronutrients consist of carbohydrates, fats, and proteins which supply nutrients and calories. Some elements such as calcium, sodium, potassium, chloride, and phosphorus are consumed in relatively large amounts, while many such as iron, iodine, and zinc are consumed in small amounts. Vitamins such as B12 and folic acid and the minerals cooper, selenium, and chromium are consumed in very small or trace amounts. In as much as the human body does not synthesize many compounds which are essential to the human body, these specific vitamins and minerals can be obtained from only two sources: food and supplements. The primary source of all nutrients is food. However, the majority of people do not meet the RDA of the foods containing these essential compounds and elements. Thus vitamin and mineral supplementation has become a recognized method of meeting accepted medical and health standards.
An international panel of diet and cancer experts announced in London on Sep. 30, 1997, that as many as 30 to 40 percent of all cancer cases worldwide—3 to 4 million a year—could be avoided if people ate a healthy diet and got enough exercise. USA Today , Oct. 1, 1997. However, for some nutrients, the amounts proposed as being healthy apparently cannot be provided by a reasonable quantity and variety of natural foods. Thus nutrient supplements may be important for health promotion and prevention of chronic diseases. Journal of the American Medical Association , May 7, 1997.
Recent studies have illustrated the important physiological roles played by vitamins and minerals and established a correlation between deficiencies or excesses of these nutrients and the etiologies of certain disease states in humans. Homocysteine is a homolog of cysteine and is produced by the demethylation of methionine, and is an intermediate in the biosynthesis of cysteine from methionine via cystathionine. Homocysteine is being referred to as the “cholesterol of the 21 st century.” Homocysteine is not inherently bad, as it is a necessary by-product in the break down of the essential amino acid methionine, which is found primarily in red meat and diary products. However, as with cholesterol, homocysteine may get out of balance as a result of genetics or poor diet. The main concern is having too much homocysteine.
As stated in the Journal of the American Medical Association , “A high level of homocysteine confers a risk of vascular disease similar to that of cigarette smoking, elevated cholesterol, and other blood lipids. Also, it increases the risk associated with smoking and high blood pressure.” Journal of the American Medical Association, Jun. 11, 1997. Elevated blood levels of homocysteine increase the risk of atherosclerosis, a clogging of the arteries that is the main factor in the majority of heart attacks and strokes. Elevated homocysteine levels are found in 25% of heart attack patients, 40% of stroke patients, and may also be associated with Alzheimer's disease.
It has recently been discovered that folic acid, when combined with vitamins B6 and B12, has the potential of dramatically lower the homocysteine levels, thereby protecting against high homocysteine-related diseases. Journal of the American Medical Association , Oct. 4, 1995.
Coronary artery disease is one of the major causes of heart attacks and occurs when there is atherosclerosis in the vital coronary arteries, which supply the nutrient rich blood to the interior of the heart muscle. High levels of LDL cholesterol have been linked to the development of atherosclerosis in the coronary arteries. However, free radicals have received more attention as the culprit of the disease. It appears that clogging occurs after the LDL cholesterol is oxidized within the wall of the blood vessel by exposure to free radicals. The white blood cells attempt to remove the damaged LDL cholesterol by engulfing them. Unfortunately, after ingesting the LDL cholesterol, the cells cannot rid themselves of the cholesterol portion and swell up, thus the process of atherosclerosis (thickening of the artery wall and narrowing of the coronary arteries) begins. Therefore, it is not the LDL cholesterol that blocks the artery, but the oxidized LDL that has been engulfed by the white blood cells that actually causes the damage.
Free radicals may be activated by factors such as cigarette smoke, pollution, excessive exercise, and other stressors. The LDL cholesterol can fight these free radicals with antioxidants such as vitamins C and E, but before long the LDL's antioxidants are depleted and the LDL is left defenseless. It has been discovered that at least 1000 mg of vitamin C coupled with 1000 I.U. of vitamin E (d-alpha tocopherol) taken in conjunction with a 900-calorie meal containing 50 grams of fat blocked the detrimental effects of a fatty meal on blood circulation. Journal of the American Medical Association , Nov. 26, 1997. In addition, it has been discovered that 100 I.U. of vitamin E supplements taken for two years or longer reduced deaths of coronary artery disease by 40% in 87,245 nurses and by 37% in 39,910 male health professionals. New England Journal of Medicine , May 20, 1993.
There exists a need for a nutritional supplement for men and post-menopausal women which supplies the right amount of the right micronutrients at the right time to assure adequate intake of micronutrients needed for disease prevention and protection against nutritional losses and deficiencies due to lifestyle factors and common inadequate dietary patterns.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a multi-vitamin and mineral supplement specifically tailored to men and post-menopausal women, pre-menopausal women, and athletes which supplies the right amount of the right micronutrients at the right time to assure adequate intake of micronutrients needed for disease prevention and protection against nutritional losses and deficiencies due to lifestyle factors and common inadequate dietary patterns.
Further, in accordance with the present invention, there is provided a new and improved multi-vitamin and mineral supplement which can be used for providing the necessary nutrients to allow the users of such supplement to maintain their present health and positively influence their future health.
Still further in accordance with the present invention, there is provided a multi-vitamin and mineral supplement wherein the supplement is comprised of from about 5000 I.U. to about 10,000 I.U. of vitamin A; from about 1000 mg to about 2000 mg of vitamin C; about 400 I.U. of vitamin D; from about 800 I.U. to about 1200 I.U. of vitamin E; about 25 mcg of vitamin K; about 3 mg of vitamin BI; about 10 mg of vitamin B2; about 20 mg of niacinamide; about 25 mg of vitamin B6; about 800 mcg of folic acid; about 400 mcg of vitamin B12; about 300 mcg of biotin; about 10 mg of pantothenic acid; up to about 18 mg of iron dosed in the form of a pharmaceutically acceptable iron compound; about 150 mcg of iodine dosed in the form of a pharmaceutically acceptable iodine compound; about 400 mg of magnesium dosed in the form of a pharmaceutically acceptable magnesium compound; about 15 mg of zinc dosed in the form of a pharmaceutically acceptable zinc compound; from about 100 mcg to about 200 mcg of selenium; about 2 mg of copper dosed in the form of a pharmaceutically acceptable copper compound; about 100 mcg of chromium dosed in the form of a pharmaceutically acceptable chromium compound; about 400 mg of potassium dosed in the form of a pharmaceutically acceptable potassium compound; about 500 mg of choline dosed in the form of a pharmaceutically acceptable choline compound; about 10 mg of lycopene; and about 50 mg co-enzyme Q-10 dosed in the form of a pharmaceutically acceptable co-enzyme Q-10 compound.
An advantage of the present invention is that the multi-vitamin and mineral supplement supplies the right amount of the right micronutrients at the right time to assure adequate intake of micronutrients needed for disease prevention and protection against nutritional losses and deficiencies due to lifestyle factors and common inadequate dietary patterns.
Another advantage of the present invention is that the multi-vitamin and mineral supplement provides the necessary nutrients to allow the users of such supplement to maintain their present health and positively influence their future health.
Another advantage of the present invention is that the multi-vitamin and mineral supplement decreases plasma homocysteine levels, reduces the susceptibility of LDL cholesterol to oxidation, and lowers plasma glucose levels.
These and other advantages and benefits of the invention will be apparent to those skilled in the art upon reading and understanding of the following detailed description.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
This invention is directed to a multi-vitamin and mineral supplement comprised of from about 5000 I.U. to about 10,000 I.U. of vitamin A; from about 1000 mg to about 2000 mg of vitamin C; about 400 I.U. of vitamin D; from about 800 I.U. to about 1200 l.U. of vitamin E; about 25 mcg of vitamin K; about 3 mg of vitamin B1; about 10 mg of vitamin B2; about 20 mg of niacinamide; about 25 mg of vitamin B6; about 800 mcg of folic acid; about 400 mcg of vitamin B12; about 300 mcg of biotin; about 10 mg of pantothenic acid; up to about 18 mg of iron dosed in the form of a pharmaceutically acceptable iron compound; about 150 mcg of iodine dosed in the form of a pharmaceutically acceptable iodine compound; about 400 mg of magnesium dosed in the form of a pharmaceutically acceptable magnesium compound; about 15 mg of zinc dosed in the form of a pharmaceutically acceptable zinc compound; from about 100 mcg to about 200 mcg of selenium; about 2 mg of copper dosed in the form of a pharmaceutically acceptable copper compound; about 100 mcg of chromium dosed in the form of a pharmaceutically acceptable chromium compound; about 400 mg of potassium dosed in the form of a pharmaceutically acceptable potassium compound; about 500 mg of choline dosed in the form of a pharmaceutically acceptable choline compound; about 10 mg of lycopene; and about 50 mg co-enzyme Q-10 dosed in the form of a pharmaceutically acceptable co-enzyme Q-10 compound.
All amounts specified in the application are based on milligrams unless otherwise indicated. The term “I.U.” represents International Units.
The multi-vitamin and mineral supplement is comprised of vitamin A. Vitamin A prevents night blindness and other eye disorders, keeps skin moist and elastic, maintains healthy hair, skin, and gums, reduces the risk of breast cancer, helps alleviate mastodynia, reduces the risk of lung cancer, maintains cell structure and integrity, works as antioxidant to prevent cell aging, helps prevent infection, and negates skin wrinkling and the effects of sun damage. Vitamin A is a fat soluble vitamin. The term vitamin A is used to include retinol and other chemically similar compounds referred to as retanoids. Beta-carotene and other carotenoids are provitamins and are only turned into retinol as the body requires. Preferably, in the multi-vitamin and mineral supplement, vitamin A is provided in the form of beta-carotene and other mixed carotenoids. Preferably, the mixed carotenoids are lutein and zeaxanthine. Lutein and zeaxanthine have been found to decrease the risk and even reverse the development of macular degeneration, the leading cause of blindness in those over the age of 65.
For premenopausal women, post-menopausal women, and men, the multi-vitamin is preferably comprised of about 5000 I.U of vitamin A and about 6000 mcg of lutein and zeaxanthine. More preferably, the multi-vitamin and mineral supplement is comprised of about 5000 I.U. of vitamin A in the form of natural mixed beta-carotene and about 6000 mcg of lutein and zeaxanthine. The amount of lutein and zeaxanthine present in the multi-vitamin and mineral supplement must be sufficient to ensure that one's intake of these carotenoids is adequate to achieve the benefits associated with these carotenoids.
For athletes, the multi-vitamin is preferably comprised of about 10,000 I.U of vitamin A and about 6000 mcg of lutein and zeaxantine. More preferably, the multi-vitamin and mineral supplement is comprised of about 10,000 I.U. of vitamin A in the form of natural mixed beta-carotene and about 6000 mcg of lutein and zeaxanthine. The higher level of vitamin A present in this formulation is required to fight the high level of free-radicals produced by athletes. The body's need for oxygen during exercise produces free radicals, which can oxidize the fats in muscle cell membranes in a process known as “lipid preoxidation” and which make the cells more susceptible to aging and other damage.
Vitamin C, also known as ascorbic acid, is necessary for the synthesis of collagen and is used as an antioxidant. Vitamin C fights infection, reduces inflammation, heals wounds, reduces the risk of heart disease, lowers cholesterol, reduces the risk of lung, stomach, and esophageal cancers, reduces cervical epithelial abnormalities, inhibits N-nitrosamine, and reduces the severity of colds.
For pre-menopausal women, post menopausal women, and men, the multi-vitamin and mineral supplement is preferably comprised of about 1000 mg of vitamin C. For athletes, the multi-vitamin and mineral supplement is preferably comprised of about 2000 mg of vitamin C. The higher level of vitamin C is required to fight the high level of free-radicals produced by athletes and helps to revive vitamin E.
Vitamin D is also an essential vitamin that is included in the multi-vitamin and mineral supplement of the present invention. Vitamin D assists in the mineralization and calcification of bone, prevents rickets in children, prevents osteomalacia in adults, preserves bone and tooth growth, and lowers blood pressure. Vitamin D is fat soluble. Preferably, the multi-vitamin and mineral supplement is comprised of about 400 l.U. of vitamin D.
Vitamin E is needed for the maintenance of cell membranes and for neurological health.
Vitamin E relieves hot flashes, relieves mastodynia, helps in fighting fibrocystic breast disease, reduces mammary tumors, reduces the risk of lung cancer, and reduces the risk of heart disease.
Vitamin E is the generic term for a group of related substances which include alpha-tocopherol, beta-tocopherol, gamma-tocopherol, and delta-tocopherol. In addition, each of these four compounds have a “d” form, which is the natural form, and a “dl” form which is the synthetic form. Preferably, in the multi-vitamin and mineral supplement, vitamin E is provided in the form of d-alpha tocopherol succinate.
For pre-menopausal women, post-menopausal women, and men, the multi-vitamin and mineral supplement is preferably comprised of about 800 I.U. of vitamin E. More preferably, the multi-vitamin and mineral supplement is comprised of about 800 I.U. of vitamin E in the form of d-alpha tocopherol succinate. Research has shown that 400 I.U. of vitamin E is the minimum dosage needed to significantly decrease susceptibility of LDL cholesterol to oxidation. Patients with coronary atherosclerosis which were taking 400 or 800 I.U. of vitamin E daily had a statistically significant reduction in the incidence of non-fatal myocardial infarction. Therefore, the amount of vitamin E present in the multi-vitamin and mineral supplement must be sufficient to ensure that that one's intake of vitamin E is adequate to achieve the benefits associated with vitamin E.
For athletes, the multi-vitamin and mineral supplement is preferably comprised of about 1200 I.U. of vitamin E. More preferably, the multi-vitamin and mineral supplement is comprised of about 1200 I.U. of vitamin E in the form of d-alpha tocopherol succinate. The higher level of vitamin E present in this formulation is required to fight the high level of free-radicals produced by athletes.
The multi-vitamin and mineral supplement includes vitamin K. Vitamin K is an active blood clotting agent and assists in bone formation. Preferably, the multi-vitamin and mineral supplement is comprised of about 25 mcg of vitamin K.
The multi-vitamin and mineral supplement is comprised of most of the B complex of vitamins. The B vitamins are water-soluble. The B vitamins included in the multi-vitamin and mineral supplement are thiamin (vitamin B1), riboflavin (vitamin B2), niacin (vitamin B3), pantothenic acid (vitamin B5), pyridoxine (vitamin B6), biotin, folic acid, the cobalamins (vitamin B12), and choline.
Vitamin B1 or thiamin helps keep collagen-rich connective and mucous membranes healthy, helps to maintain smooth muscles, helps in the formation of blood cells, and is necessary for proper nervous system function. Preferably, the multi-vitamin and mineral supplement is comprised of about 3 mg of vitamin B1.
Vitamin B2 or riboflavin is necessary for healthy hair, nails, and mucous membranes and is involved in red blood cell formation, antibody production, and overall growth. Preferably, the multi-vitamin and mineral supplement of the present invention is comprised of about 10 mg of vitamin B2.
Vitamin B3 or niacin helps in the production of most of the sex hormones, dilates blood vessels, lowers cholesterol, and helps maintain blood circulation. Niacin is the generic name for a group of compounds which exhibit niacin activity, and includes niacinamide and nicotinic acid. Preferably, in the multi-vitamin and mineral supplement, vitamin B3 is provided as niacinamide. Preferably, the multi-vitamin and mineral supplement is comprised of about 20 mg of vitamin B3. More preferably, the multi-vitamin and mineral supplement is comprised of about 20 mg of vitamin B3 in the form of niacinamide.
Vitamin B6 or pyridoxine is involved in the production of ribonucleic acid (RNA) and deoxyribonucleic acid (DNA) and many other reactions in the body. Pyridoxine refers to and includes three different compounds: pyridoxine, pyridoxamine, and pyridoxal. Preferably, in the multi-vitamin and mineral supplement, vitamin B6 is in the form of pyridoxine hydrochloride.
Preferably, the multi-vitamin and mineral supplement is comprised of about 25 mg of vitamin B6. More preferably, the multi-vitamin and mineral supplement is comprised of about 25 mg of vitamin B6 in the form of pyridoxine hydrochloride. Vitamin B6, when combined with folic acid and vitamin B12, has been found to decrease homocysteine levels. Such decreases in homocysteine levels have been found with about 25 mg to about 50 mg of vitamin B6.
Folic acid is essential in the production of red blood cells, the production of hormones, and the synthesis of DNA. Preferably, the multi-vitamin and mineral supplement is comprised of about 800 mcg of folic acid.
Vitamin B12 or the cobalamins is necessary for overall metabolism, the function of the nervous system, metabolism of folic acid, and the production of red blood cells. There are at least three active forms of cobalamin: cyanocobalamin, hydroxocobalamin, and nitrocobalamin. Preferably, in the multi-vitamin and mineral supplement of the present invention, vitamin B12 is provided in the form of cyanocobalamin. Preferably, the multi-vitamin and mineral supplement is comprised of about 400 mcg of vitamin B12. More preferably, the multi-vitamin and mineral supplement is comprised of about 400 mcg of vitamin B12 in the form of cyanocobalamin.
Biotin is necessary for the metabolism of carbohydrates, proteins, and fats and is needed for healthy skin and hair. Preferably, in the multi-vitamin and mineral supplement, biotin is provided in the form of d-biotin. Preferably, the multi-vitamin and mineral supplement is comprised of about 300 mcg of biotin. More preferably, the multi-vitamin and mineral supplement is comprised of about 300 mcg of biotin in the form of d-biotin.
Pantothenic acid is important for the production of adrenal gland hormones, increases overall energy, and helps convert food into energy. Preferably, in the multi-vitamin and mineral supplement, pantothenic acid is in the form of d-calcium pantothenate. Preferably, the multi-vitamin and mineral supplement is comprised of about 10 mg of pantothenic acid. More preferably, the multi-vitamin and mineral supplement is comprised of about 10 mg of pantothenic acid in the form of d-calcium pantothenate.
Choline is necessary for nervous system function and brain function. It is also important for gall bladder and liver function. Preferably, in the multi-vitamin and mineral supplement, choline is provided in the form choline bitartrate. Preferably, the multi-vitamin and mineral supplement is comprised of about 500 mg of choline. More preferably, the multi-vitamin and mineral supplement is comprised of about 500 mg of choline in the form of choline bitartrate.
Iron is used in the production of hemoglobin and myoglobin. In the multi-vitamin and mineral compound, the iron is dosed in the form of a pharmaceutically acceptable iron compound. As used herein, pharmaceutically acceptable is a component which is suitable for use in humans without undue side effects, such as irritation, toxicity, and allergic response. Useful pharmaceutically acceptable iron compounds include, but are not limited to, ferrous fumarate, ferrous sulfate, iron carbonyl, ferrous glucomate, ferrous chloride, ferrous lactate, ferrous tartrate, ferrous succinate, ferrous glutamate, ferrous citrate, ferrous pyrophosphate, ferrous cholinisocitrate, ferrous carbonate, iron-sugar-carboxylate complexes, and combinations thereof. Preferably, the pharmaceutically acceptable iron compound is iron carbonyl. Iron carbonyl is easier on the digestive tract than other forms of iron, such as ferrous fumerate. In addition, the Food and Drug Administration does not require a warning label on the toxicity to children for this form of iron as it is safe for children who accidentally ingest this form of iron.
For post-menopausal women and men, the multi-vitamin and mineral supplement is substantially free of iron. Research has shown that high stored levels of iron are associated with an increased risk of myocardial infarction. Post menopausal women and men do not need additional iron through supplements, unless otherwise recommended by a physician. In addition, a growing percentage of the population suffers from a disease known as hemochromatosis, an abnormally high level of iron in the blood. These people cannot take iron in supplement form.
For pre-menopausal women and athletes, the multi-vitamin and mineral compound is preferably, comprised of about 18 mg of iron dosed in a pharmaceutically acceptable iron compound. More preferably, the multi-vitamin and mineral supplement is comprised of about 18 mg of iron dosed in the form of iron carbonyl. Women in their child-bearing years need supplemental iron as deficiencies are common. Iron deficiencies are also common in athletes.
Iodine helps to metabolize fats, is necessary for proper thyroid function, and reduces fibrocystic breast conditions. In the multi-vitamin and mineral supplement of the present invention, iodine is dosed in the form of a pharmaceutically acceptable iodine compound. Useful pharmaceutically acceptable iodine compounds include, but are not limited to, potassium iodide, sodium iodide, and combinations thereof.
Preferably, the pharmaceutically acceptable iodine compound is potassium iodide. Preferably, the multi-vitamin and mineral supplement is comprised of about 150 mcg of iodine dosed in the form of a pharmaceutically acceptable iodine compound. More preferably, the multi-vitamin and mineral supplement is comprised of about 150 mg of iodine dosed in the form of potassium iodide.
Magnesium is used in bone formation and growth, prevents bone loss, relaxes coronary arteries, is used in managing pre-eclampsia, treating cardiac arrhythmias, and managing diabetes.
In the multi-vitamin and mineral supplement, magnesium is dosed in the form of a pharmaceutically acceptable magnesium compound. Useful pharmaceutically acceptable magnesium compounds include, but are not limited to, magnesium stearate, magnesium carbonate, magnesium oxide, magnesium hydroxide, magnesium sulfate, and combinations thereof.
Preferably, the pharmaceutically acceptable magnesium compound is magnesium oxide.
Preferably, the multi-vitamin and mineral supplement is comprised of about 400 mg of magnesium dosed in the form of a pharmaceutically acceptable magnesium compound. More preferably, the multi-vitamin and mineral supplement is comprised of about 400 mg of magnesium dosed in the form of magnesium oxide.
Zinc is required for proper formation of DNA and RNA and is needed for growth and sexual development of women. In the multi-vitamin and mineral supplement of the present invention, zinc is dosed in the form of a pharmaceutically acceptable zinc compound.
Pharmaceutically acceptable zinc compounds include, but are not limited to, zinc sulfate, zinc chloride, zinc oxide, and combinations thereof. Preferably, the pharmaceutically acceptable zinc compound is zinc oxide.
Preferably, the multi-vitamin and mineral supplement is comprised of about 15 mg of zinc dosed in the form of a pharmaceutically acceptable zinc compound. More preferably, the multi-vitamin and mineral supplement is comprised of about 15 mg of zinc dosed in the form of zinc oxide.
Selenium reduces the risk of heart attacks and heart disease, reduces the risk of cancer, protects against metal poisoning, and is synergistic with vitamin E. Preferably, in the multi-vitamin and mineral supplement, selenium is obtained from rice bran chelate.
For pre-menopausal women, post-menopausal women, and men, the multi-vitamin and mineral supplement is preferably comprised of about 100 mcg of selenium. For athletes, the multi-vitamin and mineral supplement is preferably comprised of about 200 mcg of selenium.
The higher level of selenium is required to fight the high level of free-radicals produced by athletes and selenium works synergistically with vitamin E.
Copper helps keep blood vessels elastic, is needed for the formation of elastin and collagen, functions as an iron oxidizer, and is needed for the proper functioning of vitamin C. In the multi-vitamin and mineral supplement, copper is dosed in a pharmaceutically acceptable copper compound. Pharmaceutically acceptable copper compounds include, but are not limited to, cupric oxide, cupric sulfate, cupric gluconate, and combinations thereof. Preferably, the pharmaceutically acceptable copper compound is cupric gluconate.
Preferably, the multi-vitamin and mineral supplement is comprised of about 2 mg of copper dosed in the form of a pharmaceutically acceptable copper compound. More preferably, the multi-vitamin and mineral compound is comprised of about 2 mg of copper dosed in the form of cupric gluconate.
Chromium assists in the regulation of glucose metabolism, is used in the synthesis of fatty acids and cholesterol, assists in transporting proteins, lowers LDL blood levels, and raises high density lipoproteins blood levels. In the multi-vitamin and mineral supplement, chromium is dosed in a pharmaceutically acceptable chromium compound. Useful pharmaceutically acceptable chromium compounds include, but are not limited to, yeast-bound chromium, GTF chromium, niacin-bound chromium. Preferably, the pharmaceutically acceptable chromium compound is chromium amino acid chelate.
Preferably, the multi-vitamin and mineral supplement is comprised of about 100 mcg of chromium dosed in the form of a pharmaceutically acceptable chromium compound. More preferably, the multi-vitamin and mineral supplement is comprised of about 100 mcg of chromium dosed in the form of chromium amino acid chelate. Chromium is present in the multi-vitamin and mineral supplement at a level that meets the 100% daily value. Research has shown that the average person consumes less than 50 mcg of chromium a day.
Potassium is needed to regulate water balance, levels of acidity, blood pressure, and neuromuscular function. Potassium is also required for carbohydrate and protein metabolism. In the multi-vitamin and mineral supplement, potassium is dosed in the form of a pharmaceutically acceptable potassium compound. Useful pharmaceutically acceptable potassium compounds include, but are not limited to, potassium chloride, potassium glycerophosphate, potassium citrate, potassium gluconate, potassium phosphate, and combinations thereof. Preferably, the pharmaceutically acceptable potassium compound is potassium phosphate.
Preferably, the multi-vitamin and mineral supplement is comprised of about 400 mg of potassium dosed in the form of a pharmaceutically acceptable potassium compound. More preferably, the multi-vitamin and mineral supplement is comprised of about 400 mg of potassium dosed in the form of potassium phosphate.
Lycopene has been found to reduce the risk of cancer and has antioxidant capabilities. Lycopene is found primarily in tomatoes, red grapefruit, watermelon, and other sources, and is a carotenoid. Preferably, in the multi-vitamin and mineral supplement, the lycopene is obtained from tomatoes.
Preferably, the multi-vitamin and mineral supplement is comprised of about 10 mg of lycopene. Lycopene has been linked to lower rates of prostate cancer. Research has shown that four to seven servings of red tomato products per week can reduce deaths from prostate cancer by 20%. Therefore, the amount of lycopene present in the multi-vitamin and mineral supplement must be sufficient to ensure that that one's intake of lycopene is adequate to achieve the benefits associated with lycopene.
Co-enzyme Q10, also known as ubiquinone, is an antioxidant which protects the body from radicals. Co-enzyme Q10 aids metabolic reactions, such as the complex process of transforming food into ATP, and helps people with congestive heart failure and angina. Co-enzyme Q10 is depleted in people taking lovastatin and pravastatin which are cholesterol lowering drugs.
Preferably, the multi-vitamin and mineral supplement is comprised of about 50 mg of co-enzyme Q10. Co-enzyme Q10 is very costly and the amount of co-enzyme Q10 present in the multi-vitamin and mineral supplement is sufficient to ensure that that one's intake of co-enzyme Q10 is adequate to achieve the benefits associated with co-enzyme Q10.
The nutritional supplements of the present invention are suitably provided in any suitable dosage form known in the art. For example, the compositions are suitably incorporated into tablets, powders, granules, beads, chewable lozenges, capsules, liquids, or similar conventional dosage forms, using conventional equipment and techniques known in the art. Tablet dosage forms are preferred.
When preparing dosages forms incorporating the compositions of the present invention, the nutritional components are normally blended with conventional excipients such as binders, including gelatin, pregelatinzed starch, and the like; lubricants, such as hydrogenated vegetable oil, stearic acid and the like; diluents, such as lactose, mannose, and sucrose; disintegants, such as carboxymethyl cellulose and sodium starch glycolate; suspending agents, such as povidone, polyvinyl alcohol, and the like; absorbents, such as silicon dioxide; preservative, such as methylparaben, propylparaben, and sodium benzoate; surfactants, such as sodium lauryl sulfate, polysorbate 80, and the like; and colorants, such as F.D & C. dyes and the like.
For preparing the composition from the compounds described by this invention, inert, pharmaceutically acceptable carriers are used which are either solid or liquid form. Solid form preparations include powders, tablets, dispersible granules, capsules, and cachets. A solid carrier is suitably one or more substances which may also act as diluents, flavoring agents, solubilizers, lubricants, suspending agents, binders or tablet disintegrating agents. The solid carrier material also includes encapsulating material. In powders, the carrier is finely divided active compounds. In the tablet, the active compound is mixed with the carrier having the necessary binding properties in suitable proportions and compacted in the shape and size desired. Suitable solid carriers include, but are not limited, to magnesium carbonate, magnesium stearate, talc, sugar, lactose, pectin, dextrin, starch, gelatin, tragacanth, methylcellulose, sodium carboxymethylcellulose, a low melting wax, cocoa butter, and the like. The term preparation is intended to include the formulation of the active compounds with encapsulating material as the carrier providing a capsule in which the active component (with or without other carriers) is surrounded by carrier, which is thus in association with it. Tablets, powders, cachets, and capsules may be used in a solid dosage form suitable for oral administration.
Liquid form preparations include solutions, suspensions, and emulsions. Aqueous solutions suitable for oral use are prepared by dissolving the active component in water or other suitable liquid and adding suitable colorants, flavors, stabilizing agents, and thickening agents as desired. Aqueous solutions suitable for oral use may also be made by dispersing the finely divided active component in water or other suitable liquid with viscous material, such as natural or synthetic gums, resins, methylcellulose, sodium carboxymethylcellulose, and other suspending agents known in the art.
Also included are solid form preparations which are intended to be converted, shortly before use, to liquid form preparations for either oral or parental administration. Such liquid forms include solutions, suspensions, and emulsions. These particular solid form preparations are provided in unit dose form and as such are used to provide a single liquid dosage unit. Alternatively, sufficient solid preparation may be provided so that the after conversion to liquid form, multiple individual liquid doses may be obtained by measuring predetermined volumes of the liquid form preparation as with a syringe, teaspoon, or other volumetric contained.
The solid and liquid forms may contain, in addition to the active material, flavorants, colorants, stabilizers, buffers, artificial and natural sweeteners, dispersants, thickeners, solubilizing agents, and the like. The liquid utilized for preparing the liquid form preparation is suitably water, isotonic water, ethanol, glycerin, propylene glycol, and the like as well as combinations thereof. The liquid utilized will be chosen with regard to the route of administration.
Preferably, the preparations are unit dosage form. In such form, the preparation is subdivided into unit doses containing appropriate quantities of the active components. The unit dosage form can be a packaged preparation, such as packaged tablets or capsules. The unit dosage can be a capsule, cachet, or tablet itself or it can be the appropriate number of any of these in packaged form.
The quantity of active material in a unit dose of preparation is varied according to the particular application and potency of the active ingredients.
Determination of the proper dosage for a particular situation is within the skill of the art. For convenience, the total daily dosage may be divided and administered in portions during the day if desired. Controlled and uncontrolled release formulations are also included.
Although the products of the invention are preferably intended for administration to humans, it will be understood that the formulation may also be utilized in veterinary therapy for other animals.
The present invention is further exemplified in the following example It is understood that the example is only for illustrative purposes wherein the claims set forth the scope of the present invention.
EXAMPLE
The effect of the multi-vitamin and mineral supplement of the present invention on blood lipids, serum concentration of vitamins, serum concentration of homocysteine, LDL oxidation rates, plasma glucose levels, and levels of other elements in the blood was studied. One hundred fifty-one human subjects participated in the study.
The participants underwent an initial six week washout period during which no vitamin or mineral supplements, except calcium, were taken. After undergoing the six-week washout period, the participants had blood drawn for blood chemistry analysis. After the washout period, the participants took the prescribed dosage of the multi-vitamin and mineral supplement in the form of three tablets, twice daily with food for six months. Participants returned to have their blood drawn and analyzed at the end of three months of taking the supplement, and again at the end of the six month period. The participants were required to keep a three-day dietary record for the three days immediately prior to each of the blood draws. In addition, the participants were required to fast (to stop eating and drinking everything except water) for twelve hours prior to each blood draw.
All participants completed a vitamin supplement questionnaire as to what supplements were taken before the six week washout period. The questionnaires indicated that 34% were taking a multi-vitamin, 33% were taking vitamin E, 38% were taking vitamin C, 22% were taking beta-carotene, and 13% were taking selenium. At the end of the six months, 2% of the participants were taking vitamin C, 1% were taking vitamin E, and 0.7% were taking a multi-vitamin and beta-carotene supplement.
The demographic and medical information for the participants is shown in Table 1 below.
TABLE 1
Characteristics of Participants
Female
48%
Age (years)
50.9 ± 12.3
Non-Hispanic White
93%
Married
90%
Education ≧ 16 years
77%
Current smokers
5%
Walk or Jog
61%
Weight (kg)
76.2 ± 17.9
Height (m)
1.73 ± 0.11
BMI(kg/m 2 )
25.3 ± 4.5
History of myocardial infarction
0.7%
History of chest pain with exertion
2.8%
History of stroke
0.7%
History of cancer
11%
History of hypertension
14%
History of high cholesterol
30%
History of diabetes
0.7%
History of thyroid disease
6%
History of arthritis
17%
History of depression
11%
Family history of CVD
29%
The blood chemistry analysis of the participants analyzed the level of certain blood lipids, such as cholesterol and triglycerides, and other components present in blood serum. The results of this analysis is shown in Table 2 below.
TABLE 2
Blood lipids and other measurements in Participants
Variable
Month 0
Month 3
Month 6
Cholesterol (mg/dl)
201.4 ± 41.6
199.0 ± 38.3
207.6 ± 39.5
HDL-Chol (mg/dl)
58.6 ± 18.0
58.7 ± 17.5
59.4 ± 17.9
LDL-Chol (mg/dl)
122.1 ± 65.0
114.8 ± 32.2
123.5 ± 33.3
VLDL-Chol (mg/dl)
24.6 ± 16.1
23.9 ± 13.8
24.6 ± 14.7
Triglyceride (mg/dl)
123.3 ± 87.5
118.8 ± 73.2
121.9 ± 74.4
Glucose (mg/dl)
98.2 ± 15.8
94.1 ± 11.7***
94.7 ± 14.4***
Potassium (mEq/L)
4.5 ± 0.5
4.5 ± 0.5
4.6 ± 0.4
Sodium (mEq/L)
139.2 ± 2.0
140.2 ± 2.2
140.1 ± 2.2
Calcium (mg/dl)
8.9 ± 0.4
9.4 ± 6.1
8.9 ± 0.4
Phosphorus (mg/dl)
3.3 ± 0.4
3.3 ± 0.5
3.2 ± 0.4
Bilirubin (U/L)
0.7 ± 0.3
0.7 ± 0.3
0.7 ± 0.3
ALT (U/L)
22.5 ± 11.2
27.5 ± 19.8***
27.4 ± 16.6***
AST (U/L)
20.2 ± 5.1
23.6 ± 8.1***
24.0 ± 7.4***
ALP (U/L)
66.5 ± 15.9
64.9 ± 18.4
65.4 ± 14.9
All Protein (g/dl)
7.2 ± 0.4
7.3 ± 0.4
7.3 ± 0.4
Albumin (g/dl)
4.5 ± 0.3
4.4 ± 0.4
4.5 ± 0.4
Uric Acid (mg/dl)
5.4 ± 1.4
5.1 ± 1.3
5.1 ± 1.4
Urea Nitrogen
15.4 ± 3.8
15.2 ± 4.0
15.2 ± 3.6
(mg/dl)
Creatinine (mg/dl)
1.1 ± 0.2
1.1 ± 0.2
1.1 ± 0.2
LD (U/L)
142.1 ± 24.0
145.1 ± 32.3
139.6 ± 27.1
CK (U/L)
104.6 ± 68.4
111.4 ± 88.6
111.4 ± 88.6
***P < 0.0001 when compared with month 0.
The expected range for total cholesterol is between 130-200 mg/dL. Table 2 shows that the participants had a slightly higher than the expected or normal values for total cholesterol. Cholesterol is further divided into high density cholesterol (HDL), low density cholesterol (LDL), and very low density cholesterol (VLDL) fractions. HDL is known as the good cholesterol because higher levels have been associated with a lower risk of cardiovascular disease and heart attacks. The normal levels for HDL are 45-70 mg/dL for men and 55-85 mg/dL for women. As shown in Table 4, the participants had a normal range of HDL for the duration of the study. LDL is known as the bad cholesterol as it has been linked to the development of atherosclerosis in the coronary arteries. The normal range for LDL cholesterol is between 65-130 mg/dL. The participants had a normal range of LDL cholesterol, which remained consistent throughout the study, as shown in Table 2.
VLDL is another component of total cholesterol. More research must be conducted on VLDL to better understand its function. The normal range of VLDL is 0-25 mg/dL for men and 0-14 mg/dL for women. The participants had normal VLDL levels from the first visit to the third visit.
ALT, also known as alanine aminotransferase, and AST, also known as aspartate aminotransferase, are enzymes which are related to liver function in general. The normal range for ALT is 0-65 U/L and the normal range for AST is 8-40 U/L. There was a significant increase in these enzymes from the beginning of the study to the sixth month, although these values did not approach or exceed the normal levels as indicated.
Glucose is blood sugar. Significantly high levels of glucose may indicate a diabetic tendency or actual diabetes. Low levels of glucose are suggestive of hypoglycemia. The expected or normal range for glucose is 80-120 mg/dL. Another object of the study was to determine the effect of the supplement on fasting serum glucose. The results are shown in Table 2 and in Table 3 below.
TABLE 3
Effect of Supplement on Fasting Glucose Levels
Variable
N
Month 0
Month 3
Month 6
80-109
134
94.7 ± 6.8
91.7 ± 8.0***
91.7 ± 13.8***
(mg/dl)
110-125
10
114.4 ± 3.6
110.2 ± 8.7
107.8 ± 8.7#
(mg/dl)
126-205
4
173.0 ± 36.0
139.0 ± 30.5
136.5 ± 27.2
(mg/dl)
All Subjects
148
98.2 ± 15.8
94.1 ± 12.7***
94.7 ± 14.3***
***P < 0.0001 when compared with month 0.
#P < 0.05 when compared with month 0.
The average of fasting glucose levels significantly decreased from the beginning (98.2 mg/dL), to month 3 (94.1 mg/dL), to the end of the study (94.7 mg/dL). The decrease in plasma glucose levels were presented in 14 subjects with impaired fasting glucose or diabetes (−16.9 mg/dL) and 134 subjects with normal glucose levels (−3.1 mg/dL). These results indicate that the multi-vitamin and mineral supplement may lower plasma glucose levels.
Another objective of the study was to determine if the homocysteine levels lowered after supplementation with the multi-vitamin and mineral supplement of the present invention. As discussed above, homocysteine is not inherently bad, but too much homocysteine may cause problems. High levels of homocysteine confers a risk of vascular disease, increases the risk of atherosclerosis, and may be associated with Alzheimer's disease. The following ranges provide the risk ranges for cardiovascular diseases, as well as other homocysteine-related diseases:
5 micromoles per liter or less -
very low risk
6-9 micromoles per liter
low risk
10-12 micromoles per liter
moderate risk
13-18 micromoles per liter
high risk
19 micromoles per liter or higher
very high risk
The preferable level of homocysteine is below 10 micromoles per liter.
It has been discovered that folic acid has the potential of dramatically lowering homocysteine levels, particularly when combined with vitamin B6 and B12. Another objective of the study was determine how well vitamin B6, B12, and folic acid were absorbed. The results of the effect of the supplement on serum concentrations of vitamins and homocysteine are shown in Table 4 below.
TABLE 4
Effect of Supplement on The Serum Concentrations of Vitamins and
Homocysteine
Variable
Month 0
Month 3
Month 6
Cysteine
271.7 ± 42.2
278.1 ± 41.5
281.3 ± 42.5
(nmol/ml)
Homocysteine
7.9 ± 2.4
6.7 ± 1.7***
6.7 ± 1.9***
(nmol/ml)
Pyridoxal-5-
75.2 ± 65.1
430.0 ± 176.8***
391.2 ± 170.3***
phosphate
(pmol/ml)
Folate (ng/ml)
9.3 ± 3.4
13.1 ± 3.8***
12.4 ± 4.0***
vitamin B 12
454.9 ± 138.2
729.3 ± 234.0***
800.3 ± 281.4***
(pg/ml)
***p < 0.0001 when compared with month 0.
**p < 0.0001 when compared with month 0.
As shown in Table 4, the levels of the vitamin B6, B12, and folic acid increased significantly indicating that the vitamins were easily and readily absorbed. As further shown in Table 3, the participants had an average of 7.9 nmol/ml of homocysteine at the first visit and an average of 6.7 nmol/ml of homocysteine at the third visit. At the end of the six month study, the participants had an average 12% reduction in homocysteine levels. As is shown in Table 6 below, those participants with a homocysteine level above 10 nmol/l at the first visit had a 31% reduction in homocysteine levels at the third visit. Therefore, the multi-vitamin and mineral supplement of the present invention may reduce cardiovascular risk by decreasing homocysteine levels.
As discussed above, high levels of LDL cholesterol has been linked to the development of atherosclerosis in the coronary arteries. Clogging of the arteries occurs after LDL cholesterol is oxidized within the blood vessel walls after exposure to free radicals. The white blood cells attempt to remove the damaged LDL cholesterol by engulfing them. After ingesting the LDL cholesterol, the white blood cells cannot rid themselves of the cholesterol and swell, beginning the process of atherosclerosis. LDL cholesterol can fight the free radicals with antioxidants such as vitamin C and E, but before long the antioxidants are depleted and the LDL is left defenseless. Another objective of the study was to determine if vitamin C, E, and beta-carotene in the supplement reduced the oxidation of LDL cholesterol. The results of the effects of the supplement on LDL oxidation kinetics are shown in Tables 5 and 6 below.
TABLE 5
Effect of Supplement on LDL Oxidation Kinetics
Variable
Month 0
Month 3
Month 6
LDL Oxidation
57.5 ± 13.9
63.5 ± 19.0***
63.8 ± 16.3***
Lag time (minutes)
LDL Oxidation Rate
9.7 ± 3.0
7.1 ± 2.5***
6.0 ± 2.0***
(umol/min/g protein)
Lipid-Standard?
9.0 ± 0.3
1.3 ± 0.4***
1.4 ± 0.4***
Vitamin C
Lipid-Standard?
33.0 ± 11.3
55.0 ± 23.4***
49.5 ± 18.0**
Vitamin E
Lipid-Standard?
0.2 ± 0.2
0.4 ± 0.3***
0.4 ± 0.3***
Beta-Carotene
***p < 0.0001 when compared with month 0.
**p < 0.0001 when compared with month 0.
TABLE 6
Effect of Supplement on the Serum Concentrations of Homocysteine and LDL oxidation
% change
% change
Subgroup
Month 0
Month 3
(0-3 M)
Month 6
(0-6 M)
Homocysteine
HCT ≦ 10 (nmol/ml)
128
7.2 ± 1.6
6.3 ± 1.3
−10***
6.4 ± 1.7
−8***
(nmol/ml)
HCT > 10 (nmol/ml)
22
12.0 ± 2.2
8.8 ± 2.0
−27***
8.1 ± 1.9
−31***
LDL Oxidation
LDL ≦ 130 (mg/dl)
114
9.6 ± 3.1
7.1 ± 2.7
−17***
5.9 ± 1.9
−35***
Rate
LDL > 130 (mg/dl)
28
10.2 ± 2.3
7.0 ± 2.1
−22***
6.8 ± 2.1
−24***
(umol/min/g)
Oxidation Lag
LDL ≦ 130 (mg/dl)
118
57.3 ± 14.2
63.2 ± 20.2
18***
63.7 ± 17.2
23***
Time
(minutes)
LDL > 130 (mg/dl)
28
58.3 ± 12.5
64.9 ± 12.5
16***
63.0 ± 12.8
12***
***p < 0.0001
Measurement of LDL oxidation include lag time and oxidation rate. Lag time is a measurement (in minutes) of the susceptibility of LDL cholesterol to oxidize, thus, the longer the duration the better. The participants had a significant increases in lag time from an average of 57.5 minutes at the first visit to 63.8 minutes at the third visit. The oxidation rate is the rate at which the LDL oxidizes and a slower rate is preferable. The participants had a significant decrease in oxidation rate from 9.7 umol/min/g protein at the first visit to 6.0 umol/min/g protein at the third visit, a 32% reduction. It is also noted that the blood levels of vitamin C, E, and beta-carotene significantly increased from the first visit to the third visit, thus indicating that these antioxidants were well absorbed. Therefore, the multi-vitamin and mineral supplement of the present invention may reduce cardiovascular risk by decreasing the susceptibility of LDL to oxidation.
While various embodiments of a multi-vitamin and mineral supplement have been disclosed, it should be understood that modifications and adaptations thereof will occur to one skilled in the art. Other features and aspects of this invention will be appreciated by those skilled in the art upon reading and comprehending this disclosure. Such features, aspects, and expected variations and modifications of the reported results and examples are clearly within the scope of the invention where the invention is limited solely by the scope of the following claims.
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This invention is directed to a multi-vitamin and mineral supplement tailored to men and post-menopausal women, pre-menopausal women, and athletes which supplies the right amount of the right micronutrients at the right time to assure adequate intake of micronutrients needed for disease prevention and protection against nutritional losses and deficiencies due to lifestyle factors and common inadequate dietary patterns. The multi-vitamin and mineral supplement is comprised of vitamin A, vitamin C, vitamin D, vitamin E, vitamin K, vitamin B1, vitamin B2, niacinamide, vitamin B6, vitamin B12, biotin, pantothenic acid, iron, iodine, magnesium, zinc, selenium, copper, chromium, potassium, choline, lycopene, and co-enzyme Q-10.
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This application is a divisional of application Ser. No. 08/343,126, filed 22 Nov. 1994 now U.S. Pat. No. 5,536,559.
FIELD OF THE INVENTION
This invention relates generally to imaging, and relates more specifically to a device for mounting an imaging mask.
BACKGROUND OF THE INVENTION
Lithography is a commonly used technique for etching a desired pattern into a substrate. Typically, the substrate to be etched is secured into place with a vacuum chuck or other securing device opposite a radiation source. A lithography mask is mounted between the radiation source and the substrate. The lithography mask is formed of a material that is opaque to radiation produced by the source but includes a radiation-transparent window with an opaque pattern. When the radiation source is activated, radiation emitted therefrom travels through the transparent portions of the window to the substrate but is prevented from passing through the opaque portions. A photoresist on the substrate is exposed in the desired pattern by the radiation passing through the transparent portions of the mask window. The photoresist is then developed and then used as a mask to etch the substrate.
In the lithography imaging process, particularly for the production of microelectronic components, patterns recorded onto photo-resist covered semiconductor wafers should be precisely positioned relative to pre-existing structures. For example, in 1× proximity lithography, variations of only a few nanometers over a pattern area of up to 50 millimeters×50 millimeters are permissible for acceptable pattern definition. Any stress present in the lithographic mask can distort the X-ray image and thus render the registration of the pattern with the substrate to be unacceptable. Such stress can be induced by many sources, including the actual gripping of the mask by its mounting structure. In particular, stress can be induced in the mask by a mismatch of the mask and its mounting structure. Of the mask itself is not planar, or if the mounting structure includes mounting surfaces that are not coplanar, the mask may be required to deform in order to be secured. Often, sufficient deformation (and, as a result, stress) is induced in the mask to adversely affect imaging.
One solution to reducing or eliminating stress in a mask through the design of its mounting structure stems from recognizing that any rigid planar or nonplanar surface can be supported at three points without further deformation. In addition, the stress in a mask can be reduced by enabling three such support points to move in such a way as to comply with any inplane dimensional changes of either the mask or mask mount (such as those unused by thermal expansion) after the two are joined. These three points must be compliant, yet must constrain the mask sufficiently to maintain a precise location relative to a mounting device for the mask.
Mask mounts exist which attempt to address these design parameters, with the methods of holding and providing compliance differing between the mount designs. Designs for X-ray lithography mask mounts generally employ a mask-to-wafer gap of typically 10-50 micrometers. This gap precludes the use of any holding or clamping hardware from being located on the mask front (wafer side) surface. One mask mount design has a mask with a thin, radially outwardly projecting lip. This lip is located nearer to the mount than the plane defined by the mask front surface. The mask is attached to a cassette by three clamps, each of which pinches a portion of the mask outer lip to hold the mask in place. All clamps are 120° apart and include a ball bearing that contacts the surface of the mask lip. In one clamp, the ball bearing is nested within an indented ball seat in the mask ring, and thus does not allow that mask mount point to move relative to the cassette. Another clamp is designed so that its ball fits within a linear V-groove channel on the mask lip. This clamp allows the mask to move relative to the cassette, in a direction defined by the V-groove. The third clamp is made so that its ball contacts on a flat surface on the mask lip, and thus is able to move in any direction parallel to the flat surface. The in-plane compliance achieved via the ball seat, V-groove and flat are referred to as a 1-2-3 kinematic mount. Once the mask is loaded within the cassette, the cassette is then attached to the stepper using a full surface vacuum chuck.
This design has certain shortcomings. The use of this mount is limited to masks that have a radially outwardly extending lip and the described ball grooves. This mask format is new and would require industry to forego existing mask formats and retool for this new format. In addition, finite element modeling has indicated that misalignment of the clamping pinchers could torque and distort the mask. This mask is more massive, which could lead to greater distortions due to gravitational sag; also, greater mask mass can negatively impact the performance of future mask/wafer aligners, which may have fast alignment stages which, in order to provide fast response time, should employ low inertia masks.
In a second design, the mask mount includes three metal vacuum cups, each of which pivots about a ball and socket joint. The mask is attached by suction to the rim of each cup. The cups are able to pivot in any direction to conform to the plane of the mask. However, their movement is not limited to directions parallel to the plane of the mask, as any pivoting by a cup distorts the attached mask out of its natural plane. In addition, because none of the cups are fixed into position, errors in remounting can lead to inconsistent imaging. Air leaks occurring at the metal cup rim will also generate vibrations, which distort the image.
In another design, a vacuum groove is machined into a metal plate. The mask ring and plate make full surface contact; the vacuum is applied to secure the mask to the plate. If nonplanarities exist between the mask ring and the vacuum plate, the ring will comply with the stiff plate surface and induce stress in the mask.
SUMMARY OF THE INVENTION
In view of the foregoing, it is an object of the present invention to provide a mask mount that induces little to no stress in a mask mounted thereto.
It is also an object of the present invention to provide a mount upon which masks having nonplanarities can be mounted without inducing stress.
It is a further object of the present invention to provide a mount that does not overconstrain the mask or cause post-mask mounting distortions.
It is shall be an object of the present invention to provide a microelectronic imaging apparatus that utilizes such a mask mount.
These objects and others are satisfied by the present invention, which provides a mask mount and apparatus that reduces or eliminates stress induced by mounting in an imaging mask mounted thereto. The mount comprises a support block and a trio of mounting pads connected thereto. At least two of the mounting pads are connected to the support block so that their respective positions are adjustable within a predetermined plane which is preferably substantially parallel to a surface of a substrate to be imprinted. Each of the mounting pads includes means for securing an imaging mask generally parallel to the predetermined plane. The positions of the adjustable mounting pads adjust within a predetermined plane responsive to post-mask mounting planar dimensional changes in either the mask or the mask mount. This mount provides sufficient constraints to hold a mask in a precise location without overconstraining it. The absence of stress on the mask will yield a reduced degree of distortion of the radiation passing through the mask and on to the imaged surface.
In one embodiment, the mount comprises two adjustable mounting pads. A first of these adjustable mounting pads is adjustable in a first linear direction, and the second is adjustable in the first linear direction and in a second linear direction that is perpendicular to the first linear direction. Preferably, the mount further comprises a flexural hinge that connects the first mounting pad to the support block and a pair of perpendicularly oriented cooperating flexural hinges connecting the second mounting pad to the support block.
In another embodiment, the mount comprises three adjustable mounting pads, each of which is adjustable in a respective linear direction. Each of the linear directions is separated by approximately 120 degrees from each of the other linear directions. Preferably, a trio of flexural hinges connects a respective one of the trio of mounting pads.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of a lithography assembly of the present invention.
FIG. 2 is a cross-sectional side view of the lithography assembly of FIG. 1.
FIG. 3 is an enlarged top view of a unidirectional mounting pad of a lithography mount.
FIG. 4 is a cross-sectional side view of a lithography mask in position for securing to a mounting pad of a lithography mount.
FIG. 5 is a cross-sectional side view of a lithography mask secured to a mounting pad.
FIG. 6 is a cross-sectional view of a prior art lithography mask and mount.
FIG. 7 is a cross-sectional view of the lithography mask and mount of FIG. 6 showing in exaggerated fashion the distortion of the lithography mask due to the nonplanar nature of the mount.
FIG. 8 is a top view of a lithography mount showing an immobile mounting pad, a unidirectional mounting pad, and a bidirectional mounting pad.
FIG. 9 is a top view of another embodiment of a lithography mount having an immobile mounting pad, a unidirectional mounting pad, and a bidirectional mounting pad.
FIG. 10 is a top view of another embodiment of a lithography mount having three unidirectional mounting pads.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will now be described in greater detail hereinbelow. This invention may be embodied in many 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 will fully convey the scope of the invention to those skilled in this art.
FIG. 1 illustrates a lithography imaging apparatus 20, which comprises a radiation source 22, a substrate chuck 24 that secures a microelectronic substrate 28, and a mount 30 that secures a lithography mask 40. The radiation source 22, which preferably produces X-rays but can produce other forms of electromagnetic radiation suitable for lithography such as UV or visible optical radiation, provides imaging radiation along a radiation path, the direction of which is defined generally by the center line shown in FIGS. 1 and 2. The substrate chuck 24 secures the microelectronic substrate 28 in the radiation path. Illustratively and preferably, the substrate chuck 24 includes vacuum nozzles 26 that fix the microelectronic substrate 28 in the radiation path; however, other means known to those skilled in this art for securing a microelectronic substrate in position for imaging can also be used with the present invention. The microelectronic substrate 28 is typically a semiconductor material, but can be other materials, such as multilayer ceramic substrates or printed circuit boards, on which lithographic processes can be used, and preferably includes a photoresist layer on the surface to be imaged.
The mask mount 30 comprises a rigid support block 31 having a front surface 32, a trio of mounting pads 34, 36, and 38, and a vacuum 56. The support block includes a centrally located mount aperture 35 positioned in the radiation path through which radiation from the radiation source 22 passes. The mounting pads 34, 36, and 38 are arranged radially equidistant from the center line of the mount aperture 35 and circumferentially equidistant from one another. The support block 31 also includes three alignment apertures 33: one of which is located laterally of the mount aperture 35, and two of which are located beneath the mount aperture 35.
The lithography mask 40 comprises a glass ring 42 and a mask layer 46. A substantially square mask window 43 is centrally located in the mask layer 46 and provides a passageway for radiation from the radiation source 22. The mask window 43 includes both an opaque portion and a transparent portion; together, these portions define the desired pattern to be imaged on the microelectronic substrate 28. The mask 40 also includes a flat portion 45 at its lower edge. This flat portion 45 rest against two of a trio of alignment pins 47 that are inserted into alignment apertures 33. A third alignment pin 47 is inserted into the lateral alignment aperture 33. The alignment pins 47 ensure that the mask 40 is properly positioned relative to the center line.
The spatial relationship of the components of the lithography apparatus 20 is illustrated in FIG. 2. The radiation source 22 emits radiation, illustrated by the arrows shown in FIG. 2, that travels along the radiation path. The radiation first travels through the mount aperture 35, then through the glass ring 42 and the mask window 43 of the lithograph mask 40. Any radiation striking either the opaque portion of the mask window 43 or the mask layer 46 itself is lost from the radiation path; radiation striking the transparent portions of the mask window 43 passes therethrough. The radiation then crosses a small gap, typically about 10 to 50 microns in width, between the mask layer 46 and the microelectronic substrate 28, which is presented for imaging by the substrate chuck 24. Radiation reaching a portion of the microelectronic substrate 28 causes photoresist on the substrate to record an image at that location. Areas of the photoresist on the substrate 28 that are not irradiated by the radiation are not affected. As a result, the photoresist is developed in the desired pattern.
The mounting pad 36, which is exemplary of mounting pads 34 and 38, is shown in greater detail in FIGS. 3 through 5. The mounting pad 36 comprises an O-ring 50, preferably formed of a resilient flexible material, a centrally located registry pin 52, and a vacuum tunnel 54 having an outlet at the front surface 32 within the area defined by the O-ring 50. The vacuum tunnel 54 is fluidly connected with the vacuum source 56, which is capable of exerting a negative pressure at the vacuum tunnel outlet.
Securing of the lithograph mask 40 to the mounting pad 34 is illustrated in FIGS. 4 and 5. The lower surface of the glass ring 42 is lowered onto the O-ring 50. As the lower surface of the glass ring 42 contacts the O-ring a seal is formed therebetween. Application of negative pressure via the vacuum 56 through the vacuum tunnel 54 draws the lower surface of the glass ring 42 toward and onto the free end of the registry pin 52, with the O-ring 50 flexing in response to this movement. The distance between the lower surface of the glass ring 42 and the mask mount front surface 32 is defined by the height of the registry pin 52, which provides a point load to the glass ring. The glass ring 42 need not be secured precisely perpendicularly to the registry pin 52, as the resilience of the O-ring 50 enables the glass ring 42 to remain sealed thereto. As a result, slight nonplanarities in the glass ring 42 can be accommodated by the mounting pad 36. The O-ring 50 also 50, provides vibration dampening to the mask 40. Notably, the mask 40 is secured to the mask mount 30 without any structure of the mount 30 extending beyond the plane defined by the mask 40.
The distortion created in a lithograph mask through securing of the mask to a mount can be understood by the illustrations of a prior art mount 80 in FIGS. 6 and 7. The mount 80 is a simple vacuum chuck that secures a mask 82 via a vacuum applied thereto through vacuum tunnels 81. However, as is illustrated in FIGS. 6 and 7, if the front surface 83 of the mount 80 is uneven, securing of the mask 82 thereto causes distortion in the mask, which in turn adversely effects the etching process. Similarly, thermal expansion of the mask 82 relative to the mount 80 can also cause distortion.
The mounting pad 36 itself is adjustably connected to the support block 31 via a quartet of flexural hinges 70 (FIG. 3). Three interconnected inner slots 62, 63, 64 form three sides of a square around the mounting pad 36. These slots extend through the thickness of the support block 31. Each of the ends of each of these slots 62, 63, 64 merges with an aperture 65 that also extends through the thickness of the support block 31. Three outer slots 66, 67, 68, two of which (slots 66 and 68) are located adjacent opposing inner slots 62 and 64 and a third of which (slot 67) is located opposite the third inner slot 63, also form three sides of a square around the mounting pad 36. Four apertures 69 are positioned adjacent apertures 65 on outer slots 66, 68 so that a flexural hinge 70 is formed between each pair of adjacent apertures 65, 69.
The flexural hinges 70 are each able to flex so that the mounting pad 34 is free to move unidirectionally along a translation line parallel to the opposed inner and outer slots 63, 67 within the plane defined by the mount front surface 32. However, the flexural hinges 70 do not permit the mounting pad 36 to twist about its translation line or to move perpendicular thereto.
As shown in FIG. 8, the mounting pad 38 is connected to the support block 31 through a pair of cooperating flexural hinge quartets 90, 92. Each of these flexural hinge sets 90, 92 is configured similarly to those of the unidirectional mounting pad 36 illustrated in FIG. 3, but they are oriented so as to have translational directions that are perpendicular to one another. Consequently, the mounting pad 38 is free to move in any direction within the plane defined by the mount front surface 32. Also, the mounting pad 34 is fixed to the support block 34 and thus is immobile.
The combination of the immobile mounting pad 34, the unidirectional mounting pad 36, and the bidirectional mounting pad 38 provides the mount 30 with a configuration that can adjust to inplane dimensional changes in either the mask 40 or mask mount 30 after the two are joined. This mount provides enough constraints to hold the mask in position, without over constraining it and inducing stress. This kinematic mount configuration can be explained in terms of the principles of rigid body behavior. To remain fixed in space, a rigid body, such as the mask 40, must be constrained from translatory movement in three directions (defined by an arbitrary set of orthogonal x-, y- and z-axes), and constrained from rotating about any of these three axes. Each of these potential translations or rotations (totalling six) is deemed a "degree of freedom". If additional constraints are applied to the rigid body, the rigid body can respond only by deforming or deflecting to satisfy these constraints. One example of a mask mount with overconstraints is illustrated in FIGS. 6 and 7. When two nonplanar surfaces are forced to join and comply with each other, (such as is the case in FIGS. 6 and 7), overconstraints exist which stress the mask 40.
In contrast, the mount 30 of the present invention provides only six constraints corresponding to the six degrees of freedom, and thus does not force the mask 40 to deform in order to be secured thereto. Looking at the individual mounting pads, and assigning a Cartesian coordinate axis system so that the x-axis extends from the registry pin 52 of the immobile mounting pad 34 to the registry pin 52 of the unidirectional mounting pad 36, the y-axis extends perpendicularly to the x-axis within the plane of the page of FIG. 8, and the z-axis is normal to the plane of the page of FIG. 8, the registry pin 52 and the vacuum tunnel 54 of the immobile mounting pad 34 together provide constraints in the x, y, and z-directions. The unidirectional mounting pad 36 and the immobile mounting pad 34 combine to provide constraints to rotation about the y- and z-axes. The combination of the immobile mounting pad 34 and the bidirectional mounting pad 38 provides a constraint to rotation about the x-axis. However, these are the only constraints placed on the mask 40; the ability of the unidirectional mounting pad 36 and the bidirectional mounting pad 38 to shift within the plane of the mount front surface 32 enables the mask 40 to be secured to the mount 30 without being forced to deform. As a result, little to no stress is induced in the mask 40 due to its being secured to the mount 30, and therefore radiation passing through the mask 40 is not distorted.
FIG. 9 illustrates an additional mask mount 100 of the present invention which, like the embodiment illustrated in FIG. 8, includes an immobile mounting pad 102, and unidirectional mounting pad 104, and a bidirectional mounting pad 106; however, the flexural hinges 114, 126 connecting the mounting pads 104 and 106 to the mask mount 100 are configured somewhat differently. A set of slots 111 is arranged as a discontinuous square that surrounds the unidirectional mounting pad 104; a pair of parallel slots 112 extend from the discontinuity in the slots 111 to a pair of adjacent apertures 113 that define the flexural hinge 114. The flexural hinge 114 confines the movement of the unidirectional mounting pad 104 to that along a line parallel with a line between the immobile mounting pad 102 and the unidirectional mounting pad 104.
Two discontinuous square slots 120, 122 are arranged in a nested pattern about the bidirectional mounting pad 106, with their discontinuous portions being on opposite sides thereof. Each of the square slots 120, 122 includes six apertures 124, each of which is adjacent a corresponding aperture 124 of the other square slot. The adjacent pairs of apertures 124 define six flexural hinges 126. This flexural hinge configuration enables the bidirectional mounting pad 106 to move within the plane of the front surface of the mount 100.
Like the embodiment of the present invention illustrated in FIGS. 1 through 8, the combination of the immobile mounting pad 102, the unidirectional mounting pad 104, and the bidirectional mounting pad 106 enables the mount 100 to secure a lithography mask without inducing undesirable deformation therein. Consequently, the precision of lithographic processes is improved. Those skilled in this art will appreciate that, although the illustrated configurations of flexural hinges are preferred, other flexural hinge configurations known to those in this art, such as those disclosed in Paros et al., How to Design Flexural Hinges, Machine Design (Nov. 25, 1965), that provide in-plane flexure can also be used with the present invention.
A further embodiment of the present invention is illustrated in FIG. 10. In this embodiment, a mount 130 of the same general configuration as the mounts illustrated in FIGS. 1 through 9 comprises three unidirectional mounting pads 132, 134, 136. Each of the mounting pads is positioned radially equidistant from the center of a mount aperture 138 and circumferentially equidistant from one another. Each of the mounting pads 132, 134, 136 is connected with the mount 130 through a respective flexural hinge quartet 133, 135, 137 of the configuration illustrated in FIG. 3. As a result, each mounting pad 132, 134, 136 is able to move unidirectionally along a line between the particular mounting pad and the center of the mount aperture within the plane defined by the front surface of the mount 130; thus, the movement direction of each of the mounting pads 132, 134, 136 from the other movement directions is separated by approximately 120 degrees.
Like the embodiments of FIGS. 1 through 9, this configuration enables the mounting pads 132, 134, 136 to adjust within this plane in response to the securing of a lithography mask and thus constrains a lithography mask secured to the mounting pads 132, 134, 136 only in the six degrees of freedom described above. Accordingly, securing of the mask does not induce deflection, and as a result undesirable stress, therein.
Any of the above-described embodiments are also suitable for other imaging processes in which an imaging or optical element can benefit from being mounted with little to no stress. Exemplary alternative processes include metrology systems, holographic systems, x-ray, optical mask inspection, or any system in which a pattern or optical property could be adversely influenced by mounting stresses.
The foregoing embodiments are illustrative of the present invention, and are not to be construed as limiting thereof. The invention is defined by the following claims, with equivalents of the claims to be included therein.
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An imaging mount and apparatus that reduces or eliminates stress induced in an imaging mask mounted thereto. The mount comprises a support block and a trio of mounting pads connected thereto. At least two of the mounting pads are connected to the support block so that their respective positions are adjustable within a predetermined plane which is preferably substantially parallel to a surface of a substrate to be imaged. Each of the mounting pads including means for securing the imaging mask generally parallel to the predetermined plane. The positions the adjustable mounting pads adjust within the predetermined plane responsive to securing of the lithography mask thereto so that the imaging mask is essentially undeflected due to the securing thereof. The absence of deformation (and, as a result, stress) in the imaging mask due to its being secured to the mount reduces the degree of distortion of radiation passing through the mask and to the imprinted surface.
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This application is a continuation of application Ser. No. 08/306,989, filed on Sep. 16, 1994, now abandoned, which is a continuation of application Ser. No. 08/094,109 filed on Jul. 28, 1993, now U.S. Pat. No. 5,405,204, which is a 35 U.S.C. §371 of application Ser. No. PCT/US92/00824 filed on Feb. 2, 1992. Application Ser. Nos. 08/094,109 and PCT/US92/00824 are a continuation-in-part of application No. 07/648,628 filed on Feb. 1, 1991, now abandoned.
BACKGROUND OF THE INVENTION
In the design of alphanumeric keyboards for use in typewriters, computers, typesetters, and certain scientific and technical instruments, it has been generally assumed that the keyboard must be tilted forward, that is, the front or operator edge of the keyboard surface must be lower than the rear edge of the keyboard surface. It will be recognized that the word keyboard in this patent application will generally be used to apply to the above types of keyboards as opposed to the keyboards found in musical instruments. The assumption that this orientation is the proper way to design a keyboard may have many origins. Certainly, from the point of view of mechanical orientation of the mechanical links found in early keyboard systems, this arrangement was probably necessary. Furthermore, for operators who are not "touch" typists, it was generally necessary and desirable that the keys be arranged in such a way that their identity, designated by symbols on the keys, could be easily visible to the operator by tipping the surface of the keyboard toward the operator. Furthermore, a somewhat mechanistic concept of how the human hand operates might well suggest that the forward tipping of the keyboard would be the most efficient way of positioning the keyboard before the operator. For these and other reasons, the forward tipping of the keyboard plane is essentially universal. Such a typical orientation is shown in FIG. 1 of the drawings.
In a separate development, the medical community has become increasingly aware of an extremely irritating, but non-lethal physical affliction, known generally as the "carpal tunnel" syndrome. In this affliction, the median nerve, which extends down the arm and out to the human hand, can be damaged at the point at which it passes through the human wrist joint. The occurrence of this affliction has a large number of unpleasant physical consequences. Generally, the affliction is associated with situations in which the hand and wrist are bent upward and backward and, while in that position, significant weight is applied to the wrist. This phenomenon which is very common among serious bicycle riders can result in long term pain and disability.
It has been observed that the carpal tunnel syndrome is frequently associated with persons who are professional keyboard operators. It appears that the forward tilt of the keyboard, which is universally accepted as the proper design for a keyboard, may well force the operator, on a long term, continuous basis, to arch back the hand and wrist in such a way that, over the many years that the operator may be sitting before the keyboard, permanent work place injury could result. This unfortunate circumstance may well be resulting in serious long term human suffering and, of course, the financial liabilities and difficulties which can be associated with such human suffering. This problem is compounded by another aspect of conventional keyboard design. Ordinarily, the operator is required to sit before the keyboard with hands extended over the keyboard. Holding the hands over the keyboard for hours at a time places tremendous stress on the operator's shoulder and neck muscles. In conventional mechanical typewriters, this uncomfortable and potentially harmful condition was constantly relieved by the peripheral activities required by the mechanical typewriter; i.e., hitting the carriage return bar and changing sheets of paper. With modern word processing systems, the operator can literally spend hours without removing his or her hands from the keyboard. The long term effect of holding one's hands over the keyboard, day after day, year after year, may well cause harmful neck and shoulder muscle stress. In addition, muscle stress and fatigue in the hands are compounded by the fact that some keyboards are not sturdily built. For instance, if the keyboard is not anchored properly, there is generally a "springiness" when typing. This bounce in the keyboard exacerbates the carpal tunnel syndrome. These and other difficulties, experienced with the prior an devices, have been obviated in a novel manner by the present invention.
It is, therefore, an outstanding object of the invention to provide a keyboard positioning system in which the keyboard is tipped backward so that the operator's hands and wrist assume a position which does not cause irritation or damage to nerves which pass through the wrist joint.
Another object of the invention is the provision of a keyboard positioning system which holds the keyboard in a position in which it is tipped backwards in order to provide a more comfortable and restful orientation for professional or long term keyboard operators.
A further objective of the present invention is to provide a keyboard system which supports the operator's hands in a proper position over the keyboard in order to minimize neck and shoulder muscle strain.
It is still a further object of the present invention to provide a keyboard system which holds the keyboard in a solid position without any bounce or shake when the user is typing.
A further object is to provide a simple keyboard system which can be easily accessed and stored away below a desk.
Another object of the present invention is to provide a keyboard positioning system in which the keyboard can be easily replaced or taken off of its support on runners.
Another object of the present invention is to provide a keyboard support that adapts to a wide range of keyboard sizes with minimum need for adjustment.
Another object of the present invention is to provide a keyboard support which is easily convertible from a temporary orientation in which ease of installation and minimum permanent effect on the work station is the priority to a permanent orientation in which maximum effectiveness is the priority.
With these and other objects in view, as will be apparent to those skilled in the art, the invention resides in the combination of parts set forth in the specification and covered by the claims appended hereto.
SUMMARY OF THE INVENTION
This invention is a keyboard positioning system which allows the keyboard to be positioned so that it is tipped backward. By "tipped backward" is meant that the rear edge, or plane, which is away from the operator, is below the forward edge, or edge closest to the operator. By orienting the keyboard in this way, the position of the operator's hand can be moved at least to the point where the plane of the hand is parallel to the line of the lower arm, thereby eliminating the stress which leads to the carpal tunnel syndrome. It has been found that, in fact, it is sometimes preferred to allow the plane of the wrist to be positioned slightly downward of the line of the lower arm. In fact, the operators have found this to be a very comfortable position in which to function. Obviously, this position is probably not acceptable to amateur keyboard operators since the visibility of the keyboard, a matter which would be important to amateurs, would be somewhat inhibited.
The keyboard positioning system would be provided with a support bar which supports the operator's hands over the keyboard. In the preferred orientation, the bar would be positioned in front of and below the front edge of the keyboard and would engage the large fleshy portion which lies at the base of the palm of the operator's hands, hereinafter proximal palm portion. The ideal is a "neutral" position.
In addition, the keyboard positioning system may also contain a stabilizing bar between the securing brackets and a tray to hold the keyboard. These elements will help support the keyboard positioning system when typing. The design allows for easy movement on a set of runners in or below a desk.
BRIEF DESCRIPTION OF THE DRAWINGS
The character of the invention, however, may be best understood by reference to one of its structural forms as illustrated by the accompanying drawings, in which:
FIG. 1 is a perspective view of the prior art keyboard orientation.
FIG. 2 is a perspective view of an embodiment of the present invention.
FIG. 3 is another perspective view of an embodiment of the present invention.
FIG. 4 is a perspective view of the holding clamp and positioning clamp which would be employed at the far end of the embodiments shown in FIGS. 2 and 3, but without the keyboard in the way.
FIG. 5 is a perspective view of the inside view of the system which has the brackets in the embodiments shown in FIGS. 1 and 2.
FIG. 6 is a perspective view of a preferred orientation of the system.
FIG. 7 is a perspective view of the orientation shown in FIG. 6.
FIG. 8 is a figurative view of the preferred orientation of the system and operator's hand.
FIG. 9 is a detailed view of a preferred orientation of the palm support.
FIG. 10 is a detailed view of another orientation of the palm support.
FIG. 11 is a perspective view of a second embodiment of the keyboard system in use.
FIG. 12 is a close-up perspective view of the keyboard positioning system and angle adjustment capability.
FIG. 13 is a perspective view of a second embodiment of the keyboard positioning system separated from a securing structure.
FIG. 14 is a side view of an interchangeable temporary clamp which can be used in the second embodiment.
FIG. 15 is a side view of an interchangeable permanent bracket which can be used in the second embodiment.
FIG. 16 is a diagramatic side view of a keyboard in a conventional position showing the hand extention necessary to reach the far rows of keys.
FIG. 17 is a diagramatic side view of a keyboard oriented to embody the principles of the present invention, showing the ease by which the user can reach the near keys.
FIG. 18 is a diagramatic side view of a keyboard oriented to embody the principles of the present invention, showing the ease by which the user can reach the mid keys.
FIG. 19 is a diagramatic side view of a keyboard oriented to embody the principles of the present invention, showing the ease by which the user can reach the far keys.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 2, where are best shown the general features of the present invention, it can be seen that the keyboard positioning system, generally denominated by the numeral 10, includes a base or desk surface 11, positioning brackets 12 and 29 (not shown) connected to the base 11, clamping element 13 and 30 (not shown), which is adjustably connected to the positioning brackets 12 and 29, respectively, and a keyboard 14 of the conventional computer keyboard type.
The clamping element 13 is shown adjustably locked to the positioning bracket 12 by a wing nut and bolt combination 16 and 17. At the forward, or operating edge 18 of the clamping element 13 is a hand support 19 which extends across the front edge 20 of the keyboard and hand support holder 23 which is attached to the clamping element by means of a wing nut 21 and bolt 22. The clamping element 13 has a holding element 24 (set-screw) which holds the keyboard in the clamping element 13.
The hands 23 of the operator extend over the wrist support bar and hang downwardly toward the keys 25 of the keyboard 14.
The surface 26 of the keyboard is positioned at an angle of approximately 45° from the horizontal with the rear edge 27 lowered. More specifically, if the keyboard plan is defined as the plane which approximates the upper surfaces of all of the keys, then the preferred embodiment puts the keyboard plan from 30° to 60° down from the horizontal. The invention appears to be beneficial from 10° to 70° and offers some benefit from 0° to 70°.
Referring now to FIG. 3, it can be seen that both of the hands 23 and 28 of the operator carry over the hand support bar and downward toward the keys 25.
Referring to FIG. 4, it can be seen that the inside surface of the clamp 30 is provided with an upper clamping flange 31 and lower clamping flange 32 which oppose one another and engage the side edge of the keyboard. A set screw 33 allows the clamping elements to securing engage the keyboard so that it does not slide out.
FIG. 5 shows a view of the inside surface of the clamping system and because it is a side elevational view, the angularity of the clamp with respect to the vertical and horizontal portions of the positioning element can be more clearly seen.
FIG. 6 shows a perspective view of the system with the wrist support in the preferred orientation, i.e., below the front edge 20 of the keyboard 14. FIG. 7 is a closer view of the orientation in FIG. 6, showing the operator's hand 23.
FIG. 8 is a diagrammatic view of the preferred orientation of the operator's hand 28, the front edge 20 of the keyboard 14 and the hand support 19. The hand support 19 engages and supports the proximal palm 34. The palm 35 curves over (without touching) the front edge 20 of the keyboard 14 and the fingers 36 reach to the keys 25.
FIGS. 9 and 10 show the orientations of the hand support 19, the hand support holder 37, and the forward edge 38 of the clamping element 30. The hand support holder 37 (of which there is one at each end of the hand support) is formed of a plate 39 and a pin 40 mounted on the plate and extending outward from the plane of the drawing. The plate 39 is adjustably mounted to the clamping element 30 by the bolt 41 which extends through the slot 42 in the plate to allow both rotation and radial positioning of the pin 40. The pin 40 is shaped to engage the end of the hand support 19. The hand support 19 is formed of a hollow cylinder which can be easily cut to length and engaged by the pin 40, on one end, and a corresponding pin on the other end. In this way, the system can be adapted to the various widths of the keyboards.
FIG. 11 is a perspective view of a second embodiment of this invention in use.
FIG. 12 shows the keyboard positioning system 110, shown in FIG. 11, with a downward or backward keyboard slant and tray 142 positioned at the bottom of positioning brackets 143 and 144. The brackets are attached to desk 145.
FIG. 13 shows the keyboard positioning system with hand support 19 attached by means of adjustment knobs 150 and 151 to tray 142 which holds a keyboard (not shown). The tray 142 is attached by height adjustment knobs 153 and 154 (not shown) on both the left and right sides of two positioning brackets 143 and 144. The positioning brackets may be connected to a pair of runners 154 and 155 which are connectable to a desk 145 (not shown). A support bar 146 is positioned between the positioning brackets 143 and 144, to make the entire structure very rigid. The positioning brackets 143 and 144 have knobs 152 and 153 which screw into the tray 142 and which allow for height and angle adjustment by slots 157 and 158 in each of the positioning buckets 143 and 144, respectively.
One special feature of the second embodiment is the means by which the system is attached to the desk. It has been found that the long-term benefits of the present invention can be best accomplished by maximizing the rigidity of the system as it is attached to a desk. However, the rigid and permanent installation tends to be time consuming and tends to leave permanent disfigurement (i.e., screw holes) in the underside of the desk. It has been found that these aspects of the permanent installation tend to discourage many potential users from trying the system and receiving its benefits. This embodiment is, therefore, provided with easily interchangeable clamps which allow the system to be quickly and easily attached to a desk for test use. The clamps do not require damage to the desk. In that way, the user can test the system with minimum objection and thereby discover its benefits.
FIG. 14 shows a side view of the attachment portion of the system. The positioning bucket 144 is rigidly attached to the clamp 162 by a threaded bolt 161, which passes through an aperture in the bracket 144 and engages a threaded aperture in the clamp 162. The clamp 162 has an upper arm 164 which engages the upper surface of the desk 145. The clamp also has a lower arm 165 which extends a substantial distance under the desk 145. The lower arm has a threaded vertical bore which carries a threaded shaft 166. The lower end of the shaft 166 has a clamping knob 167, which, when turned, allows the upper end of the shaft 166 and a pad 163 thereon to engage or disengage the lower surface of the desk. This clamp 162 and a similar clamp 168 (not shown) on the other bracket 143 allow the system to be easily and quickly attached to the desk for test purposes.
Once the benefits of the present invention have become clear to the user during testing, it is possible to replace the clamps 162 and 168 with a more aesthetic and functionally superior attachment means shown in FIG. 15. This alternative arrangement not only provides optimally rigid support for the keyboard, but also allows the keyboard to be slid under the desk surface when the keyboard is not in use.
To convert from the clamp structure shown in FIG. 14 to the bolt-on structure shown in FIG. 15, the clamp 162 is separated from the bracket 144 by removing the bolt 161. The bracket 144 is then attached to the runner or bolt-on bracket 155 using the bolt 161. The bolt passes through the aperture in the bracket 144, through an aperture in the bolt-on bracket 155, and engages a threaded bore in the end of the stabilizing bar 146.
There are bolt-on brackets 154 and 155 for each of the brackets 143 and 144. The bolt-on brackets are mirror images of one another. Bolt-on bracket 155 consists of an elongated frame 171, several flanges (only flange 172 is shown in FIG. 15) which allow the frame to be rigidly bolted to the underside of the desk 145, and a slider 175. The slider is elongated and is slidably mounted in ball-beatings, for horizontal linear movement, in the frame 171. One end of the slider 175 is the pan of the bolt-on bracket 155 which is attached to the bracket 144. The sliding action of the bolt-on brackets allows the system to easily move the keyboard from a working position away from the desk to a storage position near and beneath the desk.
The present invention does something no other prior art product can do and that is to place and maintain the hand and wrist of the operator at or near a physiologically neutral position. The emphasis on the neutral position is critical because this is the position which really helps dedicated (full-time) keyboard users to minimize the damage caused by the bending of the median nerve and associated wrist structures.
The present invention's use of the sliders, in combination with a very thin holding tray, allows for the computer keyboard to be pulled up into the operator's lap. This brings recognized comfort, but more importantly, it allows and encourages a medically beneficial sitting position. That position acts to reduce upper torso stresses in the arms, neck, and upper extremities.
The adjustable palm bar, with its unique small diameter (3/4" to 11/8" in outer diameter, preferably 7/8"), allows for minute adjustments of the wrist position in relationship to the keys and for the overall comfort of the hand as it is placed over the computer keyboard.
The backward-tilt holding tray for the computer keyboard helps to dramatically reduce the amount of flexing the fingers must do while operating the keyboard. This contributes significantly to the reduction in overall stress to the associated tendons of the hand and wrist. It also reduces stress on the median nerve. No prior art product can make this claim. Only the unique position of the keyboard and the unique effect of the palm bar appear to achieve this important effect.
One important aspect of the keyboard orientation is the manner in which the position of the palm rest and the back-tilted orientation of the keyboard allows the fingers to reach the most-used keys with a maximum of hand and finger flexion (ventral bending) and minimum of hand and finger extension (dorsal bending). As shown in FIG. 16, the conventional keyboard orientation requires that a hand position which allows contact with the first row of keys also must involve extreme extension of the fingers to reach the upper row of the main keys. This extension of the fingers places severe strain on the muscles and tendons that cause extension of the fingers and, as a result, the hands are either fatigued or the wrist is forced out of the neutral position. The result, over a long term, is wrist damage and carpal tunnel syndrome.
The present invention, on the other hand, allows reaching the keys while keeping the fingers in flexure. FIGS. 17-19 show this effect graphically.
The present invention is the first device to be totally adjustable to all operators. The height and keyboard angle can be quickly and easily adjusted by the tightening knobs. The present invention has overall ability to address the unique physiological requirements of any operator, regardless of size. It allows for the correct straight up-and-down sitting posture for the back, at the same time, adding strong support for the arms. This is because the hands, via the palm rest, act to support the upper torso weight.
The present invention, while appearing similar in some respect to prior an products in the computer keyboard storage tray market, is radically different. The present invention is designed for one primary function and that is to provide a device to respond to the computer keyboard operator's physical needs. Primarily, this is accomplished by placing the operator's wrists in a continuous neutral position while the operator continues to operate the keyboard. This is achieved by three physical aspects, (1) combining a backward tilted holding tray with (2) a moveable approximately 3/4" diameter round palm rest, and (3) attached to computer tray sliders. The ability of the three movable aspects to be minutely adjusted to the operator's own physical requirements maximizes the benefit.
The present invention develops a new aspect in the ergonomic field with regards to accepted sitting positions for keyboarding. It is generally accepted that the hand and arm should be held between 90 degrees and 70 degrees relative to the vertical upper arm. The present invention is particularly effective when the hand and arm are positioned at a downward angle of 110 degrees down to 160 degrees relative to the vertical upper arm. No other product has advocated using this extreme position. In field rials, the present invention has won the praise of its operators. The present invention is proving to be innovative in bringing relief with this new, radical position.
Some prior art units must be fully extended to be operated. That is, the unit must be fully extended from the work station to be operative and to allow the holding tray to be rotated to the desired position. Compared to the critical positions of the present invention in the backward tilt, the prior art units assume only limited positions. This does not allow for the minute adjustments afforded by the present invention. The critical position for the operator to maintain while operating the computer keyboard is a position which causes the wrist to remain in neutral position and reduces the repetitive extension (dorsal bending back) of the wrist. The present invention does this, but the prior art products do not enforce the optimum position of the hand and arm so that the wrist remains neutral throughout the operation of the computer keyboard. The prior art wrist rests serve as support for the wrist, rather than the palm. The whole wrist must be placed on the prior art support tray. The present invention requires only the distal surface of the base part of the palm to rest on the small diameter round bar. The fatty tissue in the palm allows for a natural cushion. The prior art units require the wrist, with its veins and tendons close to the skin surface, to be in constant and potentially damaging contact with the wrist rest.
An important feature of the palm rest is that it allows for greater movement of the hand with..less obstruction from the supporting surface of the hand support. With the prior art units, the whole wrist is in contact with the supporting surfaces. The present invention only requires contact between the support and the base of the operator's palms. This allows for a more natural movement of the fingers and hands, reducing stress and fatigue to the operator.
Vibration is an important aspect to consider when operating the computer keyboard on a continuous basis. It is analogous to being in a rough riding car versus a smooth riding car. For the dedicated keyboard operator, it is important for the keyboard to provide a firm, energy absorbing or "damped" surface. If this is not accomplished, then the operator cannot fully relax his or her upper torso when his or her hands are placed on the palm rest or wrist rest. The result of not having a secure-feeling resting surface for the hands is the tightening of the neck and arm muscles. This is extremely harmful to a full-time keyboard operator.
The prior art units are described as convenient storage systems for the computer keyboard, and they all promoted for the comfort of the computer keyboard operator. However, the majority of the prior an products vibrate to a great degree in use. One of the reasons is the perceived need to have a product that will appeal to everyone's needs. This means products with a wide range of versatility. In the process of trying to achieve this market capability, the products are designed in an unstable form. This unstable form interfere with their ability to be very stable in use and to absorb the continuous vibration from the continuing key strokes.
The present invention has carefully taken into account the need to provide the dedicated (full-time) operator with a sturdy work platform. The present invention is designed much as an athlete's apparatus for a sport would be designed. It must do the job and hold up under duress and provide maximum comfort to the users. An operator who is subject to hand support vibration while using a computer keyboard for extended periods of time, will suffer quickly from fatigue and this may result in the injuries now being experienced in the work place. While the present invention provides for the maximum comfort of the operator, the device is primarily intended to encourage the optimum position for the computer keyboard operator and that is the wrist neutral position. Therefore, the present invention's concept of comfort for the operator includes the long-term comfort which results from the design function of having the computer keyboard operator maintain this neutral, and therefore less injurious, hand and wrist posture. The other prior an products do not recognize this specific mode of operation. It is only maximally achievable with the special (approximately) 3/4" diameter adjustable palm bar and backward tilted keyboard holding tray in conjunction with the mechanical design and superior construction of the materials used to make the present invention.
The present invention also focuses on the "palm only" resting on the palm support. The prior an units show or describe the whole wrist resting on the wrist rest. In order for the operation of the prior art units, the wrist must be moved continuously over the surface to reach the keys. That does not allow for the wrist and hand to be placed in a continuous neutral position. The fingers must be extended (bent dorsally) for each key stroke of operation. The present invention allows for the fingers to be moved in a non-stress downward movement, without significant need for full extension (dorsal bending) of the fingers.
An important aspect of the key stroke operation on the backward tilted keyboard is the ability to keep the hand in a semi-cupped position. This allows for the hand to work without being forced to reach, in extension, for the computer keyboard keys. This, incidentally, adds to the speed of the operator's typing ability, because the fingers have less range to travel in the stroking of the keys. Over a short period of time, this adds to the productivity of the operator with much less fatigue. The present invention, while somewhat similar in oven appearance to some prior art units, is uniquely different from any other prior art product. The present invention is designed to address the dedicated (full-time) keyboard user's physical need for ergonomic adjustment while operating the computer keyboard. No other product has been effectively designed to do this.
It is obvious that minor changes may be made in the form and construction of the invention without departing from the material spirit thereof. It is not, however, desired to confine the invention to the exact form herein shown and described, but it is desired to include all such as properly come within the scope claimed.
The invention having been thus described what is claimed as new and desired to be secured by letters patent is:
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Disclosed is a support mechanism for mounting a keyboard to a base. In on embodiment, the support mechanism comprises a bracket member which is adapted to mount to the base and a support tray which is adapted to movably mount to the bracket member. The support tray comprises first and second side portions and a support surface adapted to receive the keyboard. The support tray is adapted such that it is movable to a position where the first side portion is disposed below the second side portion. The support mechanism further comprises a palm rest having a longitudinally disposed surface. The palm rest is movably connected to the support tray.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is the National Stage of PCT/DE2012/100002 filed on Jan. 3, 2012, which claims priority under 35 U.S.C. §119 of German Application No. 10 2011 000 037.2 filed on Jan. 5, 2011, the disclosures of which are incorporated by reference. The international application under PCT article 21(2) was not published in English.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a thermal reactor for the continuous thermolytic recycling of granules of scrap tires, vulcanization residues and waste plastics, and of similar products, said thermal reactor featuring a feed portion, a central heating-zone portion and a discharge portion arranged vertically one below the other.
2. Description of the Related Art
According to the prior art, recycling of granulated scrap tires, vulcanization residues and waste plastic for purposes of re-use is mostly performed in rotating tubular reactors and less often in fluid(ized) bed reactors or entrained-bed reactors as these are still at the developmental stage. Shaft or vertical reactors, as they are termed, have hitherto been used primarily as heat exchangers for the heating, sintering and cooling of pourable bulk solids or for the pyrolysis of organic waste in order to generate refuse-derived fuels. From the WO 2010/127664 A1, a multi-stage, energy self-sufficient and continuously operating pyrolysis method for the fractionated recovery of valuable substances and energy from pourable, cross-linked organic compounds of high molecular weight, in particular from granules of scrap tires, sealing profiles and other plastic materials, and an apparatus for carrying out said method, are known. In order to develop an energy self-sufficient, continuously operating pyrolysis method for pourable organic granules according to the preamble, it is proposed there that the granules pass gravimetrically through a vertical, multi-stage pyrolysis reactor from top to bottom, said granules being heated to process temperatures that can be set incrementally to different values ranging from 300 to 1,200° C. and being pyrolyzed. Oil and gas compounds are recovered via subsequent fractionated condensation of the pyrolysis vapors, while downstream motor-based use of the pyrolysis gas generates the energy required for the pyrolysis process.
SUMMARY OF THE INVENTION
The object of this invention is to develop a continuously operating thermal reactor for a pyrolysis process of such kind, with which granules of scrap tyres, vulcanisation residues and waste plastics can be subjected to continuous thermolytic recycling without additional, motor-driven rotary conveying and mixing devices or pneumatic loosening-up devices.
This object is established according to the invention in that
the thermal reactor features a feed portion, a central heating-zone portion and a discharge portion arranged vertically one below the other, an extraction pipe is located centrally in the central heating-zone portion of the thermal reactor, the lateral surface of said extraction pipe featuring numerous holes and/or slits for withdrawal of the vaporized short-chain hydrocarbon compounds being formed, and the extraction pipe having conical bells that have been pushed onto it one above the other, and means being provided for withdrawing the vaporized hydrocarbon compounds out of the extraction pipe, and a multiplicity of radially arranged heating plates are disposed on the lateral surface of the reactor in its central heating-zone portion, the heating plates being arranged at the heating levels, which lie one above the other, such that the plates are mutually offset.
It has been found within the scope of the invention that it is possible to continuously recycle granules of scrap tires, vulcanization residues and waste plastics in a vertical thermal reactor of this kind, despite the poor thermal conductivity of these substances, because they are subjected to homogeneous mixing and heating. The substances pass through the vertical reactor from top to bottom in an oxygen-deficient atmosphere of sub-atmospheric pressure and are broken down thermally into short-chain, vaporous hydrocarbon compounds and into solids (coke), which are valuable raw materials.
The material is metered into the thermal reactor via the feed portion. In the central heating-zone portion, the thermolysis products formed undergo fractionated separation into solids and vapour at temperatures preferably between 500° C. and 600° C. The vaporized hydrocarbon compounds in the central heating-zone portion are extracted and subsequently condensed out to oil compounds of different compositions and to permant gas. Coke-like solid matter formed during the thermolysis process collects in the discharge portion and is withdrawn from the thermal reactor via a solids-discharge means.
It is within the scope of the invention that short and long heating plates are arranged alternately both within a heating level and from one heating level to the neighbouring heating level.
This measure effects good mixing and homogeneous heating of the material thanks to the offset arrangement of the heating plates.
A preferred refinement of the invention consists in that the heating plates can be pushed into, and removed from, correspondingly-sized slots in the thermal reactor's lateral surface.
This permits rapid maintenance and/or rapid exchange of defective plates.
It is to advantage that the heating plates can be heated electrically.
In this connection, it is to advantage that means to control the temperature profile in the thermal reactor and to individually adjust the temperature of each heating plate are provided.
Another embodiment of the invention consists in that the means for withdrawing the vaporized hydrocarbon compounds from the extraction pipe is configured as a short vapour-discharge pipe, which is connected to a polycondensation unit.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained in detail below by reference to drawings.
The drawing in
FIG. 1 shows a longitudinal section through a thermal reactor according to the invention, without a catalyst device
FIG. 2 shows a cross-section (section A-A) through the upper portion of the thermal reactor shown in FIG. 1 ,
FIG. 3 shows the unrolled lateral surface of the thermal reactor according to the invention, with the arrangement of offset heating-plate levels,
FIG. 4 and
view A show an electrically heated heat-exchanger plate and a detailed view thereof
FIG. 5 shows a longitudinal section through a thermal reactor according to the invention, including a catalyst device
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The thermal reactor ( 1 ) is configured according to the invention as a vertical pressure vessel comprising a plurality of parts flanged together. On account of its high temperature loads, it is made entirely of heat-resistant steel or alloys such as 1.4828, 1.4841, AVESTA 253 MA, Nicrofer 45 TM or similar materials.
FIG. 1 shows a longitudinal section through the thermal reactor ( 1 ) according to the invention and reveals the basic design principle. Viewed from top to bottom, the thermal reactor ( 1 ) features a truncated feed portion ( 2 ) adjoined by a central cylindrical heating-zone portion ( 3 ) which is adjoined in turn by a truncated discharge portion ( 4 ).
In order to minimize penetration of oxygen into the thermal reactor ( 1 ), which is undesirable for thermolysis technology, the granule feed and discharge into and of the reactor ( 1 ) are effected via a material feed system. The material feed system preferably consisits of a shock-pressure resistant cellular wheel sluice with an easily detachable rotor, means to regulate the rotary speed via a frequency converter, an inerting connection, and a gate value for bulk solids.
The granules are metered into the thermal reactor ( 1 ), via the short solids-infeed pipe ( 6 ), from a granule hopper above the reactor ( 1 ). A material distributor ( 10 ) distributes the granules uniformly over the entire circular cross-section of the reactor ( 1 ). A packed-bed column, which is a function of the granule size and type of material, forms in the interior of the thermal reactor ( 1 ) and moves from top to bottom through the thermal reactor ( 1 ) as a result of gravity. The column of granules is confined by the reactor's cylindrical lateral surface ( 14 ), the built-in components ( 5 ), the long and short radial heating plates ( 9 ) attached alternately to the lateral surface ( 14 ), which project into the interior of the reactor ( 1 ), and the fill level in the reactor ( 1 ).
The column of granules is divided into small sections resembling pieces of cake by the radial arrangement of the heating plates ( 9 ) and the offset arrangement thereof at the heating levels disposed one above the other. Good mixing of the granules, and thus uniform heating thereof, is effected, for one, by the offset arrangement of long and short heating plates ( 9 ) and, for another, by the internal built-in components ( 5 ) in the heating-zone portion ( 3 ) of the thermal reactor ( 1 ), which are configured as displacement and circulation components and even out the speed profile of the granules in the thermal reactor ( 1 ).
Thanks to the close contact which the granules are forced to make with the preferably electrically heated heating plates ( 9 ), they can be heated steplessly to reaction temperatures adjustable up to 950° C. and broken down thermally. The reaction temperatures are controlled via a process control system ( 21 ) as a function of the kind of material, the granule size and their heat-conductng properties. The temperature profile in the thermal reactor ( 1 ) may be varied over the reactor cross-section and the height of the entire central heating-zone portion ( 3 ), and the temperature of each heating plate ( 9 ) may be regulated individually.
The granule fill level in the thermal reactor ( 1 ) is measured and controlled via a y fill-level measuring and control device ( 15 ). The granule residence time in the thermal reactor ( 1 ) at a specified reaction temperature, and thus the degree to which multiple bonds in the hydrocarbon compounds are broken, are also determined and controlled automatically by the process control system ( 21 ).
The central extraction pipe ( 11 ) installed in the centre of the thermal reactor ( 1 ) has numerous holes and/or slits in its lateral surface, through which the vaporized short-chain hydrocarbon compounds formed are withdrawn. These vapours flow transverse to the flow of solids, i.e. they form a cross-flow. To prevent the withdrawal of granules or dust, the extraction apertures are covered over and shielded by conical bells, referred to as internal built-in components ( 5 ), which are pushed onto the extraction pipe ( 11 ) and are disposed one above the other. The vapours formed during thermolysis reach the extraction apertures through the open underside of the bells and enter the extraction pipe ( 11 ) through the apertures. They are then conveyed by virtue of negative pressure averaging −50 mbar to −75 mbar, via the vapour discharge means ( 8 ), to a polycondensation unit ( 26 ), where they condense out to oil compounds of different compositions, viscosities and calorific values, and to permanent gas.
The solids fraction of approx. 45 to 52 wt. % coke granules obtained from the thermolysis of scrap-tire granules consists of approx. 70 to 90% pure carbon and approx. 10 to 25% inorganic fillers that were added during new-tire manufacture. The mean net calorific value NCV is approx. 23 to 30 MJ/kg, and the mean BET surface area approx. 80 to 120 m 2 /g. The coke granules collect in the truncated discharge portion ( 4 ) and are supplied, via the short solids discharge pipe ( 7 ) and a material discharge system constructed in the same way as the material feed system but designed for high temperatures, to a water-cooled cooling coil, cooled to room temperature and stored temporarily in storage devices.
FIG. 2 shows the distribution principle according to the invention, comprising long and short heating plates ( 9 . 1 , 9 . 2 ) inside the thermal reactor ( 1 ). The spacing t between the heating plates ( 9 . 1 , 9 . 2 ) at the periphery of the thermal reactor ( 1 ) is determined by the thermal conductivity λ of the granular material to be processed and the granule size.
EXAMPLE
Assuming the maximum depth to which heat penetrates the granule layer is 100 mm and the circumference of the thermal reactor ( 1 ) is 4,800 mm, the number of heating plates required is n=4 800 mm: 100 mm=48 heating plates.
The angle α t subtended by two adjacent plates is α t =360°: 48 heating plates=7.5°
The design principle accordingly dictates that 24 long and 24 short heating plates ( 9 . 1 ; 9 . 2 ) would be needed per heating level. The overall number and heating capacity of the heating plates are calculated according to the general design rules for heat exchangers.
In FIG. 3 , the reactor's lateral surface ( 14 ) has been unrolled to show the offset arrangement principle for the heating plates ( 9 . 1 ; 9 . 2 ) at the heating levels. The offset arrangement of heating plates ( 9 . 1 , 9 . 2 ) can be seen clearly. The arrangement and configuration of the electrically heated heat-exchanger plates ( 9 . . . 9 n ) attached radially to the lateral surface ( 14 ) effect optimal heat transfer into the granules, as both the spacing t between the heat-exchanger plates ( 9 . . . 9 n ) in the horizontal and the spacing between the heating levels in the vertical and their offset arrangement are configured as a function of the size and kind of granules to be processed and accordingly lead to very high levels of efficiency.
FIG. 4 shows how the heating plates ( 9 . 1 ; 9 . 2 ) are attached to the reactor's lateral surface ( 14 ). The heating plates ( 9 . 1 , 9 . 2 ) are inserted into correspondingly sized slots in the lateral surface ( 14 ) of the thermal reactor ( 1 ) and can be withdrawn again individually from the lateral surface ( 14 ) of the thermal reactor ( 1 ) for maintenance purposes or to be exchanged.
FIG. 5 shows a thermal reactor ( 1 ) which, according to the invention, offers the possibility of additional catalytic treatment for the vaporized hydrocarbons. In principle, the assembly and configuration of the thermal reactor ( 1 ) is comparable with that of FIG. 1 . The only difference is that the discharge portion ( 4 ) is modified to the effect that an additional row of heating plates ( 9 ) is fitted therein, which guarantee a temperature of 600° C. for the vapours formed. In the discharge portion ( 4 . 1 ), a packed-bed filter ( 22 ) for catalysts is shown, in which the vapours are in direct contact with the catalyst granules at the point where the vapours are formed. The temperatures required for the vapour cracking processes are controlled by the process control system. It is important in this context that a minimum temperature of approx. 550° C. and a negative pressure of at least 50 mbar be maintained.
As some vapour components already begin to condense out at temperatures of approx. 450° C. to 500° C. and, together with the ultrafine dust formed in the plant, form matter that tends to carbonize, there is a risk that the vapour line leading to the polycondensation unit ( 26 ) will clog up. Electrically heated heating mats or heating wires configured with all-over high-temperature insulation are useful as an additional protective measure against these occurrences.
Mixed catalysts commonly used in the petrochemical industry, such as SiO 2 /Al 2 O 3 , Cr 2 O 3 /Fe 2 O 3 and zeolites, have proved suitable as catalysts for the packed-bed filter ( 22 ).
For strength-related reasons and on account of the considerable linear expansion in the operating state, the reactor ( 1 ) is suspended by supporting brackets ( 17 ) at the point where its tensile strength is greatest, in the upper portion of the heating zone ( 3 ).
According to the invention, the thermal reactor ( 1 ) is engineered in flanged form and is sub-divided into process sections. A thermal reactor ( 1 ) engineered in this way offers technical and technological advantages, such as easier manufacture, repair and exchange possibilities, better handling during transport and assembly and a high degree of flexibility with respect to the products to be processed, easier correction in the event of capacity ramp-up and modifications in the nature and proportioning of the desired end products.
The structural design of the thermal reactor ( 1 ) was deliberately kept very simple in the invention and was configured to facilitate maintenance and repair by means of practical features such as manholes ( 12 ) in the upper reactor portion ( 2 ) and manholes ( 13 ) in the lower reactor portion ( 4 ) and by designing the internal built-in components ( 5 ), material distributor ( 10 ) and central extraction pipe ( 11 ) such that they are easy to remove.
This thermolysis reactor lends itself to an environmentally friendly, residue-free and energy self-sufficient recycling process, which boasts a high level of technological flexibility in terms of the size of the granules and the kinds of materials to be processed, easier correction in the event of capacity ramp-up and modifications in the nature and proportioning of the end products.
The permanent gas, which has a net calorific value n.c.v. of 30 to 45 MJ/m 3 and an average methane number of 60, may be used for the purpose of a self-sufficient energy supply by converting the gas to electricity in a gas motor/generator unit, as a rule in a cogeneration unit. The solid matter, which is composed of approx. 45 to 52 wt. % pure carbon in the form of granules and soot, with a mean BET surface area of 80 to 120 m 2 /g and a mean net calorific value n.c.v. of approx. 23 to 30 HJ/kg, and of approx. 10 to 25 wt. % inorganic fillers, can be supplied to the tire and/or rubber industries for re-use.
The wide range of thermolytic oil fractions set free during thermolysis in the thermal reactor ( 1 ) and in the polycondensation unit ( 26 ) may be supplied to oil refineries, the plastics, paint or rubber industries, producers of heating oil or fuel and to carbon-black manufacturers for further processing.
LIST OF REFERENCE NUMERALS
1 Thermal reactor
2 Feed portion
3 Central heating-zone portion
4 Discharge portion
5 Internal built-in components
6 Short solids infeed pipe
7 Short solids discharge pipe
8 Vapour discharge means
9 Heating plates
10 Material distributor
11 Central vapour extraction pipe
12 Upper manholes
13 Lower manholes
14 Cylindrical lateral surface
15 Fill-level measuring and control device
16 Inerting connection
17 Supporting brackets
18 Measuring and control devices for temperature, pressure and oxygen content
19 Catalyst feed
20 Catalyst discharge
21 Process control system (PCS) with stored program controller (SPC)
22 Packed-bed filter
26 Polycondensation unit
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A thermal reactor for the continuous thermolytic recycling of granules of scrap tires, vulcanization residues and waste plastics, and of similar products features a feed portion, a central heating-zone portion and a discharge portion arranged vertically one below the other. An extraction pipe is located centrally in the central heating-zone portion of the thermal reactor, the lateral surface of the extraction pipe featuring numerous holes and/or slits for withdrawal of the vaporized short-chain hydrocarbon compounds being formed, and the extraction pipe having conical bells pushed onto it one above the other. A device withdraws the vaporized hydrocarbon compounds from the extraction pipe. Radially arranged heating plates are provided on the lateral surface of the reactor in its central heating-zone portion, the heating plates being arranged at the heating levels, which lie one above the other, such that the plates are mutually offset.
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BACKGROUND OF THE INVENTION
1. Field of The Invention
The present invention relates to a vehicle automatic transmission with means for automatically controlling the gear shifts thereof, and particularly relates to a hydraulic control unit for controlling the operation of the automatic transmission.
The present invention also relates to a hydraulic control unit for an automatic transmission with means to appropriately engage a frictional engaging element for engine braking.
2. Description of The Prior Arts
Automatic Transmissions for use on automobiles and other vehicles have a plurality of power transmitting gear trains each of which has a specific rear ratio. These transmitting gear trains are selectively switched into operation to effectuate a gear shift by controlling engagement or disengagement of frictional engaging means such as clutches and brakes. The engagement of the frictional engaging means is hydraulically controlled by a hydraulic control unit. The hydraulic control unit often comprises a hydraulic regulator valve for producing a line pressure, and an operating pressure control means for producing an operating pressure supplied to the frictional engaging means by regulating the line pressure. The operating pressure control means is provided to reduce a shift-shock which is caused when engaging the frictional engaging means. Specifically, a duty-ratio on-off controlled solenoid valve is often used for the operating pressure control means. An apparatus to reduce a shift-shock during a shift is disclosed in the Japanese Patent Publication No. 61-136055.
In the automatic transmission, a specified frictional engaging means which is engaged at a specified gear position (such as at a reverse gear position) is sometimes required to have a fairly large engaging force because of the gear ratio between the power source (the engine) and the specified frictional engaging means. To obtain such a large engaging force, a high operating pressure is often needed.
Therefore some hydraulic control units have a line pressure switching means to control the regulator valve so as to produce a high line pressure and a low line pressure. The high line pressure is used at the specified gear position (such as at the reverse gear position) and the low line pressure is used at the other gear positions (such as at the forward gear positions).
However, the engagement of the specified frictional engaging means under the high line pressure may cause a jerky shift which is not preferable. It is desirable to control the operating pressure control means so as to supply a low operating pressure during engagement (from the start of engagement until the completion of engagement), and then to supply a high operating pressure after completion of engagement to firmly maintain the engaging state of the specified frictional engaging means.
However, if the high line pressure is supplied to the operating pressure control means to produce the low operating pressure, it is difficult to produce it from the high line pressure. For example, relationships between duty-ratios (%) and operating pressures (kg/mm 2 ) in the duty-ratio on-off controlled solenoid valve (of normal open type) are shown in FIG. 6. As shown by a line "B" in the figure, if the high line pressure (P2) is used, the duty ratios required to produce the low operating pressures to engage the specified frictional engaging means smoothly (the operating pressures within the shaded range in the figure) must be controlled within a very narrow range. Since the duty ratios are controlled in correspondence with the electric voltage supplied to the solenoid, it is very difficult to control the duty ratio within the narrow range.
In an automatic transmission, as described above, shift controls are carried out by selecting a gear train (a power transmitting path) from a plurality of gear trains which are included in the transmission. The gear train is selected by engaging one or two frictional engaging means such as clutches and brakes. A specified gear position corresponding to a specified gear train, for example 1ST gear position, often includes a one-way clutch or one-way brake. The one-way clutch or one-way brake allows only one-way transmission of power, i.e. it allows a power transmission from an engine to wheels, but it does not allow a power transmission from the wheels to the engine. Accordingly, when the 1ST gear position is selected with a one-way clutch being operated, no engine brake can be effectuated during deceleration running.
However, engine brake is sometimes required during deceleration running at 1ST gear position to effectively slow down the vehicle speed. In order to make the engine brake available, a specified frictional engaging means (an engine-brake engaging means) is engaged to directly connect an input member with an output member of the one-way clutch, allowing the power transmission from the wheels to the engine.
Meanwhile, a torque converter which is included in an automatic transmission often comprises a lock-up means. The lock-up means as well as the engine brake engaging means are usually operationally controlled by a common operational pressure.
One example of a prior art hydraulic circuit to control operations of the engine brake engaging means and the lock-up means is shown in FIG.10.
The hydraulic circuit comprises an engine brake frictional engaging element B2, a switching valve 45 by which an operating hydraulic pressure is selectively supplied through a shuttle valve 56 to the engine brake engaging means B2 and a lock-up clutch (L/C) of a torque converter (not shown), a solenoid valve SE (an operating pressure control means) which controls the operating pressure supplied to the switching valve 45, and a manual valve 25 which controls the supply of a line pressure P1 (a base pressure) to the solenoid valve SE and which is shifted to a position corresponding to a shift range selected based on the driver's operation of a shift lever. It further comprises a solenoid valve SD which controls a supply of a pilot pressure Pp to the switching valve 45 to control the operation of the switching valve. In U.S. Pat. No. 4,936,166, a hydraulic circuit in which an engine brake engaging means and a lock-up clutch control means are controlled by a common pressure supplied from one solenoid valve is disclosed.
In the above constructed hydraulic circuit, when the manual valve 25 is shifted to a position corresponding to "1-range", oil under the line pressure P1 exerted from a pump (not shown) and regulated by a regulator valve is supplied to the solenoid valve SE. Then, when the solenoid valve SE is opened, the oil under the line pressure P1 is supplied to the switching valve 45.
Since the solenoid valve SD is closed and the pilot pressure is not applied on the switching valve 45 at 1-range, a spool 46 of the switching valve 45 is shifted to the left biased by the line pressure P1 applied on the right end thereof, whereby the operating pressure is supplied to the engine brake engaging means B2. Accordingly, the solenoid valve SE can control the operation of the engine brake engaging means B2 by a supply control of the line pressure thereto to control the engine braking.
When the manual valve 25 is shifted to a D-range, the operating pressure is supplied to the switching valve 45 through the opened solenoid valve SE. Since the solenoid valve SD is opened at D-range, the pilot pressure Pp is supplied to the left end of the switching valve 45 to move the spool 46 to the right. As a result, the operating pressure is supplied to the lock-up means no control the operation thereof. Therefore at D-range, when 1ST gear position is selected, the engine brake engaging means B2 is not engaged and no engine brake is available.
However, even if the manual valve is shifted to the D-range at which no engine braking is required, the switching valve may not shift to the lock-up control side because of, for example, a malfunction of the solenoid valve SD or a sticking of the spool of the switching valve. When the switching valve is not shifted to the lock-up control side, the operating pressure exerted from the solenoid valve SE is not supplied to the lock-up control means but is supplied to the engine brake engaging means, which is not preferable for smooth running of the vehicle.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a hydraulic control unit for an automatic transmission by which the low operating pressure to engage the frictional engaging means smoothly can be produced easily.
It is another object of the invention to provide a hydraulic control unit by which the high operating pressure to firmly engage the specified frictional engaging means can also be produced easily after the completion of the engagement.
It is a further object of the invention to provide a hydraulic control unit to positively avoid an accidental supply of the operating pressure to the engine brake engaging means when a shift range in which no engine brake is required is selected.
In order to achieve the objects, a hydraulic control unit for an automatic transmission having a plurality of power transmitting paths and a plurality of engaging means for selecting any one of the transmitting paths to set a gear position comprises a regulator valve means for producing a line pressure, an operating pressure control means for producing an operating pressure supplied to the engaging means by regulating the line pressure from the regulator valve, and a line pressure switching means for making the line pressure produced by the regulator valve low at a specified gear position when a target operating pressure selected by the operating pressure control means is lower than a specified value and making the line pressure high when the target operating pressure is higher than the specified value.
The hydraulic control unit for an automatic transmission comprises a regulator valve means for producing a line pressure, an operating pressure control means for producing an operating pressure supplied to the engaging means by regulating the line pressure from said regulator valve, a shift lever for selecting a shift range, a manual valve moved to a position corresponding to the shift range selected by the shift lever, the operating pressure being allowed by said manual valve to be supplied to the engaging means corresponding to the selected shift range, an opening-closing valve disposed in a hydraulic passage connecting the operating pressure control means with an engine brake engaging means which is engaged when an engine braking is required, and the operations of the opening-closing valve being controlled based on the position of the manual valve. The opening-closing valve is opened when the manual valve is moved to a position corresponding to a shift range in which the engine brake is required, and it is closed when the manual valve is moved to a position corresponding to a shift range in which the engine braking is not required.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic drawing of an automatic transmission which has a hydraulic control unit according to the present invention.
FIGS. 2 to 4 are hydraulic circuit diagrams of the hydraulic control unit.
FIG. 5 is a graph showing time-dependent changes of the operating pressure regulated by the hydraulic control unit.
FIG. 6 is a graph showing characteristics of a duty-ratio controlled solenoid valve used in the hydraulic control unit.
FIG. 7 is a hydraulic circuit diagram of an open-close switching valve used in the hydraulic control unit.
FIG. 8 is a hydraulic circuit diagram of a line-pressure regulating valve and an open-close switching valve in the hydraulic control unit according to a modified embodiment of the invention.
FIG. 9 is a hydraulic circuit diagram according to another modified embodiment of the invention.
FIG. 10 is a hydraulic circuit diagram of the prior art hydraulic control unit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A power-line construction of an automatic transmission which incorporates a hydraulic control unit according to the present invention is shown in FIG. 1. The automatic transmission is mounted in an automobile (not shown).
The automatic transmission shown in FIG. 1 comprises a torque converter 10 coupled to an engine output shaft 9 of the engine mounted in the automobile, and a transmission mechanism having a transmission input shaft 8a connected to the turbine of the torque converter 10.
The transmission mechanism has first, second and third planetary gear trains G1,G2,G3 disposed in serial relationship on the transmission input shaft 8a. The planetary gear trains G1,G2,G3 have respectively first, second and third sun gears S1,S2,S3 positioned centrally, first, second and third planetary pinions P1,P2,P3 meshing with the first, second and third sun gears S1,S2,S3 and revolvable around the first, second and third sun gears S1,S2,S3 while rotating about their own axes, first, second and third carriers C1,C2,C3 on which the first, second and third planetary pinions P1,P2,P3 are rotatably supported and rotatable in unison with the first, second and third planetary pinions P1,P2,P3 as they revolve around the first, second and third sun gears S1,S2,S3, and first, second and third ring gears R1,R2,R3 comprising internal gears meshing with the first, second and third planetary pinions P1,P2,P3.
Each of the first and second planetary gear trains G1,G2 comprises a double-pinion planetary gear train. The first planetary pinion P1 comprises two pinion gears P11,P12, and the second planetary pinion P2 comprises two pinion gears P21,P22. The third planetary gear train G3 comprises a single-pinion planetary gear train.
The first sun gear S1 is fixedly coupled to the input shaft 8a, and the first carrier C1 is fixed against rotation at all times. The first ring gear R1 is disconnectably coupled to the second sun gear S2 through a third clutch K3. The second sun gear S2 can be fixed against rotation by a first brake B1. The second carrier C2 is directly coupled to the third carrier C3, and also to an output gear 8b. Therefore, rotation of the second and third carrier C2,C3 is transmitted from the output gear 8b as output rotation of the transmission mechanism. The second ring gear R2 is directly coupled to the third ring gear R3. The second and third ring gears R2,R3 can be fixed against rotation by a second brake B2. The second and third ring gears R2,R3 are disconnectably coupled to the transmission input shaft 8a by a second clutch K2. The third sun gear S3 is disconnectably coupled to the transmission input shaft 8a through a first clutch K1. The second and third ring gears R2,R3 can also be braked by a one-way brake B3 disposed parallel to the second brake B2.
The first, second and the third clutches K1,K2,K3, and the first and second brakes B1,B2 are controlled, i.e., engaged and disengaged, to establish gear positions and control gear shifts or speed changes. Specifically, when the first, second and third clutches K1,K2,K3 and the first and second brakes B1,B2 are engaged and disengaged as shown in Table 1 below, the transmission mechanism can establish five forward gear positions (1ST,2ND,3RD,4TH and 5TH) and one reverse gear position (REV). Speed reduction ratios in the respective gear positions, which vary depending on the number of teeth of the gears, are also given by way of example. In the embodiment, the second brake corresponds to the engine brake frictional engaging means.
TABLE 1______________________________________GearPosition K1 K2 K3 B1 B2 Ratio______________________________________1ST ◯ (◯) 3.5772ND ◯ ◯ 2.1003RD ◯ ◯ 1.4004TH ◯ ◯ 1.0005TH ◯ ◯ 0.711REV ◯ ◯ 2.953______________________________________
In Table 1, those clutches and brakes which are marked with ◯ are engaged. The second brake B2 is marked with (◯) in the 1ST gear position because power from the engine can be transmitted through one-way brake B3 even if the second brake B2 is not engaged. Specifically, when the first clutch K1 is engaged, power from the engine can be transmitted at the speed reduction ratio of the 1ST gear position and the 1ST gear position is established even if the second brake B2 is not engaged. However, since power from the road to the engine cannot be transmitted through the one-way brake B3, an engine braking cannot be applied in the 1ST gear position when the second brake B2 is not engaged. The engine braking can be applied in the 1ST gear position when the second brake B2 is engaged.
The hydraulic control unit according to the present invention for controlling engagement and disengagement of the first, second and the third clutches K1,K2,K3, and the first and second brakes B1,B2 will be described below with reference to FIGS. 2 through 4. FIGS. 2 through 4 show different sections of the hydraulic control unit, and jointly represent the hydraulic control unit in its entirety.
In these figures, hydraulic passages whose ends are marked with alphabetical letters A through T enclosed by a circle are connected to hydraulic passages whose ends are marked with identical alphabetical letters A through T enclosed by a circle.
Ports marked with "X" are connected to a drain.
The first, second and third clutches K1,K2,K3 and the first and second brakes B1,B2 are controlled in operation by the pressure of working oil supplied from an oil tank 90 by an oil pump 91. As shown in FIG. 2, the working oil supplied by the oil pump 91 to a hydraulic passage 101 is applied through a hydraulic passage 101a to a regulator valve 20 by which the pressure is regulated to a first predetermined line pressure P1.
Part of the working oil is then supplied from the regulator valve 20 under the line pressure PR to the hydraulic passage 102. The remaining working oil is supplied from the regulator valve 20 to a hydraulic passage 151. The working oil flowing to the hydraulic passage 151 is supplied to a torque converter (not shown).
The working oil in the hydraulic passage 102, whose pressure has been to the line pressure P1, is supplied to various components shown in FIGS. 2 to 4 for controlling gear shifts to be made by the automatic transmission.
The hydraulic control unit as shown in FIGS. 2 to 4 includes a manual valve 25 which is manually operable by a driver of the automobile and is connected to the shift lever at the driver's seat, five solenoid valves SA to SE (operating pressure control means) controlled by an electric controller (not shown) in response to the operation of the manual valve 25, four hydraulically operated valves 30,35,40,45 which are operationally controlled in response to the operations of the manual valve 25 and the solenoid valves SA to SE, four accumulators 51 to 54, and five oil pressure sensors PS.
The solenoid valves SA, SC are of normal-open type, and are open when their solenoids are turned off (not energized). The solenoid valves SB,SD,SE are of normal-closed type, and are closed when their solenoids are turned off (not energized).
The valve 30 will be referred to as a first pressure relief valve, the valve 35 as a second pressure relief valve, the valve 40 as a brake relief valve, and the valve 45 as a switching valve.
Depending on the operation of the manual valve 25 and the solenoid valves SA to SE, the valves 30,35,40,45 are actuated to control gear shifts and also the operation of a lockup clutch of the torque converter. The relationship between the operations of the solenoid valves SA to SE and the gear positions established in response to the operations of these valves is shown in Table 2 below. In Table 2, "ON" and "OFF" represents the turning-on and turning-off, respectively, of the solenoids of the solenoid valves SA through SE. While the solenoid valves SA through SE are indicated as being selectively turned on and off in Table 2, each of the solenoid valves SA through SE comprises a duty-ratio controlled solenoid valve, and its duty ratio is controlled to achieve a desired gear shift characteristic upon a gear shift.
TABLE 2______________________________________GEAR SOLENOIDPOSITION SA SB SC SD SE______________________________________1ST OFF OFF ON OFF OFF*2ND OFF OFF ON ON OFF**3RD OFF OFF OFF OFF OFF**4TH OFF ON ON OFF OFF**5TH ON ON OFF OFF OFF**REV OFF OFF OFF OFF OFF (ON)______________________________________ *ON when an engine brake is applied. **ON when the torque converter is locked up
The process of establishing the gear positions with the solenoid valves SA through SE according to Table 2 will be described below.
At first, a condition that a D(drive) range is selected by a shift lever with a spool 26 of the manual valve 25 being moved to a D-position is described. As shown in FIG. 4, when a hook portion in the right end of the spool 26 is moved to the right into a position indicated by D, the spool 20 is placed in the D-position, the hydraulic passage 101 communicates with a hydraulic passage 103 and the working oil under the line pressure P1 is supplied to the hydraulic passage 103. Since the hydraulic passage 103 is connected with the solenoid valves SC and SE, the line pressure P1 is always applied to the solenoid valves SC and SE. Further, the working oil under the line pressure P1 is also supplied to a hydraulic passage 110 which is branched from the hydraulic passage 101 and connected with the solenoid SA (see FIG.2). Accordingly, the line pressure P1 is always applied to the solenoid SA, too.
The hydraulic passage 101 is connected with hydraulic passage 102 through the regulator valve 20. Hydraulic passages 102b through 102e which are branched from the passage 102 are respectively connected with the right ends of the first and second relief valves 30,35, the brake relief valve 40 and the switching valve 45.
Accordingly, spools of these valves 30,35,40,45 are pushed to the left by the line pressure P1 supplied through the passages 102b to 102e.
When the D-range is selected, a gear position is determined in the D-range depending on the engine load and the automobile running speed. Operation of the solenoid valves SA through SE is controlled to achieve the determined gear positions as shown in Table 2 above.
The clutches and the brakes are actuated by the solenoid valves in each of the gear positions as follows:
It is assumed that the 1ST gear position is to be established. In the 1ST gear position, the solenoid of the solenoid valve SC is turned on, and the solenoids of the other four solenoid valves are turned off. At this time, only the solenoid valve SA is open, and the other four solenoid valves are closed.
Since the line pressure P1 is applied through the hydraulic passage 110 to the solenoid valve SA, the working oil flows under the line pressure P1 through the solenoid valve SA into a hydraulic passage 120. The hydraulic passage 120, which is connected to the manual valve 25, is brought into communication with a hydraulic passage 121 connected with the first clutch K1 when the manual valve 25 is at the D-position. Thus, the working oil under the line pressure P1 is supplied through the oil passage 121 to the first clutch K1, which is engaged. Hydraulic passages 120a,120b are respectively connected with a hydraulic pressure sensor PS and a first accumulator 51. The first accumulator 51 prevents an abrupt increase of the operating pressure applied to the first clutch K1, thereby reducing shift shocks.
The line pressure P1 also acts on a left end of the first relief valve 30 through a hydraulic passage 121a connected with the hydraulic passage 121. Since the hydraulic force acting through the passage 102b on the first relief valve 30 is larger than the hydraulic force acting through the passage 121a because of different pressure-bearing areas of the right and left ends of the first relief valve 30, the spool 31 of the first relief valve 30 is shifted to the left as shown in FIG. 3.
A hydraulic passage 125 connected with the second clutch K2 is connected with the solenoid valve SB, and also with the second accumulator 52 and one of the hydraulic pressure sensors PS. Inasmuch as the solenoid valve SB is closed, the hydraulic passage 125 is connected with the drain through the solenoid valve SB, and hence the second clutch K2 is disengaged.
A hydraulic passage 130 connected with the third clutch K3 is connected with a hydraulic passage 131 or a hydraulic passage 133 through a shuttle valve 57. The passage 131 is connected with the manual valve 25. When the manual valve 25 is at the D-position, the hydraulic passage 131 is connected with the drain through an internal passage 26a of the spool 26 in the manual valve 25.
The hydraulic passage 133 is connected with the solenoid valve SC. Since the solenoid of the solenoid valve SC is turned on thereby closing the valve, the passage 133 is connected with the drain through the solenoid valve SC, whereby the third clutch K3 is also disengaged. The hydraulic passages 133a,133b are respectively connected with the pressure sensor PS and the fourth accumulator 54. A hydraulic passage 175 branched from the passage 133 is connected with the middle portion of the first relief valve 30 and the left end of the second relief valve 35.
A hydraulic passage 140 connected with the first brake B1 through a hydraulic passage 145 is connected with the solenoid valve SD. Since the solenoid valve SD is closed, the passage 145 is connected with the drain through the solenoid valve SD, whereby the first brake B1 is also disengaged. Hydraulic passages 140a,140b branched from the passage 140 are connected with the pressure sensor PS and the third accumulator 53. Also, a hydraulic passage 141 branched from the passage 140 is connected with the switching valve 45.
A hydraulic passage 167 connected with the second brake B2 is connected either with a hydraulic passage 166 or with a hydraulic passage 170 through a shuttle valve 56. The passage 170 is connected to the left end of the manual valve 25. The passage 166 is connected with the brake relief valve 40. When the manual valve 25 is at the D-position, hydraulic passages 132,104 are connected with the drain through the internal passage 26a of the spool. Accordingly, a spool 41 is moved to the left by the line pressure P1 applied on its right end through the passage 102d, whereby the passage 166 is blocked from the passage 165.
No working oil is supplied to the second brake B2 and accordingly the second brake B2 is also disengaged. Therefore at the 1ST gear position in the D-range, no engine brake is obtained.
However, when the manual valve 25 is moved to the "1"-position shown in FIG.4 to shift to the "1"-range, an engine brake can be obtained. When the manual valve 25 is moved to the "1"-position, the hydraulic passage 104 is connected with the hydraulic passage 101 to apply the line pressure P1 on the left end of the brake relief valve 40, whereby the spool 41 is moved to the right. Since the solenoid of the solenoid valve SC is turned on and the solenoids of the solenoid valves SB,SD are turned off in "1"-range as in the D-range, the spool 46 of the switching valve 45 is held to be moved to the left. Accordingly, the hydraulic passage 166 is connected with the passage 165, and the hydraulic passage 167 connected with the second brake B2 is connected with the solenoid valve SE through the passages 166,165, the switching valve 45 and the passage 163. When the solenoid of the solenoid valve SE is turned on to open the solenoid valve SE as shown in Table 2, the operating hydraulic pressure is supplied to the second brake B2 to obtain an engine brake.
Now, it is assumed that the 2ND gear position is to be established while in the D-range selection. To achieve the 2ND gear position from the 1ST gear position, only the solenoid of the solenoid valve SD is switched from the turned-off state to the turned-on state, opening the solenoid valve SD. The first clutch K1 remains engaged. When the solenoid valve SD is opened, the working oil under the line pressure P1 is supplied to the first brake B1 through hydraulic passages 105,105a branched from the passage 105, the second relief valve 35, the passage 106 and the passage 145, engaging the first brake B1. An abrupt engagement of the first brake B1 is restrained by means of the third accumulator 53 to reduce a shift shock.
Thus, the first clutch K1 and the first brake B1 are engaged to establish the 2ND gear position.
When the solenoid valve SD is open, the working oil under the line pressure P1 acts on the left end of the spool 46 of the switching valve 45 through the hydraulic passages 140,141. Although the line pressure P1 acts on the right end of the spool 46 through the hydraulic passage 102e, the spool 46 is moved to the right because of the difference in pressure bearing area. When the spool 46 is moved to the right, the hydraulic passage 163 is connected with the passage 164. The passage 164 is connected with the above-mentioned lock-up control hydraulic circuit. Therefore, as shown in Table 2, when the solenoid of the solenoid valve SE is turned on, operation of the lock-up clutch can be controlled by supplying the operating pressure.
Now, it is assumed to be shifted to the 3RD gear position from the 2ND gear position while in the D-range selection. To shift from the 2ND to the 3RD gear position, the solenoids of the solenoid valves SC,SD are turned off, and hence the solenoids of all the solenoid valves SA,SB,SC,SD,SE are turned off. From the 2ND gear position, the solenoid valve SC is opened, and the solenoid valve SD is closed. Since the solenoid valve SA is open, the first clutch K1 remains engaged. Further, since the solenoid of the solenoid valve SD is turned off thereby closing the valve, the hydraulic passage 145 is connected with the drain through the solenoid valve SD, disengaging the first brake B1.
When the solenoid valve SC is opened, the working oil under the line pressure P1 is supplied to the hydraulic passage 133. Accordingly, the working oil is supplied to the third clutch K3 through the shuttle valve 57 to engage the third clutch K3. The fourth accumulator 54 helps to reduce a shift shock.
Thus the first and the third clutches K1,K2 are engaged to establish the 3RD gear position.
At the 3RD gear position, the solenoid of the solenoid valve SD is turned off and therefore the hydraulic passage 145 is connected with the drain through the solenoid valve SD. As a result, the pressure in the passages 140,141 which act on the spool 46 of the switching valve 45 is reduced to zero. While, since the solenoid of the solenoid valve SC is turned off, the line pressure P1 acts on the left end of the second relief valve 35 through the passages 133,175, whereby the spool 36 is moved to the right because of the difference in pressure bearing area. Then the hydraulic passage 105a which is communicated with the passage 103 is connected with the passage 178. The line pressure P1 acts on the left end of the switching valve 45 to keep the spool 46 of the switching valve 45 moved to the right. When the solenoid of the solenoid valve SE is turned on, the lock-up clutch can be operationally controlled.
Now, the transmission is to be shifted from the 3RD gear position to the 4TH gear position while in the D-range selection. From the 3RD gear position, the solenoids of the solenoid valves SB,SC are turned on. The solenoid valve SB is opened and the solenoid valve SC is closed. As the solenoid valve SA has already been open, the first clutch K1 remains engaged. Further, when the solenoid valve SC is closed, the supply of the line pressure P1 to the third clutch K3 is stopped to disengage it.
The spool 31 of the first relief valve 30 is moved to the left as shown in FIG.3, allowing the working oil under the line pressure P1 to flow from the hydraulic passage 103 through the first relief valve 30 to a hydraulic passage 107, from which the working oil is supplied through the solenoid valve SB and the hydraulic passage 125 to the second clutch K2, which is now engaged. The second accumulator 52 helps to reduce a shift shock.
The first clutch K1 and the second clutch K2 are thus engaged to establish the 4TH gear position.
Since the solenoid of the solenoid valve SB is turned on, the line pressure P1 acts on a left second port of the second relief valve 35 through the passage 125c to move the spool 36 to the right. Accordingly, the line pressure through passage 178 acting on the left end of the switching valve 45 allows the spool 46 to move to the right. As clearly understood, when the solenoid of the solenoid valve SE is turned on, the lockup clutch can be operationally controlled.
Now, the transmission is to be shifted from the 4TH gear position to the 5TH gear position while in the D-range selection. To effect a shift from the 4TH gear position to the 5TH gear position, the solenoid of the solenoid valve SA is turned on and the solenoid of the solenoid valve SC is turned off. Therefore, from the 4TH gear position, the solenoid valve SA is closed and the solenoid valve SC is opened.
When the solenoid valve SA is closed, the supply of the line pressure P1 through the hydraulic passage 120, 121 is cut off, disengaging the first clutch K1.
The hydraulic pressure supplied to the hydraulic passage 121a is also reduced to zero, so that the spool 31 of the first relief valve 30 remains shifted to the left. Since the solenoid of the solenoid valve SB remains turned on, the second clutch K2 remains engaged.
When the solenoid valve SC is opened, the working oil under the line pressure P1 is supplied to the hydraulic passage 133, and then through the shuttle valve 57 to the third clutch K3, thereby the third clutch K3 is engaged. The fourth accumulator 54 helps to reduce a shift shock.
In this manner, the second clutch K2 and the third clutch K3 are thus engaged to establish the 5TH gear position.
Operations of the lock-up clutch can be controlled at the 5TH gear position as at the 4TH gear position.
As described above, each gear position can be set at D-range. Further, the operations of the lock-up clutch can be controlled at the 2ND through 4TH gear positions. However, at these gear positions the solenoid valve SC may malfunction to be remained turned on at 3RD gear position which should be turned off, or the solenoid valve SB may malfunction to be remained turned off at 4TH or 5TH gear position which should be turned on, whereby the line pressure P1 which works as a pilot pressure cannot be supplied to the left end of the switching valve 45. Further, the spool 46 of the switching valve 45 may stick and stay moved to the left. Under these malfunctioning or sticking conditions, when the solenoid valve SE is opened to engage the lock-up clutch, the operating hydraulic pressure which should be supplied to the lock-up clutch is supplied to the second brake B2 to create engine brake if the hydraulic passage 163 is directly connected with the hydraulic passage 165 as in the hydraulic circuit of the prior art.
However, in the hydraulic control unit according to the present embodiments, the spool 41 of the brake relief valve 40 is moved to the left and the hydraulic passage 166 is disconnected from the hydraulic passage 165 by the spool 41 at 2ND through 4TH gear positions. Further, the passage 166 is connected with the drain through an inner passage in the brake relief valve 40. Accordingly, even if the spool 46 of the switching valve 45 is not moved to the right because of the above-mentioned malfunction or sticking, no operating pressure is supplied to the second brake B2 to avoid creating an unintentional engine brake. In the embodiment, the brake relief valve 40 is used as an opening-closing valve.
Meanwhile, in the above embodiment, the brake relief valve 40 is opened to connect the hydraulic passage 165 with the passage 166 when the line pressure P1 (the pilot pressure) is supplied. The hydraulic control unit according to the present invention is not limited to the above embodiment. For example, as shown in FIG.9, the brake relief valve 40' can be constructed so as to be closed to disconnect the passage 165 from the passage 166 when the line pressure P1 (the pilot pressure) is supplied. The numerals shown in FIG.9 correspond to those shown in FIG.4.
The brake relief valve 40' and the manual valve 25' shown in FIG.9 are slightly different from the brake relief valve 40 and the manual valve 25 shown in FIG.4. In the brake relief valve 40', the second port from the left is connected with the hydraulic passage 165 and the central port (which is connected with the passage 165 in FIG. 4) is connected with the drain.
The manual valve 25' has two additional ports at the right end thereof and also has a new configuration at the right end of the spool 26' as shown in the figure. One of the additional ports is connected with the hydraulic passage 101b which is branched from the passage 101. The other of the additional ports is connected with the hydraulic passage 104 which connect with the left-end port of the brake relief valve 40'.
In the hydraulic circuit as constructed above and shown in FIG.9, when the manual valve 25' is moved to a position corresponding to the D-range, the hydraulic passage 101b is connected with the passage 104 to supply the line pressure P1 (the pilot pressure) to the left end of the brake relief valve 40'. Accordingly, the spool 41' of the brake relief valve 40' is moved to the right to disconnect the hydraulic passage 165 from the passage 166. However, when the manual valve 25' is moved to a position corresponding to the 1-range, the hydraulic passage 101b is closed by the spool 26' of the manual valve 25' and the passage 104 is connected with the drain through the internal passage 26a' in the spool 26'. Accordingly, the line pressure P1 is drained through the left end of the brake relief valve 40' to move the spool 41' to the left (to open the brake relief valve 40'). Since the hydraulic passage 165 is connected with the passage 166, the engine braking can be obtained at 1-range.
When the shift lever is moved to the position corresponding to the 1-range to move the manual valve 25 to the 1-range position in the embodiment of FIGS. 2-4, the spool 26 of the manual valve 25 is moved to a position at which the end connecting hole 26c locates at 1-position from D-position. Accordingly, at 1-range, the hydraulic passage 101 to which the line pressure is always supplied is connected with the passage 104 as well as the passage 103. The passage 120 is disconnected from the passage 121. The passage 120 is blocked by the land surface of the spool 26. The passage 121 is connected with the passage 132 through the groove 26b.
The 1ST gear position is always held at the 1-range. The solenoid valves SA through SE are turned on or off as shown at 1ST gear position in Table 2.
Since the hydraulic passage 104 is connected with the hydraulic passage 101, the line pressure is applied on the left end of the brake relief valve 40 to move the spool 41 to the right. The solenoid valve SC is turned on and the solenoid valves SB,SD are turned off at 1-range. No biasing force to the right is applied on the spool 46 of the switching valve 45 to keep the spool 46 moved to the left. The hydraulic passage 166 is connected with the passage 165 through the brake relief valve 40 and the hydraulic passage 167 which is connected with the second brake B2 is connected with the solenoid valve SE through the passages 166,165,163 and the switching valve 45. Accordingly, as shown in Table 2, when the solenoid valve SE is turned on and opened, the operating pressure is supplied to the second brake B2 to engage it and the engine braking can be obtained.
Since the hydraulic passage 120 is blocked by the land surface of the spool 26, the operating pressure supplied to the hydraulic passage 120 from the solenoid valve SA cannot be supplied further. While, since the hydraulic passage 121 is connected with the passage 132 through the groove 26b and the passage 132 is further connected with the passage 104, the line pressure P1 is always supplied to the first clutch K1 through the hydraulic passages 101,104,132 and 121.
At 1-range, the first clutch K1 and the second brake B2 are always engaged to set the 1ST gear position with the engine braking.
As shown in Table 1, in the hydraulic control circuit constructed as described above, the first clutch K1 is engaged to set the 1ST through 4TH gear positions at D-range. Further, it is engaged at 1-range to set the 1ST gear position. The engagement control of the first clutch K1 is carried out by the solenoid valve SA at D-range.
When the solenoid SA malfunctions electrically because of an electric wire disconnection or malfunctions mechanically because of a sticking of the spool, it may happen that the first clutch K1 cannot be engaged.
If the first clutch K1 cannot be engaged, none of the 1ST through 4TH gear positions can be set at D-range. Only the 5TH gear position can be obtained at D-range which severely deteriorates the running characteristics of the vehicle. However, in the present hydraulic control unit, when the shift lever is operated to move the manual valve 25 from the D-range position to the 1-range position, the line pressure is supplied to the first clutch K1 through the manual valve 25 bypassing the malfunctioned solenoid valve SA to engage the first clutch SA. In other words, even if the solenoid valve SA malfunctions at D-range, the operation of the shift lever from D-range position to the 1-range position allows engagement the first clutch K1 to establish the 1ST gear position. Accordingly, the running characteristics of the vehicle under the malfunctioning condition of the solenoid valve SA can be greatly improved.
In the present embodiment, the 1ST gear position is fixedly selected at the 1-range. But, the 1ST and 2ND gear positions can be selected at the 1-range. If so, under the malfunction condition of the solenoid valve SA, either the 1ST gear position or the 2ND gear position can be set at 1-range.
Following the above description about the operations at D-range and 1-range, then the operations at N-range are described hereinafter. When the N-range is selected, the clutches K1,K2,K3 and the brakes B1,B2 are connected with the drain through the manual valve 25, and hence are disengaged to bring the transmission into a neutral condition.
It is now assumed that an R(reverse)-range is selected by the shift lever. The spool 26 of the manual valve 25 is moved to the left, supplying the working oil under the line pressure P1 from the hydraulic passage 101 to the passage 131. The solenoids of all the solenoid valves SA,SB,SC,SD,SE are turned off except at the beginning of a shift to the R-range.
The hydraulic passage 121 connected with the first clutch K1 is drained by the manual valve 25, disengaging the first clutch K1. The hydraulic passage 125 connected to the second clutch K2 is drained by the solenoid valve SB, disengaging the second clutch K2.
Since the hydraulic passage 130 connected with the third clutch K3 is connected with the hydraulic passage 131 through the shuttle valve 57, the working oil supplied under the line pressure P1 to the hydraulic passage 131 is supplied to the third clutch K3, engaging the third clutch K3. The 4TH accumulator 54 helps to lessen a shift shock during engagement of the third clutch K3.
The hydraulic passage 145 connected with the first brake B1 is drained by the solenoid valve SD, disengaging the first brake B1.
The hydraulic passage 167 connected with the second brake B2 is connected with the solenoid valve SA through the shuttle valve 56, the passage 170, the manual valve 25 and the passage 120. Since the solenoid valve SA is of normal open type, the working oil under the line pressure P1 flows into the passage 170 to engage the second brake B2. At the same time, the working oil under the line pressure P1 flows into the first accumulator 51 to move the piston 51a to the left.
A back-pressure leading passage 181 branched from the passage 131 is connected to the middle portion of the first accumulator. A back-pressure supplying passage 182 is connected to the right end of the spool 21 of the regulator valve 20. A hydraulic groove 51b is formed on the central portion of the piston 51a. When the piston 51a is moved to the left, the back-pressure leading passage 181 is connected with the back-pressure supplying passage 182 through the hydraulic groove 51b. When the piston 51a is moved to the right, the back-pressure leading passage 181 is disconnected from the back-pressure supplying passage 182.
Accordingly, when the piston 51a of the first accumulator 51 is moved to the left, the line pressure P1 acts on the right end of the spool 21 of the regulator valve 20 as a back-pressure, through the passage 131, the back-pressure leading passage 181 and the back-pressure supplying passage 182. This hydraulic force tends to push the spool 21 toward the left and assists the force of the spring in regulator valve 20 to move the main spool leftward to increase the line pressure. Hence the line pressure is increased to a new line pressure P2 (P2>P1) which is supplied to the second brake B2. Therefore, the second brake B2 is strongly engaged by an engaging force larger than that at 1ST gear position.
The third clutch K3 and the second brake B2 are thus engaged to establish the reverse gear position.
However, if the second brake B2 is being engaged by a strong engaging force caused by the high line pressure P2 during the shift to the reverse gear position, the shift shock created by the engagement of the second brake B2 may be large. In order to maintain the engagement force low during engagement (from the beginning of the shift to the completion thereof), the solenoid valve SA is duty-ratio controlled. Therefore, "ON" mark enclosed by a parenthesis is added for the solenoid SA at REV in Table 2.
Specifically, from the beginning of the engagement of the second brake B2 to the completion of the engagement thereof (about 0.3 to 0.5 second), the solenoid valve SA is duty-ratio controlled so as to produce a specified low operating pressure (such as pressures of 2 to 3 kg/mm 2 ), whereby the piston 51a of the first accumulator 51 remains moved to the right to disconnect the back-pressure leading passage 181 from the back-pressure supplying passage 182. As a result, the low line pressure P1 (8 kg/mm 2 ) is produced and supplied to the solenoid valve SA. As shown by the line A in FIG. 6, under the low line pressure P1, the duty ratios required to obtain the low operating pressure to engage the second brake B2 smoothly (the operating pressures within the shaded range in FIG. 6) are 50 to 65% which are rather wide and are easy to control.
If the high line pressure P2 is used, as shown by the line B in FIG. 6, the duty ratios required to obtain the low operating pressure to engage the second brake B2 smoothly (the operating pressures within the shaded range in FIG. 6) are 92 to 93% which are very narrow. It is very difficult to control the duty ratios within such a narrow range.
Further, since the solenoid valve SA is operated under the low line pressure P1, it can be made compact which is advantageous.
As generally shown in FIG.5, when the solenoid valve SA is turned off after the second brake B2 is engaged under the low line pressure P1, the working oil having the line pressure P1 is supplied to the hydraulic passage 121, whereby the piston 51a of the first accumulator 51 is moved to the left. As a result, the line pressure is increased to the high line pressure P2 to apply a fairly large engaging force to the second brake B2. Since the high line pressure P2 is supplied to the second brake B2 after the completion of the engagement, no shift shock is created. In the present embodiment, the solenoid valve SA is used as operating pressure controlling means and the first accumulator is used as line pressure switching means.
In the above embodiment, although the piston 51a of the first accumulator 51 is used as on-off switching means, an on-off switching valve 70 as shown in FIG.7 can be provided additionally. A hydraulic passage 120b' connected with the passage 121 is connected with the right end of the on-off switching valve 70. When the hydraulic pressure supplied through the passage 120b' exceeds a specified pressure to move the spool 71 to the left against the biasing force of a spring 72, a back-pressure leading passage 181' is connected with a back-pressure supplying passage 182' in the middle portion of the on-off switching valve 70. In this manner, the on-off switching valve 70 serves as on-off switching means instead of the first accumulator 51 shown in FIG. 2.
In the above embodiment, the line pressure is increased when a back-pressure is supplied to the regulator valve 20, i.e. the back-pressure is used as an assist pressure to increase the line pressure. A regulator valve 20" as shown in FIG. 8 can also be used. When an internal pressure (an assist pressure) is supplied to the left second port through a internal pressure supplying passage 182" in the regulator valve 20", the line pressure is lowered.
When the regulator valve 20" is used, the first accumulator 51" is slightly different from the first accumulator 51 shown in FIG.2. An internal pressure leading passage 181" instead of the back-pressure leading passage 181 is connected with the first accumulator (on-off switching means) 51". An internal pressure supplying passage 182" instead of the back-pressure supplying passage 182 is also connected with the first accumulator 51" Further a new drain port is added.
In the hydraulic circuit shown in FIG. 8, when the operating pressure supplied to the right end of the first accumulator 51" through a passage 120b" branched from the output passage of the solenoid valve SA is lower than a specified pressure, the piston 51a" of the first accumulator 51" is moved to the right to connect the internal-pressure leading passage 181" with the internal-pressure supplying passage 182". Since an internal pressure acts on the regulator valve 20" through the internal-pressure supplying passage 182", the low line pressure is produced which is supplied to the solenoid valve SA.
When the operating pressure supplied to the right end of the first accumulator 51" through a passage 120b" is higher than a specified pressure, the piston 51a" of the first accumulator 51" is moved to the left to disconnect the internal-pressure leading passage 181" from the internal pressure supplying passage 182". At the same time, the internal pressure supplying passage 182" is connected with the drain. Accordingly, no internal pressure is supplied to the regulator valve 20", and the internal pressure in the regulator valve 20" is reduced to zero. As a result, the line pressure produced by the regulator valve 20" is increased.
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A hydraulic control unit for an automatic transmission having a plurality of power transmitting paths and a plurality of engaging clutches and/or brakes for selecting any one of the transmitting paths to set a gear position. The unit comprises a regulator valve for producing a line pressure, an operating pressure control valve for producing an operating pressure supplied to the engaging clutch or brake by regulating the line pressure from the regulator valve, and a line pressure switching valve for making the line pressure produced by the regulator valve low at a specified gear position when a target operating pressure set by the operating pressure control valve is lower than a specified value and making the line pressure high when the target operating pressure is higher than the specified value.
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RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. §119 to Japanese Patent Application No. JP2008-320584 filed on Dec. 17, 2008, the entire content of which is hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a sample processing system, a sample processing method, and a computer program product. The present invention particularly relates to: a sample processing system including a plurality of sample processing apparatuses; a sample processing method using the plurality of sample processing apparatuses; and a computer program product for controlling the plurality of sample processing apparatuses.
BACKGROUND OF THE INVENTION
[0003] Conventionally, there is a known sample processing system including a plurality of sample processing apparatuses.
[0004] JP laid-open patent 2000-028620 and JP laid-open patent 2001-349897 each disclose a multiple-sample analysis system (a sample processing system) that includes: a plurality of analyzers (sample processing apparatuses) that are arranged so as to be adjacent to each other; and rack transporting means (a transporting apparatus) for transporting samples to the plurality of analyzers.
[0005] In such a sample processing system that includes a plurality of analyzers, there is a case where maintenance work is performed on side faces, of adjoining analyzers, which are opposed to each other. In such a case, it is necessary to widen a space between the adjoining analyzers in order to obtain sufficient space for the maintenance work. However, the overall size of such a sample processing system is required to be reduced. Accordingly, in some cases, in order to perform maintenance work on one of the side faces, of the adjoining analyzers, which are opposed to each other, moving only an analyzer that is subjected to the maintenance work is not enough to obtain sufficient space for the maintenance work, and the other analyzer which is operating normally and which does not need maintenance at the time also needs to be moved.
[0006] However, when it is necessary in the sample processing systems of JP laid-open patent 2000-028620 and JP laid-open patent 2001-349897 to move the normally operating analyzer as described above, there is a necessity to stop the sample processing that is being performed by the normally operating analyzer and then move the analyzer. Thus, it is impossible to continue the sample processing while obtaining sufficient space for the maintenance work.
SUMMARY OF THE INVENTION
[0007] The scope of the invention is defined solely by the appended claims, and is not affected to any degree by the statements within this summary.
[0008] A first aspect of the present invention is a sample processing system comprising: a transporting apparatus for transporting samples to a first loading position, a second loading position, and a third loading position; a first sample processing apparatus capable of being set in a first setting position and a third setting position, wherein when the first sample processing apparatus is set in the first setting position, the first sample processing apparatus is capable of being loaded with the sample having been transported to the first loading position and processing the loaded sample, and when the first sample processing apparatus is set in the third setting position, the first sample processing apparatus is capable of being loaded with the sample having been transported to the third loading position and processing the loaded sample; a second sample processing apparatus capable of being set in a second setting position, wherein when the second sample processing apparatus is set in the second setting position, the second sample processing apparatus is capable of being loaded with the sample having been transported to the second loading position and processing the loaded sample; and a controller including a memory under control of a processor, the memory storing instructions enabling the processor to carry out operations comprising: controlling the transporting apparatus so as to transport a sample to the first loading position when the first sample processing apparatus is set in the first setting position; and controlling the transporting apparatus so as to transport a sample to the third loading position when the first sample processing apparatus is set in the third setting position.
[0009] A second aspect of the present invention is a sample processing method comprising: transporting a sample to a first loading position; performing loading and processing, of the sample having been transported to the first loading position, by a first sample processing apparatus that is set in a first setting position; transporting a sample to a second loading position; performing loading and processing, of the sample having been transported to the second loading position, by a second sample processing apparatus that is set in a second setting position; transporting a sample to a third loading position when the first sample processing apparatus is set in a third setting position; and performing loading and processing, of the sample having been transported to the third loading position, by the first sample processing apparatus set in the third setting position.
[0010] A third aspect of the present invention is a computer program product for a sample processing system comprising: a transporting apparatus for transporting samples; a first sample processing apparatus for being loaded with and processing a sample; a second sample processing apparatus for being loaded with and processing a sample; and a computer, the computer program product comprising a computer readable medium for storing instructions enabling the computer to carry out operations comprising: controlling the transporting apparatus so as to transport a sample to a first loading position; controlling the first sample processing apparatus set in a first setting position such that the first sample processing apparatus is loaded with the sample having been transported to the first loading position and processes the loaded sample; controlling the transporting apparatus so as to transport a sample to a second loading position; controlling the second sample processing apparatus set in a second setting position such that the second sample processing apparatus is loaded with the sample having been transported to the second loading position and processes the loaded sample; controlling the transporting apparatus so as to transport a sample to a third loading position when the first sample processing apparatus is set in a third setting position; and controlling the first sample processing apparatus set in the third setting position, such that the first sample processing apparatus is loaded with the sample having been transported to the third loading position and processes the loaded sample.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective view showing an overall configuration of a blood analyzer according to an embodiment of the present invention;
[0012] FIG. 2 is a schematic diagram showing measurement units and a sample transporting apparatus of the blood analyzer according to the embodiment shown in FIG. 1 ;
[0013] FIG. 3 is a perspective view showing the measurement units and the sample transporting apparatus of the blood analyzer according to the embodiment shown in FIG. 1 ;
[0014] FIG. 4 is a perspective view showing a rack and sample containers of the blood analyzer according to the embodiment shown in FIG. 1 ;
[0015] FIG. 5 is a perspective view illustrating a base of the blood analyzer according to the embodiment shown in FIG. 1 ;
[0016] FIG. 6 is a schematic diagram illustrating configurations of the measurement units of the blood analyzer according to the embodiment shown in FIG. 1 ;
[0017] FIG. 7 is a schematic diagram illustrating configurations of the measurement units of the blood analyzer according to the embodiment shown in FIG. 1 ;
[0018] FIG. 8 is a perspective view illustrating the base of the blood analyzer according to the embodiment shown in FIG. 1 ;
[0019] FIG. 9 is a plan view illustrating the sample transporting apparatus of the blood analyzer according to the embodiment shown in FIG. 1 ;
[0020] FIG. 10 is a side view illustrating the sample transporting apparatus of the blood analyzer according to the embodiment shown in FIG. 1 ;
[0021] FIG. 11 is a side view illustrating the sample transporting apparatus of the blood analyzer according to the embodiment shown in FIG. 1 ;
[0022] FIG. 12 is a block diagram illustrating a control apparatus of the blood analyzer according to the embodiment shown in FIG. 1 ;
[0023] FIG. 13 is a flowchart illustrating operations that are performed, in measurement processes based on measurement process programs, by the blood analyzer according to the embodiment shown in FIG. 1 ;
[0024] FIG. 14 is a flowchart illustrating the details of operations that are performed by the blood analyzer according to the embodiment shown in FIG. 1 in a normal mode based on a measurement process ( 1 ) program, a measurement process ( 2 ) program, and a sampler operation process program;
[0025] FIG. 15 is a flowchart illustrating the details of operations that are performed by the blood analyzer according to the embodiment shown in FIG. 1 in the normal mode based on the measurement process ( 1 ) program, the measurement process ( 2 ) program, and the sampler operation process program;
[0026] FIG. 16 shows positional relationships between sample containers and each position in the blood analyzer according to the embodiment shown in FIG. 1 in the normal mode;
[0027] FIG. 17 shows positional relationships between the sample containers and each position in the blood analyzer according to the embodiment shown in FIG. 1 in the normal mode;
[0028] FIG. 18 is a flowchart illustrating operations that are performed in a maintenance measurement mode switching process by the blood analyzer according to the embodiment shown in FIG. 1 ;
[0029] FIG. 19 shows a service control screen that is displayed on a display of the blood analyzer according to the embodiment shown in FIG. 1 ;
[0030] FIG. 20 shows a service menu screen that is displayed on the display of the blood analyzer according to the embodiment shown in FIG. 1 ;
[0031] FIG. 21 shows a measurement unit selection screen that is displayed on the display of the blood analyzer according to the embodiment shown in FIG. 1 ;
[0032] FIG. 22 shows a movement confirmation screen that is displayed on the display of the blood analyzer according to the embodiment shown in FIG. 1 ;
[0033] FIG. 23 shows a service control screen that is displayed on the display of the blood analyzer according to the embodiment shown in FIG. 1 ;
[0034] FIG. 24 is a flowchart illustrating the details of operations that are performed by the blood analyzer according to the embodiment shown in FIG. 1 in a maintenance measurement mode based on the measurement process ( 1 ) program, the measurement process ( 2 ) program, and the sampler operation process program;
[0035] FIG. 25 is a flowchart illustrating the details of operations that are performed by the blood analyzer according to the embodiment shown in FIG. 1 in the maintenance measurement mode based on the measurement process ( 1 ) program, the measurement process ( 2 ) program, and the sampler operation process program;
[0036] FIG. 26 shows positional relationships between sample containers and each position in the blood analyzer according to the embodiment shown in FIG. 1 in the maintenance measurement mode; and
[0037] FIG. 27 shows positional relationships between the sample containers and each position in the blood analyzer according to the embodiment shown in FIG. 1 in the maintenance measurement mode.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] Hereinafter, an embodiment of a sample processing system of the present invention will be described in detail with reference to the accompanying drawings.
[0039] FIG. 1 is a perspective view showing an overall structure of a blood analyzer according to the embodiment of the present invention. FIGS. 2 to 12 each illustrate, in detail, components of the blood analyzer according to the embodiment shown in FIG. 1 . First, an overall structure of a blood analyzer 1 according to the embodiment of the present invention will be described with reference to FIGS. 1 to 12 . Note that the present embodiment describes a case where the present invention is applied in the blood analyzer that is an example of the sample processing system.
[0040] As shown in FIG. 1 , the blood analyzer 1 according to the present embodiment includes: two measurement units that are a first measurement unit 3 disposed on an upstream side of a transporting direction in which a sample is transported toward a below-described analyzed rack holder 42 (i.e., disposed on an arrow X 2 direction side) and a second measurement unit 2 disposed on a downstream side of the transporting direction in which the sample is transported toward the analyzed rack holder 42 (i.e., disposed on an arrow X 1 direction side); a sample transporting apparatus (sampler) 4 disposed in front of the first measurement unit 3 and the second measurement unit 2 (i.e., disposed on an arrow Y 1 direction side); and a control apparatus 5 structured as a PC (Personal Computer) that is electrically connected to the first measurement unit 3 , the second measurement unit 2 , and the sample transporting apparatus 4 . Further, the blood analyzer 1 is connected to a host computer 6 (see FIG. 2 ) via the control apparatus 5 .
[0041] Further, as shown in FIGS. 1 to 3 , the first measurement unit 3 and the second measurement unit 2 are measurement units of practically the same type, which are arranged so as to be adjacent to each other. To be specific, in the present embodiment, the second measurement unit 2 uses the same measurement principle as that of the first measurement unit 3 to measure a sample for the same measurement item as that of the first measurement unit 3 . The second measurement unit 2 further performs measurement for measurement items for which the first measurement unit 3 does not perform measurement. As shown in FIG. 2 , the second measurement unit 2 includes: a sample aspirator 21 for aspirating a blood sample from a sample container (test tube) 100 ; a specimen preparation section 22 for preparing a detection specimen from the blood aspirated by the sample aspirator 21 ; and a detector 23 for detecting blood cells from the detection specimen prepared by the specimen preparation section 22 . Also, the first measurement unit 3 includes: a sample aspirator 31 for aspirating a blood sample from a sample container (test tube) 100 ; a specimen preparation section 32 for preparing a detection specimen from the blood aspirated by the sample aspirator 31 ; and a detector 33 for detecting blood cells from the detection specimen prepared by the specimen preparation section 32 .
[0042] As shown in FIG. 2 , the second measurement unit 2 further includes: a unit cover 24 for accommodating therein the sample aspirator 21 , the specimen preparation section 22 , and the like; a sample container transporter 25 for loading a sample container 100 into the inside of the unit cover 24 and for transporting the sample container 100 to an aspirating position 600 of the sample aspirator 21 ; and a fixedly holding part 26 for fixedly holding the sample container 100 in the aspirating position 600 . Also, the first measurement unit 3 further includes: a unit cover 34 for accommodating therein the sample aspirator 31 , the specimen preparation section 32 , and the like; a sample container transporter 35 for loading a sample container 100 into the inside of the unit cover 34 and for transporting the sample container 100 to an aspirating position 700 of the sample aspirator 31 ; and a fixedly holding part 36 for fixedly holding the sample container 100 in the aspirating position 700 .
[0043] As shown in FIG. 2 , the sample aspirator 21 ( 31 ) includes a piercer 211 ( 311 ). The tip of the piercer 211 ( 311 ) is formed so as to be able to penetrate (pierce) through a below-described sealing cap 100 a (see FIG. 4 ) of the sample container 100 . Further, the piercer 211 ( 311 ) is configured to move in vertical directions (arrow Z 1 and Z 2 directions) through an operation of a piercer drive section that is not shown.
[0044] The detector 23 ( 33 ) is configured to perform RBC detection (detection of red blood cells) and PLT detection (detection of platelets) by the sheath flow DC detection method, and to perform HGB detection (detection of hemoglobin in blood) by the SLS-hemoglobin method. The detector 23 ( 33 ) is also configured to perform WBC detection (detection of while blood cells) by flow cytometry using semiconductor laser. Detection results obtained by the detector 23 ( 33 ) are transmitted to the control apparatus 5 as measurement data (measurement results) of the sample. Note that the measurement data is used as a basis for final analysis results provided to a user (such as a red blood count, platelet count, amount of hemoglobin, white blood count, and the like).
[0045] As shown in FIG. 3 , the sample container transporter 25 ( 35 ) has: a hand part 251 ( 351 ) capable of holding a sample container 100 ; an opening/closing part 252 ( 352 ) capable of opening/closing the hand part 251 ( 351 ); a vertically moving part 253 ( 353 ) for rectilinearly moving the hand part 251 ( 351 ) in vertical directions (the arrow Z 1 and Z 2 directions); and an agitator 254 ( 354 ) for moving the hand part 251 ( 351 ) in the vertical directions (the arrow Z 1 and Z 2 directions) in a swinging manner. Further, as shown in FIG. 2 , the sample container transporter 25 ( 35 ) has: a sample container moving part 255 ( 355 ) for horizontally moving the sample container 100 in the arrow Y 1 and Y 2 directions; and a bar code reader 256 ( 356 ).
[0046] The hand part 251 ( 351 ) is disposed above a transporting path on which a rack 101 is transported by the sample transporting apparatus 4 . The hand part 251 ( 351 ) is configured to, when a sample container 100 has been transported by the sample transporting apparatus 4 to a below-described second loading position 43 b (first loading position 43 a ) (see FIG. 2 ), move downward (in the arrow Z 2 direction) and then be caused by the opening/closing part 252 ( 352 ) to open and close to hold the sample container 100 accommodated in the rack 101 .
[0047] Further, the hand part 251 ( 351 ) is configured to move the held sample container 100 upward (in the arrow Z 1 direction) to remove the sample container 100 from the rack 101 , and then be moved in a swinging manner by the agitator 254 ( 354 ) (e.g., 10 reciprocatory swinging movements). In this manner, the hand part 251 ( 351 ) is capable of agitating the blood contained in the held sample container 100 . The hand part 251 ( 351 ) is configured to move, after the agitation has ended, downward (in the arrow Z 2 direction) and then be caused by the opening/closing part 252 ( 352 ) to release the holding of the sample container 100 . To be specific, the hand part 251 ( 351 ) is configured to set the sample container 100 into a sample setting part 255 a ( 355 a ) that has been moved by the sample container moving part 255 ( 355 ) so as to be disposed in a sample setting position 610 ( 710 ) (see FIG. 2 ). Note that as shown in FIG. 2 , the second loading position 43 b and the sample setting position 610 coincide with each other when viewed in a plan view. Also, the first loading position 43 a and the sample setting position 710 coincide with each other when viewed in a plan view.
[0048] The opening/closing part 252 ( 352 ) is configured to cause, based on the dynamics of an air cylinder 252 a ( 352 a ), the hand part 251 ( 351 ) to open and close so as to hold the sample container 100 .
[0049] The vertically moving part 253 ( 353 ) is configured to move, based on the dynamics of a stepping motor 253 a ( 353 a ), the hand part 251 ( 351 ) along a rail 253 b ( 353 b ) in the vertical directions (the arrow Z 1 and Z 2 directions).
[0050] The agitator 254 ( 354 ) is configured to move the hand part 251 ( 351 ) in the vertical directions (the arrow Z 1 and Z 2 directions) in a swinging manner based on the dynamics of a stepping motor that is not shown.
[0051] As shown in FIGS. 1 and 3 , the sample container moving part 255 ( 355 ) has the sample setting part 255 a ( 355 a ), and is capable of moving the sample setting part 255 a ( 355 a ) to predetermined positions in accordance with operations performed during a measurement process. To be specific, the sample container moving part 255 ( 355 ) is capable of disposing the corresponding sample setting part in the aspirating position 600 ( 700 ) shown in FIG. 2 , and disposing the corresponding sample setting part in the sample setting position 610 ( 710 ) shown in FIG. 2 .
[0052] The bar code reader 256 ( 356 ) is configured to read a bar code 100 b (shown in FIG. 4 ) affixed to each sample container 100 . The bar code 100 b of each sample container 100 is uniquely assigned to the sample therein, and used to manage analysis results of each sample.
[0053] The fixedly holding part 26 ( 36 ) is configured to fixedly hold a sample container 100 having been moved to the aspirating position 600 ( 700 ). To be specific, as shown in FIG. 2 , the fixedly holding part 26 ( 36 ) has a pair of chuck parts 261 ( 361 ). The pair of chuck parts 261 ( 361 ) are configured to move closer toward each other so as to hold the sample container 100 therebetween.
[0054] As shown in FIGS. 5 to 7 , the second measurement unit 2 and the first measurement unit 3 have four casters 27 and four casters 37 , respectively, on the bottom faces thereof, and are thereby configured to be able to move on a base 200 . Accordingly, it is possible to obtain work space between the first measurement unit 3 and the second measurement unit 2 by widening a distance therebetween. Further, the base 200 has side face guides 201 at both side faces thereof (a side face on the arrow X 1 direction side and a side face on the arrow X 2 direction side), respectively, and has a top face guide (not shown) on the top face thereof. Accordingly, as shown in FIG. 6 , the first measurement unit 3 can be rotated, while being prevented from falling off the base 200 , such that a front face 341 thereof faces in the arrow X 2 direction. Further, as shown in FIG. 7 , the second measurement unit 2 can be rotated, while being prevented from falling off the base 200 , such that a front face 241 thereof faces in the arrow X 1 direction. Owing to the above configuration, maintenance work can be readily performed on side faces, of the first measurement unit 3 and the second measurement unit 2 , which are opposed to each other.
[0055] As shown in FIG. 2 and FIG. 5 , the first measurement unit 3 and the second measurement unit 2 are each configured to be fixed to the base 200 by a side face fixing member 202 . The side face fixing members 202 are configured to fix the first measurement unit 3 and the second measurement unit 2 to the base 200 in their normal mode setting positions shown in FIG. 2 (a first setting position and a second setting position), respectively, in which the first measurement unit 3 and the second measurement unit 2 both operate normally. As shown in FIG. 7 , the side face fixing member 202 is configured to be able to fix the first measurement unit 3 to the base 200 in a third setting position that is shifted, by a distance equivalent to four sample containers 100 held in the rack 101 , from the first setting position of the normal mode in the arrow X 2 direction (a direction away from the second setting position). Further, as shown in FIG. 6 , the side face fixing member 202 is configured to be able to fix the second measurement unit 2 to the base 200 in a fourth setting position that is shifted, by a distance equivalent to four sample containers 100 held in the rack 101 , from the second setting position of the normal mode in the arrow X 1 direction (a direction away from the first setting position). Note that the first measurement unit 3 and the second measurement unit 2 are capable of performing sample processing in the third setting position and in the fourth setting position, respectively, during a maintenance measurement mode that is described later.
[0056] As described below, the third setting position is set as a position in which all the sample containers 100 in the rack 101 transported by the rack transporter 43 can be loaded into the first measurement unit 3 . The same is true for the fourth setting position and the second measurement unit 2 . To be specific, when the rack 101 is disposed, on the rack transporter 43 , at the end of the upstream side of the transporting direction (i.e., at the end of the arrow X 2 direction side), the first measurement unit 3 in the third setting position can be loaded with a sample container 100 that is held, in the rack 101 , at the end of the downstream side of the transporting direction (at the end of the arrow X 1 direction side of the rack 101 ). Similarly, when the rack 101 is disposed, on the rack transporter 43 , at the end of the downstream side of the transporting direction (i.e., at the end of the arrow X 1 direction side), the second measurement unit 2 in the fourth setting position can be loaded with a sample container 100 that is held, in the rack 101 , at the end of the upstream side of the transporting direction (at the end of the arrow X 2 direction side of the rack 101 ). A moving distance from the first setting position to the third setting position, and a moving distance from the second setting position to the fourth setting position, are each equivalent to a distance of maximum movement, of one measurement unit (measurement unit that is to continue the measurement), in a direction away from the other measurement unit (measurement unit that is a subject of maintenance work), the movement being in such a range as to allow all the sample containers 100 held in the rack 101 to be loaded into the one measurement unit. In the present embodiment, this distance is equivalent to four sample containers held in the rack 101 . In this manner, the one measurement unit having been moved (the measurement unit that is to continue the measurement) can perform sample processing with the same sample processing capability as in a proper position (the first setting position or the second setting position), and at the same time, space for performing the maintenance work on the other measurement unit can be obtained as widely as possible.
[0057] As shown in FIG. 8 , the first measurement unit 3 and the second measurement unit 2 are each configured to be fixed to the base 200 also by a front face fixing member 203 provided at the front side of the base 200 (arrow Y 1 direction side). Formed in the front face fixing member 203 are: a first positioning hole 203 a , a second positioning hole 203 b , a third positioning hole 203 c , and a fourth positioning hole 203 d , each of which has an elongated shape; and a pair of first fixing holes 203 e , a pair of second fixing holes 203 f , a pair of third fixing holes 203 g , and a pair of fourth fixing holes 203 h , each of which has a round shape. The first measurement unit 3 is configured to be positioned in the first setting position when a protrusion (not shown) provided on the front face (on the arrow Y 1 direction side) of the first measurement unit 3 is inserted into the first positioning hole 203 a . Also, the first measurement unit 3 is configured to be positioned in the third setting position when the protrusion (not shown) thereof is inserted into the third positioning hole 203 c . Similarly, the second measurement unit 2 is configured to be positioned in the second setting position or in the fourth setting position when a protrusion (not shown) provided on the front face (on the arrow Y 1 direction side) of the second measurement unit 2 is inserted into the second positioning hole 203 b or into the fourth positioning hole 203 d , respectively. In this manner, positioning of each of the first measurement unit 3 and the second measurement unit 2 can be readily performed. The pair of first fixing holes 203 e and the pair of third fixing holes 203 g are configured to be used as screw holes for fixing the first measurement unit 3 in the first setting position and in the third setting position, respectively. Further, the pair of second fixing holes 203 f and the pair of fourth fixing holes 203 h are configured to be used as screw holes for fixing the second measurement unit 2 in the second setting position and in the fourth setting position, respectively.
[0058] As shown in FIGS. 2 and 3 , the sample transporting apparatus 4 includes: an unanalyzed rack holder 41 capable of holding a plurality of racks 101 each accommodating sample containers 100 that contain unanalyzed samples; an analyzed rack holder 42 capable of holding a plurality of racks 101 each accommodating sample containers 100 that contain samples having been analyzed; a rack transporter 43 for horizontally and rectilinearly moving a rack 101 in the arrow X 1 and X 2 directions; a bar code reader 44 ; a presence/absence detection sensor 45 for detecting presence/absence of a sample container 100 ; and a rack sending out section 46 for moving the rack 101 to the inside of the analyzed rack holder 42 .
[0059] The unanalyzed rack holder 41 has a rack feeder 411 , and is configured such that the racks 101 held by the unanalyzed rack holder 41 are pushed, one by one, onto the rack transporter 43 by the rack feeder 411 moving in the arrow Y 2 direction. The rack feeder 411 is configured to be driven by a stepping motor (not shown) provided below the unanalyzed rack holder 41 . Further, the unanalyzed rack holder 41 has a restricting portion 412 (see FIG. 3 ) near the rack transporter 43 , and is configured to restrict, by the restricting portion 412 , the movement of the racks 101 such that once a rack 101 is pushed onto the rack transporter 43 , the rack 101 does not return to the inside of the unanalyzed rack holder 41 .
[0060] The analyzed rack holder 42 has a restricting portion 421 (see FIG. 3 ) near the rack transporter 43 , and is configured to restrict, by the restricting portion 421 , the movement of the racks 101 such that once a rack 101 is moved to the inside of the analyzed rack holder 42 , the rack 101 does not return to the rack transporter 43 .
[0061] In the present embodiment, as shown in FIG. 2 , the rack transporter 43 is configured to transport the rack 101 , thereby disposing a predetermined sample container 100 , which is held in the rack, in the first loading position 43 a at which the predetermined sample container is loaded into the first measurement unit 3 disposed in the first setting position, and disposing a predetermined sample container 100 , which is held in the rack, in the second loading position 43 b at which the predetermined sample container is loaded into the second measurement unit 2 disposed in the second setting position. The rack transporter 43 is also configured to be able to transport each sample container 100 to a sample presence/absence detection position 43 c at which the presence/absence detection sensor 45 confirms presence or absence of each sample container 100 , and to transport each sample container 100 to a reading position 43 d at which the bar code reader 44 reads the bar code 100 b of each sample container 100 (see FIG. 4 ). Further, in the below-described maintenance measurement mode, the rack transporter 43 is configured to be able to transport a predetermined sample container 100 , which is held in the rack, to a third loading position 43 e at which the predetermined sample container is loaded into the first measurement unit 3 disposed in the third setting position shown in FIG. 7 , and transport a predetermined sample container 100 , which is held in the rack, to a fourth loading position 43 f at which the predetermined sample container is loaded into the second measurement unit 2 disposed in the fourth setting position shown in FIG. 6 . Further, the rack transporter 43 is configured to be able to transport all the sample containers 100 (ten containers), which the rack 101 can hold, to any of the first loading position 43 a , the second loading position 43 b , the third loading position 43 e , and the fourth loading position 43 f.
[0062] In addition, the rack transporter 43 is configured to, as a result of the control apparatus 5 executing a below-described sampler operation process program 54 c (see FIG. 12 ), transport a predetermined sample container 100 to a predetermined position, based on a transporting distance from a reference position to the predetermined position, the transporting distance being set by the sampler operation process program 54 c . To be more specific, a rear edge of the rack 101 (an edge of the arrow X 2 direction side of the rack 101 ) in a position on the rack transporter 43 , into which position the racks 101 are fed from the unanalyzed rack holder 41 (hereinafter, referred to as a rack feeding position), is set as the reference position. Based on this, the sampler operation process program 54 c presets the transporting distance to the predetermined position. In the case where a predetermined sample container 100 is transported to the third loading position 43 e during the maintenance measurement mode, the transporting distance, which is currently set as a distance from the reference position to the first loading position 43 a , is changed to a distance from the reference position to the third loading position 43 e , whereby the rack transporter 43 is enabled to transport the predetermined sample container 100 to the third loading position 43 e . The transporting of a predetermined sample container 100 to the fourth loading position 43 f is also enabled when the transporting distance, which is currently set as a distance from the reference position to the second loading position 43 b , is changed to a distance from the reference position to the fourth loading position 43 f , whereby the rack transporter 43 is enabled to transport the predetermined sample container 100 to the fourth loading position 43 f . Note that the third loading position 43 e is located so as to be shifted from the first loading position 43 a in the arrow X 2 direction by a distance equivalent to four sample containers 100 held in the rack 101 . Also, the fourth loading position 43 f is located so as to be shifted from the second loading position 43 b in the arrow X 1 direction by a distance equivalent to four sample containers 100 held in the rack 101 .
[0063] As shown in FIG. 9 , the rack transporter 43 has two belts that are a first belt 431 and a second belt 432 capable of moving independently of each other. A width b 1 of the first belt 431 in the arrow Y 1 direction and a width b 2 of the second belt 432 in the arrow Y 2 direction are each equal to or smaller than the half of a width B of the rack 101 in the arrow Y 1 and Y 2 directions. This allows the first belt 431 and the second belt 432 to be arranged in parallel to each other and not to be displaced from the width B of the rack 101 when the rack transporter 43 transports the rack 101 . Further, as shown in FIGS. 10 and 11 , the first belt 431 and the second belt 432 are each formed in an annular shape, and are provided so as to be wound around rollers 431 a to 431 c and rollers 432 a to 432 c , respectively. The outer periphery of the first belt 431 has two protrusions 431 d formed thereon and the outer periphery of the second belt 432 has two protrusions 432 d formed thereon, such that an interval between the protrusions 431 d and an interval between the protrusions 432 d have an inner width w 1 (see FIG. 10 ) and an inner width w 2 (see FIG. 11 ), respectively, which are both slightly greater (e.g., by approximately 1 mm) than a width W of the rack 101 in the arrow X 1 and X 2 directions. The first belt 431 is configured to move, when holding the rack 101 between the protrusions 431 d , the rack 101 in the arrow X 1 or X 2 direction as a result of being moved around the rollers 431 a to 431 c by a stepping motor 431 e (see FIG. 3 ). Also, the second belt 432 is configured to move, when holding the rack 101 between the protrusions 432 d , the rack 101 in the arrow X 1 or X 2 direction as a result of being moved around the rollers 432 a to 432 c by a stepping motor 432 e (see FIG. 3 ). The first belt 431 and the second belt 432 are configured to be able to move the rack 101 independently of each other.
[0064] The bar code reader 44 is configured to read the bar code 100 b of each sample container 100 shown in FIG. 4 and a bar code 101 a affixed to the rack 101 . The bar code reader 44 is configured to read the bar code 100 b of a target sample container 100 accommodated in the rack 101 when the target sample container 100 is being horizontally rotated by a rotator (not shown) without being removed from the rack 101 . Accordingly, even in the case where the bar code 100 b of the sample container 100 is affixed at the opposite side to the bar code reader 44 , the bar code 100 b can be caused to face the bar code reader 44 . Note that the bar code 101 a is uniquely assigned to each rack 101 , and used for, e.g., managing analysis results of the samples.
[0065] The presence/absence detection sensor 45 has a curtain-like contact segment 451 (see FIG. 3 ), a light emitting element for emitting light (not shown), and a light receiving element (not shown). The presence/absence detection sensor 45 is configured such that the contact segment 451 is bent when contacted by a detection subject, and as a result, the light emitted from the light emitting element is reflected by the contact segment 451 and then incident on the light receiving element. Accordingly, when a sample container 100 which is accommodated in the rack 101 and which is a detection subject passes below the presence/absence detection sensor 45 , the contact segment 451 is bent by the sample container 100 . As a result, the presence of the sample container 100 can be detected.
[0066] The rack sending out section 46 is disposed so as to be opposed to the analyzed rack holder 42 while having the rack transporter 43 positioned therebetween, and is configured to horizontally move in the arrow Y 1 direction. The rack sending out section 46 is configured to push, by horizontally moving in the arrow Y 1 direction, the rack 101 that is placed, on the rack transporter 43 , in a position between the analyzed rack holder 42 and the rack sending out section 46 (hereinafter, referred to as a rack sending out position), toward the analyzed rack holder 42 side.
[0067] As shown in FIGS. 1 , 2 and 12 , the control apparatus 5 is structured as a personal computer (PC) or the like. The control apparatus 5 includes: a control section 51 (see FIG. 12 ) including a CPU, ROM, RAM and the like; a display 52 ; and an input device 53 . The display 52 is provided so as to display analysis results and the like that are obtained by analyzing digital signal data transmitted from the first measurement unit 3 and the second measurement unit 2 .
[0068] As shown in FIG. 12 , the control apparatus 5 is structured as a computer 500 of which the main components are the control section 51 , the display 52 , and the input device 53 . The main components of the control section 51 are a CPU 51 a , a ROM 51 b , a RAM 51 c , a hard disk 51 d , a readout device 51 e , an input/output interface 51 f , a communication interface 51 g , and an image output interface 51 h . The CPU 51 a , ROM 51 b , RAM 51 c , hard disk 51 d , readout device 51 e , input/output interface 51 f , communication interface 51 g , and the image output interface 51 h are connected to each other via a bus 51 i.
[0069] The CPU 51 a is capable of executing computer programs stored in the ROM 51 b and computer programs loaded into the RAM 51 c . The computer 500 acts as the control apparatus 5 through execution, by the CPU 51 a , of application programs 54 a , 54 b and 54 c that are described below.
[0070] The ROM 51 b is structured as a mask ROM, PROM, EPROM, EEPROM or the like, and stores computer programs to be executed by the CPU 51 a and stores data to be used by the computer programs.
[0071] The RAM 51 c is structured as an SRAM, DRAM or the like. The RAM 51 c is used for reading computer programs stored in the ROM 51 b and the hard disk 51 d . The RAM 51 c is used as a work area for the CPU 51 a when the CPU 51 a executes these computer programs.
[0072] Installed in the hard disk 51 d are: various computer programs to be executed by the CPU 51 a , such as an operating system and application programs; and data to be used for executing these computer programs. A measurement process ( 1 ) program 54 a for the first measurement unit 3 , a measurement process ( 2 ) program 54 b for the second measurement unit 2 , and a sampler operation process program 54 c for the sample transporting apparatus 4 are also installed in the hard disk 51 d . Through the execution of these application programs 54 a to 54 c by the CPU 51 a , operations of respective components of the first measurement unit 3 , the second measurement unit 2 , and the sample transporting apparatus 4 are controlled. Further, a measurement result database 54 d is also installed in the hard disk 51 d.
[0073] The readout device 51 e is structured as a flexible disc drive, CD-ROM drive, DVD-ROM drive or the like. The readout device 51 e is capable of reading computer programs or data, which are stored in a portable storage medium 54 . The portable storage medium 54 stores therein the application programs 54 a to 54 c . The computer 500 is capable of reading the application programs 54 a to 54 c from the portable storage medium 54 to install the read application programs 54 a to 54 c in the hard disk 51 d.
[0074] Note that the application programs 54 a to 54 c can be provided to the computer 500 not only via the portable storage medium 54 , but also from an external device via a telecommunication line (regardless of whether wired or wireless), which external device is communicably connected to the computer 500 by the telecommunication line. For example, the application programs 54 a to 54 c are stored in a hard disk of a server computer on the Internet. The computer 500 can access the server computer, and download the application programs 54 a to 54 c from the server computer to install the application programs 54 a to 54 c in the hard disk 51 d.
[0075] Also, an operating system that provides a graphical user interface environment, for example, Windows (registered trademark) manufactured and sold by Microsoft Corporation, is installed in the hard disk 51 d . In the description below, it is assumed that the application programs 54 a to 54 c run on the operating system.
[0076] For example, the input/output interface 51 f is configured as: a serial interface such as USB, IEEE1394 or RS-232C; a parallel interface such as SCSI, IDE or IEEE1284; or an analogue interface including a D/A converter, A/D converter and the like. The input device 53 is connected to the input/output interface 51 f . A user can input data to the computer 500 by using the input device 53 .
[0077] The communication interface 51 g is an Ethernet (registered trademark) interface, for example. The computer 500 is capable of transmitting/receiving data to/from the first measurement unit 3 , the second measurement unit 2 , the sample transporting apparatus 4 , and the host computer 6 via the communication interface 51 g , using a predetermined communication protocol.
[0078] The image output interface 51 h is connected to the display 52 that is structured with LCD, CRT or the like. Video signals corresponding to image data, which are supplied from the CPU 51 a , are outputted to the display 52 . The display 52 is configured to display an image (screen) in accordance with the inputted video signals.
[0079] The control section 51 having the above configuration is configured to use measurement results transmitted from the first measurement unit 3 and the second measurement unit 2 to analyze components that are analysis subjects, and obtain results of the analysis (red blood count, platelet count, amount of hemoglobin, white blood count, and the like).
[0080] As shown in FIG. 4 , in the rack 101 , ten container accommodating portions 101 b are formed so as to be able to accommodate ten sample containers 100 in line. Further, the container accommodating portions 101 b are each provided with an opening 101 c such that the bar code 100 b of each sample container 100 accommodated therein can be visually recognized.
[0081] FIG. 13 is a flowchart illustrating operations that are performed, in measurement processes based on the measurement process programs, by the blood analyzer according to the embodiment of the present invention. Described next with reference to FIG. 13 are operations that are performed, in measurement processes based on the measurement process programs 54 a and 54 b , by the blood analyzer 1 according to the present embodiment.
[0082] First, at step S 1 , the sample aspirator 31 aspirates a sample from a sample container 100 having been transported to the aspirating position 700 (see FIG. 2 ). Then, at step S 2 , a detection specimen is prepared from the aspirated sample by the specimen preparation section 32 . At step S 3 , the detector 33 detects, from the detection specimen, the components that are analysis subjects. Then, at step S 4 , measurement data is transmitted from the first measurement unit 3 to the control apparatus 5 . Thereafter, at step S 5 , the control section 51 analyzes, based on the measurement data transmitted from the first measurement unit 3 , the components that are analysis subjects. The analysis of the sample is completed at step S 5 , and the operations end.
[0083] FIGS. 14 and 15 are flowcharts each illustrating the details of the operations that are performed by the blood analyzer in the normal mode based on the measurement process ( 1 ) program, the measurement process ( 2 ) program, and the sampler operation process program. FIGS. 16 and 17 each show positional relationships between sample containers and each position in the blood analyzer according to the embodiment of the present invention. Described next with reference to FIGS. 14 to 17 is a series of operations that are performed by the first measurement unit 3 , the second measurement unit 2 , and the sample transporting apparatus 4 when the blood analyzer 1 according to the present embodiment is in the normal mode. Note that the flowcharts in FIGS. 14 and 15 each show, in the right side rows thereof, the operations performed based on the measurement process ( 1 ) program 54 a , and show, on the left side rows thereof, the operations performed based on the measurement process ( 2 ) program 54 b , and show, in the central rows thereof, the operations performed based on the sampler operation process program 54 c . Further, in FIGS. 16 and 17 , state numbers indicating positional relationships between the sample containers 100 and each position are provided so as to correspond to step numbers shown in FIGS. 14 and 15 . For example, positional relationships between the sample containers 100 and each position in STATE 13 of FIG. 16 are positional relationships between the sample containers 100 and each position at step S 13 of FIG. 14 . Note that as shown in FIGS. 14 and 15 , the measurement process ( 1 ) program 54 a , the measurement process ( 2 ) program 54 b , and the sampler operation process program 54 c are practically executed in parallel in the normal mode of the blood analyzer 1 .
[0084] First, when the blood analyzer 1 is started by a user, the sample transporting apparatus 4 is initialized at step S 11 . At this point, the protrusions 431 d of the first belt 431 are moved to predetermined positions. These positions are set as original positions of the first belt 431 . At step S 12 , the two protrusions 431 d are moved to positions corresponding to the rack feeding position. Then, the rack 101 is fed between the two protrusions 431 d of the first belt 431 . At this point, positional relationships between the sample containers 100 and each position are as shown in STATE 12 of FIG. 16 . Note that in the description below, positional relationships between the sample containers 100 and each position in each state shown in FIGS. 16 and 17 are not described.
[0085] At step S 13 , the rack 101 is moved in the direction of the second measurement unit 2 (forward direction). At step S 14 , presence or absence of the first sample container 100 accommodated in the rack 101 is detected at the sample presence/absence detection position 43 c by the presence/absence detection sensor 45 . Then, at step S 15 , presence or absence of the second sample container 100 is detected at the sample presence/absence detection position 43 c . At step S 16 , the bar code 100 b of the first sample container 100 is read at the reading position 43 d by the bar code reader 44 , and presence or absence of the third sample container 100 is detected at the sample presence/absence detection position 43 c . Note that detection results obtained by the presence/absence detection sensor 45 and bar code information read by the bar code readers 44 , 256 and 356 are transmitted to the host computer 6 at any time as necessary. At step S 17 , the rack 101 is moved such that the first sample container 100 is disposed in the second loading position 43 b . At this point, the bar code 101 a of the rack 101 is read by the bar code reader 44 . Then, at step S 18 , the first sample container 100 having reached the second loading position 43 b is removed from the rack 101 by the hand part 251 of the second measurement unit 2 . At this point, the rack 101 is stationary such that the first sample container 100 is disposed in the second loading position 43 b . At step S 19 , the sample in the first sample container 100 held by the hand part 251 is agitated in the second measurement unit 2 , and the rack 101 from which the first sample container 100 has been removed is moved in a reverse direction that is the opposite direction to the forward direction.
[0086] At step S 20 , in the second measurement unit 2 , the first sample container 100 is set into the sample setting part 255 a , and the bar code 100 b of the second sample container 100 in the rack 101 is read, and presence or absence of the fourth sample container 100 is detected. At step S 21 , in the second measurement unit 2 , the bar code 100 b of the first sample container 100 is read by the bar code reader 256 . At step S 22 , the first sample container 100 held by the sample setting part 255 a is held at the aspirating position 600 by the pair of chuck parts 261 , and the piercer 211 of the sample aspirator 21 penetrates through the sealing cap 100 a of the first sample container 100 . Here, the rack 101 is moved such that the second sample container 100 is disposed in the first loading position 43 a . Thereafter, at step S 23 , in the second measurement unit 2 , the sample contained in the first sample container 100 is aspirated by the sample aspirator 21 , and the second sample container 100 is removed at the first loading position 43 a from the rack 101 by the hand part 351 .
[0087] At step S 24 , in the second measurement unit 2 , the first sample container 100 is removed from the sample setting part 255 a by the hand part 251 , and specimen preparation, agitation, and analysis are performed on the sample aspirated by the sample aspirator 21 . Further, in the first measurement unit 3 , the sample contained in the second sample container 100 held by the hand part 351 is agitated, and the rack 101 is moved in the forward direction. At step S 25 , in the first measurement unit 3 , the second sample container 100 is set into the sample setting part 355 a , and the bar code 100 b of the third sample container 100 in the rack 101 is read, and presence or absence of the fifth sample container 100 is detected. Then, at step S 26 , in the second measurement unit 2 , the measurement of the sample contained in the first sample container 100 ends, and in the first measurement unit 3 , the bar code 100 b of the second sample container 100 is read by the bar code reader 356 . Further, the bar code 100 b of the fourth sample container 100 in the rack 101 is read, and presence or absence of the sixth sample container 100 is detected. Note that “ending of the measurement of a sample” in this description means the completion of measurement data transmission at step S 4 shown in FIG. 13 . That is, at step S 26 , even when the measurement of the sample contained in the first sample container 100 has ended, the process of analyzing the measurement data at step S 5 has not been completed yet.
[0088] At step S 27 , the second sample container 100 held by the sample setting part 355 a of the first measurement unit 3 is held at the aspirating position 700 by the pair of chuck parts 361 , and the piercer 311 of the sample aspirator 31 penetrates through the sealing cap 100 a of the second sample container 100 . Here, the rack 101 is moved in the forward direction. Then, at step S 28 , the first sample container 100 is returned from the second measurement unit 2 to a container accommodating portion 101 b of the rack 101 , which is the original storing position of the first sample container 100 , and in the first measurement unit 3 , the sample contained in the second sample container 100 is aspirated by the sample aspirator 31 . At step S 29 , in the first measurement unit 3 , the second sample container 100 is removed from the sample setting part 355 a by the hand part 351 , and specimen preparation, agitation, and analysis are performed on the sample aspirated by the sample aspirator 31 . Further, the rack 101 is moved in the forward direction. At step S 30 , the third sample container 100 is removed from the rack 101 by the hand part 251 of the second measurement unit 2 . At this point, the rack 101 is stationary such that the third sample container 100 is disposed in the second loading position 43 b . At step S 31 , in the second measurement unit 2 , the sample contained in the third sample container 100 held by the hand part 251 is agitated, and the rack 101 is moved in the reverse direction. Also, in the first measurement unit 3 , measurement of the sample contained in the second sample container 100 ends.
[0089] Then, at step S 32 , in the second measurement unit 2 , the third sample container 100 is set into the sample setting part 255 a . At step S 33 , in the second measurement unit 2 , the bar code 100 b of the third sample container 100 is read by the bar code reader 256 . Also, the second sample container 100 is returned from the first measurement unit 3 to a container accommodating portion 101 b of the rack 101 , which is the original storing position of the second sample container 100 . At step S 34 , the third sample container 100 is held at the aspirating position 600 by the pair of chuck parts 261 . Also, the piercer 211 of the sample aspirator 21 penetrates through the sealing cap 100 a of the third sample container 100 . Further, the rack 101 is moved in the forward direction. Thereafter, for the other sample containers 100 , the first measurement unit 3 and the second measurement unit 2 perform the measurement processes and the sample transporting apparatus 4 performs the process of transporting the rack 101 in the same manner as described above. Therefore, in order to simplify the drawings, it is assumed that the predetermined processes are performed in the respective positions at step S 35 . Accordingly, the series of operations performed in the normal mode by the first measurement unit 3 , the second measurement unit 2 , and the sample transporting apparatus 4 continue to be performed.
[0090] FIG. 18 is a flowchart illustrating operations that are performed in a maintenance measurement mode switching process by the blood analyzer according to the embodiment shown in FIG. 1 . FIGS. 19 to 23 each show a screen that is displayed on the display of the blood analyzer according to the embodiment shown in FIG. 1 . Described next with reference to FIGS. 18 to 23 are operations that are performed in the maintenance measurement mode switching process by the blood analyzer according to the embodiment shown in FIG. 1 .
[0091] First, at step S 41 , a log-on screen (not shown) is displayed on the display 52 , which prompts an input of a service password. Then, at step S 42 , the CPU 51 a of the control apparatus 5 determines whether or not the service password has been inputted. This determination step is repeated until the service password in inputted. When the service password is inputted, a service control screen 521 is displayed on the display 52 at step S 43 as shown in FIG. 19 . The service control screen 521 shows, in a selectable manner, a plurality of icons for performing various settings and the like. One of such icons shown in the screen is a service icon 521 a . Note that the service icon 521 a is shown only when log-on is performed using the service password. Accordingly, only a particular person who owns the service password (e.g., a service person who performs maintenance work) can select the service icon 521 a.
[0092] At step S 44 , it is determined whether or not the service icon 521 a has been selected. When a different icon from the service icon 521 a is selected, a process corresponding to the selected icon is performed at step S 57 , and then the operations end. When the service icon 521 a is selected, a service menu screen 522 is displayed at step S 45 as shown in FIG. 20 . The service menu screen 522 shows a plurality of icons in a selectable manner, including a maintenance measurement mode icon 522 a . Then, at step S 46 , the CPU 51 a determines whether or not the maintenance measurement mode icon 522 a has been selected. When a different icon from the maintenance measurement mode icon 522 a is selected, the processing proceeds to step S 57 . When the maintenance measurement mode icon 522 a is selected, a measurement unit selection screen 523 is displayed over the service menu screen 522 at step S 47 . Note that as a result of the maintenance measurement mode icon 522 a being selected, the mode is switched from the normal mode to the maintenance measurement mode. The measurement unit selection screen 523 shows a first measurement unit button 523 a and a second measurement unit button 523 b , and also shows a message that prompts selection of one of the measurement units, which is to continue the measurement during the maintenance measurement mode.
[0093] At step S 48 , it is determined whether or not one of the measurement units has been selected. This determination step is repeated until one of the measurement units is selected. When one of the measurement units is selected, a movement confirmation screen 524 for confirming whether or not to move the selected one of the measurement units is displayed over the service menu screen 522 at step S 49 as shown in FIG. 22 . The movement confirmation screen 524 shows a “YES” button 524 a and a “NO” button 524 b . At step S 50 , it is determined whether or not the “YES” button 524 a has been selected. Here, the “YES” button 524 a is selected in the case where the measurement unit, which is selected as a measurement unit to continue the measurement, is moved from the proper position of the normal mode (the first setting position or the second setting position). To be specific, in the case of the first measurement unit 3 , the “YES” button 524 a is selected when the first measurement unit 3 is moved from the first setting position to the third setting position. In the case of the second measurement unit 2 , the “YES” button 524 a is selected when the second measurement unit 2 is moved from the second setting position to the fourth setting position. In the case of not changing the position of the measurement unit, which is selected as a measurement unit to continue the measurement, from the proper position of the normal mode (the first setting position or the second setting position), the “NO” button 524 b is selected.
[0094] In the case where the “YES” button 524 a is selected, a setting is performed at step S 51 such that sample containers 100 are not transported to the other measurement unit (the measurement unit that is a subject of maintenance work) that has not been selected as a measurement unit to continue the measurement. To be specific, in the case where the second measurement unit 2 is selected as a measurement unit to continue the measurement, a setting is performed such that sample containers 100 are not transported to the first loading position 43 a or the third loading position 43 e , which are positions each for supplying a sample to the first measurement unit 3 . In the case where the first measurement unit 3 is selected as a measurement unit to continue the measurement, a setting is performed such that sample containers 100 are not transported to the second loading position 43 b or the fourth loading position 43 f , which are positions each for supplying a sample to the second measurement unit 2 .
[0095] Then, at step S 52 , a setting is changed to change the position at which a sample is supplied to the measurement unit that is to continue the measurement. To be specific, in the case where the second measurement unit 2 is to continue the measurement, the position at which a sample is supplied to the second measurement unit 2 (i.e., loading position coordinates) is changed from the second loading position 43 b to the fourth loading position 43 f . To be more specific, based on the sampler operation process program 54 c , a setting is changed such that the transporting distance is changed from the one between the reference position and the second loading position 43 b to the one between the reference position and the fourth loading position 43 f . In this manner, the position at which a sample is supplied to the second measurement unit 2 (i.e., loading position coordinates) is changed from the second loading position 43 b to the fourth loading position 43 f . Note that in the case where the first measurement unit 3 is to continue the measurement, the position at which a sample is supplied to the first measurement unit 3 (i.e., loading position coordinates) is changed from the first loading position 43 a to the third loading position 43 e in the same manner as described above.
[0096] Meanwhile, when the “NO” button 524 b is selected, a setting is performed at step S 53 in the same manner as the above step S 51 such that sample containers 100 are not transported to the other measurement unit (the measurement unit that is a subject of maintenance work) that has not been selected as a measurement unit to continue the measurement. Thereafter, it is determined at step S 54 whether or not a measurement start instruction has been provided. This determination step is repeated until the measurement start instruction is provided. When the measurement start instruction has been provided, the transporting operation and the measurement process operation are performed at step S 55 with the changed setting. Then, at step S 56 , as shown in FIG. 23 , the service control screen 521 shows, in an area 521 b provided at a lower left portion thereof, a message informing that the current mode is the maintenance measurement mode. Thereafter, the operations end.
[0097] FIGS. 24 and 25 are flowcharts each illustrating the details of operations that are performed by the blood analyzer in the maintenance measurement mode based on the measurement process ( 1 ) program, the measurement process ( 2 ) program, and the sampler operation process program. FIGS. 26 and 27 each show positional relationships, in the maintenance measurement mode, between sample containers and each position in the blood analyzer according to the embodiment of the present invention. Described next with reference to FIGS. 24 to 27 is a series of operations that are performed at step S 55 of FIG. 18 by the first measurement unit 3 , the second measurement unit 2 , and the sample transporting apparatus 4 during the maintenance measurement mode. Hereinafter, described is a case where the first measurement unit 3 has been selected at step S 48 of FIG. 18 as a measurement unit to continue the measurement, and the “YES” button 524 a has been selected at step S 50 of FIG. 18 (i.e., a case where the first measurement unit 3 is to be moved). That is, as shown in FIG. 7 , the second measurement unit 2 is in a state where maintenance work is performable thereon and the first measurement unit 3 is disposed in the third setting position. In FIGS. 26 and 27 , state numbers indicating positional relationships between the sample containers 100 and each position are provided so as to correspond to step numbers shown in FIGS. 24 and 25 . As shown in FIGS. 24 and 25 , the measurement process ( 1 ) program 54 a , the measurement process ( 2 ) program 54 b , and the sampler operation process program 54 c are practically executed in parallel in the maintenance measurement mode of the blood analyzer.
[0098] First, the sample transporting apparatus 4 is initialized at step S 61 . To be specific, the protrusions 431 d of the first belt 431 are moved to predetermined positions. These positions are set as original positions of the first belt 431 . At step S 62 , the two protrusions 431 d are moved to positions corresponding to the rack feeding position. Then, the rack 101 is fed between the two protrusions 431 d of the first belt 431 . At this point, positional relationships between the sample containers 100 and each position are as shown in STATE 62 of FIG. 26 . Note that in the description below, positional relationships between the sample containers 100 and each position in each state shown in FIGS. 26 and 27 are not described.
[0099] At step S 63 , the rack 101 is moved in the forward direction (the arrow X 1 direction). At step S 64 , presence or absence of the first sample container 100 accommodated in the rack 101 is detected at the sample presence/absence detection position 43 c by the presence/absence detection sensor 45 . Then, at step S 65 , presence or absence of the second sample container 100 is detected at the sample presence/absence detection position 43 c . At step S 66 , the bar code 100 b of the first sample container 100 is read at the reading position 43 d by the bar code reader 44 , and presence or absence of the third sample container 100 is detected at the sample presence/absence detection position 43 c . Note that detection results obtained by the presence/absence detection sensor 45 and bar code information read by the bar code readers 44 and 356 are transmitted to the host computer 6 at any time as necessary.
[0100] In the present embodiment, at step S 67 , the rack 101 is moved in the reverse direction (the arrow X 2 direction) such that the first sample container 100 is disposed in the third loading position 43 e . To be specific, the first sample container 100 , of which the bar code 100 b has been read, is moved not to the sample supplying position for the second measurement unit 2 undergoing maintenance (the second loading position 43 b or the fourth loading position 430 but to the third loading position 43 e for the first measurement unit 3 having been moved. Further, when the rack 101 is transported in the reverse direction, the bar code 101 a of the rack 101 is read by the bar code reader 44 . Then, at step S 68 , the first sample container 100 having been moved to the third loading position 43 e is removed from the rack 101 by the hand part 351 of the first measurement unit 3 . At this point, the rack 101 is stationary such that the first sample container 100 is disposed in the third loading position 43 e . At step S 69 , in the first measurement unit 3 , the sample in the first sample container 100 held by the hand part 351 is agitated, and the rack 101 from which the first sample container 100 has been removed is moved in the forward direction.
[0101] At step S 70 , in the first measurement unit 3 , the first sample container 100 is set into the sample setting part 355 a , and the bar code 100 b of the second sample container 100 in the rack 101 is read, and presence or absence of the fourth sample container 100 is detected. At step S 71 , in the first measurement unit 3 , the bar code 100 b of the first sample container 100 is read by the bar code reader 356 . At step S 72 , the first sample container 100 held by the sample setting part 355 a is held at the aspirating position 700 by the pair of chuck parts 361 , and the piercer 311 of the sample aspirator 31 penetrates through the sealing cap 100 a of the first sample container 100 . Thereafter, at step S 73 , in the first measurement unit 3 , the sample contained in the first sample container 100 is aspirated by the sample aspirator 31 .
[0102] At step S 74 , the first sample container 100 is removed from the sample setting part 355 a by the hand part 351 , and specimen preparation, agitation, and analysis are performed on the sample aspirated by the sample aspirator 31 . Further, the rack 101 is moved in the reverse direction. Then, at step S 75 , the measurement of the sample contained in the first sample container 100 ends.
[0103] Next, at step S 76 , the first sample container 100 in the third loading position 43 e is returned from the first measurement unit 3 to a container accommodating portion 101 b of the rack 101 , which is the original storing position of the first sample container 100 . At step S 77 , the rack 101 is moved in the forward direction. Then, at step S 78 , the second sample container 100 having been transported to the third loading position 43 e is removed from the rack 101 by the hand part 351 of the first measurement unit 3 . At step S 79 , in the first measurement unit 3 , the sample in the second sample container 100 held by the hand part 351 is agitated, and the rack 101 is moved in the forward direction.
[0104] Then, at step S 80 , in the first measurement unit 3 , the second sample container 100 is set into the sample setting part 355 a , and the bar code 100 b of the third sample container 100 in the rack 101 is read, and presence or absence of the fifth sample container 100 is detected. At step S 81 , in the first measurement unit 3 , the bar code 100 b of the second sample container 100 is read by the bar code reader 356 . At step S 82 , the second sample container 100 held by the sample setting part 355 a is held at the aspirating position 700 by the pair of chuck parts 361 , and the piercer 311 of the sample aspirator 31 penetrates through the sealing cap 100 a of the second sample container 100 . Thereafter, at step S 83 , in the first measurement unit 3 , the sample contained in the second sample container 100 is aspirated by the sample aspirator 31 .
[0105] At step S 84 , the second sample container 100 is removed from the sample setting part 355 a by the hand part 351 , and specimen preparation, agitation, and analysis are performed on the sample aspirated by the sample aspirator 31 . Further, the rack 101 is moved in the reverse direction. Then, at step S 85 , the measurement of the sample contained in the second sample container 100 ends.
[0106] Next, at step S 86 , the second sample container 100 in the third loading position 43 e is returned from the first measurement unit 3 to a container accommodating portion 101 b of the rack 101 , which is the original storing position of the second sample container 100 . At step S 87 , the rack 101 is moved in the forward direction.
[0107] Thereafter, for the third and other sample containers 100 , the first measurement unit 3 performs the measurement process and the sample transporting apparatus 4 performs the process of transporting the rack 101 in the same manner as descried above. Therefore, in order to simplify the drawings, it is assumed that the predetermined processes are performed in the respective positions at step S 88 . Accordingly, the predetermined processes in the maintenance measurement mode continue to be performed. Note that when the second measurement unit 2 is selected at step S 48 of FIG. 18 as a measurement unit to continue the measurement, the predetermined processes are performed in the same manner as described above. If the “NO” button 524 b is selected at step S 50 of FIG. 18 , the sample containers 100 are transported to the first loading position 43 a or the second loading position 43 b in accordance with the measurement unit that is to continue the measurement. Then, at the first loading position 43 a or the second loading position 43 b , the sample containers 100 are loaded into the measurement unit.
[0108] As described above, in the present embodiment, the control apparatus 5 is provided for, when the first measurement unit 3 is moved from the first setting position at which a sample transported to the first loading position 43 a can be loaded into the first measurement unit 3 , to the third setting position at which a sample transported to the third loading position 43 e can be loaded into the first measurement unit 3 , controlling the sample transporting apparatus 4 so as to transport samples to the third loading position 43 e . Accordingly, when maintenance work needs to be performed on the second measurement unit 2 , the first measurement unit 3 is moved from the first setting position to the third setting position in order to obtain space for the second measurement unit 2 to move, or to obtain space for the maintenance work to be performed, and thereafter, the measurement can be performed in the first measurement unit 3 by loading the samples thereinto. Thus, when the maintenance work is performed, the sample processing can be continued while obtaining space that is sufficient for the maintenance work.
[0109] Further, in the present embodiment, the control apparatus 5 is configured to be able to, when the second measurement unit 2 is moved from the second setting position to the fourth setting position at which a sample transported to the fourth loading position 43 f is loaded into the second measurement unit 2 , control the sample transporting apparatus 4 so as to transport samples to the fourth loading position 43 f , and control the second measurement unit 2 such that the second measurement unit 2 processes the samples, which are transported to the fourth loading position 43 f to be loaded into the second measurement unit 2 . Accordingly, when maintenance work needs to be performed on the first measurement unit 3 , the second measurement unit 2 is moved from the second setting position to the fourth setting position in order to obtain space for the first measurement unit 3 to move, or to obtain space for the maintenance work to be performed, and thereafter, the measurement can be continued in the second measurement unit 2 . Thus, the sample processing can be continued while obtaining space that is sufficient for the maintenance work, not only when the maintenance work is performed on the second measurement unit 2 but also when the maintenance work is performed on the first measurement unit 3 .
[0110] Still further, in the present embodiment, the sample transporting apparatus 4 is configured to transport the samples in accordance with the set transporting distance. The control apparatus 5 is configured to control the sample transporting apparatus 4 so as to transport the samples to the third loading position 43 e , in response to the setting being changed such that the transporting distance is changed from the one between the reference position and the first loading position 43 a to the one between the reference position and the third loading position 43 e . Accordingly, the samples can be transported to different loading positions (different loading position coordinates) only by changing the setting of the transporting distance. Thus, the position to which the samples are transported can be readily changed.
[0111] Still further, in the present embodiment, the sample transporting apparatus 4 is configured to be able to transport all the sample containers 100 (ten sample containers) held in the rack 101 to any of the first loading position 43 a , the second loading position 43 b , and the third loading position 43 e . Accordingly, even if the first measurement unit 3 is moved to the third setting position, the measurement can be performed on all the samples held in the rack 101 . This suppresses reduction in the sample processing capability.
[0112] Note that the embodiment disclosed herein is merely illustrative in all aspects and should not be recognized as being restrictive. The scope of the present invention is defined by the scope of the claims rather than by the description of the above embodiment, and includes meaning equivalent to the scope of the claims and all modifications within the scope.
[0113] For instance, the present embodiment describes the measurement units used for the blood analysis, as an example of sample processing apparatuses. However, the present invention is not limited thereto. For example, the sample processing apparatuses may be different sample processing apparatuses such as smear preparing apparatuses.
[0114] Further, as an example of a sample processing system, the present embodiment describes the blood analyzer that includes two measurement units that are the first measurement unit and the second measurement unit. However, the present invention is not limited thereto. The blood analyzer may include three or more measurement units.
[0115] Still further, the present embodiment describes a configuration example in which the CPU of the control apparatus controls both the transporting of the rack and the loading of the samples. However, the present invention is not limited thereto. The transporting of the rack and the loading of the samples may be controlled by separate control sections, respectively. In this case, the control section for controlling the transporting of the rack may be provided in the transporting apparatus, and the control section for controlling the loading of the samples may be provided in each measurement unit.
[0116] Still further, the present embodiment describes a configuration example in which an input of the service password is required in order to change the mode to the maintenance measurement mode. However, the present invention is not limited thereto. The mode may be switched to the maintenance measurement mode without requiring the input of the password.
[0117] Still further, the present embodiment describes a configuration example in which when the mode is switched to the maintenance measurement mode, the selection of the measurement unit to continue the measurement is accepted. However, the present invention is not limited thereto. For example, from among the first measurement unit and the second measurement unit, selecting a measurement unit that stops the measuring and is subjected to the maintenance work, that is, selecting a different measurement unit from a measurement unit that is moved to the third or fourth setting position and then performs the measurement, may be accepted. In this case, the control apparatus accepts a selection as to whether or not to move the measurement unit, which has not been selected, to a repair-period position (a position to which the measurement unit is moved in order to obtain space for repair work to be performed on the different measurement unit) (see FIG. 22 ). When accepting a selection indicating that the measurement unit is to be moved to the repair-period position, the control apparatus transports the samples to the third or fourth loading position corresponding to the measurement unit, which has not been selected. Also, the control apparatus controls the sample transporting apparatus so as not to transport the samples to the different measurement unit, which has been selected. When accepting a selection indicating that the measurement unit, which has not been selected, is not to be moved to the repair-period position, the control apparatus controls the sample transporting apparatus so as to transport the samples to the first or second loading position corresponding to the measurement unit, which has not been selected, and so as not to transport the samples to the different measurement unit, which has been selected.
[0118] Still further, as an example of a sample processing system, the present embodiment describes the blood analyzer in which both the first measurement unit and the second measurement unit are configured to be able to perform the measurement after being moved. However, the present invention is not limited thereto. As long as one of the first measurement unit and the second measurement unit is capable of continuing the measurement after being moved, the other measurement unit does not have to be capable of continuing the measurement after being moved.
[0119] Still further, the present embodiment describes an example in which the sample transporting apparatus is configured to transport a sample container to a predetermined position in accordance with the set transporting distance. However, the present invention is not limited thereto. For example, the sample transporting apparatus may be configured to transport a sample container to a predetermined position by using a position detection sensor or the like.
[0120] Still further, as an example of a transporting apparatus, the present embodiment describes the sample transporting apparatus that is capable of transporting all the sample containers (ten sample containers) held in the rack to any of the first, second, third and fourth loading positions. However, the present invention is not limited thereto. The sample transporting apparatus may be capable of transporting only a part of the plurality of samples held in the rack to the third loading position or the fourth loading position, which are sample supplying positions for a measurement unit that has been moved in order to allow maintenance work to be performed on the other measurement unit.
[0121] Still further, as an example of computer programs, the present embodiment describes three computer programs that are the measurement process ( 1 ) program, the measurement process ( 2 ) program, and the sampler operation process program. However, the present invention is not limited thereto. The computer program may be a single computer program that includes the contents of the measurement process ( 1 ) program, the measurement process ( 2 ) program, and the sampler operation process program.
[0122] Still further, the present embodiment describes an example in which the presence/absence detection position and the bar code reading position are different positions. However, the present invention is not limited thereto. The presence/absence detection position and the bar code reading position may be the same position.
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A sample processing system comprising: a transporting apparatus for transporting samples to a first loading position, a second loading position, and a third loading position; a first sample processing apparatus capable of being set in a first setting position and a third setting position; a second sample processing apparatus capable of being set in a second setting position; and a controller including a memory under control of a processor, the memory storing instructions enabling the processor to carry out operations comprising: controlling the transporting apparatus so as to transport a sample to the first loading position when the first sample processing apparatus is set in the first setting position; and controlling the transporting apparatus so as to transport a sample to the third loading position when the first sample processing apparatus is set in the third setting position, is disclosed. A sample processing method and a computer program product are also disclosed.
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TECHNICAL FIELD
The present disclosure relates generally to debris guards for tracked machines, and more particularly to a debris guard for inhibiting entry of debris from an exterior to an interior of a track roller frame.
BACKGROUND
Track type tractors are one type of machine that utilize an idler recoil system in order to better allow the tracks of the machine to interact with variable loads encountered when the machine is being maneuvered over the ground. A typical track system may include a forward idler that is supported in a track roller frame assembly about which the track is mounted. The track typically includes a series of shoes that contact the ground on one side, and an inner track chain that is driven to rotate to propel the machine in a travel direction. The idler may typically be supported by a yoke that may slide fore and aft within the track roller frame in order to react to various loads that are transmitted from the track to the idler. The yoke in turn acts upon a spring that is compressed when the idler and yoke are pushed into the track roller frame assembly. The spring then recoils back on the yoke and the idler to return both toward their undisturbed operating configuration.
Because tracked machines often work in extremely hostile environments that may include mud, sand, rocks, soil and a wide variety of other debris, there is often a risk of debris entering the track roller frame and eventually undermining operation of the recoil system and/or otherwise damaging the machine. Free flowing debris generally enters the lower moving undercarriage of a tracked machine at the track frame ends when the machine is turning, or between the track rollers due to a sloped surface operation. In one specific example, long exposure to mud can become caked or bricked inside the track roller frame inhibiting the ability of the recoil system to respond to various loads on the track, undermining machine operation and potentially leading to failure. In another example, rocks digested into the track roller frame may lead to fracture or breakage of track components, idlers, rollers and a variety of other components associated with the recoil system. Debris can often build up on the top of a track roller frame by either being carried to the top side of the track shoes and dropped onto the track roller frame top, or by being deposited on top of the track roller frame from track frames submerged in debris.
Over the years, engineers have devised a long list of guarding strategies intended to inhibit digestion of debris into the track roller frame of a tracked machine. In fact, guarding strategies date as far back as 1928, where the model Twenty Caterpillar track type tractor included guarding surfaces and skirting intended to inhibit the digestion of debris into its track roller frame assembly. From that time forward, virtually every manufacturer of tracked machines has included some guarding strategy to inhibit digestion of debris into their respective track roller frames. Many of these guard designs are particular to the specific track structure and other machine geometry features that are not easily transferable to different designs. Thus, a guarding strategy for one machine may be totally ineffective and inappropriate for a different machine design. With every new design, new guarding strategies must be devised in order to specifically address the needs and geometry of each new design.
The present disclosure is directed toward problems associated with guarding against ingestion of debris into a track roller frame.
SUMMARY OF THE DISCLOSURE
In one aspect, a debris guard assembly for a machine includes a pair of guard plates with a leading edge shaped as an arc of a circle. The pair of guard plates are separated by a distance to flank a track chain. An inboard shield is attached between the plates and defines an idler slot sized for receiving an idler about a same diameter as the circle.
In another aspect, a machine includes a pair of idler axle blocks slidably mounted in a track roller frame. An idler is rotatably supported by and between a pair of idler axle blocks. A recoil yoke is attached to the pair of idler blocks. A track that includes track chain is mounted around the track roller frame. A debris guard is attached to at least one of the pair of idler blocks and the recoil yoke. The debris guard includes an inboard shield that defines a slot that receives the idler, and pair of guard plates that flank opposites sides of a segment of the track chain in contact with the idler.
In still another aspect, a method of inhibiting debris entry into an interior of a track roller frame includes blocking debris greater than a first size by defining a first clearance slit between an outer width of a track chain and pair of guard plates. Debris greater than a second size is blocked by defining a second clearance slit between an idler and an inboard shield. The first clearance slit and the second clearance slit are arranged in series to define portions of a debris entry pathway from an exterior to an interior of the track roller frame.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a machine according to one aspect of the present disclosure;
FIG. 2 is a diagrammatic view of a track roller frame, idler, debris guard and track according to another aspect of the present disclosure;
FIG. 3 is a side view of a track roller frame and idler equipped with a debris guard according to the present disclosure;
FIG. 4 is a perspective view of a preassembled unit according to another aspect of the present disclosure; and
FIG. 5 is a perspective view of a debris guard assembly according to another aspect of the present disclosure.
DETAILED DESCRIPTION
Referring to FIGS. 1-5 , a machine 10 according to the present disclosure may be a track type tractor or some other machine that includes a track 13 mounted about a track roller frame 11 and idler 12 . For instance, a variety of track type machines, including but not limited to excavators, loaders and landfill equipment, as well as others, are within the contemplated scope of the present disclosure. Machine 10 includes a variety of features including a debris guard 40 to inhibit entry of debris into track roller frame 11 , which could undermine a recoil system (not shown) or damage other aspects of machine 10 , such as produce excessive wear or breakage of a variety of track roller frame related components.
Referring specifically to FIG. 5 , a debris guard assembly 40 according to the present disclosure may include a pair of guard plates 42 and 43 that are attached on opposite sides of an inboard shield 41 . Guard plates 42 and 43 each include a respective leading edge 50 and 52 that is shaped as an arc of a circle. The pair of guard plates 42 and 43 may be separated by a distance to flank opposite sides of a track chain 15 , such that the track chain 15 is received between the pair of guard plates 42 and 43 , as best shown in FIG. 2 . This provides a first line of defense by the track chain 15 and the respective guard plates 42 and 43 defining a first clearance slit 65 , also as best shown in FIG. 2 . In order to provide an adequate thickness to guard plates 42 and 43 without excessive weight, each guard plate may be a composite of thinner plates welded at their periphery with the inner most plate being hollow. Each of the guide plates 42 and 43 may also include a mounting feature, such as an idler axle block mount 51 and 53 as best shown in FIGS. 4 and 5 . This aspect of the disclosure allows for the guard plates 42 and 43 to move with the idler as it undergoes recoiling events during normal operation to maintain the geometry of clearance slit 65 , even during dynamic movements. The guide plates 42 and 43 may be attached to the inboard shield 41 in any suitable manner such as via a weld seam along an inner surface of the respective guide plates 42 and 43 .
Inboard shield 41 includes a top right guard 44 , a top left guard 45 and a rear guard 46 as best shown in FIG. 5 . Inboard shield 41 defines a slot 47 that surrounds and receives a portion of idler 12 as best shown in FIG. 2 . In addition, slot 47 terminates in an enlarged opening 48 sized to received a rim 18 of the idler 12 . As best shown in FIG. 5 (see location of numeral 47 ) and as shown in FIG. 2 , a segment of idler slot 47 is located between, but separated from, the guard plates 42 and 43 . Together, inboard shield 41 and idler 12 define a second clearance slit 66 that provides a second line of defense against debris entry into the interior of track roller frame 11 . Together, slits 65 and 66 form portions of a serpentine shaped debris entry pathway 67 extending between an exterior and an interior of the track roller frame 11 . Like guard plates 42 and 43 , the inboard shield 41 includes a mount, in particular, a yoke mount 55 that results in the inboard shield also moving with idler 12 during dynamic recoil events to maintain the geometry of clearance slit 66 throughout operation of machine 10 . Although debris guard assembly 40 includes block mounts 51 and 53 as well as a yoke mount 55 , those skilled in the art will appreciate that other attachment strategies could be substituted while remaining within the intended scope of the present disclosure. As best shown in FIG. 4 , the debris guard 40 may include an orientation alignment feature 57 that interacts with an end 29 of a recoil shaft 28 to prevent the recoil shaft 28 from rotating about its axis. Nevertheless, this feature may be eliminated in the favor of an alternative strategy for inhibiting rotation of shaft 28 , if desired. This aspect of the disclosure is best shown in FIG. 4 .
Referring specifically to FIG. 3 , the leading edges 50 and 52 of the guard plates 42 and 43 are shaped as an arc of a circle which spans about one quadrant 60 . Nevertheless, those skilled in the art will appreciate that the arcuate span may be selected to suit the particular geometry of any given application. The diameter of the circle corresponding to the leading edges 50 and 52 of guard plates 42 and 43 is about the same as the base diameter of idler 12 so that the leading edges 50 and 52 remain about the same distance away from the underside of shoes 14 as the face of the individual teeth (if any) of idler 12 . In this way, as wear occurs during normal operation of machine 10 , indexing on the idler 12 and wear to track chain 15 can reduce the separation distance between both the rim 18 of idler 12 as well as the leading edges 50 and 52 with respect to the shoes 14 . In other words, providing that wear is not so severe that idler remains out of contact with shoes 14 , the guard plates 42 and 43 will also remain out of contact with shoes 14 during normal intervals of wear that periodically require a belt tensioning adjustment in a known manner.
Although not necessary, guard plates 42 and 43 may be parallel to one another and perpendicular to an axis of rotation of idler 12 . Nevertheless, alternative geometry's, such as an inward slant would also fall within the intended scope of the present disclosure. Although not necessary, the present disclosure contemplates a preassembled unit strategy that better facilitates the debris guard features by allowing them to be assembled as shown in FIG. 4 prior to installation in track roller frame 11 . In particular, a preassembled unit 20 may include idler 12 , a pair of idler axle blocks 21 , a yoke 22 and debris guard 40 all preassembled as a unit. This preassembled unit is then installed in track roller frame 11 by sliding the idler axle blocks 21 between wear plates until yoke 22 abuts end 29 of recoil shaft 28 . At the same time, the orientation alignment feature 57 engages the outer edges of end 29 of recoil shaft 28 to prevent it from rotating.
Those skilled in the art will appreciate that sizing of slot 47 verses the thickness of idler 12 may be selected to shape clearance slit 66 to prevent entry of debris having a size greater than the width of the slit. Likewise, the thickness and spacing of guard plates 42 and 43 along with the width track chain 15 may be selected to prevent entry of debris of size that is different or the same as the width of clearance slit 65 . Although not necessary, the clearance slit 65 may be chosen to be slightly larger than the inner clearance slit 66 due to the fact that more movement in track 13 is generally allowed for normal operation, and larger clearance 65 can prevent contact between guard plates 42 and 43 while preventing a bulk of potential debris from gaining entry into debris pathway 67 . By arranging clearance slits 65 and 66 in series, and by appropriately sizing the same, the serpentine entry pathway 67 can inhibit entry of most undesirable debris without substantially affecting performance of machine 10 generally, or the track system specifically.
INDUSTRIAL APPLICABILITY
The present disclosure finds potential application to any tracked machine in which their is a desire to inhibit debris from entering a track roller frame that rotationally supports an idler about which a track is mounted. The present disclosure find particular application in track systems that include an idler that is received into the track chain rather than riding on an outer surface of a track chain as in many prior art systems. This strategy allows the debris guard of the present disclosure to interact with the track chain and idler to define a serpentine debris pathway that includes at least two clearance slits in series to present a layered line of defense against entry of undesirable debris into the interior of a track roller frame. The present disclosure finds specific applicability to track type tractors and like machines that operate in hostile environments, including but not limited to mud, rocks, sand and a variety of other debris that could potentially undermine a recoil system or another machine feature if becoming lodged in an undesirable location.
The debris guard strategy of the present disclosure also has the advantage of moving with the idler during dynamic recoil events to maintain the geometry of the clearance slits to inhibit ingestion of debris even when the idler is recoiling and moving with regard to other components of machine 10 . By including an arc shape on the guard plates of the debris guard with a diameter about the same as the idler, and with the spacing as taught above, the clearance slit geometry also is maintained during normal wear of the track system. In particular, as the idler becomes more indexed and the track chain 15 wears, the idler rim 18 will tend to ride closer to the underside of the track shoes 14 . As long as this wear does not become excessive, the guard plates 42 and 43 will also remain out of contact with the underside of shoes 14 during normal wear cycles.
It should be understood that the above description is intended for illustrative purposes only, and is not intended to limit the scope of the present disclosure in any way. Thus, those skilled in the art will appreciate that other aspects of the disclosure can be obtained from a study of the drawings, the disclosure and the appended claims.
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A tracked machine may be equipped with a debris guard in order to inhibit entry of debris from an exterior to an interior of a track roller frame. An idler, track roller frame, track and debris guard may be configured to create a difficult to traverse serpentine debris entry pathway into the track roller frame. This may be accomplished by flanking opposite sides of a track chain with a pair of guard plates, and further inhibiting debris entry by including an in board guard shield that defines a slot that surrounds a portion of the idler.
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REFERENCE TO PENDING PRIOR PATENT APPLICATIONS
[0001] This patent application:
[0002] (i) is a continuation-in-part of pending prior U.S. patent application Ser. No. 13/348,416, filed Jan. 11, 2012 by Arnold Miller et al. for METHOD AND APPARATUS FOR TREATING VARICOSE VEINS (Attorney's Docket No. AM-0708), which patent application claims benefit of prior U.S. Provisional Patent Application Ser. No. 61/431,609, filed Jan. 11, 2011 by Arnold Miller for METHOD AND APPARATUS FOR TREATING VARICOSE VEINS (Attorney's Docket No. AM-7 PROV); and
[0003] (ii) claims benefit of pending prior U.S. Provisional Patent Application Ser. No. 61/620,787, filed Apr. 5, 2012 by Arnold Miller et al. for TEMPORARY ARTERIAL OCCLUSION FOR MILITARY AND CIVILIAN EXTREMITY TRAUMA (Attorney's Docket No. AM-9 PROV).
[0004] The three (3) above-identified patent applications are hereby incorporated herein by reference.
FIELD OF THE INVENTION
[0005] This invention relates to surgical methods and apparatus in general, and more particularly to surgical methods and apparatus for the occlusion of blood vessels and the treatment of varicose veins. This invention also relates to a minimally invasive means for fastening mechanical structures to tissues or blood vessels, for example, for drug delivery.
BACKGROUND OF THE INVENTION
Varicose Veins in General
[0006] There are three sets of veins in the legs: (i) superficial veins that lie under the skin and may be seen and felt when standing; (ii) deep veins that lie within the muscles and are not seen or felt; and (iii) perforating or connecting veins that join the two systems (i.e., the superficial veins and the deep veins).
[0007] Veins lie within all tissues. Veins return blood to the heart. When muscles in the leg contract, blood is pumped back to the heart. Valves inside the veins direct the flow of blood back to the heart.
[0008] The veins are relatively weak tubes. Under the skin there is no support for these veins, so that when the pressure in the veins is elevated, areas of weakness occur and the veins enlarge, both in size and length. In some cases the veins can become twisty and bulge significantly. This condition is commonly referred to as varicose veins.
[0009] Very small varicose veins are sometimes called spider veins. Unlike the larger varicose veins, these spider veins lie in the skin.
[0010] The cause of the increased pressure in the veins is due to the occurrence of “leaky” valves within the veins. The main valve is in the groin region, i.e., in the great sapheous vein near the sapheno-femoral junction. See FIG. 1 , which shows a leg 5 of a patient, the femoral vein 10 , the great saphenous vein 15 , the sapheno-femoral junction 20 , and the main valve 25 in the great saphenous vein near the sapheno-femoral junction. Once this main valve in the saphenous vein becomes leaky, the pressure in the vein increases and the veins below the saphenous vein start to enlarge. This causes the next set of valves in the saphenous vein to leak. The raised pressure caused by the leaky valves in the saphenous vein is transmitted to the feeder veins, which distend and their valves also malfunction and become leaky. As this process carries on down the leg, many of the valves in the leg veins become incompetent, with high pressures occurring in the veins, especially on standing.
[0011] Initially, the problem is primarily cosmetic. The veins bulge and look unsightly. However, there is commonly also discomfort in the legs upon standing. This discomfort is the result of the veins distending due to the increased pressure.
[0012] With time, the high pressure in the veins is transmitted to the surrounding tissues and skin. Small veins within the skin (i.e., spider veins) enlarge and become visible. Blood cells may escape into the tissues and break down, causing areas of discoloration. Because the pressure in the tissues is high, the skin swells and the nutrition of the skin deteriorates. This lowers the local tissue resistance and allows infection to occur. Eventually skin may break down with the development of sores (i.e., ulcers).
Incidence of Varicose Veins
[0013] Nearly 40 percent of women and 25 percent of men suffer from lower extremity venous insufficiency and associated visible varicose veins. Primary risk factors include heredity, gender, pregnancy and age. Most of these patients have long-standing leg symptoms which compromise their daily routine, with symptoms worsening during the day while the patients are at work or simply living their lives. Without varicose vein treatment, these symptoms can progress to a lifestyle-limiting condition.
Treatment of Varicose Veins
[0014] Treatment of varicose veins is undertaken for relief of the symptoms, i.e., the removal of the unsightly veins and the prevention of the discomfort and late-stage manifestations described above.
[0015] 1. Non-Surgical Treatment.
[0016] The simplest treatment is a non-surgical treatment directed against the high pressure in the varicose veins. More particularly, fitted elastic stockings, strong enough to overcome the increased pressure caused by the “leaky” valves, are used. These fitted elastic stockings control the symptoms and may prevent the veins from further enlargement, however, they are not curative. Good results require consistent, every-day use of the stockings.
[0017] 2. Surgical/Interventional Treatment.
[0018] The aim of the surgical/interventional treatment is (i) the elimination of the cause of the high venous pressure (i.e., the “leaky” valves at the groin); and (ii) the removal of the unsightly veins.
[0019] The early approach of “stripping” the saphenous vein (the main vein in the leg) as the sole manner of treatment has now been largely abandoned. This is because the “stripping” approach caused too much trauma and did not remove all of the superficial varicose veins: many of the superficial varicose veins were tributaries of the main superficial vein of the leg (i.e., the saphenous vein) that was stripped, and these tributary veins were not removed by this procedure.
[0020] There are currently three basic approaches for treating varicose veins: chemical—sclerorosants and glues; venous ablation using thermal treatments; and open surgery.
[0021] A. Sclerotherapy.
[0022] Sclerotherapy (the use of sclerosants) is generally used for treating the smaller varicose veins and spider veins that do not appear to be directly associated with “leaky” valves. It is primarily a cosmetic procedure.
[0023] In this approach, a sclerosant (i.e., a substance irritating to the tissues) is injected into the smaller varicose veins and spider veins, causing inflammation of the walls of these veins. As a result of this inflammation, the walls of the vein stick together and occlude the lumen of the vein so that no blood can pass through the vein. Eventually these veins shrink and disappear.
[0024] The disadvantages of sclerotherapy include: (i) in the presence of high venous pressure (i.e., with leaky valves and the larger varicose veins), the results are uncertain and the recurrence rate is high; and (ii) the erroneous injection of the sclerosant into the surrounding tissues can result in damage to the surrounding tissues, with areas of discoloration of the skin and even ulceration.
[0025] Recently, mixing the sclerosant with air to form a “foam” has been used to destroy the lining of the main vein (i.e., the saphenous vein) of the leg. To date, the results are somewhat unpredictable and there is a danger of the sclerosant escaping through the saphenous vein and into the deep veins and then embolizing into the lungs, which is harmful and dangerous for the patient.
[0026] B. Venous Ablation.
[0027] Venous ablation for varicose veins can be effected in two ways, i.e. percutaneously and endovenously.
[0028] With the percutaneous approach, the superficial smaller varicose veins and spider veins are “heated” and coagulated by shining an external laser light through the skin. However, if the veins are too large, the amount of energy needed to destroy the veins may result in damage to the surrounding tissues. Percutaneous laser treatment is primarily an alternative to the sclerotherapy discussed above, and generally suffers from the same disadvantages described above with respect to sclerotherapy.
[0029] With endovenous ablation, a special laser or radio-frequency (RF) catheter is introduced, with local anesthesia, through a needle puncture into the main superficial vein (i.e., the saphenous vein) of the leg. Entry is made in the region around the knee, and the catheter is passed up towards the groin, advancing to the site where the saphenous vein joins the deep veins at the site of the main “leaky” valves. Then, as the catheter is slowly withdrawn back through the vein, the laser light or radio-frequency (RF) energy heats up the wall of the vein, endoluminally coagulating the proteins and destroying the lining surface of the vein. The destruction of the lining surface of the vein causes the vein walls to adhere to one another, thereby eliminating the lumen within the vein and thus preventing the flow of blood. This is a process somewhat similar to sclerotherapy, but no substance is injected into the vein. This procedure takes care of the “leaky” valves and high venous pressures, however, the larger superficial varicose veins in the leg may still need to be removed. This may be done at the same time as the endovenous ablation or at a later time, either by open surgery (phlebectomy) or sclerotherapy. Placement of the laser or radio-frequency (RF) catheter is guided by ultrasound.
[0030] The advantages of endovenous laser/radio-frequency (RF) therapy include: (i) it is a minimally invasive procedure and can be done with local anesthesia, either in an operating room or a physician's office; (ii) it does not require hospitalization; (iii) it does not require open surgery with incisions; (iv) recovery is easier than with open surgery, inasmuch as most patients are back at work within a day or two; and (v) some of the prominent varicosities may disappear and may not require a secondary procedure (i.e., either phlebectomy or sclerotherapy).
[0031] The disadvantages of endovenous laser/radio-frequency (RF) therapy include: (i) generally, only one leg is done at a time; (ii) the procedure typically requires significant volumes of local anesthetic to be injected into the patient in order to prevent the complications of the heat necessary to destroy the lining of the vein; (iii) if too much heat is applied to the tissue, there can be burning in the overlying skin, with possible disfiguring, including scarring; (iv) prior to the performance of a subsequent phlebectomy procedure, an interval of up to 8 weeks is required in order to evaluate the effectiveness of the venous ablation procedure; and (v) varicosities that remain after this interval procedure still require separate procedures (i.e., phlebectomy or sclerothapy).
[0032] C. Open Surgery.
[0033] The aim of open surgery is to eliminate the “leaky” valve at the junction of the superficial and deep veins (the cause of the high venous pressure in the leg), as well as the leaky valves in the tributaries of the saphenous vein that may enlarge over the years and result in a recurrence of the varicose veins. This open surgery is directed to removal of some or all of the affected veins.
[0034] There is still some controversy as to how much of the saphenous vein needs to be removed for the best results. The current “teaching” is that removing the entire segment of saphenous vein in the thigh reduces the incidence of recurrence. However, the data for this is very weak. Removal of a very short segment of the proximal saphenous vein and the main tributaries at the sapheno-femoral junction is the alternative procedure and, provided that it is combined with removal of all visible varicosities, the results are very similar to removal of the entire thigh segment of the saphenous vein. The advantage of the latter procedure is the increased preservation of the saphenous vein which, in 50-60% or more of varicose vein patients, is not involved in the varicose vein process and is otherwise normal and hence usable for other procedures (such as a bypass graft in the heart or limbs).
[0035] The surgery is performed in the operating room under light general or regional (spinal or epidural) anesthesia. An incision (e.g., 1-2 inch) is made in the groin crease and the veins dissected out and the proximal saphenous vein and tributaries excised. The wound is closed with absorbable sutures from within. Once this is completed, small (e.g., 2-4 mm) stab wounds are made over any unsightly varicose veins (these veins are marked out just prior to the surgery with the patient standing) and the varicose veins are completely removed. The small stab wounds associated with removal of the marked-out veins are generally so small that they typically do not require any stitches to close them. When all the previously marked-out veins are removed, the wounds are cleaned and a dressing applied. The leg is wrapped in elastic bandages (e.g., Ace wraps).
[0036] In the post-operative care, the dressings and Ace wraps are usually changed in the doctor's office at the first post-operative visit, typically within 24 hours of the open surgical procedure. The patient and a family member or friend is instructed on proper care of the wounds. A simple dressing is applied to cover the small wounds in the legs for the next 2-3 days. After 2-3 days no further treatment is generally required. Recovery is generally rapid, with the patient returning to work within 5-7 days.
[0037] The advantages of open surgery include: (i) varicose veins of both extremities can be done at a single operation, which generally takes 1-2 hours; (ii) the procedure typically does not require hospitalization and is an “out patient” procedure; (iii) the wounds are minimal, with minimal discomfort which is easily managed with oral analgesics (i.e., pain medicine); (iv) the results are generally excellent, with a minimum of recurrence (the results of open surgery remain the “gold standard” against which the sclerotherapy and laser/radio-frequency (RF) venous ablation therapies are compared); (v) recurrent or residual (i.e., those missed at surgery) veins are generally managed with sclerotherapy or phlebectomy under local anesthesia in a doctor's office or in an ambulatory procedure room; and (vi) the saphenous vein, if normal and without varicosities, is preserved and is therefore available for use (e.g., for bypass surgery) in the future if it should be needed.
[0038] The disadvantages of open surgery include: (i) it is an open surgical procedure requiring an anesthetic (either general or regional), with its associated discomfort and with its attendant risks (which may depend on the health or age of the patient); and (ii) recovery generally takes 3-5 days.
[0039] Thus it will be seen that varicose veins present a significant problem for many patients which must be addressed, and all of the current procedures for treating varicose veins suffer from a number of significant disadvantages.
SUMMARY OF THE INVENTION
[0040] The present invention provides a new and improved approach for treating varicose veins and other blood vessels.
[0041] More particularly, the present invention comprises the provision and use of a novel occluder which is used to occlude a vein (e.g., the proximal saphenous vein, the small saphenous vein, tributaries, the perforator veins, etc.) so as to restrict blood flow through the vein and thereby treat varicose veins below the point of occlusion. Significantly, the novel occluder is configured to be deployed using a minimally-invasive approach (i.e., either percutaneously or endoluminally), with visualization being provided by ultrasound and/or other visualization apparatus (e.g., CT, MRI, X-ray etc.). As a result, the novel treatment can be provided in a doctor's office, with minimal local anesthetic, and effectively no post-operative care.
[0042] In one form of the invention, there is provided apparatus for occluding a blood vessel, the apparatus comprising:
[0043] an occluder, the occluder being configured so that at least a portion of the occluder may assume (i) a diametrically-reduced configuration for disposition within the lumen of a tube, and (ii) a diametrically-expanded configuration for disposition adjacent to the blood vessel, such that when said at least a portion of the occluder is in its diametrically-expanded configuration adjacent to the blood vessel, the occluder will cause occlusion of the blood vessel.
[0044] In another form of the invention, there is provided a method for occluding a blood vessel, the method comprising:
[0045] providing apparatus comprising:
an occluder, the occluder being configured so that at least a portion of the occluder may assume (i) a diametrically-reduced configuration for disposition within the lumen of a tube, and (ii) a diametrically-expanded configuration adjacent to the blood vessel, such that when said at least a portion of the occluder is in its diametrically-expanded configuration adjacent to the blood vessel, the occluder will cause occlusion of the blood vessel; and
[0047] positioning the occluder adjacent to the blood vessel so as to cause occlusion of the blood vessel.
[0048] In another form of the invention, there is provided apparatus for delivering a substance to a location adjacent to a blood vessel, the apparatus comprising:
[0049] a carrier, the carrier being configured so that at least a portion of the carrier may assume (i) a diametrically-reduced configuration for disposition within the lumen of a tube, and (ii) a diametrically-expanded configuration for disposition adjacent to the blood vessel, such that when the substance is attached to the carrier and said at least a portion of the carrier is in its diametrically-expanded configuration adjacent to the blood vessel, the substance will be disposed adjacent to the blood vessel.
[0050] In another form of the invention, there is provided a method for delivering a substance to a location adjacent to a blood vessel, the method comprising:
[0051] providing apparatus comprising:
a carrier, the carrier being configured so that at least a portion of the carrier may assume (i) a diametrically-reduced configuration for disposition within the lumen of a tube, and (ii) a diametrically-expanded configuration for disposition adjacent to the blood vessel, such that when the substance is attached to the carrier and said at least a portion of the carrier is in its diametrically-expanded configuration adjacent to the blood vessel, the substance will be disposed adjacent to the blood vessel; and
[0053] positioning the carrier adjacent to the blood vessel so that the substance is disposed adjacent to the blood vessel.
[0054] In another form of the invention, there is provided apparatus for percutaneously occluding a hollow structure, said apparatus comprising:
[0055] an occluder, said occluder comprising a first component and a second component, wherein said first component is configured so that it may assume (i) a diametrically-reduced configuration for disposition within the lumen of a hollow tube, and (ii) a diametrically-expanded configuration for disposition adjacent to the hollow structure, whereby to occlude the hollow structure, and further wherein said second component percutaneously connects said first component to a site remote from said first component.
[0056] In another form of the invention, there is provided a method for percutaneously occluding a hollow structure, the method comprising:
[0057] providing apparatus comprising:
an occluder, said occluder comprising a first component and a second component, wherein said first component is configured so that it may assume (i) a diametrically-reduced configuration for disposition within the lumen of a hollow tube, and (ii) a diametrically-expanded configuration for disposition adjacent to the hollow structure, whereby to occlude the hollow structure, and further wherein said second component percutaneously connects said first component to a site remote from said first component; and
[0059] positioning said occluder adjacent to the hollow structure so as to occlude the hollow structure.
[0060] In another form of the invention, there is provided an occluder for occluding a hollow structure, wherein the occluder is configured to be percutaneously delivered to an internal site and thereafter expanded so as to cause complete or partial occlusion of the hollow structure, and further wherein the occluder is configured so that the expansion of the occluder may thereafter be reversed in full or in part so as to completely or partially restore the hollow structure to its original condition.
[0061] In another form of the invention, there is provided a method for occluding a hollow structure, wherein an occluder is percutaneously delivered to an internal site and thereafter expanded so as to cause complete or partial occlusion of the hollow structure, and further wherein the occluder is configured so that the expansion of the occluder may thereafter be reversed in full or in part so as to completely or partially restore the hollow structure to its original condition.
[0062] In another form of the invention, there is provided apparatus for occluding a hollow structure, wherein the apparatus comprises an occluder, a device for percutaneously delivering the occluder to an internal site and deploying the occluder so that it completely or partially occludes the hollow structure, and a device for removing some or all of the occluder so as to completely or partially restore the hollow structure to its original condition.
[0063] In another form of the invention, there is provided a method for treating a patient, wherein the method comprises percutaneously delivering an occluder to an internal site so that it completely or partially occludes the hollow structure, and further wherein the method comprises thereafter removing some or all of the occluder so as to completely or partially restore the hollow structure to its original condition.
BRIEF DESCRIPTION OF THE DRAWINGS
[0064] These and other objects and features of the present invention will be more fully disclosed or rendered obvious by the following detailed description of the preferred embodiments of the invention, which is to be considered together with the accompanying drawings wherein like numbers refer to like parts, and further wherein:
[0065] FIG. 1 is a schematic view showing various aspects of the venous system of the leg;
[0066] FIGS. 2-4 are schematic views showing an occluder occluding a blood vessel in accordance with one form of the present invention;
[0067] FIG. 5 is a schematic view showing one possible construction for the occluder shown in FIGS. 2-4 ;
[0068] FIGS. 6 and 7 are schematic views showing an exemplary syringe-type inserter which may be used to deploy the occluder shown in FIGS. 2-4 ;
[0069] FIGS. 8-10 are schematic views showing an occluder occluding a blood vessel in accordance with another form of the present invention;
[0070] FIGS. 11-14 are schematic views showing an occluder occluding a blood vessel in accordance with still another form of the present invention;
[0071] FIGS. 15-17 are schematic views showing other possible constructions for the occluder of the present invention;
[0072] FIGS. 18-20 are schematic views showing the occluders of the types shown in FIGS. 15-17 occluding a blood vessel in accordance with yet another form of the present invention;
[0073] FIGS. 21-24 are schematic views showing an occluder occluding a blood vessel in accordance with another form of the present invention;
[0074] FIGS. 25-27 are schematic views showing an occluder occluding a blood vessel in accordance with still another form of the present invention;
[0075] FIGS. 28 and 29 are schematic views showing an occluder occluding a blood vessel in accordance with yet another form of the present invention;
[0076] FIGS. 30 and 31 are schematic views showing an occluder occluding a blood vessel in accordance with another form of the present invention;
[0077] FIGS. 32 and 33 are schematic views showing an occluder occluding a blood vessel in accordance with still another form of the present invention;
[0078] FIGS. 34 and 35 are schematic views showing a drug/cellular delivery body being attached to a blood vessel in accordance with one form of the present invention;
[0079] FIGS. 36 and 37 are schematic views showing a drug/cellular delivery body being attached to a blood vessel in accordance with another form of the present invention;
[0080] FIGS. 38 and 39 are schematic views showing a drug/cellular delivery body being attached to a blood vessel in accordance with still another form of the present invention;
[0081] FIGS. 40 and 41 are schematic views showing a drug/cellular delivery body being attached to a blood vessel in accordance with yet another form of the present invention;
[0082] FIGS. 42-48 are schematic views showing a two-part occluder formed in accordance with another form of the present invention;
[0083] FIGS. 49-58 are schematic views showing installation apparatus which may be used to deploy the two-part occluder of FIGS. 42-48 ;
[0084] FIGS. 59-82 are schematic views showing the two-part occluder of FIGS. 42-48 being deployed across a blood vessel using the installation apparatus of FIGS. 49-58 ;
[0085] FIGS. 83-86 are schematic views showing another two-part occluder formed in accordance with the present invention;
[0086] FIGS. 87-90 are schematic views showing still another two-part occluder formed in accordance with the present invention;
[0087] FIGS. 91-94 are schematic views showing yet another two-part occluder formed in accordance with the present invention;
[0088] FIGS. 95-100 are schematic views showing another two-part occluder formed in accordance with the present invention;
[0089] FIGS. 101-103 are schematic views showing a temporary occluder formed in accordance with the present invention;
[0090] FIGS. 104-107 are schematic views showing another temporary occluder formed in accordance with the present invention;
[0091] FIGS. 108-124 are schematic views showing still another temporary occluder formed in accordance with the present invention;
[0092] FIGS. 125 and 126 are schematic views showing yet another temporary occluder formed in accordance with the present invention;
[0093] FIGS. 127-142 are schematic views showing another temporary occluder formed in accordance with the present invention;
[0094] FIGS. 143-148 are schematic views showing still another temporary occluder formed in accordance with the present invention;
[0095] FIG. 149 is a schematic view showing yet another temporary occluder formed in accordance with the present invention; and
[0096] FIG. 150 is a schematic view showing another temporary occluder formed in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0097] The present invention provides a new and improved approach for treating varicose veins and other blood vessels.
[0098] More particularly, the present invention comprises the provision and use of a novel occluder which is used to occlude a vein (e.g., the proximal saphenous vein, the small saphenous vein, tributaries, the perforator veins, etc.) so as to restrict blood flow through the vein and thereby treat varicose veins below the point of occlusion. Significantly, the novel occluder is configured to be deployed using a minimally-invasive approach (i.e., either percutaneously or endoluminally), with visualization being provided by ultrasound and/or other visualization apparatus (e.g., CT, MRI, X-ray etc.). As a result, the novel treatment can be provided in a doctor's office, with minimal local anesthetic, and effectively no post-operative care.
Percutaneous Approach
[0099] In the percutaneous approach, the occluder is delivered by percutaneously advancing the occluder through the skin, through intervening tissue and then across some or all of the blood vessel (e.g., the great saphenous vein near the sapheno-femoral junction) so as to occlude the blood vessel. This occlusion (or multiple of these occlusions) will thereby treat varicose veins. In one form of the invention, the occluder is configured to occlude the vein by compressing the vein and closing down its lumen; and in another form of the invention, the occluder is configured to occlude the vein by depositing a mass within the lumen of the vein so as restrict blood flow through the lumen of the vein. The occlusion of the lumen may be complete or partial. If the occlusion is partial, some blood may continue to flow in the vein. Such partial occlusion can act to relieve some of the pressure on the valve, thereby improving its function. In some applications, an occlusion of 70% or greater of the lumen may be desired and realized based on the current invention. In other applications, an occlusion of 80% or greater of the lumen may be desired and realized based on the current invention. In one embodiment, the occlusion pressure applied may be greater than 40 mm of mercury. In another embodiment of the present invention, the occlusion pressure may be greater than the pressure of the typical blood flow in the vein.
[0100] Looking first at FIGS. 2-4 , in one form of the invention, there is provided an occluder 30 . Occluder 30 comprises an elastic filament 35 which, in an unconstrained condition, comprises a generally non-linear configuration (e.g., a coiled mass) but which, when properly restrained, can maintain a linear configuration (e.g., in the narrow lumen 40 of a needle 45 , or where the filament is formed out of a shape memory material, by appropriately controlling its temperature and hence its shape); when the restraint is removed (e.g., the elastic filament 35 is extruded from the constraining lumen 40 of the needle 45 , or the temperature of the shape memory material is elevated such as by body heat), elastic filament 35 will return to its generally non-linear configuration, whereby to provide enlarged masses for occluding the vein.
[0101] In one form of the invention, the occluder is formed out of a shape memory material (e.g., a shape memory alloy such as Nitinol, or a shape memory polymer), with the shape memory material being configured to provide superelasticity, or temperature-induced shape changes, or both).
[0102] In one preferred method of use, the occluder 30 is installed in the narrow lumen 40 of a needle 45 ( FIG. 2 ), the needle is introduced percutaneously and advanced across the vein which is to be occluded (e.g., the great saphenous vein 15 ), a first length of the occluder is extruded from the needle on the far side of the vein so that a portion of the occluder is restored to a coiled mass configuration 50 on the far side of the vein ( FIG. 3 ), the needle is withdrawn back across the vein, and then the remainder of the occluder is extruded on the near side of the vein ( FIG. 4 ), whereupon the remainder of the occluder is restored to a coiled mass configuration 55 , with a portion 57 of the occluder extending across the lumen 60 of the vein 15 , and with the portions of the occluder on the far and near sides of the vein (i.e., the coiled masses 50 and 55 , respectively) being drawn toward one another under the coiling force inherent in the elastic filament so as to compress the vein there between and occlude its lumen 60 , whereby to restrict blood flow through the vein and thereby treat the varicose veins.
[0103] As noted above, occluder 30 may be formed out of a shape memory material (e.g., a shape memory alloy such as Nitinol, or a shape memory polymer, etc.), with the shape memory material being configured to provide superelasticity, or temperature-induced shape changes, or both).
[0104] In the form of the invention shown in FIGS. 2-4 , occluder 30 is formed out of a single elastic filament 35 , and a shape transition (i.e., from substantially linear to a pair of opposing coiled masses 50 , 55 ) is used to cause occlusion of the target blood vessel. In this respect it should be appreciated that the aforementioned coiled masses 50 , 55 may comprise substantially random turns of the elastic filament arranged in a substantially three-dimensional structure (i.e., somewhat analogous to a ball of string), or the coiled masses 50 , 55 may comprise highly reproducible structures such as loops, coils, etc., and these loops, coils, etc. may or may not assume a substantially planar structure. See, for example, FIG. 5 , where coiled masses 50 , 55 comprise highly reproducible loops and coils.
[0105] FIGS. 6 and 7 show an exemplary syringe-type inserter 65 which may be used to deploy the novel occluder of the present invention. The syringe-type inserter 65 may contain one occluder 30 or multiple pre-loaded occluders 30 , e.g., where syringe-type inserter 65 comprises multiple occluders 30 , the occluders may be disposed serially within the syringe-type inserter, or they may be disposed parallel to one another within the syringe-type inserter (i.e., in the manner of a “Gatling gun” disposition), etc. When the syringe-type inserter 65 is activated, an occluder 30 is deployed out of the distal end of needle 45 .
[0106] In FIGS. 2-4 , occluder 30 is shown occluding the vein by compressing the vein between the two coiled masses 50 , 55 , whereby to close down its lumen 60 . However, in another form of the invention, the occluder 30 can be used to occlude the vein without compressing the vein. This is done by depositing a coiled mass within the lumen of the vein, whereby to restrict blood flow through the lumen of the vein. More particularly, and looking now at FIGS. 8-10 , in this form of the invention, the needle 45 is passed into the interior of the vein 15 and one coiled mass 50 of the occluder 30 is extruded into the lumen 60 of the vein ( FIG. 8 ) so as to occlude the lumen of the vein, the needle 45 is withdrawn to the near side of the vein ( FIG. 9 ), and then another coiled mass 55 is disposed on the near side of the vein ( FIG. 10 ), with the portion 57 of the occluder extending through the side wall of the vein so as to stabilize the occluder relative to the vein (i.e., so as to attach the occluder to the vein and prevent the occluder from moving relative to the vein).
[0107] FIGS. 11-14 show another approach where a coiled mass of the occluder 30 is deposited within the interior of the blood vessel so as to obstruct blood flow through the vessel. More particularly, in this form of the invention, the needle 45 is passed completely through the vein ( FIG. 11 ), a coiled mass 50 of the occluder is deposited on the far side of the vein ( FIG. 12 ), the needle is withdrawn into the interior of the vein where another coiled mass 55 of the occluder is deposited ( FIG. 13 ), and then the needle is withdrawn to the near side of the vein where another coiled mass 70 of the occluder 30 is deposited ( FIG. 14 ). In this form of the invention, coiled mass 55 resides within the lumen 60 of the vein and obstructs blood flow while coiled masses 50 and 70 compress the vein inwardly and stabilize the disposition of the intraluminal coiled mass 55 .
[0108] FIGS. 15 and 16 show occluders 30 formed out of a single strand of elastic filament. In FIG. 15 , the occluder 30 comprises a relatively ordered coil where the turns 72 of the coil are unidirectional. In FIG. 16 , the occluder 30 comprises another relatively ordered coil but where the turns rotate in opposite directions on different sides of a midpoint 75 . Of course, it should also be appreciated that the occluder 30 can be constructed so as to form a relatively disordered coil, i.e., where the strand of the filament follows a relatively random pattern (see, for example, the disordered coils illustrated in FIGS. 8-10 ). Indeed, where it is desired that the mass of the reformed coil itself provide a flow obstruction (e.g., where the reformed coil is disposed intraluminally so as to impede blood flow through the vein), it is generally preferred that the elastic filament reform into a relatively disordered coil having a relatively random disposition, since this can provide a denser filament configuration.
[0109] FIG. 17 shows an occluder 30 formed out of multiple strands of elastic filaments 35 . In one form of the invention, these multiple strands are joined together at a joinder 80 . Again, the coils (e.g., the aforementioned coiled masses 50 , 55 , 70 ) formed by these multiple strands can be relatively ordered or relatively disordered. FIGS. 18 and 19 show how the multistrand occluder of FIG. 17 can be used to occlude a vein by forming coiled masses 50 , 55 to compress the side wall of the vein inwardly so as to restrict blood flow through the vein. FIG. 20 shows how the multi-strand occluder 30 of FIG. 17 can be used to occlude a vein by depositing a coiled mass 55 within the lumen 60 of the vein, whereby to restrict blood flow through the lumen of the vein. In FIG. 20 , a number of the elastic filaments 35 are shown piercing the side wall of the vein so as to hold the coiled mass 55 in position within the lumen of the blood vessel.
[0110] FIGS. 21-24 show another form of occluder 30 where the occluder is formed by structures other than a filament. By way of example but not limitation, the occluder 30 may comprise a transluminal section 85 , a far side lateral projection 90 and a near side lateral projection 95 , with the far side lateral projection 90 and the near side lateral projection 95 being held in opposition to one another so as to close down the lumen 60 of the vein 15 . Such an arrangement may be provided by many different types of structures, e.g., such as the “double T-bar” structure shown in FIGS. 25-27 where the transluminal section 85 of the occluder 30 is formed out of an elastic material which draws the two opposing T-bars 90 , 95 of the occluder together so as to provide vessel occlusion. Still other arrangements for connecting and drawing together a far side lateral projection 90 and a near side lateral projection 95 will be apparent to those skilled in the art in view of the present disclosure. By way of further example but not limitation, far side lateral projection 90 and near side lateral projection 95 may be connected together by a loop of suture, with the loop of suture being lockable in a reduced size configuration (i.e., so as to maintain occlusion) with a sliding locking knot.
[0111] Furthermore, multiple occluders 30 may be used on a single blood vessel or tissue to occlude the blood vessel more completely, or to occlude a blood vessel in multiple regions, or to attach a material (e.g., a drug or cellular delivery element) in multiple places to the blood vessel. The occluders may be coated with a drug-eluting compound, or the occluders may be electrically charged to enhance or prevent clotting or to deliver a desired compound or agent to the blood vessel, etc. If desired, the location of the occluding or attachment element may be precisely controlled to deliver the desired compound or agent at a specific anatomical location.
Endoluminal Approach
[0112] In the endoluminal approach, the occluder 30 is delivered to the occlusion site by endoluminally advancing the occluder up the vein using a catheter, and then deploying the occluder in the vein, with the occluder acting to occlude the vein and thereby treat varicose veins. In this form of the invention, the occluder is preferably passed through one or more side walls of the vein so as to stabilize the occluder relative to the vein. In one form of the invention, the occluder is configured to occlude the vein by depositing a mass within the lumen of the vein so as to restrict blood flow through the lumen of the vein; and in another form of the invention, the occluder is configured to occlude the vein by compressing the vein and closing down its lumen.
[0113] More particularly, and looking now at FIGS. 28 and 29 , a catheter 100 is used to endoluminally advance the occluder 30 up the interior of the vein 15 to a deployment site. Then one end of the occluder is passed through the side wall of the vein so as to deposit a coiled mass 50 of the occluder 30 outside the vein, and the remainder of the occluder is deposited as a coiled mass 55 within the lumen 60 of the vein, with a portion 57 of the occluder extending through the side wall of the vein so as to attach the occluder to the side wall of the vein and thereby stabilize the occluder relative to the vein. Thus, in this form of the invention, a coiled mass 55 of the occluder is deposited within the interior of the vein so as to restrict blood flow through the vein and thereby treat varicose veins.
[0114] FIGS. 30 and 31 show how two separate occluders 30 , each used in the manner shown in FIGS. 28 and 29 , can be used to increase the coiled mass of occluder contained within the lumen of the vein, whereby to increase the extent of occlusion of the lumen of the vein.
[0115] FIGS. 32 and 33 show how an occluder 30 can be delivered endoluminally and used to compress the outer walls of the vein so as to occlude blood flow through the lumen of the vein. More particularly, in this form of the invention, the occluder 30 is advanced endoluminally through the vein to the deployment site, one end of the occluder is passed through one side wall of the vein so as to deposit a coiled mass 50 on one side of the vein and the other end of the occluder is passed through the other side wall of the vein so as to deposit another coiled mass 55 on the other side of the vein, with the two coiled masses being connected together by the intermediate portion 57 of the occluder and with the two coiled masses being drawn toward one another under the coiling force inherent in the elastic filament so as to apply compressive opposing forces on the two sides of the vein, whereby to compress the vein and close down its lumen.
Occlusion in Combination with Phlebectomy
[0116] If desired, the novel occluder of the present invention can be used in conjunction with the removal of the large varicose veins (i.e., phlebectomy). The phlebectomy can be done at the same time as the occlusion of the vein or at another time. For this surgical procedure, minimal local anesthetic is needed.
Occluding Tubular Structures for Purposes Other than Treating Varicose Veins
[0117] It will be appreciated that the novel occluder of the present invention can also be used to occlude tubular structures for purposes other than treating varicose veins. By way of example but not limitation, the novel occluder of the present invention can be used to occlude other vascular structures (e.g., to occlude arteries so as to control bleeding), or to occlude other tubular structures within the body (e.g., phallopian tubes, so as to induce infertility), etc.
Drug/Cellular Delivery Applications
[0118] Furthermore, using the foregoing concept of minimally-invasive hollow tube penetration, and attachment and fixation of the device to the vessel wall, either percutaneously or endoluminally, the occluder 30 may be modified so as to allow drug/cellular delivery at fixed points within or adjacent to the vasculature or other hollow bodily structure. In this form of the invention, the device functions as a drug/cellular delivery stabilizer, and may or may not function as an occluder. See, for example, FIGS. 34 and 35 , where an elastic filament 35 , having a drug/cellular delivery body 105 attached thereto, is advanced across a blood vessel 110 using a needle 115 , with the distal end of the elastic filament forming a coiled mass 120 on the far side of the blood vessel and the drug/cellular delivery body 105 being securely disposed within the lumen 125 of the blood vessel. FIGS. 36 and 37 show a similar arrangement where a catheter 130 is used to deliver the device endoluminally. FIGS. 38 and 39 show another arrangement wherein the device is delivered percutaneously so that the coiled mass is disposed inside lumen 125 of the blood vessel and the drug/cellular delivery body 105 is disposed outside the blood vessel, and FIGS. 40 and 41 show how the device is delivered endoluminally so that the coiled mass is disposed inside lumen 125 of the blood vessel and the drug/cellular delivery body 105 is disposed outside the blood vessel. These drug/cellular delivery devices may be passive or active polymers or silicon-based or micro- and nanotechnology devices, or matrices of materials, etc.
Two-Part Occluder
[0119] Looking next at FIG. 42 , there is shown a two-part occluder 200 formed in accordance with the present invention. Two-part occluder 200 generally comprises a distal implant 205 and a proximal implant 210 .
[0120] Distal implant 205 is shown in further detail in FIGS. 43-46 . Distal implant 205 comprises a distal implant body 215 and a distal implant locking tube 220 . Distal implant body 215 comprises a tube 225 having a distal end 226 , a proximal end 227 , and a lumen 230 extending therebetween. Tube 225 is slit intermediate its length so as to define a plurality of legs 235 . A set of inwardly-projecting tangs 240 are formed in tube 225 between legs 235 and proximal end 227 . A set of windows 245 are formed in tube 225 between inwardly-projecting tangs 240 and proximal end 227 . Distal implant body 215 is preferably formed out of an elastic material (e.g., a shape memory material having superelastic properties such as Nitinol or superelastic polymers, including superelastic plastics) and constructed so that its legs 235 normally project laterally away from the longitudinal axis of tube 225 (e.g., in the manner shown in FIGS. 43 and 44 ), however, due to the elastic nature of the material used to form distal implant body 215 , legs 235 can be constrained inwardly (e.g., within the lumen of a delivery needle, as will hereinafter be discussed) so that distal implant body 215 can assume a substantially linear disposition. See, for example, FIG. 46 , which shows legs 235 moved inwardly relative to the position shown in FIGS. 43 and 44 . However, when any such constraint is removed, the elastic nature of the material used to form distal implant body 215 causes legs 235 to return to the position shown in FIGS. 43 and 44 .
[0121] Distal implant locking tube 220 ( FIG. 45 ) comprises a generally tubular structure having a distal end 250 , a proximal end 260 and a lumen 262 extending therebetween. A set of windows 265 are formed in the distal implant locking tube 220 , with windows 265 being disposed distal to proximal end 260 .
[0122] Distal implant locking tube 220 is disposed within lumen 230 of distal implant body 215 . When distal implant 205 is in its aforementioned substantially linear condition (i.e., with legs 235 restrained in an in-line condition), distal implant locking tube 220 terminates well short of tangs 240 of distal implant body 215 , so that the proximal end 227 of distal implant body 215 can move longitudinally relative to distal end 226 of distal implant body 215 . However, when the proximal end 227 of distal implant body 215 is moved distally a sufficient distance to allow full radial expansion of legs 235 (see FIG. 42 ), locking tangs 240 of distal implant body 215 will be received within windows 265 of distal implant locking tube 220 , whereby to lock distal implant 205 in its radially-expanded condition (i.e., with legs 235 projecting laterally away from the longitudinal axis of tube 225 , e.g., in the manner shown in FIGS. 43 and 44 ). Spot welds applied via openings 270 formed in the distal end 226 of distal implant body 215 serve to lock distal implant locking tube 220 to distal implant body 215 , whereby to form a singular structure (see FIGS. 43 and 46 ).
[0123] Looking next at FIGS. 47 and 48 , proximal implant 210 comprises a tube 275 having a distal end 280 , a proximal end 285 , and a lumen 290 extending therebetween. Tube 275 is slit at its distal end so as to define a plurality of legs 295 . A set of inwardly-projecting tangs 300 are formed in tube 275 between legs 295 and proximal end 285 . Proximal implant 210 is preferably formed out of an elastic material (e.g., a shape memory material having superelastic properties such as Nitinol) and constructed so that its legs 295 normally project laterally away from the longitudinal axis of tube 275 (e.g., in the manner shown in FIG. 47 ), however, legs 295 can be constrained inwardly (e.g., within the lumen of a delivery tube, as will hereinafter be discussed) so that proximal implant 210 can assume a substantially linear disposition. See, for example, FIG. 48 , which shows legs 295 moved inwardly relative to the position shown in FIG. 47 . However, when any such constraint is removed, the elastic nature of the material used to form proximal implant 210 causes legs 295 to return to the position shown in FIG. 47 .
[0124] As will hereinafter be discussed, distal implant 205 and proximal implant 210 are configured and sized so that tube 225 of distal implant body 215 can be received in lumen 290 of proximal implant 210 , with the expanded legs 235 of distal implant 205 opposing the expanded legs 295 of proximal implant 210 (see, for example, FIG. 82 ), whereby to impose a clamping action on the side wall of a blood vessel (e.g., vein) disposed therebetween and thereby occlude the blood vessel, as will hereinafter be discussed in further detail (or, as an alternative, the opposing expanded legs of the proximal and distal implants could interdigitate to impose the clamping action). Furthermore, distal implant 205 and proximal implant 210 are configured and sized so that they may be locked in this position, inasmuch as inwardly-projecting tangs 300 of proximal implant 210 will project into windows 245 of distal implant 205 .
[0125] Two-part occluder 200 is intended to be deployed using associated installation apparatus. This associated installation apparatus preferably comprises a hollow needle 305 ( FIG. 49 ) for penetrating tissue, a distal implant delivery tube 310 ( FIG. 50 ) for delivering distal implant 205 through hollow needle 305 to the far side of the blood vessel which is to be occluded, a composite guidewire 315 ( FIGS. 51-56 ) for supplying support to various components during delivery and deployment, a push rod 320 ( FIG. 57 ) for delivering various components over composite guidewire 315 , and a proximal implant delivery tube 330 ( FIG. 58 ) for delivering proximal implant 210 for mating with distal implant 205 , as will hereinafter be discussed.
[0126] Hollow needle 305 ( FIG. 49 ) comprises a distal end 335 , a proximal end 340 and a lumen 345 extending therebetween. Distal end 335 terminates in a sharp point 350 . In one preferred form of the invention, hollow needle 305 comprises a side port 355 which communicates with lumen 345 .
[0127] Distal implant delivery tube 310 ( FIG. 50 ) comprises a distal end 360 , a proximal end 365 and a lumen 370 extending therebetween.
[0128] Composite guidewire 315 ( FIGS. 51-56 ) comprises a guidewire rod 370 and a guidewire sheath 380 . Guidewire rod 370 comprises a distal end 385 and a proximal end 390 . Distal end 385 terminates in an enlargement 395 . Guidewire sheath 380 comprises a distal end 400 , a proximal end 405 and a lumen 410 extending therebetween. The distal end 400 of guidewire sheath 380 comprises at least one, and preferably a plurality of, proximally-extending slits 415 . Proximally-extending slits 415 open on the distal end of guidewire sheath 380 and allow the distal end of guidewire sheath 380 to radially expand somewhat. As will hereinafter be discussed, guidewire rod 370 and guidewire sheath 380 are configured and sized so that guidewire rod 370 can be received in lumen 410 of guidewire sheath 380 . Furthermore, when guidewire rod 370 is forced proximally relative to guidewire sheath 380 , the proximally-extending slits 415 in guidewire sheath 380 allow the distal end of the guidewire sheath 380 to expand somewhat so as to receive at least some of the enlargement 395 formed on the distal end of guidewire rod 370 . As this occurs, the distal end of guidewire sheath 380 will expand radially.
[0129] Push rod 320 ( FIG. 57 ) comprises a distal end 420 , a proximal end 425 and a lumen 430 extending therebetween.
[0130] Proximal implant delivery tube 330 ( FIG. 58 ) comprises a distal end 435 , a proximal end 440 and a lumen 445 extending therebetween.
[0131] Two-part occluder 200 and its associated installation apparatus are preferably used as follows.
[0132] First, hollow needle 305 (carrying distal implant delivery tube 310 therein, which in turn contains the composite guidewire 315 therein, upon which is mounted distal implant 205 ) is passed through the skin of the patient, through intervening tissue, and across the blood vessel (e.g., vein 450 ) which is to be occluded. See FIGS. 59-61 . As this is done, any blood flowing out side port 355 can be monitored—excessive or pulsatile blood flow can indicate that hollow needle has accidentally struck an artery.
[0133] Next, hollow needle 305 is retracted, leaving distal implant delivery tube 310 extending across the blood vessel. See FIG. 62 .
[0134] Then distal implant delivery tube 310 is retracted somewhat so as to expose the distal ends of composite guidewire, or rod, 315 and distal implant 205 . See FIG. 63 .
[0135] Next, composite guidewire 315 , push rod 320 and distal implant 205 are all moved distally, so as to advance the distal ends of composite guidewire 315 and the distal implant 205 out of the distal end of distal implant delivery tube 310 . As this occurs, legs 235 of distal implant 205 are released from the constraint of distal implant delivery tube 310 and expand radially. See FIGS. 64 and 65 .
[0136] Then, with push rod 320 being held in place against the proximal end of distal implant 205 , composite guidewire 315 is pulled proximally so as to bring the distal end of distal implant 205 toward the proximal end of distal implant 205 , whereby to cause locking tangs 240 of distal implant body 215 to enter windows 265 of distal implant locking tube 220 , whereby to lock legs 235 in their radially-expanded condition (see FIG. 66 ).
[0137] At this point, hollow needle 305 , distal implant delivery tube 310 and push rod 320 may be removed ( FIG. 67 ), leaving distal implant 205 mounted on composite guidewire 315 , with the legs 235 fully deployed on the far side of the blood vessel and the proximal end of distal implant 205 extending into the interior of the blood vessel ( FIG. 68 ).
[0138] Next, proximal implant delivery tube 330 (carrying proximal implant 210 therein) is advanced down composite guidewire 315 , until the distal end of proximal implant delivery tube 330 sits just proximal to the blood vessel ( FIGS. 69-72 ).
[0139] Then push rod 320 is used to advance the distal end of proximal implant 210 out of the distal end of proximal implant delivery tube 330 . As this occurs, legs 295 are released from the constraint of proximal implant delivery tube 330 and open radially. See FIGS. 73-76 .
[0140] Next, using push rod 320 , proximal implant 210 is pushed distally as distal implant 205 is pulled proximally using composite guidewire 315 . More particularly, guidewire rod 370 is pulled proximally, which causes enlargement 395 on the distal end of guidewire rod 370 to expand guidewire sheath 380 to a size larger than lumen 262 in distal implant locking tube 220 , which causes guidewire sheath 380 to move proximally, which causes proximal movement of distal implant 205 . As distal implant 205 and proximal implant 210 move together, their legs 235 , 295 compress the blood vessel, thereby occluding the blood vessel. Distal implant 205 and proximal implant 210 continue moving together until inwardly-projecting tangs 300 of proximal implant 210 enter windows 245 of distal implant 205 , thereby locking the two members into position relative to one another. See FIG. 77 .
[0141] At this point push rod 320 and proximal implant delivery tube 330 are removed. See FIG. 78 .
[0142] Next, composite guidewire 315 is removed. This is done by first advancing guidewire rod 370 distally ( FIG. 79 ), which allows the distal end of guidewire sheath 380 to relax inwardly, thereby reducing its outer diameter to a size smaller than lumen 262 in distal implant locking tube 220 . As a result, guidewire sheath 380 can then be withdrawn proximally through the interior of two-part occluder 200 . See FIG. 80 . Then guidewire rod 370 can be withdrawn proximally through the interior of two-part occluder 200 . See FIG. 81 .
[0143] The foregoing procedure leaves two-part occluder 200 locked in position across the blood vessel, with the opposing legs 235 , 295 compressing the blood vessel, whereby to occlude the blood vessel.
[0144] FIGS. 83-86 illustrate another two-part occluder 200 A having a distal implant 205 A and a proximal implant 210 A. Two-part occluder 200 A is generally similar to the aforementioned two-part occluder 200 , except that distal implant 205 A utilizes a unibody construction.
[0145] FIGS. 87-90 illustrate another two-part occluder 200 B. Two-part occluder 200 B is generally similar to the aforementioned two-part occluder 200 A, except that distal implant 205 B utilizes a friction fit to lock distal implant 205 B to proximal implant 210 B.
[0146] FIGS. 91-94 illustrate another two-part occluder 200 C having a distal implant 205 C and a proximal implant 210 C. Two-part occluder 200 C is generally similar to the aforementioned two-part occluder 200 , except that distal implant 205 C comprises a tube 225 C which receives and secures the proximal ends of legs 235 C. Legs 235 C are preferably elongated elements (e.g., bent wires) formed out of a superelastic shape memory material so as to provide the legs 235 C with the desired degree of elasticity.
[0147] FIGS. 95-100 illustrate another two-part occluder 200 D having a distal implant 205 D and a proximal implant 210 D. Two-part occluder 200 D is generally similar to the aforementioned two-part occluder 200 , except that distal implant 205 D comprises a tube or rod 225 D which receives and secures the proximal ends of legs 235 D. Legs 235 D are preferably coils formed out of a superelastic shape memory material so as to provide the legs 235 D with the desired degree of elasticity.
[0148] In the foregoing disclosure, there is a disclosed a composite guidewire 315 for use in delivering distal implant 205 and proximal implant 210 to the anatomy. As noted above, composite guidewire 315 is formed from two parts, i.e., a guidewire rod 370 and a guidewire sheath 380 . By providing composite guidewire 315 with this two-part construction, composite guidewire 315 can have its distal diameter enlarged or reduced as desired so as to permit composite guidewire 315 to bind to distal implant 205 , or be separable from the distal implant 205 , respectively. However, if desired, composite guidewire 315 can be replaced by an alternative guidewire which includes a mechanism for releasably binding the alternative guidewire to distal implant 205 . By way of example but not limitation, such an alternative guidewire may include screw threads, and distal implant 205 may include a screw recess, so that the alternative guidewire can be selectively secured to, or released from, the distal implant 205 , i.e., by a screwing action.
Temporary Blood Vessel Occlusion for Extremity Trauma
[0149] Uncontrolled hemorrhage remains the most significant cause of death in victims who survive a major initial trauma, particularly in truncal and extremity injuries. A loss of 50% of blood volume without replenishment is frequently fatal, and a hypotensive patient, who has lost 30%-35% of blood volume and is in uncompensated shock, is generally close to death.
[0150] Establishing and maintaining hemostasis at the site of an injury is an important consideration in the acute management of trauma patients. The tourniquet, with or without local compression, remains the time-honored method for controlling extremity bleeding following trauma. However, tourniquets are generally only useful for controlling bleeding in limbs, and even then tourniquets suffer from the disadvantage that they limit blood flow to the entire limb and cannot target individual blood vessels within the limb. It is estimated that of all military wounded whom ultimately succumb to their wounds, approximately 10-20% die from blood loss due to inadequate compression or tourniquet application.
[0151] Thus there is also a need for effective temporary blood vessel occlusion for military and civilian trauma cases.
[0152] In addition to trauma applications, there are many instances where an occlusion device may be implanted and then, at a later time (e.g., days, months, years), may be removed. Examples of such uses of temporary occlusion devices include reversible occlusion of fallopian tubes, temporary occlusion of the saphenous vein during pregnancy and subsequent removal of the occlusion device at the conclusion of pregnancy so as to restore blood flow through, etc.
[0153] The present invention also envisions deployment of temporary occlusion devices that can be left in the body permanently.
[0154] The present invention also provides a novel temporary occlusion device (hereinafter sometimes referred to as a “temporary occluder”) that can be deployed percutaneously to temporarily occlude major blood vessels (e.g., arteries) until specialized care can be obtained to surgically control massive hemorrhage following civilian or military trauma. The novel temporary occluder of the present invention may be used as an alternative to a conventional tourniquet to control major extremity bleeding following trauma, providing a more effective, reliable and highly targeted method to control major blood vessel hemorrhage. Furthermore, unlike a conventional tourniquet, the temporary occluder of the present invention may be used even in the presence of soft tissue injury with minimal patient discomfort. Once deployed, minimal post-deployment supervision is required during the time required to transport the patient to the specialized care required to surgically repair the damaged blood vessel. The present invention requires accessing the damaged blood vessel (e.g., major artery) with a needle or other device, but this is typically within the level of expertise expected of the average military medic or civilian emergency medical technician. The utilization of ultrasound to identify and access the damaged blood vessel significantly simplifies the temporary occlusion procedure. Deployment comprises passing a portion of the temporary occluder across the blood vessel (e.g., artery) so that a distal portion of the temporary occluder bears against the outside surface of the blood vessel on the far side of the blood vessel, and positioning a proximal portion of the temporary occluder against the outside surface of the blood vessel on the near side of the blood vessel, or against the outside surface of the skin, whereby to establish an occluding compression across the blood vessel. Once deployed, removal of the temporary occluder may be performed in the specialized care center at the appropriate time. Following removal of the temporary occluder, hemostasis of the punctures caused by deployment of the temporary occluder across the blood vessel may be obtained with standard manual compression of the blood vessel, thus minimizing the need for further blood vessel repair. Alternatively, other means such as cauterization of the tissue, deploying a polymeric sealant, or deploying gauze or a pad, or positioning a coated stent in the vessel, may be used to arrest blood flow.
[0155] Looking now at FIGS. 101-103 , there is shown a temporary occluder 500 formed in accordance with the present invention. Temporary occluder 500 may be used percutaneously to temporarily occlude a blood vessel 505 disposed beneath the surface of skin 510 , wherein intervening tissue 512 is disposed between the surface of skin 510 and blood vessel 505 .
[0156] Temporary occluder 500 generally comprises a distal portion 515 and a proximal portion 520 . Distal portion 515 generally comprises a cylindrical body 525 having a plurality of laterally-expandable legs 530 connected thereto. By way of example but not limitation, distal portion 515 may be formed out of a Nitinol cylinder having distal slits formed therein, whereby to form cylindrical body 525 and laterally-expandable legs 530 . Proximal portion 520 generally comprises a cylindrical body 535 having a plurality of laterally-expandable legs 540 connected thereto. By way of example but not limitation, proximal portion 520 may be formed out of a Nitinol cylinder having proximal slits formed therein, whereby to form cylindrical body 535 and laterally-expandable legs 540 . In one embodiment, each laterally-expandable leg 530 , 540 is designed with an appropriate length to minimize penetration into any tissues which may reside adjacent to the blood vessel. In one embodiment, each laterally-expandable leg 530 , 540 is less than about 20 mm in length. In one embodiment, the cylindrical bodies 525 , 535 are both less than about 18 gauge. Distal portion 515 is sized to be concentrically received within proximal portion 520 (see FIG. 101 ). In one preferred form of the invention, cylindrical body 535 of proximal portion 520 is approximately aligned with the distal ends of laterally-expandable legs 530 of distal portion 515 , and cylindrical body 525 of distal portion 515 is approximately aligned with the proximal ends of laterally-expandable legs 540 of proximal portion 520 .
[0157] Temporary occluder 500 also comprises a flexible filament 545 having a distal end 550 and a proximal end 555 ( FIG. 103 ). Distal end 550 of flexible filament 545 is secured to cylindrical body 525 of distal portion 515 .
[0158] Temporary occluder 500 is intended to be deployed using a needle 560 , or other tubular element. Needle 560 comprises a distal end 565 , a proximal end 570 and a lumen 575 extending therebetween. Needle 560 is sized to slidably receive temporary occluder 500 within its lumen 575 .
[0159] In use, and looking now at FIG. 101 , needle 560 , carrying temporary occluder 500 therein, with flexible filament 545 extending from proximal end 570 of needle 560 , is advanced through the skin 510 of the patient, through the intervening tissue 512 , and across the blood vessel 505 which is to be occluded. Then distal portion 515 of temporary occluder 500 is pushed out of needle 560 so that laterally-expandable legs 530 of distal portion 515 deploy on the far side of blood vessel 505 . As distal portion 515 of temporary occluder 500 is pushed out of needle 560 , cylindrical body 525 of distal portion 515 is set so that it is approximately aligned with cylindrical body 535 of proximal portion 520 . Then needle 560 is withdrawn proximally, allowing laterally-expandable legs 540 of proximal portion 520 to deploy on the near side of blood vessel 505 , with laterally-expandable legs 530 of distal portion 515 cooperating with laterally-expanding legs 540 of proximal portion 520 so as to occlude blood vessel 505 ( FIG. 102 ). Needle 560 may then be completely removed, leaving flexible filament 545 extending from the occlusion site up to the surface of the skin 510 .
[0160] Thereafter, when occlusion of blood vessel 505 is no longer necessary, the proximal end 555 of flexible filament 545 (which extends above the surface of skin 510 ) is pulled proximally, whereby to pull distal portion 515 of temporary occluder 500 free of proximal portion 520 of temporary occluder 500 , and thereby restore normal blood flow through blood vessel 505 ( FIG. 103 ).
[0161] In another embodiment of the present invention, the laterally-expandable legs 530 , 540 may be replaced by resilient (e.g., polymer) disks or umbrella structures that can open laterally.
[0162] In another form of the invention, and looking now at FIGS. 104-107 , temporary occluder 500 omits the aforementioned flexible filament 545 , and instead provides an introducer 580 for deploying temporary occluder 500 out of needle 560 ( FIGS. 104 and 105 ). However, in this form of the invention, introducer 580 is withdrawn with needle 560 , leaving the deployed temporary occluder 500 isolated at the occlusion site.
[0163] When occlusion of blood vessel 505 is no longer necessary, a guidewire 585 is passed down the lumen 590 of blood vessel 505 and through the deployed temporary occluder 500 . Then an appropriately-sized, non-compliant balloon 595 (e.g., an angioplasty balloon) is advanced, in its deflated state, over guidewire 585 until balloon 595 spans temporary occluder 500 . Then balloon 595 is expanded ( FIG. 106 ) so as to separate distal portion 515 of temporary occluder 500 from proximal portion 520 of temporary occluder 500 , thereby restoring normal blood flow through blood vessel 505 . Finally balloon 595 and guidewire 585 are withdrawn ( FIG. 107 ).
[0164] The balloon 595 may also be made out of an elastomer, e.g., latex or silicone. The balloon 595 may be filled with water or a compound of higher molecular weight than air. The balloon 595 may also be inflated with a polymer that hardens in situ, for applications where it is desirable to permanently maintain occlusion of the blood vessel.
[0165] Alternatively, balloon 595 may be inflated with a polymer that hardens in situ and thereafter bio-degrades over time.
[0166] Looking next at FIG. 108 , in another form of the invention, there is provided a temporary occluder 600 . Temporary occluder 600 generally comprises a filament 605 having a distal portion 610 attached thereto, and a proximal portion 615 . Distal portion 610 comprises a plurality of laterally-expanding legs 620 secured to distal portion 610 .
[0167] Temporary occluder 600 is intended to be deployed using a needle, e.g., the aforementioned needle 560 ( FIG. 109 ).
[0168] In use, and looking now at FIGS. 110-124 , when blood vessel 505 is to be occluded ( FIG. 110 ), filament 605 is loaded into lumen 575 of needle 560 so that distal portion 610 of temporary occluder 600 has its laterally-expanding legs 620 contained within distal end 565 of needle 560 . This may be accomplished by feeding the proximal end 625 ( FIG. 108 ) of filament 605 into distal end 565 of needle 560 , advancing proximal end 625 of filament 605 out of proximal end 570 of needle 560 , and then pulling on proximal end 625 of filament 605 so that laterally-expanding legs 620 are drawn into distal end 565 of needle 560 . Then needle 560 , carrying filament 605 and distal portion 610 therein, is advanced through skin 510 ( FIG. 111 ), through intervening tissue 512 ( FIG. 112 ) and then across the blood vessel 505 which is to be occluded, so that the distal end of needle 560 resides on the far side of the blood vessel ( FIG. 113 ). Then filament 605 is advanced distally so that laterally-expanding legs 620 of distal portion 610 are pushed out of distal end 565 of needle 560 , whereupon the laterally-expanding legs 620 expand ( FIG. 114 ). Then needle 560 is retracted, and proximal portion 615 of temporary occluder 600 is advanced distally along needle 560 and filament 605 so that proximal portion 615 of temporary occluder 600 presses against the outer surface of the skin 510 , whereby to compress blood vessel 505 and the intervening tissue 512 ( FIGS. 115 and 116 ). Then proximal portion 615 of temporary occluder 600 is locked or secured in place ( FIG. 117 ). At this point needle 560 may be completely withdrawn, leaving blood vessel 505 occluded ( FIG. 118 ).
[0169] When occlusion is to be thereafter withdrawn, proximal portion 615 of temporary occluder 600 is removed ( FIG. 119 ), needle 560 is advanced back down filament 605 ( FIG. 120 ), through skin 510 , through intervening tissue 512 , through blood vessel 505 ( FIG. 121 ) and then over laterally-expanding legs 620 ( FIG. 122 ), causing laterally-expanding legs 620 to enter the interior of needle 560 , collapsing laterally-expanding legs 512 in the process. Then needle 560 is withdrawn ( FIG. 123 ), carrying filament 605 and distal portion 610 of temporary occluder 600 with it ( FIG. 124 ).
[0170] FIGS. 125 and 126 show a temporary occluder 625 which comprises another form of the invention. Temporary occluder 625 is substantially the same as the two-part occluder 200 A shown in FIGS. 83-86 , except that (i) temporary occluder 625 comprises a distal implant 630 having a distal implant body 635 of increased length sufficient to protrude above the surface of skin 510 , and a proximal implant 640 having a proximal implant body 645 of increased length sufficient to protrude above the surface of skin 510 , and (ii) temporary occluder 625 comprises fingers 650 on proximal implant body 645 allowing proximal implant 640 to be unlocked from distal implant 630 when desired.
[0171] FIG. 127 shows a temporary occluder 655 which comprises another form of the invention. Temporary occluder 655 is substantially the same as the two-part occluder 200 A shown in FIGS. 83-86 , i.e., it comprises a distal implant 660 and a proximal implant 665 , etc., except that in this form of the invention, the proximal end of distal implant 660 is threaded (not shown) as will hereinafter be discussed.
[0172] In this form of the invention, when temporary occluder 655 is to be removed from the patient, a removal device 670 is advanced through skin 510 and intervening tissue 512 until the distal tip 675 of removal device 670 contacts the proximal end of proximal implant 665 ( FIG. 128 ). Ultrasound guidance may be used to facilitate such docking. Then a shaft 680 is extended out of removal device 670 and threaded into distal implant 660 ( FIGS. 128 and 129 ). Next, a pusher tube 685 is advanced over shaft 680 and unlatches proximal implant 665 from distal implant 660 ( FIGS. 130 and 131 ). Pusher tube 685 itself latches onto proximal implant 665 using latching grooves 690 formed in pusher tube 685 , which receive latches 695 of proximal implant 665 ( FIG. 132 ) so as to effect the desired connection. Then shaft 680 is pulled proximally, pulling distal implant 660 through pusher tube 685 and out of the patient ( FIGS. 133-137 ). Next, an external sheath 700 is extended down over pusher tube 685 ( FIG. 138 ) whereby to capture proximal implant 665 , within the external sheath, whereupon proximal implant 665 is removed from the surgical site by pulling pusher tube 685 out of the patient through external sheath 700 ( FIGS. 139 and 140 ). Finally, external sheath 700 is removed from the patient ( FIGS. 141 and 142 ). It should also be appreciated that various other means of attachment and securing the various elements will be apparent to those skilled in the art in view of the present disclosure.
[0173] In another form of the invention, and looking now at FIGS. 143-148 , a pair of balloons 705 , which may be made of a polymer, or a thin metal or other material, and may be made out of an elastomer, e.g., latex or silicone, are selectively inflated by an inflation line 710 , may be used to establish temporary occlusion of a blood vessel. More particularly, as seen in FIGS. 143 and 144 a needle 560 is passed from the surface of the skin 510 , through intervening tissue 512 and through a blood vessel 505 . Then a deflated balloon 705 (and its inflation line 710 ) is passed through needle 560 and the needle is deployed on the far side of blood vessel 505 ( FIG. 145 ). Then needle 560 is retracted, paying out inflation line 710 as it goes ( FIG. 146 ). On the near side of blood vessel 505 , a second balloon 505 is positioned (in its deflated condition) on the near side of blood vessel 505 , and then needle 560 , paying out inflation line 710 as it goes, is retracted out of the tissue ( FIG. 147 ). Then inflation line 710 is used to inflate both balloons 705 , whereby to occlude blood vessel 505 ( FIG. 148 ).
[0174] When temporary occlusion is to be withdrawn, balloons 705 are deflated using inflation line 710 , and then the two balloons are pulled free of the anatomy by pulling proximally on inflation line 710 .
[0175] In another form of the invention, and looking now at FIG. 149 , a balloon 705 may be positioned on the far side of the blood vessel, a cap 615 may be positioned about inflation line 710 at the surface of skin 510 , balloon 705 may be inflated and then tension pulled between inflated balloon 705 and cap 615 so as to occlude blood vessel 505 .
[0176] When temporary occlusion is to be withdrawn, balloon 705 is deflated using inflation line 710 , and then balloon 705 is pulled free of the anatomy by pulling proximally on inflation line 710 .
[0177] In still another form of the invention, and looking now at FIG. 150 , a balloon 705 may be positioned on the near side of the blood vessel, and then inflated using inflation line 710 so as to bear against blood vessel 505 and thereby occlude the blood vessel. Thus, in this form of the invention, temporary occlusion can be achieved without penetrating the blood vessel.
[0178] When temporary occlusion is to be withdrawn, balloon 705 is deflated using inflation line 710 , and then balloon 705 is pulled free of the anatomy by pulling proximally on inflation line 710 .
[0179] The balloon(s) 705 may be filled with air, water or a compound of higher molecular weight than air. The balloon 705 may also be inflated with a polymer that hardens in situ, for applications where it is desirable to permanently maintain occlusion of the blood vessel. Alternatively, balloon 705 may be inflated with a polymer that hardens in situ and thereafter bio-degrades over time.
[0180] In another embodiment of the present invention, the occluder may comprise a sealed tube having two regions that may be inflated into balloons. These balloon regions are expanded using air or liquid pressure.
[0181] In the foregoing disclosure, there is described an occluder (permanent or temporary, utilizing various constructions) which occludes a hollow structure (e.g., a blood vessel). In this respect it should be appreciated that the occluder may be positioned directly against a surface (e.g., an outer surface) of the hollow structure, or the occluder may be positioned such that an intervening structure or structures (e.g., anatomical tissue) may reside between the occluder and the hollow structure which is to be occluded. In this latter situation, the occluder applies a force to the intervening structure or structures, whereby to occlude the hollow structure which is to be occluded.
Using the Temporary Occluder to Occlude Tubular Structures Other than Blood Vessels
[0182] It will be appreciated that the temporary occluder of the present invention can also be used to occlude tubular structures other than blood vessels. By way of example but not limitation, the temporary occluder of the present invention can be used to occlude other structures within the body (e.g., tubes such as fallopian tubes and/or vas deferens for temporary or permanent sterilization, ducts such as bile ducts and cystic ducts for cholecystectomy, lymphatic vessels, including the thoracic duct, fistula tracts, etc.).
Modifications of the Preferred Embodiments
[0183] It should be understood that many additional changes in the details, materials (e.g., shape memory polymers that are permanent or that dissolve over time, or carbon nanotube based), steps and arrangements of parts, which have been herein described and illustrated in order to explain the nature of the present invention, may be made by those skilled in the art while still remaining within the principles and scope of the invention.
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Apparatus for percutaneously occluding a hollow structure, said apparatus comprising:
an occluder, said occluder comprising a first component and a second component, wherein said first component is configured so that it may assume (i) a diametrically-reduced configuration for disposition within the lumen of a hollow tube, and (ii) a diametrically-expanded configuration for disposition adjacent to the hollow structure, whereby to occlude the hollow structure, and further wherein said second component percutaneously connects said first component to a site remote from said first component.
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FIELD OF THE INVENTION
The present invention relates to the processing of clay minerals and, more particularly, is directed to the processing of kaolinitic clays at high solids under acidic conditions to produce an improved paper filler composition.
Further, this invention relates to a simplified method for producing a high solids kaolin slurry at a acid pH, that is usable by the paper industry as a paper filler without filtration or spray drying yet with attainment of rheological properties similar to those obtained using spray dried product.
BACKGROUND OF THE INVENTION
In the course of manufacturing paper and similar products, including paperboard and the like, it is well-known to incorporate quantities of inorganic materials into the fibrous web in order to improve the quality of the resulting product. In the absence of such fillers, the resultant paper can have a relatively poor texture due to discontinuities in the fibrous web. The said fillers are also important in improving the printing qualities of the paper, i.e., by improving the surface characteristics of same. The use of appropriate such fillers further vastly improves the opacity and the brightness of a paper sheet of a given weight. The brightness and opacifying sheet, one which incorporates whiteness, high opacity, good printability and light weight.
According to Koppelman et al. in U.S. Pat. No. 4,650,521, it has become customary in the industry to beneficiate the crude kaolinitic clays used in clay filler compositions for paper making to improve particle size distribution and also improve color characteristics by removing ferric iron-containing compounds in the clay. Such ferric iron-containing compounds impart a non-white color to the clay and reduce the overall brightness or reflectance to visible light of the clay. It is well-known that the effect of these ferric iron-containing compounds may be reduced by treating the clay with a reducing agent which converts the ferric ion to the less highly colored ferrous ion. A variety of reducing agents are known to be suitable for treating kaolinitic clays, but the most commonly used reducing agents are water-soluble dithionites or sulphites, such as sodium dithionite, zinc dithionite, sodium bisulphite, sodium hydrosulphite, and sodium pyrosulphite. Further, according to the patentees, in the conventional process for reducing the ferric iron-containing impurities in a kaolinitic clay to the ferrous state, a low solids aqueous suspension of the crude clay is first formed, then if desired, degritted to remove large particles, and then treated with a reducing agent to convert the ferric ions therein to the ferrous state. The ferrous ion is generally very soluble in water and will pass into the water in which the clay is suspended. The treated clay is then thickened, dewatered by filtration and the resultant filter cake thermally dried to produce a clay filler product having a high solids content suitable for economic transport. Such a low solid content process requires that the clay suspension be in a fluid state, that is, that the solids content of the crude clay suspension be less than about 50% by weight and usually in the range of 20% to 35% by weight. Unfortunately such low solids processing of the crude kaolin requires that significant dewatering and drying be carried out to ready the treated clay product for economic transport. Significant economic benefits would be obtained if the crude kaolin clay could be processed at a high solids content so that the dewatering and subsequent drying of the treated clay could be minimized or eliminated.
These are also some of the objectives of the present invention but simplified measures and lower work input are used for their attainment.
Thus, an object of the invention is to produce a bleached, dispersed, high solids slurry from unprocessed crudes at low pH, and with minimum work input, and to make the slurry at the highest solids possible without filtration or spray drying.
A further object is the production of fine coating clay slurries for paper using fine clays such as the South Carolina clays.
SUMMARY OF THE INVENTION
The invention is directed to a process for treating a crude kaolin clay mineral which comprises: (a) blunging the clay in sufficient water to form an aqueous suspension having a solids content of at least 60% by weight, adding sufficient ammonia to adjust the pH to within the range of about 3.0 to below 6.0 and adding polyacrylic acid as a dispersant; (b) degritting to remove particles larger than those that would pass through a 200 mesh screen; (c) bleaching the suspension with a reducing bleaching agent; and (d) recovering a clay suspension of increased brightness and improved color having a solids content of at least 60% by weight.
The crude kaolin is processed at a solids content of at least 60% by weight, preferably at least 70% by weight and at an acid pH in the range of about 3.0 to below 6.0, preferably about 3.0 to about 4.5. Degritting may be accomplished by screening, preferably by centrifugation.
It may be noted that in contrast to the method of U.S. Pat. No. 4,650,521 in which a combination dispersing agent made up of sodium carbonate, sodium polyacrylate and sodium metaphosphate is used, the present process uses only a single dispersing agent, polyacrylic acid (PAA). Also, whereas the patentees in Example 1A blunge a 72% solids suspension for 18 hours, by contrast in the present method, owing to better dispersion and homogeneity, it is only necessary to blunge for short times measurable in minutes rather than hours. The resulting suspensions are stable and fully bleach responsive.
It has now been found that acidity is important in order for the clay to respond to reductive bleaching. Clay slurries respond to reductive bleaching with thiosulphates at low pH; this response increases with decreasing pH.
Another factor to be considered in the processing of crudes at high solids, is the presence, and concentration, of residue in the final slurry since large particles could be abrasive to the paper-making machinery. The high solids slurry has to be fluid to allow either screening through a fine mesh screen, or centrifugation, to reduce its residue content; consequently, its low shear viscosity should be relatively low.
Experiments with crudes of different particle size distributions indicate that it is possible to produce low pH, high solids slurries using polyacrylic acid as the dispersant. Slurries with solids concentrations at or above 70% can be achieved at pH below 6.0. These slurries are stable and homogeneous, and have rheological properties similar to those produced using spray dried product.
BRIEF DESCRIPTION OF THE DRAWING
The drawing is a flow diagram illustrating the process of the invention.
DETAILED DESCRIPTION
In the following experiments, the method of the invention was applied to a variety of kaolin crudes obtained from different mines in South Carolina.
The general procedure used for preparing the high solids clay slurries was as follows:
a. A premeasured amount of clay was added to enough water in a blunging cell to make the slurry at the required solids concentration. The clay was blunged with the water for two to three minutes, after which 1.5 ml of ammonia was added in 0.5 ml. aliquots to adjust the initial pH of the slurry.
b. Polyacrylic acid was added to the clay slurry in 1.00 lb./ton clay aliquots, and the low shear rheology of the slurry was measured after each addition to determine the slurry's dispersant demand. The point of maximum dispersion was reached when the low shear rheology of the clay slurry reached a minimum.
c. The clay slurry was subjected to screening through a 325 mesh screen, or to centrifugation, to reduce its residue content. Centrifugation was the preferred method due to the very thick nature of the high solids slurry, and the very high screening times required to screen the product through the fine mesh screen.
d. The slurry was finally bleached by the addition of 8 lbs./ton clay of Hydroline (sodium thiosulfate).
The flow diagrams shows one embodiment according to the invention of the processing steps used in the production of the high solids slurry.
The crudes used in these experiments were Harrison, Elkins, Continental Can, and Walden A. These crudes were chosen for the study because of their varied particle size distributions.
TABLE 1______________________________________Physical properties of the crudes used for theevaluation of polyacrylic acid (Rohm & Hass productU-1010) CONT.Crude HARRISON ELKINS CAN WALDEN A______________________________________Brightness 81.6 84.0 86.6 80.9Residue 1.4 4.3 0.9 5.8% ≦ 2 μm 59.0 76.0 86.0 92.0Surface Area 15.1 15.4 21.2 23.5______________________________________
The makedown properties of each one of the crudes tested are described below.
HARRISON
The maximum solids reached for the slurry of Harrison crude dispersed at pH 3.6 was 60.8 wt %. This crude had a dispersant demand of 8.9 lbs./ton dry clay at this pH and solids concentration. Table 2 shows the results.
TABLE 2______________________________________Properties of slurry made with Harrison crude Dosage Brookfield Herculesml. PAA lbs./ton clay (cp @ 20 rpm) (dy/4400)______________________________________ 7.6 6.70 580 6.58.9 7.84 270 7.010.1 8.90 210 7.011.4 10.04 220 7.012.7 11.19 240 7.0______________________________________Ammonia used 4.0 mlpH of final slurry 3.6Percent solids 60.8%BrightnessCrude 81.6Bleached (day one) 82.6Bleached (day ten) 83.2Residue of product (325 mesh) 0.597______________________________________
The pH of the slurry was increased from 3.6 to 4.0 in order to make a slurry at higher solids using the same crude. This increase produced a very stable slurry at 71.4% solids with very stable, good low shear viscosity and bleach brightness response. The dispersant demand of this slurry was 13.2 lbs./ton clay. Table 3 summarizes the physical properties of this slurry.
TABLE 3______________________________________Properties of slurry made with Harrison crude(centrifuged) Dosage Brookfield Herculesml. PAA lbs./ton dry clay (cp @ 20 rpm) (dy/rpm)______________________________________6 9.93 300 18/4607 11.59 1508 13.24 1209 14.90 12010 16.55 12011 18.21 120 18/400______________________________________Ammonia used 6.5 mlpH of final slurry 4.0Percent solids (after centrifuging) 71.4%BrightnessCrude 81.6Bleached (day one) 82.3Bleached (day ten) 83.7Residue of product (325 mesh) 0.0017______________________________________
CONTINENTAL CAN
Continental Can was dispersed at 60.4% solids and a pH of 3.8. The dispersant demand of the slurry was 14.6 lbs. PAA/ton dry clay under these conditions and the dispersant demand for a 71.1% solids slurry at pH 5.1 was 9.1 lbs. FAA/ton dry clay. Tables 4 and 5 summarize the physical properties of these slurries.
TABLE 4______________________________________Properties of slurry made with Continental Can crude(screened) Dosage Brookfield Herculesml. PAA lbs./ton dry clay (cp @ 20 rpm) (18 dynes/rpm)______________________________________2.0 11.16 1230 18002.2 12.28 8202.4 13.40 5602.6 14.51 5002.8 15.63 5803.0 16.74 730 920______________________________________ Ammonia used 1.9 mlpH of final slurry 3.8Percent solids (after screening) 60.4%BrightnessCrude 86.6Bleached (day one) 87.0Bleached (day ten) 88.0Residue of product (325 mesh) 0.293______________________________________
TABLE 5______________________________________Properties of slurry made with Continental Can(centrifuged) Dosage Brookfieldml. PAA lbs./ton dry clay (cp @ 20 rpm)______________________________________1.1 5.22 18401.4 6.52 6701.7 7.83 5702.0 9.13 5502.2 10.43 580______________________________________Ammonia used 2.0 mlpH of final slurry 5.1Percent solids (after centrifuging) 71.8%BrightnessCrude 86.2Bleached (day one) 86.6______________________________________
The tables above show that Continental Can crude can be dispersed at high solids (71.8%) and low pH. The low shear viscosity of the slurries with concentrations of this crude above 60 wt. % cannot be adjusted to less than 500 cps. The dispersant demand of the crude decreases with increasing concentration, but the pH of the slurry has to be adjusted upwards in order to reach higher concentrations of the crude in the slurry.
WALDEN-A
Table 6 shows the physical properties of a slurry made with Walden A crude at 64.1% solids, and Table 7 shows the physical properties of a 68.0% solids slurry of Walden A at a pH of 5.5.
Walden A presented problems during the dispersion in the blunging cell; the slurry makedown required a high amount of polyacrylic acid for dispersion, and high work input. The slurry behaved during makedown as if the dispersant had degraded due to the high heat produced as a consequence of the high work input required by the crude to make down. A second slurry was made at similar pH but with less work input. Tables 6 and 7 show the physical properties of the slurries made down at the different work inputs. The amount of work required to make to second slurry was lowered by using a Waring blender instead of the blunging cell.
TABLE 6______________________________________Properties of the slurry made with Walden-A crude(centrifuged) Dosage Brookfield Herculesml. PAA lbs./ton clay (cp @ 20 rpm) (dy/rpm)______________________________________6 8.73 18/6207 10.188 11.649 13.09 38010 14.55 49011 16.00 590 18/560______________________________________Ammonia used 12.0 mlpH of final slurry 5.4Percent solids (after centrifuging) 64.1%BrightnessCrude 80.9Bleached (day one) 83.4Bleached (day ten) 84.0Residue of product (325 mesh) 0.015%______________________________________
Table 7 shows the results of a second attempt to disperse Walden A crude at high solids. The slurry was made down at 68% solids and pH 5.5. The slurry required a lesser amount of PAA for dispersion, but it produced a slurry of very high low shear rheology.
TABLE 7______________________________________Properties of slurry made with Walden-A crude(centrifuged) Dosage Brookfieldml. PAA lbs./ton dry clay (cp @ 20 rpm)______________________________________0.4 2.24 13400.7 3.36 11900.9 4.48 1170______________________________________Ammonia used 1.0 mlpH of final slurry 5.5Percent solids (after centrifuging) 68.0%BrightnessCrude 80.9Bleached (day one) 83.3______________________________________
Both Tables 6 and 7 indicate that it is possible to produce slurries with Walden A crude; however, they require more work for the makedown and a relatively high pH.
ELKINS
Elkins was another crude that gave problems during makedown at low pH with U-1010. The crude required high input of work and did not mix well during blunging. Table 8 summarizes the physical properties of the slurry.
TABLE 8______________________________________Properties of slurry made with Elkins crude Dosage Brookfield Herculesml. PAA lbs./ton clay (cp @ 20 rpm) (dy/4400)______________________________________12.9 11.10 1850 514.2 12.22 158015.5 13.34 136016.8 14.46 133018.1 15.58 135019.4 16.70 133020.6 17.73 138021.9 18.85 1460 6______________________________________Ammonia used 8.5 mlpH of final slurry 3.2Percent solids (after centrifuging) 60.4%BrightnessCrude 84.0Bleached (day one) 85.2Bleached (day ten) 85.0Residue of product (325 mesh) 0.223______________________________________
Elkins is a crude that produces very good slurries when dispersed at higher pH.
Conclusions
The results gathered in these experiments indicate that it is possible to process crudes in the acid range of the pH scale using polyacrylic acid as the dispersant. Slurries of high solids (above 70%) can be made at pH values between 4.5 and 6.0 depending on the crude used. The pigment in the slurries can be bleached using conventional Hydroline at regular dosages (8 lbs./ton clay); however, the bleach response of the clay increases with decreasing pH and increasing contact time.
The processing properties of the crudes appear to be dependent on the concentration of residue in the crude. The best working parameters were found in the crudes with the lesser amount of residue, such as Continental Can and Harrison crudes.
While the present invention has been particularly set forth in terms of specific embodiments thereof, it will be understood in view of the instant disclosure, that numerous variations upon the invention are now enabled to those skilled in the art, which variations yet reside within the scope of the present teaching. Accordingly, the invention is to be broadly construed, and limited only by the scope and spirit of the claims now appended hereto.
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A bleached, dispersed, high solids slurry is produced from unprocessed crudes at low pH and with minimum work input, using polyacrylic acid as the dispersant. The process involves making the slurry at the highest solids possible without resorting to filtration or spray drying.
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This application claims priority under 35 U.S.C. §§119 and/or 365 to 9903560-2 filed in Sweden on Oct. 1, 1999 and 0001996-8 filed in Sweden on May 26, 2000; the entire content of which is hereby incorporated by reference.
BACKGROUND
Generally speaking, the present invention relates to a portable communication apparatus for providing communication services to a user through a man-machine interface of the apparatus. More specifically, the invention relates to a portable communication apparatus of the type having a controller, an operating system, a local storage device for storing a first application, a secure resource which is only accessible from the operation system, and wireless interface for connecting the portable communication apparatus to a remote device.
Examples of a portable communication apparatus as set out above are a mobile telephone, a cordless telephone, a portable digital assistant, a communicator, a paging device, an electronic payment device, or a portable navigating device. For the rest of this document, reference will be made to a mobile telephone for any mobile communications network such as GSM, EDGE or UMTS. However, the invention is not limited to merely a mobile telephone. On the contrary, the invention is best defined by the appended independent claims.
Traditionally, older mobile telephones were only capable of providing speech communication between two human users through a mobile communications network and, in many situations, a public switched telephone network. More recently, mobile telephones have been provided with additional functionality, such as capability of providing data or facsimile communication between the portable communication apparatus and another electronic device. Moreover, such telephones often contain simple utility applications, such as a built-in electronic telephone book, a calculator, an alarm function or a video game.
Even more recently, numerous advanced additional utility applications have been introduced for mobile telephones. Such advanced utility applications include short-range supplementary data communication between the mobile telephone and for instance a portable computer, a printer, a wireless headset accessory, etc. One example of such short-range supplementary data communication facilities is commonly referred to as Bluetooth and operates in a 2.4 GHz frequency band, which is often referred to as ISM (“Instrumental, Scientific and Medical”).
Other examples of advanced utility applications are wireless electronic payment (“electronic wallet”), smartcard applications (such as SIM Toolkit applications), wireless access to global networks (such as WAP-“Wireless Application Protocol” for accessing resources on the Internet), etc.
Consequently, a mobile telephone of today, and certainly in the future, will host a number of applications, which share common resources of the mobile telephone. The commonly shared resources will include the man-machine interface, particularly a display of the mobile telephone, but also secure or private resources, such as information stored in a SIM card (“Subscriber Identification Module”) or another memory in the mobile telephone. These applications will be executed in different environments within the mobile telephone, for instance in a WAP/Java/HTML (“Hyper Text Markup Language”) browser, a processor on the SIM card or another type of smartcard, directly in the operating system of the mobile telephone, etc. Moreover, some applications may be executed outside the mobile telephone in an external device connected to the telephone. Furthermore, applications may be downloaded to the mobile telephone after the manufacturing thereof.
Many of these applications may be activated or launched by events occurring without reach of the user's immediate control or attention. In most cases the applications will communicate with the user through the man-machine interface of the mobile telephone, particularly its display. Due to the limited size of the display, an active application will often have full control of the entire display. When another application is activated, it may then take over the control of the display and other parts of the man-machine interface, such as the keyboard of the mobile telephone. Sudden switches between such applications running in different environments inside the mobile telephone or in an external device will be difficult for the user to notice, understand and handle correctly. Consequently, it will be hard for the user to realize that an application from a different origin, of a different type or in a different environment is now suddenly in control of the man-machine interface.
Moreover, an application running in a low-security environment could impersonate an application running in a high-security environment. For instance, a WAP application could pretend to be a SIM/smartcard-based application. Similarly, an external application could pretend to be an application within the mobile telephone.
The above is of particular concern, if the user uses the mobile telephone to perform some kind of secure transaction on behalf of him/her based on secure resources in the mobile telephone. For instance, if the mobile telephone is used as a wireless electronic payment device, it is utterly important for the user to know, without any doubt, what type of application that he/she is currently communicating with through the man-machine interface, that the active application is trustworthy, and that the application is communicating securely and directly with the secure resources of the mobile telephone and the man-machine interface thereof without any risk of another application interfering with, modifying or capturing any secure data involved in the communication.
Unfortunately, in most existing utility application environments for mobile telephones, the security issues are only optional but not mandatory. For instance, security features like WTLS (“Wireless Transport Layer Security”) are only optional in WAP 1.1 and 1.2 and also WIM (“Wireless Identity Module”).
Moreover, short-range supplementary data applications (such as Bluetooth) may be activated through suddenly established links, if the user carries the mobile telephone in a vicinity of a remote device capable of such communication.
In view of the above, when it comes to advanced utility applications, the only existing safe alternative for a user of a mobile telephone according to the above is to verify the mobile telephone itself as well as its implementation of optional parts of the communication standards involved, the SIM-card/smartcard provided by the telephone operator and, finally, the security of each individual node in the communication link between the mobile telephone and a remote device.
SUMMARY
It is an object of the present invention to provide a substantial improvement of the above situation, with particular focus on keeping the user aware of the momentary security situation in the application environment of the mobile telephone.
The above object has been achieved, according to the invention, by the provision of a security indicator, which only the operating system of the mobile telephone is capable of indicating to the user through the man-machine interface of the telephone. The security indicator, which preferably is provided visually on the display of the telephone, but which alternatively may be provided as an audible or tactile signal, provides the user with certain information regarding the security of the connection between a secure resource in the mobile telephone and an active application, which is either executed internally in the telephone or is executed in a remote device connected to the telephone. In both cases, the active application will use the man-machine interface of the mobile telephone. The security indicator may also indicate a type, origin or certificate of the active application. Moreover, it may indicate the location of execution for the active application.
The solution to the above object is best defined by the appended independent patent claims. Other objects, features and advantages will appear from the following detailed disclosure, from the sub claims as well as from the accompanying drawings.
BRIEF DESCRIPTIONS OF THE DRAWINGS
Preferred and alternative embodiments of the present invention will now be described in more detail, reference being made to the accompanying drawings, in which:
FIG. 1 is a schematic block diagram of a portable communication apparatus and a utility application environment, in which it may operate,
FIG. 2 is a block diagram of the portable communication apparatus shown in FIG. 1 , and
FIGS. 3 , 4 a - 4 b , 5 a - 5 c , 6 and 7 illustrate a part of a man-machine interface of the portable communication apparatus according to different embodiments.
DETAILED DESCRIPTION
Reference is first made to FIG. 1 , which illustrates a portable communication apparatus in the form of a mobile telephone 1 , as well as the environment in which it operates. In a normal fashion, the mobile telephone 1 comprises a display 2 , a keyboard 3 , a loudspeaker 4 , and a microphone 5 . The components 2 - 5 together form a man-machine interface, through which a user of the mobile telephone 1 may interact with and operate the mobile telephone. Moreover, the mobile telephone 1 comprises a first antenna 6 for establishing a wireless connection 9 to a mobile telecommunications network 11 through a base station 10 . The mobile telecommunications network 11 may be a GSM network (“Global System for Mobile communications”), EDGE (“Enhanced Data Rates for GSM Evolution”) or UMTS (“Universal Mobile Telephone System”). The mobile telephone 1 may also be used for accessing a global information network 13 , through a gateway 12 , over the wireless link 9 . The global information network 13 may preferably be the Internet, and the gateway 12 may be a WAP server.
The mobile telephone 1 also comprises a second antenna 7 , which may be used for establishing a short-range supplementary data connection 14 to a remote device 15 . The link 14 may preferably be a Bluetooth link, as described in previous sections of this document. The remote device 15 may e.g. be a printer, a facsimile device, a cordless telephone accessory (such as a head set), a computer (e.g. a stationary desktop computer or a portable laptop computer), but many other devices are also possible.
The second antenna 7 may also be used for establishing a short-range supplementary data connection 16 to an electronic payment system 18 through a gateway 17 .
In addition to the above, the mobile telephone 1 further comprises an IR (infrared) interface 8 , by means of which the mobile telephone 1 may establish an IR link 19 to a remote device 20 . The remote device 20 may e.g. be a computer (stationary, laptop or pocket), a modem, a printer, etc.
In FIG. 2 the mobile telephone 1 of FIG. 1 is shown i more detail. As previously mentioned, the telephone 1 comprises a man-machine interface 21 , including the display 2 , the keyboard 3 , the loudspeaker 4 and the microphone 5 . A central processing unit (CPU) 23 is responsible for the overall control of the mobile telephone 1 together with a memory 24 and an operating system 25 . The central processing unit 23 may be implemented by any commercially available microprocessor or another type of programmable electronic circuitry. The memory 24 may be implemented as a random-access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM, EEPROM), a flash memory, or any combination of such memories. Preferably, the operating system 25 is stored in a part of the memory 24 .
The mobile telephone 1 also has a SIM module 33 , preferably in the form of a smart card in which there is stored private data regarding a mobile telephony subscription for the mobile telecommunications network 11 . The SIM card 33 may also comprise one or a plurality of SIM Toolkit applications.
The mobile telephone 1 also has radio circuitry 30 , which will be used in combination with the first antenna 6 for establishing the wireless link 9 of FIG. 1 . Similarly, the mobile telephone 1 comprises circuitry 31 for short-range supplementary data connectivity, to be used for establishing the links 14 or 16 through the second antenna 7 of FIG. 1 . The circuitry 31 may e.g. be adapted for Bluetooth communication. Additionally, the mobile telephone comprises IR circuitry 32 , to be used for establishing an infrared link 19 to the remote device 20 shown in FIG. 1 . The IR circuitry 32 may preferably be adapted for IrDA communication. The radio circuitry 30 , the short-range supplementary data circuitry 31 and the IR circuitry 32 are all already commercially available, form no central part of the present invention and are therefore not described in any detail herein.
Indicated in FIG. 2 is also a trusted module 29 , which may involve private keys, secret data, etc., for use together with a WIM module (“Wireless Identity Module”), which is used in WAP applications. The trusted module 29 may also relate to a SWIM module, e.g. a WIM module implemented on the SIM card 33 . In some embodiments, the trusted module 29 may be stored in the memory 24 .
FIG. 2 also contains an indication of a protocol structure used for the different wireless links 9 , 14 , 16 , and 19 of FIG. 1 . The protocol structure essentially follows the well-known seven-layer OSI structure. At the bottom of the protocol structure there is provided first and second baseband layers 34 for the wireless link 9 to the mobile telecommunications network 11 and the global network (Internet) 13 . Moreover, there is provided corresponding first and second baseband layers 35 for the Bluetooth circuitry 31 and the IR circuitry 32 .
Next, on a third level, there is provided a network layer, such as IP over PPP (“Internet Protocol”, “Peer to Peer Protocol”). A transport layer 37 is provided on level 4. The transport layer may e.g. be TCP (“Transport Control Protocol”), UDP (“User Datagram Protocol”) or WDP (“Wireless Datagram Protocol”).
On layer 5 there is provided a WAP session layer 38 , comprising e.g. WSP (“Wireless Session Protocol”) or WAE (“Wireless Application Environment”). All protocols, which have been mentioned with respect to the layers 34 , 35 , 36 , 37 and 38 above, are all believed to be well-known in the technical field and are not described in any detail herein.
At a sixth level there is provided a security protocol 39 , e.g. SMT (“Secure Mobile Transaction”). SMT is a security protocol on an application level, which addresses limitations in communication with a mobile personal device. Currently SMT is under development and is therefore not yet a standard.
The protocol structure described above is capable of serving a plurality of applications, which are executed in different environments inside and outside the mobile telephone 1 . Consequently, a first application 26 may communicate directly with the transport layer 37 and the man-machine interface 21 . The application 26 is preferably stored in the memory 24 and is executed by the central processing unit 23 under the operating system 25 . Additionally, a second application 27 may communicate with the WAP layer 38 or the security layer 39 and the man-machine interface 21 . Correspondingly, the application 27 may be stored in the memory 24 and be executed by the central processing unit 23 under the operating system 25 . Alternatively, the applications 26 and/or 27 may be stored in the SIM-card 33 or the trusted module 29 .
The mobile telephone 1 is also capable of serving an external application 28 , which is located in a remote device. Such a remote device may e.g. be any of the devices 11 , 12 , 13 , 15 , 17 , 18 or 20 indicated in FIG. 1 . Such an external application 28 will communicate with the mobile telephone 1 over any of the wireless links 9 , 14 , 16 , or 19 (i.e., radio, short-range supplementary data or infrared). The user will interact with the external application 28 through the man-machine interface 21 of the mobile telephone 21 .
In order to solve the above-mentioned object of the invention, the mobile telephone is provided with a security indicator 22 , which is part of the man-machine interface 1 , and which is only controllable from the operating system 25 . More particularly, an application 26 , 27 , 28 may only affect the security indicator 22 through certain operating system calls to the operating system 25 . Thus, no application may modify the security indicator 22 without the cooperation and consent of the operating system 25 . According to different embodiments of the invention, the security indicator 22 comprises one or more than one special graphical icon ( 22 a in FIG. 3 ), which preferably resides in a separate portion of the display 2 and which may only be updated by the operating system 25 through aforesaid operating system calls. Alternatively, the security indicator may be provided as a special alpha numeric character or as a special text message ( 22 b in FIG. 4 a ), having a special font ( 22 c in FIG. 4 b ) size or color different from normal text messages ( 42 and 43 in FIG. 3 ) presented on the display 2 . Icons 40 and 41 in FIG. 3 are conventional indicators for signal strength and battery capacity, respectively.
As an alternative to the above types of security indicator, the security indicator 22 may be provided as an audible signal through the loudspeaker 4 of the mobile telephone 1 . As yet another alternative, the security indicator may be provided as a tactile signal (preferably a vibrating signal) generated by other means in the mobile telephone 1 .
The purpose of the security indicator 22 is to provide information to the user about a current level of security as regards an active application currently communicating with the user through the man-machine interface 21 . Since the security indicator 22 may be controlled only from the operating system 25 , the user may rely on the information provided by the security indicator. According to one embodiment, the security indicator may indicate a type, security level, or origin of an active application, which the user is currently communicating with through the man-machine interface 21 . For instance, as shown in FIG. 5 a , the security indicator 22 d may indicate that the active application is local (stored and executed within the mobile telephone 1 ). Correspondingly, an external application stored and/or executed in a remote device outside the telephone 1 may be indicated through the security indicator 22 e ( FIG. 5 b ). As shown in FIG. 5 c , the security indicator 22 f may indicate a more detailed type of the active application, e.g. that it is a SIM Toolkit application. The security indicator may also indicate that the active application runs in a WAP/Java/HTML browser.
Alternatively, the security indicator 22 g may indicate that the active application is certified in some way (FIG. 6 ). The security indicator may also indicate a switch from a previously active application to a currently active application.
According to some embodiments, the security indicator may indicate whether the active application was provided in the mobile telephone 1 already at the manufacture thereof, or whether the active application has been downloaded to the telephone 1 at a later time.
If the currently active application is an external application, the security indicator 22 may represent the level of security of the link between the mobile telephone 1 and the remote device, where the external application resides. The level of security may then advantageously be indicated graphically as indicated by the icon 22 a in FIG. 3 . Three key symbols in the icon 22 a represent a high-level security, whereas two key symbols represent a medium-level security, only one key symbol represents a low-level security and, finally, no key symbol at all represents no security.
The security indicator ( 22 h in FIG. 7 ) may also provide an indication about a type of a link between the mobile telephone 1 and a remote device, such as a Bluetooth link ( 14 , 16 ), an infrared link ( 19 ), or a radio link ( 9 ).
Moreover, the security indicator 22 may indicate that a transaction currently performed by the active application is atomic in the sense that the transaction cannot be interrupted, manipulated or interpreted by any other application than the active application. The security indicator 22 could also indicate important parameters of such a secure transaction, such as key length for a used encryption method, etc.
In addition to the above, the security indicator 22 may indicate if any of the wireless links 9 , 14 , 16 or 19 is currently established, a status thereof, or a physical quality (signal strength, etc.) of such an established link.
To summarize the above, in its general form, the present invention provides a security indicator through the man-machine interface of a portable communication apparatus, wherein the security indicator represents a security of a connection between a secure resource of the portable communication apparatus and an active application, which is currently using the man-machine interface. The term secure resource is to be interpreted broadly and covers inter alia, a certain part of the mobile telephone 1 (e.g. its man-machine interface 21 ), private keys or other secure data stored in the mobile telephone, e.g. in the trusted module 29 , the memory 24 or the SIM-card 33 .
The present invention has been described above with reference to some embodiments. However, other embodiments than the ones referred to above are equally possible within the scope of invention, which is best defined by the appended independent claims.
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A portable communication apparatus has a man-machine interface, a controller, an operating system, a local storage device for storing a first application, a secure resource which is only accessible from the operating system, and a wireless interface for connecting the portable communication apparatus to a remote device. The man-machine interface provides interaction between a user of the portable communication apparatus and the first application when the first application is executed by the controller and the operating system. The man-machine interface also provides interaction between the user and a second application originating from the remote device. Only the operating system can provide a security indicator through the man-machine interface. The security indicator indicates a secure connection between the secure resource and either the first application or the second application, whichever is interacting with the man-machine interface.
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PRIORITY
[0001] This application is a continuation-in-part of U.S. application Ser. No. 09/717,553, filed Nov. 21, 2000.
FIELD OF INVENTION
[0002] This invention relates generally to slip resistant, anti-skid or anti-creep mats.
BACKGROUND OF THE INVENTION
[0003] In the past, floor mats, consisting of rubber backed carpet tuft, were made with either a smooth back primarily for solid or non carpeted floors, or with a variety of “grippers” or “cleats” arranged to reduce the movement on carpeted floors. However, both of these approaches resulted in floor mats that were not skid resistant on smooth floors, especially those floors with high traffic areas or loads being moved over them. The movement of the mat in the gripper/cleat mat design results from the force of foot and vehicle traffic on the mat which causes a deformation around the compressed area and then upon removal of such force the mat returns to a different position. For the smooth back mats, movement of the mat results from similar forces and the lack of any device or feature intended to secure the mat in place.
[0004] A number of approaches have been taken to attempt to reduce the movement of mats. One known approach to the problem is to fasten the mat to the intended surface by various devices, such as that suggested by Kessler in U.S. Pat. No. 6,068,908 which utilizes a system by which a mat is fastened to the surface using a clip system. While this approach is well-developed it results in floor mats that are difficult or impossible to move from place to place and the structures required to attach the mat add cost to the mat and difficulty to the installation. Also, attached mats are more rigid.
[0005] Another approach involves the use of a frame into which the mat is placed, such as the frames used by Moffitt, Jr. in U.S. Pat. No. 4,361,614 and Kessler in U.S. Pat. No. 6,042,915. The frame can be located upon the flooring surface or inlaid to be flush with the flooring surface. In either circumstance, unless the frame is fastened as mentioned above or embedded in the surface the frame still has a tendency to shift on the surface. If the frame is fastened or embedded, the other problems mentioned above still remain.
[0006] Another approach involves the use of suction cups, such as those commonly found on shower and bath mats, examples of which can be found by Lindholm in U.S. Pat. No. 6,014,779 in which the corners of a rectangular mat are held by four suction cups and by Gavlak in U.S. Pat. No. 2,081,992 in which a plurality of suctions cups hold the bathtub mat to the surface. While this approach provides acceptable slip-resistance for light shower and bath mat applications, traditional suctions cups are not sufficient to provide sufficient anti-skidding forces to prevent slipping and movement in high traffic and high load areas. Traditional suction cups also result in a wavy mat surface which is more difficult for individuals and loads to traverse.
[0007] As mentioned, existing approaches to reducing movement of mats include significant limitations. Further, the known approaches require additional space, components, installation effort and expense. As a result, significant improvement can still be made relative to reducing the movement of mats.
SUMMARY OF THE INVENTION
[0008] The object of the present invention is to utilize recessions formed on the underside of the mat coupled with suction cups to reduce movement of the mat on the intended surface, typically floors. The present invention utilizes a plurality of recessions with partially inset suction cups to reduce the movement of the mat. The recessions have a suction cup set inside the recession and the top surface of the recession is connected with the top surface of the suction cup, either directly or by using a supporting pillar. Upon an initial force being applied to the mat, such as a footstep or vehicular traffic, the suction cup is deformed and the air is forced out of the suction cup which creates a low pressure area or near vacuum inside of the suction cup, thereby providing a force that acts to adhere the mat to the surface and assist in retaining the mat in its original position. As the force over a particular recession increases, if the force is sufficiently large, the suction cup will deform itself into the recession, and the recession itself will receive a compression force that will create a low pressure area or near vacuum inside the recession being impacted against the surface on which the mat rests. At the same time, as a result, the low pressure areas of both the recessions and suction cups then create forces that act to oppose the lateral motion of the mat that would otherwise result from the applied forces.
[0009] The size and shape specifications of the recessions and suction cups can be varied and they can be positioned in a variety of arrangements. The recessions can be any shape that is formed on the underside of the mat does not extend through the top of the mat (i.e., is contained within the mat), and adjoins the floor in a continuous manner to permit the formation of a low pressure area or near vacuum. The suction cups are at least partially inset into the recessions and can be any shape provided that the edges of the suction cups contact the surface on which the mat rests prior to the full compression of the recessions. In one embodiment, the recessions are cylinders or recessed circles having a width of 2.5 cm and a depth of 0.125 cm, the circular pillar connecting the recessions and the suction cups has a width/diameter of 0.625 cm and a depth/thickness of 0.0802 cm, the suction cup and pillar have a cumulative depth of 0.375 cm from the top surface of the recession, and the suction cup has an inner depth of 0.20 cm, an edge to edge width of 1.62 cm, and a contacting surface lip width of 0.12 cm. Also, in one embodiment the recessions are positioned in evenly spaced parallel and perpendicular rows resulting in an evenly spaced grid arrangement, although they can be spaced in an infinite number of combinations. In one embodiment, the pattern does not extend to the edge of the mat in order to prevent tearing and permit the edge of the mat to be uniformly thick. Further, in one embodiment, the top surfaces of the recessions are connected to the side surfaces of the recessions by an angled edge, which serves to add structural integrity to the mat and decrease the volume of the recessions, thereby decreasing the volume of air needing to be expelled to create a low pressure or near vacuum area and increasing the surface adhesion of the mat.
[0010] In another embodiment, the recessions and suction cups are different sizes and shapes. The existence of multiple sizes and shapes of recessions and suction cups permits improved performance on a variety of floor surfaces since larger recession an suction cup units perform better on some surfaces and smaller recessions and suction cup units perform better on others.
[0011] In another embodiment, the recessions and suction cups are formed in a base layer of material and then the base layer of material is laminated to one or more other top layers of material. While the layers can be made from different materials, the base layer and any intermediate layers are typically sheets of rubber and the uppermost of the top layers is a union of a rubber sheet with carpet, yarn or other fabric on top. The base layer can be formed from a soft, low durometer rubber compound, such as LD-35, by being plied to a T6 aluminum mold to form the recessions and the suction cups. This base layer is then laminated with one or more upper layers formed from Millennium Mat M-M 170 rubber compound with the uppermost layer bonded with a yarn/carpet material. In this embodiment, after lamination of the layers, the laminated sheet is pricked to avoid the accretion of gases during the curing process. Also, if desired, additives can be introduced to the mat to make it anti-bacterial.
[0012] One advantage of the present invention is that the mat resists slipping to a much greater extent than existing mat designs. Another advantage of the invention is that the edges of the mat are more stable and therefore it is less of a tripping hazard or obstacle than traditional mats in which the edge of the mat easily rolls up onto or under the mat. Another advantage is that it provides the enhanced slip-resistance without adding any weight or installation complexity to existing mat designs. Another advantage is that the invention does not require any permanent fastening means and is therefore easy to move to different locations. Another advantage is that the recessions provide some additional cushioning for pedestrian and vehicular traffic. Another advantage is that the cushioning of the recessions and suction cups yields an anti-fatigue effect, thereby resulting in reduced wear and tear and routine maintenance and increased user comfort, especially for locally stationed employees spending long period of time on the mat. Another advantage of the invention is that the slip-resistance is effective on a wide variety of surfaces because recession and suction cup combination and the use variable spaced, sized and shaped recessions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a bottom fragmentary view of one embodiment of the present invention.
[0014] FIG. 2 is a fragmentary side elevational view of one embodiment of the present invention taken across Line 2 - 2 .
[0015] FIG. 3 is a fragmentary side elevational view of another embodiment of the present invention taken across Line 2 - 2 .
[0016] FIG. 4 is a fragmentary side elevational view of another embodiment of the present invention taken across Line 2 - 2 .
[0017] FIG. 5 is a fragmentary side elevational view of a single recession, pillar and suction cup group in one embodiment of the present invention.
[0018] FIGS. 6A, 6B , 6 C and 6 D are a fragmentary side elevational view of a single recession in one embodiment and the forces impacting such recession.
DETAILED DESCRIPTION
[0019] FIG. 1 illustrates a portion of a mat 20 with a plurality of recessions 25 and inset suction cups 30 that extend nearly to the edge of the mat 15 .
[0020] FIG. 2 illustrates a view of a cross-section of a single laver mat 20 . The mat 20 has a single layer 40 which contains recessions 30 in the underside 61 of the bottom layer 40 . Pillars 24 connect the recession top surfaces 22 to suction cups 26 that have contacting edges 28 that make contact with the surface on which the mat 20 rests. The recession top surfaces 22 are joined to the recession side surfaces 23 by recession angled edges 25 .
[0021] FIG. 3 illustrates a view of a cross-section of a layered mat 20 . The mat 20 has a single bottom layer 40 which contains recessions 30 in the underside 61 of the bottom layer 40 . Pillars 24 connect the recession top surfaces 22 to suction cups 26 that have contacting edges 28 that make contact with the surface on which the mat 20 rests. The recession top surfaces 22 are joined to the recession side surfaces 23 by recession angled edges 25 . The bottom layer has a yarn, carpet or other fabric layer 52 laminated or othervise bonded to the upper surface 60 of the bottom layer 40 .
[0022] FIG. 4 illustrates a view of a cross-section of a multi-layer laminated mat 20 comprised of a bottom layer 40 and an upper layer 50 . The upper surface 60 of the bottom layer 40 is laminated to or otherwise bonded with the lower surface 70 of the support layer 51 of the upper layer 50 . The upper layer 50 has a yarn, carpet or other fabric layer 52 laminated or otherwise bonded on the upper surface 71 of the support layer 51 . The bottom layer 40 contains recessions 30 in the underside 61 of the bottom layer 40 . Pillars 24 connect the recession top surfaces 22 to suction cups 26 that have contacting edges 28 that make contact with the surface on which the mat 20 rests. The recession top surfaces 22 are joined to the recession side surfaces 23 by recession angled edges 25 .
[0023] FIG. 5 is an unscaled depiction of a single recession 30 , pillar 24 and suction cup 26 unit in the mat 20 . The recession 30 has a width WR extending from the left edge 31 to the right edge 32 and a depth d R extending from the recession top surface 22 to the underside 61 which is less than the depth d M of the mat 20 extending from the upper surface 60 to the underside 61 . The suction cup 26 is attached to the recession top surface 22 by a pillar 24 which has a width w P and a depth d P . The suction cup has a depth d S extending from the suction cup inner top edge 42 to the surface on which the mat 20 rests, an outer width w SO extending across the outer edges 41 a of the suction cup bottom edge 41 and an inner width S SI extending across the inner edges 41 b of the suction Cup bottom edge 41 . The suction cup 26 has a volume v S enclosed between the suction cup inner edges 41 b and the surface on which the mat 20 rests. The entire structure of the pillar 24 and suction cup 26 has a depth d ST extending from the recession top surface 22 to the surface on which the mat 20 rests that is flush with the suction cup bottom edge 41 . The recession top surface 22 is joined with the recession side surface 23 by recession angled edges 25 .
[0024] FIGS. 6A & 6B each depict an unscaled single recession 30 , pillar 24 and suction cup 26 unit in a mat 20 . FIG. 6A depicts the unit at rest without the impact of any external force f. FIG. 6B depicts the unit being impacted and compressed by a force f. As foot or vehicle traffic impacts the mat 20 , a force f is applied to the mat 20 . In the vast majority of circumstances the force f does not impact the mat 20 in a completely vertical or horizontal manner; hence the force f consists of both horizontal force components f(x) and f(y) and a vertical force component f(z). The vertical force component f(z) created by the force f and the gravitational force g, act together to press the mat down against the surface 10 and hold the mat 20 against the surface 10 as is the case in all traditional mats. Further, the vertical force component f(z) acts to compress the suction cup 26 against the surface 10 thereby evacuating the air in the suction cup volume v S and creating a near vacuum or low pressure area in the volume v S which results in an effective resistant downward suction cup force s S . Additionally, if sufficient force exists, as the suction cup 26 is being compressed the vertical force component f(z) also compresses the recession 30 against the surface 20 thereby creating a low pressure area or near vacuum in the recession 30 between the mat 20 and the surface 10 which results in an effective resistant downward recession force S R . The downward suction cup force s S and downward recession forces S R act in combination with the vertical force component f(z) and gravitational force g to oppose the horizontal force components f(x) and f(y) that would other-vise result in lateral movement of the mat 20 .
[0025] The preceding description of the invention has shown and described certain embodiments thereof; however, it is intended by way of illustration and example only and not by way of limitation. Those skilled in the art should understand that various changes, omissions and additions may be made to the invention without departing from the spirit and scope of the invention.
[0026] This application is a continuation of and claims priority to U.S. application Ser. No. 10/132,008 filed Apr. 25, 2002, entitled, “Slip Resistant Mat,” which is a continuation-in-part of U.S. application Ser. No. 09/717,553, filed Nov. 21, 2000. The entire contents of U.S. application Ser. No. 10/132,008 are hereby incorporated by reference.
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A slip resistant floor mat composed of one or more layers of material the bottom layer of which incorporates a plurality of recessions with inset suction cups in the bottom surface of the bottom layer that comes into contact with the intended surface, such as a floor.
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BACKGROUND OF THE INVENTION
The present invention is related to fluidic demand apparatus, in general, and more particularly, to fluidic demand apparatus employing a microvalve or micro electro-mechanical system (MEMS) flow sensor, and the microvalve or MEMS flow sensor itself.
An example of a fluidic demand apparatus includes an Oxygen conserver which is shown by way of example in the fluidic schematic diagram of FIG. 1 . An Oxygen conserver controls the flow of Oxygen gas from a source to a patient on demand, i.e. when a patient inhales. Referring to FIG. 1 , in fluidic demand apparatus, the fluid, like Oxygen gas, for example, is generally provided from a high pressure source, such as a storage tank 10 . From the tank 10 , the fluid is usually regulated by a regulator 12 . A pressure gauge 14 may be provided at the tank 10 as an indication of the fluid remaining in the tank 10 . In the present example, the fluid in the tank 10 is at a pressure of 2,000 pounds per square inch (psi) and the regulator 12 reduces the pressure to approximately 40 psi.
The fluid may exit from the regulator 12 at a pressure of approximately 40 psi through two tubes or passageways 16 and 18 . The tube 16 may be coupled to a delivery tank 40 which is coupled through a tube 22 to an input of a shuttle valve 24 . A variable flow restrictor 25 may be disposed at the tube 16 . An output of the shuttle valve 24 is coupled through a tube 26 to a passageway 28 leading to the patient. Within the valve 24 is a piston 30 which is movable from a bottom or closed position to a top or open position (see dashed lines). The tube 18 may be coupled to a tee connection 32 which may be coupled to the top of the valve 24 through a tube 34 and to a bottom of a diaphragm container 38 through a tube 36 . Fixed fluid flow restrictors 40 and 42 may be disposed at the tubes 18 and 36 , respectively. Another tube 44 may couple the bottom of container 38 to the atmosphere through a variable restrictor 46 . Yet another tube 48 couples a top of container 38 to the patient's tube 28 through a check valve 50 . A diaphragm 52 within container 38 may be in a spring loaded position (solid line) to close off a passage between tubes 36 and 44 .
In operation, when the patient starts to inhale fluid through tube 28 , fluid is conducted through the check valve 50 in tube 48 which creates a pressure differential across the diaphragm 52 in container 38 . When the differential pressure overcomes the spring bias force, the diaphragm 52 is forced upwards (see dotted line position) which permits fluid to flow from the regulator 12 through tubes 18 and 36 , through an open passageway in container 38 and through tube 44 exiting to the atmosphere. Thus, the fluidic pressure holding piston 30 in valve 24 in the closed position is relieved allowing piston 30 to rise to the open position (dotted line). In this position, fluid flows from the delivery tank 20 through tubes 22 , 26 and 28 to the patient. The apparatus will remain in this state while the patient is inhaling.
When the patient stops inhaling, the spring bias force on diaphragm 52 forces it downward to block the fluid passageway between tubes 36 and 44 . In this state, fluidic pressure builds up in tube 34 to force the piston 30 to the closed position (solid line), thereby closing off the fluid flow between tubes 22 and 26 and to the patient via tube 28 . The foregoing described operation will repeat itself upon demand. In the present example, this demand results from commencement of inhalation of the patient. Note that the demand should be sufficient enough to overcome the spring bias of the diaphragm 52 in container 38 . Otherwise, no fluid will flow to the demanding entity. The fluid flow in the present example is limited by the various restrictors in the tubes. In some apparatus, the valve 24 , diaphragm container 38 and restrictors 40 , 42 and 46 may be integrated in a common mechanical unit.
The foregoing described mechanical fluidic demand apparatus is adequate for controlled delivery of fluid to a demanding entity; however, it has a number of drawbacks. For example, such apparatus is comprised of many individual fluidic components which are complex and expensive to assemble. The overall manufacture of such apparatus generally involves special tooling, and set-up and quality assurance procedures. In addition, the mechanical fluidic apparatus is difficult to service in the field leading to reliability and cost issues. Generally, field service of the apparatus involves replacement of parts. Also, from a clinical perspective, the response to patient inhalation is not considered sensitive enough for triggering fluid flow, i.e. the patient has to draw harder.
The present invention overcomes these drawbacks of the current fluidic demand apparatus by replacing the mechanically active parts with miniature, low power electrically operative units as will become more evident from the detailed description of the invention found herein below.
SUMMARY OF THE INVENTION
In accordance with one aspect of the present invention, a microvalve sensor for sensing fluid flow therethrough and generating an electrical signal indicative thereof comprises: a housing connectable inline with a fluid passageway; a microvalve disposed in the housing to permit fluid to flow unidirectionally through the housing, the microvalve including: a substrate; an insulating layer disposed over the substrate, the substrate and insulating layer including an orifice to accommodate fluid flow through the housing; and a diaphragm element disposed over the insulating layer, the diaphragm element including: a solid center portion having an area sufficient to cover the orifice, and an outer portion surrounding the center portion having a plurality of apertures for passing fluid from the orifice through the housing, the outer portion being affixed to the insulating layer around a periphery thereof, the diaphragm element and substrate forming opposite plates of a capacitor having a capacitance which changes with fluid flow through the housing; and a circuit coupled across the opposite plates of the capacitor and powered by an electrical source for measuring the capacitance of the capacitor and generating an electrical signal indicative thereof.
In accordance with another aspect of the present invention, fluidic demand apparatus for conducting fluid from a fluid source under pressure to a demanding entity comprises: an electrically operative fluidic valve connectable between the fluid source and demanding entity; and a fluid flow sensor connectable in a fluid passageway to the demanding entity, the sensor including a microvalve operative electrically to sense fluid flow demand from the demanding entity through the passageway and to generate an electrical signal to drive the fluidic valve in response thereto.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fluidic schematic diagram of exemplary fluidic demand apparatus, like an Oxygen conserver, for example.
FIG. 2 is a block diagram schematic of fluidic demand apparatus suitable for embodying one aspect of the present invention.
FIG. 3 is a break-away sketch of a microvalve fluid flow sensor suitable for embodying another aspect of the present invention.
FIG. 4 is a cross-sectional, cut-away sketch of an exemplary microvalve suitable for use in the fluid flow sensor embodiment of FIG. 3 .
FIGS. 5A and 5B are cross-sectional sketches of operational states of the fluid flow sensor embodiment of FIG. 3 .
FIG. 6 is a block diagram schematic of an exemplary circuit embodiment suitable for use in the fluid flow sensor embodiment of FIG. 3 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 2 is a block diagram schematic of fluidic demand apparatus suitable for embodying one aspect of the present invention. Many of the components of the embodiment of FIG. 2 remain the same as described in connection with the embodiment of FIG. 1 and thus, will maintain their same functions and reference numbers. In the present embodiment, an electrically operated, fluidic valve 60 has its input and output fluidic ports coupled to tubes 22 and 26 , respectively, and is driven by a voltage across electrical pins 62 to conduct fluid from tube 22 to tube 26 . The fluidic valve 60 may be of the type manufactured by The Lee Company under model no. LHLXO500300B, for example. In addition, a flow rate sensor 64 is disposed at tube 48 between tube 28 and atmosphere, and employs a MEMS microvalve in its operation which will become more evident from the more detailed description found herein below. The sensor 64 is operative to perform the functions of check valve operation, differential pressure operational valve setting adaptable to the demanding entity, and flow rate sensing. The sensor 64 is operative to produce an electrical signal over signal lines 66 which are coupled to electrical pins 62 of the fluidic valve 60 .
In operation, the patient or demanding entity will initially draw fluid from the atmosphere through tubes 28 and 48 and sensor 64 . Note that the unchecked flow direction of the sensor 64 is from the atmosphere to the demanding entity or patient. When the sensor 64 senses fluid flow through the MEMS microvalve therein indicative of fluid demand, it produces the electrical signal over lines 66 at a level sufficient to drive the fluidic valve 60 open to deliver fluid from the delivery tank 20 to the demanding entity or patient through tubes 22 , 26 and 28 . In this state, the sensor 64 checks delivery of fluid to the atmosphere via lines 26 and 48 . The fluidic valve 60 may be latched in the open position until the flow demand ceases. The foregoing described operation will continue for each flow demand cycle.
FIG. 3 is a break-away sketch of sensor 64 shown coupled to tube 48 . Referring to FIG. 3 , sensor 64 may include two housings or compartments 70 and 72 for containing a MEMS microvalve 74 which may be of the type marketed by iACTIV Corporation under the model no. GP-03×, for example. In the present embodiment, the microvalve 74 is fabricated using MEMS micromaching techniques in a spooked wheel design comprising a center hub 76 , a plurality of radial spokes 78 which extend from the hub 76 to an outer annular surface area 80 . The overall diameter of the microvalve may be approximately 250 micrometers (μm), for example. The center hub 76 may have a diameter of approximately 150 μm and each of the radial spokes 78 may be about 20 μm in width. The center hub 76 and spokes 78 may be approximately 5 μm thick. The spokes 78 are spaced about the periphery of the hub 76 to permit passage of fluid through the open spaces therebetween as will become more evident from the following description.
FIG. 4 is a cross-sectional, cut-away sketch of an exemplary microvalve 74 . Referring to FIG. 4 , the microvalve 74 includes a disc shaped, rigid substrate 82 which may be fabricated from a silicon wafer. The thickness of the substrate 82 is commensurate with the thickness of the fabricating wafer which may vary between 50–100 μm, for example, from wafer to wafer. Disposed over the substrate 82 is an electrically insulating layer 84 which may be silicon nitride, for example, at a thickness of approximately a few μm, for example. A tapered orifice 86 may be micromachined through the substrate 82 and insulating layer 84 to permit fluid to flow therethrough. The diameter of the orifice 86 may be around 60–80 μm at its smallest opening.
The hub 76 and spokes 78 may be micromachined from a polysilicon layer over the insulating layer 84 with the hub 76 centered about the orifice 86 and the spokes 78 attached at one end to the hub 76 and at the other end to layer 84 . Note that only one end of each of the spokes 78 is attached to the layer 84 . The thickness of the polysilicon spokes 78 are such to provide an elastic stretching thereof to permit the hub 76 to extend above the layer 80 (as shown) so that fluid may flow through the orifice 86 and the openings between the spokes 78 . In this manner, the hub 76 and spokes 78 act as a diaphragm with openings for fluid to flow through.
FIGS. 5A and 5B are cross-sectional sketches exemplifying operational states of the sensor 64 . The unchecked flow direction is shown by the arrowed line in the FIGS. 5A and 5B . Referring to FIGS. 5A and 5B , the housing 70 includes an opening 90 through which one section of tube 48 may be attached. Around the circumference of opening 90 in housing 70 is an annular indented area 92 on which to seat and attach the substrate 82 of microvalve 74 in a permanent position. Housing 70 further includes a cavity 94 above the microvalve 74 and large enough to permit the hub 76 to extend upwards to an open position (see FIG. 5B ). The height of the hub 76 in the open position may be approximately 20 μm above the orifice 86 . Housing 72 also includes an opening 96 through which the other section of tube 48 may be attached. Housings 70 and 72 may be attached together and sealed around a seam 98 to encase the microvalve 74 therein.
In a no flow demand state, the hub 76 of microvalve 74 is seated on layer 84 over the orifice 86 as shown in FIG. 5A . In the present embodiment, the hub 76 may be held against the layer 84 with an adjustable electrostatic bias force. Referring back to FIG. 4 , an integrated circuit 100 may be fabricated on the surface of layer 84 , for example, and powered by an electrical source 102 which may be a miniature Lithium battery, for example. The circuit 100 may include an inverter circuit (not shown) to amplify the voltage potential of the battery source 102 to higher output voltage potentials. Output leads 104 and 106 from the inverter circuit of circuit 100 may be connected across the hub 76 and substrate 82 with opposite positive and negative polarities to impose the output voltage potential thereacross and create an attractive electrostatic force to maintain the hub against the layer 84 , thus sealing off flow through the orifice 86 .
In the example as shown in FIG. 4 , lead 104 may be connected to a bonding pad 108 fabricated into the hub 76 and lead 106 may be connected to a bonding pad 110 fabricated into the substrate 82 . Accordingly, the bias force or bias differential pressure to be overcome by the demand may be set by adjusting the voltage potential applied across the hub 76 and substrate 82 . Note that fluid may not flow through the microvalve 74 in the checked direction, i.e. opposite the arrowed line, because the differential pressure in the checked direction will add to the electrostatic force to maintain the hub 76 against the layer 84 and seal off the orifice 86 as shown in FIG. 5A .
A block diagram schematic of an exemplary integrated circuit 100 suitable for use in the embodiment of FIG. 4 is shown in FIG. 6 . Referring to FIG. 6 , as noted above, an inverter circuit 120 may be included in integrated circuit 100 to boost the DC voltage of the source 102 which may be around 1.5 volts to a higher electrostatic DC voltage applied across the diaphragm 76 / 78 and substrate 82 via leads 104 and 106 , respectively. In the present embodiment, the electrostatic voltage may be adjustable through the inverter circuit 120 depending on the demand application and may vary from 20 volts DC to 80 volts DC, for example.
Once the bias electrostatic force on hub 76 is overcome by the demand, e.g. patient inhalation, the differential pressure across hub 76 will force it away from the orifice 86 as shown in the sketch of FIG. 5B . In this state, fluid may flow in the unchecked direction through the orifice 86 and openings between the spokes 78 . Thus, in the present example, fluid may be drawn from the atmosphere through tube 48 as an indication of fluid demand or commencement of inhalation from the patient. The sensor 74 also includes circuitry to sense this flow rate and generate a voltage signal over lines 66 to drive the fluidic valve 60 (see FIG. 2 ).
It is recognized that the substrate 82 and diaphragm, comprising hub 76 and spokes 78 , of the microvalve 74 form two plates of a capacitor. The distance between these two plates, i.e. substrate 82 and diaphragm 76 / 78 , is held constant by the insulating (dielectric) layer 84 when the hub 76 is maintained against the orifice 86 (see FIG. 5A ), but changes as the hub 76 moves away from the orifice 86 during fluid flow (see FIG. 5B ). During fluid flow, the dielectric of the capacitor also changes to include both the insulating layer 84 and the fluid itself. Thus, the capacitance formed by the substrate 82 and diaphragm 76 / 78 changes between the no flow and flow states and is commensurate with the flow rate. A measure of this capacitance will provide an indication of fluid flow through the microvalve 74 in the present embodiment.
Referring back to FIG. 6 , a capacitance measuring circuit 130 may be included in the integrated circuit 100 for measuring the capacitance between the plates 82 and 76 / 78 . The circuit 130 may employ any of the well-known techniques for measuring capacitance comprising determining a resonance frequency of a tank circuit including the varying capacitance or determining time transient behavior of the varying capacitance in the time domain, for example. These techniques generally involve applying a stimulus signal over signal lines 132 across the capacitor and measuring a response signal from the capacitor over signal lines 134 . Since in the present embodiment, the capacitor plates are at a DC voltage higher than the operating voltage of the circuit 130 which may be powered by the source 102 , for example, the stimulus signal 132 may be A/C coupled to leads 104 and 106 through a coupler circuit 136 and the response signal 134 may be decoupled from the DC voltage of leads 104 and 106 by a decoupling circuit 138 . Thus, the coupling circuits 136 and 138 permit the AC stimulus and response signals to modulate the quiescent electrostatic voltage signal of the leads 104 and 106 .
In the present embodiment, the capacitance measuring circuit 130 determines the capacitance from the response signal 134 and produces therefrom a signal over line 140 indicative of the flow rate through the sensor 74 . The flow rate signal 140 may be applied to one input of an amplifier circuit 142 to be compared with a set point signal that may be applied to another input of amplifier 142 . The set point signal is adjustable according to the demand application to be commensurate with the minimum fluid flow rate through the sensor 74 for commencement of demand. Accordingly, when the signal 140 exceeds the set point signal, amplifier 142 generates a signal over lines 66 sufficient to drive the latching valve 60 to the open state whereupon fluid is delivered to the demanding entity (e.g. patient) via lines 22 , 26 and 28 (see FIG. 2 ). Note that the microvalve 74 in sensor 64 will check fluid flow from dumping to the atmosphere through tube 48 . When the demand is reduced below the minimum flow to keep valve 60 latched, it will close and cease delivery of fluid. The foregoing described cycle will be repeated for each new demand.
While the present invention has been described herein above in connection with one or more embodiments, it is understood that such embodiments were presented by way of example and not intended to limit the invention in any way. Accordingly, the present invention should not be limited to any specific embodiment, but rather construed in breadth and broad scope in accordance with the recitation of the claims appended hereto.
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A microvalve sensor for sensing fluid flow therethrough and generating an electrical signal indicative thereof comprises: a housing connectable inline with a fluid passageway; a microvalve disposed in the housing to permit fluid to flow unidirectionally through the housing, the microvalve including: a substrate; an insulating layer disposed over the substrate, the substrate and insulating layer including an orifice to accommodate fluid flow through the housing; and a diaphragm element disposed over the insulating layer, the diaphragm element including: a solid center portion having an area sufficient to cover the orifice, and an outer portion surrounding the center portion having a plurality of apertures for passing fluid from the orifice through the housing, the outer portion being affixed to the insulating layer around a periphery thereof, the diaphragm element and substrate forming opposite plates of a capacitor having a capacitance which changes with fluid flow through the housing; and a circuit coupled across the opposite plates of the capacitor and powered by an electrical source for measuring the capacitance of the capacitor and generating an electrical signal indicative thereof.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This patent application is a continuation-in-part application of U.S. Ser. No. 853,908, filed Apr. 26, 1986, in the names of Dale B. Hoggard and Mark K. Fishler and assigned to Vesuvius Crucible Company, the assignee of the present patent application.
BACKGROUND OF THE INVENTION
In the continuous casting of steel, special refractories are used to control the flow of the molten steel and protect the molten steel from oxidation as it is poured from steel ladles to tundishes and from tundishes to continuous casting molds. Such refractories includes lide gate plates or stopper rods used in molten metal flow control, various collector nozzles in ladles and tundishes, and protective ladle shrouds and submerged pouring nozzles employed to protect molten metals from oxidation. THese types of specialty refractories are subjected to severe operating conditions such as thermal shock, molten steel erosion, and slag attack.
Such specialty refractories are usually carbon-containing refractories and, more specifically, carbon-bonded refractories. They are usually composed of refractory grain such as aluminum oxide, zirconium oxide, clays, magnesium oxide, silicon carbide, silica, or other dense grain of specific mesh size; carbon from flake graphite, amorphous graphite, carbon black, coke and like forms; and a carbonaceous binder derived from pitch or resin.
Some oxidation takes place during the manufacture of steel, and considerable amounts of oxygen may dissolve in the molten metal. In the ensuing solidification of the steel during casting, much of the dissolved gas is expelled and, in the case of oxygen, it reacts with carbon to produce evolved carbon monoxide. The dispelled oxygen, carbon monoxide and other gases create undesirable porosity, cracks, and internal defects which lower the quality of the finished steel. In order to eliminate the problem of dissolved oxygen, molten steels are deoxidized or "killed" by the addition of aluminum metal, ferromanganese, or ferrosilicon. In the case of aluminum-killed steel, the aluminum reacts with dissolved oxygen or iron oxide to form finely-dispersed aluminum oxide, some of which floats into the slag above the molten steel and some of which remains as highly-dispersed micro particles in the solidified steel. During continuous casting, this extremely fine dispersed portion of alumina has a tendency to either precipitate out of the molten steel onto the cooler refractory surfaces or react and stick to the ceramic refractories that control the molten steel in its path from ladle to tundish to casting mold.
This precipitated alumina has a particular affinity to the typical carbon-bonded alumina-graphite refractories commonly utilized as ladle shrouds and submerged pouring nozzles, the latter also referred to as a subentry nozzle or simply as "SEN". The alumina will continue to build up in the interior of the SEN until the flow of molten steel is reduced to a point where the tube must be lanced open by an oxygen torch or the SEN is discarded. If oxygen lancing becomes necessary, the casting process is disrupted costing time and money, casting efficiency decreases, and the quality of the steel must be downgraded. A total alumina blockage of a SEN decreases the expected life of the refractories and is very costly to steel producers. In alumina-killed steels where high dissolved-oxygen concentrations are expected, the useful life of a submerged pouring nozzle may be limited to 2-3 ladles due to heavy alumina buildup on the interior diameter of the tube.
Heretofore, one of the solutions to this problem has been the development of an argon injected SEN, which allows high pressure argon to permeate the porous interior diameter of the nozzle during casting, thereby forming a protective layer of inert gas which hinders the bonding of the dispersedalumina to the refractory. The argon also reduces the oxygen partial pressure at the refractory-molten metal interface, again decreasing the possibility for adherence of alumina deposits. Exemplary of such is the gas permeable immersion pouring nozzle disclosed in UK patent application GB 2,111,880 A, to Gruner et al. The argon-injection technology has extended SEN life a step further at an ever increasing cost--the expense of large volumes of argon required during casting and the increased manufacturing costs of the more complex SEN-argon nozzles. It has been observed as well that the argon may introduce objectionable pinholes into the cast steel through absorption and subsequent expulsion of the gas as the molten metal solidifies.
It has also been proposed to provide a pouring nozzle with a lower melting point liner composition which prevents alumina buildup. Liner materials developed to date include the use of CAO-MgO-Al 2 O 3 liners, as disclosed in UK patent application GB 2,170,131 A to Tate, which develop low melting eutectics (between 1350° C.-1600° C.) which are washed out of the nozzle as alumina is deposited and reacts with the liner. The melting action prevents the alumina buildup and allows for the free flow of molten steel. Also reported to be effective in prevention of alumina adhesion is a sleeve of Magnesium oxide (MgO) according to UK patent application GB 2,135,918 to Rosenstock et al.
It has still further been proposed in UK patent application GB 2,110,971 A to Kurashina et al. to provide a submerged nozzle of a modifiedgeometry wherein the lower portion of the inner nozzle diameter is greater than the top, with an angled step therebetween to prevent blockage of the flow passage. The upper portion of the nozzleis comprised of alumina-graphite and the lower portion is zirconia-graphite.
The present invention provides a method of preventing Al 2 O 3 buildup during casting and an article of manufacture of a refractory composition that is formed as an interior liner on submerged pouring nozzles, ladle shrouds, collector nozzles and like components. The invention thus inhibits the buildup of alumina and other oxides on such specialty refractories used in the flow control and protection of molten steel during continuous casting of aluminum-killed steels and the like.
Still further,the present invention provides an interior liner composition for subentry pouring nozzles which substantially prevents alumina from adhering to the refractory by improving the nonwetting characteristics at the molten metal/nozzle interface. The invention provides a nozzle liner of a composition having similar thermal expansion properties tot he alumina-graphite and zirconia-graphite refractories presently in use so as to prevent cracking during firing in manufacture and during casting operations. Still further, the liner composition of the present invention provides superior steel erosion resistance, similar to the aluminagraphite body of existing SEN nozzles to allow for long casting sequences and low permeability to decrease the opportunity for unwanted exidation.
The present invention further provides a submerged pouring nozzle or SEN for continuous casting of killed steels which resists buildup of alumina on a level equal to or better than the current argon SEN. The SEN of the present invention includes a liner material which is simultaneously pressed and fired with the other conventional refractories comprising the nozzle. The invention thus achieves the desired goal of reducing alumina buildup to superior levels without the need for expensive inert gas hardware and the complicated and expensive gas permeable nozzles heretofore required in such practice.
SUMMARY OF THE INVENTION
Briefly stated, the present invention provides a method and a refractory article for minimizing alumina and other oxide buildup in pouring nozzles and like shapes during the continuous casting of aluminum-killed steels. A pouring nozzle according to the present invention comprises a nozzle body having a central bore extending axially therethrough from an inlet end to an outlet end. The nozzle body is preferably formed of a conventional carbon-bonded, alumina-graphite refractory and may also contain a slagline sleeve around a circumferential portion of the exterior in contact with the molten slag. The slagline sleeve may be a conventional zirconia-graphite refractory or it may be formed of an improved carbon-bonded SiAlON composition disclosed in the above-referenced, copendig patent application, Ser. No. 853,908. The central bore of the nozzle body includes an integral lining therearound of a SiAlON-graphite composition set forth below. The nozzle further includes exit ports at the outlet end which also preferably are lined with the carbon-bonded SiAlON material of the present invention so as to minimize unwanted alumina formations and thus preclude blockage of molten metal flow. The liner material can conveniently be isostatically pressed simultaneously with the alumina-graphite body and the zirconia-graphite or SiAlON-graphite slagline sleeve and then fired in a reducing atmosphere. The finished or fired liner thickness in the nozzle bore is preferably between about 5 to 25 mm (millimeters) in thickness, the thickness being dependent upon the continuous casting conditions and the quality of the steel.
In accordance with the present invention, a method is provided to resist alumina or other oxide buildup in a subentry nozzle or refractory like shape during continuous casting of steel, comprising the steps of providing a refractory shape having a liner adapted to contact the molten steel of a composition within a preferred range and consisting essentially of:
______________________________________Constituent Amount in Weight %______________________________________(a.) Carbon about 4-50%(b.) SiAlON (Si.sub.6-z Al.sub.z O.sub.z N.sub.8-z)where 0 z 5 about 20-90%(c.) Antioxidant (B.sub.4 C and the like) about 2-8%(d.) Binder - (Pitch, Resin orthe like) about 0-10%(e.) Diluting refractory grains(SiO.sub.2, Al.sub.2 O.sub.3, ZrO.sub.2 andthe like) about 0-70%;______________________________________
and passing molten steel over said liner composition, whereby alumina or other oxide buildup is resisted so as to extend the life of the nozzle or like shape.
BRIEF DESCRIPTION OF THE DRAWING
The drawing figure depicts a partially fragmented, cross-sectional side view of a bottom pour tundish with a subentry nozzle having an anti-alumina buildup liner of the present inventionshown delivering molten metal to a continous casting mold.
DETAILED DESCRIPTION OF THE INVENTION
In the drawing, a subentry nozzle (SEN) 10 is shown in place on a conventional bottom pour tundish 2. The tundish has a refractory lining 4 which contains a molten bath of metal 6, for example, aluminum-killed steel, which is transferred by way of the nozzle 10 to a conventional continuous casting mold 8. The mold 8 includes a water jacket 9 therearound for chilling of the mold. The nozzle 10 has an internal bore 12 extending axially from an inlet end at the tundish 2 to an outlet end positioned within the mold 8. A plurality of exit ports 14 are formed at the outlet end of the nozzle and communicate with the internal nozzle bore 12. During a continuous casting run, the molten steel 6 flows from the tundish 2 to the SEN 10, passes through the internal bore 12 and exits the nozzle via ports 14 beneath a surface 16 of the molten metal. The discharge end of the SEN is thus positioned within the interior of a molten metal core 15 of a solidified strand 17 which slowly descends from the bottom of the mold 8. Use of a submerged entry nozzle, such as SEN 10, prevents splashing and oxidation of the molten steel, among other well known advantages. A commonly used refractory for the body of nozzle 10 is alumina-graphite which is particularly suited for this environment due to its excellent thermal shock resistance and steel erosion resistance.
It is also common in continuous casting operations to employ a layer of mold powder above the metal surface 16 in order to capture and prevent entry of nonmetallic inclusions in the molten metal. In addition, the mold powder serves as a lubricant and provides surface protection for the strand of metal 17 as it leaves the mold 8. Commonly used mold powders are comprised of mixtures of oxides having a relatively low melting point which form a molten slag layer 18 that floats on the surface 16 of the molten metal in the mold. It is observed that the area of a subentry nozzle in contact with the slag layer 18, referred to as the slagline or powder line area, undergoes corrosion or erosion at a higher rate than the balance of the nozzle body. In order to extend the life of the alumina-graphite nozzle body 10, it is common to provide subentry nozzles with a slagline sleeve or insert 20, of a material which is of a higher resistance to the mold powder slag attack. Such materials which may be used as a suitable refractory for the slagline sleeve 20 are a known zirconia-graphite refractory or the novel carbon-bonded SiAlON compositions set forth in co-pending application Ser. No. 853,908.
With nozzle life effectively extended through the use of such improved slagline materials, the limiting factor affecting nozzle life has now become its ability to remain open during casting. The use of improved commercial zirconia-graphite slagline sleeves has increased the normal life expectancy of the average alumina-graphite submerged pouring nozzle up to 2-6 ladles of steel during continuous casting. The longer casting times have thus magnified the clogging problem found characteristic of alumina-graphite nozzles. As discussed above, there is a tendency for dispersed alumina, expecially in aluminum-killed steels, to precipitate on and adhere to the cooler interior diameter surfaces of the alumina-graphite SEN. This buildup normally continues until the flow of steel is restricted or blocked, requiring oxygen lancing to restore normal flow. Often times the SEN must be discarded and replaced due to alumina blockage.
We have discovered that a refractory liner 22 formed around the central nozzle bore 12 and a liner 22' around the exit ports 14 of a SiAlON-graphite composition, described below, dramatically increases the life of the nozzle 10, exceeding that of argon injected nozzles which heretofore have offered superior anti-alumina buildup characteristics. A nozzle 10 having a liner 22 and 22' according to the present inventio resists the formation and buildup of alumina or other oxides, during the continuous casting of aluminum-killed steel and the like. A preferred starting raw material composition for the carbon bonded SiAlON liner 22 and 22' refractory consists essentially of, in weight percent:
______________________________________(a) Carbon (C) about 4-50%(b) SiAlON, wherein the SiAlON has a composition (Si.sub.6-z Al.sub.z O.sub.z N.sub.8-z) having one or more "z" values within a range of greater than zero to five. about 20-90%(c) Antioxidant constituent, such as SiC, SiO.sub.2, B.sub.4 C, Boron compounds, aluminum, silicon, other silicon- containing compounds, other glass- forming compounds, or the like. about 2-8%(d) Carbonaceous binders selected from about 0-25% and pitch or resin or some other preferably about carbonaceous material; and 2-15%(e) Other diluting refractory grains or powders well known in the refractory industry such as clay, alumina, zirconia, zircon, silica, silicon carbide, mullite, chromia, iron chromite, magnesia, mag- nesium aluminate, or the like, or lesser known refractory materials such aluminum nitride, boron nitride, or the like. about 0-70%______________________________________
Thus, the liner composition is prepared by combining SiAlON grain or fine powder and elemental carbon, preferably graphite. Additional known refractory grain may also be added to the mixture, as less expensive dilutents, which are then blended with a carbonaceous binder, such as resin or pitch, along with a known antioxidant, such as SiC, SiO 2 , B 2 O 3 or other boron compounds or like antioxidant materials. The carbonaceous binder is employed to give the pressed and cured shaped mechanical strength prior to firing. The binder loses about 50% of its initial weight during thermal treatment. The carbonaceous binder, depending on the amount used, thus contributes from trace amounts up to about 13% by weight of the final carbon content of the composition after firing. The liner material 22 and 22' is preferably isostatically pressed simultaneously with the nozzle body 10 and the slagline sleeve 20 to produce the composite nozzle or SEN shown in the drawing. The pressed composite is cured and fired in a known manner in a reducing atmosphere, usually at temperatures between about 800° C. and 1500° C. As shown in the drawing, the liner 22 surrounds the internal nozzle bore 12 while the liner portions 22' surround the outlet ports 14 of the SEN 10. The thickness of liner portions 22 and 22' is preferably between about 5 to 25 mm, the thicknesses chosen being dependent upon dependent anticipated casting conditions and steel qualtiy.
A typical SEN such as the submerged nozzle 10 shown in the drawings may be a carbon containing shape made up of two different refractory compositions. The main body portion of such a commonly used nozzle maybe composed of a carbon-bonded alumina-graphite material. Heretofore alumina-graphite refractory has been successfully used as a submerged pouring nozzle material in the continuous casting of steel due to its excellent thermal shock resistance and erosion resistance. The slagline area 20 is preferably made of a known carbon-bonded zirconia-graphite material or of the SiAlON carbon-bonded refractory referred to herein and in the referenced co-pending patent application, Ser. No. 853,908. Typical chemistries of a commercialalumina-graphite body 10 and zirconia-graphite slagline sleeve 20 with which the liner of the present invention may be used are set forth below in Table I, by weight percent.
TABLE I______________________________________ Nozzle Body (10) Slagline Sleeve (20) Alumina Graphite Zirconia Graphite______________________________________C 32 wt. % 16.5 wt. %Al.sub.2 O.sub.3 52 wt. % 1.0 wt. %SiO.sub.2 14 wt. % 2.0 wt. %Minor 2 wt. % 1.5 wt. %ZrO.sub.2 -- 75.0 wt. %CaO -- 4.0 wt. %______________________________________
SiAlON is defined as a solid solution and/or dispersion of aluminum oxide and aluminum nitride throughout a silicon nitride matrix. Generally, SiAlON is described as a refractory material composed of at least 80% by weight of silicon-aluminum oxynitride which has a crystal structure based upon beta silicon nitride (Si 3 N 4 ), but of increased unit cell dimensios which obeys the formula:
Si.sub.6-z Al.sub.z O.sub.z N.sub.8-z
where "z" is greater than zero but less than or equal to five. The SiAlON grain used herein was produced by the carbothermal reduction of alumina-silica materials in nitrogen.
In the examples described below, the particle sizes of the SiAlON, and other refractory grains and powders used in making the various test compositions, ranged from less than about a -4 mesh (U.S. Standard Seive Size) for the grain, down to about 0.5 microns average particle size for the fine powders. Grains and powders having a particlesize intermediate those two extremes are suitable for use as starting materials in practicing our invention. The elemental carbon addition in the mixture may be in the form of graphite, carbon black, petroleum coke or the like. In the examples presented below, the carbon additions were made using graphite in the form of natural vein or flake graphite, commonly referred to as crystalline graphite, with a carbon content of greater than about 70% by weight. The particle size of the graphite is preferably less than -8 mesh, U.S. Standard. The flake graphite has a platelet structure which may be preferred in certain applications due to its high thermal conductivity.
EXAMPLE I
In the following example, two SiAlON compositions were made, wherein z=1.5 and z=3. SiAlON grain was obtained by sintering with yttria at 1700° C. The grain was crushed and sized and iron magnetically removed.
Various compositions of carbon-bonded SiAlON-graphite were mixed and blended, isostatically pressed into cylinders 50 mm ID×115 mm OD×180 mm 1 g. and fired in a reducing atmosphere. Bars were cut from the cylinders 20 mm×20 mm×150 mm 1 g. and were mounted in sets of four for steel erosion and alumina buildup testing. A low carbon 1010 steel scrap was melted by induction in an MgO crucible. In order to obtain the maximum concentration of aluminum oxide in the molten steel, the steel oxygen level was increased and carbon content decreased by directly injecting gaseous oxygen into the molten bath, following which 0.2-0.5% aluminum metal was added and temperature stabilized between 1680°-1720° C.
The aluminum metal was added to the molten steel to deoxidize or "kill" the steel. The four sample bars as a test group, were mounted together, immersed in the aluminum-killed steel, and rotated for 10 minutes at 20 revolutions per minute. Following the tests, a thick coat of fine powdery alumina was deposited on certain samples having a tendency toward alumina buildup in practice. To differentiate between compositions, alumina buildup for each sample was described and documented. Based on these physical observations, each sample was ranked against the others in the set of four. A ranking of "one" indicating excellent resistance to alumina buildup; a ranking of "four" indicating poor resistance to the buildup of alumina. After several tests, the buildup resistance ranking was averaged and the material ranked according to its cumulative performance. Although not quantitative in nature, the buildup ranking is a convenient and effective indicator of the susceptability of refractory composites to alumina buildup problems.
Reported below in Table II, is a summary which details the fired composition and the comparative alumina buildup rankings of the improved carbon-bonded SiAlON liner compositions tested. These results are compared to the known alumina-graphite and zirconia-graphite materials which served as standards during testing. The alumina buildup resistance parameter is the average value of the number of test samples indicated. Table II follows hereinafter.
TABLE II__________________________________________________________________________ Composition No. (Weight %)Composition/Properties #1 #2 #3 #4 #5 #6 #7 #8 #9 #10 #11* #12**__________________________________________________________________________C 28 28 29 28 22 27 18 31 29 34 32 16.5SiAlON (z =1.5) 67 67 66 42 36 43 -- 18 53 28 -- --SiAlON (z =3) -- -- -- -- -- -- 48 49 -- -- -- --Al.sub.2 O.sub.3 -- -- -- -- -- -- -- -- -- -- 52 1ZrO.sub.2 -- -- -- -- 38 27 31 -- -- -- -- 75SiO.sub.2 1 1 1 1 0.5 -- -- -- 14 15 14 2CaO -- -- -- -- 2 1.5 1.5 -- -- -- -- 4Antioxidant 4 4 4 4 3.5 2 2.5 3 4 4 -- --AlN -- -- -- 25 -- -- -- -- -- -- -- --BN -- -- -- -- -- -- -- -- -- 20 -- --Minor -- -- -- -- -- -- -- -- -- -- 2 1.5No. of Test Samples: 2 7 5 10 4 4 4 2 3 4 45 5Alumina BuildupResistance Ranking: 1.4 1.5 1.7 1.8 1.8 1.8 1.6 1.3 1.4 1.8 3.4 2.3(l = excellent, 4 = poor)__________________________________________________________________________ *Standard AluminaGraphite **Standard ZirconiaGraphite
The above test results reported in Table II demonstrate that liner materials in accordane with the present invention, represented by Composition Nos. 1 through 10, based on the carbon-bonded SiAlON system, are clearly superior to the standard alumina-graphite (Composition No. 11) and also superior to the zirconia-graphite refractory (Composition No. 12) in terms of alumina buildup resistance. It is also observed that SiAlON material of differing "z" values can be mixed, as in Composition No. 8, to produce superior anti-alumina formation properties in a nozzle liner.
EXAMPLE II
Several full-size submerged pouring nozzles such as nozzle 10 of the present invention with the anti-alumina buildup liner composition shown in Table III, below, were isostatically pressed, fired, and tested as trial pieces at a commerical steel manufacturer that specializes in continuous casting of low carbon aluminum-killed steel.
TABLE III______________________________________(in weight percent)______________________________________C 29%SiAlON (z = 1.5) 67SiO.sub.2 1Antioxidant 3______________________________________
The submerged nozzle 10 of the present invention with the SiAlON-graphite liner composition of Table III was tested side-by-side in a twin strand caster with a commerical SEN argon injected nozzle. The SEN argon was a commercial submerged nozzle designed to allow pressurized argon gas to permeate the interior lining of the nozzle commonly used to prevent alumina buildup and internal clogging. The SEN argon nozzle of the type tested has heretofore offered superior anti-buildup performance. These test nozzles were positioned so as to transfer the molten steel from the tundish into the continuous casting molds. Type 2848 steel was continuously cast at ladle temperatures of about 1544°-1570° C. The casting tests indicated that the nozzle 10 having the SiAlON-graphite anti-buildup liner 22 and 22' functioned flawlesslyfor a nine ladle sequence. This is approximately double the number of ladle pours normally expected from submerged nozzles without a liner or without argon injection. The SEN argon control nozzle which ran side-by-side with the SiAlON-graphite lined SEN 10 required lancing with oxygen after the seventh ladle pour and was totally blocked after the ninth ladle. Thus, the need for expensive argon injection is eliminated by the SEN 10 nozzle of the present invention.
The mechanism of alumina buildup in submerged nozzles appears to relate to the wetting and freezing of molten steel as well as the precipitation of alumina on the cooler refractory surfaces, after which the deposits grow from the nucleated sites. The SiAlON-graphite liner of the invention develops a vitreous, high melting glassy layer at the liner-molten steel interface due to oxidation of the silicon nitride material during casting. This glassy boundary has been shown to be passive and quite protective during mormal preheat operations and it is expected that similar characteristics are evident in a molten steel environment, resulting in controlled erosion of the liner. It is theorized that the controlled erosion of the SiAlON-graphite liner also prevents the nucleation of alumina and hinders the buildup of alumina deposits. Nucleation and buildup of oxides other than alumina are also resisted.
While specific embodiments of the inventin have been described in detail, 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. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention which is to be given the full breadth of the appended claims and any and all equivalents thereof.
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The invention is directed to a lining composition for submerged entry pouring nozzles and like shapes used in the continuous casting of metals, particularly aluminum killed, low carbon steels. The lining prevents harmful buildup of alumina and other oxides within the nozzle bore which may cause premature nozzle clogging. The nozzle liner comprises a carbon-bonded, SiAlON-graphite refractory material. Small amounts of antioxidants and additional amounts of less expensive refractory grain or powder are also added to dilute the more expensive SiAlON material.
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This application is a divisional of application Ser. No. 11/756,965, filed Jun. 1, 2007 now U.S. Pat. No. 7,682,320, which is hereby incorporated by reference.
BACKGROUND
Pain management has become a significant struggle in the lives of many people today. Often pain is attempted to be controlled through medication, both through prescription and over the counter forms, with varying degrees of success. Other pain management techniques are also employed, including homeopathic remedies, chiropractic treatments, and acupuncture, to name a few. The efficacy of any type of pain management technique is determined by the skill of the practitioner, whether it be a medical doctor or acupuncturist, for example, and by the receptiveness of the patient to the treatment.
Additionally, most types of pain management or control techniques work by treating the symptoms, or apparent source, of the pain. Massage therapy, for example, is directed to relieving soreness or tightness of particular muscles, and often causes increased discomfort or pain before improvement is felt. What is needed is a process, technique, or device that relieves pain without forcing a patient to feel worse before they feel better. The present disclosure is directed to just such techniques and associated devices.
SUMMARY
The present disclosure is directed to a therapeutic method for normalizing a spine of an individual including identifying a first point on the spine that exhibits the greatest degree of spinal misalignment and the hemisphere of the misalignment. A second point on the back of the individual is found using a measuring device to measure along the spine a calculated distance specific to the individual. The second point on the back is then translated to a third point on the front of the individual opposite the second point. Application of therapeutic treatment near the third point normalizes the spine. In one embodiment, the distance is calculated by dividing the height of the individual by eight.
Further objects, embodiments, forms, benefits, aspects, features and advantages of the present disclosure may be obtained from the description, drawings, and claims provided herein.
DESCRIPTION OF THE DRAWING
FIG. 1 is a front diagrammatic view of a portion of the human anatomy, illustrating a correlation in accordance with the present disclosure.
FIG. 2 illustrates a front diagrammatic view of a human form, showing the location of relationship zones in accordance with the present disclosure.
FIGS. 3A , 3 B, 3 C, and 3 D show the location and arrangement of relationship zones in the arm in accordance with the present disclosure, as the arm is held in different positions.
FIG. 4 is a front diagrammatic view of the head, showing the location of relationship zones in accordance with the present disclosure.
FIG. 5 is a side diagrammatic view of the head, showing the location of relationship zones in accordance with the present disclosure.
FIG. 6 is a front diagrammatic view of a portion of the human anatomy similar to that shown in FIG. 1 , illustrating additional correlations in accordance with the present disclosure.
FIG. 7 is a side diagrammatic view illustrating relationship zones in the arm and the leg, and also showing a correlation in accordance with the present disclosure.
FIG. 8 is a side diagrammatic view of another portion of the human anatomy, illustrating another correlation in accordance with the present disclosure.
FIG. 9A is a back diagrammatic view illustrating a portion of the typical human anatomy including the spine, illustrating a correlation in accordance with the present disclosure.
FIG. 9B is a front diagrammatic view illustrating a view of a human torso, illustrating a correlation in accordance with FIG. 9A .
FIG. 10 is a front diagrammatic view of the height measurement of a person between the top of the head and the sole of the feet.
DETAILED DESCRIPTION
The present disclosure describes unique pain management or treatment methods, techniques, and devices that operate under the theory that when muscles are relaxed and in balance, the skeletal system of the body will have a tendency to be aligned, and will thus be structurally strengthened. Skeletal alignment improves circulation of the vascular and the nervous systems, increasing energy flow throughout the body, which enhances and allows the body to better heal itself.
Specifically, the present disclosure describes a process that from any specific pain location on the body, a series of specific related points can be found. When these related points are treated, either individually or in some combination, the pain felt at the original complaint point is alleviated or reduced.
In order to describe this process, reference is made to FIG. 1 , which shows a drawing 10 illustrating a portion of the typical human anatomy. Drawing 10 shows the head 12 , torso 14 , arms 16 , hands 18 , and the upper part of legs 20 . Also shown in FIG. 1 is an overlay 22 of a pair of feet. Overlay 22 is scaled to provide a precise correlation between the dimensions of the feet and a particular part of the human anatomy, namely the torso. As can be seen in FIG. 1 , overlay 22 extends so as to completely overlay torso 14 thereby providing visible correlations as will be described below. Drawing 10 may be a photograph or outline drawing of an individual patient, and overlay 22 may be a scaled photograph or outline drawing of the actual feet of such patient. Drawing 10 may also be merely a representation of a typical or generic human form, with overlay 22 also being merely a representation of generic human feet. For purposes of explaining the pain treatment method of the present disclosure, the representations are equivalent. In practice, the skill of the therapist or practitioner may determine whether actual or generic patient representations are needed and used. Highly skilled practitioners may not require the creation of a drawing 10 and overlay 22 at all, as they may be able to visualize the feet to torso correlation for a particular patient. Less experienced practitioners or therapists, or those being trained or still learning the methods and techniques of the present disclosure, may find it helpful to create or refer to an actual drawing and overlay in order to understand the principles of the disclosure.
As previously described, overlay 22 is scaled to match the vertical dimensions of torso 14 such that there is a correlation between the torso and the top 24 (toes) and bottom 26 (heel) of the feet, as well as correlations between the feet and the top of the shoulders 28 , the fifth metatarsal bone in the foot to the lower rib, the heel 26 to the top of the hip 30 , the waistline to the feet, the groin to the heel 26 , and the feet to the chest and abdomen. These correlations are formed as part of a locator system that is integral with the present disclosure. The locator system involves, in one component, a series of measurements that are developed for an individual patient to determine the location of the various points on the patient's body that are to be treated. The use of the locator system will be explained in the following paragraphs.
In accordance with one embodiment of the disclosure, an individual (e.g., patient or client) presents themselves to a practitioner of the method of the disclosure with a problem or condition that is causing pain. In some cases the patient may be able to describe the initial event that originally caused the problem, but in other cases the patient may just know that some area of the body hurts or is sore. The practitioner then identifies, through sight or by touch, the spots or areas of tenderness or soreness on the patient's feet. There may be multiple points, spots, or areas of tenderness on the patient's feet. These points or areas of tenderness or soreness, referred to as congested areas, may or may not be related to each other, but typically the most tender spot will relate to that particular pain of which the patient is primarily complaining. The spot or area on the feet that is determined to be the most tender or sore is designated as the primary reference point. In FIG. 1 , this is designated as point 32 .
As described above, overlay 22 correlates the feet of the patient to torso 14 . By this correlation, point 32 on the feet of the patient physically corresponds to a spot or point on torso 14 ; in FIG. 1 , this is illustratively shown as point 32 ′. This corresponding point 32 ′ is designated as the primary referral point. The patient will typically experience some degree of pain or soreness when the primary referral point is touched. Treating or working the primary referral point 32 ′, e.g., through massage, will relieve at least some, and occasionally all, of the original pain complained of by the patient. The locator system is used to identify additional points or areas of the patient's body which, when treated, will further relieve or alleviate the patient's original pain. These points or spots are designated as related referral points and helper referral points and are located as follows.
With the patient lying down, the therapist or practitioner measures the height or length of the patient from the top of the head to the sole of the feet, i.e., the feet are held perpendicular to the body. This measurement is then divided by four to determine the distance between related referral points, i.e., the distance from the primary referral point to a related referral point and the distance from one related referral point to the next referral point. The distance between related referral points is also divided by two to determine helper referral measurement 67 , the distance from a related referral point to a helper referral point. One method of locating referral points is to measure whole number multiples of helper referral measurement 67 away from primary reference point 66 . Even whole number multiples, e.g., 2, 4, etc., locate related referral points while odd whole number multiples, e.g., 1, 3, etc., locate helper referral points. The body height or length measurement is recommended to be made with a metric (i.e., base 10 ) ruler or measuring tape for ease in calculating the related referral point and helper referral point distances. Treating or working each referral point, whether it be a primary referral point, a related referral point, or a helper referral point, will act to reduce or alleviate the pain experienced by the patient. However, merely knowing the distances between referral points is not enough to accurately locate those points on the patient. The additional information that is needed is described as follows.
related
.
referral
.
measurement
=
height
4
(
1
)
helper
.
referral
.
measurement
=
related
.
referral
.
measurement
2
=
height
8
(
2
)
Referring now to formulas (1) and (2), the calculations for the related referral measurement and the helper referral measurement are expressed as mathematical equations. Referring to formula (2), the helper referral measurement can be calculated by either dividing the related referral measurement by two or by dividing the height of the patient from the top of the head to the sole of the feet by eight.
Referring to FIG. 10 , the measurements and calculations discussed above are illustrated. FIG. 10 depicts a front view of person 60 including top of the head 61 and sole of the feet 63 . Height H is the distance between top of the head 61 and sole of the feet 63 . Related referral measurement 69 is determined by dividing height H into four equal lengths, as shown in FIG. 10 .
Once the distances between the various referral points are calculated, placement of the actual referral points is made by using the calculated distances and measuring within the particular body zone in which the primary referral point is located. Referring now to FIG. 2 , there is shown a human form diagram 34 with body zones identified in accordance with the present disclosure. Diagram 34 comprises a plurality of longitudinal body zones that progress laterally from the median plane. Central zone 36 begins at the top of the head and follows a path through the torso and includes an inner region of each leg and each foot. Symmetrical zones 38 L and 38 R are located on either side of central zone 36 , followed by symmetrical zones 40 L and 40 R, symmetrical zones 42 L and 42 R, and symmetrical zones 44 L and 44 R. The arms 46 of the human form in diagram 34 comprise zones flowing from the head and neck. These zones run diagonally across the vertical zones in the torso and also directly correlate to the respective zones in the rest of the body described above. These zones are identified as zones 48 L and 48 R, 50 L and 50 R, 52 L and 52 R, 54 L and 54 R, and 56 L and 56 R. The zones of arms 46 can be seen more clearly in FIGS. 3A and 3B . Each zone defines a particular shape or contour along diagram 34 . In accordance with the present disclosure, each related or helper referral point will be located within the same zone as is their primary referral point. With reference to FIGS. 1 and 2 , it is apparent that primary referral point 32 ′ is located within zone 40 L. Each of the related referral points and helper referral points identified by use of the locator system previously described will therefore also be located within zone 40 L. The various zones as illustrated in FIGS. 1-3 are illustratively shown as being well defined with sharp or precise delineations. In practice, however, the crossover between one zone and another may be less sharp, but an experienced practitioner will be able to accurately separate one zone from another through treatment and patient feedback.
FIGS. 4 and 5 illustrate the zones of the head. Although the head zones are continuations of the body zones illustrated in FIG. 2 and consequently are correlated to the body zones, the head zones have particular shapes and define much more specific regions than do the zones that comprise the body, as is particularly apparent in FIG. 5 . For that reason, treatment of the head for purposes of pain management requires precision in the locating and defining of the particular zone in which the relevant referral points are to be found.
FIG. 6 illustrates one example of how various referral points can be located on an individual or person 60 . The representation of person 60 in FIG. 6 illustrates the previously described zones of the body, head and arms, as well as a scaled overlay 62 of the feet of person 60 . As described above, a point of soreness or tenderness in the feet of person 60 defines a primary reference point 64 on overlay 62 . This correlates to a primary referral point 66 on the torso of person 60 . As can be seen, primary referral point 66 is located within zone 42 R. Therefore, all related referral points will also be located within zone 42 R. There may, of course, be other areas or points of soreness that define other primary reference points or primary referral points that are located in other zones, but the referral points associated with primary referral point 66 will all be located within zone 42 R.
Related referral point 65 is identified and its location determined by measuring one related referral measurement 69 below primary referral point 66 within zone 42 R using measuring device 71 . (Note that other related referral points can also be located above primary referral point 66 , if space permits.) Helper referral points 68 and 70 can be identified and their location determined by measuring one helper referral measurement 67 above and below primary referral point 66 or related referral point 65 within zone 42 R using measuring device 71 . The locator system can also be used to find additional helper referral points from helper referral points 68 and 70 . Treating the various related referral points through massage, manipulation, heat, or other therapeutic means, singly or in combination, will relieve or lessen the soreness associated with primary referral point 66 . By treating the helper referral points as well as the primary referral point, pain relief can be realized while avoiding repeated painful treatment or manipulation of only the “sore spot.”
The pain management method of the present disclosure therefore can be used to relieve pain without subjecting the patient or client to the added pain of the treatment itself. For this reason, the disclosed pain management method can be used on babies and individuals having low pain tolerance or acute localized pain without aggravating the source of the pain.
Related referral points can be directly correlated from the feet to the torso, from the head or the legs to the torso, or from the torso to the head or legs. Due to a difference in scaling factor, the locator system does not permit direct correlation to and from the arms. However, as shown in FIG. 7 , the arm 72 of a patient or client can be physically correlated or scaled to the patient's or client's leg 74 , such as along illustrative transfer or correlation lines 76 , for example, such that referral points located in the leg can be transferred to the arm, within the corresponding zone (e.g., zones 78 and 78 ′), for treatment, or points of soreness in the arm can be transferred to the leg where the locator system will then allow direct correlation to the primary referral point 66 on the torso, and subsequently, other body parts to locate the related referral points such that treatment of such referral points will act to alleviate the pain or soreness in the arm.
The previous description has explained the correlation between tenderness or soreness along the bottom of a patient's feet with a source of pain or discomfort in other regions of the body. Human form diagram 34 , depicted in FIG. 2 , illustrates that the spine and the inside of the feet are all in zone 36 and that the left foot is in the left hemisphere and the right foot is in the right hemisphere. FIG. 8 illustrate a correlation of the spine to the feet. An area of discomfort, or “sore spot,” along the inside of the feet can be correlated to skeletal pain in the spine or back. FIG. 8 depict an overlay of foot 88 superimposed on spine 84 . From the depicted overlay, it is possible to translate pain in the inside of foot 88 to a specific area or location along spine 84 that is causing the associated body or skeletal pain. For example, as depicted in FIG. 8 , sore spot 86 along the inside of foot 88 correlates to a primary referral point 86 ′ on spine 84 . Using the locator system described above with respect to primary referral point 86 ′ on spine 84 will lead to the identification of related and helper referral points that, when treated, will aid in the overall reduction of pain and discomfort felt by the patient.
Another embodiment of the disclosure is depicted in FIGS. 9A and 9B which show drawing 90 illustrating a portion of the typical human anatomy including spine 91 illustrated in FIG. 9A . This embodiment deals with normalizing the spine using the same overall techniques described above. With the patient lying on their stomach, the therapist or practitioner observes the spine to find the point at which the spine is exhibiting the greatest degree of misalignment, which is illustrated as point 92 in FIG. 9A . The therapist or practitioner also notes whether the spine at point 92 is being pulled to the right or left hemisphere of the torso.
The therapist or practitioner then measures up (or down) one helper referral measurement 67 from point 92 to point 94 in zone 36 and either physically or mentally marks point 94 on the back. The actual treatment area 94 ′ is on the front of the torso, directly opposite point 94 , as illustrated in FIG. 9B .
The therapist or practitioner then works treatment area 94 ′ on the front of the torso. The therapist or practitioner interacts with the patient to verify the exact location by degree of tenderness or soreness and then works that area until the tenderness/soreness subsides. Zone 36 (the zone the spine is in) extends to both the left and right hemispheres of the body. The therapist or practitioner works in the same hemisphere of the body that the spine is pulled towards at point 92 . By relaxing the tight muscles that are pulling the spine to either the right or left hemispheres of the torso, the spine is allowed to normalize by reverting to its normal, straight, position.
The therapist or practitioner then rechecks the alignment of the spine with the patient lying on their stomach. For some patients, the spine will normalize itself very easily. In other patients, it may take several iterations of the process described above to fully normalize the spine. After each iteration, the therapist or practitioner rechecks the spine for the point of greatest misalignment. If a new point of misalignment is discovered, this creates a new treatment point 92 and thus, a different treatment area 94 ′ as detailed above.
Spine normalization, as described herein, when used in conjunction with the other embodiments described herein, may provide an overall reduction of pain related to other treatments and for some patients, spine normalization increases how long the benefits of other treatments last. Thus, it is preferable to use spine normalization as the first treatment applied to a patient.
While the disclosure has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiments have been shown and described and that all changes, modifications and equivalents that come within the spirit of the disclosure provided herein are desired to be protected. The articles “a”, “an”, “said” and “the” are not limited to a singular element, and may include one or more such elements.
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Disclosed is a method of normalizing a spine of an individual including identifying a first point on the spine that exhibits the greatest degree of spinal misalignment and the hemisphere of the misalignment. A second point on the back of the individual is identified using a measuring device to measure along the spine a calculated distance specific to the individual. The second point on the back is then translated to the front of the individual opposite the second point to identity a third point. Application of therapeutic treatment near the third point normalizes the spine. In one embodiment, the distance is calculated by dividing the height of the individual by eight.
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CROSS-REFERENCED APPLICATION
[0001] This application claims priority from Taiwan patent application number 101109979 filed on March 23, 2012, incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] The invention relates to the pharmaceutical combination for the treatment of renal failure caused by various diseases in pets.
BACKGROUND
[0003] Renal failure is one of the common diseases in human or animals. Diagnosis of renal failure means that more than 75% of kidney loses normally physiological functions, leading to retention of metabolic toxins, disturbance of body fluids, electrolytes and pH, and even to serious systemic complications causing death. Lin (Lin Kai-Wei, “ Prognostic Indicators Affecting the Outcome of Acute Renal Failure in Small Animals and Evaluation of Related Infection by Using Central Venous Catheter in Dogs ”, Veterinary Medicine Institute of National Chung-Hsing University, master thesis, 2007) reports that renal damage caused by acute renal failure (ARF) is reversible, however the mortality rates of ARF following different treatments (for example, traditional infusion therapy, peritoneal dialysis therapy and hemodialysis therapy) still remain between 30-83%. (Behrend E N, Grauer G F, Mani I, Groman R P, Salman M D, Greco D S, “ Hospital - acquired acute renal failure in dogs: 29 cases ” (1983-1992), J Am Vet Med Assoc 208: 537-541, 1996; Crisp M S, Chew D J, DiBartola S P, Birchard S J, “ Peritoneal dialysis in dogs and cats: 27 cases ” (1976-1987), J Am Vet Med Assoc 195: 1262-1266, 1989; Forrester S D, McMillan N S, Ward D L, “ Retrospective evaluation of acute renal failure in dogs”, J Vet Intern Med 16: 354, 2002.) Also, Lin reports that in the period of from January of 2000 to December of 2006, 1339 dogs and 241 cats received medical treatments due to renal failure in Veterinary Teaching Hospital of National Chung-Hsing University, and the yearly prevalence rate and mortality rate of renal failure are respectively 4-10% and 49-59% in dogs, and 2-10% and 33-62% in cats. In animals determined as suffering acute renal failure (including 501 dogs and 69 cats), the overall yearly morality rate is 81.2% in dogs and 65.2% in cats.
[0004] Due to high morality rate of ARF in small animals, the prognostic indications associated with ARF have been intensively investigated to act as early prognostic indication and in turns for selection of appropriate treatment. The prognosis of ARF depends on the cause, severity of renal injury, and accompanying diseases, however literature data in this context are still limited and the results reported are not always consistent.
[0005] Current renal failure treatments in small animals include traditional therapy, renal replacement therapy, and diet therapy. Traditional therapy and renal replacement therapy are further described.
1. Transitional Therapy
[0006] Traditional therapy for renal failure in small animals mainly includes supportive therapy and infusion therapy (namely, vascular fluid infusion), in combination with medication if necessary, for the correction of body fluids, electrolytes and pH, and reduction of advanced renal damage. Traditional therapy for renal failure are mainly focused on the treatment of reversible renal failure where kidney is temporarily injured or the kidney index is temporarily increased due to other factors and can be resumed after treatment. Irreversible renal failure generally progresses to more severe conditions leading to kidney diseases and even to death. If the kidney index such as BUN (blood urea nitrogen) and CRE (creatinine) becomes worse, the veterinarian will announce euthanasia or advise peritoneal dialysis or hemodialysis therapy, however sometimes the pet still can not recover from renal failure and even die after peritoneal dialysis and hemodialysis therapy.
2. Renal Replacement Therapy
[0007] Renal replacement therapy refers to the treatment of temporary substitution for kidney functions in order to restore normal kidney functions, including peritoneal dialysis, hemodialysis, and even kidney transplants and the likes. ARF is one of indications of peritoneal dialysis or hemodialysis in dogs and cats. Traditionally, the response from supportive therapy (i.e., vascular fluid infusion) for 3 to 4 weeks is a criterion to determine whether the pet can recover from renal failure. Specifically, if a pet's health can not be restored from renal failure after supportive therapy and/or fluid infusion therapy, the pet will be requested for dialysis therapy. The pet with renal failure may survive for additional several months via intervention of dialysis therapy. When animals suffer severe oligouria or even anuria, and traditional therapies (supportive therapy and/or fluid infusion therapy) are ineffective to improve azotemia and correct body fluids, electrolytes and pH, a dialysis therapy (peritoneal dialysis or hemodialysis) must be conducted immediately. (Cowgill L D, Elliott D A. Hemodialysis. In: DiBartola S P, ed. “ Fluid Therapy in Small Animal Practice”, 2th ed. W.B. Saunder Co., Philadelphia, USA, 1615-1633, 2000; Whittemore J C, Webb C B. “ Beyond Fluid Therapy: Treating Acute Renal Failure”, CompCont Ed Pract Vet, 27: 288-297, 2005) Hemodialysis is technically feasible in the treatment of severe uremia, however it is not very common in consideration of availability and economy (about 160,000 NT dollars per week, with uncertain results in the continuous treatment). Peritoneal dialysis and hemodialysis will be described respectively.
A. Peritoneal Dialysis (PD)
[0008] Principle and Method:
[0009] Peritoneal dialysis is the method of implanting a permanent dialysis catheter into body for direct infusion of a dialysis solution containing electrolytes and glucose in an approximate physiological concentration into abdominal cavity, thereby small molecules (such as uremia waste) and ions in plasma can be exchanged with the dialysis solution through peritoneum acting as dialysis film by diffusion, convention or microfiltration, to correct disturbed electrolytes and body fluids.
[0010] Contraindications and Indications:
[0011] Peritoneal dialysis is mainly dependent on peritoneum as a dialysis film for substance exchange, thus any conditions which impede the exchange of dialysis solution will retard the feasibility of peritoneal dialysis, for example abdominal wall damage or peritoneal infection leading to the loss of the peritoneal exchange area of more than 50%. The contraindications of peritoneal dialysis in animals may include severe hypoalbuminemia or conditions which may interfere with implantation of peritoneal dialysis catheter, such as severe ascites, recently received abdominal surgery, abdominal mass or intestinal dilation and the likes. In addition, after long-term dialysis, peritoneum may become fibrillated, resulting in deterioration and inefficiency of peritoneal dialysis.
[0012] Problems and Complications:
[0013] Peritoneal dialysis is technically simple but highly possibly causes complications, thereby its common use is limited. Common complications of peritoneal dialysis include hypoalbuminemia and other problems such as the retention of dialysate, obstruction of dialysis catheter and peritonitis, thus the overall survival rate is only 22% (Crisp M S, Chew D J, DiBartola S P, Birchard S J. “ Peritoneal Dialysis in Dogs and Cats: 27 Cases ” (1976-1987), J. Am. Vet. Med. Assoc., 195: 1262-1266, 1989). In addition, Beckel et. al. (Beckel N F, Toole T E, Rozanski E A, Labato M A. “ Peritoneal Dialysis in the Management of Acute Renal Failure in 5 Dogs with Leptospirosis”, J. Vet. Emerg. Crit. Care, 15:201-205, 2005) reports that peritoneal dialysis in 6 dogs with Leptospirosis shows that the subjects of about 60% take place complications including hypokalemia.
B. Hemodialysis (HD)
[0014] Principles and Methods:
[0015] Hemodialysis is in principle similar to peritoneal dialysis, however dialysis catheter (hemodialyzer) is the place where solutes are exchanged instead of peritoneum. Its methodology comprises direct exchange of blood with the dialysis solution by extracorporeal circulation, and in order to prevent the solutes from balance during hemodialysis, the blood and dialysis solution shall be continuously refreshed to maintain a concentration gradient thereby to reach a maximum diffusion.
[0016] Timing and Indications:
[0017] The indications of hemodialysis in dogs and cats mainly are ARF and its complications, acute poisoning and excessive body fluids and so on. In addition, hemodialysis is useful for acute rejection after kidney transplant until the critical conditions are eliminated.
[0018] Complications:
[0019] Hemodialysis is a technically complicated process and can be applied to physiologically and metabolically disordered patients. Common complications include catheter malfunction or catheter-related infection, low blood pressure, neurologic complications, respiratory complications, panleukopenia and thrombocytopenia, anemia, and amino acid loss. In addition, due to the complexity of the dialysis process per se and the complications of renal failure, the complications of hemodialysis adversely affect various outside kidney systems, therefore it is not easy to determine whether the adverse effects are caused by dialysis therapy itself or uremia, however the frequency and intensity of those adverse effects are generally decreased when the animals are adapted to dialysis or the uremic clearance is under control. (Cowgill L D, Langston C E. “ Role of Hemodialysis in the Management of Dogs and Cats with Renal Failure”, Vet. Clin North. Am. Small Anim. Pract., 26: 1347-1378, 1996)
[0020] The mortality rate of traditional therapies for renal failure in pets are still high, and the efficiency and cost of peritoneal dialysis and/or hemodialysis therapy still need to be improved, thus there still needs a new treatment for renal failure in pets.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 shows the results of Example 1 and Table 1.
[0022] FIG. 2 shows the results of Example 2 and Table 2.
[0023] FIG. 3 shows the results of Example 3 and Table 3.
[0024] FIG. 4 shows the results of Example 4 and Table 4.
[0025] FIG. 5 shows the results of Example 5 and Table 5.
[0026] FIG. 6 shows the results of Example 6 and Table 6.
[0027] FIG. 7 shows the results of Example 7 and Table 7.
[0028] FIG. 8 shows the results of Example 8 and Table 8.
[0029] FIG. 9 shows the results of Example 9 and Table 9.
[0030] FIG. 10 shows the results of Example 10 and Table 10.
[0031] FIG. 11 shows the results of Example 11 and Table 11.
DESCRIPTION OF THE INVENTION
[0032] In order to overcome aforesaid drawbacks of the methods currently used for the treatment of renal failure in pets, in one embodiment, the present invention provides a novel pharmaceutical combination for treating renal failure in pets.
[0033] In another embodiment, the present invention provides a novel pharmaceutical combination for treating renal failure in pets by subcutaneous injection.
[0034] In further another embodiment, the present invention provides a novel pharmaceutical combination for treating renal failure in pets by subcutaneous injection, comprising Solution A and Solution B, wherein the Solution A and the Solution B respectively contain the following components and contents:
Solution A
[0035]
[0000]
component
concentration
glucose
7~42.5
g/L
sodium ion
70~132
mEq/L
chloride ion
45~196
mEq/L
calcium ion
1.5~3.5
mEq/L
magnesium ion
0.2~0.5
mEq/L
lactate ion
20~40
mEq/L
Solution B
[0036]
[0000]
component
concentration
sodium ion
60~130 mEq/L
chloride ion
50~109 mEq/L
lactate ion
15~28 mEq/L
potassium ion
2.2~4 mEq/L
calcium ion
1.5~3.0 mEq/L
[0037] In a preferred embodiment, the present invention provides a pharmaceutical combination for treating renal failure in pets by subcutaneous injection, comprising Solution A and Solution B, wherein the Solution A and the Solution B respectively contain the following components and contents:
Solution A
[0038]
[0000]
component
concentration
glucose
7~15
g/L
sodium ion
70~132
mEq/L
chloride ion
45~96
mEq/L
calcium ion
1.5~3.5
mEq/L
magnesium ion
0.2~0.5
mEq/L
lactate ion
20~40
mEq/L
Solution B
[0039]
[0000]
component
concentration
sodium ion
60~130 mEq/L
chloride ion
50~109 mEq/L
lactate ion
15~28 mEq/L
potassium ion
2.2~4 mEq/L
calcium ion
1.5~3.0 mEq/L
[0040] Solution A is known in the art, however it is mainly used for treating renal failure through peritoneal dialysis in abdominal cavity in order to reduce the toxin level. When Solution A is used for peritoneal dialysis in pets, however the efficiency is not quite satisfied and the pets are liable to infection with peritonitis. The inventor finds that when Solution A is administered to pets by subcutaneous injection, the exchange rate of toxins is dramatically enhanced owing to the fact that toxins are exchanged through subcutaneous tissues instead of peritoneum, and in turns the survival rate of pets is significantly improved.
[0041] Solution B is known in the art, however it is mainly applied to human or animals by vascular fluid infusion, for the purpose of supplementing body fluids lost due to burns or diarrhea, along with supplementation of electrolytes and rectification of acidosis. It has been reported that Solution B may be used in the treatment of renal failure in pets, however the efficiency is not very satisfied and a high dose is required, for example 40-60 mL/kg body weight per day, for example a dog weighing 20 kg requires fluid infusion of 800-1200 mL of Solution B per day, or a cat weighing 5 kg requires fluid infusion of 100-200 mL of Solution B twice per day. Such a high dose of infusion fluid very likely causes a serious burden on pet's body.
[0042] The inventor has conducted an intensive study and numerous clinical treatments, and found that the combination of Solution A and Solution B (hereinafter sometimes referred to as “Solution A+B”) surprisingly exhibits a synergistic effect in the treatment of renal failure in animals. Specifically, the pharmaceutical combination of the present invention comprising Solution A and Solution B, when administered by subcutaneous injection, surprisingly exhibits a synergistic effect in the treatment of renal failure in animals, along with significant promotion of excretion of toxins out of the body (measured as BUN and CRE). Such synergistic effect is never suggested or taught in the prior art.
[0043] Here, the terms “combination of Solution A and Solution B” and “Solution A+B”, used alternatively, do not intend to limit the manner and order of Solution A and Solution B in use. In other words, when “combination of Solution A and Solution B” or “Solution A+B” is mentioned, any one of the following conditions may be inferred: subcutaneous injection of Solution A prior to subcutaneous injection of Solution B in animals, subcutaneous injection of Solution B prior to subcutaneous injection of Solution A in animals, and direct subcutaneous injection of a mixed solution of Solution A and Solution B in animals.
[0044] In one embodiment of the present invention, the ratio of Solution A to Solution B is preferably about 1:1. However, the relative proportion of Solution A and Solution B may be adjusted by clinical veterinarians depending on the health status of animals based on their clinical experience and judgment, and is still encompassed within the scope of the invention.
[0045] Further, the inventor also found that as compared with the prior art, Solution A+B of the present invention in a very low dose can quickly excrete toxins through urine outside the body to achieve a therapeutic efficiency, without causing a serious burden on pet's body. Specifically, according to the present invention, a recommended dosage is 0.1-10 mL/kg body weight per day for Solution A and 0.1-10 mL/kg body weight for Solution B, each 1-3 times per day. However, the actual therapeutic dose may be adjusted based on experience and judgment of veterinarians depending on the health status and body weight of animals.
[0046] In one embodiment, the dose of Solution A and Solution B each generally starts at a lower level and then is gradually increased based on the experience and judgment of veterinarians depending on the health status of pets. For example, the dose of Solution A and Solution B each initially is 0.1-5 mL/kg body weight, 1-3 times per day for about 1-3 days. After the pet is adapted to the drug, the dose for injection is slowly increased (e.g., 5-10 mL/kg of body weight, 1-3 times per day) for a period of time, until the pet reaches a recovery rate of 50-90% or more (the recovery rate is varied with the age and health status of individual animal). If a continuous care treatment is required, the dose may be further decreased to 0.1-5 mL/kg body weight, 1-3 times per day, depending on the health status. In some cases of large dogs, the dose of Solution A+B for the continuous care treatment can be even decreased to, for example, 75 mL/32 kg body weight (about 2.3 mL/kg body weight) per day.
[0047] In addition, the dose of the pharmaceutical combination of the present invention may need to be modified in accordance with the body weight of animals to be treated. The dose for heavier animals (weighing more than 5 kg) is calculated in a different way. Specifically, animals weighing more than 5 kg are preferably administered at a dose of about 50-70% of the original dose calculated as mentioned above. For example, for an animal weighing 20 kg, the original dose is 20 kg×10 mL/kg =200 mL, thus the preferred dose for injection is ranging from 100 mL (=200 mL×50%) to 140 mL (=200 mL×70%). In other words, for a 20-kg animal, solution A and solution B are each administered by subcutaneous injection with a dose of approximately 100-140 mL for about 1-10 days, and then the dose may be further reduced after the animal restores its health. Therefore, the dose of the pharmaceutical combinations of the present invention is much lower than the conventional dose of Solution B as mentioned above. For example, the conventional dose of Solution B is 40-60 mL/kg body weight per day, namely 800-1200 mL for a 20-kg pet, such a high infusion dose will impart a serious load to the body and cause subcutaneous injury.
[0048] The pharmaceutical combination of the present invention is administered by subcutaneous injection to the pets in order to improve or treat renal failure, thereby it is different from traditional fluid infusion therapy, peritoneal dialysis and hemodialysis, with respect to the route of administration and the therapeutic mechanism.
[0049] The term “renal failure” herein is meant by renal failure defined and determined by the criteria known to people of ordinary skill in the art, including, for example, acute renal failure and chronic renal failure, or prerenal renal failure and intrinsic renal failure (see, for example, Liu, Chia-Yuan, “ The study of short - term prognostic factors in canine and feline renal failure ”, National Taiwan University, master thesis, 2005; Tsai, Han-Ju, “ The Evaluation of Hemodialysis on Dogs with Renal Failure ”, Taiwan Vet J., 29:353-358, 2003; Lin, Kai-Wei, “ Prognostic Indicators Affecting the Outcome of Acute Renal Failure in Small Animals and Evaluation of Related Infection by Using Central Venous Catheter in Dogs ”, National Chung Hsing University, master thesis, 2007). In one embodiment, the pharmaceutical combination of the present invention is preferably useful in the treatment of acute renal failure and chronic renal failure.
[0050] In another embodiment, the pharmaceutical combination of the present invention is useful in the emergent rescue of acute renal failure, in the treatment of acute poisoning, and in the life-sustaining continuous care treatment of chronic renal failure in dogs and cats.
[0051] Herein, the term “emergent rescue” is meant by emergent treating behaviors conducted on a pet with renal failure who is requested for peritoneal dialysis or hemo dialysis or even is advised to give euthanasia by veterinarians after the pet is ineffective to any forms of treatment or does not receive any treatments. The purpose of emergent rescue is to maintain pet's life, prevent from progression of renal failure, and promote healing and so on.
[0052] The criteria to determine pet renal failure are generally based on blood gas level, hemobiological indices and blood electrolyte levels (such as sodium, potassium, chloride). Typically, acute renal failure and chronic renal failure are determined by BUN and CRE values. For healthy dogs and cats, normal BUN values are respectively 6-33 mg/dL and 12-41 mg/dL, and normal CRE values are respectively 0.6-1.6 mg/dL and 0.7-2.5 mg/dL. With reference to the standards for classification of renal failure in dogs and cats established by International Renal Internal Society (IRIS), based on the CRE concentration, the pet is diagnosed as end-stage or acute renal failure when the CRE value is 5 mg/dL or more. Thus, the therapeutic index or renal failure index is meant by BUN and CRE values in the present invention. In one embodiment of the present invention, the improvement and/or treatment of renal failure means that the therapeutic index or renal failure index is decreased to close to or within the normal range after being treated with the pharmaceutical combinations of the present invention.
[0053] In some cases, the BUN and/or CRE values of a pet with renal failure do not increase rapidly, but its physical conditions apparently become worse. Therefore, the status of a pet with renal failure is additionally evaluated by observation of its appearance and activity. The symptoms for diagnosis of acute renal failure generally include, for example, fatigue, drowsiness, depression, weakness, loss of appetite, dehydration, vomiting and diarrhea, as well as less common symptoms including seizures, syncope and ataxia, and the likes. Thus, in another embodiment of the present invention, improvement and/or treatment of renal failure means that aforesaid symptoms are mitigated and/or eliminated after being treated with the pharmaceutical combinations of the present invention.
[0054] In one embodiment of the present invention, the renal failure index is significantly reduced, and preferably decreased to the normal range after being treated with the pharmaceutical combinations of the present invention. Specifically, BUN and/or CRE values are significantly decreased to close to or within the normal range. In another embodiment, the renal failure index can be significantly decreased in 1-10 days, and preferably decreased to close to or within the normal range. In another embodiment, the morality rate of dogs and cats with renal failure can be significantly decreased, for example, to about 15-25% in young dogs and cats. In another embodiment, pets with renal failure are recovered in 1-10 days from initially inactive, vomiting, drowsy and convulsive conditions to active, not vomiting and motility-improved conditions, without other uncomfortable changes, and gradually return to normal physical conditions. In another embodiment, the pharmaceutical combination for the treatment of renal failure in pet according to the present invention provides a recovery rate of 50-90% or more, preferably a recovery rate of 60-90% or more, and the younger the animals are, the higher the recovery rate is. Therefore, the pharmaceutical combination of the present invention provides a significantly improved effect in the treatment of renal failure, as compared with traditional therapies (fluid infusion, peritoneal dialysis or hemodialysis) which lead to a yearly morality rate of 81.2% and 65.2% in dogs and cats respectively (i.e., a survival rate of 18.8% and 34.8% respectively).
[0055] For a pet with end-stage renal failure (where therapeutic index can not be decreased further), veterinarians generally advise peritoneal dialysis or hemodialysis or even recommend euthanasia. In the case that a pet with irreversible serious renal failure requires peritoneal dialysis for emergent rescue, the pet may need peritoneal dialysis 8-12 times per day, however its physical condition may be still getting worse and even dying. Normally, a pet may be given peritoneal dialysis about 2-5 times per day. If a pet requires peritoneal dialysis many more times per day, it implies that the exchange rate trough peritoneum of the pet to be treated is no longer efficient and can not be recovered, thereby euthanasia may be recommended. In another embodiment, when emergent rescue is conducted on a pet with renal failure with the pharmaceutical combination of the present invention, the recovery rate (of emergent rescue for 1-10 days) is 60-90% or more in young dogs and cats (0-6 years) and about 50-60% in old dogs and cats (7 years or more), thus the overall recovery rate is 50-90% or more in dogs and cats.
[0056] In further another embodiment, the pharmaceutical combination of the present invention provides a significantly increased recovery rate in the continuous care treatment of pets with renal failure. To date, no specific methods are available in the continuous care treatment for both reversible and irreversible forms of renal failure. Pets with reversible renal failure may remain stable after peritoneal dialysis or hemodialysis therapy is removed. However, the continuous care treatment becomes a serious problem in the case of irreversible renal failure, since the renal failure index generally rise again after removal of catheter for peritoneal dialysis or hemodialysis even the pets is stable before. Therefore, in another embodiment, the pharmaceutical combination of the present invention is useful in the continuous care treatment, in addition to the treatment of renal failure in pets. As long as no other deterioration factors causing death, after recovered well through treating with the pharmaceutical combination of the present invention, the pet with renal failure may be continuously administered with the pharmaceutical combination of the present invention for the continuous care treatment. Therefore, the pharmaceutical combination of the present invention is useful for the continuous care treatment of pets with renal failure, thereby providing a much enhanced outcome.
[0057] Therefore, the pharmaceutical combination for the treatment of renal failure by subcutaneous injection in pets according to the present invention has the following advantages:
(1) The pharmaceutical combination for the treatment of renal failure according to the present invention is different from the methods currently used in the art for the treatment of renal failure with respect to the route of administration and therapeutic mechanisms, and has a significantly improved efficiency in the removal of toxins (measured as BUN and CRE), thereby the toxin level in pet's body can be more rapidly reduced, so that the pets can quickly restore and maintain health. (2) For a pet at the end stage of renal failure, when the therapeutic indices continuously rise even after traditional therapy and peritoneal dialysis or hemodialysis, it means that maintaining pet life is difficult, then veterinarians usually recommend palliative care (or euthanasia). The present invention provides a pharmaceutical combination which is effective in life-sustaining care for pets for whom other therapies are ineffective or euthanasia is requested. (3) The pharmaceutical combination for the treatment of renal failure according to the present invention is useful in the treatment of in-hospital determined acute renal failure or chronic renal failure in pets. (4) The pharmaceutical combination of the present invention improves the recovery rate of renal failure by 60-90% or more (about 50-60% for animals of 7 years or older), and can be continuously used to perform the continuous care treatment. (5) The present invention provides a pharmaceutical combination which is simple and convenient in the treatment of renal failure, and thus can be used to perform continuous care treatment by pet owner at home after the pet is discharged from the hospital, thereby the recovery rate can be further improved. (6) The pharmaceutical combination of the present invention is administered by subcutaneous injection, and does not require surgery, hospitalization, or intravenous infusion. Infections can be reduced and free movement is allowed. Thereby, pets with renal failure can be treated in a humanistic way and live with dignity, with a prolonged life. (7) The dose of the pharmaceutical combination of the present invention for subcutaneous injection (0.1-10 mL/kg body weight) is much lower than the dose conventionally used in the art for the treatment of renal failure (for example, 40-60 mL/kg body weight for Solution B). (8) The pharmaceutical combination of the present invention has much less adverse effects. Many infections such as catheter-related infections can be avoided since no fluid infusion or dialysis is used, thus complications and infections are much less, thereby safety is relatively improved a lot.
[0066] According to the present invention, the term “recovery rate” means a proportion of the number of pets with renal failure who can not restore health without treatment or after antecedent treatment through fluid infusion or peritoneal dialysis or hemodialysis requested by veterinarians, and thus are treated with the pharmaceutical combination of the present invention for 1-10 days, from which the normal health status is restored back by 50-90% or more, and/or BUN and/or CRE value is significantly reduced to close to or within the normal range, and/or pet's activity is restored with no vomiting and other special uncomfortable changes, to the number of pets with renal failure under the same condition but not treated with the pharmaceutical combination of the present invention.
[0067] According to the invention, the terms “pet” and “animal” mean dogs, cats, rabbits, mice and other small animals, preferably dogs or cats.
[0068] The following examples will further describe the representative embodiments of the present invention, however these examples are intended only for illustration absolutely not for limitation of the content and scope of the present invention. People of ordinary skill in the art will understand that many modifications and variations may be made thereto in light of the above teachings to obtain the same or equivalent results, without departing from the scope of the appended claims.
EXAMPLE
Preparation:
[0069] Solution A and Solution B are formulated to have the following components and contents:
Solution A containing: 15 g IL of glucose, 132 mEq/L of sodium ion, 96 mEq/L of chloride ion, 3.5 mEq/L of calcium ion, 0.5 mEq/L of magnesium ion, and 40 mEq/L of lactate ion. Solution B containing: 130 mEq/L of sodium ion, 109 mEq/L of chloride ion, 28 mEq/L of lactate ion, 4 mEq/L of potassium ion, and 3.0 mEq/L of calcium ion.
Method of Testing and Evaluation:
[0072] The effect of the pharmaceutical combination of the present invention in the treatment of renal failure in pets is evaluated by measuring BUN and CRE values and by observing the appearance and activity in pets. BUN and CRE values are measured on a biochemical analyzer (SPOTCHEM, model 4430, manufactured by Arkray Inc.). The ranges of BUN and CRE values of dogs and cats in different health status are listed as follows:
[0000]
BUN
CRE
(mg/dL)
(mg/dL)
dog
normal status
6-33
0.6-1.6
cat
normal status
12-41
0.7-2.5
dog/cat
renal failure
80-100
8-10
[0073] Additionally, the health status of pets with renal failure is evaluated by observation of appearance and activity. Specifically, the effect in the treatment of renal failure is evaluated by observation of alleviation and/or elimination of symptoms including fatigue, depression, weakness, loss of appetite, dehydration, vomiting and diarrhea and the like in pets.
Procedures of Treatment:
[0074] Prior to administration, the health status of individual pets to be treated is evaluated by measuring BUN and CRE values and blood gas values, as well as by observing pets' appearance and activity. In the drug running-in period, Solution A (0.1-5 mL/kg body weight) is injected subcutaneously into one side of the back of the pet body, followed by subcutaneous injection of Solution B (0.1-5 mL/kg body weight) into the other side of the back of the pet body. In some cases, a mixed solution of Solution A and Solution B is directly administered by subcutaneous injection when the health status of the pet is allowed. (Days 1-3) The same amount of Solution A and Solution B is repetitiously administered by subcutaneous injection every 8-12 hours (i.e., 2-3 times per day), with periodic measurement of BUN and CRE values and observation of pet's appearance and activity. (Days 4-10) When the pet is acceptable to the running-in drug, the amount of Solution A and Solution B is gradually increased to 5-10 mL/kg body weight (1-3 times per day). If the pet is detoxified at the drug running-in period (namely, Days 1-10, called prime time of rescue) and the pet's health is restored by 50-90% or more (the recovery rate of individual animals is varied with age and health status), the amount of injection can be reduced to less than 10 mL/kg body weight. If the pet recovers well and looks good in activity and movement in 7-10 days, a mixed solution of Solution A and Solution B may be directly subcutaneously injected. The extension of days for injection or reduction of the dose may be adjusted individually depending on the health status of the pet.
Example 1 (Dog)
[0075] Basic information: breed variety: Maltese; gender: female; age: 14 years old; body weight: 4 kg.
Animal health status before injection (day 0): the animal was diagnosed as acute renal failure due to inappropriate steroid treatment and its health was deteriorated rapidly. Medical treatment and method: Solution A and Solution B each were administered by subcutaneous injection to each side of the back of the animal, and then (starting at day 3) Solution A+B (a mixed solution of Solution A and Solution B) was directly injected subcutaneously, with the dose being gradually reduced.
[0077] The result of the treatment by the pharmaceutical combination of the present invention is shown in Table 1 and FIG. 1 .
[0000]
TABLE 1
day
day 0
day 6
day 184
appearance
lethargic,
normal,
normal,
inactive,
active
active
vomiting
BUN (mg/dL)
92
117
17
CRE (mg/dL)
7.9
8.4
1.1
Example 2 (Dog)
[0078] Basic information: breed variety: hybrid; gender: female; age: 6 years old; body weight: 18 kg.
Animal health status before injection (day 0): the animal was diagnosed as acute renal failure due to inappropriate steroid treatment and its health was deteriorated rapidly. Medical treatment and method: direct subcutaneous injection of Solution A+B.
[0080] The result of the treatment by the pharmaceutical combination of the present invention is shown in Table 2 and FIG. 2 .
[0000]
TABLE 2
day
day 0
day 13
appearance
bad breathing,
normal,
inactive, vomiting
active
BUN (mg/dL)
158
18
CRE (mg/dL)
6.7
1.9
Example 3 (Dog)
[0081] Basic information: breed variety: Husky; gender: male; age: 5 years old; body weight: 19.6 kg.
Animal health status before injection (day 0): the animal was antecedently treated in other hospital with fluid infusion which however was ineffective, with progression to acute renal failure, and then was requested for peritoneal dialysis or hemodialysis or euthanasia by veterinarian. Medical treatment and method: direct subcutaneous injection of Solution A+B.
[0084] The result of the treatment by the pharmaceutical combination of the present invention is shown in Table 3 and FIG. 3 .
[0000]
TABLE 3
day
day 0
day 7
appearance
inactive,
normal,
vomiting
active
BUN (mg/dL)
147
92
CRE (mg/dL)
9.4
7.3
Example 4 (Dog)
[0085] Basic information: breed variety: Labrador; gender: female; age: 6 years old; body weight: 31.85 kg.
Animal health status before injection (day 0): the animal was antecedently treated in other hospital with fluid infusion and then subcutaneous injection which however were ineffective, with progression to acute renal failure, and then was requested for peritoneal dialysis or hemodialysis or euthanasia by veterinarian. Medical treatment and method: Solution A+B was initially subcutaneously injected, and starting at day 60, only Solution A was injected and the dose was reduced to 75 mL once per day.
[0088] The result of the treatment by the pharmaceutical combination of the present invention is shown in Table 4 and FIG. 4 .
[0000]
TABLE 4
day
day 0
day 67
day 131
day 207
appearance
inactive,
normal,
normal,
normal,
vomiting
active
active,
active,
increasing
increasing
body weight
body weight
BUN (mg/dL)
77
63
60
52
CRE (mg/dL)
11.1
3.9
3.8
3.7
Example 5 (Cat)
[0089] Basic information: breed variety: hydrid; gender: male; age: 4 years old; body weight: 4.8 kg.
Animal health status before injection (day 0): the animal was antecedently treated in other hospital with fluid infusion and then subcutaneous injection with Solution B, which however were ineffective, with progression of from chronic renal failure to acute renal failure, and then was requested for peritoneal dialysis or hemodialysis or euthanasia by veterinarian. Medical treatment and method: Solution A was initially subcutaneously injected, and then starting at day 364, Solution A+B was subcutaneously injected, with the dose being gradually reduced.
[0092] The result of the treatment by the pharmaceutical combination of the present invention is shown in Table 5 and FIG. 5 .
[0000]
TABLE 5
day
day 0
day 36
day 306
day 364
day 399
appearance
inactive
normal,
normal,
normal,
normal,
active
active
active
active
solution
A
A
A
A + B
A + B
injected
BUN (mg/dL)
140
36
60
ND*
46
CRE (mg/dL)
17.5
4.0
5.8
ND*
4.1
*ND: undetermined
Example 6 (Cat)
[0093] Basic information: breed variety: Persian; gender: male; age: 10 years old; body weight: 6.1 kg.
Animal health status before injection (day 0): the animal was antecedently treated in other hospital with fluid infusion and then subcutaneous injection with Solution B, which however were ineffective, with progression of from chronic renal failure to acute renal failure, and then was requested for peritoneal dialysis or hemo dialysis or euthanasia by veterinarian. Medical treatment and method: direct subcutaneous injection of Solution A+B.
[0096] The result of the treatment by the pharmaceutical combination of the present invention is shown in Table 6 and FIG. 6 .
[0000]
TABLE 6
day
day 0
day 14
day 21
appearance
inactive
normal,
normal,
active
active
BUN (mg/dL)
107
79
88
CRE (mg/dL)
7.8
7.9
4.6
Example 7 (Cat)
[0097] Basic information: breed variety: Persian; gender: female; age: 13 years old; body weight: 2.55 kg.
Animal health status before injection (day 0): the animal was antecedently treated in other hospital with fluid infusion which however was ineffective, with progression to acute renal failure, and then was requested for peritoneal dialysis or hemodialysis or euthanasia by veterinarian. Medical treatment and method: direct subcutaneous injection of Solution A+B.
[0100] The result of the treatment by the pharmaceutical combination of the present invention is shown in Table 7 and FIG. 7 .
[0000]
TABLE 7
day
day 0
day 7
appearance
inactive,
normal
heavy breathing
BUN (mg/dL)
174
95
CRE (mg/dL)
10.6
6.8
Example 8 (Cat)
[0101] Basic information: breed variety: hydrid; gender: female; age: 3 years old; body weight: 2.9 kg.
Animal health status before injection (day 0): the animal with acute renal failure was antecedently treated in other hospital with fluid infusion which however was ineffective, and was then requested for emergent peritoneal dialysis by veterinarian. Medical treatment and method: direct subcutaneous injection of Solution A+B, with the dose being gradually reduced.
[0104] The result of the treatment by the pharmaceutical combination of the present invention is shown in Table 8 and FIG. 8 .
[0000]
TABLE 8
day
day 0
day 13
day 58
day 86
appearance
inactive
normal
normal
normal
BUN (mg/dL)
113
89
34
41
CRE (mg/dL)
8.7
7.4
4.6
3.5
Example 9 (Cat)
[0105] Basic information: breed variety: hybrid; gender: female; age: 3 years old; body weight: 2.6 kg.
Animal health status before injection (day 0): the animal with acute renal failure was antecedently treated in other hospital with peritoneal dialysis which however was ineffective, and then was requested for peritoneal dialysis or hemodialysis or euthanasia by veterinarian. Medical treatment and method: direct subcutaneous injection of Solution A+B.
[0108] The result of the treatment by the pharmaceutical combination of the present invention is shown in Table 9 and FIG. 9 .
[0000]
TABLE 9
day
day 0
day 15
day 25
appearance
inactive,
normal
normal
uncomfortable
BUN (mg/dL)
149
82
50
CRE (mg/dL)
5.0
5.8
4.0
Example 10 (Cat)
[0109] Basic information: breed variety: American Shorthair; gender: male; age: 4 years old; body weight: 3.35 kg.
Animal health status before injection (day 0): the animal was antecedently treated in other hospital with peritoneal dialysis which however was ineffective, with progression of from chronic renal failure to acute renal failure. Medical treatment and method: direct subcutaneous injection of Solution A+B followed by subcutaneous injection of the same solution but in a gradually reduced dose.
[0112] The result of the treatment by the pharmaceutical combination of the present invention is shown in Table 10 and FIG. 10 .
[0000]
TABLE 10
day
day 0
day 8
day 24
appearance
inactive,
normal, active,
normal,
vomiting
trying to pull out catheter
active
BUN (mg/dL)
156
126
60
CRE (mg/dL)
15.6
6.7
5.8
Example 11 (Cat)
[0113] Basic information: breed variety: Himalayan; gender: male; age: 16 years old; body weight: 2.35 kg.
Animal health status before injection (day 0): the animal was diagnosed as acute renal failure without any treatment, and looked very uncomfortable. Medical treatment and method: direct subcutaneous injection of Solution A+B.
[0116] The result of the treatment by the pharmaceutical combination of the present invention is shown in Table 11 and FIG. 11 .
[0000]
TABLE 11
day
day 0
day 5
day 8
appearance
inactive,
gradually normal
improved activity,
lethargic
but still weak
good appetite and
running
BUN (mg/dL)
99
89
ND*
CRE (mg/dL)
3.7
3.2
ND*
*ND: undetermined
|
The present invention relates to a pharmaceutical combination for the treatment of renal failure in pets, caused by various diseases or ineffective to traditional renal therapy or renal replacement therapy thereby incapable of restoring health. The pharmaceutical combination of the present invention is administered by subcutaneous injection to pets in need thereof, with various advantages including simple use, no requirement for surgery, hospitalization and/or fluid infusion, faster recovery of health status, reduced medical costs, significantly improved recovery rate, reduced mortality and the likes. The pharmaceutical combination of the present invention can also be used for the continuous care treatment of pets with renal failure.
| 0
|
This application is a continuation, of application Ser. No. 08/404,268, filed Mar. 14, 1995, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to vacuum microelectronic devices. More particularly, the invention relates to micro vacuum tubes having cold emitters and methods of producing such cold emitters and micro vacuum tubes.
2. Description of the Related Art
It has been proposed to produce a micro vacuum tube having a field-emission type cathode, i.e., a cold emitter. For example, C. A. Spindt et al., J. Appl. Phys., vol. 47, 5248 (1976) discloses a method, known as "rotation vacuum deposition", for producing a cold emitter. Under this method, a SiO 2 layer disposed on a Si substrate has a pinhole exposing a surface of the Si substrate. A gate layer also disposed on the SiO 2 layer contains a pinhole. A Mo layer is deposited on the Si substrate, which is rotated during deposition. As a result, a cone-shaped cold emitter is formed directly on the Si substrate at the pinhole.
This method has drawbacks. For example, it is difficult to form cold emitters having the same shape and height using this method. Each cold emitter may have a different distance from an anode disposed above the cold emitters. Also, each cold emitter may have a different distance from the gate electrode. As a result, each emitter possesses different electrical properties, e.g., a threshold voltage of emission, or resistance due to the variation in distances. When plural cold emitters are used in parallel connection, current will be concentrated in, for example, the cold emitter having the lowest electric resistance, eventually causing damage to that cold emitter.
Moreover, it is difficult to make a cold emitter having a sharp tip using this method. Therefore, a micro vacuum tube manufactured using this method exhibits poor field emission efficiency.
Another reference, U.S. Pat. No. 4,940,916, discloses a micro vacuum tube and its application for display means. The micro vacuum tube provides cold emitters produced by the method of rotation vacuum deposition. Plural cold emitters are formed on a continuous resistive layer. The resistive layer is formed on an electrically conductive layer connected to a power source and formed on a substrate. Since the resistive layer is inserted between each cold emitter and electrically conductive layer, the resistive layer averages currents flowing in each cold emitter.
However, the problems of forming plural cold emitters with the same shape, the same height, the same distance from the gate electrode, and a sharp tip still remain.
U.S. Pat. No. 4,307,507 discloses another method for producing a cold emitter. This method uses a Si substrate as a mold. The Si substrate is etched by anisotropic etching so as to have pyramid-shape pits. A thick film of polysilicon is filled in the pits and the surface of the Si substrate. After that, the Si substrate is removed by etching. As a result, a polysilicon substrate providing pyramid-shaped cold emitters is obtained. An insulator layer and a gate electrode are then provided on the pyramid-shaped cold emitters.
In accordance with the above-described method, cold emitters must be made of materials having small inner stress, such as polysilicon, because it is difficult to form thick films with a material having large inner stress. As a result, it is difficult to obtain a cold emitter using a material having a low working function, i.e., a material easy to emit an electron.
Furthermore, a large force might be applied between a cold emitter and a gate electrode, requiring the cold emitter to have sufficient strength so as to maintain the distance between the cold emitter and the gate electrode to avoid concentration current. However, it is difficult to obtain a cold emitter made of a material having such a high strength.
SUMMARY OF THE INVENTION
Accordingly, the present invention is directed to a micro vacuum tube that substantially obviates one or more of the problems due to limitations and disadvantages of the related art.
One object of the present invention is to provide a micro vacuum tube including a cold emitter composed of a material having large inner stress.
Another object of the present invention is to provide a micro vacuum tube including a cold emitter having sufficient strength.
Still another object of the present invention is to provide a micro vacuum tube including a cold emitter having a sharp tip.
Yet another object of the present invention is to provide a micro vacuum tube including cold emitters having substantially the same shape.
A further object of the present invention is to provide a micro vacuum tube including cold emitters having a resistive layer which can average the currents flowing in each cold emitter.
To achieve these and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, one aspect of the invention includes a vacuum microelectronic device comprising a core layer having at least one outward protuberance on a top surface of the core layer, and an emitter layer formed on the core layer, wherein a portion of the emitter layer formed on the protuberance culminates at a tip.
In another aspect, the invention includes a method for producing a vacuum microelectronic device, comprising the steps of: forming a dent in one surface of a mold substrate; depositing an emitter layer on the one surface; depositing a core layer on the emitter layer; and removing the mold substrate at the dent by etching so as to obtain a protuberance composed of the emitter layer and the core layer covered with the emitter layer.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description, serve to explain the objects, advantages, and principles of the invention. FIGS. 1(a)-(h) are cross-sectional views of a cold emitter at different phases of a process for producing a cold emitter in accordance with a first embodiment of the present invention;
FIG. 2 is a cross-sectional perspective view of a cold emitter in accordance with the first embodiment of the invention;
FIG. 3 is a cross-sectional view of a cold emitter of a micro vacuum tube in accordance with a second embodiment of the present invention;
FIG. 4 is a cross-sectional view of a cold emitter of a micro vacuum tube in accordance with the second embodiment of the present invention;
FIG. 5 is a conceptual view of a micro vacuum tube in accordance with a third embodiment of the present invention;
FIG. 6 is a cross-sectional view of a cold emitter of a micro vacuum tube in accordance with a fourth embodiment of the present invention;
FIG. 7 is a conceptual view of a display using a micro vacuum tube in accordance a fifth embodiment of the present invention;
FIG. 8 is a perspective view of a cold emitter of a micro vacuum tube in accordance with a sixth embodiment of the present invention;
FIGS. 9(a)-(i) are cross-sectional views of a cold emitter at different phases of a process for producing a cold emitter of a micro vacuum tube in accordance with a seventh embodiment of the present invention;
FIG. 10 is a cross-sectional view of a cold emitter of a micro vacuum tube in accordance with an eighth embodiment of the present invention;
FIG. 11 is a cross-sectional view of a cold emitter of a micro vacuum tube in accordance with a ninth embodiment of the present invention;
FIG. 12 is a conceptual view of a micro vacuum tube in accordance with a tenth embodiment of the present invention;
FIGS. 13(a) and (b) are cross-sectional views of a micro vacuum tube in accordance with an eleventh embodiment of the present invention;
FIG. 14 is a plan view of a micro vacuum tube in accordance with a twelfth embodiment of the present invention; and
FIGS. 15(a) and (b) are cross-sectional views of a micro vacuum tube in accordance with a thirteenth embodiment of the present invention.
DETAILED DESCRIPTION
FIGS. 1(a)-(h) are cross-sectional views of a cold emitter at different phases of a process for producing a cold emitter composing a micro vacuum tube in accordance with a first embodiment of the present invention.
A substrate 11 made of, for example, Si, has a dent 12, which may be produced by etching. Substrate 11 is preferably a p-type Si monocrystal having a crystal direction of (100). An oxide layer is formed on the substrate by thermal dry oxidation, where the oxide layer has a thickness of about 0.1 μm. Using a photo-etching process involving, for example, a mixture of NH 4 F and HF, an opening is provided in the oxide layer. Then, by anisotropic etching (e.g., using an aqueous solution containing 30 wt % of KOH) a pyramid-shaped dent 12 can be obtained corresponding to the opening. Subsequently, the remaining oxide layer is removed (FIG. 1(a)) by etching, for example, with an aqueous solution containing 30 wt % of KOH. When the opening is a 0.8 μm square, a depth of dent 12 would be about 0.56 μm.
Substrate 11 preferably provides plural dents 12, although FIG. 1(a) shows only one dent 12. Anisotropic etching is effective to obtain a sharp tip on dent 12, and, further, to obtain plural dents 12 having the same shape. However, other methods besides anisotropic etching can be used to produce dent 12 in accordance with the invention.
A doped layer 13 having the thickness of about 100 nm is formed on the surface of substrate 11, for example, by thermal diffusion. Since doped layer 13 will be used as an etching stopper, the thickness is preferably about 20 nm or more, and a doping concentration is preferably about 3×10 19 cm -3 or more. Dopants that cause a doped layer to have a different etching rate from substrate 11, such as, B (boron), can be used.
An insulator layer 14 is formed on doped layer 13, for example, by thermal dry oxidation. Also, insulator layer 14 will be used as an etching stopper. Therefore, the thickness is preferably about 50 nm or more (e.g., 100 nm). If the insulator layer 14 can be sufficiently used as the etching stopper, the doped layer 13 could be eliminated.
Insulator layer 14 may be formed by other methods such as chemical vapor deposition (CVD). However, thermal oxidation is more preferable than CVD or other methods. A thickness of insulator layer 14 at sides of dent 12 is thicker than at the tip with thermal oxidation so as to make a sharper tip. Therefore, thermal oxidation is effective to obtain a sharp tip. Further, even if each depth of plural dents 12 is a little different, thermal oxidation can relieve the difference.
An emitter layer 15 is formed on insulator layer 14, for example, by sputtering. Emitter layer 15 provides a dimple corresponding to dent 12.
Emitter layer 15 is preferably composed of a material which is chemically and physically stable, and has a small work function, e.g., W, Mo, Ta, or LaB 6 . The thickness is preferably about 20 nm or more (e.g., 200 nm). Excessive thickness causes emitter layer 15 to peel off of mold 11, if the material has a large inner stress.
A core layer 16 is formed on emitter layer 15 so as to fill the dimple of emitter layer and make a flat surface, for example, by sputtering. Emitter layer 15 and core layer 16 will compose a cold emitter.
Core layer 16 is preferably composed of a material having an inner stress smaller than that of a material composing emitter layer 15, such as Al or polysilicon. Therefore, the core layer includes a material stronger than a material of the emitter layer. Further, when a cold emitter has a smaller electric resistance, core layer 16 is preferably composed of a material having a smaller electric resistance than that of a material composing emitter layer 15. Also, when a large electric resistance is required, core layer 16 is preferably composed of a material having a larger electric resistance than that of a material composing emitter layer 15, such as Ru, C, Si, In 2 O 3 , SnO 2 , or ZnO.
Moreover, if core layer 16 is used as a ballast resistance layer, the emitter layer 15 is preferably divided into cold emitters or small groups of cold emitters.
A conductive layer 17 (e.g., about 1 μm) is formed on core layer 16 (FIG. 1(b)). Conductive layer 17 is made of a material having a lower electric resistance than core layer 16, such as ITO, Cu, Ag, Au, or Al. When core layer 16 and emitter layer 15 have a sufficiently low electric resistance, conductive layer 17 is not necessary.
A structural substrate 19 providing a back coating conductive layer 18 on one side (e.g., about 0.4 μm of Al), is joined with conductive layer 17 at the other side (FIG. 1(c)). For example, "Pyrex" glass having a thickness of about 1 mm can be used. Structural substrate 19 may be composed of glasses or ceramics, which are insulators.
When an electrostatic bonding method is used to join structural substrate 19 with conductive layer 17, structural substrate 19 is required to provide back coating conductive layer 18 so as to apply a voltage between a back coating conductive layer 18 and conductive layer 17. After bonding, back coating conductive layer 18 may be removed by, for example, a mixture solution of HNO 3 , CH 3 COOH, and HF. However, back coating layer 18 could be used as a shield against electromagnetic noises.
Substrate 11 is removed so that doped layer 13 is exposed (FIG. 1(d)) by etching, for example, with a mixed aqueous solution of ethylen diamine, pyrocatechol, pyrazine, and water (=75 cc: 12 g:3 mg:10 cc). Doped layer 13 fills the role of an etching stopper so as to defend a tip of a cold emitter, i.e., the bottom of dent 12 against etching. As a result, a protuberance 20, i.e., a cold emitter, is obtained. Since substrate 11 is used as a mold, substrate 11 can be called a mold substrate.
Protuberance 20 is composed of emitter layer 15 deposited on core layer 16 and has a pyramid-shape. Further, protuberance 20 is coated with insulator layer 14 and doped layer 13.
When a gate electrode is not provided in connection with the cold emitter, doped layer 13 and insulator layer 12 may be removed to obtain an uncovered surface of cold emitter. However, a gate electrode could be provided in connection with the cold emitter by the following steps.
A gate electrode layer 21 (e.g., about 200 nm of W) is deposited on doped layer 13, for example, by sputtering. Gate electrode layer 21, doped layer 13, and insulator layer 12 at a top of protuberance 20 are removed so that emitter layer 15 appears at the top of protuberance 20.
For example, a photoresist layer 22 having a thickness of about 200 nm is coated on gate electrode layer 21 (FIG. 1(e)). Then, photoresist layer 22 is thinned by etching (e.g., dry etching with oxygen plasma) so that insulator layer 12 and doped layer 13 at the top of protuberance 20 appear around approximately a 400 nm square (FIG. 1(f)).
Then gate electrode layer 21 at the top of protuberance 20 is removed by etching, for example, reactive ion etching or wet-etching (FIG. 1(g)). Doped layer 13 and insulator layer 12 at the top of protuberance 20 are removed by etching (e.g., with a mixture of NH 4 F and HF) so that a tip of protuberance of emitter layer 15 are exposed (FIG. 1(h)), then photoresist layer 22 is removed.
The exposed emitter layer 15 is surrounded by gate electrode layer 21. FIG. 2 shows a partially cutaway perspective view of FIG. 1(h). Therefore, a cold emitter providing a gate electrode is obtained.
Since insulator layer 14 could also fill the role of an etching stopper, doped layer 13 can be omitted. FIG. 3 shows a cross-sectional view of a cold emitter of the present invention which does not provide doped layer 13. Except for doped layer 13, the cold emitter of FIG. 3 has the same structure of FIG. 1(h). Accordingly, the number of steps needed to produce a cold emitter of this embodiment can be reduced.
Further, when doped layer 13 has a sufficiently low electrical resistance, for example, about 10 -4 ω. cm or less, or has a sufficiently high doping concentration, such as at least 10 20 cm -3 or 10 21 cm -3 , doped layer 13 acts as a conductive layer and a gate electrode. In such a case, gate electrode layer 21 can be omitted.
FIG. 4 shows a cross-sectional view of a cold emitter of the second embodiment of the present invention. This cold emitter of FIG. 4 provides the same structure as the cold emitter shown in FIG. 1(h), except for gate electrode layer 21. In this embodiment, the number of steps needed to produce this cold emitter can be reduced from the number of steps needed to produce the cold emitter shown in FIG. 1(h). Furthermore, a gate electrode can be more accurately disposed closer to a cold emitter.
The above-mentioned cold emitters can be used in a micro vacuum tube with an anode electrode disposed above the cold emitters in a vacuum.
FIG. 5 shows a conceptual view of a micro vacuum tube of the third embodiment of the present invention. Cold emitter 51 providing gate electrode 21 is disposed above an anode electrode 53 at a distance between, for example, about 5 μm and 200 μm so electrons are emitted from the tip of the protuberance to anode electrode 53 with a bias voltage between conductive layer 17 and anode electrode 53, and between conductive layer 17 and gate electrode layer 21. This micro vacuum tube serves as a triode device.
A cold emitter according to the present invention can also be applied to a diode. In a diode, gate electrode 21 is not required. FIG. 6 shows a cross-sectional view of a cold emitter according to the fourth embodiment of the present invention, wherein gate electrode layer 21 and doped layer 13 are not provided. Insulator layer 14 can also be eliminated. Except for gate electrode layer 21, doped layer 13 and insulator layer 14, the cold emitter of FIG. 6 has the same structure as the emitter of FIG. 1(h).
A micro vacuum tube of the present invention can be used as a current control device with high speed switching or with a large current flow, since electrons flow in a vacuum. The large current control device preferably provides plural cold emitters.
Further, a micro vacuum tube of the present invention can be used as a display. In such a case, for example, a phosphor layer is provided on an anode electrode to emit light.
Plural cold emitters may be controlled together by either turning all of the emitters on or off. Also, plural cold emitters may be individually controlled by controlling individual emitters or groups of emitters.
FIG. 7 shows a conceptual view of a display according to the fifth embodiment of the present invention. An anode plate 71, which is made of a transparent material such as glass, an anode electrode layer 72 and a phosphor layer 73 are disposed above cold emitters of the same structure shown in FIG. 1(h). Plural emitters may be monolithic corresponding to a single color. Plural emitters of one unit are turned on together by supplying a bias voltage between gate electrodes 21, and turned off together by stopping supply of the bias voltage. Current supply lines or signal lines (not shown) can be provided by, for example, semiconductor processes. Moreover, if core layer 16 is used as a ballast resistance layer, the emitter layer 15 is preferably divided into individual cold emitters or groups of cold emitters.
The cold emitter is not limited to a pyramid-shape. For example, a cold emitter of the present invention could have a roof-shape having a ridge 80 as shown in FIG. 8. The cold emitter in FIG. 8 would have a large current capacity. Such a cold emitter could be obtained by the same method of FIG. 1(a).
For example, as discussed above in FIG. 1(a), a pyramid-shaped dent 12 is obtained by using the oxide layer providing a square opening as a resist for anisotropic etching. If the opening is a rectangle, dent 12 would have the same shape as the protuberance in FIG. 8.
Also, in FIG. 1(a), protuberance 20 is composed of emitter layer 15, and core layer 16 coated with emitter layer 15. Therefore, it is possible to change materials between emitter layer 15 and core layer 16.
Most of the materials that readily emit electrons have large inner stress. Therefore, a thick film of the materials is difficult to obtain. However, according to the present invention, even if materials have large inner stress, since an emitter material could be disposed only at a surface of a protuberance, a cold emitter composed of the materials having a large inner stress could be produced. As a result, a micro vacuum tube can efficiently emit electrons.
Further, when an electric resistance of core layer 16 is larger than that of emitter layer 15, core layer 16 may fill a electric resistance to average currents flowing in each cold emitter. When a current is concentrated in one cold emitter, a bias voltage of that cold emitter would be reduced due to the electric resistance of the core layer. In this usage, the emitter layer 15 is preferably divided in each cold emitter or in small groups of cold emitters.
Furthermore, when a core layer is composed of hard materials, the distance between a tip of a cold emitter and a gate electrode can be maintained, if a large force is applied by an electric field.
Also, according to the method of the present invention, emitter materials can be selected from a wide variety of materials. Further, if plural cold emitters are provided, it is possible to produce the plural cold emitters having the same shape, since anisotropic etching can be used.
Moreover, while protuberance 20 has been described as having two layers, i.e., core layer 15 and emitter layer 16, three or more layers can be provided in protuberance 20 for example, by providing two or more layers of core layer 15.
Furthermore, a micro vacuum tube according to the present invention could provide two or more gate electrodes in a direction between an anode electrode and a cold emitter, such as a tetrode device or a pentode device.
The micro vacuum tube would be required to provide a spacer to maintain a distance between a cold emitter and an anode electrode. The spacer would be a frame or plural small beads like an LCD. However, the spacer can also be provided as one body.
FIGS. 9(a)-(i) are cross-sectional views of a cold emitter at different phases of a process for producing a cold emitter of a seventh embodiment of the present invention, including a spacer.
A Si substrate 31 having a dent 32 on one side is provided and can be obtained in the manner described above. An oxide layer 33 (e.g., about 100 nm) is formed on substrate 31 by a thermal dry oxidation and a photoresist 34 is formed on oxide layer 33 (FIG. 9(a)) by spin coating.
Using a photo-etching process employing a mixture of NH 4 F and HF, an opening 35, such as 1 μm square, is provided in oxide layer 33 (FIG. 9(b)). After that, by anisotropic etching with an aqueous solution containing 30 wt % of KOH, dent 32 can be obtained (FIG. 9(c)). When opening 35 is 1 μm square, the depth of dent 32 is about 710 nm. Oxide layer 33 is then removed. Substrate 31 preferably includes plural dents 32, although FIGS. 9(a)-(i) show only a single dent 32.
Substrate 31 is oxidized so as to form an insulator layer 36, which may be a 300 nm layer of SiO 2 on the surface of dent 32 (FIG. 9(d)). After that, substrate 31 is etched from the other side to make a hole 37 so that insulator layer 36 is exposed (FIG. 9(e)
Substrate 31 is oxidized so as to form an insulator layer 38 (e.g., 200 nm thick) on the surface providing hole 37. An emitter layer 39, which may be a 800 nm layer of W. a core layer 40, and a conductive layer 41 approximately 1 μm thick are sequentially formed on dent 32 (FIG. 9(f)). As a result, a protuberance 42 composed of core layer 40 coated with emitter layer 39 is obtained.
A gate electrode layer 43 that may be a 900 nm layer of W, is deposited on insulator layer 38 on the opposite side of dent 32 (FIG. 9(g)). A photoresist layer 44 is coated on gate electrode layer 43 and then an opening (e.g., 700 nm square) is formed in photoresist layer 44 so that the top of protuberance 42 is covered with insulator layer 36 and gate electrode layer 43 by etching (FIG. 9(h)).
Then gate electrode layer 43 at the top of protuberance 20 is removed by etching (FIG. 9(i)). As a result, a tip of protuberance 42 and a tip of emitter layer 39 are surrounded by gate electrode layer 43.
A doped layer 45 can also be provided, as shown in FIG. 10. Also, gate electrode layer 43 could be replaced by doped layer 45, as shown in FIG. 11.
The remaining portions of substrate 31 can be used as a spacer to maintain a distance between cold emitter 42 and an anode electrode. FIG. 12 shows a micro vacuum tube using cold emitter of FIG. 9(i). An anode electrode plate 46 is disposed on substrate 31 to compose a micro vacuum tube with insulator layer 47.
Since substrate 31 remains, it may not be necessary to provide structural substrate 19 of FIG. 1(h). However, a structural substrate could be provided to strengthen a micro vacuum tube. Also, if core layer 40 has a sufficient thickness, core layer 40 could fill the role of a structural substrate.
An anode electrode could be also provided to a micro vacuum tube monolithically.
FIGS. 13(a) and (b) show cross-sectional views of a micro vacuum tube of another embodiment using the cold emitter of FIG. 1(h) according to the present invention. A cold emitter shown in FIG. 1(h) is used in this embodiment.
A removable insulator layer 24, such as a PSG (P-doped silicate glass), is deposited on gate electrode layer 21 and protuberance 20. To obtain a flat surface, after sputtering of removable insulator layer 24, removable insulator layer 45 is etched back. An anode electrode layer 25, such as W, Mo, or Ta, is deposited on removable insulator layer 24, for example, by sputtering.
Anode electrode layer 25 provides a throughhole 26 above protuberance 20 (FIG. 13(a)). Removal insulator layer 24 is partially removed through throughhole 26 so as to make a space 27 between anode electrode layer 25 and the tip of protuberance 20 (FIG. 13 (b)), for example, by etching with a mixture solution of NH 4 F and HF.
Throughhole 26 is preferably not right above the tip of protuberance 20 so as to protect the tip from etching. For example, the distribution of throughhole 26 is shown in FIG. 14, which is a plane view of a micro vacuum tube of the embodiment of the present invention. Anode electrode layer 25 provides throughholes 26 at both sides of each tips of protuberances 20.
According to this embodiment, a micro vacuum tube could provide an anode, an emitter, and a gate as a single body.
FIGS. 15(a) and (b) show cross-sectional views of a micro vacuum tube of yet another embodiment using the cold emitter of FIG. 9(i) according to the present invention. In this case, the same method could be used as FIGS. 13 (a) and (b). A cold emitter shown in FIG. 9(i) is used in this embodiment.
A removable insulator layer 44 is deposited on gate electrode layer 43 so as to fill hole 37. Anode electrode layer 45 is deposited on removable insulator layer 24.
Anode electrode layer 45 provides a throughhole 46 above protuberance 42 and therefore above hole 37. The throughhole 46 however, is not right above the tip of protuberance 42 (FIG. 15(a)). Removal insulator layer 43 is partially removed through throughhole 46 so as to make a space 47 between anode electrode layer 46 and the tip of protuberance 42 (FIG. 15(b)).
It will be apparent to those skilled in the art that various modifications and variations can be made in the micro vacuum tube of the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
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A microelectronic field emission device includes a core layer (16) having at least one outward protuberance on a top surface of the core layer, and an emitter layer (15) formed on the core layer to cover at least a top portion of the outward protuberance, the material of the core layer having a larger electrical resistance than the material of the emitter layer, wherein the top portion of the outward protuberance culminates to a tip and a portion of the emitter layer (15) formed on the protuberance culminates to a tip. The microelectronic device may further include a substrate (19), a conductive layer (17), an anode electrode (53) including a phosphor layer, and a gate electrode (21) having an opening thereby exposing the tip of the emitter layer.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process for manufacturing a spherical cerium-activated catalyst for the synthesis of ammonia.
More particularly the invention concerns a process in which cerium-activated catalysts in the form of spheres having regular diameters of from 1 to 25 mm are prepared by mixing magnetite with (by weight) 2--3.5% of aluminium oxide, 0.8-2% potassium hydroxide, 2-3.5% calcium oxide, 0.1-0.4% magnesium oxide and 0.2-0.5% silica; melting this mixture in a furnace at a temperature of at least 1600° C.; air-cooling the molten mass, removing melted slag; crushing the deslagged mass in a crusher and pulverising it in a rod-mill; adding in a mixer to the so obtained powder a cerium nitrate solution in quantities to obtain in the final catalyst a metallic cerium concentration of 0.5 to 2.5%; pelletising the so added powder in a tray pelletiser to obtain a sphere shaped catalyst; drying said catalytic spheres in a furnace at 100°-200° C., and sintering them in an argon atmosphere at a temperature of 1250°-1350° C.
The invention also comprises a cerium-activated catalyst in form of pelletised spheres, which contain from 0.5 to 2.5% cerium, show a high activity, a high resistance to thermal stresses and to chemical poisons, a uniform distribution of the synthesis gas and a low pressure drop, and are safe to handle and not-brittle.
2. Description of the Prior Art
It is known from old literature that elements such as ruthenium, cerium, titanium activate iron-based catalysts for ammonia synthesis when skillfully added in small quantities.
Processes have been recently disclosed in which the promoted and reduced iron oxides are treated with an aqueous solution of a cerium nitrate. More particularly the process according to U.S. Pat No. 3,951,862 (Lummus) comprises: mixing an iron oxide with traces of conventional promoters (alumina, calcium oxide, potassium and silica); fusion of the blend in the presence of 0.1-0.2 powdered graphite; crushing and screening of the fused and cooled pig; reduction of the catalyst with H 2 or H 2 +N 2 gas mixture; treatment of the reduced catalyst with a cerium nitrate solution; and drying. In the U.S. Pat. No. 3,992,328 (also to Lummus) the fused and reduced catalyst is submitted to a process in which air is evacuated from the pores before impregnating it with the aqueous solution of a cerium salt or of a mischmetal salt including cerium.
Accordingly the main features of the processes described in the above Patents are:
(1). the form of the catalysts is that obtained by breaking the pig with a hammer, by crushing and by screening (the under- and oversized material being recycled); irregular granules of 1-3 mm are used which however are scarcely efficient in certain plants (especially where there is no radial stream);
(2) a first reduction of the catalyst with H 2 or H 2 +N 2 is necessary;
(3) the treatment with the cerium nitrate solution is carried out on the catalyst so reduced;
(4) complex treatments with mixtures of oxygen and nitrogen (1% O 2 and 99% N 2 in a first step, and 5% O 2 and 95% N 2 in the third step) are necessary;
(5) the catalyst undergoes full oxidation by the air and nitrous and nitric oxide gases formed by the decomposition of the cerium nitrate;
(6) a second reduction is thus necessary;
(7) although it is said that the amount of cerium added to the reduced catalyst may range from 0.1 to 1.5%, effective results are obtained with 0.3-0.8% particularly with 0.45-0.7% by weight of cerium;
(8) the catalysts seem most efficient within a temperature range of from 400° to 480° C.
U.S. Pat. No. 4,073,749 (S.I.R.I.) describes a spherical catalyst which is pelletized thanks to the addition of water and bentonite to the catalyst powder, i.e. by the addition of a binder mixture which reduces the catalyst activated means.
SUMMARY OF THE INVENTION
Applicants now have discovered that ammonia synthesis catalyst, which make ammonia production possible to lower temperatures and/or lower pressures, can be prepared in form of pelletized spheres by incorporating cerium nitrate into a fused but unreduced catalyst (based on promoted iron oxides) before pelletization.
It is accordingly an object of this invention to prepare a spherically pelletized cerium activated catalyst. Another object is to prepare an oxidized pelletized cerium activated catalyst with a wide range of metallic cerium of from 0.5 to 2.5%. A further object is an oxidized catalyst in the form of regular spheres with diameters of from 1 to 25 mm, containing metallic cerium from 0.5 to 25% and showing a high catalytic activity particularly in the temperature range of 370°-450° C., a high resistance to thermal stresses and to chemical poisons, a uniform distribution of the synthesis gas and a low pressure drop. Still another object of the invention is a process to prepare the above catalyst, which may be easily and advantageously employed on an industrial scale. Finally another object is a process in which the double catalyst reduction is avoided and the cerium nitrate is added before the pelletization and acts therein as binder and thereafter is decomposed to penetrate, during sintering, into the catalyst structure as a metallic promoter.
Since the equilibrium in the formation of ammonia is favoured by low temperature, it follows that the spherical catalyst according to the invention, other conditions being equal (pressure, space velocity, etc.), will effect a faster conversion to ammonia, hence higher production.
This advantage can be particularly useful with Casale reactors where, to avoid overheating of the catalytic mass central part, temperature in the terminal part of the reaction zone must sometimes be kept below 400° C.
In the process according to this invention the catalyst is obtained by: mixing magnetite with (by weight) 2-3.5% of aluminum oxide, 0.8-2% potassium hydroxide, 2-3.5% calcium oxide, 0.1+0.4% magnesium oxide and 0.2-0.5% silica; melting this mixture in a furnace at a temperature of at least 1600° C.; air-cooling the molten mass, removing melted slag, crushing the deslagged mass in a crusher and pulverising it in a rod-mill; adding in a mixer to the so obtained powder a cerium nitrate solution in quantities to obtain in the final catalyst a metallic cerium concentration of 0.5 to 2.5%; pelletising the so added powder in a tray pelletiser to obtain a sphere shaped catalyst; drying said catalytic spheres in the furnace at 100°-200° C., and sintering them in an argon atmosphere at a temperature of 1250°-1350° C.
BRIEF DESCRIPTION OF THE DRAWINGS
The various features and advantages of the invention will better appear from the description of the non-limiting embodiment shown in the attached drawings in which
FIG. 1 is a flow-sheet of the process and
FIG. 2 are diagrams reporting the activity (NH 3 production as a function of the catalyst temperatures, at pressures of 315 kg/cm 2 and 150 kg/cm 2 , respectively, at a space velocity of 20.000, of catalyst spheres having diameters of 1.8 to 2.5 mm). The activity of the catalysts A (1.29% Ce), B (2.3% Ce) and C (0.64% Ce) according to the invention is compared to that of the spherical catalyst according to the U.S. Pat. No. 4,073,749 (containing no cerium) at a parity of all other conditions.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will be now described with reference to the attached drawings and illustrated by means of the following examples without however limiting the invention itself.
With reference to FIG. 1 the reference numeral 1 denotes the mixer for the loading powder consisting of magnetite, aluminum oxide, potash, calcium oxide and magnesium oxide.
It has been found as extremely advantageous that: (1) all promoters be added directly as oxides (and not as salts or other compounds); (2) the percent of said promotors be kept within the intervals (by weight on the magnetite weight) 2.0-3.5 aluminium oxide, 0.8-2 potash, 2-3.5 calcium oxide, 0.1-0.4 magnesium oxide and 0.2-0.5 silica respectively; (3) the magnetite have a critical ratio of FeO/Fe 2 O 3 comprised between 27-30% preferably 28-29% FeO.
From said mixer 1 the mixed charge is transferred to the furnace 2, preferably of the resistance type and melted at temperature not less than 1600° C. When the melting stage is ended, the molten mass is first left to solidify and cool in air, in the crucible inside the furnace, then the mass is removed from the crucible, further cooled in air 3 and freed from the slag. The air cooling (i.e. a low velocity cooling) has been found important as it does not essentially modify the FeO/Fe 2 O 3 ratio of the magnetite. The deslagged mass from 3 is then crushed in crusher 4 and pulverized in rod (bar) mill 5 from which a rugged, wrinkly and porous powder is obtained which is transferred into mixer 6 where it is added with a cerium nitrate solution concentrate to obtain in the final catalyst a cerium concentration (expressed as metal) of from 0.5 to 2.5% by weight on the total unreduced catalyst composition.
It has surprisingly been noted that while a ball mill gives small powdery granules having smooth and levigated surface which not only absorbs a negligible cerium nitrate amount but moreover does not allow the successive pelletisation, the small powdery granules from bar-mill 5, being unlevigated and extremely porous, absorb a consistent amount of Ce-nitrate (corresponding to a metallic cerium concentration up to 2.5% (which is very high in comparison to the maximum efficient amount incorporated in the unreduced catalysts of the U.S. Pat. Nos. 3,992,328 and 3,951,862); furthermore this porous powder from the bar mill 5 makes possible the successive pelletisation which otherwise would not occur.
The catalyst powder added with cerium nitrate in mixer 6 is transferred to tray granulator 7 allowing the catalyst to be obtained in the form of spherical granules. Said granulator 7 is provided with an internal dish (having f.i. a diameter of from 90 to 150 cm) whose inclination over an horizontal plane can be regulated from about 5° to 85° , the lower the inclination angle the lower the diameter of the spheres formed thereupon. It has been found that by using in combination a bar-mill 5 (giving a unlevigated powder) and a tray granulator 7, the pelletisation in this last occurs regularly and without powder loss. Indeed the porous powder from 5 (which has easely absorbed the cerium nitrate in mixer 6) forms immediately regular granules while falling on the dish of the tray granulator 7, which granules grow, in very short time, in the form of regular spheres absorbing all the powder fed to same granulator. Indeed the granule growing is only a function of the powder feed to 7 whereby there is practically no loss of powder. Moreover the pelletised catalyst spheres from 7 are, surprisingly, easy to handle and non-brittle. They can thus be easily manipulated and treated for preliminary drying at 100°-200° C. in furnace 8 and then sintered therein in an argon atmosphere at 1250°-1350° C.
EXAMPLE 1
A charge consisting of 200 kg of natural magnetite, 4.6 kg of aluminum oxide, 2.7 kg of potassium hydroxide, 6.7 kg of calcium oxide and 0.28 kg of magnesium oxide, 1.44 kg of silica is transferred to a mixer and then melted at 1600° C. within 1 hour.
The above mixture had a content of 61.4% Fe 2 O 3 and of ca. 28% FeO.
The mass obtained from melting, after being solidified by air cooling inside the crucible, is removed from the crucible and, after the mass has been fully cooled, it is deslagged, crushed and pulverised in rod mill 5.
The powder obtained from rod mill weighing 5 kg and having the following granulometry:
______________________________________mesh 65-120 120-220 220-250 250-270 270-325______________________________________% 20.94 11.60 4.36 18.18 44.92______________________________________
is sprayed in mixer 6 with a solution of 0.2 kg cerium nitrate Ce(NO 3 ) 3 .6H 2 O in 0.2 kg of water (1.29% weight of metallic Ce in the finished product; CAT. A). The so sprayed powder is sent on the dish (having a diameter of 125 cm and an inclination of 60° on the horizontal plane) of tray granulator 7 on which in short time the powder is transformed into spherical granules which have diameters of from 0.2 to 0.5 mm and which grow, also in very short time, into spheres of diameters 1.5-2.5 mm by absorbing substantially all the powder as this last is gradually fed.
After granulation the product has the appearance of spherical granules (diameters of 1.5 to 2.5 mm) and is treated in an electric cockle 8 for a preliminary drying phase at 150° C. and the next sintering treatment in the said furnace in argon ambient at 1350° C.
EXAMPLE 2
2.8 kg of catalyst powder from rod mill 5 are sprayed with a solution consisting of 0.2 kg of cerium nitrate and 0.1 kg of water (2.3% weight of metallic Ce in the finished product; CAT B). The sprayed powder is granulated, dried and sintered as described in Example 1. The sphere diameter (1.5-2.5) is maintained for comparison purpose.
EXAMPLE 3
5 kg of catalyst powder from rod mill 5 are treated with a solution consisting of 0.1 kg of cerium nitrate and 0.2 kg of water (0.64% by weight of metallic Ce in the finished product; CAT. C).
The sprayed powder is granulated dried and sintered as in example 1.
The activity of the catalysts (A-B-C), according to the invention, have been tested in an experimental reactor with the results shown in the attached diagram (FIG. 2) as compared to catalyst (CAT. D) known from U.S. Pat. No. 4,073,749.
The activity curves in the diagram show that the cerium-activated catalyst, compared with the known catalyst, at the same experimental conditions i.e. space velocity S.V.H-1=20,000 H-1, pressures=315 and 150 kg/cm 2 , respectively, and with the same average sphere diameter, (1.5-2.5 mm) presents a very high activity. More particularly it has been found that the efficiency of a cerium-activated catalyst gets higher as the temperature gets lower (350°-400°)C.).
Measurements have been taken under the following experimental conditions:
Pressures=150; 315 kg/cm 2
Temperature=370°-400°-450°-475°-500° C. ##EQU1##
The catalysts of Examples 1-3 have been submitted to thermal resistance tests, consisting in determining the loss of activity at the same test conditions, before and after the same charge has been maintained for 10 hours at 600° C. and 315 abs.atm and a spacial velocity of 20,000. From the measures carried out it appeared that the catalyst A.B.C maintained their initial activity.
Furthermore, as pointed out, pelletisation of the known catalyst of U.S. Pat. No. 4.073,749 is effected by adding water and bentonite to the catalyst powder, while pelletisation of the catalyst according to this invention is effected by adding only an aqueous solution of cerium nitrate.
The behaviour of the nitrate is unexpected: indeed it distributes itself uniformly on the whole catalyst surface and acts as a binder in the granulation step while it decomposes in the successive drying and sintering steps in which the nitrogen oxides are automatically eliminated (without thus requiring a controlled calcination treatment as in the Lummus Patents) and the metallic cerium penetrates in the catalyst structure as compatible activity promoter in the sintering phase (which is an incipient fusion). This allows the obtainement of catalyst spheres with the whole surface active whereas, on the contrary, the bentonite added in the U.S. Pat. No. 4,073,749, though allowing as a binder a good granulation and sintering could remain on small surface portions and reduce their activity.
Accordingly the composition and succession of the process steps are critical as:
the slow cooling does not alter the starting activity of the magnetite;
the bar mill allows the obtainement of an unlevigated porous powder;
said porous powder can absorb consistent amounts of cerium nitrate,
the dish granulator gives immediately small spherical granules which grow quickly to spheres by absorbing all the powder supplied; by simply varying the inclination angle of the dish it is possible to obtain spheres having diameters of from 1 to 25 mm which are safe to handle and not brittle;
the sintering in an argon atmosphere avoids the formation of oxides of nitrogen and allows, at the temperatures of 1250°-1350° C., the penetration of the metallic cerium into the catalyst structure. Particularly advantageous results have been obtained by using catalyst spheres according to the invention of 10-12 mm diameter to replace conventional irregular catalyst particles having sizes of from 12-21 mm: a much lower pressure drop has been measured together with a higher activity and thermoresistance, and with a uniform gas distribution. This is important because, as above stated, small catalyst particle sizes can not be used in many plants.
The present invention has been described and illustrated in one preferred embodiment, it is however understood that variations and changes with respect thereto might be practically adopted without departing from the scope of the invention.
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A spherical cerium-activated catalyst for the NH 3 synthesis is prepared by: mixing magnetite with (by weight): 2-3.5% of aluminum oxide, 0.8-2% potasium hydroxide, 2-3.5% calcium oxide, 0.1-0.4% magnesium oxide and 0.2-0.5% silica; melting this mixture in a furnace at a temperature of at least 1600° C.; air-cooling the molten mass, removing melted slag; crushing the deslagged mass in a crusher and pulverizing it in a rod-mill; adding in a mixer to the so obtained powder a cerium nitrate solution in quantities to obtain in the final catalyst a metallic cerium concentration of 0.5 to 2.5%; pelletizing the so added powder in a tray pelletizer to obtain a sphere shaped catalyst; drying said catalytic spheres in a furnace 100°-200° C.,and sintering them in an argon atmosphere at a temperature of 1250°-1350° C.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to the production of ink and paper pigments and fillers and more specifically to the production of under four-micron sized particles of basic potassium or sodium aluminum sulphate to substitute for relatively more expensive pigments including titanium dioxide.
2. Description of the Prior Art
Titanium dioxide is principally used as a pigment to provide brightness, whiteness and opacity for paints and coatings, plastics, paper, inks, fibers, food and cosmetics. Titanium dioxide is by far the most widely used white pigment in the world, having a refractive index second only to diamonds. A high refractive index translates to high opacity. Although magnesium oxide is whiter than titanium dioxide, its refractive index is much lower than that for titanium dioxide. Relatively more magnesium oxide would be needed in a paint to obtain the same opacity, therefore for practical purposes, titanium dioxide is preferred.
Nature does not provide titanium dioxide in a form that is directly usable. Nature usually associates titanium dioxide with iron, either as ilmenite or leuxocene ores. Titanium dioxide is mined in one of its purest forms, rutile beach sand. The most important deposits in the world include rutile beach sand and ilmenite soaps, and these ores are the principle raw materials used in the prior art manufacture of titanium dioxide pigment.
Reportedly, in 1995, the titanium dioxide pigment market, was valued at about $2.6 billion; was supplied primarily by five producer companies at eleven manufacturing plants in nine American states; about forty-seven percent of titanium dioxide production was used in paint, varnishes, and lacquers; about twenty-four percent was used in paper; about eighteen percent was used in plastics; and about eleven percent went into miscellaneous uses such as catalysts, ceramics, coated fabrics and textiles, floor coverings, printing ink, roofing granules, etc.
The conventional production of titanium dioxide pigments involves a two step process. The first step is to purify the ore, and is basically a refinement step. This may be achieved by either the sulfate process, which uses sulfuric acid as a liberating agent, or the chloride process, which uses chlorine as the liberating agent. Once refined, and developed to the appropriate particle size, the pigment may be surface treated with inorganic oxides or an organic material to give each grade its unique characteristics.
The sulfate process for producing titanium dioxide pigments is often referred to as the older process, relative to the more modern chloride process. The sulfate process is used to produce high quality titanium dioxide pigment grades for the ink, fibers and paper industries. Kronos, Inc. (Houston, Tex.), for example, was granted patents for the sulfate process and has been producing titanium dioxide pigment using this process continuously since 1916. Since the late 1970's, Kronos has also manufactured grades using the chloride process. The chloride process was developed by the Kronos research and development group in Leverkusen, Germany, and commissioned its first chloride plant in the late 1970's.
A high purity rutile titanium dioxide is used in electro-ceramics for its dielectric properties, in vitreous enamels for its ease of fusion, in glasses to modify the refractive index and to improve the thermal and mechanical properties, in containers to absorb ultraviolet light for food preservation, in ceramics to enhance sintering and improve the thermal and chemical resistance, and in arc welding to ensure excellent ionization and easy re-ignition of the electrode to prevent electrode sputtering and control slag fluidity.
The rutile titanium dioxide grade is typically produced via the sulfate process, with low abrasion and high gloss. High brightness and very good opacity allows for this to be an ideal pigment for ink formulations, particularly rotogravure and polyamide flexo inks where it combines excellent dispersion, high gloss and opacity with very low abrasion.
Titanium dioxide pigments can be designed for ease of dispersion in many aqueous applications with minimal requirement for dispersing agents. Such pigment can be added at the beater or hydropulper to improve the opacity and brightness of the finished sheet. It can be used in the dry state as received, or can be slurried in water at the mill site to take advantage of slurry additions. It is also used to enhance opacity and brightness of paper coatings. It disperses readily in water at high solids without additional dispersing agent over that normally used in the coating mixture. The pigment can be used for white sidewall rubber goods that provide self-cleanup through chalking and resistance to ozone cracking. Its low abrasion properties promote its application in rubber thread compounds, both extruded and cut rubber thread. Cost effectiveness may be obtained in white plastic film, sheeting and profiles. Titanium dioxide pigment is used in traffic marking paints where an anatase grade is permitted. Field tests of traffic stripes indicate that the weathering of pigmented traffic stripes result in improved night visibility with minimal film loss. Titanium dioxide pigment may be used in white exterior aqueous and non-aqueous paints to impart controlled chalking.
Titanium dioxide pigment can be used in melamine laminate compositions where its resistance to ultraviolet light discoloration is outstanding. Titanium dioxide pigment can provide high brightness and very high resistance to ultra-violet discoloration in pigmented decorative papers for melamine formaldehyde laminates. KRONOS 2081 pigment is suitable for use in printing inks which are used in melamine-formaldehyde laminate systems. KRONOS 2081 pigment is suitable for pigmentation of melamine formaldehyde resins.
SUMMARY OF THE PRESENT INVENTION
An object of the present invention is to provide a method for the production of pigment fillers and coating materials for paper.
Another object of the present invention is to provide a pigment filler for use in the production of plastics, paints, and inks, and any other use requiring very small particle sizes (less than four microns), extreme whiteness, and brightness exceeding 90 on a scale of 1 to 100.
Briefly, a method embodiment of the present invention includes a process for making white pigment directly from constituent materials without byproducts. The process comprises the steps of inputting three material flows comprising a sulphate source, an alkali source, and an aluminum source. And, recycling and mixing into the three material flows a process return from a separation and wash stage and condensed vapors from a pressure let-down stage. This is followed by heating and holding a mixture of recycled process returns and the three material flows at elevated pressure in a reactor for a minimum predetermined residence time, followed by letting down pressure in a flow from the reactor to produce a pre-wash flow. Then, the separating, classifying, and delaminating the pre-wash flow into a first and second pigment or filler, that are differentiated by their respective average particle distribution sizes, are conducted.
An advantage of the present invention is that it provides a process for producing high quality white pigment.
Another advantage of the present invention is that it provides an inexpensive process for making pigments and fillers useful in paints, paper, inks, and plastics.
These and other objects and advantages of the present invention will no doubt become obvious to those of ordinary skill in the art after having read the following detailed description of the preferred embodiment that is illustrated in the drawing figures.
IN THE DRAWINGS
FIG. 1 is a process flow diagram of a batch process embodiment of the present invention for making pigments and fillers useful in paints, inks, paper, and plastics;
FIGS. 2A and 2B are schematic diagrams of two stirred reactor vessels used in the process of FIG. 1;
FIG. 3 is a schematic diagram of a vessel-reactor continuous process embodiment of the present invention for making pigments and fillers useful in paints, paper and plastics; and
FIG. 4 is a schematic diagram of a pipe-reactor continuous process embodiment of the present invention for making pigments and fillers useful in paints, paper and plastics.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a process embodiment of the present invention, and is referred to by the general reference numeral 10. The process 10 is a batch mode process with a feed preparation unit 12 with three source material inputs 14, 16 and 18. The input 14 is a sulfuric acid (H 2 SO 4 ) stream. The input 16 is a sodium hydroxide (NaOH), i.e., "caustic", stream typically about fifty percent solution. These are mixed with the input 18 which is an aluminum hydroxide stream, and a recycle stream 20. A combined mixture is heated in a stirred-vessel reactor (R1) within the feed preparation unit 12 to a temperature in the approximate range of 110° C. and 140° C., preferably about 130° C. The stirred-vessel reactor (R1) is illustrated in FIG. 2A. A heated mixture stream 22 is then transferred to a pigment reactor 24, which is detailed more fully in FIG. 2B. A reaction mixture 26 flows to a product separation and wash unit 28 that separates the solid pigment product from a solution of unreacted components, e.g., by filtering. A filtrate is recycled in recycle flow 20 to feed preparation unit 12 to become part of a next production cycle. A small purge flow 30 is used to control a buildup of impurities that could otherwise occur. A product pigment can be washed either as a part of the filtration operation, or in a separate step. In general, the particular washing method chosen is not important, except whatever method is chosen preferably must use a minimum of clean water. Any spent wash water is recycled and joins the filtrate as part of recycle flow 20. A washed product is made into a slurry by adding water and it leaves the separation and wash unit 28 in three washed filter cake flows, 32, 34, and 36. Such flows typically have a wide particle size distribution that may embrace several product specification ranges of individual commercial-product materials. A first product output 38 is produced by adding a first classified output 40 with particle size distribution over one micron from a classifier 42. A second classified output 44 with particle size distribution under one micron is mixed with a delaminated flow 46 from a delaminator 48 to produce a second product output 50.
Any suitable mechanical device may be used to separate the two products based upon particle size distribution. In one such device a specially adapted and modified centrifugal classifier is used to separate the two products. For example, high centrifugal bowl units made by Bird Machine Company, Robatel, Hutchison Hayes, or Humbolt may be adapted for use, or a modified hydrocyclone or any other particle classifying device capable of separating particles into two or more size ranges. Classification is generally accomplished by centrifuging the output from the step of delaminating in a bowl-type centrifuge. There are preferably at least two bowl-centrifuge liquid taps at different radial points to bifurcate a pigment substitute material output into a first product with an average particle size under a micron in diameter, and at least one other product with an average particle distribution size of one to four microns.
The first product flow 38 is produced with a paper filler particle size distribution range, e.g., 0-7 microns, but preferably in the range of 1-4 microns. The pigment particle size distribution is reduced by the delaminator 48 and the moisture content is adjusted to suit customer requirements, e.g., such as for paper coatings with a particle size distribution of less than one micron.
Referring to FIG. 2A, one or more of the reactant flow inputs 14, 16, or 18 may be individually connected to a stirred-vessel reactor (R1) 60. At the temperatures mentioned, the pressure within the stirred-vessel reactor (R1) 60 typically rises to equal the vapor pressure of the solution within, approximately 30-40 PSIG. The temperature is preferably increased by pumping the input-material mixture through a heat exchanger 62 that can use either steam or hot oil input, depending on which is more economical. A plate-type exchanger is generally preferred, but any conventional heat exchanger can be used, provided it can tolerate the temperature, pressure, process chemistry, and suspended solids unique to this process. Alternatively, the input-material mixture in stirred-vessel reactor (R1) 60 may be heated directly by injecting steam into it. Further heating of the mixture may be accomplished by a combination of direct and indirect methods. A motorized mixer 64 is used to stir the contents and a pump 66 is used to circulate the contents through the heat exchanger 62. A purge flow 68 may be taken from stream 22 if necessary to remove impurities that may have been precipitated in the feed preparation unit 12.
Referring now to FIG. 2B, the pigment reactor 24 is also preferably a stirred-vessel reactor (R2) 70, and is heated by a heat exchanger 72. The heating of the mixture is such that the temperature is raised to between 170° C. and 220° C., and preferably about 200° C. Any type heat exchanger is acceptable provided it can tolerate the temperature, pressure, process chemistry, and suspended solids. A motorized mixer 74 is used to stir the contents and a pump 76 is used to circulate the contents through the heat exchanger 72. The mixture is temperature controlled for a "residence time", that can span between several seconds and several minutes, depending upon the desired characteristics of the reaction product. For example, by speed control of pump 76 or by using a flow control valve on the pump discharge. After completing a predetermined reaction time, the pressure in stirred-vessel reactor (R2) 70 is reduced to 0-30 PSIG by venting through line 20. The vented vapors are cooled, condensed, and added to the plant recycle material. The reaction mixture is then transferred to the product separation and wash unit 28.
A product pigment composed of a double salt of the type wK 2 SO 4 ·xAl 2 O 3 ·ySO 3 ·zH 2 O or vNa 2 SO 4 ·xAl 2 O 3 ·ySO 3 ·zH 2 O, is formed by the present invention. Where, "v" is the stoichiometric coefficient of Na 2 SO 4 (generally in the range of zero to one); "w" is the stoichiometric coefficient of K 2 SO 4 (generally in the range of zero to one); "x" is the stoichiometric coefficient of Al 2 O 3 (generally about three); "y" is the stoichiometric coefficient of SO 3 (generally about four); and, "z" is the stoichiometric coefficient of H 2 O (generally about nine). Using both of the alkali metals, K and Na, as the raw materials produces a combination represented by the above-described double salts. Also, a pigment product may be produced without the alkali component (i.e., stoichiometric coefficients "v" and "w" are zero). In this case the feed preparation section would be modified accordingly.
FIGS. 3 and 4 illustrate continuous-mode process embodiments of the present invention, which are alternative to the batch-mode process 10. In general, the major process parts are about the same as in the batch mode process 10. In a vessel-reactor type continuous-mode process 100, as shown in FIG. 3, a set of three raw materials flows 102, 104, and 106, and a process recycle flow 108 are fed into a feed preparation unit 110. Such material inputs are mixed and raised in temperature to a range of approximately 15° C.-130° C. and preferably to approximately 100° C.-120° C. The raw material and recycle mixture (reactants) are then transferred in a flow 112 by a pump 114 and then a flow 116 through a heat exchanger 118. A steam or hot oil flow 120 gives up its heat to a flow 122 that enters a vessel reactor 124. The reactants are pumped continuously with pump 114. The heat exchanger 118 raises the temperature of flow 122 to 150° C.-220° C. The heat exchanger 118 may be of any type which can handle the reactant mixture, which may contain solid particles, but generally a plate-type heat exchanger is preferred. A reactor 126 is designed to hold the hot input flow at-temperature for a predetermined "residence time", e.g., several seconds to several minutes, determined by feed rate and reactor volume. Reactor 126 may be a single open-chamber vessel, a baffled vessel designed to prevent back mixing, or a series of vessels designed to produce an environment approaching plug flow. A small amount of steam flow 127 may be injected to maintain the target temperatures within reactor 126. The pressure in reactor 126 will typically be approximately 50-250 psig, as determined by the vapor pressure of the reacting mixture. From the reactor 126 a slurry flow 128 is transferred through a level control valve 129 into a pressure letdown system. The residence time in reactor 126 is indirectly controlled by the level control valve 129.
The pressure letdown system may be either a single or multiple-stage system. FIG. 3 illustrates a two-stage system that includes a first flash vessel 130 with a pressure regulating valve 132 and a level control valve 134. A second flash vessel 136 with a pressure regulating valve 138 and a level control valve 140. The vapors produced by pressure letdown from pressure regulating valves 132 and 138 are condensed and become part of the recycle flow 108. A reaction mixture 142 flows to a product separation and wash unit 144 that separates the solid pigment product from a solution of unreacted components, e.g., by filtering. A filtrate is recycled in recycle flow 108 to feed preparation unit 110 to become part of a next production cycle. A small purge flow 145 is used to control a buildup of impurities that could otherwise occur. A product pigment can be washed either as a part of the filtration operation, or in a separate step. In general, the particular washing method chosen is not important, except whatever method is chosen preferably must use a minimum of clean water. Any spent wash water is recycled and joins the filtrate as part of recycle flow 108. A washed product is made into a slurry by adding water and it leaves the separation and wash unit 144 in three washed filter cake flows 146, 148, and 150. Such flows typically have a wide particle size distribution that may embrace several product specification ranges of individual commercial-product materials. A first product output 152 is produced by adding a first classified output 154 with particle size distribution over one micron from a classifier 156. A second classified output 158 with particle size distribution under one micron is mixed with a delaminated flow 160 from a delaminator 162 to produce a second product output 164.
In a vessel-reactor type continuous-mode process 200, as shown in FIG. 4, a set of three raw materials flows 202, 204, and 206, and a process recycle flow 208 are fed into a feed preparation unit 210. Such material inputs are mixed and raised in temperature to a range of approximately 50° C.-130° C., and preferably to approximately 100° C.-120° C. The raw material and recycle mixture (reactants) are then transferred in a flow 212 by a pump 214 and then a flow 216 through a heat exchanger 218. A steam or hot oil flow 220 gives up its heat to a flow 222 that enters a pipe reactor 224. The reactants are pumped continuously with pump 214. The heat exchanger 218 raises the temperature of flow 222 to approximately 150° C.-220° C. The heat exchanger 218 may be of any type which can handle the reactant mixture, which may contain solid particles, but generally a plate-type heat exchanger is preferred. A pipe 226 is used to hold the hot input flow at-temperature for relatively short "residence times", e.g., closer to several seconds rather than several minutes. A small amount of steam flow 227 may be injected to maintain the target temperatures within pipe 226. The pressure in pipe 226 will typically be in the range of approximately 50-250 psig, as determined by the vapor pressure of the reacting mixture. From the pipe 226 a slurry flow 228 is transferred through a back pressure control valve 229 into a pressure letdown system. The residence time in pipe 226 is indirectly controlled by the feed rate from pump 214 and the volume of the system between heat exchanger 218 and the pressure valve 229.
The pressure letdown system may be either a single or multiple-stage system. FIG. 4 illustrates a two-stage system that includes a first flash vessel 230 with a pressure regulating valve 232 and a level control valve 234. A second flash vessel 236 with a pressure regulating valve 238 and a level control valve 240. The vapors produced by pressure letdown from pressure regulating valves 232 and 238 are condensed and become part of the recycle flow 208. A reaction mixture 242 flows to a product separation and wash unit 244 that separates the solid pigment product from a solution of unreacted components, e.g., by filtering. A filtrate is recycled in recycle flow 208 to feed preparation unit 210 to become part of a next production cycle. A small purge flow 245 is used to control a buildup of impurities that could otherwise occur. A product pigment can be washed either as a part of the filtration operation, or in a separate step. In general, the particular washing method chosen is not important, except whatever method is chosen preferably must use a minimum of clean water. Any spent wash water is recycled and joins the filtrate as part of recycle flow 208. A washed product is made into a slurry by adding water and it leaves the separation and wash unit 244 in three washed filter cake flows, 246, 248, and 250. Such flows typically have a wide particle size distribution that may embrace several product specification ranges of individual commercial-product materials. A first product output 252 is produced by adding a first classified output 254 with particle size distribution over one micron from a classifier 256. A second classified output 258 with particle size distribution under one micron is mixed with a delaminated flow 260 from a delaminator 262 to produce a second product output 264.
Alternatively, the pressure in the last flash vessel may be controlled below atmospheric pressure without pressure regulation valve 232 by cooling vapors below their normal boiling points and controlling the pressure downstream of the condenser.
Although the present invention has been described in terms of the presently preferred embodiments, it is to be understood that the disclosure is not to be interpreted as limiting. Various alterations and modifications will no doubt become apparent to those skilled in the art after having read the above disclosure. Accordingly, it is intended that the appended claims be interpreted as covering all alterations and modifications as fall within the true spirit and scope of the invention.
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A process for making white pigment directly from constituent materials without byproducts. The process comprises the steps of inputting three material flows comprising a sulphate source, an alkali source, and an aluminum source. And, recycling and mixing into the three material flows a process return from a separation and wash stage and vapors from a pressure let-down stage. This is followed by heating and holding a mixture of recycled process returns and the three material flows at elevated pressure in a reactor for a minimum predetermined residence time. Afterwards, letting down pressure in a flow from the reactor to produce a pre-wash flow. Then, separating, classifying, and delaminating the pre-wash flow into a first and second pigment or filler that are differentiated by their respective average particle distribution sizes.
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TECHNICAL FIELD
The present invention relates to gas generators or inflators, for inflating vehicle restraint cushions, commonly known as air bags. Air bags have been used for some time to provide impact protection to occupants of passenger vehicles. More particularly, this invention relates to an improved inflator that can provide varying rates of inflation of the air bag. The rate of air bag inflation can be controlled through the inventive inflator to adapt to various crash conditions and/or occupant positions.
BACKGROUND ART
The present invention relates to an apparatus used to stage the inflation of an airbag in a vehicle occupant restraint system. Inflation of an airbag through the use of gas generators is well known and understood. This invention, a dual stage pyrotechnic inflator (DSP), is a two-stage gas generator used to provide a variable gas output so that the rate of airbag inflation can be controlled. Controlling the rate of gas generation and thereby the rate of rise of pressure within the airbag provides better protection for a wider range of vehicle occupants while minimizing the risk of injury resulting from the airbag deployment. Currently, single stage inflators are designed to inflate rapidly in order to meet required United States Government injury criterion. With single stage inflators, smaller and out of position occupants are at risk of being injured during the airbag deployment. The use of a staged output inflator coupled to the appropriate sensing device reduces the likelihood of injury to the vehicle occupant.
The primary objective of this invention is to supply gas used to fill an airbag in either a single stage or multistage manner. This is accomplished through the use of two combustion chambers in isolation, containing gas generant. Deployment modes may involve deployment of both stages at once or the primary followed by the secondary at some later time to provide the desired gas delivery event.
Controlled inflation of an airbag as taught by Cuevas et al. in U.S. Pat. No. 5,558,367 employs a hybrid inflator containing an inflating fluid and two igniters. The fluid is released by activation of the first igniter. A second igniter is used to ignite combustible material for the purpose of increasing the temperature and pressure of the contained fluid. Buchanan et al., U.S. Pat. Nos. 5,582,428, 5,630,619, and 5,709,406, describe the use of hybrid technology to address the staging problem. The invention describe herein is not a hybrid inflator.
Marchant in U.S. Pat. No. 5,221,109 incorporates into the gas generator, a venting mechanism used to control gas output. Esterberg in U.S. Pat. No. 5,346,254 describes a single combustion chamber inflator design, which employs dual output igniter. The first stage of the igniter provides the ignition impulse required to ignite the gas generant and some point in time later the second stage of the igniter is fired, cracking the gas generant thereby increasing the surface area available for combustion.
Hock in U.S. Pat. Nos. 5,368,329 and 5,398,966 discloses an elongated inflator housing, containing gas-generating wafers spaced along the length of the tube, containing two igniters. The primary igniter provides the ignition source required to ignite the gas generant and the second igniter is used to shatter the wafer when fired at a latter time. Shattering of the gas generant wafer increases burning surface area and thereby the mass generation rate of gas. The DSP does not employ generant shattering technology.
U.S. Pat. No. 5,564,743 to Marchant discloses a multiple stage air bag inflator system wherein the inflator housing contains two separated chambers, each containing gas generating material and an ignition system. The wall that separates the two chambers has a frangible section designed to rupture in response to a predetermined level of gas pressure in one of the chambers, thus providing fluid communication between the chambers.
Faigle et al. in U.S. Pat. No. 5,460,405 describes an apparatus containing a controller and a collision and position sensor for controlling the actuation of the first and second fluid source required to inflate the air bag.
Gioutos et al. in U.S. Pat. No. 5,400,487 discloses a system whereby multiple individual gas generators are used to generate the desired airbag inflation rate. No mention is made of the use of a single staged inflator. Schluter et al. in U.S. Pat. No. 5,839,754 describes a multichambered gas generator and a single ignition source used to ignite the gas generant in the primary chamber. The gas generant in the primary chamber serves as an ignition source for the gas generant housed in the secondary chamber by forcing hot burning gas through bores and into the secondary chambers.
OBJECTIVES AND SUMMARY OF THE INVENTION
The objective of the present invention is to provide variable output levels of inflation gas to an airbag used in a vehicle occupant restraint system. This is accomplished through the physical partitioning of a quantity of gas generating pellets into two chambers equipped with separate ignition systems, filters and a common exit port. Through the use of a variable output inflator, air bag performance tailorability can be achieved. The performance range stretches from low to high gas output levels. Staging is accomplished through the use of a gas generator with two separate levels of gas output. The two gas output levels are independent of each other and can be activated on demand. The combustion of the gas generant is conducted in such a manner to minimize the generation of noxious gasses.
A further objective is to provide a reliable inflator which can generate inflation gas quickly, efficiently, and with minimal noxious products.
An inflator constructed in accordance with this invention consists of a two-piece housing welded together. The internal volume of this housing is divided into two chambers using a third steel member to provide an annular space between the third member and the lower of the two main housings. A gas generating material, filters and ignition systems are placed in each of the two chambers. Other objectives and advantages of the invention shall become apparent from the following description of the invention and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features of the present invention will become apparent to those skilled in the art to which the present invention relates from reading the accompanying drawings, in which:
FIG. 1 shows a side cross-sectional view of an inflator constructed in accordance with the instant invention; and
FIG. 2 is cross-sectional view of an inflator in accordance with the invention taken along line 2 — 2 of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, an embodiment of an inflator constructed in accordance with this invention is generally designated by reference number 30 . The inflator 30 has two discreet chambers: a primary combustion chamber 1 and a secondary combustion chamber 2 . The primary stage gas generator deployment occurs when a first body of gas generating means (not shown for the purpose of clarity) housed in the primary combustion chamber 1 is ignited and gas is produced. Likewise, the secondary stage gas generator deployment occurs when a second body of gas generating means (not shown for purpose of clarity) in the secondary combustion chamber 2 is ignited and begins to produce gas. A plurality of primary gas exit ports 7 in the upper housing 3 control the pressure development in both the primary 1 and secondary 2 combustion chambers. In an event requiring a low output deployment only the gas generant housed in the primary combustion chamber 1 is ignited. When a high output deployment is required the gas generant in both the primary 1 and the secondary 2 combustion chambers will be ignited simultaneously. Staging at intermediate levels will involve ignition of the primary combustion chamber gas generant followed by ignition of the secondary combustion chamber gas generant at some point later in the event. Staging thereby controls rate of generation of inflating gases going into the airbag and thereby the inflation rates. In a preferred embodiment the primary chamber 1 contains from 50% to 80% of the total gas generant load, and the secondary chamber 2 contains from 20% to 50% of the total gas generant load.
The inflator 30 has two chambers housing gas generant. A cup shaped upper housing 3 and a cup shaped lower housing 4 form the primary combustion chamber 1 . Referring to FIGS. 1 and 2, the upper housing 3 contains a plurality of primary gas exit ports 7 . The primary gas exit ports 7 may be, but are not limited to, a single diameter. A primary closure 24 , such as a thin metallic foil 24 adhesively-bonded to the upper housing 3 or a plug over the port, serves as a hermetic seal. Two circular holes are located in the lower housing 4 to accept the two igniter retainers 11 and 25 . The upper housing 3 and lower housing 4 are configured in such a manner as to be welded together. A flange 23 is attached to the upper housing 3 by welding or crimping, although it could also be attached or consolidated into the lower housing 4 . The volume defined by the interior of the upper housing 3 and the lower housing 4 is separated into two chambers by a divider plate 5 . The divider plate 5 is cup shaped and consists of a substantially circular end plate and an outer tubular wall containing a plurality of secondary gas exit ports 22 . The secondary gas exit ports 22 are of circular holes through the divider plate 5 and may be, but are not limited to, a single diameter. The secondary gas exit ports 22 are closed by a secondary closure 6 , such as thin metallic foil adhesively bonded over the gas exit ports. The secondary closure 6 prevents the gasses produced by combustion in the primary combustion chamber 1 from entering the secondary combustion chamber 2 during a low output deployment and subsequent ignition of the gas generant housed therein. The outer tubular wall of the divider plate 5 is joined to the lower housing 4 and is retained by a close fit with a retaining ring 32 positioned between the lower housing 4 and the divider plate 5 .
The primary combustion chamber enhancer tube 12 and the secondary combustion chamber enhancer tube 13 are inserted into the substantially circular end plate of the divider plate 5 and retained in place by a press fit and/or weld. The primary enhancer tube 12 is positioned in such a manner as to place the primary enhancer tube exit ports 14 in the primary chamber 1 . The secondary enhancer tube exit ports 15 are positioned in such a manner as to place the secondary enhancer ports 15 in the secondary combustion chamber 2 . The primary enhancer tube 12 and the secondary enhancer tube 13 comprise a substantially circular end plate and an outer tubular wall with a plurality of enhancer ports 14 and 15 . The enhancer ports 14 and 15 are circular and distributed circumferentially around the outer tubular walls of the enhancer tubes 12 and 13 . The enhancer ports may be, but are not limited to, a single diameter. The primary combustion chamber igniter retainer 11 is welded into the lower housing 4 and protrudes into the open end of the primary enhancer tube 12 . A press fit is utilized to insure a gas tight seal between the primary combustion chamber enhancer tube 12 and the primary combustion chamber igniter retainer 11 . Similar assembly is required for the secondary combustion chamber enhancer tube 13 and the secondary combustion chamber igniter retainer 25 . The primary enhancer 17 (not shown for reasons of clarity) housed inside the primary igniter tube 12 comprises of an ignition material in the form of powder, granules and/or pellets. A primary igniter means 9 ignites the primary enhancer 17 after receiving an electrical signal from the sensor diagnostic means 40 . The secondary combustion chamber igniter retainer 25 , secondary igniter 8 , and the secondary enhancer 16 (not shown for reasons of clarity) are similar in design and function to their primary stage counterparts. The primary filter 18 cools and filters particulates from the gas stream prior to the gas leaving the inflator through the primary gas exit ports 7 . The primary filter is held in place by primary filter seals 34 and 36 . The secondary filter 19 performs a similar function in the secondary combustion chamber 2 , and is held in place with secondary filter seals 38 and 39 .
In operation the inflator functions after receiving an electric signal from sensor diagnostic means, which determines the type of airbag inflation required for optimal vehicle occupant protection depending on the severity of a crash and the occupant position and size. The airbag inflation will begin with the deployment of the low output mode of the inflator or only the primary stage. The low output mode or primary stage functions when the primary igniter means 9 receives an electric signal from the sensor diagnostic means 40 . When the igniter means 9 receives the signal, and activation occurs, ignition of the primary enhancer 17 results. The burning primary enhancer 17 produces hot gas and particles, which are expelled from the primary enhancer tube 12 through the primary enhancer ports 14 and into the primary combustion chamber 1 igniting the primary gas generant, housed therein. Once the primary gas generant 1 is ignited, gas flows through the primary filter 18 and into a first gas collection plenum 20 . When the pressure inside the primary combustion chamber 1 reaches a predetermined level the primary closure 24 ruptures allowing the gas to flow through the primary exhaust ports 7 and into the airbag. The secondary closure 6 prevents sympathetic ignition of secondary stage by preventing the hot gasses from entering the secondary combustion chamber 2 through secondary gas ports 22 and igniting gas generant housed therein.
The high output mode requires that both the primary 9 and secondary igniter means 8 are activated simultaneously by sensor diagnostic means 40 . The primary combustion chamber 1 would function as described above. The secondary stage occurs when the gas generant housed in the secondary combustion chamber 2 has been ignited. Function of the second stage occurs in a manner similar to the primary stage. The secondary igniter means 8 ignites the secondary enhancer 16 . The burning secondary enhancer 16 produces hot gas and hot particles which are expelled from the secondary enhancer tube 13 through the secondary enhancer ports 15 and into the secondary gas generant housed in the secondary combustion chamber 2 . The secondary gas generant when ignited produces gas, which flows through the secondary filter 19 and into a second gas plenum 21 . As the secondary combustion chamber 2 pressure increases the secondary closure 6 opens allowing the gas to flow through the secondary gas ports 22 and into the first gas collection plenum 20 and through the primary gas ports 7 into the airbag.
The secondary stage can be deployed simultaneously with the primary stage or the secondary stage may be delayed to some time later as determined by sensor diagnostic means 40 . The function of each chamber or stage is the same in all cases. In the case of long interstage delays, the primary stage deployment may be completed prior to function of the secondary chamber. The secondary gas ports 22 are sized properly to provide for proper combustion of the secondary gas generant and minimal noxious effluents while limiting the gas output to an acceptable level.
In the event that the inflator 30 is exposed to fire or other sources of extreme heat the inflator 30 is designed to autoignite and function in the normal manner. An autoignition element 10 is placed in intimate thermal contact with the lower housing 4 in the secondary chamber 2 . In the event of exposure to high temperatures the autoignition element 10 deploys igniting the secondary gas generant 2 . The gasses produced by the gas generant flow through the secondary enhancer ports 15 and ignite the secondary enhancer 16 and secondary igniter 8 . As the gasses enter the first plenum 20 they also pass through the primary filter 18 and ignite the primary gas generant 1 , primary enhancer 17 and primary igniter 9 .
It is to be understood that while the presently preferred embodiments of the present invention have been described, various changes and modifications may be made by those skilled in the art without departing from the scope of the invention as set forth in the claims.
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A dual stage gas generator for inflating an airbag used in vehicle occupant restraint systems. Wherein the gas generator contains primary and secondary combustion chambers and a common gas exiting port for controlling the combustion pressure in both combustion chambers. Said gas generator when activated can cause an airbag to inflate at different rates dependent on the firing sequence used. The low output performance level occurs when only the primary stage is deployed. Simultaneous firing of both the primary and secondary stage constitutes the upper performance limits, while staging results from deployment of the primary stage and some time later deployment of the secondary stage. The staging provides a means to supply inflation gas in a variable rate fashion.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to methods and systems for authoring, referencing, and manipulating documents and more specifically to a method and systems for linking sources to text copied from these sources.
BACKGROUND OF THE INVENTION
[0002] Computer objects such as texts or images are very often cut or copied from one document e.g., from a web page, and pasted into another document e.g., in a Lotus WordPro document (Lotus and WordPro are Trademarks of International Business Machine Corporation). Different types of objects, such as text portions, images, or audio clips, can be copied by a user from multiple source documents and pasted into an object document. It is a common practice today, for many people, to compose documents including portions that are “imported” i.e., copied and pasted, from another documents e.g., from web pages accessed through the Internet.
[0003] Most of modern word processing application programs allow a user to copy blocks of text from different documents and to transfer them to another document. Copying an item such as a block of text from a first document into a second document is generally referred to as a “copy and paste operation”. When an item is copied from a source document, it is generally stored in a temporary buffer called a clipboard. This allows the user to later paste the item into the desired object document, at the right location. The action of transferring the copied item to a determined location of the object document is referred to as “paste”.
[0004] Authors and publishers place considerable proprietary value in their creations and in particular, in the textual passages they generate e.g., in newspapers and magazine articles. Unfortunately, the ease with which textual passages can be duplicated in electronic storage media presents the problem that such passages can be copied and/or incorporated into other electronic documents without proper attribution or remuneration of the original author. This copy may occur either without modification of the original passage or with minor revisions such that original authorship cannot reasonably be disputed. Furthermore, authors and researchers often have the need to locate the sources of given passages cited in documents, but frequently do not know the title, author, date of publication, or other identifying features of the original work. As a consequence, unless the user has an exact quotation, it can be very difficult to find the source of the passage in order to give proper recognition to the original author.
[0005] When objects such as text portions are copied from one or from several source documents into an object document, source information is the information required to identify the source documents from which each one of said text portions have been copied. Source information may include, for example, address where the document can be found, copyright information, authorship information, references to contract's terms and conditions, citations and footnotes. When portions of documents are copied through networks, such as the Internet, source information may include, for instance, the Uniform Resource Locator (URL) of a web page from which a text portion has been copied.
[0006] According to the prior art, several systems and methods exist for providing source information of an object copied from a first document and inserted into a second document. For example, U.S. patent application Ser. No. 10/165,083, by Keohane et al., discloses a method, apparatus, and computer instructions for automatically generating source information for an object that is cut or copied from a document and inserted into another document. The source information can be stored, hidden, or pasted into the destination document, and can also trigger automatically the generation of a footnote for the destination document.
[0007] An important limitation not solved by Keohane et al., nor by the other known methods for providing source information of copied textual objects, lies in the lack of persistency of the source information. By lack of persistency of the source information, one should understand that, if an object e.g., a portion of text, copied by a user from a source document to an object document, is itself edited by the user in the second document e.g., a portion of the copied text is modified, or if a sub-portion is cut and pasted by the user into a different paragraph of the object document, the source information associated to the copied portion, and the generated sub-portions, is lost.
[0008] The traceability and the persistency of copied objects is an important issue for intellectual property protection and copyrights enforcement. As it is widely established by copyright laws in most countries, material paraphrased or summarized from other sources should be, clearly indicated as such, and it should be clearly distinct from the author's own statements and credited to the original source.
[0009] Moreover, not merely to enforce copyrights protection, but also for the purposes of authoring, documenting and referencing edited materials, when the copy and paste process is used during a document edition, it would be very useful to automatically create a link, or hyperlink, from each textual portion copied into an object document, to the source document from which said textual portion has been copied. Furthermore, it would be required not only to automatically associate links, or hyperlinks, from copied textual portions to the source information, but also from all textual sub-portions or textual fragments that could be generated therefrom when editing the object document.
[0010] Therefore, there is a need to provide a method and systems for identifying imported textual objects which have been copied or have been generated by editing textual objects already copied from other source documents. There is also a need to provide a method and systems for referencing and accessing, from imported textual objects, copied from different documents, or originated by editing text already copied from different documents, the source documents from which they have been copied.
SUMMARY OF THE INVENTION
[0011] Thus, it is a broad object of the invention to remedy the shortcomings of the prior art as described here above.
[0012] It is another object of the present invention to provide a method and systems for identifying into a text document, textual portions that have been copied or imported from other documents, while referencing, in each copied portion, the source document from which it has been copied.
[0013] It is another object of the invention to provide a method and systems for marking and highlighting copied textual portions and for warning a user when attempting to edit a copied textual portion.
[0014] It is another object of the invention to provide a method and systems for persistently identifying all textual sub-portions generated when splitting copied textual portions or removing words or letters in copied textual portions, and to reference, in each of them, the corresponding source documents from which they have been copied.
[0015] It is still another object of the invention to provide a method and systems for accessing, from a selected copied textual portion or sub-portion, the source document from which said portion or sub-portion has been copied.
[0016] It is a particular object of the invention to provide a method and systems for automatically identifying and highlighting copied textual portions or sub-portions in the object document.
[0017] The accomplishment of these and other related objects is achieved by a temporary computer object for copying and pasting text from a first electronic document to a second electronic document, said computer object comprising,
a first tag marking the beginning of the header of said temporary computer object; the address of said first electronic document; a second tag marking the end of said header of said temporary computer object; said copied text to be pasted; and, a third tag marking the end of said temporary computer object,
[0023] by a method for copying a selected text from a first electronic document into a temporary computer object as defined above, said method comprising the steps of,
creating said temporary computer object; getting the address of said first electronic document; copying said address of said first electronic document into said created temporary computer object; getting said selected text from said first electronic document; copying said selected text into said created temporary computer object; and, storing said created temporary computer object, by a method for pasting a text from a temporary computer object as defined above into a second electronic document, said method comprising the steps of, checking if said second electronic document comprises said first tag marking the beginning of the header of a temporary computer object; if said second electronic document comprises said first tag marking the beginning of the header of a temporary computer object, checking if the text to paste stored within said temporary computer object comprises said first tag marking the beginning of the header of said temporary computer object; if the text to paste stored within said temporary computer object comprises said first tag marking the beginning of the header of said temporary computer object,
extracting the identifiers associated to each of said first tag marking the beginning of the header of the temporary computer object comprised within said text to paste;
extracting the identifier associated to said temporary computer object; and, modifying all of said extracted identifiers that are identical to the one contained within said second electronic document,
[0037] by a method for checking edited text to track modifications in text copied from a first document, said copied text being stored according to the temporary computer object structure as defined above, said method comprising the steps of,
if a portion of text is removed or inserted in said copied text,
inserting said third tag marking the end of a temporary computer object, at the position where said portion of text is removed or at the position preceding the one where said portion of text is inserted; and, inserting a string formed by concatenating said first tag marking the beginning of the header of a temporary computer object, the address associated to said copied text, and said second tag marking the end of the header of a temporary computer object, at the position where said portion of text is removed or at the position preceding the one where said portion of text is inserted;
[0041] and by a method for accessing a first electronic document from a second electronic document comprising a portion of text pasted from a temporary computer object as defined above, said temporary computer object storing said portion of text extracted from said first electronic document and the address of said first electronic document, said method comprising the steps of,
selecting said temporary computer object storing said portion of text; extracting the address stored within said selected temporary computer object; accessing said first electronic document using said address; and, displaying said first electronic document.
[0046] Further embodiments of the invention are provided in the appended dependent claims.
[0047] According to one aspect of the invention, a method is disclosed for enabling the author of an object document to import textual portions from other source documents, and to edit said object document while automatically referencing and linking all imported textual portions and all textual sub-portions created from them when editing the object document, to the source documents from which they have been imported.
[0048] According to another aspect of the invention, a method is disclosed for enabling the author or the recipient of a document comprising textual portions or fragments of textual portions copied from a plurality of source documents, to identify those textual portions.
[0049] According to another aspect of the invention, a method is disclosed for enabling the author or the recipient of a document comprising textual portions or fragments of textual portions copied from a plurality of source documents, to access the corresponding source documents, and to automatically search and locate in said source documents, source text from which said textual objects have been copied.
[0050] One of the advantages of the invention is that, not only all copied textual portions, but also all textual sub-portions generated from a textual portion copied from a source document in the object document, remain persistently linked to the source document from which the original textual portion has been copied.
[0051] The invention can be practiced by means of software implementing the disclosed systems and method running on word processors, web browsers, and the likes.
[0052] Further advantages of the present invention will become apparent to the ones skilled in the art upon examination of the drawings and detailed description. It is intended that any additional advantages be incorporated herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0053] FIG. 1 illustrates a block diagram of a generic computer device in which the present invention can be implemented.
[0054] FIG. 2 depicts the main steps of the modified copy function according to the invention.
[0055] FIG. 3 shows the main steps of the access function according to the invention.
[0056] FIG. 4 , comprising FIG. 4 a to FIG. 4 e , illustrates the main steps of the use of the modified copy function according to the invention.
[0057] FIG. 5 illustrates an example of the warning message displayed to the user when attempting to copy a copied text.
[0058] FIG. 6 depicts an example of accessing the source document from a copied portion of text.
[0059] FIG. 7 , comprising FIGS. 7 a and 7 b , depicts an example of the use of the encapsulated object structure according to one embodiment of the invention.
[0060] FIG. 8 depicts the main steps of the modified copy function for encapsulated object structure according to the invention.
[0061] FIG. 9 shows the main steps of the access function for encapsulated object structure according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0062] FIG. 1 illustrates a block diagram of a generic computer device, handheld device, or any kind of network connected device, generally referred to as computer 100 , in which the present invention can be implemented. The system has a central processing unit (CPU) 105 , a Read-only Memory (ROM) 110 , a Random Access Memory (RAM) 115 , and an I/O subsystem 120 , all of them being connected to a system bus 125 . The I/O subsystem 120 may include one or more controllers for input/output devices such as keyboard 130 , cursor control device 135 , display device 140 , mass storage device 145 , and network interface 150 . Depending upon the application of the system 100 , one or more further I/O devices may be connected to the I/O subsystem 120 . Typically, the hardware system 100 is controlled by an operating system that can be stored in ROM 110 or in mass storage device 145 , which in turn controls various tools and applications that are generally loaded in RAM 115 .
[0063] According to the invention there is provided a set of modified functions for word processors, web browsers, and more generally for all computer applications allowing text copy, cut and/or paste functions, and text edit function. The aim of this modified set of functions is to get the data source information of a text when it is copied and to transmit this data source information within the text when it is pasted or edited.
[0064] Set of Modified Functions
[0065] The set of modified function comprises at least a modified copy function and a modified paste function. In a preferred embodiment, the set of modified functions further comprises an edit monitoring function and an access function.
[0066] Modified Copy Function
[0067] According to the modified copy function, source information associated to the selected text to be copied is extracted and associated with the selected text to be copied in a dedicated data structure, referred to as copied object. In a preferred embodiment, the copied object structure is as follows,
<{circle around (c)}href=“path or URL”; optional data {circle around (c)}> copied text </{circle around (c)}>
wherein,
[0069] <{circle around (c)}marks the beginning of the header of the copied object structure;
[0070] href=“path or URL” encodes the path or URL of the document from which the copied text has been extracted;
[0071] ; is a separator. This symbol is used only in the case where “optional data” is stored in the object along with the source information;
[0072] optional data encodes additional optional source information, such as the name of the author, the date of creation, and the owner of intellectual property rights of the source document;
[0073] {circle around (c)}> marks the end of the copied object structure header;
[0074] copied text is the portion of text that has been extracted from the source document; and,
[0000] </{circle around (c)}> marks the end of the copied object structure.
[0075] As illustrated on FIG. 2 and according to the modified copy function, the following steps are executed when this function is invoked, once having selected the text to be copied,
creating a copied object (step 200 ); getting the source information (step 205 ); copying the source information within the header of the created copied object (step 210 ); getting the selected text to be copied (step 215 ); copying the selected text within the created copied object (step 220 ); and, storing the created copied object into the clipboard buffer (step 225 ).
[0082] The source information can be easily accessed from the information associated to the document from which the text is being copied, or from the properties of this document. For example, according to Lotus WordPro word processor (Lotus and WordPro are Trademarks of International Business Machine Corporation), the file path, the name of the author, the date of creation, and many other attributes can be viewed when looking at the document properties.
[0083] As it will become apparent to the one skilled in the art, the modified copy function can be used to create a modified cut function where the main differences consist in the further step of removing the selected text in the source document.
[0084] In a further embodiment, the modified copy function further comprises a test to determine whether or not the selected text has been previously copied from another source document. Such enhanced modified copy function further comprises the steps of,
parsing the selected text for checking the presence of copied text portions by checking the presence of tags marking the beginning of copied object structure headers e.g., <{circle around (c)}, the presence of tags marking the end of copied object structure headers e.g., {circle around (c)}>, or the presence of tags marking the end of copied object structures e.g., </{circle around (c)}>; and, if copied text portions are found in the selected text, forewarning the user.
[0087] Preferably, the source addresses or URLs of the copied text portions are shown to the user when he/she is forewarned, by extracting the path or URL from the header of each copied object found in the selected text.
[0088] Modified Paste Function
[0089] The standard paste function is not modified in itself. It essentially consists in copying the copied object stored into the clipboard, in the object document, at the cursor location. The copied object is copied in the object document, in its entirety i.e., the text to be copied and the source information are copied in the object document. Depending upon display option setup, source information is displayed or not. In a preferred embodiment, the copied text is highlighted so that it appears differently than text that has not been copied or that has been copied from different sources. Still in a preferred embodiment, the copied text is highlighted only when the cursor is located over an area of copied text. To that end, the application checks the tag marking the end of the copied object header e.g., {circle around (c)}>, and the tag marking the end of the copied object e.g., </{circle around (c)}>, and highlights the text comprised between both tags if the cursor is located over the corresponding text. For example, highlighting copied text can consist in using a particular background colour e.g., yellow background.
[0090] When only displaying the copied text of a copied object i.e., when the source information must not been displayed, the display function parses the copied object to determine the tags marking the copied object e.g. <{circle around (c)}, {circle around (c)}>, and </{circle around (c)}>, and the data comprised in the header e.g., between tags <{circle around (c)}, {circle around (c)}>. The tags marking the copied object e.g. <{circle around (c)}, {circle around (c)}>, and </{circle around (c)}>, and the data comprised in the header e.g., between tags <{circle around (c)}, {circle around (c)}>, are not displayed.
[0091] Edit Monitoring Function
[0092] Editing a text implies that the text can be modified: some portions of the text can be removed and/or other portions of text can be inserted. An inserted portion of text can be typed or can be copied from another document. As a consequence, when a text is edited, the system must be able to track which parts of text have been modified and must keep the source information of copied text that is not modified.
[0093] If a portion of text is copied from another source document, the modified copy and paste functions are used to associate the source information to the copied text, as described above.
[0094] According to the invention, a background function, referred to as edit monitoring function, monitors the position of the cursor in the text in order to determine if portions of text are inserted or removed in the copied text, preferably highlighted.
[0095] When a portion of text is inserted or removed, the edit monitoring function checks if the cursor is positioned within copied text. This is done by checking if the text portion comprising the cursor is highlighted, by checking if the tag marking the beginning of the copied object structure header e.g., <{circle around (c)}, is located before the cursor and no tag marking the end of the copied object structure e.g., </{circle around (c)}>, is located between the cursor and the tag marking the beginning of the copied object structure header, or by checking if the tag marking the end of the copied object structure e.g., </{circle around (c)}>, is located after the cursor and no tag marking the beginning of the copied object structure header e.g., <{circle around (c)}, is located between the cursor and the tag marking the end of the copied object structure.
[0096] When a portion of text is removed from a copied text, the tag marking the end of the copied object structure e.g., </{circle around (c)}>, is inserted where the portion of text has been removed. The header of the copied object preceding the cursor, with the tags marking the beginning and the end of the copied object structure header, is copied where the portion of text has been removed, behind the inserted tag marking the end of the copied object structure.
[0097] Let us consider, for sake of illustration, the following text, where the tags and the source information are apparent, This is an example of copied text, <{circle around (c)}href=“C:\tmp\test.txt”{circle around (c)}> here is copied text </{circle around (c)}>.
[0098] If the word “the” of the copied text is removed, the new text, where the tags and the source information are apparent, looks like, This is an example of copied text, <{circle around (c)}href=“C:\tmp\test.txt”{circle around (c)}> here is </> <{circle around (c)}href=“C:\tmp\test.txt”{circle around (c)}> copied text <{circle around (c)}>.
[0099] If a portion of text is inserted in a copied text, the tag marking the end of a copied object structure e.g., </{circle around (c)}>, is inserted where the portion of text has been inserted, preceding the inserted portion of text. The header of the copied object preceding the cursor, including the tags marking the beginning and the end of the copied object structure header, is copied where the portion of text has been inserted, behind the inserted portion of text.
[0100] Let us consider, for sake of illustration, the previous example, where the tags and the source information are apparent, This is an example of copied text, <{circle around (c)}href=“C:\tmp\test.txt”{circle around (c)}> here is the copied text </{circle around (c)}>.
[0101] If the words “example of” are inserted after the word “the” of the copied text, the new text, where the tags and the source information are apparent, looks like,
[0000] This is an example of copied text, <{circle around (c)}href=“C:\tmp\test.txt”{circle around (c)}> here is the </{circle around (c)}> example of <{circle around (c)}href=“C:\tmp\test.txt”{circle around (c)}> copied text </{circle around (c)}>.
[0102] In another embodiment, the edit monitoring function comprises the step of marking all the words of copied text so as to identify non marked words corresponding to words that have been added. According to this embodiment, the edit monitoring function comprises the steps of,
prior to editing a copied text, marking all the words of the copied text e.g., by appending the symbol ‘*’ in front of each word of the copied text; and, after editing the copied text,
identifying all marked word fragments i.e., sets of contiguous marked words; and, for each marked word fragment, creating an object structure that header is the one of the copied object corresponding to the edited copied text.
[0107] Obviously, different marking symbols can be used to mark portions of text copied from different source documents.
Access Function
[0108] An access function is preferably provided to the user so that he/she could readily identify, locate and retrieve the source document from which the text that he/she is manipulating e.g., displaying or editing, has been copied. Such function can be triggered when the cursor is located over an area of copied text, either by clicking the pointing device on the copied text area, by selecting the access function in a menu or a popup menu, or even by using control keys. As shown on FIG. 3 , the main steps of the access function are,
selecting the copied object corresponding to the copied text pointed by the cursor (step 300 ); extracting the path or URL stored within the selected copied object (step 305 ); accessing the source document using the path or URL (step 310 ); and, displaying the source document (step 315 ).
[0113] Displaying the source document can be done according to the standard method consisting in analyzing the type of the source document e.g., according to the file extension, and launching the corresponding application according to a correspondence table e.g., file MIME type, generally maintained by the operating system.
[0114] In a further embodiment, the copied text portion is highlighted in the source document. Searching the copied text can be done, for example, by means of standard string matching algorithm, by sequentially comparing the copied text portion with the source document.
Example
[0115] FIGS. 4 a to 4 e illustrate the main steps of the method of using the modified copy function, according to the invention. FIG. 4 a shows a typical example of an e-mail 400 in which a user wants to copy the text selected on the web page shown on FIG. 4 b . As illustrated, the e-mail 400 comprises a header 405 with information about the sender, the recipient, and the e-mail subject, and a text area 410 where the user types his/her message. In this example, the user has already typed a first part of the message. The cursor 415 points to the position where the user can type new text or where he/she can paste copied text. The web page 420 of FIG. 4 b comprises selected text 425 that the user wants to copy in his/her e-mail at the cursor position. FIG. 4 c shows the copied object created after copying the selected text of FIG. 4 b , including the corresponding source information i.e., the URL 430 .
[0116] FIG. 4 c depicts the copied object created after copying the selected text 425 from the web page 420 shown on FIG. 4 b . As described above, the created copied object comprises a tag <{circle around (c)}marking the beginning of the copied object structure header, the hyperlink reference 435 comprising the URL 430 , a tag {circle around (c)}> marking the end of the copied object structure header, the text 440 which is copied, that corresponds to selected text 425 , and a tag </{circle around (c)}> marking the end of the copied object structure.
[0117] FIG. 4 d shows the e-mail 400 after the copied text has been pasted, where the source information, as well as the control symbols, are being displayed; FIG. 4 e illustrates the same e-mail after the copied text has been pasted, where the source information and the control symbols are being hidden. As mentioned above, the choice of displaying or not the source information and the control symbols, as illustrated on FIGS. 4 d and 4 e , respectively, can be controlled by the application display setup. For sake of illustration, the copied text is highlighted.
[0118] FIG. 5 illustrates an example of a warning message 500 displayed to the user when attempting to copy a text already copied from a source document. In this example, the user, after having selected a portion of the text 505 , has invoked either the modified copy or cut function. In such case, the copied object is created as described above, but the user is also warned that he/she may infringe copyrights.
[0119] FIG. 6 shows an example of accessing the source document of a copied portion of text. As illustrated, the copied text is highlighted when the user places the cursor 600 on the copied text area. Then, the user can choose to invoke the access function by different means e.g., editor tolls, menu, pop-up menu, left mouse click, or control keys. When the access function is called, a confirmation window 605 is preferably displayed, showing the path or URL extracted from the copied object associated to the copied text under the cursor position, so that the user can choose accessing or not the source document. Availability of this function is particularly useful, for example, when the source document should be accessed through a network e.g., the Internet, while the user is disconnected.
[0120] Encapsulated Object Structure
[0121] In a further embodiment, the encoding of the source information and copied text comprises an identifier allowing encapsulated identification of the source information. According to this embodiment, the copied object structure is as follows,
<{circle around (c)}ID href=“path or URL”; optional data {circle around (c)}> copied text </{circle around (c)}ID> wherein,
[0123] <{circle around (c)}marks the beginning of the header of the copied object structure;
[0124] ID is the unique identifier of the copied object;
[0125] href=“path or URL” encodes the path or URL of the document from which the copied text has been extracted;
[0126] ; is a separator. This symbol is used only in the case where “optional data” is stored in the object along with the source information;
[0127] optional data encodes additional optional source information such as the name of the author, the date of creation, and the owner of intellectual property rights of the source document;
[0128] {circle around (c)}> marks the end of the copied object structure header;
[0129] copied text is the portion of text that has been extracted from the source document; and, </{circle around (c)}ID> marks the end of the copied object structure having ID as identifier.
[0130] Using a unique identifier per copied object enables to build encapsulated references, useful to trace the history of the source documents, and incidentally, to check and attribute the copyrights. For example, if a user pastes portions of text from two different source documents in a first target document and then, a second user copies the text of the first target document and pastes it into a second target document, it can be of utmost importance not only to identify the sources of each part of the text but also the source of the compilation.
[0131] FIG. 7 , comprising FIGS. 7 a and 7 b , depicts an example of the use of the encapsulated object structure. FIG. 7 a shows a document 700 comprising text. Some portions of the text of document 700 have been typed by the author of such document while other portions, referred to as 705 and 710 , have been copied from two different sources, as shown encoded within the source information. Document 700 is locally stored on a computer, having the file name “test.txt” and being accessible through the full path 715 : “D:\my_documents\test.txt”. As shown on FIG. 7 a , the copied object corresponding to the first part of copied text has a first identifier, ID1, while the copied object corresponding to the second part of copied text has a second identifier, ID2. FIG. 7 b depicts another document 720 wherein text imported from document 700 has been copied. As illustrated on FIG. 7 b , a copied object has been created for the highlighted copied text 725 . The identifier of this object is different than that of the other copied objects contained within the document 720 . The path associated to this new created copied object is that of the document 700 from which the text has been copied. As a consequence, document 720 contains references not only to document 700 from which the text of document 720 has been copied but also to other documents from which portions of text were themselves copied into document 700 .
[0132] The modified set of functions handling the encapsulated object structure is slightly different than the one described above.
[0133] Modified Copy Function for Encapsulated Object Structure
[0134] Since the encapsulated object structure comprises an identifier, it is required to determine the identifiers of the copied objects embedded within the text to be copied when creating the copied object which stores the text to be copied and the source information. As depicted on FIG. 8 and according to the modified copy function for encapsulated object structure, the following steps are executed when this function is called after having selected the text to be copied,
creating a copied object (step 800 ); getting the source information (step 805 ); copying the source information within the header of the created copied object (step 810 ); getting the selected text to be copied (step 815 ); determining the identifiers of the copied object that tag marking the beginning of the header is located before the selected text and that tag marking the end is located behind the selected text (step 820 ) and for each of these determined identifiers,
inserting the header of the corresponding copied object at the beginning of the selected text (step 825 ); and, inserting the tag marking the end of the corresponding copied object at the end of the selected text (step 830 );
determining the identifiers of the copied object that tag marking the beginning of the header is located before the selected text and that tag marking the end is located in the selected text (step 835 ) and for each of these determined identifiers,
inserting the header of the corresponding copied object at the beginning of the selected text (step 840 );
determining the identifiers of the copied object that tag marking the beginning of the header is located in the selected text and that tag marking the end is located behind the selected text (step 845 ) and for each of these determined identifiers,
inserting the tag marking the end of the corresponding copied object at the end of the selected text (step 850 );
checking if copied text portions are present in the selected text by parsing the selected text and determining if the selected text comprises tags marking the beginning and the end of a temporary computer objects (step 855 ); if copied text is found in the selected text,
extracting the identifiers of the copied objects embedded within the selected text (step 860 ); assigning a new identifier, different than the extracted identifiers (step 865 );
else, if no copied text is found in the selected text, assigning an identifier (step 870 ); copying the selected text within the created copied object (step 875 ); and, storing the created copied object with the assigned identifier into the clipboard buffer (step 880 ).
[0153] In a further embodiment, the user is forewarned when copied text is found in the text to be copied. In such case, the source of each copied text is preferably indicated to the user, by extracting the path or URL of each copied object, as described above.
[0154] Modified Paste Function for Encapsulated Object Structure
[0155] The paste function is slightly modified to prevent for pasting copied objects having the same identifier as another copied object already present in the document where the text is being pasted. For this purpose, before pasting a copied object, the paste function parses the document, searching for identifiers of copied objects already present in it. If no copied object is found in the document, the paste function operated similarly to the one described above. In the case where copied objects are found in the document, the identifiers of these copied objects are compared with those of the copied object containing the text to be pasted. It should be noticed that the copied object corresponding to the text to paste may contain itself several copied objects. If one or more identifiers are identical, the common identifiers are modified so that all resulting identifiers become different. When modifying an identifier, the identifier value is changed in the copied object header and in the set of tags marking the end of the copied object structure. Once all the identifiers are different, the paste function is applied, as described above by reference to non-encapsulated copied object structure.
[0156] Edit Monitoring Function for Encapsulated Object Structure
[0157] As mentioned above, a background function, referred to as edit monitoring function, monitors the position of the cursor in the text in order to determine if portions of text are inserted or removed in copied text. If a portion of text is inserted or removed, the edit monitoring function checks if the cursor is positioned within copied text. To that end, the edit monitoring function checks if the cursor is located between the tags marking the beginning and the end of a same copied object structure, by checking tags and identifiers. In this case, the edit monitoring function determines all the identifiers associated to tags marking the beginning and the end of a copied object structure that are arranged on each side of the cursor. These identifiers are preferably stored in a list of identifiers.
[0158] If a portion of text is removed from a copied text i.e., the list of identifiers comprises at least one identifier, the tag marking the end of the copied object structure e.g., </{circle around (c)}ID>, is inserted where the portion of text has been removed. One tag is inserted for each identifier of the list of identifiers, with the corresponding identifier. Likewise, the copied object headers corresponding to the identifiers of the list of identifiers are inserted where the portion of text has been removed, after the inserted tags marking the end of the copied object structure. The inserted copied object headers comprise the tags marking the beginning and the end of the copied object structure header, with the corresponding identifier, the path or URL, and the optional data (if present).
[0159] Let us consider, for sake of illustration, the following text, where the tags and the source information are apparent, This is an example of copied text, <{circle around (c)}ID1 href=“C:\tmp\test1.txt”{circle around (c)}> here is a <{circle around (c)}ID2 href=“C:\tmp\test2.txt”{circle around (c)}> copied </ID2> text including several text portions </ID1> <{circle around (c)}ID3 href=“C:\tmp\test3.txt” {circle around (c)}> from different sources by </{circle around (c)}ID3>.
[0160] If the word “several” of the copied text is removed, the new text, where the tags and the source information are apparent, is as follows,
[0000] This is an example of copied text, <{circle around (c)}ID1 href=“C:\tmp\test1.txt”{circle around (c)}> here is a <{circle around (c)}ID2 href=“C:\tmp\test2.txt”{circle around (c)}> copied </{circle around (c)}ID2> text including </ID1> <{circle around (c)}ID1 href=“C:\tmp\test1.txt”{circle around (c)}> text portions </{circle around (c)}ID1> <ID3 href=“C:\tmp\test3.txt”{circle around (c)}> from different sources </{circle around (c)}ID3>.
[0161] If a portion of text is inserted in a copied text i.e., the list of identifiers comprises at least one identifier, the tag marking the end of the copied object structure e.g., </{circle around (c)}ID>, is inserted where the portion of text has been inserted, in front of the inserted portion of text. One tag is inserted for each identifier of the list of identifiers, with the corresponding identifier. Likewise, the copied object headers corresponding to the identifiers of the list of identifiers are inserted where the portion of text has been inserted, after the inserted portion of text. The inserted copied object headers comprise the tags marking the beginning and the end of the copied object structure header, with the corresponding identifier, the path or URL, and the optional data (if present).
[0162] Let us consider, for sake of illustration, another example, where the tags and the source information are apparent, This is an example of copied text, <{circle around (c)}ID1 href=“C:\tmp\test1.txt”{circle around (c)}> here is a <{circle around (c)}ID2 href=“C:\tmp\test2.txt”{circle around (c)}> copied text</{circle around (c)}ID2> including several text portions </ID1> <{circle around (c)}ID3 href=“C:\tmp\test3.txt” {circle around (c)}> from different sources </{circle around (c)}ID3>.
[0163] If the words “and linked” are inserted after the word “copied” of the copied text, the new text, where the tags and the source information are apparent, looks like, This is an example of copied text, <{circle around (c)}ID1 href=“C:\tmp\test1.txt”{circle around (c)}> here is a <{circle around (c)}ID2 href=“C:\tmp\test2.txt”{circle around (c)}> copied </ID2> </ID1> and linked <{circle around (c)}ID1 href=“C:\tmp\test1.txt”{circle around (c)}> <{circle around (c)}ID2 href=“C:\tmp\test2.txt”{circle around (c)}> text </{circle around (c)}ID2> including several text portions </ID1> <{circle around (c)}ID3 href=“C:\tmp\test3.txt”{circle around (c)}> from different sources </{circle around (c)}ID3>.
[0164] Access Function for Encapsulated Object Structure
[0165] As mentioned above, an access function is preferably provided to the user so that he/she could easily browse or retrieve the source document from which the text he/she is manipulating e.g., displaying or editing, has been copied. Such function can be activated when the cursor is located in the area of copied text by different means e.g, by clicking the pointing device in the area of copied text, by selecting the access function in a menu or a popup menu, or by using control keys. As shown on FIG. 9 , the main steps of the access function are as follows,
identifying copied objects comprising the copied text where the cursor is located (step 900 ); extracting the paths or URLs of the copied text from the identified copied objects (step 905 ); checking the number of identified paths or URLs (step 910 ), if there are more than one path or URL,
providing the choice to the user for selecting one path or URL from the identified paths or URLs (step 915 ); receiving the user's choice of the selected path or URL (step 920 );
else, if only one path or URL is identified, selecting this path or URL (step 925 ); accessing the source document using the selected path or URL (step 930 ); and, displaying the source document (step 935 ).
[0175] Displaying the source document is done according to the standard method consisting in analyzing the type of the source document e.g., according to its extension, and launching the corresponding application according to the correspondence table of the operating system.
[0176] Naturally, in order to satisfy local and specific requirements, a person skilled in the art may apply to the solution described above many modifications and alterations all of which, however, are included within the scope of protection of the invention as defined by the following claims.
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A method and systems for copying textual objects from source documents into an object document, and for tagging, linking and processing said copied textual portions, including the disclosure of a new type of hyperlinking mechanism, for enabling to identify and trace the sources and the authorship of said copied textual portions or of all textual sub-portions or fragments of text that could be generated from said copied textual portions by editing the object document. The invention can be implemented by means of software implementing the disclosed system and method running on word-processors and web browsers.
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BACKGROUND OF THE INVENTION
Safe deposit box nests typically are available in various compartment sizes to accommodate safe deposit boxes of different dimensions insofar as their height and width are concerned. But basically each nest is usually formed within a standard sized outer housing, a number of which are stacked together to form overall banks of boxes of varying sizes. For instance, some housings might each contain 30 compartments 2 inches high and 10 inches wide, some 24 compartments 5 inches high and five inches wide, others 21 compartments 3 inches high and 10 inches wide, still others 60 compartments 2 inches high and 5 inches wide, and so on. In order to keep manufacturing costs within reason, obviously it is necessary that the compartment construction and arrangement within each housing be as modular as possible. This in turn requires designs that allow the interior of each housing to be assembled from parts which differ from each other as little as possible and which are also as rudimentary as possible. At the same time, the need to work or rework parts individually by hand in order that they fit properly within allowed tolerances must be kept to a minimum. The goal, therefore, is a design which allows the compartments to be built up from a stock of standard, readily fabricated parts that require the least possible amount of labor to assemble in finished form.
The chief obstacle to the foregoing centers about the compartment doors themselves which must fit the fronts of the individual compartments to fairly close tolerances. While the doors alone can readily be fabricated uniformly, yet it has proven difficult to provide sufficiently uniform openings at the fronts of the compartments with the consequence that the doors must be individually fitted by hand, not just once but often several times. There are several reasons for this. In the first place, the compartments are typically formed by a number of horizontal shelves between which are vertical partitions. The shelves are usually plate or sheet material so that their spacing and thickness determine the height of the doors. But the thickness of such material varies enough so that the height of the front openings of the compartments is not sufficiently uniform. Hence, each door must be fitted for height to its individual compartment.
In the second place, the doors are typically hinged to and strike against upright members which form front side edges of the compartments, the partitions which are normally sheet material extending rearwardly from the upright members. In order for the width of the compartments to be uniform, therefore, cross-sectional variations in the upright members must be minimal and their lateral spacing must be accurate. Then, usually, the hinge knuckles are separately applied to the doors and to the upright members requiring still more individual fitting. Complicating things further is the fact that after assembly of the shelves and partitions and the fitting of the doors, every thing is normally fastened together and to the outer housing by welds. The latter produce various distortions among the parts which in turn often affects the front openings of some of the compartments and thus their doors. Hence the latter doors again must be individually refitted. In short, a great deal of painstaking hand labor is typically required to achieve a satisfactory final fit of the doors, and since each door is individually fitted, interchangeability of doors is impossible.
The primary objects of the present invention are therefore to provide a safe deposit box nest construction and a method of accomplishing same in which the need for individual hand-fitting of the doors is eliminated and in which the number of parts necessary to construct nests of differing compartment size is reduced.
SUMMARY OF THE INVENTION
The objects of the invention are achieved by several basic departures from traditional practice in safe deposit box nest construction. The first of these is to form the upright members to which the doors are hinged and against which they strike as individual posts cut to length from long aluminum extrusions, the ends of the posts of vertically adjacent compartments butting against the shelf therebetween. Hinge knuckles are integrally formed with the posts, and each vertical tier of posts is precisely located by steel bars running vertically through the posts and the shelves between them. Second, the front edge portion of the shelf between each pair of posts is formed by a rearward fold of the material upon itself to provide a uniform shelf thickness between the two posts. The foregoing are then employed with a mode of construction in which the outer housing consists essentially of two parts. The first of these is a rectangular "frame" which ultimately forms the forward edge portion of the housing. The manner in which that "frame", together with the posts, partitions and shelves, is assembled results in the "frame" in effect enveloping the posts and the folded shelf edges. The remaining part constitutes the housing bottom, side, top and rear walls.
The use of aluminum extruded posts is important for several reasons. The traditional equivalents of the posts have been uprights of long lengths of formed sheet metal running through the shelves the full height of the housing or as short lengths of same disposed between the shelves. Traditionally also, the hinge knuckles have been separately fashioned from brass, which has to be machined, and then screwed or riveted to the uprights. Extrusions, on the other hand, can be held to very close tolerances so that no final machining or other reworking is necessary to achieve the right fit and size. But brass cannot readily be extruded to close tolerances and because of its abrasive characteristics tool life would be short anyway. Aluminum, however, is ideally suited to being extruded so that long bars of correct and accurate cross-section can be turned out and then cut up into proper lengths for the posts. At the same time, the post hinge knuckles can be formed integrally with the posts, the latter tumbled to remove burrs and sharp edges and finally anodized to appropriate color. The accuracy of the extruded posts, plus the uniform thickness of the forward portions of the shelves owing to the folds therealong, plus the precise location of the posts by the vertical bars passing through them and the shelf folds, all enable the forward openings of the compartments to be built to a uniform size within very close tolerances. This is especially true because, in addition as previously noted, a front "frame" of the housing containing or surrounding the compartment openings is constructed during assembly of the posts, partitions and shelves, which "frame", as will be later explained, involves a minimum of welding, none of which can warp or affect the size of the compartment openings. Consequently, there is no need to fit the doors individually to the compartments even once, let alone several times. Instead, all the doors can be made to a uniform finished size initially with assurance that they will fit any compartment without need for individual reworking. Hence the amount of labor, particularly hand labor, and thus the cost both of labor and material is greatly reduced for a safe deposit box nest constructed according to the present invention.
Other and further features and advantages of the present invention will become apparent from the drawings and the more detailed description which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially exploded, isometric view of a safe deposit box nest constructed according to the invention but with the compartment doors omitted.
FIG. 2 is an end view of one of the three configurations of posts employed in the construction of a nest according to the invention.
FIG. 3 is a side view of the post of FIG. 2.
FIG. 4 is an isometric view of a second configuration of posts employed in the construction of a nest according to the invention.
FIG. 5 is an edge view of a typical compartment door for use with the nest of the present invention.
FIG. 6 is a view of the rear face of the door of FIG. 5.
FIG. 7 is a front elevational view of the nest of FIG. 1 with the compartment doors in place.
FIG. 8 is a front elevational view of a nest constructed according to the invention but having compartments of different height and width from those of the nest of FIG. 1.
FIG. 9 is an isometric view of the third configuration of posts employed in the nest of FIG. 8.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As noted, each safe deposit box nest 10 is built up within a standard size outer housing, numbers of which are arranged together side-by-side and/or upon each other to form an overall bank of compartments of one or several modular dimensions each. In FIGS. 1 and 7, for instance, the nest 10 consists of four tiers of compartments, each of which consists in turn of six side-by-side compartments, all of the compartments being identical in size. Exteriorly, the nest 10 comprises a forward rectangular frame 11 made up from four lengths of flat bar stock 11a, 11b, 11c, and 11d. The rear inner edges of the latter are rabbetted at 12 to receive the forward edges of bottom, side and top plates 13, 14, 15 and 16, the rear of the nest 10 being closed by a back plate 17 overlapping the rear edges of the plates 13-16 which in turn overlap each other. The rabbets 12 are such that the outer faces of the frame 11 stand proud of those of the plates 13-16 while their respective inner faces are flush with each other. To the inner faces of the upright frame members 11b and 11c are secured a pair of nosings 18, of a somewhat upturned, hat-shaped cross-section, whose forward edges form door strikes 19 disposed rearwardly of the forward edges of the frame members 11b and 11c a distance equal to the thickness of the compartment doors later described.
Referring now to FIGS. 2, 3 and 4 in addition to FIGS. 1 and 7, the essential constituents of the interior of the nest 10 consist of posts 20 and 30, partitions 40 and shelves 50. As mentioned, the posts 20 are cut to length, namely, the height of each compartment, from long aluminum extrusions. Grade 6061-T6 aluminum has proved suitable. Each post 20 is of overall uniform thickness having a radiused nose 21 which is longitudinally drilled at 22. The nose 21 is then relieved at appropriate locations to form upper and lower integral hinge knuckles 23 and 24, separated by a rear-set face 20a, into whose bores 22 are pressed hinge pins 25. A squat T-shaped slot 26 extruded longitudinally through the entire length of the post 20 opens at 26a in turn through one flank as shown in FIGS. 2 and 3. The forward end of the slot 26 is circularly enlarged at 27 into the upper end of which is pressed a post locating pin 28. The rear edge of the post 20 is provided with an extruded longitudinal retaining slot 29 having an inner offset enlargement as shown in FIG. 2. The posts 30 are also cut to the same length as the posts 20 from long aluminum extrusions. However, each post 30 (see FIG. 4) is somewhat cruciform in cross section to provide a pair of door strikes 31 on its opposite flanks disposed rearwardly of the front face 30a of the post 30 a distance equal to the thickness of the compartment doors later described. The rear portions of the two flanks are splayed and radiused to form box guide noses 32 flush with the outer reaches of the strikes 31. A similar T-shaped slot 33 extruded longitudinally through the post 30 opens at 33a through one flank and is circularly enlarged at its forward end 34 into the upper end of which is pressed a post locating pin 35. The rear end of the post 30 is likewise formed with an offset retaining slot 36 identical to the retaining slot 29 of the posts 20, and the depths of the posts 20 and 30 from faces 20a and 30a are equal.
The rectangular partions 40 are formed from suitable sheet metal and of the same height as the posts 20 and 30. The forward edge of each partition 40 is reversely folded to form a bead 41, which slidably interlocks with the rear retaining slots 29 and 36 of the posts 20 and 30, while the rear edge is rolled to form an "eye" 42. The rectangular shelves 50 are also formed from suitable sheet material, the forward edge of each shelf 50 being reversely folded at 51 upon itself to provide a ledge 52 of uniform thickness to very close tolerances and of a depth equal to the aforesaid depths of the posts 20 and 30. The forward corners of the shelves 50 are contour punched at 53 to fittingly abut the nosings 18 while their side edges are downwardly flanged at 54 to lie against the inner faces of the side plates 14 and 15. The ledges 52 of the shelves 50 are punched at spaced locations according to the spacing of the posts 20 and 30 with rectangular slots 55 identical to the post slots 26 and 32 while the rear edges of the shelves 50 are punched with likewise spaced U-shaped notches 56 having the same radius as that of the interior of the partition eyes 42.
When a nest 10 according to the invention is assembled, the frame members 11a-11d are welded in a fixture to their respective plates 13-16 along the corners formed by the rear edges of the members 11a-11d and the outer faces of the plates 13-16. Then the assembled frame members 11a-11c and plates 13-15 are placed in a suitable jig and rigidly held in position, the nosings 18 having been previously spot welded to the side frame members 11b and 11c. The lower most tier of posts 20 and 30 are next placed in position, their lower ends having been fitted with additional post locating pins 28a and 35a which seat in spaced drillings in the bottom frame member 11a in order to laterally located the posts 20 and 30 accurately. The beads 41 of a set of partitions 40 are then slipped into the retaining slots 29 and 36 and the first shelf 50 then laid in position over them. The next tier of posts 20 and 30 and partitions 40 are installed, the pins 25 and 35 of the lower most tier of posts 20 and 30 locating the tier above by extending up through the shelf slots 55 and fitting into the enlargements 27 and 34 at the forward ends of the post T-slots 26 and 33. The next shelf 50 is laid down and the process repeated until the upper most tier of posts 20 and 30 and partitions 40 are in position. At this time a set of long rectangular locking bars 60, of the same cross-sectional dimensions as the slots 26 and 33 rearward of the locating pins 28, 28a, 35 and 35a, are driven down through the aligned slots 26 and 33 of the respective tiers of posts 20 and 30 and the slots 55 of the shelves 50, the lower ends of the bars 60 abutting the lower frame member 11a while the upper ends of the bars 60 are flush with the top of the upper most tier of posts 20 and 30. A similar set of locking rods 65 are next driven down through the respective partition eyes 42 and shelf notches 56 in order to locate the rear ends of the partitions 40. The upper frame member 11d, which is also provided with spaced drillings to receive the locating pins 28 and 35 of the upper most tier of posts 20 and 30, and plate 16 are then placed and held in position. The frame 11 is then compressed together and checked for accuracy. If everything is as it should be, the adjoining ends of the frame members 11a-11d are welded to each other. Then the lower and upper ends of the bars 60 (through the openings 26a and 33a), are welded to the upper and lower frame members 11a and 11d as indicated in FIG. 1, thus rigidly and accurately fixing the posts 20 and 30 in position along the shelf ledges 52. The forward corners of the shelves 50 are tack welded to the nosings 18 and their rear flanges 54 spot welded to the side plates 14 and 15, also as indicated in FIG. 1. The adjoining edges of the bottom, side and top plates 13-16 are welded to each other and finally the rear plate 17 is welded to the latter to complete the nest 10 except for the doors. Accordingly, as will be observed, since there is no welding at the front of the nest 10 except to the rigidly held frame 11, there is no opportunity for distortion of the compartment front opening to affect the fit of the doors. The compartment fronts remain uniform so that the doors can be uniformly fabricated with assurance they will all fit properly.
The doors 70, as shown for example in FIGS. 5 and 6, are formed from suitable steel plate as blanks 71 and beveled rearwardly along their top, bottom and free edges at 72. The rear faces of door blanks 71 are appropriately drilled at 73 for mounting their locks (not shown) whose noses open forwardly from bores 74 through the blanks 71. The hinged edges of the blanks 71 are suitably notched at 75 and drilled at 76 to receive hinge knuckles 77, secured by screws 78, which are bored at 79 to slip down over the hinge pins 25 of the post 20. However, as will be observed from FIG. 7, each pair of doors 70 hinged to a post 20 are formed as mirror images of each other, and in addition, the hinge knuckles 77 of one of the two doors 70 are offset relative to those of the other. Hence, the location of the hinge knuckle notches 75 along the door blanks 71 must be different from the doors 70 to the right of the post 20 than it is for those to the left.
It will be apparent that different numbers and sizes of compartments can be provided within the same overall size of a nest 10. This is readily accomplished, according to the construction of the invention, by increasing or decreasing the heights of the posts 20 and 30 and/or varying their spacing to form other modular arrangements of compartments. Different heights of posts 20 and 30 are easily accommodated since both are cut to length from long uniform extrusions. The partitions 40, except for their number and height, and the shelves 50, except also for their number and the spacing of their slots 55 and notches 56 to accommodate different compartment widths, remain the same as do essentially all other components. The technique of assembly is also identical. Only in those cases in which a post must provide for a door hinge on one side and a door strike on the other, rather than two hinges or two strikes, is an additional component required. Such as instance is illustrated in FIG. 8 in the case of a nest 10' and frame 11' of identical overall dimensions but divided into a greater number of tiers of wider but shallower compartments than the nest 10. In the nest 10' the posts 20' are identical, except for height, to the posts 20 of the nest 10 but the posts 80 differ from the posts 30 as shown in detail in FIG. 9, being an amalgamation of the posts 20 and 30. Each post 80 is also cut from long aluminum extrusions and includes a rounded front nose 81 which is longitudinally drilled at 82. The nose 81 is relieved at 81a to provide hinge knuckles 83 and 84 which are fitted with hinge pins 85 in the bores 82. A squat T-shaped slot 86 extends longitudinally through the post 80 and opens through one flank at 86a, the forward end of the slot 86 being circularly enlarged at 87 and fitted with a post locating pin 88. The other flank of the post 80 is formed with a door strike 89 and a box guide nose 90 while the rear edge includes a longitudinal offset slot 91. The nature and dimensions of the foregoing details of the posts 80 are identical to those of the respective corresponding details of the posts 20 and 30 so that all three are interchangeable with each other insofar as their fit and assembly with the other components are concerned. From the foregoing it will be apparent to those skilled in the art that other nests, identical in overall dimensions with the nests 10 and 10' but having compartments of other combinations of width and height, may be constructed in the manner and with the components of the invention. Furthermore, if desired, the side and rear plates 14,15 and 17 can take the form of a U-shaped bending from a single piece of material, and the bottom and top plates 13 and 16 in turn can be formed as shallow pans, open at their fronts, whose side and rear walls exteriorly overlap and are welded to the corresponding side and rear walls of the bending.
Though the present invention has been described in terms of particular embodiments, being the best mode known of carrying out the invention, it is not limited to those emobodiments alone. Instead, the following claims are to be read as encompassing all modifications and adaptations of the invention falling within its spirit and scope.
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A safe deposit box nest includes an outer housing into which are assembled a number of sheet metal partitions and shelves to form compartments. In order to eliminate the need for individually fitting each compartment door, each such door is hinged to and strikes against posts formed by extruded members such as aluminum attached to the front of the partitions. To the same end the forward edges of the shelves are disposed between the posts and doors and are folded rearwardly upon themselves and compressd to form shelf edge portions of uniform thickness. Finally, the nest is constructed in a manner which reduces welding to a minimum and helps insure accurate and uniform compartment openings to which the doors are applied.
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BACKGROUND TO THE INVENTION
This invention relates to a mineral mining installation, and in particular to an installation for winning material such as coal.
In place of conventional winning machines such as coal ploughs or shearers (which win coal mechanically), it is known to use machines which win coal by hydraulic pressure. Typically, such a machine has a plurality of nozzles which are fed with hydraulic fluid under a high pressure of 400 to 1,000 bars or even higher. Usually, the hydraulic fluid is water, though other fluids could also be used. One known hydraulic winning machine has a drum provided with high-pressure nozzles on its circumference, and another has a plough body provided with high-pressure nozzles in place of plough cutter bits (see DT-OS No. 2548951 and DT-OS No. 2307413). It is also known to provide a plough body with high-pressure nozzles as well as cutter bits (see GB-PS No. 672,336). In this case the plough body is provided with a high-pressure pump which raises the pressure of hydraulic fluid from that of the supply to that necessary for the hydraulic winning work.
Unfortunately, the known types of hydraulic winning machines suffer from difficulties which have prevented them from becoming established as practical devices. In particular, such machines require a very large input of water, and difficulties arise in the production and feed of high-pressure water to the nozzles of a high-speed winning machine.
The aim of the invention is to provide a winning machine which utilises the hydraulic winning method but does not suffer from these disadvantages.
SUMMARY OF THE INVENTION
The present invention provides a mineral mining installation comprising a mechanical winning machine and a hydraulic winning machine, the hydraulic winning machine having a plurality of high-pressure nozzles and a high-pressure pump for supplying the nozzles with high-pressure hydraulic fluid, wherein means are provided for moving each winning machine independently of the other along a mineral face. Preferably, each winning machine is provided with independent drive means.
With this installation, it is possible to carry out combined mechanical and hydraulic winning using separate mechanical and hydraulic winning machines. The mechanical winning machine will usually carry out the main winning work in the conventional manner, whilst the hydraulic winning machine fulfils an auxiliary winning function. For example, the hydraulic winning machine can be used to cleave or loosen mineral from the face, to win mineral from the upper or lower regions only of the face, or to win material in faulty seam zones of the face. In all these cases, the winning work of the mechanical winning machine (usually a high speed plough or shearer) is facilitated and the output is increased even under difficult working conditions. The main reason for this is that the mechanical winning machine can move along the face at its normal speed without interference from the slower moving hydraulic winning machine. In this case, it is preferable for each winning machine to be drivable along a respective guide extending, in use, along the mineral face, the two guides being so positioned that the two winning machines can be driven past one another. Where it is not essential for the two winning machines to pass one another, they may be drivable along a common guide extending, in use, along the mineral face.
Advantageously, detachable coupling means are provided for coupling the two winning machines together for conjoint movement along the mineral face. This coupling of the two winning machines is useful, particularly when the hydraulic winning machine is being used to win mineral material in a faulty seam zone. In this case, the winning work is usually effected solely by the mechanical winning machine, the hydraulic winning machine only being brought into operation when needed.
Preferably, the mechanical winning machine is also provided with high-pressure nozzles for supplying said nozzles with high-pressure hydraulic fluid from the pump of the hydraulic winning machine. In this case, the pump may be arranged to supply only the nozzles on the mechanical winning machine.
The hydraulic winning machine may be provided with an electric motor for driving the pump. Advantageously, the pump is a multiple radial-piston pump, and preferably, the pump is capable of delivering hydraulic fluid at different pressures. In this case, the pump may supply hydraulic fluid to the nozzles of the hydraulic winning machine at a first pressure, and to the nozzles of the mechanical winning machine at a second pressure lower than said first pressure. Preferably, said first pressure lies in the range of from 2,000 to 4,000 bars and said second pressure lies in the range of from 1,000 to 2,000 bars.
Advantageously, the installation further comprises means for loading won mineral material onto a conveyor which extends along the mineral face. Preferably, the mechanical winning machine and/or the hydraulic winning machine is provided with said loading means.
The hydraulic winning machine may be provided with a current pick-up arm which, in use, picks up electric current from a conductor housed in a conduit extending along the mineral face, the pick-up arm entering the conduit through a slot extending therealong. Advantageously, the conduit is provided with elastic seals for covering said slot, the pick-up arm extending through the elastic seals, and the conduit is filled with a pressurized gas such as compressed air or nitrogen enriched compressed air. This reduces the risk of underground explosions arising from methane entering the conduit.
Advantageously, the hydraulic winning machine is provided with a collector arm which, in use, picks up hydraulic fluid from a channel extending along the mineral face, the collector arm entering the channel through a slot extending therealong. Preferably, the channel is provided with elastic seals for covering said slot.
The invention also provides a hydraulic winning machine for use in a mineral mining installation as defined above, the hydraulic winning machine being movable, in use, along the mineral face to be won, and having a plurality of high-pressure nozzles, a multiple radial-piston pump for supplying the nozzles with high-pressure hydraulic fluid, and an electric motor for driving the pump, wherein the hydraulic winning machine is provided with a current pick-up arm which, in use, picks up electric current from a conductor housed in a conduit extending along the mineral face, the pick-up arm entering the conduit through a slot extending therealong, and wherein the hydraulic winning machine is provided with a collector arm which, in use, picks up hydraulic fluid from a channel extending along the mineral face, the collector arm entering the channel through a slot extending therealong.
The invention further comprises mineral winning apparatus which, in use, extends along a mineral face to be won, a guide provided on the face side of the conveyor, and a hydraulic winning machine movable along the guide, the hydraulic winning machine being as defined above. Advantageously, the electrical supply conduit and the hydraulic fluid supply channel are arranged, in use, on the goaf side of the conveyor, the hydraulic winning machine being provided with a portal arm which extends over the conveyor and which carriers the pick-up arm and the collector arm. Preferably, the pump is provided at the goaf side of the portal arm.
The advantage of using a multiple radial-piston pump is that such a pump has relatively small external dimensions but can generate high pressures of the order of 4,000 bars. Moreover, by arranging for this pump to operate in different pressure ranges, the apparatus can readily be adapted to winning mineral materials of different hardness. For example, rock may require pressures of 2,000 to 4,000 bars, whereas coal can be won with lower pressures. The feed system constituted by the electrical supply conduit and the hydraulic fluid (usually water) supply channel enables the hydraulic winning machine to operate safely even at high working speeds.
BRIEF DESCRIPTION OF DRAWINGS
Several forms of mineral mining installations, each constructed in accordance with the invention, will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a part-sectional end elevation of a hydraulic winning machine forming part of a first form of installation;
FIG. 2 is a plan view of the machine of FIG. 1;
FIG. 3 is a part-sectional end elevation of a second form of installation, and showing a hydraulic winning machine and a mechanical plough;
FIG. 4 is a part-sectional end elevation of part of the second form of installation and showing the hydraulic winning machine coupled to the mechanical plough;
FIG. 5 is a perspective view of a third form of installation;
FIG. 6 is a part-sectional end elevation of part of the installation of FIG. 5, and
FIG. 7 is a view similar to that of FIG. 6 but showing a modified embodiment.
DESCRIPTION OF PREFERRED EMBODIMENT
Referring to the drawings, FIGS. 1 and 2 show a scraper chain conveyor 10 provided with a ramp-like guide 11 on the coal face side thereof. A hydraulic winning machine 12 is guided for movement along the conveyor 10. The hydraulic winning machine 12 has an electric motor 13, a high-pressure pump 14 and a pressurised water vessel 15, all arranged within the outer casing of the hydraulic winning machine. A protective channel 16 is provided on the goaf side of the conveyor 10, the channel housing a hose 17 for supplying low-pressure water to the vessel 15, and a supply cable 18 leading to the electric motor 13. The electric motor 13 is provided to drive the pump 14. The hydraulic winning machine 12 can be driven too and fro along the conveyor by means of a conventional chain drive system, a rack-and-pinion drive or any other known type of drive arrangement.
The hydraulic winning machine 12 is effectively constituted by a plough body provided with a plurality of high-pressure nozzles 19 which are arranged in columns, each column having several nozzles arranged one above another. Each of the nozzles 19 is mounted for vertical displacement and/or for lateral pivoting. During the winning work, the hydraulic winning machine moves along the coal face, the high-pressure water jets issuing from the nozzles 19 serving to cut away coal from the face. Won coal is loaded onto the conveyor 10 by means of inclined loading surfaces 20 which direct such loose coal over the guide 11 and onto the conveyor.
The hydraulic winning machine 12 is used in conjunction with any standard mechanical coal-winning plough (not shown in FIGS. 1 and 2), which is also reciprocable along the guide 11 provided on the coal face side of the conveyor 10. In this case, the hydraulic winning machine 12 need only be used where this is necessary for example in faulty seam zones. It can also be used, however, to win coal along the entire length of the face, for example from upper portions of the seams. It can also be used to remove pockets of waste or to loosen the seam in order to facilitate the winning action of the mechanical plough. In other words, the hydraulic winning machine 12 is used merely as an auxiliary winning machine and so its use does not lead to excessive use of high-pressure water.
The installation shown in FIGS. 3 and 4 again has a conveyor 10, a guide 11 and a hydraulic winning machine 12. These figures also show, however, a mechanical coal-winning plough 23 which is provided with a plurality of cutters bits 23A and a plurality of high-pressure nozzles 23B. This plough 23 would be used with the hydraulic winning machine of FIGS. 1 and 2. The plough 23 is driven in known manner by means of an endless plough drive chain, the return run 21 of which is guided in an upper channel beneath the guide 11, and the traction run 22 of which is guided in a lower channel also situated beneath the guide 11. The hydraulic winning machine 12 is guided for movement along the coal face by means of guide rails 24 and 25 which are positioned above the guide 11, the guide rail 24 being situated at the face side of the conveyor 10, and the guide rail 25 being situated at the goaf side.
The hydraulic winning machine 12 of FIGS. 3 and 4 is basically the same as that of FIGS. 1 and 2, and is provided with an electric motor, a high-pressure pump and a pressurised water vessel (none of which are shown in FIGS. 3 and 4 for reasons of clarity). The hydraulic winning machine 12 is also provided with high-pressure nozzles 26 which are arranged in echelon formation so as to cut away the upper portion of the seam 27 being won, the plough 23 serving to win coal in the lower seam region.
The hydraulic winning machine 12 is movable along the face 27 independently of the plough 23. This enables the plough 23 to be driven at a relatively fast speed and the hydraulic winning machine 12 at a relatively low speed. Both machines can, therefore, be operated under optimum working conditions. In the embodiment of FIGS. 3 and 4, the hydraulic winning machine 12 is driven by means of an endless chain 20 which is guided in channels 29 and 30 arranged on the goaf side of the conveyor 10. The hydraulic winning machine 12 is provided with a portal arm 31 which extends over the conveyor and is coupled to the traction run of the chain 28 in the upper channel 29. Adjacent to the channels 29 and 30 on the goaf side of the conveyor 10, are channels 32 and 33 housing respectively the electric cable 18 and the supply hose 17. In the embodiment of FIG. 3, the plough 23 can run through beneath the hydraulic winning machine 12, the plough doing the main winning work and the hydraulic winning machine fulfilling an auxiliary winning function in the upper zone of the seam. The won material is loaded onto the conveyor 10, however, solely by the plough 23.
It is also possible to couple the hydraulic winning machine 12 and the plough 23, this coupling being effected by means of coupling elements 34 (see FIG. 4). In this case, the combined unit can be moved along the face by the plough drive system and/or the drive system for the hydraulic winning machine 12. The high-pressure nozzles 23B of the plough 23 are fed with water under high pressure from the hydraulic winning machine. Preferably, the coupling elements 34 are arranged to be of the quick-release variety.
It will be apparent that the hydraulic winning machine 12 of the embodiment of FIGS. 3 and 4 could be arranged to win coal from the base of the seam 27 rather than the top. The hydraulic winning machine could also be used as a stable-hole plough.
FIG. 5 shows a hydraulic winning machine 112 which can be used in place of the hydraulic winning machine 12 of the embodiments of FIGS. 1 to 4. This machine 112 could also be used without a conventional mechanical winning machine such as a plough or a shearer. The body 100 of the hydraulic winning machine 112 is guided on a guide 11 provided at the face side of a conveyor 10, a portal arm 31 extending over the conveyor for guidance by a guide rail 25 on the goaf side thereof. The goaf side of the conveyor 10 is also provided with upwardly extending guard plates 113 and with cover plates 114 connected to the guard plates. These plates 113 and 114 define upper and lower channels 115 and 116. The upper channel 115 serves as an electrical supply to the pump drive system (to be described below) of the hydraulic winning machine 112, and the lower channel 116 is a water supply channel. A high-pressure multiple radial-piston pump 117 is provided at the goaf side of the portal arm 31, the pump receiving electric current and water from the channels 115 and 116. The pistons of the pump 117 each have a diameter which is relatively small (10 mm. at the most). The pump 117 provides high-pressure water to a plurality of nozzles 26 provided at the face-side of the hydraulic winning machine 112. The nozzles 26 may be formed in plough cutter bits so that the machine 112 also wins coal mechanically as well as hydraulically. Such cutter bits are fitted with hard metal tips.
As best seen in FIG. 6, electrical conductor rails 119 are arranged in the channel 115. A current pick-up arm 120 is provided on the portal arm 31, the pick-up arm entering the channel 115 from above and being in sliding contact with the rails 119. The pick-up arm 120 is connected to a motor 118 driving the pump 117 via a cable 121. The upper side of the channel 115 is closed by means of elastic seals 122, through which the pick-up arm 120 extends to make contact with the rails 119. In order to reduce the dangers of explosions, the channel 115 is supplied with a pressurised gas (compressed air and/or nitrogen) so that methane enriched air cannot penetrate the channel from the exterior.
The water-supply channel 16 is provided with a side-opening through which a collector arm 123 extends, the collector arm serving to draw low pressure water from the channel 116 and deliver it to the pump 117. The delivery side of the pump 117 is connected to the high-pressure nozzles 26 via high-pressure conduits provided within the portal arm 31 and the body 100. Thus, there is no need for flexible water supply hoses. As with the current supply channel 115, the water-supply channel 116 is closed by means of elastic seals (not shown) through which the collector arm 123 extends.
The radial-piston pump 117 may be arranged to deliver water at different working pressures. In particular, the pump 117 may be arranged to deliver water at a first, very high pressure (say 2,000-4,000 bars) to the cutter nozzles 26, and to deliver water at a second, lower pressure (say 1,000-2,000 bars) to cutter nozzles (not shown) arranged on a plough (not shown but similar to the plough 23 of the embodiment of FIGS. 3 and 4). It is also possible to apply different working pressures to different sections of the nozzles 26.
FIG. 7 shows a hydraulic winning machine 112 which is similar to that of FIGS. 5 and 6, but which is driven by a rack-and-pinion drive rather than by an endless chain drive. Thus, the winning machine 112 of FIG. 7 has an electrically driven pinion 124 which meshes with a rack 125 attached to the conveyor 10 on the goaf side. The motor (not shown) for driving the pinion 124 is mounted on the goaf side of the portal arm 31, and is fed by a pick-up arm (not shown but similar to the arm 120) from the currentsupply channel 115.
It will be apparent that the installation described above could be modified in many ways. In particular the hydraulic winning machine 12 of the embodiments of FIGS. 1 to 4 could be supplied with water and electric current in the same manner as the machines 12 of FIGS. 5 to 7. Moreover, any other type of mechanical winning machines (such as a shearer) may be used in place of the plough 23.
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A mineral mining installation comprises a mechanical mining machine (such as a plough or a shearer) and a hydraulic winning machine. The hydraulic winning machine has a plurality of high-pressure nozzles and a high-pressure pump for supplying the nozzles with high-pressure water (or other hydraulic fluid). Means are provided for driving each of the two winning machines independently of the other along a mineral face. This permits the mechanical winning machine to operate at its optimum, high speed rate without interference from the slower moving hydraulic winning machine. The pump is preferably a multiple radial-piston pump powered by an electric motor. Both electric power and water may be supplied to the hydraulic winning machine via pick-up arms on the machine and supply channels extending along the face.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2002-250824, filed Aug. 29, 2002, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a laser scanning microscope for scanning a laser beam onto a sample to detect fluorescence from the sample by a photodetector.
2. Description of the Related Art
In Jpn. Pat. Appln. KOKAI Publication No. 2000-275529, a laser scanning microscope is disclosed including a first optical scanning system A for obtaining a scanned image of fluorescence from the sample and a second optical scanning system B for expressing peculiar phenomena such as cleavage of a caged reagent in a specific portion of the sample.
FIG. 1 is a diagram showing a constitution of a conventional laser scanning microscope. A sample 79 is irradiated with laser beams from the second optical scanning system B in synchronization with the scanning of the laser beams of the first optical scanning system A, and changes of the sample 79 with an elapse of time can be measured. The synchronization is carried out, when a control unit 81 controls a laser shutter 63 , optical scanning unit 64 , and photoelectric conversion device 70 of the first optical scanning system A, and a laser shutter 72 and optical scanning unit 73 of the second optical scanning system B.
The caged reagent and a fluorescent indicator having sensitivity to concentration of ions such as calcium ions are injected into the sample 79 . The sample 79 in which the caged reagent has been injected is irradiated with the laser beams from a laser unit 71 of the second optical scanning system B. A caged group of the caged reagent in the irradiated portion is cloven, and materials enclosed inside are released. The change of an ion concentration distribution in the sample 79 by this release is measured by a fluorescent image obtained by the laser beams from a laser unit 61 of the first optical scanning system A. With the cleavage of the caged reagent or by the irradiation with the laser beams of the second laser unit 71 , the fluorescent indicator of the sample 79 produces a certain degree of fluorescence. However, the control unit 81 controls an opening/closing timing of the laser shutters 63 , 72 of each laser beam and a detection timing in the photoelectric conversion device 70 with the elapse of time. Therefore, a spectrum of fluorescence can be detected by a photodetector to obtain the fluorescent image without being influenced by the change of a fluorescent intensity from the fluorescent indicator with the cleavage of the caged reagent.
However, in the laser scanning microscope including first and second optical scanning systems described in the Jpn. Pat. Appln. KOKAI Publication No. 2000-275529, there is possibility that the laser beams of the second optical scanning system are detected by the photodetector of the first optical scanning system. This has left much room for improvement in obtaining a desired fluorescent image.
For example, the use of a UV pulse laser (wavelength of 351 nm) as the laser unit 71 of the second optical scanning system B for cleaving the caged reagent is considered. Since much light intensity is required for cleaving the caged reagent, a reflected light of the laser beams of the second optical scanning system from the irradiated sample 79 is also intense. A dichroic mirror 75 does not sufficiently absorb the reflected light of the UV pulse laser beams, and a slight amount of the light is transmitted through an optical path of the first optical scanning system A. However, in a dichroic mirror 62 and filters such as a laser cut filter 67 usually for use in the first optical scanning system A, that is, an optical scanning system for acquiring images, transmission capabilities with respect to a short wavelength band of the UV laser are hardly considered. The wavelength of the UV pulse laser is reflected, transmitted, and detected by the photoelectric conversion device 70 , and a clear fluorescent image cannot be obtained.
Similarly, the use of an IR pulse laser (wavelength of 710 nm) as the laser unit 71 of the second optical scanning system B for cleaving the caged reagent is considered. It is to be noted that this IR pulse laser is assumed as laser capable of causing two photon excitation. Also for the IR pulse laser, the intense reflected light from the sample 79 is not sufficiently reflected by the dichroic mirror 75 , and the slight amount of the light passes through the optical path of the first optical scanning system A. For the filters usually for use in the first optical scanning system A, that is, the optical scanning system for acquiring the images, a long path filter which reflects a short wavelength and transmits a long wavelength is used in many cases. For these laser cut filters, transmission characteristics in the long wavelength band of IR are not considered. Therefore, the wavelength of IR pulse laser beams, which is longer than that of the fluorescence, passes through the laser cut filter, and is detected by the photodetector. Therefore, the clear fluorescent image cannot be obtained.
Moreover, to prevent the above-described phenomenon, as described in the Jpn. Pat. Appln. KOKAI Publication No. 2000-275529, it is considered that the control unit 81 , for example, shifts a timing of laser irradiation to control the first and second optical scanning systems, and influences of the laser beams of the second optical scanning system B are avoided. However, in this case, since it is necessary to simultaneously control the optical scanning system and an optical detection system at a high speed, a complicate control is required for realizing this. Furthermore, in the technique described in the Jpn. Pat. Appln. KOKAI Publication No. 2000-275529, the sample cannot be irradiated with two types of laser beams at the same time. Therefore, when the changes of the sample 79 with the elapse of time are measured, real time characteristics drop.
BRIEF SUMMARY OF THE INVENTION
According to a first aspect of the present invention, there is provided a laser scanning microscope comprising: a first optical scanning system which scans a first laser light having a spectrum in a visible range on a sample to excite fluorescence; a first dichroic mirror which separates the fluorescence from the sample from an optical path of the first laser light; a photodetector which detects the fluorescence separated by the first dichroic mirror; an emission filter which is disposed between the first dichroic mirror and photodetector to cut off the first laser light and to transmit desired fluorescence; a second optical scanning system which introduces a second laser light having the spectrum in an ultraviolet or infrared region into a specific portion on the sample; and a laser cut filter which is disposed between the first dichroic mirror and detector to limit transmission of the second laser light.
Moreover, according to another aspect of the present invention, there is provided a laser scanning microscope comprising: a first optical scanning system which scans a first laser light for observing a sample on the sample; a first light branch device which branches a light from the sample from an optical path of the first laser light; a photodetector which detects the light from the sample separated by the first light branch device; a second optical scanning system which irradiates a specific portion on the sample with a second laser light for stimulating or operating the sample; and a wavelength selection device which is disposed between the first light branch device and photodetector and which includes a first function of transmitting a desired observation light and a second function of limiting transmission of the second laser light.
Advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out hereinafter.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention, and together with the general description given above and the detailed description of the embodiments given below, serve to explain the principles of the invention.
FIG. 1 is a diagram showing a conventional laser scanning microscope;
FIG. 2 is a diagram showing a laser scanning microscope according to a first embodiment of the present invention;
FIGS. 3A , 3 B are diagrams showing transmittance wavelength characteristics of a filter;
FIGS. 4A , 4 B, 4 C are diagrams showing the transmittance wavelength characteristics of a dichroic mirror;
FIGS. 5A , 5 B are concept diagrams showing characteristics and constitution of a laser cut filter;
FIG. 6 is a diagram of the laser scanning microscope according to another embodiment; and
FIG. 7 is a diagram of the laser scanning microscope according to another embodiment.
DETAILED DESCRIPTION OF THE INVENTION
A first embodiment of the present invention will be described. FIG. 2 is a diagram of a laser scanning microscope according to the present invention.
The laser scanning microscope includes a first optical scanning system A and second optical scanning system B. The first optical scanning system A is an optical system for observation, which scans the surface of a sample 29 with a laser light 11 a outputted from a first laser unit 11 . The second optical scanning system B is an optical system for expressing a peculiar phenomenon in a specific portion of the sample. That is, the second optical scanning system B irradiates an arbitrary position of the sample 29 with a laser light 21 a outputted from a second laser unit 21 to release a caged reagent.
The first optical scanning system A includes the first laser unit 11 , dichroic mirror 12 , first laser shutter 13 , first optical scanning unit 14 , pupil projection lens 15 , and mirror 16 . Furthermore, an optical detection system C is disposed in a branched optical path of the dichroic mirror 12 of the first optical scanning system A. The optical detection system C includes a laser cut filter 31 , dichroic mirror 17 , mirror 18 , fluorescence emission filters 19 a and 19 b , confocal lenses 110 a and 110 b , confocal apertures 111 a and 111 b , and photoelectric conversion devices 112 a and 112 b.
The laser cut filter 31 has characteristics for absorbing a reflected light of the laser light 21 a of the second optical scanning system B from the sample 29 . A UV light is usually used to release the caged reagent. Therefore, the following laser unit is considered to be used.
(a) A UV pulse laser (wavelength of 351 nm) is used as the second laser unit 21 .
(b) An IR pulse laser (wavelength of 710 nm) is used as the second laser unit 21 . It is to be noted that the IR pulse laser is assumed as a laser capable of causing a two photon excitation phenomenon.
Therefore, the laser cut filter 31 has the characteristics to absorb the laser light as described above. Concretely, a filter having the characteristics shown in FIG. 3 is used.
FIG. 3A is a diagram showing filter characteristics to cut off the UV pulse laser (wavelength of 351 nm), and FIG. 3B is a diagram showing the filter characteristics to cut off the IR pulse laser (wavelength of 710 nm).
The second optical scanning system B includes the second laser unit 21 for releasing the caged reagent, and a second laser shutter 22 , second optical scanning unit 23 , pupil projection lens 24 , and dichroic mirror 25 . Optical axes of the first and second optical scanning systems A, B are synthesized by the dichroic mirror 25 , and introduced into an image forming lens 26 and objective lens 27 . Focal positions of the pupil projection lens 15 and pupil projection lens 24 are disposed to agree with the focal position of the image forming lens 26 . The sample 29 is laid on a stage 28 .
Here, a supposed combination of the first laser unit 11 and second laser unit 21 , and the characteristics of the dichroic mirror 25 which agree with conditions will be described hereinafter.
When a visible continuous laser (wavelength of 488 nm) is used in the first laser unit 11 , and the UV pulse laser (wavelength of 351 nm) is used in the second laser unit 21 , for transmittance wavelength characteristics of the dichroic mirror 25 , as shown in FIG. 4A , the visible continuous laser (wavelength of 488 nm) and fluorescence (wavelength of 530 nm) are transmitted, and the UV pulse laser (wavelength of 351 nm) is reflected.
When the visible continuous laser (wavelength of 488 nm) is used in the first laser unit 11 , and the IR pulse laser (wavelength of 710 nm) is used in the second laser unit 21 , for the transmittance wavelength characteristics of the dichroic mirror 25 , as shown in FIG. 4B , the dichroic mirror 25 transmits the visible continuous laser (wavelength of 488 nm) and fluorescence (wavelength of 530 nm) and reflects the IR pulse laser (wavelength of 710 nm).
When the IR pulse laser (wavelength of 850 nm) is used in the first laser unit 11 , and the IR pulse laser (wavelength of 710 nm) is used in the second laser unit 21 , for the transmittance wavelength characteristics of the dichroic mirror 25 , as shown in FIG. 4C , the IR pulse laser (wavelength of 850 nm) and fluorescence having a wavelength of 530 nm are transmitted, and the IR pulse laser (wavelength of 710 nm) is reflected.
It is to be noted that the IR pulse laser for use herein is a laser capable of causing a two photon excitation phenomenon.
The first laser shutter 13 , second laser shutter 22 , first optical scanning unit 14 , second optical scanning unit 23 , and photoelectric conversion devices 112 a and 112 b are connected to a control unit 211 . The control unit 211 is connected to a CRT display 212 . As described later, the control unit 211 synchronizes the irradiation of the sample 29 with the laser light from the second optical scanning system B with the scanning of the first optical scanning system A.
Next, a function of the laser scanning microscope will be described. The laser light 11 a from the first laser unit 11 passes, when the first laser shutter 13 controlled to open/close by the control unit 211 is in an opened state. Subsequently, the laser light 11 a is guided into the first optical scanning unit 14 , and controlled by the control unit 211 to be scanned in an arbitrary direction. The laser light 11 a is further converged onto a section 210 of the sample 29 via the pupil projection lens 15 , mirror 16 , dichroic mirror 25 , image forming lens 26 , and objective lens 27 to two-dimensionally scan inside the section 210 of the sample.
A fluorescent indicator (e.g., fluo-3, excitation wavelength of 488 m, fluorescent wavelength of 530 nm) excited by the wavelength of the first laser unit 11 is injected in the sample 29 . When the section 210 of the sample is scanned by the laser light, the fluorescent indicator is excited to generate the fluorescence. The fluorescence incident upon the objective lens 27 travels in an opposite direction in the same optical path as that of the laser light, and is guided into the objective lens 27 , image forming lens 26 , and dichroic mirror 12 . The dichroic mirror 12 includes characteristics to reflect the light which has a wavelength longer than that of the laser light 11 a from the first laser unit 11 . Therefore, the fluorescence is accordingly reflected by the dichroic mirror 12 , and introduced into the optical detection system C.
When the sample 29 is multiple-dyed in the optical detection system C, the fluorescence transmitted through the laser cut filter 31 is split into the fluorescence having each wavelength by the dichroic mirror 17 . Among the split lights, the light having the specific wavelength passes through the fluorescence emission filters 19 a and 19 b , and is focused by the confocal lenses 110 a and 110 b . Moreover, only the light from the section 210 of the sample is incident upon the photoelectric conversion devices 112 a and 112 b by the confocal apertures 111 a and 111 b disposed in positions optically conjugated with the section 210 of the sample.
Output signals from the photoelectric conversion devices 112 a and 112 b are guided into the control unit 211 . The output signals are converted to digital signals in synchronization with scanning control, and displayed on a screen of the CRT display 212 in accordance with a scanned position. The displayed image indicates the fluorescent image which is a two-dimensional distribution of a fluorescent luminance in the section 210 of the sample, that is, the distribution in the section 210 having an ion concentration.
On the other hand, the laser light 21 a from the second laser unit 21 passes, when the second laser shutter 22 controlled to open/close by the control unit 211 is in the opened state. The laser light 21 a proceeds on the same optical axis as that of the laser light 11 a from the first optical scanning system A via the second optical scanning unit 23 , pupil projection lens 24 , and dichroic mirror 25 . Moreover, the laser light 21 a passes through the image forming lens 26 and objective lens 27 to irradiate the section 210 of the sample 29 . At this time, since the control unit 211 controls the second optical scanning unit 23 , an irradiation position in the section 210 can be selected independently of the scanned position of the first optical scanning system A.
The sample 29 in which the caged reagent has been injected is irradiated with the laser light 21 a from the second laser unit 21 . Then, the caged group of the caged reagent of the irradiated portion is cloven, and substances enclosed inside are released. The change of the ion concentration distribution in the sample 29 by the release can be measured by the fluorescent image obtained by the first optical scanning system A.
At this time, the reflected light including the laser light 21 a from the second laser unit 21 reflected on the sample 29 proceeds in the same optical path as that of the fluorescence generated on the section 210 of the sample 29 . Several % of the reflected light including the laser light 21 a which has reached the dichroic mirror 25 passes through the dichroic mirror 25 and is introduced into the optical path of the first optical scanning system A. The reflected light including the second laser light guided into the first optical scanning system A passes through the mirror 16 , pupil projection lens 15 , and optical scanning unit 14 , and is reflected by the dichroic mirror 12 , and guided into the optical path of the optical detection system.
The reflected light including the laser light 21 a reflected by the dichroic mirror 12 is absorbed by the laser cut filter 31 which is disposed on the optical path of the optical detection system C beforehand and which has characteristics to absorb the laser light 21 a . Therefore, only the fluorescence passes through the laser cut filter 31 , and is detected by the photoelectric conversion devices 112 a and 112 b.
Here, transmission characteristics of the laser cut filter 31 for use in the present embodiment will be described.
With respect to the intensity of the laser light 21 a from the second optical scanning system B as an excitation laser light with which the sample 29 is irradiated, the intensity of the fluorescence generated from the sample 29 is very weak. Therefore, even when the laser light 21 a reflected by the sample 29 is reflected by the sample or an optical system midway and accordingly attenuated, the intensity becomes 1000 times or more that of the fluorescence generated from the sample 29 and directed toward the devices 112 a and 112 b . Therefore, in order to clearly acquire the fluorescent image without being influenced by the reflected laser light 21 a , as laser cut filter characteristics for transmitting the fluorescence, the transmittance of the reflected laser light 21 a needs to be at least 0.01% or less.
Additionally, in order to realize the characteristics, an interference filter using a multilayered film coating is used. For the interference filter, a large number of layers different in refractive index and film thickness are superimposed on one another, and the interference filter controls the transmittance by optical interference. However, for the interference filter, it is difficult to realize flat transmittance characteristics with respect to the wavelength band. Therefore, usually, targeted transmission wavelength and cut-off wavelength are set, and the filter is manufactured so as to obtain desired characteristics with the wavelength. As a filter which has actually heretofore been manufactured as the laser cut filter for selecting a fluorescent wavelength, it has been general to set the transmittance to 0.01% or less with respect to only an excitation wavelength corresponding to the fluorescence.
That is, the conventional laser cut filter is a filter having “a function of extracting the fluorescence”, and is assumed not to include a function of cutting off the “second laser light” in a case where the second optical scanning system is disposed. The laser cut filter 31 for use in the present embodiment further includes this function.
FIG. 5A is an explanatory view of the characteristics of the laser cut filter according to the present embodiment.
In FIG. 5A , the first laser light is represented as the visible continuous laser (wavelength of 488 nm), the second laser light is represented as the UV pulse laser (wavelength of 351 nm), and the light from the sample is represented as the fluorescence from the sample (wavelength of 530 nm).
An upper part of FIG. 5A shows an intensity distribution of the first laser light, second laser light, and the light from the sample. As shown in this figure, the intensity of the second laser light is higher than that of the first laser light in many cases. This is because the second laser light is used for a purpose of exciting or operating the sample. It is seen from this that necessity of securely cutting off the second laser light rather than the first laser light is high.
A lower part of FIG. 5A shows a concept of the transmission characteristics of the laser cut filter according to the present embodiment.
As described above, the laser cut filter according to the present embodiment includes two functions. That is, the filter includes the transmission characteristics for realizing a first function which is a “function of extracting the fluorescence” and a second function which is a “function of cutting off the second laser light”. With thee two functions, it is possible to obtain a clear fluorescent image.
In order to realize the laser cut filter of the present embodiment, as shown in FIG. 2 , the fluorescence emission filters 19 a and 19 b including the “function of extracting the fluorescence” (first function) and the laser cut filter 31 including the “function of cutting off the second laser light” (second function) are disposed. Moreover, as shown in FIG. 5B , filter films 31 a , 32 a including the respective functions may be formed on opposite surfaces of one glass. The filters shown in FIG. 5B may be used instead of the filters 19 a and 19 b of FIG. 2 . At this time, the filter 31 is not required.
When the laser cut filter 31 including the above-described transmission characteristics is used and incorporated in the optical detection system C in this manner, the laser light 21 a included in the reflected light from the sample 29 can securely be removed, and the clear fluorescent image is obtained. The simultaneous irradiation with the first and second laser lights 11 a and 21 a is also possible. Furthermore, when the sample 29 is multiple-dyed, as shown in FIG. 2 , the laser cut filter 31 may be disposed in a common optical path of the optical detection system C, and therefore the system can easily be constituted.
A second embodiment of the present invention will be described. FIG. 6 is a diagram of the laser scanning microscope according to the present invention. The same components as those of the first embodiment are denoted with the same numerals, and detailed description thereof is omitted.
In the second embodiment, a UV pulse laser 34 and an IR pulse laser 35 whose wavelength can be varied and which can cause the two photon excitation phenomenon are used in the laser of the second optical scanning system B. Moreover, these lasers 34 , 35 can be selected and used by controlling the opening/closing of laser shutters 36 and 37 . The dichroic mirror 25 is disposed in a position where the optical axis of the laser light 11 a from the first optical scanning system A and that of laser light 34 a or 35 a from the second optical scanning system B are synthesized. At least one dichroic mirror 25 is disposed in an electromotive turret 32 in which a plurality of dichroic mirrors can be disposed.
Further to cut off the laser light 34 a or 35 a from the laser unit of the second optical scanning system B, the laser cut filter 31 is disposed on the optical path of the optical detection system C. At least one laser cut filter 31 is disposed in an electromotive turret 33 in which a plurality of filters can be disposed.
It is to be noted that the electromotive turrets 32 and 33 are usually of a rotary type, but may be of a slider type if necessary.
Moreover, the electromotive turrets 32 and 33 and laser shutters 36 , 37 are connected to the control unit 211 , and can be controlled by the control unit 211 .
The function of the laser scanning microscope constituted in this manner will be described. The UV pulse laser 34 is used as the laser unit of the second optical scanning system B. The laser light 11 a from the first laser unit 11 of the first optical scanning system A, and the UV pulse laser light 34 a outputted from the laser unit of the second optical scanning system B pass through the respective optical devices in the same manner as in the first embodiment. Moreover, the optical axes of the laser light 11 a from the first optical scanning system A and the UV pulse laser light 34 a from the second optical scanning system B are synthesized by the dichroic mirror 25 . The dichroic mirror 25 includes characteristics to transmit the laser light 11 a from the first optical scanning system A and to reflect the UV pulse laser light 34 a which is the laser light from the second optical scanning system B. The dichroic mirror 25 is disposed on the optical path by the electromotive turret 32 which operates in conjunction with the opening/closing operation of the laser shutter 36 .
The respective laser lights from the first and second laser units synthesized by the dichroic mirror 25 pass through the image forming lens 26 and objective lens 27 , and are focused on the section 210 of the sample 29 in the same manner as in the first embodiment. The caged reagent is released by the UV pulse laser light 34 a , and the fluorescent indicator is excited by the laser light 11 a from the first optical scanning system A to generate the fluorescence.
The fluorescence generated from the sample 29 and the UV pulse laser light 34 a which is the reflected light from the sample travel in an opposite direction through the optical path of the first optical scanning system A, and the fluorescence and the reflected light of the UV pulse laser light 34 a are introduced into the optical detection system C via the dichroic mirror 12 .
Among the fluorescence and UV pulse laser light 34 a introduced into the optical detection system C, the fluorescence passes through the laser cut filter 31 , and the UV pulse laser light is absorbed by the laser cut filter 31 . It is to be noted that the electromotive turret 33 operates in conjunction with the opening/closing operation of the laser shutter 36 , and the laser cut filter 31 including the transmission characteristics to absorb the UV pulse laser light is disposed beforehand on the optical path.
The fluorescence which has passed through the laser cut filter 31 passes through the respective optical devices in the same manner as in the first embodiment. Moreover, the fluorescence is detected by the photoelectric conversion devices 112 a and 112 b . The detection signal is processed by the control unit 211 , and subsequently displayed on the CRT display 212 .
On the other hand, in order to release the caged reagent or to light-discolor the sample in which protein (e.g., YFP) is expressed, the IR pulse laser 35 is sometimes used as the laser light of the second optical scanning system B. In this case, the dichroic mirror 25 for synthesizing the optical axes of the laser light from the first optical scanning system A and the IR pulse laser light 35 a from the second optical scanning system B includes the transmission characteristics to transmit the laser light 11 a from the first optical scanning system A and reflect the IR pulse laser light 35 a . Moreover, in conjunction with the opening/closing operation of the laser shutter 37 , the electromotive turret 32 brings the dichroic mirror 25 onto the optical path beforehand.
Moreover, also in the optical detection system C, the laser cut filter 31 includes the transmission characteristics to transmit the fluorescence and absorb the IR pulse laser light 35 a which is the reflected light. Furthermore, the electromotive turret 33 brings the laser cut filter 31 onto the optical path beforehand in conjunction with the opening/closing operation of the laser shutter 37 .
In this manner, in the second embodiment, the dichroic mirror 25 for synthesizing the optical axes of the laser lights from the first and second optical scanning systems A and B is disposed on the electromotive turret. Furthermore, in the optical detection system C, the laser cut filter 31 for absorbing the laser light of the second optical scanning system B which is the reflected light from the sample 29 is disposed in the electromotive turret 33 . Moreover, the electromotive turrets 32 and 33 are operated in conjunction with the opening/closing operation of the laser shutters 36 and 37 . Accordingly, there can be provided a system in which either the UV pulse laser 34 or IR pulse laser 35 can be selected and used as the laser unit of the second optical scanning system B for use in releasing the caged reagent.
Moreover, when a manual turret is used instead of the electromotive turrets 32 and 33 , a system including the similar function can inexpensively be provided.
A third embodiment of the present invention will be described. FIG. 7 is a diagram of the laser scanning microscope according to the present invention. The same components as those of the first and second embodiments are denoted with the same reference numerals and the detailed description is omitted.
The laser scanning microscope of the present embodiment includes a constitution in which an image forming lens 41 of the first optical scanning system A and an image forming lens 43 of the second optical scanning system B for observation are independently disposed, and the objective lens 27 is shared.
The first optical scanning system A is constituted as a laser scanning microscope D. The first optical scanning system A is constituted of the first laser unit 11 , the first laser shutter 13 , the dichroic mirror 12 , the first optical scanning unit 14 , the pupil projection lens 15 , the image forming lens 41 , a dichroic mirror 42 , and the objective lens 27 . At least one dichroic mirror 42 is disposed in an electromotive turret 47 in which a plurality of dichroic mirrors can be disposed. Furthermore, the optical detection system C is disposed on the branched optical path of the dichroic mirror 12 of the first optical scanning system A. Since the optical detection system C is the same as that of the second embodiment, the description is omitted.
The dichroic mirror 42 disposed in the electromotive turret 47 of the first optical scanning system A includes characteristics to reflect the wavelength of the laser light from the first optical scanning system A and the light having the long wavelength and to transmit the laser light from the second optical scanning system B.
The second optical scanning system B is constituted as an illuminative light introduction apparatus E. The second optical scanning system B is constituted of the second laser unit 21 , second laser shutter 22 , second optical scanning unit 23 , pupil projection lens 24 , and image forming lens 43 , and a mirror 44 .
It is to be noted that the second optical scanning unit 23 may be omitted to constitute the second optical scanning system B.
The second laser shutter 22 and second optical scanning unit 23 are controlled by a second control unit 45 . The second control unit 45 is connected to a first control unit 46 for controlling synchronization with the first optical scanning system A.
It is to be noted that the second control unit 45 is not necessarily required. The second laser shutter 22 and second optical scanning unit 23 may also directly be connected to the first control unit 46 .
Moreover, in the present embodiment, the laser scanning microscope D and illuminative light introduction apparatus E are constituted as independent units, and are structured to be attachable/detachable, for example, by a dovetail structure or bolt fastening.
Next, the function of the laser scanning microscope constituted in this manner will be described. The laser light 11 a emitted from the first laser unit 11 of the first optical scanning system A passes through the respective optical devices of the first optical scanning system A, and is formed into a parallel light by the image forming lens 41 . Moreover, the laser light 11 a is reflected by the dichroic mirror 42 and focused by the objective lens 27 to scan on the section 210 of the sample 29 . The fluorescence from the section 210 of the sample 29 travels forward in an optical path similar to that described in the first embodiment, and is detected by the optical detection system C.
On the other hand, the laser light 21 a emitted from the laser unit 21 of the second optical scanning system B passes through the respective optical devices of the second optical scanning system B, and is formed into the parallel light by the image forming lens 43 . Moreover, the laser light 21 a is reflected by the mirror 44 and synthesized with the optical axis from the first optical scanning system A via the dichroic mirror 42 . Furthermore, the laser light 21 a is focused by the objective lens 27 to irradiate the section 210 of the sample 29 .
When the first control unit 46 controls the second control unit 45 and second optical scanning unit 23 , an irradiation position and range by the second optical scanning system B can be selected independently of a scanning position and range of the first optical scanning unit 14 .
As described above, in the third embodiment, the first optical scanning system A includes the image forming lens 41 , and the second optical scanning system B includes the image forming lens 43 . Therefore, the laser light which has passed through the image forming lenses 41 , 43 forms the parallel light, and the optical axis of the first optical scanning system A can easily be matched with that of the second optical scanning system B.
That is, a luminous flux of a connecting portion of the laser scanning microscope D including the first optical scanning system A with respect to the illuminative light introduction apparatus E including the second optical scanning system B is the parallel light. Therefore, optical axis alignment is facilitated in connecting the laser scanning microscope D to the illuminative light introduction apparatus E.
Moreover, the first optical scanning system A is constituted as the laser scanning microscope D, and the second optical scanning system B can be constituted as the illuminative light introduction apparatus E. Therefore, since the respective apparatuses can be constituted as different appropriates, the illuminative light introduction apparatus E can be provided as an apparatus for upgrading the system of the laser scanning microscope D.
Furthermore, when the illuminative light introduction apparatus E includes the constitution without including the optical scanning unit 23 of the second optical scanning system B, the apparatus can be provided as an inexpensive apparatus which is easily controlled.
Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general invention concept as defined by the appended claims and their equivalents.
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There is disclosed a laser scanning microscope including a first optical scanning system which scans a first laser light for observing a sample on the sample, a first light branch device which branches the light from the sample from an optical path of the first laser light, a photodetector which detects the light from the sample, separated by the first light branch device, a second optical scanning system which irradiates a specific portion on the sample with a second laser light for stimulating or operating the sample, and a wavelength selection device which is disposed between the first light branch device and photodetector and which includes a first function of transmitting a desired observation light and a second function of limiting transmission of the second laser light.
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RELATED APPLICATION
The present disclosure relates to subject matter contained in priority Korean Application No. 10-2007-0089181, filed on Sep. 3, 2007, which is herein expressly incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a washing/drying machine, and more particularly, to mounting a washing/drying machine on a pedestal or other washing/drying machine by using a supporter.
2. Background of the Invention
In general, a washing/drying machine is an apparatus to remove stain (dirt) from clothes, bedclothes, and the like. Such the washing/drying machine may include a washing machine for washing laundry, a drying machine for drying the laundry, a washing/drying machine for performing both the washing and drying operations, and the like. In addition, a refresher has been introduced to remove wrinkles of the laundry or to supply fragrance.
With a recent trend of the washing/drying machine equipped with a pedestal for storing items therein or a supporter, the washing/drying machine, such as the washing machine, the drying machine, the washing/drying machine, etc., is configured to be fixed to an upper surface of the pedestal.
FIG. 1 is an exploded perspective view showing a conventional washing/drying machine having a pedestal. Referring to FIG. 1 , the pedestal 20 may include a housing 21 having a certain space therein, and a drawer 22 detachably inserted into the housing 21 for receiving a variety of items therein.
Here, a main body 10 of a washing/drying machine 1 and the pedestal 20 are coupled to each other by a separate coupling member 23 (e.g., a bracket, etc.). An upper end 23 a of the coupling member 23 is fixed onto one side surface of the washing/drying machine main body 10 by a double-sided tape 24 , and a lower end 23 b of the coupling member 23 is fixed onto one side surface of the housing 21 of the pedestal 20 by screws 25 .
Here, a pair of coupling members 23 is installed at each side surface of the main body 10 of the washing/drying machine 1 and the housing 21 of the pedestal 20 . That is, the upper end 23 a of the coupling member 23 is attached to the double-sided tape 24 , and both sides of the lower end 23 b thereof are coupled by the screws 25 , thereby being installed between the side surface of a lower end of the main body 10 forming an outer aspect of the washing/drying machine 1 and the side surface of the housing 21 of the pedestal 20 .
However, such conventional pedestal 20 cannot be commonly used in the washing machine, the drying machine or the like, and the separate coupling member 23 should be used for coupling the washing/drying machine 1 and the pedestal 20 , thereby having a complicated coupling process, reducing productivity, and increasing a manufacturing cost.
In addition, when the washing/drying machine 1 is to be moved or when the coupling member 23 is to be removed so as to install other washing/drying machine to the pedestal, a spot due to the double-sided tape would remain on the surface of either the washing/drying machine 1 or the pedestal 20 , or screw holes are generated, thereby deteriorating the external appearance of the product.
In addition, in the process of removing the screws 25 in order to remove the coupling member 23 , the surface of the washing/drying machine 1 or the pedestal 20 may be damaged (e.g., dented) or the coupling member 23 may be curved.
SUMMARY OF THE INVENTION
Therefore, an object of the present invention is to provide a pedestal capable of preventing a damage to a surface of the washing/drying machine and the pedestal due to a coupling unit by coupling base ribs formed at a base for supporting a lower portion of the washing/drying machine and coupling ribs of a supporter, facilitating mounting/dismounting the supporter or the pedestal, and not requiring a separate coupling member, and a washing/drying machine having the same.
To achieve this and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described herein, there is provided a washing/drying machine, including: a washing/drying machine main body; and a pedestal for mounting the main body thereon, wherein a base having legs is coupled to a lower end of the main body, and a supporter having coupling ribs for fixing the base to the pedestal is formed at an upper surface of the pedestal.
Here, the supporter includes a main body having leg holes for mounting legs of an object to support thereon, and a plurality of coupling ribs disposed at one side of the main body so as to couple the object to support disposed above or below the main body and the main body to each other.
With such configuration, the object to support and the supporter can be coupled by the coupling ribs. Accordingly, the supporter or the pedestal may be fixed to the object to support without a separate coupling means such as a conventional coupling member, thus to increase productivity.
In addition, at least two coupling ribs are formed at the supporter so as to correspond to an edge of the upper surface of the housing, and coupling holes of a coupling means may be formed at the coupling ribs. Thusly, the coupling ribs are configured to correspond to the edges of the upper surface of the pedestal housing, thereby preventing the supporter from protruding outside of the pedestal housing. Since the coupling holes are formed at the coupling ribs, there is no need to form a separate screw coupling hole on the surface of the pedestal, and damage to the outer aspect of the housing, etc. may be prevented.
In addition, an outer aspect can be maintained in a good condition by preventing the supporter from protruding from the surface of the object to support or the pedestal.
Meanwhile, at least two leg holes for mounting the support legs of the object are formed at the supporter, and the leg holes are communicated with each other or separated from each other. That is, the at least two leg holes are applied in both the washing machine and the drying machine, thus to be commonly used.
Here, the leg holes are formed to have a different depth or size, and the leg holes are disposed on the upper surface of the housing in a diagonal direction. If an object to be coupled to the supporter is the washing machine and the drying machine, legs of the drying machine are positioned inside legs of the washing machine in the diagonal direction. Thusly, the leg holes are disposed on the upper surface of the housing in the diagonal direction, thereby achieving the general use of the components. In addition, considering that the legs of the washing machine and the drying machine have different diameter or thickness, the size or the depth of the leg holes should be formed.
There is provided a washing/drying machine, including: a washing/drying machine main body performing a washing or drying operation of laundry; a base coupled to a lower end of the main body so as to support the main body and having legs; and a pedestal disposed below the main body and for supporting the main body, wherein a supporter having coupling ribs for fixing the main body to the pedestal is mounted at an upper surface of the pedestal.
Here, base ribs coupled to the coupling ribs are formed at the base.
Coupling holes communicated with each other are formed at the coupling ribs and the base ribs. After aligning the centers of the coupling holes with each other, the base and the supporter are coupled by using a screw, etc., thereby preventing the damage to the surface of the washing/drying machine and the pedestal.
Meanwhile, the washing/drying machine main body is one of a washing machine, a drying machine or a washing/drying machine. Washing machine leg holes for receiving legs mounted at the washing machine base and drying machine leg holes for receiving legs mounted at the drying machine base are formed at the supporter.
In addition, the washing machine leg holes and the drying machine leg holes may be communicated with each other or separated from each other. The supporter includes front supporters having leg holes communicated with each other and disposed at both sides on the front end of the upper surface of the pedestal, and rear supporters having leg holes separated from each other and disposed at both sides on the rear end of the upper surface of the pedestal.
Here, at least one of the washing machine leg holes or the drying machine leg holes may be formed to be open. That is, some of the leg holes may be covered so as to prevent the leg from being seen outside, and others may remain in an opened state for facilitating mounting the leg.
The present invention provides a pedestal disposed below the washing machine or the drying machine, and equipped with a supporter having coupling ribs coupled to the base that is mounted at the lower end of the washing machine or the drying machine, thus to be commonly used in the washing machine and the drying machine.
If another washing/drying machine, in addition to the washing/drying machine, is to be placed, the two washing/drying machines may be fixed by using the supporter according to the present invention. That is, the present invention provides a washing/drying machine, including: a first washing/drying machine main body; and a second washing/drying machine main body placed on the first main body, wherein a base having legs is coupled at a lower end of the second main body, and a supporter having coupling ribs for fixing the base to the first main body is mounted at an upper surface of the first main body. Here, the first main body may be the drying machine and the second main body may be the washing machine, and vice versa.
The foregoing 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
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention.
In the drawings:
FIG. 1 is an exploded perspective view showing a conventional washing/drying machine having a pedestal;
FIG. 2 is an exploded perspective view showing a washing/drying machine having a pedestal according to the present invention;
FIG. 3 is a perspective view showing a state that a supporter is mounted at the pedestal in FIG. 2 ;
FIG. 4 is a perspective view showing one exemplary supporter in FIG. 3 ;
FIG. 5 is an exploded perspective view showing a base mounted at the washing/drying machine in FIG. 2 ;
FIG. 6 is a perspective view showing a state that the base in FIG. 5 is coupled to the supporter; and
FIG. 7 is a perspective view showing another exemplary base in FIG. 5 .
DETAILED DESCRIPTION OF THE INVENTION
Description will now be given in detail of the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
FIG. 2 is an exploded perspective view showing a washing/drying machine having a pedestal according to the present invention. FIG. 3 is a perspective view showing a state that a supporter is mounted at the pedestal in FIG. 2 , and FIG. 4 is a perspective view showing one exemplary supporter in FIG. 3 .
Referring to FIGS. 2 through 4 , the washing/drying machine 100 according to the present invention may include a washing/drying machine main body 110 for performing cleaning operations of clothes, a pedestal 200 or a pedestal disposed at one surface of the washing/drying machine main body 110 and for receiving a variety of items required for cleaning the clothes, and a supporter 230 disposed between the pedestal 200 and the washing/drying machine main body 110 so as to connect the pedestal 200 and the main body 110 .
The washing/drying machine main body 110 may be one of the washing machine, the drying machine, and washing/drying machine. The pedestal 200 may be disposed at any one of left/right surfaces and upper/lower surfaces of the main body 110 , and most preferably, at the lower surface of the main body 110 .
Hereinafter, the present invention would describe that the pedestal 200 is disposed below the washing/drying machine main body 110 , and the main body 110 is either the washing machine or the drying machine. That is, the pedestal 200 is mounted at a position where the washing/drying machine 100 is to be installed, and then the washing/drying machine (i.e., the washing machine or the drying machine) main body 110 is placed and fixed onto an upper surface of the pedestal 200 .
Here, the washing machine as an example of the washing/drying machine 100 may include the main body 110 forming an external appearance, a tub (not shown) disposed inside the main body 110 in a horizontal direction so as to be dampered (attenuated) and for receiving water therein, a drum 113 rotatably mounted inside the tub for receiving clothes therein, and having a plurality of through-holes 113 a at an outer surface thereof so as to pass water or foam therethrough, a plurality of lifters 113 b mounted at an inner surface of the drum 113 and lifting laundry such that the laundry is dropped at a certain height by gravity, and a motor (not shown) mounted rear the tub for rotating the drum 113 .
A main body cover (not shown) is disposed at the front surface of the main body 110 , and a base 120 is mounted at a lower surface of the main body 110 . A top plate 111 is mounted at the upper surface of the main body 110 .
An entrance opening, through which the laundry is introduced into or removed from the drum 113 , is formed in the main body cover, and a door 112 for opening/closing the entrance opening is rotatably mounted at one side of the entrance opening. A gasket 114 for attenuating an impact by a rotation of the drum 113 as well as serving as a packing to prevent water from overflowing is installed between the tub and the door 112 .
A height adjustable leg 121 for supporting a load of the washing/drying machine (i.e., the washing machine) main body 110 is mounted at each of four corners of the base 120 so as to be ascendable or descendable.
The legs 121 are coupled to the base 120 by a coupling means such as screws, or the like. If the legs 121 are rotated in one direction, the legs 121 are configured to protrude from the base 120 , thereby increasing an installation height of the washing/drying machine 100 . If the legs 121 are rotated in another direction, the legs 121 are configured to be inserted into the base 120 , thereby reducing the installation height of the washing/drying machine 100 .
The pedestal 200 may include the box-shaped housing 210 formed to have an area enough to place the washing/drying machine 100 thereon, and a drawer 222 openably disposed at a front surface of the housing 210 so as to receive a variety of items inside the housing 210 .
The housing 210 and the drawer 222 may be formed of an injection molded plastic.
The supporter 230 for fixing the legs 121 of the washing/drying machine 100 may be installed at each of the four corners of the upper surface of the housing 210 , and a leg (not shown) for supporting the load of the washing/drying machine 100 and the pedestal 200 as well as for adjusting the height of the pedestal 200 may be installed at each of the four corners of the lower surface of the housing 210 .
The drawer 222 may include a front surface portion 221 disposed at the front surface of the housing 210 and having a handle 223 , and a receiving portion 220 formed at a rear surface of the front surface portion 221 for receiving a variety of items therein and openably disposed inside the housing 210 .
Accordingly, the pedestal 200 serves as a supporter of the washing/drying machine 100 as well as a container for receiving a variety of items required when using the washing/drying machine 100 , such as a detergent, a fabric conditioner, a bleach, maintenance tool, cleaning tool, and the like.
Referring to FIGS. 3 and 4 , the supporters 230 are mounted at the upper surface of the housing 210 of the pedestal 200 , and preferably, at each of the four corners of the upper surface thereof.
The supporter 230 may include a main body 240 having leg holes 231 , 232 for mounting the legs 121 of the washing/drying machine 100 as an object to support thereon, and a plurality of coupling ribs 233 disposed at one side of the main body 240 and for coupling the washing/drying machine 100 and the main body 240 to each other.
Here, if the washing/drying machine 100 is the washing machine, first leg holes 231 for mounting the legs 122 of the washing machine may be provided. If the washing/drying machine 100 is the drying machine, second leg holes 232 for mounting the legs 123 of the drying machine may be provided. If the washing/drying machine 100 is a refresher, etc., other than the washing machine or the drying machine, leg holes for receiving the legs of the refresher may also be provided. That is, the first and second leg holes 231 , 232 are not meant to be applied only to the washing machine and the drying machine. Therefore, preferably, at least two or more leg holes 231 , 232 are provided for a general use of the supporters 230 .
The plurality of supporters 230 may be divided into front supporters 230 ′ mounted at the front of the upper surface of the housing 210 , and rear supporters 230 ″ mounted at the rear of the upper surface thereof. Here, the front supporters 230 ′ include the leg holes 231 , 232 communicated with each other, and are respectively mounted at both sides of the front end of the upper surface of the housing 210 . The rear supporters 230 ″ include the leg holes 231 , 232 separated from each other, and are respectively mounted at both sides of the rear end of the upper surface of the housing 210 .
Here, the reason why the leg holes 231 , 232 of the front supporters 230 ′ and the rear supporters 230 ″ have a different configuration is that positions of each leg are different in the washing/drying machine 100 having the main body 110 of the same size.
For instance, if the washing/drying machine 100 is the washing machine and the drying machine, the front legs of the washing machine and the front legs of the drying machine are overlapped to each other. However, the rear legs of the washing machine and the rear legs of the drying machine are not overlapped to each other. Accordingly, the leg holes 231 , 232 of the front supporters 230 ′ should be communicated to each other, and the leg holes 231 , 232 of the rear supporters 230 ″ should be separated from each other, thereby being able to be used in both the washing machine and the drying machine.
Here, such described configurations of the leg holes are not meant to be limiting, and the shape of the leg holes 231 , 232 may be changed according to the shape of the legs of the washing/drying machine 100 to be used.
In addition, the leg holes 231 , 232 may be formed to have different depths or sizes. This is to receive a variety of leg shapes as much as possible even though a thickness, a diameter or a size of the legs 121 are all different according to the type of the washing/drying machine 100 , thus to enable the components to be widely (generally) used.
Meanwhile, if the leg holes 231 , 232 are formed to have the same depth, a separate member (e.g., a sheet-shaped washer) may be mounted at the legs 121 , so that the depth of the leg holes 231 , 232 and the height of the legs 121 can be adjusted.
In addition, at least one of the leg holes 231 , 232 may be formed to be open. That is, some of the leg holes 231 , 232 may have a covered upper portion, and others may remain in an opened state. This may prevent the legs 121 of the washing/drying machine 100 from being seen outside. Further, the washing/drying machine 100 may be firmly mounted at the pedestal 200 by stopping (locking) the legs 121 of the washing/drying machine 100 by the covered portion of the leg holes 231 , 232 .
Meanwhile, the leg holes 231 , 232 may be formed at the upper surface of the housing 210 in a diagonal direction. Such arrangement of the leg holes 231 , 232 may be determined by an arrangement of the legs 121 of the washing/drying machine 100 to be used.
Description of the supporters 230 will be given in detail.
As shown in FIG. 4 , the supporter 230 may include the main body 240 having an approximately rectangular or fan shape, and the leg holes 231 , 232 formed at a central portion of the main body 240 . Here, the leg holes 231 , 232 may be formed to be communicated or separated, as described above.
When the supporters 230 are mounted at the upper surface of the housing 210 of the pedestal 200 , the coupling ribs 233 are formed at a first side surface 230 a and a second side surface 230 b each corresponding to the corners of the housing 210 . That is, it is effective that the coupling rib 233 is formed at an edge of the supporter 230 so as to correspond to an edge of the upper surface of the housing 210 .
Preferably, the coupling rib 233 is formed at each of the first side surface 230 a and the second side surface 230 b . However, two or more coupling ribs 233 may be formed at each of the side surfaces 230 a , 230 b in consideration of a size of the pedestal 200 , or a size and a load of the washing/drying machine 100 to be mounted on the pedestal 200 , and the like.
Preferably, the coupling ribs 233 are disposed inside the side surfaces 230 a , 230 b with a stepped portion 237 from the first and second side surfaces 230 a , 230 b . This is to prevent a screw head or a bolt head from being more protruded than the side surfaces 230 a , 230 b when a coupling means such as a screw, a bolt, etc. is mounted at the coupling holes 234 formed at the coupling ribs 233 for coupling to the washing/drying machine 100 .
In addition, coupling holes 235 of the coupling means to mount the supporter 230 to the pedestal 200 are formed at the main body 240 at almost the right angle to the coupling ribs 233 . It is effective that, in consideration of a thickness of a head of the coupling means, a portion where the coupling holes 235 are formed is positioned inside the surface of the supporter main body 240 .
At least one reinforcing rib 236 is disposed at the rear of the leg holes 231 , 232 . This reinforcing rib 236 is to prevent a reduction of rigidity of the leg holes 231 , 232 in the rear direction as well as to reduce an amount of the injection-molded plastic used to manufacture the supporter 230 . That is, the amount of injection-molded plastic of the supporter 230 may be reduced by having a relatively thinner thickness of the portion except the reinforcing rib 236 .
Here, the coupling ribs 233 are respectively disposed at the first and second side surfaces 230 a , 230 b in parallel, however, the coupling ribs 233 may also be disposed perpendicular to the first and second side surfaces 230 a , 230 b . This is because a shape of the coupling rib 233 is determined by a shape of the rib of the washing/drying machine 100 coupled to the coupling rib 233 .
Hereinafter, description of a base of the washing/drying machine 100 coupled to the coupling ribs 233 will be given in detail.
FIG. 5 is an exploded perspective view showing a base mounted at the washing/drying machine in FIG. 2 , FIG. 6 is a perspective view showing a state that the base in FIG. 5 is coupled to the supporter, and FIG. 7 is a perspective view showing another exemplary base in FIG. 5 .
Referring to FIG. 5 , height-adjustable legs 121 are respectively mounted at four corners of a base 120 , and base ribs 122 are respectively formed at both sides of the leg 121 . The base ribs 122 include coupling holes 123 to be communicated with the coupling holes 234 at the coupling ribs 233 of the supporter 230 .
In order for the washing/drying machine 100 to be mounted at the pedestal 200 , the supporter 230 is disposed between the washing/drying machine 100 and the pedestal 200 , and then a coupling means (e.g., a screw, etc.) is mounted at the coupling holes 123 , 234 in a state that the coupling ribs 233 of the supporter 230 and the base ribs 122 are aligned with each other.
FIG. 6 illustrates that the washing/drying machine 100 , the supporter 230 and the pedestal 200 are coupled together by using the coupling ribs 122 , 233 .
Referring to FIG. 6 , the coupling ribs 233 of the supporter 230 are positioned outside the base ribs 122 , and the coupling means (e.g., a screw, etc.) is mounted at the coupling holes 123 , 234 , thereby coupling the coupling ribs 233 and the base ribs 122 to each other. With this configuration, the coupling ribs 122 , 233 cannot protrude more than the surface of the washing/drying machine 100 or the pedestal 200 , thus to provide a good outer aspect. Besides, there is no need to use a separate component such as a bracket, etc. for mounting the washing/drying machine 100 or the pedestal 200 to the supporter 230 .
To be certain, the base ribs 122 may be positioned outside the coupling ribs 233 of the supporter 230 .
The base 120 , as shown in FIG. 5 , is formed to have a honeycomb or grid shape, and a base 120 ′, as shown in FIG. 7 , may be formed to have a plate shape having base ribs 122 ′. Such described shape of the base 120 , 120 ′ may be changed according to the washing/drying machine 100 .
As described above, by using the coupling ribs 122 of the base 120 , the pedestal 200 may be commonly used in a variety of the washing/drying machine 100 including the washing machine and the drying machine, without a separate coupling member (e.g., a bracket, etc.).
Meanwhile, the present applicant has described the washing machine and the drying machine as an example of the washing/drying machine, however, without being limited thereto, the washing/drying machine may also include other types of washing/drying machine, such as an integrated washing system, a refresher equipped with a wrinkle reduction function, and the like.
In addition, the configuration that the washing/drying machine is installed on the pedestal having the supporter therebetween has been described, however, without being limited thereto, the washing/drying machine may be disposed in a vertical direction having the supporter therebetween. For instance, the drying machine is disposed above the washing machine, and the drying machine to be placed on the washing machine may be fixed by using the supporter according to the present invention. Alternatively, the washing machine is disposed above the drying machine, and the washing machine to be placed on the drying machine may be fixed by using the supporter according to the present invention. In addition, a front loading type washing/drying machine has been described, however, a top loading type washing/drying machine is also included in the scope of the present invention.
The foregoing embodiments and advantages are merely exemplary and are not to be construed as limiting the present disclosure. The present teachings can be readily applied to other types of apparatuses. This description is intended to be illustrative, and not to limit the scope of the claims. Many alternatives, modifications, and variations will be apparent to those skilled in the art. The features, structures, methods, and other characteristics of the exemplary embodiments described herein may be combined in various ways to obtain additional and/or alternative exemplary embodiments.
As the present invention may be embodied in several forms without departing from the characteristics thereof, it should also be understood that the above-described embodiments are not limited by any of the details of the foregoing description, unless otherwise specified, but rather should be construed broadly within its scope as defined in the appended claims, and therefore all changes and modifications that fall within the metes and bounds of the claims, or equivalents of such metes and bounds are therefore intended to be embraced by the appended claims.
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Disclosed is the washing/drying machine having a pedestal, including: a washing/drying machine main body performing a washing or drying operation of laundry; and a pedestal for mounting the main body thereon, wherein a base having legs is coupled at a lower end of the main body, and a supporter having coupling ribs for fixing the base to the pedestal is mounted at an upper surface of the pedestal, thereby preventing a damage to the surface of the pedestal or the washing/drying machine and facilitating mounting/dismounting the supporter or the pedestal.
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This is a continuation of application Ser. No. 499,275, filed Aug. 21, 1974, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to improvements in a new process for producing electric cables developed by the present inventors.
The new process referred to above is a novel process for producing electric cables having an insulating layer of a cured polymeric material by using a horizontal forming and curing zone and is operable at higher speeds than the conventional V.C.V. process, the cured polymeric insulating layer being free from voids.
According to the new process, a curable polymeric material supplied onto a conductor by an extruder or the like is formed and hot-cured by a long-land die, which is from about 1 to 50 m or more in length. To the inner surface of this die, a specific forming coagent is continuously applied, and the hot-cured insulating layer formed on the conductor is then cooled with a high-pressure cooling fluid in a cooling zone attached to the exit of the long-land die. Usable as the forming coagent in this process are those coagents described in the pending application of M. Fuwa et al, Ser. No. 212,049, filed Dec. 27, 1971, now U.S. Pat. No. 3,928,525, issued Dec. 23, 1975 and assigned to the applicants' assignees.
Although the above described new process for producing cables is satisfactory in the case of producing thin wall insulating cables or cured rubber insulating cables, serious difficulties, such as roughening of the surface of the resultant cables or lowering of the break-down voltage thereof, tend to occur when thick wall, cured-polyolefin insulting cables of voltage rating of 154 KV or 275 KV are to be produced with the use of a curable polymeric material such as polyolefin containing a curing agent, and in some cases the production thereof must be interrupted because of constantly increasing severity of the roughness of the surface of the cable.
As a result of intense studies directed toward clarifying the reason for the above described difficulties, we have found that the melted uncured polyolefin undergoes a viscous flow, which is sharply different from rubber-like compositions undergoing a plug flow, and that when the thick wall insulating cables are produced, the thick layer of polyolefin flowing through the long-land die tends to undergo an abrupt change in direction within a portion of the die ranging from the tapered portion to the land portion. For these reasons, the flowing speed of a part of the flowing layer of polyolefin is slackened along the inner surface at the entrance of the land portion. The slackened layer of the polyolefin is scorched in a very short period and the inner surface of the land portion is encrusted with scorched polyolefin. The scorched polyolefin destroys the molding ability of the land portion, and the outer surface of the cable thus produced is caused to be damaged by the scorched polyolefin on the land portion, and the breakdown voltage of the cable is thereby lowered.
Frequently, the scored polyolefine hampers and further slackens the flow of polyolefin layer near the inner surface of the land portion, the scorching of polyolefin thereby being accelerated, and the production of the cable is ultimately interrupted.
The creation of the scorched polyolefin on the inner surface of land portion depends much on the position at which the forming coagent is introduced into the inner surface of the die. In the previously described new process, the forming coagent has been supplied to the land portion of the long-land die. In this improved process, however, the forming coagent is supplied to the tapered portion of the long-land die, whereby the slackening in the flow and scorching of a part of the polyolefin are thereby prevented, and large-sized cables insulated with a thick wall of cured polyolefin and of high quality and high breakdown voltage can be produced continuously for a long period of time.
SUMMARY OF THE INVENTION
The present invention has been accomplished on the basis of the novel findings described above.
An object of this invention is to provide an improved process for producing electric cables with a long-land die.
Another object of the invention is to provide an improved process and apparatus whereby large-sized cables insulated with a thick wall of cured-polyolefin of a high quality and high breakdown voltage can be produced in a stable manner for a long period of time with polyolefin containing a curing agent used as the curable polymeric material.
BRIEF DESCRIPTION OF THE DRAWING
In the accompanying drawing, the single FIGURE is a side view, partly in longitudinal section, showing an apparatus according to the present invention for producing cables having a thick insulating layer made of a cured-polyolefin.
DETAILED DESCRIPTION OF THE INVENTION
The curable polymeric material to be used in this invention predominantly consists of an polyolefin and further contains a curing agent admixed therewith.
Preferable examples of the polyolefins are polyethylene, polypropylene, polybutene-1 and like poly-α-olefins; and ethylene-vinyl acetate, ethylene-ethylacrylate and like copolymers of poly-α-olefins, especially polyethylene.
Examples of the curing agent to be added to the polyolefin in this invention are those generally used as such and include ditertiary butyl peroxide, tertiary-butylcumyl peroxide, dicumyl peroxide, 1,3-bis-(tertiary-butylperoxy-isopropyl) benzene, 2,5-dimethyl-2,5-di(tertiary-butylperoxy)hexane, 2,5-dimethyl-2,5-di (tertiary-butylperoxy) hexyne-3, 1,1-ditertiary-butylperoxy-3,3,5-trimethylcyclohexane and like dialkyl peroxides.
The curing agent is used in an amount of about 0.1 to 10 parts by weight per 100 parts by weight of the polyolefin. Where desired, the curable polymeric material may further contain a conventional curing accelerator, curing coagent, anti-aging agent, lubricant, pigment, voltage stabilizer, filler, etc..
The present invention will be described below in greater detail with reference to the drawings showing an apparatus suitable for practicing the present process.
In the apparatus for practicing the process according to this invention, a polyolefin compound 10 mixed with a curing agent, which is supplied from a separately provided extruder (not shown), is fed into an extruding head 1 and passed successively through an annular space formed between the inner surfade of the extruder head 1 and a nipple 2 and another annular space formed between the tapered portion 3 c and the nipple 2 through which an electric conductor 11 is continuously fed, and thereafter the conductor is coated with said polyolefin compound as will be hereinafter described in more detail.
The number of the extruders to be used may amount to several, for example, three, each as described in the example set forth below, according to the number of polyolefin layers to be coated onto the conductor.
The extruder head (or a cross-head) 1 is provided at a downstream side thereof with a long-land die 3 which in turn comprises a first member 3 a and a second member 3 b forming a tapered portion 3 c in the inner bore when the two members are assembled together as described hereinafter in more detail.
Thus, the polyolefin compound 10 mixed with a curing agent fed into the annular passage around the extruding core 2 is passed into the tapered bore portion 3 c of the long-land die 3 and then to the space around the conductor 11 continuously supplied through the nipple 2 at a constant speed. The conductor 11 thus coated by the polyolefin compound 10 which is cured in the long-land die 3 is then passed into a pressurized cooling device (not shown) connected directly to the outlet end of the long-land die 3. The entire length of tapered portion 3 c , that is, the distance between its upstream end and its downstream end, is usually about 50 mm to about 200 mm.
The first member 3 a of the long-land die 3 has at its upstream end a flange portion which is forced into contact with the downstream side surface of the second member 3 b fixed to the main body of the extruding head 1 by a die holder 4. An annular gasket 5 is disposed between the contacting surfaces of the first and second members 3 a and 3 b so that a pressure-tight seal is obtained between the two members.
Radially inwardly of the annular gasket 5, an annular reservoir 7 and annular gap 8 are provided between the confronting surfaces of the first and second members, and a forming coagent 12 is introduced through a hole 6 provided in the die holder 4, the annular reservoir 7, and the annular gap 8, to the tapered bore portion 3 c of the long-land die 3. The forming coagent thus supplied to the taper portion spreads all over the inner surface of long-land die located downstream of the gap to facilitate the smooth passing of the conductor 11 with polyolefin layer thereon.
The reservoir 7 is formed by an annular recess formed in the surface of the second member 3 b and by the confronting side surface of the first member 3 a at a position inward from the annular gasket 5, and the annular gap 8 is formed between the confronting surfaces of the two members radially inwardly from the annular reservoir 7. The gap 8 is selected in a range of from about 0.005 mm to about 1 mm, preferably from about 0.01 mm to about 0.5 mm. The forming coagent is described in copending application Ser. No. 212,049 by M. Fuwa et al, filed Dec. 27, 1971, now U.S. Pat. No. 3,928,525. The forming coagent must satisfy the following four requirements.
(1) Having a viscosity of 0.5 to 3,000 centistokes at 235° C.
(2) Be not more than 100 mg./cm. 2 in its absorption ratio to the curable polymeric material at 150° C. for 45 hours.
(3) Be free of gelation when in contact with the organic peroxide in the curable polymeric material.
(4) Not be boiled during curing of the curable polymeric material.
The above-mentioned absorption ratio is determined by immersing a cured sheet (30 mm × 30 mm × 1 mm) made from the curable material to be employed in the forming coagent to be used at 150° C for 45 hours. The sheet is weighed before and after the immersion, and the difference between both weights divided by the total surface area of the sheet before immersion gives the absorption ratio.
Gelation of the coagent under normal operational conditions is determined according to a test which comprises placing a mixture of 10 parts by weight of a forming coagent and 1 part by weight of an organic peroxide in a sealed vessel provided with a mixer, heating the mixture at a rate of about 10° C. per minute up to 235° C, maintaining that temperature for 5 minutes, and subsequently measuring the viscosity (η 1 ) of the resultant liquid at 235° C. The original viscosity (η o ) of the forming coagent itself at 235° C is also measured. The forming coagents, having a ratio of η 1 /η o lower than 30, are considered not to gel for purposes of the present invention, and it is not expected to form any gelled film on the inner surface of long-land die in a continuous operation for at least several hours. When the organic peroxide is non-volatile, the heat treatment may be carried out in an open vessel. In the above test, it is not always necessary to use the organic peroxide that is actually admixed in the curable material. Other typical peroxides, for example, dicumyl peroxide, can be used without error in determination.
The quantity of the forming coagent supplied into the tapered portion 3 c of the long-land die is preferably in a range of from about 0.001 cc to about 0.1 cc per one cm 2 of the outer surface of the cables thus produced. Under the action of the forming coagent, the polyolefin composition 10 flows into the long-land die 3 without being slowed or becoming stagnant at the entrance of the long-land die and without being scorched onto the inner surface thereof at that portion, so that the polyolefin composition 10 coated on the electtic conductor 11 is sent along the long-land die with the outer surface thereof contacting smoothly along the inner surface of the long-land die.
The long-land die 3 is heated by any suitable heating device such as an electric heating device, a hot-oil jacket heating device, or the like, so that a temperature in a range of about 200° to about 300° C which is ample for thorough curing of the polyolefin composition is thereby attached. The polyolefin composition covering the conductor is thus cured completely while the covered conductor passes through the long-land die.
The length of the land portion of the long-land die 3 is varied in accordance with the thickness of the composition covering the conductor, the reaction temperature of the curing agent contained in the composition, the designed temperature of the long-land die, and the line speed of the conductor 11. In practice, the length of the land portion of the long-land die is preferably selected in a range of from about 5 m to about 30 m. The land portion of the long-land die 3 may comprise a plurality of shorter pieces of land portions which can be assembled together into a unitary land portion.
The outlet end of the long-land die 3 is connected directly to a pressurized cooling device (not shown) by, for instance, a flange coupling, and the cured insulating layer on the conductor 11 is introduced by the movement of the conductor into the pressurized cooling device at the instant of leaving the long-land die 3. The insulating layer is cooled while it passes through the pressurized cooling device containing a cooling fluid such as water. The pressurized cooling device may be any of those used with cable producing devices such as VCV, CCV, or HCV. The pressure of the cooling fluid is selected at a value at least about 7 kg/cm 2 , and preferably in a range of from about 10 kg/cm 2 to about 30 kg/cm 2 .
The exact position to which the forming coagent, according to the present invention, is supplied to the taped portion 3 c of the long-land die 3 may be selected between the upstream end of the tapered portion to the downstream end of the same portion. However, if the supplying position of the forming coagent is selected at the just downstream end of the tapered portion, no satisfactory result can be obtained. The reason for this is in that the just downstream end of the tapered portion, that is the transition position between the tapered portion to the portion of the land of constant inner diameter, is inherently a position where turbulence of flow of polyolefin tends to occur thereby causing stagnant flow and hence scorching of the polyolefin. And the tendency to turbulent flow is promoted by supplying a forming coagent to that transition point, or the just downstream end.
On the other hand, if the forming coagent is supplied to a position located upstream from the upstream end of the tapered portion, the forming coagent tends to be admixed into the polyolefin composition since turbulence in the flow of polyolefin is also severe at such a position. The admixing of the forming coagent in the pololefin composition tends to give rise to deterioration of the dielectric properties of the polyolefin composition. For the above stated reasons, a preferred position to which the forming coagent is supplied is in a range of from about 10 mm downstream from the upstream end of the tapered portion to about 2 mm upstream from the downstream end of the tapered portion.
In the example shown in the drawing, the forming coagent is supplied through the hole 6 into the annular reservoir 7, and from the reservoir 7 through the annular gap 8 to the inner surface of the tapered portion. However, the last stage of the passage of the forming coagent may further be modified in such a manner that the forming coagent is passed from the annular reservoir 7 to the inner surface of the tapered portion through a porous metal, which a part of the tapered portion of the long-land die 3 is fabricated. Such a porous metal is preferably made of sintered metal granules, the diameter of each granule being in a range of about 10 microns to 150 microns, and the thickness of the porous metal being in a range of about 5 mm to 20 mm.
For a better understanding of this invention, a comparative example and an illustrative example are given below, in which parts and percentages are all by weight. However, it is to be understood that these examples are not intended to limit the scope of the invention.
COMPARATIVE EXAMPLE
At a speed of 0.255 m/min., a stranded conductor having a sectional are of 2,700 mm 2 was, continuously passed through an electric cable manufacturing apparatus of the horizontal type comprising a conventional crosshead for simultaneously extruding three layers, a long-land die having one end connected to the crosshead and measuring 130 mm in diameter and 15 m in length, and a cooling apparatus connected to the other end of the die and having a length of 30 m. The long-land die comprised a tapered portion of 25 cm. in length converging in the downstream direction and a land portion of constant inner diameter contiguously adjoining the downstream end of the tapered portion and extending coaxially therefrom in the downstream direction. The long-land die was maintained at 250° C by a heater provided around the long-land die, whilst a forming coagent ("Unilube 75DE-2620," product of Nippon Oils & Fats Co., Ltd., Japan of a viscosity at 235° C of 425c st., absorption ratio to cured polyethylene at 150° C for 45 hours of 0.15 mg/cm 2 , B. P. above 260° C, which is free of gelation when determined in accordance with the method before mentioned) was continuously supplied to the inner surface of the die at a rate of 40cc/min. from an annular gap (gap distance; 0.08 mm) set in the wall of the land portion at a point 10 cm downstream from the entrance of the land portion.
Through the use of three extruders, a semiconductive composition for shielding the conductor, an insulating composition, and a semiconductive composition for covering the insulating layer as described below were simultaneously extruded from the crosshead onto the conductor in three layers having thicknesses of 1.0 mm, 35.0 mm, and 1.0 mm, respectively. The covering layers were passed through the long-land die and then through the cooling apparatus along with the advancing conductor.
The semiconductive composition for shielding the conductor comprised 100 parts of ethylene-vinyl acetate copolymer (containing 20% of vinyl acetate), 50 parts of carbon black, and 2.0 parts of dicumyl peroxide. The insulating composition comprised 100 parts of polyethylene (density: 0.920, melt index: 1.0, melting point: 113° C as determined according to ASTM D-1238-65T, 2.0 parts of dicumyl peroxide, and 0.2 part of 4,4'-thio-bis(6-t-butyl-m-cresol). The insulation covering composition comprised 100 parts of ethylenevinyl acetate copolymer (containing 20% of vinyl acetate) and 50 parts of carbon black. The cooling apparatus was filled, throughout its entire length, with cooling water at 20° C under a pressure of 18 kg/cm 2 .
A cured polyethylene insulating cable rated at 275 KV of a length of 90 m was manufactured after 5 hours of the production operation. However, numerous longitudinal scars were found on the outer surface of the insulating coating of the cable, and the average A.C. long-term breakdown strength and average impulse breakdown strength of five specimens of the electric cable thus produced were 28 KV/mm and 65 KV/mm, respectively. (Each of the values of breakdown strength given below is an average value of five specimens).
After a production run of 5 hours, the long-land die was disassembled, and the entrance portion of the land portions was inspected. As a result of the inspection, scorched pieces of polyethylen were found to be adhering on substantially the entire inner surface portion 6 cm or more downstream from the upstream end or entrance of the tapered portion.
EXAMPLE 1
An electric cable was produced in the same manner as in comparative example 1 except that the forming coagent was supplied through an annular gap of 0.08 mm provided at an intermediate position of the tapered portion of a long-land die, whose entire length was 25 cm. After approximately 50 hours of continuous operation, a cable of 765 m and having neat outer surface was obtained.
The electric cable obtained had an A.C. long-term breakdown strength and impulse breakdown strength of 38 KV/mm and 85 KV/mm, respectively. Upon inspection of the disassembled long-land die after the production of cables for 50 hours, no scorched polyethylene was found on the inner surface of the entrance portion of the land portion.
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Electric cables insulated with a cured polyolefin and having high electrical breakdown strength are produced, in each instance, by applying, an insulating layer of polyolefin containing a curing agent onto a conductor by means of an extruder, forming and hot-curing said layer by means of a long-land die, simultaneously applying a specific forming coagent to a tapered portion of the long-land die, and cooling the resulting hot-cured insulating layer formed on the conductor in a cooling zone.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/618, 718 filed Mar. 31, 2012. Cross reference is also made to pending U.S. patent application Ser. No. 13/252,881 filed Oct. 4, 2011 which is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to supports for hanging articles, and more specifically to support frames designed for the consumer market which can be mounted on a clothing bar or shelf for the support of hanging clothing or other articles.
BACKGROUND OF THE INVENTION
[0003] Within the merchandising environment, various displays are used to hang articles such as clothing. The most common display means for hanging garments are clothing bars which are most typically straight or circular in order to display garments for sale. The clothing bars used in commercial environments typically have a rectangular profile while those available to the consumer market have a cylindrical profile. Certain commercial clothing bars may also employ support frames which are attached to the clothing bars in order to showcase or enable sorting garments by type. Although commercial bars have more structural variation than clothing bars manufactured for non-commercial use, because of proprietary design, parts associated with commercial assemblies such as support frames and other accessories are not interchangeable with systems from other makers or with clothing bars manufactured for the consumer market such as those often sold as part of a closet storage solution.
[0004] While support apparatus are known that attach to vertically oriented poles, a support apparatus for hanging garments and other articles which is quickly attachable to a horizontally positioned cylindrical clothing bar without requiring additional tools or fasteners would be a valuable accessory to any consumer closet system.
[0005] Moreover, a such a retrofittable support frame would be especially desirable if it were strong enough to support multiple articles without slipping, relocatable to any position along the bar and easily removable.
SUMMARY OF THE INVENTION
[0006] The present invention is directed to a garment support for hanging articles that is reversibly attachable to horizontal supports such as clothing bars, shelves and the like. One embodiment according to the present invention is mounted to a typical clothing bar so as to project from the bar in order to display articles such as garments from the front rather than the sides. The garment support is especially useful for planning wardrobe changes, selecting items that need to be dry cleaned and many other wardrobe related tasks.
[0007] Multiple garment supports can attach along a clothing bar or a length of shelving to provide additional hanging space.
[0008] In one aspect according to the present invention, the garment support possesses a support frame which is firmly attachable to a horizontal cylindrical clothing bar as an attachment surface.
[0009] In another aspect according to the present invention, the garment support possesses a support frame which is firmly attachable to an edge of a solid shelf as an attachment surface.
[0010] In yet another aspect according to the present invention, portions of the garment support are extendible.
[0011] Inclusive to all the foregoing aspects, the support frame is easily re-positionable along the attachment surface of whatever kind
[0012] The description as follows is not intended to limit the scope of the invention to the particular forms set forth, but on the contrary, it is intended to cover such alternatives, modifications, combinations and equivalents as may be included within the spirit and scope of the invention as set forth in the detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a perspective view of one embodiment according to the present invention for attachment to an edge of a shelf;
[0014] FIG. 1A is a perspective view of one exemplary pivot hinge;
[0015] FIG. 2 is a perspective view of another embodiment according to the present invention for attachment to a cylindrical clothing bar;
[0016] FIG. 3 is an enlarged perspective view of the embodiment shown in ( FIG. 2 ) for attachment to a cylindrical clothing bar;
[0017] FIG. 4 is a perspective view of another embodiment according to the present invention for attachment to a cylindrical clothing bar;
[0018] FIG. 5 is a perspective view of the embodiment shown in ( FIG. 4 ) with attachable shoulder supports.
DETAILED DESCRIPTION OF THE INVENTION
Reference listing:
[0019] 100 ′ garment support
[0020] 120 support frame
[0021] 122 attachment member
[0022] 122 a pad
[0023] 122 b collar
[0024] 124 pivot hinge
[0025] 126 tightening member
[0026] 128 stay
[0027] 130 bumper
[0028] 132 hook
Definitions
[0029] Unless otherwise explained, any technical terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. 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.
[0030] Referring generally to FIGS. 1-5 , a garment support 100 ′ for displaying garments includes a rigid support arm 120 with a attachment member 122 in which the support arm is secured generally perpendicularly to a horizontal structure such as a clothing bar 136 or shelf 138 . FIG. 1 depicts a support arm attached to a shelf edge with a pivot 124 which includes an aperture that a section of the support arm fits within to permit the arm to pivot away from a perpendicular orientation relative to the shelf edge. Clothing is hung on the arm and retained in place by stays 128 which can be any portion of the arm that prevents a hanger hook from sliding unimpeded along the frame. While in the particular embodiment shown, the stays are spherical members permanently affixed along the arm, it should be understood that other stays will suggest themselves top those having the skill in the art; for example, collars with a frictional fit that slide along a cylindrical or rod-shaped frame, or which are tightened at any point along the frame by set screws.
[0031] FIG. 2 shows another embodiment according to the present invention with a semi-cylindrical attachment member that rests over a clothing bar installed in a closet. In a normal use, the end of the frame with stays 128 projects outwardly from the clothing bar, while the opposite end of the arm 120 possesses a rubber bumper 130 braced against the rear wall of the closet. The bracing effect permits the clothing bar to support the weight of several garments facing out to assist in garment selection. FIG. 3 is an enlarged partial view of the embodiment shown in ( FIG. 2 ). The amount of arm projecting from either the front or back can be adjusted by adjusting tightening member 126 which is shown here as a set screw that when loosened permits the arm to slide back and forth through collar 122 b. Preferably, the attachment member is lined with a material 122 a of any suitably non-marring material such as a rubber or felt pad. In effect, the arm is supported superiorly to the closet rod and can be easily installed thereon and removed. Weight of the garments increases the inertia of the arm by forcing bumper 130 against a back wall or against the underside of a closet shelf
[0032] Another preferred embodiment shown in FIGS. 4 and 5 , is hung from a clothing rod by hook 132 . An upper portion of a frame is fixed, while the lower arm portions 120 telescope by sliding back and forth through collar 122 b similar to the embodiment shown in FIG. 2 . One arm segment is capped by bumper 130 which is for bracing against the back wall of a closet. Both arm segments can be rotated axially and extended/retracted by loosening thumbscrew 126 . FIG. 5 shows a pair of attachable shoulder supports 140 for the shielding of garments from projecting portions of the frame.
[0033] While the invention has been described by the particular embodiments given, it is not intended that the scope of the invention be limited to the particular forms set forth. For example, the attachment member can be combined with any one of the support frames shown. The attachment member can be a spring clip or other clamping means that will suggest themselves to those skilled in the art. Whatever the attachment means to the clothing bar, it is intended that the garment support resist side to side movement experienced by conventional closet hangers. Accordingly, the invention is intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as described and shown in the disclosure.
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A system for the display and support of apparel includes a support arm which is attached to an horizontal surface such as a clothing bar or shelf The support arm extends perpendicularly relative to the horizontal surface such that hanging apparel hung from the support arm is displayed with its front showing rather than from the side.
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[0001] The present application claims priority under 35 U.S.C. §119 to Korean Patent Application No. 10-2008-0137599 (filed on Dec. 30, 2008), which is hereby incorporated by reference in its entirety.
BACKGROUND
[0002] A packaging technique for a semiconductor integrated device is continuously developed with demands for miniaturization and high capacity. In recent years, various techniques for stack package satisfying miniaturization, high capacity, and packaging efficiency are developed. In the semiconductor industry, the term “stack” refers to a technique for piling up at least two semiconductor chips or packages. This technique ensures implementation of products having memory capacity larger than memory capacity which can be implemented in a process for integrating a semiconductor in a memory device and an increase in use efficiency of a packaging area.
[0003] In accordance with the manufacturing technique, a stack package is classified into a method of stacking individual semiconductor chips and then packages the stacked semiconductor chips at a time and a method of stacking individually packaged semiconductor chips. In general, the stack package is electrically connected through metal wires or a through silicon via.
[0004] A stack package using metal wires has at least two semiconductor chips stacked on a substrate through an adhesive, and the respective chips and the substrate are electrically connected to each other through the metal wire. However, in the stack package using the metal wires, electrical signals are exchanged through the metal wire, which leads to a low operation speed, requires a large number of wires, and consequently causes deterioration in the electrical characteristics of the chips. Further, to form the metal wires, an additional area is required on the substrate, which causes an increase in the package size. In addition, a gap needs to be provided for wire-bonding to the bonding pads of the respective chips, which results in an increase in the total height of the package.
[0005] To overcome these problems in the stack package using the metal wires, a stack package structure using a through electrode is proposed for preventing deterioration in the electrical characteristics of the stack package and reduction in size.
[0006] FIG. 1 is a sectional view illustrating a stack package using a through electrode.
[0007] As illustrated in FIG. 1 , in the stack package using through electrodes, first semiconductor chip 10 is disposed at a bottom surface thereof and then second semiconductor chip 20 having through electrode 21 formed therein is stacked on and/or over first semiconductor chip 10 . In this case, a metal wire of first semiconductor chip 10 and through electrode 21 of second semiconductor chip 20 are bonded to each other by bumps 41 and bonding agent 43 . Third semiconductor chip 30 having through electrode 31 formed therein is stacked on and/or over second semiconductor chip 20 . Through electrode 31 of third semiconductor chip 30 is electrically connected to through electrode 21 of second semiconductor chip 20 or the metal wire by bumps 41 or bonding agent 43 . In this way, in the stack package using the through electrodes, electrical connection is made through the through electrodes. Therefore, electrical deterioration can be prevented, such that the operation speed of the semiconductor chips can be enhanced and miniaturization can be achieved.
[0008] The through electrode refers to a via of tens or hundreds rim. Accordingly, to form a through electrode of such size, it takes a lot of time and costs to the extent of several or tens times as much as a general semiconductor process. Moreover, yield is considerably low due to defects occurring when the through electrode is formed, defects when the devices are connected to each other through the bumps, and the like. Three or more devices are consumed due to one defect occurring during packaging, which causes an increase in the process costs of the products.
SUMMARY
[0009] Embodiments relates to a semiconductor package apparatus and a method of manufacturing the same that integrates a plurality of semiconductor devices without through electrode.
[0010] Embodiments relate to a semiconductor package apparatus and a method of manufacturing the same that does not require a through electrode needs to be formed, thereby preventing the occurrence of defects caused by the through electrode.
[0011] Embodiments relate to a semiconductor package apparatus and a method of manufacturing the same that simplifies the structure of the semiconductor chip, reduces the overall process time enhances overall production yield.
[0012] In accordance with embodiments, a semiconductor package apparatus can include at least one of the following: a first semiconductor chip bonded to a substrate with a metal wire turning upward, a second semiconductor chip conductively bonded to the first semiconductor chip in a vertical direction such that a metal wire of the second semiconductor chip and the metal wire of the first semiconductor chip have facing points, and a third semiconductor chip conductively bonded to the first semiconductor chip in a vertical direction so as to be disposed horizontally with respect to the second semiconductor chip such that a metal wire of the third semiconductor chip and the metal wire of the first semiconductor chip have facing points.
[0013] In accordance with embodiments, a method of manufacturing a semiconductor package apparatus can include at least one of the following: bonding a first semiconductor chip to a substrate with a metal wire turning upward, conductively bonding a second semiconductor chip to the first semiconductor chip in a vertical direction such that a metal wire of the second semiconductor chip and the metal wire of the first semiconductor chip having facing points, and then conductively bonding a third semiconductor chip to the first semiconductor chip in the vertical direction so as to be disposed horizontally with respect to the second semiconductor chip such that a metal wire of the third semiconductor chip and the metal wire of the first semiconductor chip having facing points.
[0014] In accordance with embodiments, a semiconductor package apparatus can include at least one of the following: a first semiconductor chip having bonded to a substrate; a first wire formed in the first semiconductor chip; a second semiconductor chip conductively bonded to the first semiconductor chip; a second wire formed in the second semiconductor chip, wherein the second metal wire of the second semiconductor chip is bonded to the first metal wire of the first semiconductor chip; a third semiconductor chip conductively bonded to the first semiconductor chip; and a third wire formed in the third semiconductor chip, wherein the third metal wire of the second semiconductor chip is bonded to the first metal wire of the first semiconductor chip.
[0015] In accordance with embodiments, a semiconductor package apparatus can include at least one of the following: a substrate; a first semiconductor chip bonded to the substrate, the first semiconductor chip having a first metal wire formed therein; a second semiconductor chip conductively bonded to the first semiconductor chip, the second semiconductor chip having a second metal wire formed therein; and a third semiconductor chip conductively bonded to the first semiconductor chip such that the third semiconductor chip is disposed laterally relative to the second semiconductor chip, the third semiconductor chip having a third metal wire formed therein, the second semiconductor chip being conductively bonded to the first semiconductor chip at an interface between the first metal wiring and the second metal wiring and the third semiconductor chip being conductively bonded to the first semiconductor chip at an interface between the first metal wiring and the third metal wiring.
[0016] In accordance with embodiments, a semiconductor package apparatus can include at least one of the following: a substrate; a first semiconductor chip having a plurality of first metal wires formed therein, the first semiconductor chip being bonded to the substrate at a first surface of the first semiconductor chip such that a second surface of the first semiconductor chip is exposed; a second semiconductor chip having a plurality of second metal wires formed therein that are spatially aligned and corresponds to a first set of the first metal wires, the second semiconductor chip being conductively bonded to the first semiconductor chip at the exposed second surface of the first semiconductor chip and at an interface between the second metal wires and the first metal wires; and a third semiconductor chip having a plurality of third metal wires formed therein that are spatially aligned and corresponds to a second set of the first metal wires, the third semiconductor chip being conductively bonded to the first semiconductor chip at the exposed second surface of the first semiconductor chip on the same plane as the second semiconductor chip and at an interface between the third metal wires and the first metal wires.
DRAWINGS
[0017] FIG. 1 illustrates a stack package using through electrodes.
[0018] Example FIGS. 2A to 7 illustrate a method of manufacturing a semiconductor package and a bonding structure of semiconductor chips, in accordance with embodiments.
DESCRIPTION
[0019] Hereinafter, embodiments will be described in detail with reference to the accompanying drawings which form a part hereof.
[0020] Example FIGS. 2A to 2C are views illustrating a method of manufacturing a semiconductor package apparatus in accordance with embodiments.
[0021] First, the structure of a semiconductor package apparatus in accordance with embodiments will be described with reference to example FIG. 2C .
[0022] As illustrated in example FIG. 2C , the semiconductor package apparatus includes first semiconductor chip 120 having at least a first metal wire formed therein. First semiconductor chip 120 is bonded to substrate 110 at a first surface thereof such that a second surface thereof is exposed.
[0023] Second semiconductor chip 130 has at least a second metal wire formed therein. Second semiconductor chip 130 is conductively bonded to first semiconductor chip 120 at the exposed second surface of first semiconductor chip 120 . Particularly, second semiconductor chip 130 is conductively bonded to first semiconductor chip 120 at interface 201 between the second metal wire of second semiconductor chip 130 and the first metal wire of first semiconductor chip 120 .
[0024] Third semiconductor chip 140 has at least a third metal wire formed therein. Third semiconductor chip 140 is conductively bonded to first semiconductor chip 120 at the exposed second surface of first semiconductor chip 120 . Particularly, third semiconductor chip 130 is conductively bonded to first semiconductor chip 120 at interface 201 between the third metal wire of third semiconductor chip 140 and the first metal wire of first semiconductor chip 120 . Accordingly, second semiconductor chip 130 and third semiconductor chip 140 are conductively bonded to first semiconductor chip 120 such that they are disposed laterally adjacent to each other.
[0025] Details of a process for manufacturing a semiconductor package apparatus configured as above will be described.
[0026] As illustrated in example FIG. 2A , first semiconductor chip 120 is bonded to substrate 110 in a vertical direction. First semiconductor chip 120 is bonded to substrate 110 at a first surface of first semiconductor chip 120 such that a second surface of first semiconductor chip 120 is exposed. Particularly, first semiconductor chip 120 is disposed such that the first metal wire formed therein is exposed. Substrate 110 and first semiconductor chip 120 may be bonded to each other using, e.g., resin or epoxy.
[0027] As illustrated in example FIG. 2B , second semiconductor chip 130 is conductively bonded to first semiconductor chip 120 in a vertical direction. Second semiconductor chip 130 is conductively bonded to first semiconductor chip 120 at the exposed second surface of first semiconductor chip 120 . Second semiconductor chip 130 is disposed such that the second metal wire formed therein corresponds spatially to the first metal wire of first semiconductor chip 120 . Second semiconductor chip 130 is conductively bonded to first semiconductor chip 120 at interface 201 between the second metal wire of second semiconductor chip 130 and the first metal wire of first semiconductor chip 120 . The bonding method between first semiconductor chip 120 and second semiconductor chip 130 may be implemented in various ways, and will be described below with reference to example FIGS. 3 to 7 .
[0028] As illustrated in example FIG. 2C , third semiconductor chip 140 is conductively bonded to first semiconductor chip 120 in a vertical direction such that it is disposed laterally with respect to second semiconductor chip 130 and vertically with respect to first semiconductor chip 120 . Third semiconductor chip 140 is conductively bonded to first semiconductor chip 120 at the exposed second surface of first semiconductor chip 120 . Third semiconductor chip 140 is disposed such that the third metal wire formed therein corresponds spatially to the first metal wire of first semiconductor chip 120 . Third semiconductor chip 140 is conductively bonded to first semiconductor chip 120 at interface 201 between the third metal wire of third semiconductor chip 140 and the first metal wire of first semiconductor chip 120 . The bonding method between first semiconductor chip 120 and third semiconductor chip 140 may be implemented in various ways, and will be described below with reference to example FIGS. 3 to 7 .
[0029] As described above, with the method of manufacturing a semiconductor package apparatus in accordance with embodiments, first semiconductor chip 120 is first bonded to substrate 110 . Accordingly, even if second semiconductor chip 130 and third semiconductor chip 140 are different in thickness, a semiconductor package apparatus can be manufactured by vertical and horizontal adhesion.
[0030] In accordance with embodiments, since second semiconductor chip 130 and third semiconductor chip 140 , i.e., other than first semiconductor chip 120 as a reference, are present in a form of flip chips, second semiconductor chip 130 and third semiconductor chip 140 can be electrically connected directly to first semiconductor chip 120 at the same exposed surface of first semiconductor chip 120 . Therefore, no formation of one or more through electrodes is required.
[0031] Therefore, in accordance with embodiments, since no through electrode needs to be formed, defects that may occur when a through electrode is formed can be prevented, the structure of the semiconductor chip can be simplified, and a process time can be reduced, which ensures enhanced in yield.
[0032] Example FIGS. 3 to 7 are sectional views illustrating the bonding structure of semiconductor chips in accordance with embodiments.
[0033] Example FIG. 3 is a sectional view illustrating the bonding structure of semiconductor chips in accordance with embodiments.
[0034] As illustrated in example FIG. 3 , first semiconductor chip 311 , second semiconductor chip 312 , third semiconductor chip 312 , conductive film 313 and a metal ball 314 are provided. The metal wires of two of the semiconductor chips can be conductively bonded to each other using conductive film 313 and metal ball 314 . Metal ball 314 may be composed of Au.
[0035] Example FIG. 4 is a sectional view of the bonding structure of semiconductor chips in accordance with embodiments.
[0036] As illustrated in example FIG. 4 , first semiconductor chip 321 , second semiconductor chip 322 , third semiconductor chip 322 , conductive film 323 , metal bumps 324 and anisotropic conductive film (ACF) 325 are provided. The metal wires of two of the semiconductor chips using conductive film 323 , metal bumps 324 and ACF 325 are conductively bonded together. Metal bumps 324 can be composed of Au bump.
[0037] Example FIG. 5 is a sectional view illustrating a bonding structure of semiconductor chips in accordance with embodiments.
[0038] As illustrated in example FIG. 4 , first semiconductor chip 331 , second semiconductor chip 332 or third semiconductor chip 332 , conductive film 333 , metal bump 334 , and photopolymerizable resin 335 are provided. The metal wires of two of the semiconductor chips can be conductively bonded to each other using conductive film 333 , metal bump 334 , and photopolymerizable resin 335 . Metal bump 334 can be composed of Au and photopolymerizable resin 335 can be composed of an ultraviolet (UV) curable resin.
[0039] Example FIG. 6 is a sectional view illustrating a bonding structure of semiconductor chips in accordance with embodiments.
[0040] As illustrated in example FIG. 6 , first semiconductor chip 341 , second semiconductor chip 342 or third semiconductor chip 342 , conductive film 343 , and conductive particles 344 are provided. The metal wires of two of the semiconductor chips can be conductively bonded to each other using conductive film 343 and conductive particle 344 .
[0041] Example FIG. 7 is a sectional view illustrating a bonding structure of semiconductor chips in accordance with embodiments.
[0042] As illustrated in example FIG. 7 , first semiconductor chip 351 , second semiconductor chip 352 or third semiconductor chip 352 , conductive film 353 , conductive particles 354 and photopolymerizable resin 355 are provided. The metal wires of two of the semiconductor chips can be conductively bonded to each other using conductive film 353 , conductive particles 354 , and photopolymerizable resin 355 . Photopolymerizable resin 355 can be composed of a UV curable resin.
[0043] Although embodiments have been described herein, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.
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A semiconductor package apparatus includes a first semiconductor chip bonded onto a substrate of which metal wire turning upward; and a second semiconductor chip conductively bonded onto the first semiconductor chip in a vertical direction such that a metal wire of the second semiconductor chip and the metal wire of the first semiconductor chip have facing points. The semiconductor package apparatus includes a third semiconductor chip conductively bonded onto the first semiconductor chip in the vertical direction to be disposed horizontally with the second semiconductor chip such that a metal wire of the third semiconductor chip and the metal wire of the first semiconductor chip have facing points.
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RELATED APPLICATIONS
[0001] This claims the benefit of U.S. Provisional Application Ser. No. 60/571,148 filed May 14, 2004 entitled “Scope Dock.”
BACKGROUND
[0002] 1. Technical Field
[0003] This disclosure relates to a medical device for docking an endoscope.
[0004] 2. Background Information
[0005] Modern, non-invasive surgical procedures often require the use of an endoscope. Endoscopes are thin, tube-like devices used to visualize human anatomies such as the gastrointestinal tract. During endoscopic procedures, a physician manually grips a proximal end of the endoscope. Additionally, in the course of most endoscopic procedures, physicians manipulate and maneuver the endoscope in a variety of ways to rotate, adjust, or torque the endoscope.
[0006] At some stage in an endoscopic procedure, a physician may need to release the endoscope, for example, to perform an ancillary procedure or write notes. To do this, the physician carefully hands the endoscope to a nurse or places the scope in a stationary docking station. Docking stations are stands for receiving and holding an endoscope. Docking stations are typically affixed to a stationary point, such as a ceiling, wall, or floor. Other docking stations can be part of or affixed to a chair, a bed, or a table.
[0007] Both handing the endoscope to a nurse and docking the endoscope in a traditional docking station present significant drawbacks. First, whether the physician hands the endoscope to a nurse or docks it in a traditional docking station, the physician is disconnected from the patient during the procedure—even though the endoscope is still engaged in the patient's body. That is, the physician loses direct control of the endoscope. Second, presently available docking stations have very limited functionality. As a result, conventional docking stations are only suited for stationary hanging or gripping an endoscope that is not in use.
BRIEF SUMMARY
[0008] Accordingly, it is an object of the present invention to provide a medical device having features that resolve or improve upon one or more of the above-described drawbacks.
[0009] The invention is defined by the following claims, and nothing in this section should be taken as a limitation on those claims.
[0010] One aspect of the present invention provides a scope dock including a harness and a main body. The harness allows the scope dock to be attached to an operator, and the main body may include a scope holder which receives a scope. The harness may be a shoulder harness, midsection harness, or any other type of harness. The scope holder may hold the scope directly or through the use of other devices situated on the scope or the scope holder.
[0011] This invention also provides a method for using a scope dock. The method comprises a step of attaching a scope dock to an operator and a step of docking a scope in the scope dock. A catheter may be inserted into the scope as another step or another medical procedure may be performed.
[0012] Other embodiments are disclosed, and each can be used alone or in combination with another.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
[0013] FIG. 1 illustrates a perspective view of a scope dock having a hub.
[0014] FIG. 2 illustrates a perspective view of a scope in a retracted position.
[0015] FIG. 3 illustrates a side view of an endoscope situated in a scope dock.
[0016] FIG. 4 illustrates a flow-chart of exemplary steps for using a scope dock.
[0017] FIG. 5 illustrates a perspective view of a scope dock having an integral device hub.
[0018] FIG. 6 illustrates a front view of a user wearing a scope dock configured with a chest support and a waist support.
[0019] FIG. 7 illustrates a front view of a user wearing a scope dock configured with a chest support.
[0020] FIG. 8 illustrates a front view of a user wearing a scope dock configured with a neck support.
DETAILED DESCRIPTION OF THE INVENTION
[0021] The invention is described with reference to the drawings in which like elements are referred to by like numerals. The relationship and functioning of the various elements of this invention are better understood by the following detailed description. However, the embodiments of this invention as described below are by way of example only, and the invention is not limited to the embodiments illustrated in the drawings. It should also be understood that the drawings are not to scale and in certain instances details have been omitted, which are not necessary for an understanding of the present invention, such as conventional details of fabrication and assembly.
[0022] Turning now to FIG. 1 , that figure discloses a scope dock 100 and a hub 102 . The scope dock 100 includes a harness 103 comprising a belt 104 , a waist adjustment 108 to adjust the length of the belt, and a belt buckle 110 to allow the belt to be buckled and unbuckled in order to put on and take off the scope dock 100 . The belt 104 is connected to a main body 106 . The main body broadens into a central portion 112 which includes a scope holder 114 and a scope pivot 116 . The scope pivot 116 is allowed to pivot by the scope holder 114 . The scope holder 114 may optionally maintain the scope pivot 116 at various pivot positions from the vertical, such as at 0°, 15°, and 30° from the vertical. The central portion also includes a release button 118 which releases the scope holder from an inactive position, where it is flush with the central portion, to an active position, where it is approximately perpendicular to the central portion. When the scope holder is in the active position, it may be locked into place, such that the scope holder may not be unlocked or moved until the release button is again pressed.
[0023] A scope bearing sleeve 120 slides onto a scope 122 , such as an endoscope. The scope bearing sleeve is optionally in a friction fit relationship with the scope, which may hold the two together in such a way that they do not move. At the same time, the scope bearing sleeve and the scope pivot are arranged such that the scope bearing sleeve is able to rotate coaxially within the scope pivot. The exemplary scope pivot shown here includes a chamfered out portion that allows the scope bearing sleeve to sit in the scope pivot. Additionally, at least one optional device hub 124 may be clipped onto the scope bearing sleeve, and the device hub may have a device clip 126 on its end. The device clip 126 may clip onto a variety of medical devices, such as catheters or other devices used with the scope.
[0024] Furthermore, the main body in this exemplary embodiment may comprise a semi-rigid over-molding, which is rubberized. Such a material may allow the main body to comfortably flow around the mid-section of the doctor while he is wearing the scope dock. Though a semi-rigid material is shown here, any variety of flexible or rigid or semi-rigid materials may be used to manufacture the main body of the scope dock.
[0025] Additionally, the belt 104 may be made of nylon braid or any suitable material, such as rubber, leather, plastic, natural or synthetic threads, or any other material that may be used to make a belt. The waist adjustment may be a single clip—or any other suitable clip or device—that allows the belt to be lengthened or shortened depending on the size of the mid-section of a doctor and the desired level of tightness about the doctor. Though the exemplary waist adjustment shown in FIG. 1 is separate of the belt buckle, it may also be integral with the belt buckle. The belt buckle shown in FIG. 1 is a parachute type belt buckle having two finger grips that may be pressed together to unbuckle the belt. Even though a parachute type belt buckle is shown here, any type of clip arrangement, belt buckle, hook and loop fastener, or other suitable device may be used to secure the belt. Moreover, though the exemplary scope dock of FIG. 1 uses a belt as a harness to secure the scope dock, a wide variety of harnesses may be used to secure the scope dock to the doctor, such as shoulder harnesses, neck harnesses, leg harnesses, or other types of harnesses.
[0026] Next, the scope bearing sleeve may be made of a hardened plastic, but the sleeve may be made of metal, rubber, a harder or softer plastic, or any other suitable material. Alternatively, the scope bearing sleeve may be disposable after one use or reusable for any number of uses. The scope bearing sleeve may also be integral with the scope or included with the scope at the time of scope purchase. Similarly, the device hub is made of a hardened plastic or any suitable material. The device hub may be disposable after one use or reusable for a number of procedures or a period of time. The device hub, as well, may be rotatable about the scope bearing sleeve, and the hub and sleeve may share a frictional or other type of fit. If a frictional fit is used, the fit may be such that the device hub and the scope bearing sleeve are stably maintained by the fit in a particular position relative to one another. At the same time, the frictional fit may optionally allow the hub and sleeve to be moved relative to one another by the application of a certain amount of force, such as a light or medium pressing of the hub by the doctor or nurse. Further, the clip of the device hub may itself be coaxially rotated, depending upon the needs of the doctor. This coaxial rotation is an optional feature of the device hub. The exemplary scope bearing sleeve of FIG. 1 is—but is not necessarily—cut to fit around the access port of the scope, and this may increases the stability of the fit such that the scope bearing sleeve not rotate in relation to the scope while in use. Optionally, the scope bearing sleeves may be different based upon the brand and type of scope used in order to fit the respective scope.
[0027] Turning now to FIG. 2 , that figure discloses a scope dock 200 similar to the one shown in FIG. 1 . The scope dock 200 has a scope holder 202 in an inactive retracted position. When a scope (not shown) is not needed at a particular time during a procedure or before a procedure, the doctor may remove the scope from the scope holder, and he may retract the scope holder. The scope holder maintains a scope pivot, in a similar way as the scope holder 114 maintains scope pivot 116 of FIG. 1 .
[0028] Because of its low profile, the exemplary scope dock 200 need not be removed when not in active use. In fact, the scope dock 200 itself may assist a doctor in bearing the weight of a lead apron (not shown), which the doctor may wear during a medical procedure. As noted earlier, in order to activate the scope holder 202 , a doctor or his assistant may press the release button 204 to allow the scope holder 202 to rotate to a locked position approximately perpendicular to a main body of the scope dock 200 .
[0029] Turning now to FIG. 3 , that figure discloses a side view of scope dock 300 , which is similar to the scope docks 100 , 200 shown in FIGS. 1 and 2 . The scope dock 300 includes a harness 301 , comprising a belt 302 , a buckle 303 , and a waist adjustment 304 , connected to a main body 306 . Extending from the main body 306 is a scope holder 308 which maintains a scope pivot 310 . The scope pivot 310 is shown at a 15° rotation from the vertical, and a scope and scope bearing sleeve are seated in the scope pivot. The scope bearing sleeve also has a device hub attached to it. In the exemplary embodiment of FIG. 3 , the scope pivot may be adjusted to a 0°, 15°, or 30° rotation from the vertical. Similar to the example in FIG. 1 , the scope bearing sleeve may rotate within the scope pivot, and the device hub may rotate about the scope bearing sleeve.
[0030] Turning now to FIG. 4 , that figure discloses an exemplary method 400 of performing a medical procedure using a scope dock similar to the ones disclosed in FIGS. 1-3 . Though the method 400 steps are shown in an order for the sake of the present example, some of them are optional, and many of them may be performed in a different order than that presented in this example. In a procedure that may involve the use of radioactive substances, a doctor may wear a lead apron or other protective clothing over standard hospital clothing. Often, this clothing extends across the region of the body upon which the scope dock will be situated, and so, the protective clothing may be in place prior to performing method 400 .
[0031] In step 402 , the scope dock is situated on the doctor. The scope dock can be fastened around the doctor's midsection ( FIGS. 1-3 ), placing a shoulder harness over his head and onto his shoulders, placing a neck harness around his neck, or situating the scope dock in any other way on the doctor. Then, in step 404 , the scope dock is secured to the doctor by buckling a belt buckle, fastening a Velcro hook and loop fastener, or securing the scope dock in any other way. In some instances, the steps 402 , 404 of situating and securing may be performed as one action or the step 402 of situating may also provide the securing onto the doctor—such as in the case of a shoulder harness that may have adjustment devices but no additional securing devices.
[0032] Step 406 comprises situating a scope bearing sleeve onto the scope. This particular step 406 is optional, depending on the scope dock in use, and may be performed at a variety of times—before the doctor even arrives in the procedure room, before the procedure has begun, just prior to use of the scope, or any appropriate time. Situating a device hub onto the scope bearing sleeve is step 408 . This step 408 is also optional, and in an alternate embodiment, the device hub may be situated onto the main body of the scope dock or onto the scope itself. This step 408 may also be performed at a any appropriate time before or during a procedure, and any number of device hubs may be situated, depending on the needs of the doctor.
[0033] The exemplary method 400 shows an optional feature of the scope dock system in step 410 . In this exemplary step 410 , a doctor performs a first procedure with the scope, after the step 402 of situating the scope dock on the doctor and before the step 414 of situating the scope in the scope dock. Though shown in this sequence for the sake of example, these steps may be performed in any order and in a variety of ways. This first procedure may be any kind of procedure, such as inserting the scope into the patient's mouth or performing a test on the scope itself.
[0034] Then, the doctor or nurse releases a scope holder on the scope dock to an active position in step 412 . This step 412 of releasing may involve the pressing of a release button—as shown on the exemplary scope docks of FIGS. 1 and 2 —manipulating the scope holder to an active position manually, or some other releasing. The releasing of step 412 is optional, as some scope docks may not have a releasing functionality, or the releasing may be performed at a different time before or during a procedure. Next, in step 414 , the doctor or nurse may situate the scope and scope bearing sleeve into the scope pivot of the scope holder by moving the scope laterally through the open portion of the scope holder and then lowering the scope and scope bearing sleeve into the scope pivot of the scope holder. The optional scope pivot featured in FIGS. 1-3 may allow coaxial rotation of the scope while situated in the scope dock, and the scope pivot may allow for the scope to be situated at different angles in relation to the scope dock or the vertical plane. As noted above in FIGS. 1-3 , the various features of the scope pivot are optional, as is the scope pivot itself. In some exemplary scope docks, the scope holder itself may hold the scope without using a scope pivot, and in some exemplary scope docks, the scope may be situated on the scope dock without using a specific scope holder portion.
[0035] In exemplary step 416 , the doctor performs a second procedure with the scope situated on the scope dock. This second procedure may be any kind of procedure, such as a inserting a catheter or wire guide into an access port of the scope, viewing the inside of the patient on a monitor, performing a cannulation using a catheter, shooting fluoroscopy inside a patient, writing a note on the condition of the patient, or any other procedure.
[0036] In step 418 , the doctor or nurse removes the scope from the scope dock. In the exemplary scope dock of FIGS. 1-3 , this may involve removing the scope bearing sleeve from the scope pivot. As noted earlier, this step 418 may be performed at a variety of times and in a variety of ways during a scope procedure. After the scope is removed from the scope dock, the scope holder may be released to the inactive position in step 420 . In the exemplary FIGS. 1-3 , this may involve pressing the release button to release the scope holder and then manually pressing the scope holder down until it is in an inactive position. Even so, the scope holder may be implemented in a variety of ways, such as being fixed in position; automatically moving from active to inactive position at the press of a button; released by using a lever, switch, or other mechanism; or in some other way.
[0037] Finally, in step 422 , the scope dock is removed from the doctor. This may involve unbuckling a belt buckle, removing a harness, or other way of releasing the scope dock. The scope dock of exemplary FIGS. 1-3 may be unbuckled by either the doctor or nurse and set aside for sanitization and the next procedure. Additionally, in step 424 , the scope bearing sleeve may be removed from the scope. After removal, the scope bearing sleeve may be thrown away, if it is a disposable sleeve, or set aside for sanitization and the next procedure, if it is a reusable sleeve. As noted above, some scope docks do not work in conjunction with a scope bearing sleeve, and therefore, in these instances, step 424 and other steps involving the sleeve would be unnecessary.
[0038] In use, a doctor may buckle the scope dock around himself prior to a procedure. Then, the scope bearing sleeve may be slid onto the scope and brought into a friction fit with it. At the appropriate point in the procedure, the scope bearing sleeve and the scope may be seated in the scope bearing hub of the scope dock. In this way, the doctor is able to have an extra free hand to write notes, to grab on to a catheter, or to perform another desired portion of the medical procedure. During a procedure, the doctor may insert a catheter into the endoscope, and after this, he may wish to dock the handle of the catheter into the device clip of the device hub. In this way, he does not need to support the other end of the catheter or worry about where the other end of the catheter is, as it would be immediately in front of him at a convenient position for hand activation. Additionally, the doctor may rotate the device hub and the device clip in order to position a handle or other end of a catheter in whatever position he desires. While in the device hub, the catheter handle may be manipulated without having to maintain the entire end of the catheter independently.
[0039] Turning now to FIG. 5 , that figure discloses an exemplary embodiment of a scope dock 500 . The scope dock 500 includes a harness 501 comprising a belt 502 , a belt buckle 504 , and waist adjustment 506 . The belt 502 is attached to a main body 508 which has a scope receiving hub 510 . A scope bearing sleeve 512 is seated in the scope receiving hub 510 , and a device hub 514 is integral with the scope bearing sleeve 512 . The scope bearing sleeve 512 is friction fit around a scope 516 , preferably prior to commencing a medical procedure involving the scope 516 . In this embodiment, the device hub 514 is rotatable within the scope bearing sleeve 512 , and the device hub 514 has an independently rotatable device clip 518 at its end. The device clip 518 is able to receive a variety of devices and is shown here attached to the wrapping portion of a catheter 520 . The catheter 520 has a handle and multiple ports. The handle may be actuated and the ports accessed while the catheter 520 is situated in the device clip 518 .
[0040] Turning now to FIG. 6 , that figure discloses an exemplary embodiment of a scope dock 600 . The scope dock 600 includes a harness 602 having midsection straps 604 , 606 , shoulder straps 608 , 610 , a shoulder support 612 , and a back plate 614 . The midsection straps 604 , 606 connect to a main body 616 by clips (not shown), which may be released by pressing clip release buttons 618 , 620 , respectively. The operator or his assistant may adjust the straps at the shoulder support 612 , belt buckles 616 , 618 , or back plate 614 . A scope bearing hub 622 receives the scope 624 . The scope 624 and the scope bearing hub 622 may share a friction fit, as well. The scope bearing hub 622 shown here is a removable ball seated in a socket joint. The scope bearing hub 622 has opposing finger rests 624 , 626 that may be squeezed together to release the scope bearing hub 622 from the socket joint and, thereby, from the main body 616 . This allows simple removal of the scope bearing hub 622 from main body 616 .
[0041] FIG. 7 illustrates an exemplary embodiment of scope dock 700 , which is configured as a chest support. Scope dock 700 includes a harness having chest straps 708 and 710 that are integral to a main body 716 . The main body is provided with a docking mechanism as described above regarding the previous embodiments. That is, the main body is outfitted with a scope receiving hub as detailed in any of the above-described embodiments. The scope receiving hub allows a physician to dock or release the endoscope as needed. As illustrated in FIG. 7 , the scope dock 700 includes a widened portion 721 . Widened portion 721 is adapted to distribute the weight of the endoscope about the chest of a physician. Widened portion 721 further provides a stable platform for the physician. Of course, scope dock 700 can alternatively be provided with without a widened portion 721 .
[0042] FIG. 8 illustrates an exemplary embodiment of scope dock 800 , which is configured as a neck support. Scope dock 800 is similar to the scope dock shown in FIG. 7 . Scope dock 800 , however, is adapted to be worn about a physician's neck, rather than the shoulders. For comfort, scope dock 800 can be provided with neck pads 810 and 808 . Neck pads 810 and 808 can be formed from a wide variety of widely available cushion materials, such as high density foam. Scope dock 800 further includes a Y-shaped main body 816 having a scope receiving hub as detailed in any of the previously described embodiments. Main body 816 can be formed of a lightweight, durable material, for example, plastic or carbon fiber.
[0043] It is to be understood that changes and modifications to the embodiments described above will be apparent to those skilled in the art, and are contemplated. Such changes include varying the configuration of the disclosed harnesses. Alternative harnesses could include strapless harness variations. For example, it will become apparent to one of ordinary skill that a protective garment, a jacket, or a vest could be used as a harness for a scope dock. Indeed, a scope dock could be provided integrally with a protective lead vest. It is therefore intended that the foregoing detailed description be regarded as illustrative rather than limiting, and that it be understood that it is the following claims, including all equivalents, that are intended to define the spirit and scope of this invention.
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A medical device for allowing a physician to unhand a scope or other instruments while maintaining control of the scope or other instruments during a medical procedure. The medical device includes at least one docks and a harness for attaching the dock to the physician's body. The harness can be adjustable, or sized to fit a specific physician. During a procedure, a physician outfitted with the medical device can place a scope and/or other instrument in the dock(s). Once the scope and/or other instrument is placed in the dock(s), the physicians hands are free to perform other procedures, while the physician continually controls the relative position of the scope with respect to the physician or the patient.
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FIELD OF THE INVENTION
The instant invention is directed to a method for producing pearlite from an iron containing article by reactive heat treatment.
BACKGROUND OF THE INVENTION
Because it is relatively inexpensive, carbon steel is the workhorse of the petrochemical industry. Chromium alloying is known to improve the corrosion resistance of carbon steel, but chromium is an expensive element. Thus, approaches whereby corrosion resistance can be achieved without expensive alloying are desirable.
Pearlite is a microstructural constituent of steels which is made up of alternating layers of ferrite (body centered cubic iron) and cementite (Fe 3 C). The pearlite microstructure is particularly resistant to certain forms of acid corrosion such as, for example, corrosion by organic acids. Thus, pearlite could be a ready substitute for expensive chromium alloying, however, the strength characteristics of pearlite limit its use as a bulk structural material for many applications since pearlite is produced from carbon steels containing at least 0.77% carbon.
Thus, what is needed in the art is a process for producing pearlite from an iron containing article which process preserves the mechanical properties of the article.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 depicts scanning electron micrographs showing (a) surface pearlitic structure on pure iron after reactive heat treatnent at 775° C. for 1 hour in 50% CO:50% H 2 environment and (b) enlarged area on surface revealing the ferrite (Fe) and cementite (Fe 3 C) forming as roughly parallel lamellae, or platelets, to produce a composite lamellar two-phase structure. In this scanning electron micrograph the cementite lamellae appear light and the ferrite appears recessed, because it has etched more deeply than the cementite. These figures show the final product having the pearlite surface, which is produced in accordance with this invention.
FIG. 2 depicts the thickness variation of surface pearlite formed by the method of this invention as a function of reaction time at 775° C. in 50% CO:50% H 2 as well as 97.5% CO:2.5% H 2 environments.
FIG. 3 depicts the thickness variation of surface pearlite formed by the method of this invention as a function of H 2 content in CO at 775° C. for 1hour.
FIG. 4 depicts the thickness variation of surface pearlite formed by the method of this invention as a function of temperature in 50% CO:50% H 2 environment for 1 hour.
SUMMARY OF THE INVENTION
The present invention is directed to a process for producing pearlite from an iron containing article comprising the steps of, (a) heating an iron containing article comprising at least 50 wt % iron for a time and at a
temperature sufficient to convert at least a portion of said iron from a ferritic structure to an austenitic structure, (b) exposing said austenitic structure, for a time sufficient and at a temperature of about 727 to about 900° C. to a carbon supersaturated environment to diffuse carbon into said austenitic structure and (c) cooling said iron containing article to form a continuous pearlite structure.
A carbon supersaturated environment is herein defined as an environment in which the thermodynamic activity of carbon is greater than unity. It is known that CO is the most potent carbon transferring molecule and the presence of hydrogen in carbon monoxide tends to facilitate carbon transfer. The following reactions can lead to the transfer of carbon to the metal surface from carbonaceous environments.
CO+H 2 ═C+H 2 O [1]
2CO═C+CO 2 [2]
CH 4 ═C+2H 2 [3]
Reaction [1] has the fastest kinetics: therefore CO—H 2 gas mixtures are the preferred gas mixtures to be used as the carbon supersaturated environments. Typical hydrogen contents in carbon monoxide can range from about 2.5 vol % to about 90 vol %, preferably about 10 vol % to about 60 vol %.
The iron articles utilized in the instant invention need not contain any carbon. It is sufficient for the carbon which forms the pearlite structure to come from the environment to which the iron article is exposed.
According to the instant invention, austenite is converted to a continuous pearlite layer. As shown in FIG. 4 , the preferred temperature range for the conversion is about 727 to about 900° C. Above this temperature, the pearlite phase will lose its continuity and fail to provide corrosion protection.
Times and temperatures for conversion of ferritic iron to austenic iron are well known in the art.
DETAILED DESCRIPTION OF THE INVENTION
The instant invention involves exposing an iron containing article, where the iron has been converted to the austenitic state, to a carbon supersaturated gaseous environment and then cooling the article to obtain a continuous layer of pearlite. The preferred temperature range for accomplishing the conversion of austenite to pearlite is shown in FIG. 4 . The preferred composition of the carbon supersaturated environment corresponds to the plateau region in FIG. 3 . In this range, the reaction times are shorter to obtain a specific thickness of pearlite and therefore, gas compositions in this range are economically more attractive. The reaction times to achieve various thicknesses of continuous pearlite can be determined by reference to FIG. 2 .
The process can be used to obtain any thickness of continuous pearlite. It can also be used to completely convert the iron-containing article to pearlite. Thus, the production of pearlite in the instant invention can be easily controlled to prepare a continuous layer of pearlite, or to convert all of the iron contained in the article to a continuous pearlite structure. Hence a pearlite structure can be a continuous layer of pearlite on the surface of the iron article being acted upon, or a completely converted pearlite article. The thickness of pearlitic layers can be controlled by the carbon supersaturated environment, the temperature and the exposure time. Such exposure times are readily determinable by the skilled artisan, as depicted in FIG. 2 .
Shown in FIG. 3 are results for the thickness variation of surface pearlite formed on pure iron after reactive heat treatment at 775° C. for 1 hour as a fuction of the composition of carbon supersaturated gas mixtures. Maximum thickness of surface pearlite was obtained in a specific range of CO—H 2 gas composition. Typical hydrogen contents in carbon monoxide can range from about 2.5 vol % to about 90 vol %, preferably about 10 vol % to about 60 vol %.
The thickness of the pearlite layer can be any thickness desired. All that is necessary is to alter the exposure time to the carbon supersaturated gaseous environment at the noted temperatures. For thinner layers, the exposure time will be less, and for thicker layers the exposure time will be greater. Typical exposure times can range from about 1 minute to about 50 hours, preferably from about 5 minutes to about 25 hours, and most preferably from about 10 minutes to about 10 hours. Thus, the exposure time and temperature will be those necessary to form a desired thickness of pearlite following step (c). It is important to note that the entire iron containing article can be converted to pearlite if desired in which case the thickness of the article will be the desired thickness.
Typical layer or structure thickness will thus range from at least about 10 microns up to the thickness of the iron article being acted on, preferably from about 10 to about 1000 microns, more preferably from about 10to about 500 microns.
When converting the iron containing article from the ferritic crystal structure to the austenitic crystal structure, all that is necessary is for the article to be heated. One skilled in the art can easily determine the time and temperature necessary to accomplish such crystal structure conversion by reference to any published Fe—C phase diagram (See for example: ASM Specialty Handbook, Carbon and Alloy Steels, Ed., by J. R. Davis, p.366 (1996) ASM International).
The cooling step (c) will determine the lamellar spacing of the pearlite formed. The cooling rate for a desired coarseness, or lamellar spacing, of the pearlite is easily determined by the skilled artisan taking into account the pearlite formation temperature, cooling rate and iron containing article composition.
The iron containing article to be acted upon will contain at least about 50 wt % iron. The article can be composed entirely of iron. The amount of carbon contained in the article can range from less than 0.77 wt % down to 0 wt % carbon. Thus, the instant invention allows the skilled artisan to prepare pearlite from an iron containing article with much better mechanical properties than carbon steels containing 0.77 wt % or more carbon. The iron containing article may further comprise other components including, but not limited to chromium, silicon and manganese. All that is necessary for the instant invention is that the article being acted upon contains at least about 50 wt % iron.
Additionally, an article already having an amount of pearlite in combination with ferrite, can be subjected to the instant invention to convert the ferrite to pearlite.
The carbon supersaturated environment to which the iron containing article is exposed is any carbon supersaturated environment. The thermodynamic carbon activity in the supersaturated environment is greater than 1. Examples of suitable environments include, but are not limited to CO, CH 4 , or other hydrocarbon gases, such as propane (C 3 H 8 ) and mixtures thereof with H 2 ,O 2 ,N 2 ,CO 2 , and H 2 O.
The instant invention allows the skilled artisan to produce steels having both corrosion resistance and mechanical properties far superior to those of carbon steels containing 0.77 wt % or more carbon. This is because the steel's mechanical properties improve as the carbon content decreases. In the instant invention, the amount of carbon diffused into the iron containing article from the carbon supersaturated environment is utilized to produce pearlite. The portion of the iron containing article not converted to pearlite, is unchanged and maintains the mechanical properties it possessed prior to treatment in accordance with the instant invention. Thus, for example, the amount of carbon necessary to form a pearlite layer of desired thickness can be diffused into the iron containing article thus forming pearlite. The mechanical properties of the remaining non-pearlitic portion of the article will be unchanged.
The following examples are illustrative and are not meant to be limiting in any way.
EXAMPLE 1
Iron of 99.99% purity is heated to a temperature of 775° C. in a hydrogen environment in a vertical quartz reactor tube and held at that temperature for ˜5 minutes. Thereupon, the environment is changed to 50% CO-50% H 2 . After 1 hour of exposure, the metal sample is cooled by lowering the furnace surrounding the quartz reactor. After the sample has attained room temperature, the surface microstructure is examined by scanning electron microscopy. FIG. 1 a reveals that a pearlite surface layer of 100 micron thickness has formed on the iron surface. A magnified view of the pearlite microstructure, showing alternating layers of ferrite and cementite, is depicted in FIG. 1 b . By changing the duration of exposure to the carbon supersaturated gaseous environment. the thickness of the pearlite layer can be changed. This is shown by the graph in FIG. 2 .
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The present invention is directed to a process for producing pearlite from an iron containing article comprising the steps of, (a) heating an iron containing article comprising at least 50 wt % iron for a time and at a temperature sufficient to convert at least a portion of said iron from a ferritic structure to an austenitic structure, (b) exposing said austenitic structure, for a time sufficient and at a temperature of about 727 to about 900° C., to a carbon supersaturated environment to diffuse carbon into said austenitic structure and (c) cooling said iron containing article to form a continuous pearlite structure.
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RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 12/827,345, filed Jun. 30, 2010, which is a continuation-in-part of U.S. patent application Ser. No. 11/386,928, filed Mar. 22, 2006, which is a continuation-in-part of U.S. patent application Ser. No. 10/905,524, filed Jan. 7, 2005, which is a continuation of U.S. patent application Ser. No. 10/345,864, filed Jan. 16, 2003, now U.S. Pat. No. 6,874,828, incorporated herein by reference, which is a continuation of U.S. patent application Ser. No. 09/962,508, filed Sep. 25, 2001 (now U.S. Pat. No. 6,581,986), incorporated herein by reference, which is based on Disclosure Document No. 453,811, filed Mar. 26, 1999, entitled “Vending Cam Lock,” incorporated herein by reference, and claims priority to U.S. Provisional Patent Application No. 60/252,210, filed Nov. 21, 2000, incorporated herein by reference. This application is also related to, and incorporates by reference, U.S. Pat. No. 6,575,504, filed Sep. 25, 2001, which descends from the aforesaid Provisional application (i.e., U.S. Provisional Patent Application Ser. No. 60/252,210).
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention relates generally to locking devices and, more particularly, to a locking system for vending machines and the like and a method for locking and unlocking the same.
BACKGROUND OF THE INVENTION
[0003] In various vending-type machines, such as food machines, candy machines, refrigerated drink machines, and the like, there is ordinarily provided a lock assembly to prevent unauthorized access to the contents. For example, some vending machines are provided with a key-activated lock assembly, such as a pop-out T-handle lock assembly, which allows an authorized user to open the door of the machine with a properly-encoded key. These T-handle lock assemblies are well-known in the art, as evidenced by numerous patents including U.S. Pat. No. 3,089,330 (Kerr), U.S. Pat. No. 3,550,412 (Pitel et al.), U.S. Pat. No. 4,552,001 (Roop), U.S. Pat. No. 4,760,721 (Steinbach), U.S. Pat. No. 4,899,561 (Myers), and U.S. Pat. No. 5,548,982 (Rawling). With such lock assemblies, the door is initially closed in a loose manner to catch the locking components of the lock assembly. Next, the handle of the locking assembly is rotated to draw the door against the housing of the vending machine and to compress a seal between the door and the housing. More modern vending machines are provided with a keypad-activated lock assembly which permits the door of the vending machine to be opened when a predetermined access code or combination is entered into the keypad. The prior art fails to provide a lock assembly which automatically pulls the door of a vending machine into a completely closed position against the housing and/or a lock assembly which utilizes a remotely controlled electronic latching mechanism to lock and unlock the door. More recently, as shown in U.S. Pat. No. 6,068,305 (Myers et al.), such a locking system was proposed. Further, as thefts and tampering with these machines increases, component refinements and improved locking systems have been sought by users and manufacturers of the machines.
[0004] The most commercially accepted electronic locking system marketed by applicants' assignee TriTeq Lock and Security, LLC. is disclosed in U.S. Pat. Nos. 6,874,828, 6,581,986, 6,575,504 and pending application Pub. No. US 2005/0161953. In each of these references a motor driven bayonet locking system has a bayonet locking element that moves both in the translational and rotational axis and co-acts with a stationary slotted plate by extending to enter the plate, rotating to create interference from being withdrawn and then retracting to pull in and lock the door.
[0005] Other approaches both prior and later, none of which are believed to have become commercially-acceptable, have sought to employ different types of mechanical latches and only uni-directional action electronic drivers such as solenoids.
[0006] U.S. Pat. No. 4,167,104 proposed the use of screw posts going into a threaded opening with a solenoid operating latching bolt. Similarly, U.S. Pat. Nos. 6,867,685 and 6,525,644, both to Stillwagon did the same with a notched post latch.
[0007] Publication US 2003/0127866 to Martinez proposes a motor driven rotary hook and u-bolt where the hook shape provides pull in cam action.
[0008] Publication No. US 2004/0154363 to Beylotte et al. has sought to motor drive a threaded post into a threaded split nut as in prior mechanically operated T-handle vending machine locks. Beylotte et al. proposed a motor driven cam hook in an alternative embodiment.
[0009] U.S. Pat. No. 6,068,308 to Myers et al. is an earlier form of latch with a pull in function.
SUMMARY OF THE INVENTION
[0010] An electro-mechanical cam-operated system having a function that facilitates specialized movements that can be utilized to secure and seal a variety of devices. The sealing action is being defined as a pulling motion of the primary mechanism. The locking action happens by virtue of a localized geometry that interfaces into another specialized designed receiver device. The receiver device is generally mounted in a stationary manner. The localized geometrically designed element is called a cam or a bayonet for the purposes of this abstract. The cam or bayonet design is not intended to be a single geometry element that unto itself is design critical to the operation concept of this mechanism. Alternate methodology may be used to facilitate the securing portion of the mechanism.
[0011] The cam is designed to operate perpendicular to the receiver in such a manner as to allow it to enter into the receiver by allowing the cam to have geometry that allows the cam to enter into it. After this is accomplished an electrical detection device sends a signal to an electrical control device. This device then sends a signal to a motor that in turn rotates a cylindrical device located about another cam. This cylindrical device has a unique geometry that interfaces with a central located tube type of device and a tubular type pin. The combined rotation causes the other cam to first rotate 90 degrees or thereabout. And then begin to wind its way up a spiral ramp located in a pocket of the cylindrical device. This cylindrical device also has two binary electrical devices that are strategically located to detect the relative position of the locking cam for both rotation and sealing (pull). This cylindrical device has a typical gear shape located on its outside diameter. This gear movement is derived from a worm gear interface that is driven by a motor. The motor derives its intelligence from the electrical controller.
[0012] The bayonet is designed to operate tangent to the receiver in such a manner as to allow it to interlock into the receiver by allowing the bayonet to have geometry that allows the bayonet to enter into and pass behind it. After this is accomplished an electrical detection device sends a signal to an electrical control device. This device then sends a signal to a motor that in turn rotates a cylindrical device located about the bayonet. This cylindrical device has a unique geometry that interfaces with a central located tube type of device and a tubular type pin. The combined rotation causes the bayonet to first rotate 90 degrees or thereabout. And then begin to wind its way up a spiral ramp located in a pocket of the cylindrical device. This cylindrical device also has two binary electrical devices that are strategically located to detect the relative position of the bayonet for both rotation and sealing (pull). This cylindrical device has a typical gear shape located on its outside diameter. This gear movement is derived from a worm gear interface that is driven by a motor. The motor derives its intelligence from the electrical controller.
[0013] In another embodiment in accordance with the present invention, an optionally keyless electronically operated bayonet locking device and method of operating the same is provided wherein a rotatable and translatable bayonet device or means having an arrow shaped end is carried by respective ones of the vending machine door and cabinet and a stationary slotted receiving member carried by the other one of the respective door and cabinet. The bayonet device arrow shaped end enters the slotted receiving member and then rotates to secure the door and the end translates longitudinally to pull in the door for effectively sealing a door gasket on the machine. The locking device is constructed so as to enable that rotation at least in the transitional phase with longitudinal translation of the arrow shaped end occurs together.
[0014] A specific intelligence is embedded into the controller that facilitates several fault modes and operational parameter of the electromechanical system. This intelligence may be delineated as relay or software type of logic. The lock controller provides two specific functions.
[0015] Access control functions to ascertain the authorized user is accessing the locking device. Several access control methodologies may be utilized such as keypads with specific codes for entry, hand-held transceivers, electronic digital keys, transponders, etc.
[0016] Typical access control functions such as keypads, remote controls and electronic keys are taught in U.S. Pat. No. 5,618,082 to Denison and U.S. Pat. No. 5,349,345 to Vandershel. The locking device may utilize any such access control methodology that is appropriate for the application for the operator and for the enclosure to which the lock is mounted.
[0017] Lock motor control functions once the controller has determined the lock is authorized to change from the locked to unlocked state, or, authorized to change from the unlocked to locked state. The components required to accomplish the required motor control operation are the motor drive, cam or bayonet, Receiver, Receiver Sensor, SW 1 end of rotation sensor, SW 2 30 degree Sensor, over-current sensor, and the CPU based controller.
[0018] The cylindrical device has a cover located about the opposite side of the area that causes the pin to wind it way on the ramp. This cover keeps the pin in a proper perpendicular path to the mechanisms securing motion.
[0019] The utilization of this device is providing simple easy access to devices that by necessity of application have a gasket or another means of sealing a door or the like. This would be described by what is common known as an automotive door. The door must be accelerated to a speed that can facilitate the compression of the gasket and then secure the door. Much like slamming of a car door. This device provides an alternate method of closing the door and pulling the gasket to a sealed condition. This device is also furthered in its invention by having methodology through electrical monitoring of the cam or bayonet conditions to adjust the pressure on the door gasket or seal. This is accommodated either by electrical position devices or detecting the motor characteristics by the electrical controller. The automotive door is used to only describe the actions, which caused the necessity of this invention. Any device that has a requirement for securing and sealing is a possible application of this device.
[0020] A non-exhaustive listing of possible applications for the present locking system includes truck doors, vending machine doors, automotive doors, refrigerator doors, and the like.
[0021] The cylindrical device with its associated motor and electrical detection devices are always mounted in a manner that separates them from the receiver unit. To further clarify this explanation consider the following sample concept, a car door has a rotary type securing device that is generally located in the door that secures its via a mechanical interface with a pin that is located in the frame of the vehicle. The cylindrical device would draw a similarity in its function as the rotary type device. The utility of this is to further the security by sealing the door after closing. Recalling that this device in its improvement into the market does not require massive forces to initiate the function of securing the cam or bayonet. This means that the device the system is mounted to would inherently be subject to less stress and wear, thus extending its life.
[0022] While there are mechanisms in the public domain that facilitate total system functionality of the specific motion similar to that being described here. One of the unique attributes of this product design is its ability to absorb very high closing impact forces without subjecting the system or the mechanism it is mounted to any impact damages. This system has shock absorbing devices located within the tube and positioned on the end of the cam or bayonet. Such is this geometry that it does not deter from the adjustment function as an independent local event in the motion of pulling in. The cam or bayonet in this system also serves to assist with alignment of the device it's attached to. By moving from the closed to the secure positions the cam or bayonet has geometry which considers the perpendicularity into its motion and effectively cams it into the perpendicular position.
[0023] Also the other commercial systems which have similar motion to securing and sealing do not utilize the unique rotary motion of the cam or bayonet used in this system.
[0024] This system replaces many devices in the public domain. Systems such a handles for vending machines. This system is designed to operate within the structure of the device it is securing. Therefore there is not external means by which to attack it. It may operate via an electrical controller that can utilize a variety of communication methods that are commercially available. These include but are not limited to Infrared, Radio frequency, and Switch keylock.
[0025] Because this design requires the application of an electrical signal to the motor to activate the system for both securing and opening sequence These activities can be monitored for later data collection. This data collection can be facilitated in many methodologies. This data then can serve the operator or owner for the purposes of detecting what key was used to gain access to the system.
[0026] One methodology which is being claimed that is unique to this design is the ability to monitor the data through acquisition of the data with the remote initialization device. Typically known as a key, Key FOB of remote control. While this data collection is not primary to the system function. It acts to enhance the product to the market place
[0027] In still another embodiment of the invention, a locking system for locking a door to an opening in a cabinet or the like comprises a latching assembly for attachment to one of either a door or a cabinet. The latching assembly comprises a motor, a first driving member operatively coupled to the motor, a second driving member having a pivot and operatively coupled to the first driving member, first and second pivotable plates, each plate having a slidable pivot point and an opening defined therein by an interior edge, a latching plate joining each of the first and second pivotable plates, and at least a first cam element fixed to a first surface of the second driving member about the pivot and positioned within the opening of the first pivotable plate to engage the interior edge. In a similar embodiment, a second cam element may be fixed to a second surface of the second driving member about the pivot and positioned within the opening of the second pivotable plate to engage the interior edge.
[0028] The locking system further comprises a receiving post for attachment to the other of the door or the cabinet, the preferred receiving post including a longitudinal axis, and a latching portion. In operation, the first driving member is rotated by the motor, while the second driving member is rotated by the first driving member. The first and second cam elements move with the second driving member to bias against the interior edge of the respective openings of the first and second pivotable plates. The first and second pivotable plates are moved by the first and second cam elements to either engage the latching plate with or disengage the latching plate from the latching portion of the receiving post. Finally, the receiving post is moved along an axis substantially parallel to the longitudinal axis of the post by a force applied by the latching plate to the latching portion.
[0029] As an aspect of an embodiment of the invention, the locking system may also comprise a first position switch for initiating operation of the motor, the first position switch being responsive to one of either the door or the cabinet. Still, a second position switch for discontinuing operation of the motor may be employed, the second position switch being responsive to one of the first pivotable plate, the second pivotable plate, the first cam element, the second cam element, the door, the receiving post, or the cabinet.
[0030] In a related method for locking a door to an opening, the method comprises the steps of operating a power train to turn a first driving member, turning a second driving member coupled to the first driving member, moving a latching plate fixed to first and second pivoting plates having corresponding respective slidable pivot points and openings defined thereon, engaging a latching portion of a receiving post having a longitudinal axis with the latching plate, continuing movement of the latching plate, drawing the receiving post in a direction parallel to the longitudinal axis, sensing a position of one of the first driving member, the second driving member, the latching plate, or the receiving post, and discontinuing operation of the power train when a predetermined position is achieved.
[0031] It is an aspect of the disclosed method that the latching plate and the receiving post are attached to one of either a door or a cabinet having an opening.
[0032] It is a further aspect of the disclosed method to include the steps of sensing a position of the door, and signaling a controller to initiate operation of the power train.
[0033] These and other aspects of the invention will be more readily understood by those skilled in the art by a careful reading of the following disclosure, including the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] FIG. 1 is a perspective view of an illustrative vending type machine A with a door B and cabinet C in a partially open position showing the locking devices;
[0035] FIG. 2 is an enlarged perspective view of the system with the door mounted receiver and cabinet mounted cam operating lock;
[0036] FIG. 3 is an enlarged perspective view of the receiver and cam operator in a locked position free of the door and cabinet;
[0037] FIG. 4 is a plan view of the receiver;
[0038] FIGS. 5A and 5B respectively are plan views showing the beginning secure functions for the cam and receiver;
[0039] FIGS. 6A and 6B are plan views showing the advancements of the cam into the receiver;
[0040] FIGS. 7A and 7B are plan views of the system showing rotational locking and drawing in by the cam;
[0041] FIGS. 8A and 8B are plan views showing the cam locking unit in its unlocked position without the receiver;
[0042] FIGS. 9A and 9B are plan views like FIGS. 8A and 8B with the receiver;
[0043] FIGS. 10A to 10F are perspective views of alternative cam designs useful with the electronic lock;
[0044] FIGS. 11 and 12 are flow charts showing respective lock and unlock sequences of operation for the cam locking system;
[0045] FIG. 13 is a perspective, partially exploded view of a modified form of a receiver and cam operator; and
[0046] FIG. 14 is a plan view partially in section of the operating lock of FIG. 13 in a locked portion
[0047] FIG. 15 is a perspective view of an illustrative vending type machine A with a door B, gasket B′ and cabinet C in a closed position and showing a remote controller D;
[0048] FIG. 16 is a perspective view of the machine of FIG. 15 with the door opened partially;
[0049] FIG. 17 is a perspective view of the machine of FIGS. 15 and 16 with the door opened and showing the locking devices;
[0050] FIG. 18 is a perspective view of the bayonet system complete less the receiver unit. Wiring has been deleted to clarify the view. Item 101 is the localized design called a bayonet, it is shown in the secure and pulled in (sealed) position. Item 102 is the cylindrical device with the gear. Item 103 located about its outside diameter. Item 104 is the cover for the cylindrical device. Item 105 is a plate which serves to mount all of the items. The plate generally is part of the device that is to be secured. Item 106 is the electrical detection mount bracket that houses Items 106 a (SW 1 ) and Item 106 b (SW 2 ) Item 107 is the local geometry which detects the position of the cylindrical device. Item 108 is the electrical controller board. Item 109 is the adjuster device that positions the bayonet. Item 110 is the motor that provides the drives the gear assembly. Item 111 is the tube. Item 112 is a snap ring that holds the cylindrical device on the tube assembly.
[0051] FIG. 19 is a perspective clarifying the position indicators Item 107 of the cylindrical device.
[0052] FIG. 20 is a perspective view of the receiver unit. Item 113 is the receiver plate. Item 114 is the housing of the receiver. Item 115 is a door or moveable plate that the bayonet Item 101 pushes as it is inserted into the receiver. Item 117 which is mounted in Item 116 and fastens to Item 114 then switches state. The controller through wiring Item 120 detects this. Items 118 and 119 serve to mount and bias the door assembly. Area Item 114 a is provided as a typical mounting scenario.
[0053] The stationary receiver unit of FIG. 20 is mounted into the stationary cabinet C as shown in FIG. 17 using the holes 114 a. The slotted plate 113 receives the end arrow section of the bayonet 101 shown in FIGS. 18 and 19 . The moveable plate 115 of FIG. 20 is pushed rearward by the arrow section of the bayonet 101 , which causes the movable plate to rotate about the axle 118 and activates the switch 117 , resulting in activation of the gear motor 110 shown in FIGS. 18 and 19 . A flat spring 206 that is nested in both sides of the receiver unit and having two curved shapes allows the slotted plate 113 to move horizontally in both directions. After the arrow section of the bayonet 101 is removed from the stationary receiver unit, the flat spring will reposition the slotted plate 113 about its original centerline position as it relates to the stationary receiver. This movement allows for horizontal manufacturing tolerance for both the cabinet C and the door B as the lock of FIG. 19 and the stationary receiver of FIG. 20 are mounted. The vertical slot in the slotted plate 113 allows for vertical tolerances.
[0054] FIGS. 21 and 22 respectively are perspective views of the beginning secure functions. Item 101 is aligned to a slot located in Item 113 . Items 111 and 102 move into position (as they are mounted to Item 105 ) this places the end of the Item 101 behind the Item 113 . ( FIG. 19 ). At this time (SW 2 ) changes state serving as a local detection device. FIG. 15 Item 106 b.
[0055] FIG. 23 is a perspective view that has Items 102 , 112 , and 104 removed. Item 111 is kept stationary via slots located in area 111 a and with conventional threads. Item 101 has a slot through it to allow a spring action provided by Item 123 as the Item 101 impacts Item 113 . The 101 a slot provides the area for this. The pin Item 122 is held in place by the geometry 111 b . The rollers Items 121 will provide antifriction surfaces during future operations.
[0056] FIG. 24 is a perspective view of the bayonet system in its secure position. The Item 102 has rotated and item 106 FIG. 18 (sw 1 ) has detected the proper position via the Item 107 geometry. Item 101 is now located behind Item 113 and is rotated 90 degrees.
[0057] FIG. 25 is a perspective view indicating what the internal geometry is in place at the same time as FIG. 21 . Pin Item 122 has moved into position along the 111 b area. This is accomplished via FIG. 23 area 102 a. Gear Item 103 rotates about the area 102 e guided by Item 111 . Surface 102 a causes pin Item 122 to move 90 degrees.
[0058] FIG. 26 , item 102 d is provided as mounting surfaces for FIG. 25 Item 104 . Surface 104 a as mounted into Item 102 provide guiding for Items 121 and then translated through to Item 122 . Area Item 104 d corresponds to Item 102 d FIG. 23 . Area 102 a has a steel reinforced arrangement to prevent deformation of the plastic as it ages.
[0059] FIG. 27 is a perspective view showing the pulling or sealing function. Item 102 has continued to rotate via the motor Item 110 . The local geometry of the ramp area 102 a through 102 b causes the rollers Items 121 to move with it. This pulls (moves) the Item 101 back away from Item 113 . This is seen by the extension of Item 109 as it protrudes from Item 111 .
[0060] FIG. 28 is a perspective view of the outer guide that mates with the FIG. 23 guide.
[0061] FIG. 29 is a perspective view of the bayonet Item 101 . Item 101 c is threaded to facilitate the adjuster screw Item 109 . This screw limits the travel of the Item 101 by intersection of the pin Item 122 with the bottom of the Item 119 .
[0062] FIGS. 30 and 31 are flow charts showing the respective lock and unlock sequences of operation for the bayonet locking system.
[0063] Between Item 102 and mounting plate Item 105 mounting plate there is a thin plate to allow for a sliding friction plate surface this allows for a lubrication area.
[0064] FIG. 32 is a side view illustrating an embodiment of a locking assembly as it would be positioned with the door in an open condition;
[0065] FIG. 33 is a side view of an embodiment of a locking assembly in an unlocked condition in accordance with the present invention;
[0066] FIG. 34 is a similar view of the embodiment of FIG. 32 showing a latched condition of the locking assembly;
[0067] FIG. 35 is a similar view of the embodiment of FIG. 32 showing a locked condition of the locking assembly;
[0068] FIG. 36 is a side view of the embodiment shown in FIG. 33 , though taken from a side opposite to the view of FIG. 33 ;
[0069] FIG. 37 is an opposite side view of the embodiment of the locking assembly shown in FIG. 34 in the latched condition;
[0070] FIG. 38 is an opposite side view of the embodiment of the locking assembly shown in FIG. 35 in a locked condition;
[0071] FIG. 39 is a perspective view of an embodiment of a receiving post made in accordance with the present invention; and
[0072] FIG. 40 is a perspective view of an embodiment of the assembly of a toothed-gear, first and second pivotable plates and the latching plate made in accordance with the present invention.
[0073] In consideration of the electrical functions of the system the following description applies to the controller utilized. This controller features unique combination of sensing and control that differentiate it from controllers used in the public domain.
DETAILED DESCRIPTION OF THE INVENTION
[0074] While the present invention is to be described herein in connection with the best mode presently contemplated by the inventor for carrying out the invention, the preferred embodiments described and shown are for purposes of illustration only, and are not to be construed as constituting any limitations of the invention. Modifications will be obvious to those skilled in the art, and all modifications that do not depart from the spirit of the invention are intended to be included within the scope of the appended claims. Those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
[0075] Locked to Unlocked for Both the Cam and Bayonet Locking Systems:
[0076] For specific details of the electronic control operation, reference may be made to our co-pending application publication Jul. 28, 2005 as US 2005/0161953 A1. In controlling the motor to change the state of the lock from locked to unlocked, the controller must first receive a valid access control signal from the operator (via a secure access control input means such as a keypad or hand-held transmitter) and shall proceed to energize the motor in the forward direction. The controller will wait for a position feedback indicator which is measured by a controller CPU to determine the lock has landed in the unlocked state. If this sensor is closed, the controller will proceed to break and de-energize the motor. In case the sensor is failed, the controller uses a motor current feedback signal to detect end of worm gear travel by sensing a stall motor condition and to de-energize the motor. In case both sensors fail, the controller will discontinue operation based on elapsed time.
[0077] In the case an over-current signal is received, the controller must determine if this signal is a function of a jammed cam with the lock still in the locked state, or if this signal is a function of the worm gear reaching the unlocked state and the sensor failed. In the case of a jam, the receiver sensor is expected to be closed and the condition is still locked. Thus, the controller will proceed to assume a locked condition. In the case the receiver sensor is open, it is assumed that the cam has unseated from the receiver and the lock is unlocked. Thus, the controller will proceed to the unlocked state.
[0078] Unlocked to Locked for the Cam Locking System:
[0079] In controlling the motor, FIG. 2 , item 10 to change the state of the lock from unlocked to locked, the controller shall wait to receive a valid lock signal from the operator. This signal shall at a minimum be a sensor signal received by the controller whether the cam, FIG. 2 , item 1 is positioned to be seated in the receiver.
[0080] The receiver 13 sensor FIG. 4 is a plate like a member with a slot opening 13 A preferably mounted to door B ( FIG. 1 ), which is open when the lock is unlocked
[0081] In FIGS. 2 and 3 there is shown the sequence of closing and locking a vending machine door in accordance with the present electronic cam lock system, Door B carrying the receiver 13 with slot opening 13 A is moved toward the cabinet C which here carries the cylinder driven unit 2 which operates the cam element 1 . In FIG. 3 , the plate receiver is guided in place by a Y slot guide 20 , the motor drive advances the cam 1 into the slot 13 A and the unit 2 is ready for rotation of the cam 1 .
[0082] As seen in FIGS. 5A and 5B , the receiver 13 will engage a spring held side 17 that can be moved horizontally to sense the positioning of the receiver with respect to the retracted or unlock position of the cam 1 . The slide 17 has a sloped notch area 18 which operates sensor switch 19 to provide the signals for when the locking and unlocking actions can be operated by a controller and the motor drive unit. When the cam 1 is in position and the sensor switch allows the motor drive to operate, FIGS. 5A and 5B , the cam 1 is advanced longitudinally as shown in FIGS. 6A and 6B so that receiver 13 is captured and the door is held closed. Referring to FIGS. 7A and 7B the cam 1 is rotated within slot 13 A and the result is that a door carrying receiver 13 would be pulled in. The drive motor 10 rotates the cam 1 in the receiver and pulls in the door until the sensor signals the cam position for the controller to stop the motor. During locking if switch 19 senses that the receiver has moved back out of position before the cam 1 enters the slot the motor is reversed and the unlock position is maintained until the next cycle.
[0083] In FIGS. 8A and 8B , the cam 1 driving unit 2 and its components are shown as mounted to a bracket 5 which is easily attachable to a cabinet as in FIGS. 1 and 2 . The cam element 1 is shown in a retracted and unlocked position.
[0084] Referring to FIGS. 10A-F , there is shown various alternative cam 1 elements which can be used with the present locking system. FIG. 10B shows the same cam as in the previous FIGS. 1-9 , and it is preferably used with a guide 20 as shown in FIG. 3 .
[0085] FIG. 10A shows a notched element 1 with a raised lip 22 and notched 23 which would co-act with receiver 13 , slot 13 A for a self guidance action. It is similar to the bayonet catch action of applicants' referenced patents.
[0086] FIG. 10C shows another notched form with a notch 23 C and a horizontal lip 22 C. This form provides a tip 24 C to guide the cam into slot 13 A.
[0087] FIG. 10D shows a cam form with a single roller 25 D and FIG. 10E shows a double roller 26 B for smoother transitions and increased cam life in more demanding and heavy duty applications, respectively. FIG. 10F shows a shaped cam 28 that is generally conical. It will enter the receiver slot and provide pull in with the longitudinal movement of the driving unit and rotation is unnecessary to its operation. Rollers, not shown, can be carried by the receiver or the conical shaped cam to reduce wear and friction.
[0088] Flow charts FIG. 11 and FIG. 12 , respectively indicate the lock to locked events and vice-versa for the cam locking system. The sensor switch 19 which is operated by slide 17 that determines the position and absence of the receiver 13 provides the requisite signals for the controller to operate the motor 10 .
[0089] Referring to FIGS. 13 and 14 there is shown a locking system like the one discussed with respect to FIG. 3 , for example, but with additional support means for the outboard end of the cam when in the extended portion. This provides additional strength against attempted prying open of the door.
[0090] In accordance with the present aspect of the invention, the cam 1 is preferably like that in FIG. 10C . A plate member 30 that can be affixed along wall bracket 5 , carries a bushing means 32 into which the extended portion 24 c of cam 1 fits and provides strengthened support of the cam outboard end.
[0091] As explained further herein, the present invention can be used with an axially rotatable pin with a finned end here shown on the door B in FIG. 17 . The pin upon rotation when the door is closed catches one of the fins against a bracket 132 on the cabinet C. Placement of at least one of such pin and bracket arrangements prevents prying of the door at a corner. With the cam locking means adjacent an opposite corner, both door opening corners are protected.
[0092] Unlocked to Locked for the Bayonet Locking System:
[0093] In controlling the motor FIG. 18 item 110 to change the state of the lock from unlocked to locked, the controller FIG. 18 Item 108 shall wait to receive a valid lock signal from the operator. This signal shall at a minimum be a sensor signal received by the controller that the bayonet FIG. 17 Item 101 is seated in the receiver as indicated by FIG. 19 (Receiver sensor closed). It is a requirement that the controller must measure the state change of the receiver sensor FIG. 20 Item 117 from open to closed circuit in order to initiate the locking event. In addition to this signal, the controller FIG. 18 Item 108 may also expect to receive a valid access control signal from the operator simultaneously, for example the electronic key. This dual signal requirement would serve the purpose of insuring the operator will not accidentally lock the access control means in the enclosure. The controller FIG. 18 Item 108 shall proceed to energize the motor FIG. 18 Item 110 in the reverse direction. The controller FIG. 18 Item 108 will wait for a position feedback indicator FIG. 18 Item 106 a (SW 1 ) which is measured by the controller CPU located on FIG. 18 Item 108 to determine the lock has landed in the secure state. In case the FIG. 18 Item 106 a (SW 1 ) sensor is failed, the controller uses a motor current feedback signal to detect end of FIG. 26 area 102 b end of travel by sensing a stall motor condition and to de-energize the motor. In case both sensors fail, the controller will discontinue operation based on elapsed time.
[0094] In addition to the typical locking control operation described above, several safety and fault tolerant monitoring processes must be included in the locking control algorithm. For example, when the controller proceeds to energize the motor, the bayonet will begin to turn and will proceed to be captured behind the stationary receiver device to accomplish the locking feature. At this interface, there can exist a misalignment of the bayonet to the receiver FIG. 17 item 113 and the bayonet Item 101 can jam into the receiver surface area FIG. 21 area 113 a , which would cause a failure of the lock. This failure can be detected by the electronics, which would proceed with a re-initialization process of the lock components (lock bayonet and controller).
[0095] The bayonet jam detection will most likely take place during the period the bayonet is rotating to pass behind the receiver. This period is detected by the controller by monitoring a feedback sensor that measures the FIG. 18 Item 102 which relates to the bayonet position, referred to as the FIG. 18 Item 106 b 30 degree sensor SW 2 . To properly recover from a bayonet jam event during the bayonet rotation period described above, the detection system we chose to implement is a system where the lock motor controller FIG. 18 Item 108 monitors two sensors and controls the lock motor FIG. 18 Item 110 as described below:
[0096] The bayonet receiver sensor FIG. 20 Item 117 , which is open when the lock is unlocked, would produce a closed signal when the bayonet seats in the receiver to initiate the locking event. Referred to as closed but not secure. If while the FIG. 18 Item 106 b (SW 2 ) sensor is closed (less than 30 degrees rotation), the receiver later produces an open signal to the controller to indicate the bayonet is no longer properly aligned behind the receiver.
[0097] A sensor that measures the current draw of the motor turning the bayonet. If while the FIG. 18 Item 106 b (SW 2 ) sensor is closed and motor current exceeds a pre-determined value which equals the stall current value of the motor selected for the application, the controller will determine that the bayonet is jammed into the receiver, or, possibly another type of bayonet restriction exists.
[0098] The bayonet jam recovery procedure that the controller shall follow is described below:
[0099] The controller FIG. 18 Item 108 shall proceed to de-energize the motor FIG. 18 item 110 to stop the bayonet FIG. 18 Item 101 from attempting to turn.
[0100] The controller shall proceed with a forward energization of the lock motor to return the bayonet to the fully unlocked position. Once the FIG. 18 Item 106 a (SW 1 ) sensor is closed and the fully unlocked position FIG. 21 is achieved by the bayonet, the controller will brake the FIG. 18 Item 110 motor and the controller FIG. 18 Item 108 will return to the unlocked operation mode. In this mode, the controller FIG. 18 Item 108 will wait for a locking initiation signal from the operator via a state change from opened to closed by the receiver sensor. FIG. 20 Item 117 .
[0101] Flow-charts FIG. 30 and FIG. 31 , respectively, indicate the lock to unlocked events and vice-versa for the bayonet locking system.
[0102] In accordance with another feature of the invention, referring to FIG. 17 , an axially rotatable pin 130 with a finned end 131 is here shown on the door B. The pin 130 upon rotation when the door is closed catches one of the fins 131 against a bracket 132 , here shown on the cabinet C. Placement of at least one of such pin and bracket arrangements prevents prying of the door at a corner. With the bayonet locking means adjacent an opposite corner, both door opening corners are protected.
[0103] With reference to FIGS. 32-40 , still another embodiment of the locking system 200 of the present invention can be understood. In this preferred embodiment, beginning with FIG. 32 , the locking system 200 consists of a latching assembly 201 including a motor 202 connected to a second drive gear 203 by a first drive gear 204 , a pair of mirror-image pivotable plates 210 A, B, and a latching plate 211 connected to the pivotable plates 210 A, B (see FIG. 40 ). The latching plate 211 connects to both latching plates 210 A, B and is configured to engage a receiving post 212 . Preferably, as shown in FIG. 40 , the latching plate 211 has a U-shaped notch 213 into which the post 212 is guided and secured.
[0104] Further, attached to a surface of the second drive gear 203 is a cam element 205 , the function of which is explained below. Alternatively, the cam element 205 may be connected through the gear 203 at a top surface with a second cam element 206 attached to a bottom surface of gear 203 , as shown in FIG. 36 . The dual cam elements divide the force applied by each can to the inner edge of the respective openings.
[0105] The cam elements 205 , 206 direct the movement of the pivotable plates 210 A, B by biasing against an inner edge 221 of the opening 217 on each plate 210 (see FIG. 40 ). The cam elements 205 , 206 may be made from a rigid material, relative to the gear 203 , or they may comprise a roller 218 or another element that would serve to apply a force on an inner edge 221 of the plate opening 217 at a reduced friction.
[0106] The pivotable plates 210 A, B are preferably held in place by a mounting post 224 through slot 225 ( FIG. 40 ). As illustrated in FIGS. 32-38 , the plates 210 A, B rotate and slide about the mounting post via slot 225 as a result of the movement of the cam elements 205 and 206 . That is, as gear 203 operates in a clockwise direction (as viewed in FIGS. 32-35 ), cam element 205 moves into contact with the inner edge 221 of the opening 217 . As a result, the pivotable plates 210 A, B are pivoted about mounting post 224 to move substantially perpendicular to a longitudinal axis of the receiving post 212 . As the gear 203 continues to rotate, the cam element 205 contacts a different portion of the inner edge 221 of the opening 217 and directs the pivotable plates 210 A, B in a direction substantially parallel to the longitudinal axis. This movement will be referenced in more detail below.
[0107] The receiving post 212 , as shown in FIG. 39 , is substantially cylindrical with two recessed flat surfaces 226 and 227 on opposing sides and positioned proximate one end of the post 212 . These surfaces 226 , 227 are engaged by the U-shaped notch 213 in the latching plate 211 of the locking system 200 . The post 212 may be round in cross-section or of any other shape, including square, polygonal, and oval. For some applications, the post 212 may include only a single recessed surface to be engaged. Preferably, the post is manufactured of a rigid material that can provide sufficient strength when engaged by the latching plate 211 , whether passing under and/or behind and/or through the post 212 .
[0108] A portion of the locking system 200 (e.g., the latching assembly 201 ) can be mounted in a door or in a cabinet, including any door jamb or frame, in any manner known to those of skill in the art. Likewise, the post 212 of the locking system 200 may be mounted in the other of the door or the cabinet, including any part of the door jamb or frame. By “cabinet” the present disclosure is meant to include a room, structure, container, box, machine, furniture, appliance, chamber, cavity, vessel, compartment, or the like, including any portion thereof, whether opened or closed, and having thereon an opening of any size or shape over which a door, panel or similar structure may be secured. Collectively, the cabinet and door may be referred to as a “unit” in this disclosure.
[0109] In a preferred embodiment, the post 212 is attached to a door (not shown) and enters an opening of the locking system 200 prior to a locking event. The locking event can be triggered by detection of the post 212 or detection of closure of the door by, for example, position switch 209 . The closing of position switch 209 sends a signal to a controller 230 , which initiates operation of the power train or motor 202 . The motor 202 will proceed to rotate a first driving member, worm gear 204 of FIG. 33 , which is coupled to turn a second driving member, gear 203 of FIG. 33 .
[0110] As described above, the rotation of gear 203 functions to move cam elements 205 , 206 about the gear axis. The first movement of the pivotable plates 210 A, B moves the latching plate 211 to engage the receiving post 212 about the recessed surfaces 216 , 217 . The drive gear 203 via cam elements 205 , 206 applies a force on the inner edge 221 of the opening 217 . As the plates 210 A, B pivot, the U-shaped notch 213 of latching plate 211 will latch onto the receiving post 212 by moving substantially latitudinal. The post 212 and the U-shaped notch 213 preferably consist of chamfered surfaces in order to guide any initial misalignment of the latch elements together properly.
[0111] Once the latching plate 211 moves latitudinal into the position of FIG. 34 , the unit is latched. The motor 202 will continue to rotate and the resulting force of the gear 203 and cam elements 205 , 206 on the shaped slot 225 of the pivotable plates 210 A, B will move the plates in a substantially longitudinal direction to the position illustrated in FIG. 35 . As the pivotable plates 210 A, B move longitudinally, the engaged post 212 is drawn inward, serving to draw the door of the cabinet into the cabinet. The motor 202 will continue to turn until the controller 230 that controls the motor 202 senses the position switches 223 and discontinues operation of the motor 232 to complete the locking operation.
[0112] To unlatch and unlock the locking system 200 in a preferred embodiment, the controller 230 will accept an access control signal from, for example, a numerical keypad (not shown), and in response the controller shall initiate the motor 202 to begin to unlatch the unit. In this embodiment, the controller reverses the motor 202 , turning the worm gear 204 and driving the gear 203 and cam element 205 , 206 . This movement occurs in an order opposite to that described above. That is, the cam elements 205 , 206 serve to move and extend the pivotable plates 210 A, B and thus the latching plate 211 longitudinally to allow the post 212 to retreat from its drawn in position shown in FIG. 35 . The resulting position is illustrated in FIG. 34 . From this position, the motor 202 continues to rotate the gear 203 and cam element 205 . The force of the cam element 205 on the opening 217 of the plates 210 A, B moves the latching plate 211 latitudinal to disengage the U-shaped notch 213 from the receiving post 212 to unlatch the unit as illustrated in FIG. 33 and allow opening of the door (see FIG. 32 ).
[0113] An advantage of the present invention is the U-shaped notch 213 in latching plate 211 which provides for two parallel engagement surfaces between the locking system 200 and the receiving post 212 . Engagement at two parallel surfaces along two surfaces of the post 212 provides 1) proper alignment of the post 212 with the latching plate 211 when the latching part of the locking process takes place, 2) greater strength of the connection, compared to the use of a single engagement surface, to allow the mechanism to draw-in the post 212 with a greater force, and 3) the ability to withstand greater pull-apart forces in the event of an attempted forced-entry to the unit. Of course, the notched surfaces of the post 212 need not be parallel to each other and the U-shaped notch 213 may take another form which provides double surface engagement.
[0114] Another advantage of an embodiment of the present invention is the shape and geometry of the pivotable plates 210 A, B. The plates 210 A, B provide two attachment arms connecting to the drive gear 203 and cam elements 205 , 206 . The two attachment arms serve to divide the load onto the two plates, instead of one, and increases the strength of the locking system 200 to prevent a forced entry.
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A locking system and a method for locking and unlocking a door to an opening in a cabinet or the like is disclosed. The locking system includes a latching assembly for attachment to one of either a door or a cabinet. The latching assembly includes a motor, a first driving member operatively coupled to the motor, a second driving member having a pivot and operatively coupled to the first driving member, first and second pivotable plates, each plate having a slidable pivot point and an opening defined therein by an interior edge, a latching plate joining each of the first and second pivotable plates, and at least a first cam element fixed to a first surface of the second driving member about the pivot and positioned within the opening of the first pivotable plate to engage the interior edge. A second cam element may be fixed to a second surface of the second driving member about the pivot and positioned within the opening of the second pivotable plate to engage the interior edge. A receiving post completes the locking system and is attached to the other of the door or the cabinet, the preferred receiving post including a longitudinal axis, and a latching portion.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to high-fidelity audio reproduction and more specifically to a method of enhancing low-frequency audio signals for better reproduction on small speakers.
2. Description of the Related Art
High-fidelity sound reproduction typically relies upon speakers capable of translating electrical impulses into sound waves that more or less accurately represent an original sound. Bass frequencies (for example, frequencies lower than 100 Hz) represent a particular challenge for the speaker design. To produce sounds at such bass frequencies, speaker designers have traditionally relied upon large and heavy designs (“woofers”) which are relatively expensive to produce. Woofers present both electrical and mechanical challenges for the manufacturer; they pose no less a problem for many consumers desirous of a more portable audio listening experience. In particular, headphones and portable “ear-bud” speakers have difficulties in reproducing bass frequencies without distortion and without loss in volume, sometimes severe.
Because of the difficulties reproducing bass frequencies, some audio reproduction systems have employed various means to enhance the bass response, or at least to improve the psychoacoustic perception of bass tones. In some schemes, psychoacoustic phenomena have been exploited to enhance a listener's subjective impression of bass tones. For example, U.S. Pat. No. 6,134,330 describes a known technique of enhancing the subjective experience of tones in the 40 to 100 Hz range by exploiting the phenomenon known as “virtual pitch” or “missing fundamental.” This phenomenon refers to the empirically verified fact that the presence of a series of harmonics can create the illusion of a fundamental tone at a lower frequency, where the harmonic or harmonics are at integer multiples of the (implied) fundamental frequency. This phenomenon is believed to be exploited by the cello, which is otherwise dimensionally too small to resonate in the lower range of the instrument. By adding harmonics, which are more easily reproducible with smaller transducers, one can create the impression of a bass fundamental that would be difficult to reproduce without large speakers.
As described in U.S. Pat. No. 6,134,330, it is known to filter an audio signal to select a bass subband, to generate harmonics of tones present in the bass subband, and the thereafter add said generated harmonics to the audio signal. The presence of the generated harmonics improves the perception of the low frequency portion of the audio. The generated harmonics are higher in frequency than the fundamental, and thus can be more efficiently reproduced with relatively small speakers.
SUMMARY OF THE INVENTION
In view of the above problems, the present invention includes a method of conditioning an audio signal to enhance perception of bass response. The method includes the steps: filtering said audio signal to produce a selected subband signal having at least one fundamental component with a fundamental frequency in a first frequency range; generating at least one harmonically-enriched signal from said selected subband signal, said harmonically enriched signal including at least one harmonic component at an integer multiple of said fundamental frequency; introducing a phase shift between said audio signal and said harmonically enriched signal to produce a phase-shifted audio signal; adding said phase-shifted audio signal to said harmonically enriched signal to produce a conditioned audio signal.
The invention in an apparatus aspect includes a signal conditioning circuit for conditioning an audio input signal to enhance perception of bass frequencies. The circuit includes: a filter, coupled to receive said audio input signal and arranged to select and to output a frequency subband signal having at least one fundamental tone; a harmonic generator, arranged to receive said frequency subband signal and generate a harmonic signal having at least one harmonic component; a phase shifter, coupled to receive said audio input signal and arranged to introduce a phase shift, thereby producing a phase-shifted audio signal; and a summing circuit, coupled to receive said phase shifted audio signal and said harmonic signal and to sum said signals to produce a conditioned audio signal having enhanced harmonics of selected frequencies.
These and other features and advantages of the invention will be apparent to those skilled in the art from the following detailed description of preferred embodiments, taken together with the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a is a graph of voltage as a function of time (on the horizontal axis) for an audio waveform in a prior art method of bass enhancement;
FIG. 1 b is a graph of a harmonic-rich waveform generated from the waveform of FIG. 1 a , by a prior art method;
FIG. 1 c is a graph showing the result of addition of the waveforms of FIGS. 1 a and 1 b by a prior art method;
FIG. 2 is a flow diagram showing steps of a method in accordance with the invention;
FIG. 3 a is a graph of voltage as a function of time (on the horizontal axis) for an audio waveform input into the method of the invention;
FIG. 3 b is a graph of a harmonic-rich waveform generated from the waveform of FIG. 3 a and phase shifted in accordance with the invention;
FIG. 3 c shows a waveform obtained by summing the waveforms of FIGS. 3 a and 3 b in accordance with the invention;
FIG. 4 is a schematic of an apparatus in accordance with the invention, with functional modules represented as blocks (“block diagram”); and
FIG. 5 is a block diagram of a signal processing system which can suitably be used to execute the method of the invention in an embodiment using a general or special purpose, programmable microprocessor.
DETAILED DESCRIPTION OF THE INVENTION
The invention concerns processing of audio signals, either in digital or analog form. In the discussion which follows, analog waveforms are often shown to illustrate the concepts; however, it should be understood that typical embodiments of the invention will operate in the context of a time series of digital bytes or words, said bytes or words forming a discrete approximation of an analog signal. The discrete, digital signal corresponds to a digital represention of a periodically sampled audio waveform. As is known in the art, the waveform must be sampled at a rate at least sufficient to satisfy the Nyquist sampling theorem for the frequencies of interest. The quantization scheme and bit resolution should be chosen to satisfy the requirements of a particular application, according to principles well known in the art. The techniques and apparatus of the invention could be, and typically would be applied independently in a number of channels, for example in a two channel “stereo” system or in a “surround” audio system having more than two channels. Although a digital realization of the invention is the primary focus of the disclosure, the invention is not limited to a digital embodiment and could be realized in analog circuitry.
FIGS. 1 a , 1 b , and 1 c show exemplary (continuous) waveforms as might be expected in a prior art method of bass enhancement by harmonic generation. FIG. 1 a shows a fundamental sinusoidal bass tone 10 . FIG. 1 b shows a harmonic-rich waveform 12 obtained by squaring the waveform of FIG. 1 a . As is known from trigonometry, the squared waveform 12 includes frequency components at 21 , where f is the frequency of the fundamental 10 . FIG. 1 c shows at 14 the sum of waveforms 10 and 12 . This waveform would be produced by prior art methods of bass enhancement by harmonic generation.
The waveform 14 does include added harmonic content (in this case even harmonic at frequency 2 f ). However, it is also apparent from the peak levels 16 (positive) and 18 (negative) that the waveform 14 has had a peak offset introduced, and is no longer symmetrical about the zero level 20 . Specifically, in the example, for normalized waveform with amplitude A, the waveform 14 has been shifted by a unwanted d.c. bias so that the positive peak 16 reaches a much higher absolute value than the negative peak at 18 .
The introduction of bias or offset in waveform 14 has undesirable consequences in that more dynamic range or “headroom” must be preserved to prevent saturation, a situation in which the wave exceeds the maximum value that can be represented in the given quantization range. For a given bit allocation, the offset will effectively reduce the usable range of values before saturation, effectively making the bit allocation less efficient. Scaling down the waveform would avoid saturation but increase quantization noise. The problem is particularly troublesome because the offset is not constant with amplitude, but instead varies with the root-mean-square (rms) value of the waveform. In the case of musical audio content, the rms value changes quickly and over a very large, unpredictable range. This makes it difficult to zero the waveform by simple subtraction of an offset. Frequent calculation of rms values would require a large number of calculations, requiring processing power and time. In many audio applications processing power and time are limited by the specification and cost considerations.
The present invention provides a simple method to reduce or eliminate the offset introduced by harmonic generation. The method of the invention consumes few processor cycles, involves little computation and memory, introduces little delay and requires relatively small amounts of memory.
FIG. 2 shows in procedural terms a generalized method in accordance with the invention. An audio signal is input in step 22 , suitably represented in time domain. For example, a linear PCM representation could be used. The input audio is split and follows parallel paths through two branches of the algorithm. In a first branch, the input audio is filtered (step 24 ) either by a low pass or bandpass filter, to select a bass frequency range which is to be enhanced. Suitably, the filtering step may extract a range of frequencies, for example from 0 to 200 Hz, for enhancement by harmonic generation. In another embodiment, the frequency range from 0 to 120 Hz is selected. The upper cutoff frequency will depend upon the anticipated limitations of the bass reproduction in the assumed speaker system that is to be employed. Multi-tap digital filters such as a finite-impulse-response (FIR) filter could be used. Alternatively, the input audio could be presented in a frequency domain representation; which can be filtered by appropriate windowing in the frequency domain. The resulting frequency representation can thereafter be converted to time domain by an inverse transformation (such as an inverse FFT).
Next, in step 26 the selected frequency range is processed by a method to generate harmonics. Any of several methods could be used. The waveform may be multiplied by itself (each sample squared) to generate “even” harmonics (at frequencies corresponding to the fundamental frequency multiplied by even integers). This method generates a strong harmonic at frequency 2 f , where f is the frequency of the selected fundamental tone. Higher ordered harmonics can be generated by cubing the signal or taking the waveform to higher (odd) powers to generate “odd” harmonics (at odd multiples of the fundamental frequency). Alternatively, the signal can be multiplied by a strongly non-linear function (such as an exponential function, analogous to a semiconductor diode junction). By whatever method, harmonics are generated to produce a harmonically enriched signal.
In step 27 the harmonically-enriched signal is filtered with a high pass or bandpass filter to attenuate the fundamental and remove D.C. components (if any, added during harmonic generation). Strong low-frequency fundamentals and D.C. components are found in some embodiments to interfere with faithful operation of a speaker system, particularly with low-cost, small speakers which are unable to cope with wide, low frequency excursions.
Removal of D.C. components from even-numbered harmonics in step 27 is optional but desirable to reduce offset. Nevertheless, the removal of D.C. offset in step 27 (or 26 ) is not sufficient-without the other steps of the invention-to completely remove unwanted offset. This is because further offset is (in conventional methods) introduced in later mixing or summation steps. Furthermore, the offset introduced in said mixing steps is highly variable, depending on signal content. This makes removal by conventional means difficult.
In a parallel signal path, the original input audio is shifted in phase (phase shift, step 28 ) preferably by an angle greater than zero degrees and less than 180 degrees (lead or lag). If we assume a strong tone at a fundamental frequency f 0 , our references to phase are measured in relation to the fundamental waveform (see FIG. 3 a ). It is found sufficient to choose an assumed fundamental frequency approximately at a centroid frequency in the bass region (for example, at 60 Hz for a Bass range defined from 0 to 120 Hz). It has been found most preferable to set the phase shift in this step 28 to approximately 90 degrees of phase. As explained below in connection with FIGS. 3 a - 3 c , this phase shift is most useful in decreasing or eliminating the offset introduced into the bass-enhanced waveform.
After phase shifting, it is optionally desirable to filter the shifted signal with a high pass filter to attenuate fundamental components below a cutoff frequency which defines the limitations of the intended bass transducers. As previously described, the presence of strong low-frequency signals or D.C. bias may interfere with the performance of low-cost, small speakers or audio transducers. Inclusion of high-pass filters in at least one of steps prevents the undue amplification of the fundamentals, which might otherwise occur.
Finally, the phase-shifted harmonic signal is added back to the original input audio signal (step 30 ). (Optionally, the phase-shifted harmonic signal might be scaled before adding it to the input audio signal, for greater control of the bass enhancement.) The sum of the input audio with the phase-shifted harmonics is output (step 32 ), either to the speaker or for further processing before eventual reproduction.
FIGS. 3 a , 3 b , and 3 c demonstrate the effect of the method of the invention on an exemplary sinusoidal waveform. One can compare these figures with the analogous FIGS. 1 a - 1 c to see the effects of phase shifting the harmonics before summing with the input audio. FIG. 3 a shows the input audio waveform at 40 . FIG. 3 b shows a waveform 42 derived by squaring (self-multiplication) the input audio 40 , filtering to remove fundamental, then phase shifting. Note that the waveform 42 differs in phase from the counterpart waveform 12 in FIG. 1 b . FIG. 3 c shows at 44 the sum of waveforms 40 and 42 . The peak positive excursion 46 of waveform 44 is noticeably lower than the peak positive excursion of the corresponding waveform 14 in FIG. 1 a . This helps prevent the digital value from exceeding the maximum value permitted within the digital representation scheme (linear pcm, for example). Peak negative excursion at 47 is almost the same absolute value as the positive excursion; compared to the prior art method of FIGS. 1 a to 1 c , bias or offset has been reduced or eliminated.
The invention may also include injection of odd harmonics (in step 26 ). Odd harmonics are less troublesome than even harmonics. The cubing of a waveform, for example, produces a wave generally symmetrical about zero, and thus does not tend to introduce offset. However, the phase shift introduced in step 28 above can also be applied to the odd harmonics without reducing the effectiveness. In addition, higher ordered even harmonics may be generated in step 26 . For example, fourth-order harmonics may be generated by raising the signal to the fourth power, and so forth.
It should be understood that the phase shift in step 28 is a relative shift, which introduces either lead or lag between the signal in the second branch and that in the first branch. In a simple variant of the invention, the signal in the opposite branch could undergo phase shifting, to produce essentially the same result. Accordingly, the method of the invention includes introducing a relative phase difference between a signal in a first branch and another signal in a second branch.
FIG. 4 shows in schematic form one embodiment of an apparatus in accordance with the invention. An audio signal is input to a first filter 50 which selects the bass region for enhancement. Suitably, the 20 to 120 Hz frequency range is selected (frequencies below 20 Hz are generally assumed absent). In a digital embodiment, the filtering may be performed by a specialized or programmable DSP integrated circuit, or by a programmable microprocessor and associated memory. The output of the first filter 50 is input to a harmonic generator 52 , which could be a programmable general or special purpose digital signal processing circuit. Harmonics may be generated numerically by the methods mentioned above, or by other known methods. The output of the harmonic generator 52 is then filtered by a second (high pass) filter 54 to attenuate the fundamental and remove any D.C. bias or offset. The result serves as a first input 56 into a summing circuit 61 .
The original input signal also passes through a phase shift circuit in a parallel branch or signal path. The phase shifting circuit suitably can be realized by a general purpose programmable microprocessor or a specialized dsp processor of the type used to implement an FIR digital filter. For example, the DSP processor chip “ADSP-21367”, available from Analog Devices, Inc. (ADI), could be programmed to introduce a suitable phase delay. In one embodiment a controlled phase is approximated by a simple delay of a predetermined number N of samples. For example, for a fundamental bass frequency of f 0 , the phase shift corresponding to a delay of tau=90 degrees is given by
delay=(sampling rate)/(4×(center frequency)) Eq. 1:
where the delay is in seconds and frequency in Hz. This is easily generalized to calculate the delay for any arbitrary Tau.
Tau=2π*delay*sampling rate Eq. 2:
(for tau in radians, delay in seconds, sampling rate in Hz).
In terms of number of samples in a discrete signal sampled at sampling rate (fs), a desired delay is approximated by the nearest integer number of samples N where N/fs equals Tau.
It can be seen that the number of samples required to introduced a desired phase delay depends on the assumed fundamental frequency of the bass fundamental tone f 0 . In a simple embodiment, the frequency can be approximated by an arbitrary frequency selected within the subband selected for enhancement, for example, the frequency situated mid-band in the subband. In one embodiment, the center frequency is assumed at 80 Hz.
In one specific embodiment, frequencies from 20 to 120 Hz are selected for enhancement. The phase delay can be approximated by introducing a delay given by the equations given above, with an assumed center frequency at 80 Hz.
In such embodiment, the delay is suitably set to 90 degrees (pi/4) at 80 Hz.
One extremely convenient method of introducing the delay is to store samples sequentially in a random access addressable memory. An memory offset number is then added or subtracted to the data address pointer, and the data retrieved is thereby delayed by a number of samples corresponding to the memory offset number. Alternatively, the audio signal data could be stored in a FIFO buffer or shift register with length corresponding to the desired delay.
After phase shifting, the phase-shifted signal is preferably filtered with a high pass filter 60 to attenuate fundamental and eliminate D.C. bias, then input into a second input 62 of the summation circuit 61 . The second input 62 of the summation circuit 61 thus receives a phase shifted and filtered version of the original audio signal. The summation circuit sums the harmonic-enriched signal with the phase shifted input audio signal to produce an output signal enriched with harmonics of bass tones in the selected bass subband. The enriched output signal is more easily reproduced by small speakers (such as headphones) to give a convincing psychoacoustic illusion of enhanced bass response.
As with the previously described filters, harmonic generator and phase shifting circuit, the summation circuit could also be realized by a programmable microprocessor suitably programmed to sum audio samples from input audio with the phase-shifted harmonic signal. This processor could be the same or a different processor working in parallel.
The method of the present invention requires little calculation and is effective over a range of amplitudes to reduce offset which would otherwise be introduced (an unwanted artifact accompanying the even harmonics of the bass tone). It thus introduces very little delay and the reduction in offset allows the processor to take advantage of a full dynamic range without saturation or re-scaling the signal.
FIG. 5 shows a block diagram of a signal processing system which can suitably be used to execute the method of the invention using a general or special purpose, programmable microprocessor. Microprocessor 100 communicates with program instructions stored in program memory 102 , which may be permanently written (firmware) or may be loaded from a mass storage device 104 . Appropriately buffered input audio samples are received at inputs 106 . The microprocessor acts under program control to perform the functions as described above in connection with FIG. 2 . Intermediate results and buffered data are written and read to/from data memory 108 , which may be random access memory. Sufficient memory to store at least sufficient samples to accommodate the required delay, plus sufficient memory for any multi-tap digital filters is required. Those with skill in the art will easily determine the memory requirements, based on these aforementioned, requirements, together with the number of channels to be accommodated and the specific frequency parameters chosen for a particular embodiment. Output signal is output in the form of a series of discrete digitized samples at output port 110 . Any suitable form of input and output interfaces may be employed, including SPDIF, HDMI, USB, “Firewire”, IIS bus, and other electrical or optical data interfaces.
It will be apparent that variations of this architecture could be employed. For example: several processors can be used in parallel or series configurations: some performing filter functions while others perform phase shifting and harmonic generation. Dedicated DSP or digital filter chips can be employed as filters. Multiple channels of audio can be processed together, either by multiplexing signals or by running parallel processors.
In other embodiments of the invention, for example and not by way of limitation, other methods of phase shifting such as the “Hilbert transform” could be substitutes for pure delay. It should also be recognized that signal phase is a relative concept. For this reason, it is possible to create numerous similar or functionally equivalent variant methods of introducing the phase shift: For example, where the above describes introducing a phase shift in a first “signal” branch of the signal path, equivalent results can be obtained by introducing a contrary phase shift in the “harmonic enriched” path. Similarly, phase shifts could be introduced in both paths in combination, to yield an algebraic sum of phase shifts.
If simple time delay is used to provide phase shift in the invention, numerous method are known and could be employed. In a processor-powered embodiment, memory offset or shifts could be introduced by various means, including indirect addressing and by using an address offset vector. In other embodiments, various delay lines could be employed including first-in, first out (FIFO) buffers, shift registers, or even analog delay lines such as charge coupled devices (CCD) or other analog memory devices.
In another subsystem of the apparatus and method, other means could be used to generate harmonics. For example, the signal could be transformed into a frequency domain representation (suitably by a discrete cosine transform). Frequency peaks in the bass region could then be pitch-shifted upward to harmonic frequencies, and the resulting signal inverse-transformed back into a time-domain representation for further processing. This method may be advantageous in some applications, but will generally require more processor power and memory allocation.
While several illustrative embodiments of the invention have been shown and described, numerous other variations and alternate embodiments will occur to those skilled in the art. Such variations and alternate embodiments are contemplated, and can be made without departing from the spirit and scope of the invention as defined in the appended claims.
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A method and apparatus for conditioning an audio input signal to enhance perception and reproduction of bass frequencies. Harmonics are generated and combined with a phase-shifted version of the audio input signal. Use of a controlled phase shift reduces or eliminates unwanted introduction of waveform asymmetry or D.C. offset.
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[0001] This application is a continuation of U.S. patent application Ser. No. 10/227,509, filed Aug. 23, 2002 (now, U.S. Pat. No. ______), and further claims priority to U.S. Provisional Application Ser. No. 60/314,674, filed Aug. 24, 2001, which is incorporated herein by reference in its entirety.
[0002] This invention was made with grant support from NIH (RO1-GM6059103) and NSF (CHE-9984282). Thus, the government has certain rights in this invention.
BACKGROUND OF INVENTION
[0003] The present invention relates to peptide chemistry. More particularly, it relates to the synthesis of anti-mitotic compounds that have use as anti-proliferative and anti-cancer agents. The compounds, which are synthetic peptide derivatives, are similar to natural substances, called diazonamides and analogues, originally isolated from a marine invertebrate, Diazona angulata . This invention relates to anti-mitotic diazonamides and analogues thereof, their use as anti-proliferative and anti-cancer agents, and methods of synthesis.
[0004] Cell mitosis is a multi-step process that includes cell division and replication. It is characterized by the intracellular movement and segregation of organelles, including mitotic spindles and chromosomes. Organelle movement and segregation are facilitated by tubulin polymerization. Microtubules are polymers of globular tubulin subunits formed into cylindrical tube structures. The dynamic polymerization of these structures is essential for cell mitosis. Gelfand and Bershadsky, “Microtubule dynamics: mechanism, regulation and function,” Ann Rev Cell Biol 1991 7:93-116.
[0005] Antimitotic compounds such as colchicine, vinblastine and taxol can inhibit microtubule polymerization. These compounds restrict tubulin polymerization and cells treated with these compounds become arrested in mitosis. During mitosis, tubulin subunits of the mitotic spindle are exchanged in a continual process with the pool of cellular tubulin. Taxol, for example, is a microtubule stabilizing drug that prevents depolymerization of the microtubules. Since blockage of spindle formation preferentially inhibits rapidly dividing cells, microtubule inhibitors have been effective agents against disorders which exhibit abnormal cell mitosis, such as cancer.
[0006] The products of secondary metabolic pathways in plants and microorganisms are a proven resource for structurally diverse and functionally unique small molecules which bind, covalently modify, or otherwise alter the function of proteins. Natural product ligands for human and pathogen proteins have revolutionized medicine in this century and have become both models and inspiration for the drug development enterprise. Cragg, J Nat Prod, 1997, 60:52-60; Shu, J Nat Prod, 1998, 61:1053-1071; Nicolaou et al. Angew Chem Int Ed, 2000, 39:44. A number of biological metabolites isolated from various sources, such as sponges, marine organisms and bacteria have been found to possess, in particular, anti-cancer activity. Fenical, “New pharmaceuticals from marine organisms,” Trends Biotech 1997, 15:339-341.
[0007] In 1991, Fenical and Clardy reported the composition and skeletal stereochemistry of two unique toxins extracted from tissues of the marine invertebrate Diazona angulata . Lindquist et al. J Am Chem Soc, 1991, 113:2303-2304. The structure of the major isolate, termed diazonamide B (1a, FIG. 1 ), was revealed upon X-ray diffraction measurements on a crystal of a p-bromobenzamide derivative (2, FIG. 1 ). These two new compounds represented a new class of halogenated, highly unsaturated cyclic peptides containing derivatives of three common amino acids, tyrosine (C1-C9), tryptophan (C18-C27) and valine (C31-35). (see 1 and 2, FIG. 1 ). These molecules possess an unusually rigid skeleton with little conformational freedom for the polycyclic core.
[0008] The diazonamides are a particularly complex expression of the more common polyoxazole/thiazole motif observed in peptidyl metabolites isolated from the marine environment. Belshaw et al. Science 1999, 284:486-489; Belshaw et al. Chem Biol, 1998, 5:373-84. Diazonamides comprise a complex arrangement of aromatic or heteroaromatic rings linked together as biaryls or as an intermediate quaternary center. Their synthesis requires three basic peptide modifications, 1) oxidative intramolecular coupling of aromatic side chains (forming cyclic biaryls and biaryl ethers), 2) electrophilic aromatic substitution, and 3) dehydrative cyclization to form oxazole and thiazole rings. An aromatic segment of unknown origin (C10-C17) and four proteinogenic amino acids have been incorporated into a rigid heterocyclic network which permits little extended conjugation of electron density. The fully substituted bis-oxazole (C26-C3 1), the C16-C18 biaryl linkage, and the hindered C10 quaternary center present a challenging molecule for synthesis.
[0009] In addition, diazonamide A has demonstrated potent antineoplastic activity. Lindquist et al. J Am Chem Soc, 1991, 113:2303-2304. In HCT-116 cells, a human colorectal carcinoma line, diazonamide exhibits GI 50 values (50% growth inhibitory concentration) of less than 15 ng/ml.
[0010] Naturally occurring diazonamide A sent for differential cytotoxicity analysis in the NCI 60 cell mean graph screening profile (COMPARE analysis) identified a correlation with known anti-mitotic agents, such as vinblastine, paclitaxel (taxol) and vincristine. (See Table 1 below.) Hélène C. Vervoort, PhD thesis, 1999, “Novel anticancer agents from Ascidiacea,” University of California, San Diego (Scripps Institution of Oceanography). The NCI (National Cancer Institute) 60-cell line human tumor screen is a measure of the effectiveness of a compound for inhibiting or killing various human cancers. It is a set of 60 different cancer cell lines against which chemical compounds can be tested against to determine if the compound has anti-cancer activity. Each compound has an individual “fingerprint” based on effectiveness in killing each of the 60 cancer cell lines. The 50% growth inhibitory concentration (GI50), total growth inhibitory concentration (TGI), 50% lethal concentration (LC50) for any single cell line are indexes of cytotoxicity or cytostasis. A pairwise correlation coefficient (PCC) is calculated for each compound in the database. Those compounds with the highest correlation coefficient are most similar to diazonamides. As a result, these compounds represent a new class of anti-tumor agents.
TABLE 1 COMPARE Analysis - Diazonamide in comparison to known anti-mitotic compounds. GI50 TGI LC50 Compound (PCC) Compound (PCC) Compound (PCC) Vinblastine 0.696 Vinblastine 0.679 Mitindomide 0.992 (antimitotic) (antimitotic) (Topo. II Inhibitor) Maytansine 0.622 Maytansine 0.615 Tetraplatin 0.961 (antimitotic) (antimitotic) (DNA Alkylating) Paclitaxel 0.618 Vincristine 0.610 5-FUDR 0.929 (antimitotic) (antimitotic) (RNA/DNA Anti- Metabolites) Vincristine 0.598 Rhizoxin 0.593 L-Alanosine 0.815 (antimitotic) (antimitotic) (RNA/DNA Anti- Metabolites)
[0011] Naturally occurring diazonamide must be isolated from the fractionation of tissues from the marine ascidian, Diazona angulata. 256.2 grams of lyophilized ascidian was originally used to collect 54 mg of diazonamide. Lindquist et al. J Am Chem Soc, 1991, 113:2303-2304. Because of the limited availability of the natural compound and its potent antimitotic properties, there have been substantial efforts made to synthesize diazonamides and their intermediates. Vedejs et al. Org. Lett., 2001, 3:2451-2454; Kreisberg et al., Tetrahedron Lett., 2001, 42:627-629; Wipf et al. Org. Lett., 2001, 3:1261-1264; Nicolaou et al., Angew Chem., 2000, 112:3615-3620; Fuerst et al., Org. Lett., 2000, 2:3521-3523; Bagley et al., Tetrahedron Lett., 2000, 41:6897-6900; Bagley et al., Tetrahedron Lett., 2000, 41:6901-6904; Lach et al. Tetrahedron Lett., 2000, 41:6893-6896; Vedejs et al. Org. Lett., 2000, 2:1031-1032; Vedejs et al. Org. Lett., 2000, 2:1033-1035; Magnus et al. Tetrahedron Lett., 2000, 41:831-834; Chan et al., Tetrahedron Lett., 2000, 41:835-838; Hang et al. Synthesis, 1999, 398-400; Magnus et al. Tetrahedron Lett., 1999, 40:451-454; Boto et al. Tetrahedron Lett., 1998, 39:8167-8170; Wipf et al. Tetrahedron Lett., 1998, 39:2223-2226; Jamison, T. F., PhD thesis, Harvard University, Cambridge Mass, 1997; Moody et al. J Chem Soc Perkin Trans, 1996, 16:2413-2419, Moody et al. Pure Appl Chem, 1994, 66:2107-2110; Ritter and Carreira, Angew Chem Int Ed. 2001, 41:2489-2495.
[0012] The challenge in synthesizing diazonamide arises from the core of the molecule, comprising a halogenated heterocyclic framework in a single atropisomeric form with a triaryl acetaldehyde and a quaternary C10 center (see 1 and 2, FIG. 1 ). Various strategies have been used to produce intermediates for diazonamide synthesis. Nicolaou and coworkers directed their effort towards the quaternary C10 center and the heterocyclic core of diazonamide. Nicolaou et al., Angew Chem., 2000, 112:3615-3620; Nicolaou et al., Angew Chem Int Ed, 2000, 39:3473-3478. They employed the Horner-Wadsworth-Emmon cyclization technique to induce ring closure of a benzofuranone-derived intermediate. They also utilized an intramolecular pinacol cyclization strategy of an aldehyde and an oxime. Nicolaou et al., Angew Chem., 2001, 113:4841-4845; Nicolaou et al., Angew Chem Int Ed 2001, 40:4705-4709. Wipf et al. discloses the approach of producing a bis-oxazoyl indole similar to that found in diazonamide A using consecutive Chang rearrangements. The endproduct of this effort does not achieve a ring closed material. Wipf et al., Org. Lett., 2001, 3:1261-1264. Vedejs and coworkers have produced a intermediate with the desired stereochemistry and ring closure using imino-Dieckman cyclization. Vedejs et al. Org. Lett., 2001, 3:2451-2454; Vedejs et al. Org. Lett., 2000, 2:1031-1032; Vedejs et al. Org. Lett., 2000, 2:1033-1035.
[0013] In an alternative approach, Magnus et al. disclosed the use of the photo-Fries rearrangement strategy to produce an intermediate that achieves ring closure and exhibits the desired stereochemistry, but does not possess the C 10 quaternary center. Magnus et al. Tetrahedron Lett., 2000, 41:831-834. The aforementioned attempts have not produced compounds with a diazonamide-like skeleton and exhibiting antimitotic activity.
[0014] The present invention describes the first successful laboratory synthesis of any diazonamide compound with antimitotic activity. Li et al. “Total synthesis of nominal diazonamides—Part I:Convergent preparation of the structure proposed for (−)-diazonamide A,” Angew Chem Int Ed, 2001, 40:4765-4769. The method described herein achieves completely synthetic diazonamide compounds through the combined use of catalytic Heck endocyclization, stereo controlled ring-contracting pinacol rearrangement, and indole arylation via internal photo induced electron transfer.
SUMMARY OF THE INVENTION
[0015] The present invention provides a method of synthesis of a broad class of heterocyclic compounds with anti-mitotic activity. Included in the invention are the compounds, compositions containing the compounds, methods of synthesis, and methods of treatment. These anti-mitotic compounds are useful as anti-proliferative/anti-cancer agents.
[0016] The present invention provides novel compounds having the general formula (I):
wherein
[0017] R 1 is OR 7 , NHR 7 ;
[0018] R 2 is H, Cl, Br, or I;
[0019] R 3 is H, Cl, Br, I, phenyl, ethynyl, straight chain saturated alkyl, or straight chain unsaturated alkyl;
[0020] R 4 is H, Cl, Br, I, phenyl, ethynyl, straight chain saturated alkyl, or straight chain unsaturated alkyl;
[0021] R 5 is H, straight chain saturated alkyl, straight chain unsaturated alkyl, branched chain saturated alkyl, branched chain unsaturated alkyl, aryl, or substituted aryl;
[0022] R 6 is O, NH, or S;
[0023] X is O, or S;
[0024] Y is O, or NR 8 ;
[0025] Z is H, 19-OH, or 21-OR 8 ;
[0026] R 7 is H, straight chain saturated alkyl, straight chain unsaturated alkyl, acyl, aryl, or heteroaryl; and
[0027] R 8 is H, straight chain saturated alkyl, straight chain unsaturated alkyl, acyl, or aryl.
[0028] The present invention also provides novel compounds having the general formula (II):
wherein
[0029] R 1 is OR 7 , NHR 7 ;
[0030] R 2 is H, Cl, Br, or I;
[0031] R 3 is H, CN, or CO 2 R 9 ;
[0032] R 5 is H, straight chain saturated alkyl, straight chain unsaturated alkyl, branched saturated chain alkyl, branched chain unsaturated alkyl, aryl, or substituted aryl;
[0033] R 6 is O, NH, or S;
[0034] R 7 is H, straight chain saturated alkyl, straight chain unsaturated alkyl, acyl, aryl, or heteroaryl;
[0035] R 9 is H, aryl, benzyl, heteroaryl, allyl, straight chain saturated alkyl, straight chain unsaturated alkyl, branched saturated chain alkyl, or branched chain unsaturated alkyl.
[0036] The preferred novel compound of this invention (JL-9) is of the following formula (III):
[0037] Also included as a preferred novel compound of this invention (JL-10) is of the following formula (IV):
[0038] The present invention further provides for novel compounds having the general formula (V):
[0039] wherein
[0040] R 1 is OR 7 , NHR 7 ;
[0041] R 2 is H, Cl, Br, or I;
[0042] R 3 is H, Cl, Br, I, phenyl, ethynyl, straight chain saturated alkyl, or straight chain unsaturated alkyl;
[0043] R 4 is H, Cl, Br, I, phenyl, ethynyl, straight chain saturated alkyl, or straight chain unsaturated alkyl;
[0044] R 5 is H, straight chain saturated alkyl, straight chain unsaturated alkyl, branched chain saturated alkyl, branched chain unsaturated alkyl, aryl, or substituted aryl;
[0045] R 6 is O, NH, or S;
[0046] X is O, or S;
[0047] Y is O, or NR 8 ;
[0048] Z is H, 19-OH, or 21-OR 8 ;
[0049] R 7 is H, straight chain saturated alkyl, straight chain unsaturated alkyl, acyl, aryl, or heteroaryl; and
[0050] R 8 is H, straight chain saturated alkyl, straight chain unsaturated alkyl, acyl, or aryl.
[0051] The present invention further provides for novel compounds having the general formula (VI):
wherein
[0052] R 1 is OR 7 , NHR 7 ;
[0053] R 2 is H, Cl, Br, or I;
[0054] R 3 is H, CN, or CO 2 R 9 ;
[0055] R 5 is H, straight chain saturated alkyl, straight chain unsaturated alkyl, branched saturated chain alkyl, branched chain unsaturated alkyl, aryl, or substituted aryl;
[0056] R 6 is O, NH, or S;
[0057] R 7 is H, straight chain saturated alkyl, straight chain unsaturated alkyl, acyl, aryl, or heteroaryl;
[0058] R 8 is H, straight chain saturated alkyl, straight chain unsaturated alkyl, acyl, aryl;
[0059] R 9 is H, aryl, benzyl, heteroaryl, allyl, straight chain saturated alkyl, straight chain unsaturated alkyl, branched saturated chain alkyl, or branched chain unsaturated alkyl.
[0060] The present invention is also directed to methods of synthesizing diazonamide and its analogs. The method comprises the steps of a) A, E and F-ring assembly (see 2, FIG. 1 ), b) Heck endocyclization, c) Ring-contracting pinacol rearrangment and d) internal indole arylation via photo-induced electron transfer cyclization.
[0061] The present invention also provides for a method of inhibiting the growth of a proliferating cell in a subject comprising administering to the subject of a compound of the formula (I), (II), (III), (IV), (V) or (VI) in an amount sufficient to inhibit the growth of the proliferating cell.
[0062] The present invention also provides for a method of inhibiting the growth of a tumor cell in a subject comprising administering to the subject of a compound of the formula (I), (II), (III), (IV), (V) or (VI) in an amount sufficient to inhibit the growth of the proliferating cell.
[0063] The compounds of the present invention described herein may be formulated into composition comprising carriers, excipients, and materials conventionally used in the production of pharmaceutical compositions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0064] The following drawings form part of the present specification and are included to further demonstrate certain aspects of the present invention. The invention may be better understood by reference to one or more of these drawings in combination with the detailed description of specific embodiments presented herein:
[0065] FIG. 1 shows the initial diazonamide structure assignments.
[0066] FIG. 2 shows the general scheme for diazonamide synthesis.
[0067] FIG. 3 shows the structures of the starting components for diazonamide synthesis.
[0068] FIG. 4 shows the early assembly steps of diazonamide synthesis.
[0069] FIG. 5 shows the Heck endocylization and ring contracting pinacol rearrangement steps of diazonamide synthesis.
[0070] FIG. 6 shows indole arylation via photo-induced electron transfer.
[0071] FIG. 7 shows the final assembly steps of diazonamide synthesis.
[0072] FIG. 8 shows the structure of synthesized diazonamide compounds, JL-9 and JL-10.
[0073] FIG. 9 shows the revised structures of diazonamide A and B.
[0074] FIG. 10 shows a partial 1 H/ 15 N-HSQC spectrum of natural diazonamide.
[0075] FIG. 11 shows the general scheme for synthesis of revised diazonamide structures.
[0076] FIG. 12 shows a scheme for the biosynthetic origin of revised diazonamide compounds.
[0077] FIG. 13 shows a bar graph comparing cytotoxic effects of JL-9, JL-10 with taxol and naturally occurring diazonamide A on SK-MEL-5 cells.
[0078] FIG. 14 shows a FACS Scan of HCT-116 cells treated with JL-9, taxol and vinblastine.
DETAILED DESCRIPTION OF THE INVENTION
[0079] The present invention relates to a broad class of heterocyclic compounds with anti-mitotic activity, diazonamide compounds and their analogs. The present invention also provides a method of synthesis of diazonamide compounds and their analogs. These anti-mitotic compounds are useful as anti-proliferative/anti-cancer agents.
[0080] In an embodiment of the invention, a method of synthesizing diazonamide compounds of formula (I), (II), (III), and (IV) is disclosed in accordance with the reaction scheme of FIG. 2 and further described in Example 1. The method of synthesis comprises generally the steps of a) A, E and F-ring assembly (see 2, FIG. 1 ), b) Heck endocyclization, c) Ring-contracting pinacol rearrangment and d) internal indole arylation via photo-induced electron transfer cyclization.
[0081] The practice of the present invention employs, unless otherwise indicated, conventional techniques of synthetic organic chemistry, protein chemistry, molecular biology, microbiology, and recombinant DNA technology, which are well within the skill of those in the art. Such techniques are explained fully in the literature. See, e.g., Scopes, R. K., Protein Purification Principles and Practices, 2d ed. (Springer-Verlag, 1987), Methods in Enzymology (S. Colowick and No. Kaplan, eds., Academic Press, Inc.), Sambrook et al., Molecular Cloning: A Laboratory Manual, 2d ed., Cold Spring Harbor Press, Cold Spring Harbor, N.Y., 1989, Handbook of Experimental Immunology, Vols. I-IV (D. M. Weir and C. C. Blackwell, eds., 1986, Blackwell Scientific Publications); House, Modern Synthetic Reactions, 2d ed., Benjamin/Cummings, Menlo Park, Calif., 1972.
[0082] FIG. 3 shows the structures of the initial components for diazonamide synthesis described herein. Tyrosine derivative 4 and bromide 5 exhibit protecting groups, N-Boc (or tert-butoxycarbonyl). Other carbamate protecting groups also suitable include trimethylsiloxycarbonyl (TeOC); benzyloxy carbonyl (CBz); and fluorenyl methyloxycarbonyl (FMoc).
[0083] In an embodiment of the invention, the structure 9 is prepared by a palladium catalyzed cross coupling reaction, also known as a Negishi coupling reaction ( FIG. 4 ). Negishi et al. Tetrahedron Lett, 1986, 27:2829-2832. A particularly useful variation of Takahashi's modification of a Negishi coupling reaction may be employed, which does not require a Zr-to-Zn transmetalation prior to the addition of the electrophile. Takahashi et al. J Am Chem Soc, 1995, 117:11039, 11040. In place of chloride 6, the corresponding styrylstannone, e.g. trimethyl or tributyl may be used (Stille coupling) or styroboronic acid (boronic ester) may be used. Lastly compounds of type 9 can be prepared by a carbonylative coupling between oxazoyl bromide 5, a molecule of carbon monoxide, and a suitable E ring nucleophile (e.g. o-benzyl-1-trimethylstanylphenol.)
[0084] Dibutylzirconocene is treated with α-chlorostyrene 6 in the presence of a solvent to generate species 8 ( FIG. 4 ). Dibutylzirconocene is generated in situ by treatment of commercial zirconacene dichloride with n-butyl lithium. Preferably, a reduced form of dibutylzirconocene is utilized to show its interaction with α-chlorostyrene 6 as an oxidative addition. Suitable solvents may include ether, dimethoxyethane, or preferably tetrahydrofuran. The aforementioned reaction occurs at a temperature of between −80° C. and −70° C., preferably −78° C., for several hours, preferably three hours.
[0085] The regiodefined vinyl Zr IV species 8 is coupled with bromide 5 in the presence of a palladium catalyst to generate species 9 ( FIG. 4 ). Suitable palladium catalysts include various palladium (0) salts and palladium (II) salts, such as palladium tetrakis (triphenylphosphine), dipalladium tris (dibenzylidene acetone) and palladium diacetate. The optimum condition utilizes a catalyst generated by pretreatment of palladium (II) acetate with tri-o-tolylphosphine (1:1 Pd:phosphine). The aforementioned reaction is incubated at a temperature of between 20° C. and 40° C., preferably room temperature, for several hours, preferably 8 hours.
[0086] The protecting groups found on species 9 may be removed to produce amine 10 in the presence of a solvent. Suitable solvents may include 1,2 dichloroethane, or preferably dichloromethane. The aforementioned reaction is run at a temperature of between −78° C. and −20° C., preferably beginning the reaction at −78° C. and allowing the reaction to warm to room temperature, for several hours, preferably 1.5 hours. Conditions for the removal of the protecting groups are well known to those familiar to the art of organic synthesis; e.g. hydrogenation to remove benzyl or benzyloxycarbonyl, a fluoride source (such as tetrabutylammonium fluoride) to remove silyl-based blocking groups, an acid source (such as trifluoroacetic acid) to remove tert-butoxycarbonyl or 4-methoxybenzyl, etc.
[0087] Referring to FIG. 4 , a tyrosine derivative 4 is condensed with species 10 in the presence of a solvent, a peptide coupling agent, and a mildly basic additive, such as puridine, triethylamine, morpholine, or preferably, diisopropylamine, to generate dipeptide 11. Suitable solvents may include ether, or preferably DMF (dimethylformamide). Suitable coupling reagents include HBTU (O-(1H-benzotriazole-1-yl)-N,N,N′,N′-tetramethyluronium hexafluorophosphate), various carbodiimides (e.g. dicyclohexocarbodiimide, diisopropylcarbodiimide), in the presence of HOBt (N-Hydroxybenzotriazole) or preferably TBTU (2-(1H-benzotriazol-1-yl)-1,1,3,3-tetramethyluronium tetrafluoroborate).
[0088] Referring to FIG. 5 , a Heck endocyclization reaction induces the formation of macrolactam 13. The reaction is catalyzed by palladium in the presence of solvent, Ag 3 PO 4 , and a phosphene ligand. Suitable palladium catalysts include palladium (0) and palladium (II) precatalysts, such as palladium tetrakis (triphenylphosphine), or dipalladium tris(dibenzylidene acetone). Phosphene additives, in general, inhibit the reactions, although 2-(di-tert-butylphosphanyl)biphenyl is used effectively; presumably not interacting with a templating effect (e.g. structure 12) thought to facilitate cyclization while still maintaining a soluble robust catalyst system by ligation of the metal. Suitable solvents may include dimethoxyethane, DMF, p-dioxane, or preferably tetrahydrofuran. The aforementioned reaction occurs at a temperature of between 60° C. and 90° C., preferably 75° C., for several hours, preferably eight hours. Ag 3 PO 4 serves to scavenge HI (hydroiodic acid) produced by the process. Other potentially applicable agents for this purpose include tertiary amines (triethylamine) and alkaline metal carbonates (e.g. K2CO3). Those familiar with the state of the art will recognize the large number of available methods to induce Heck endocyclization.
[0089] The C16 phenol of macrolactam 13 is derivatized as its 2-bromoethyl ether e in the presence of solvent, 2-bromoethyltriflate, and potassium t-butoxide, and subsequently subjected to oxidation in the presence of a dihydroxylation agent, solvent, followed by H 2 S to generate glycol 15. The dihydroxylation agent is an osmium reagent 14 preferably formed from osmium tetroxide and (1S,2S)-N,N′-bis(3,3-dimethylbutyl)-cyclohexane-1,2-diamine. The use of the osmium agent is required to override the intrinsic bias of the molecule to undergo hydroxylation with opposite face selectivity and ensure correct stereochemistry. The aforementioned reaction occurs at a temperature of between −60° C. and −30° C., preferably −50° C., for four hours. Hydrogen sulfide gas is introduced to the reaction to decompose the first formed osmium glycolate, thereby liberating the free vicinal diols.
[0090] Referring to FIG. 5 , glycol 15 is subjected to a ring contracting pinacol rearrangement under acidic conditions in the presence of p-TsOH to obtain the triaryl acetaldehyde 17 through a proposed bridging phenolium intermediate 16. The aforementioned reaction occurs at a temperature of between 80° C. and 100° C., preferably 95° C., for several minutes, preferably 40 minutes. The p-TsOH should be added in three equal portions at ten minute intervals during the first thirty minutes of the reaction.
[0091] The C2 amine of triaryl acetaldehyde 17 is carbamoylated, preferably with PhCH 2 OCO 2 Su) at room temperature (Su=N-succinimidyl). The C10 aldehyde is reduced in the presence of NaBH 4 , and CeCl3, the 2-bromoethyl ether is degraded with excess Rieke zinc at 0° C., and the E-ring phenol produced is ortho-brominated in the presence of tBuNH 2 /Br 2 complex to obtain 18.
[0092] The more acidic nucleophile in 18, (the phenol) is reetherified with o-nitro-benzylbromide (using a weak base to generate a phenoxide nucleophile) ( FIG. 5 ). The product is subsequently stirred with preferably moist trichloroacetic acid to generate a lactone 19. Other acids able to induce this internal nitrile alkoxylation include p-TsOH, dichloroacetic acid or methane sulfonic acid.
[0093] Referring to FIG. 6 , lactone 19 is opened with a tryptamine-derived methylaluminum amide 19b. A series of 10 steps are carried out to produce the aryl bromide 20.
[0094] The alcohol produced by the reaction is then oxidized with tetrapropyl ammonium perrhuthenate (TPAP) catalyst in the presence of stoichiometric amounts of n-methyl morpholine N-oxide (NMO) to give aldehyde 20. Aldehyde 20 can also be produced from 19 using a three step sequence of lactone hydrolysis, Dess Martin periodinane oxidation, and peptide coupling with tryptamine. Li et al., “Synthetic seco forms of (−)-Diazonamide A,” Angew Chem Int Ed, 2001, 40:2682-2685.
[0095] Aldehyde 20 is briefly photolyzed (350 nm, rayonet apparatus) in dilute dioxane solution (3 mM) to provide a crude C11 hemiacetal which is then acetylated with acetic anhydride (catalytic dmat, dichloromethane solvent) to afford a single diastereomer of acetate 21 ( FIG. 6 ). Techniques for photolytic decomposition of the ortho-nitrobenzo-based protecting groups are familiar in the state of the art.
[0096] A two-step oxidation/cyclodehydration protocol manipulates the acyl tryptamine segment of 21 into bis(oxazoyl)indole 22. These steps comprise subjecting 21 to DDQ (2,3-dichloro-5,6-dicyano-1,4-benzoquinone) oxidation to generate a C26 aryl ketone. This β-kyl amide is then cyclodehydrated using (Cl 3 C) 2 , Ph 3 P, and Et 3 N to afford 22. Wipf et al. Tetrahedron Lett, 1998, 39:2223-2226. The dehydration procedure can use iodine in place of (Cl 3 C) 2 , or, alternatively, preformed Ph 3 PBr 2 can be substituted for the entire (Cl 3 C) 2 , Ph 3 P, and Et 3 N.
[0097] UV irradiation of degassed solutions of 22 (300 nm, 5.0×10 −3 M in 3:1 CH 3 CN/H 2 O) results in loss of HBr and the formation of internal acylation product 25 ( FIG. 6 ). A single regioisomeric biaryl (one atropdiastereomer) is isolated from this reaction although there is competing production of uncyclized materials lacking bromine. One mechanism to interpret this Witkop-type cyclization invokes intramolecular photo-induced electron transfer from the indole chromophore to the adjacent bromo arene. Mesolytic elimination of bromide from the resultant radical-ion pair 23, biradical collapse, and prototropy in 4H-indole 24 would give 25.
[0098] To produce the dichloride 26, 25 is oxidized in the presence of 2:1 equivalence N-chlorosuccinimide (NCS) in a mixture of the THF and carbon tetrachloride as solvent. Commercial trichloroisocyanuric acid may substitute for NCS in this reaction ( FIG. 6 ).
[0099] Dichloride 26 undergoes partially hydrogenolysis under an atmosphere of hydrogen in the presence of palladium on charcoal catalyst in an alcohol solvent. The amine produced is reacylated with Z-L-Val-OH using TBTU as a coupling in DMS solvent. Stannoxane-catalyzed deacetylation of the acetyl hemiacetal and a final hydrogenolysis provides the structure originally proposed for (−)-diazonamide A 1b.
[0100] Amberlyst-15 acidic resin is mediates dealkylative C11 acetal formation ( FIG. 7 ). The benzyl carbamate of the product formed (27) is hydrogenolyzed and the free C2 amine produced acylated with L-α-hydroxy isovaleric acid using diethylphosphoryl cyanide as a coupling reagent to provide JL-9 28 ( FIG. 7 ).
[0101] After synthesis of the diazonamide compounds, the inventors performed subsequent analysis on the synthesized compounds as further described in Example 2. The synthetic material was remarkably unstable and its proton NMR spectrum differed from the spectrum of naturally occurring diazonamide. Further studies indicated that the C2 sidechain had been misassigned in the original characterization and that structure 2 ( FIG. 1 ) was also misassigned based in improper interpretation of X-ray crystallographic data. Li et al., “Total synthesis of nominal diazonamides-Part 2: On the true structure and origin of natural isolates,” 2001, Angew Chem Int Ed, 40:4770-4773. Taken together, and in light of 2-D NMR data from a trace sample of natural diazonamide A ( FIG. 10 ), the inventors have further characterized the naturally occuring diazonamides as described in Example 3 and in formulas (V) and (VI).
[0102] In another embodiment of the invention, a method of synthesizing diazonamide compounds of formula (V) and (VI) is disclosed in accordance with the reaction scheme of FIG. 11 and further described in Example 3. The revised structure assigned to diazonamide A 30 ( FIG. 9 ) indicates a direct lineage between its polycyclic structure and common amino acid components ( FIG. 12 ). Moreover, its synthesis can be approached by, in essence, remolding of a linear oligomeric precursor. Referring to FIG. 11 , polyamide 32 may be assembled by standard F-Moc-based peptide synthesis beginning with compounds 38-41. Treatment of 32 with excess (4-5 equivalence) DDQ may oxygenate the 2 indole benzylic positions to provide a diaryl ketone. This product then undergoes a double cyclodehydration when exposed to Ph3PBr2 in dichloromethane solvent. Removal of the allyl protecting groups in the bis(oxazoyl)indole product will then provide phenol 33 ( FIG. 11 ). A 2-electron oxidation of 33 using, for example, an iodine (III) reagent initiates a cyclization between an electron-deficient intermediate and the adjacent indole halo sidechain (as indicated) to afford 34. This substance may be photocyclized to a complete diazonamide skeleton 35 in a manner directly analogous to that used in the synthesis of 25 from 22 (see FIG. 6 ). Cleavage of the o-nitrophenylsulphonamide protecting group of 35 with a sulfur nucleophile provides 36a. Chlorination of 35 with n-chlorosuccinimide and cleavage of the o-nitrophenylsulphonamide protecting group with a sulfur nucleophile provides 36. The free amine can be acetylated with S-α-hydroxyisovaleric acid to provide 30a and diazonamide A 30. Moreover, beginning with components having varied substitutes as well as using alternative acetylating agents 42, a great many variants of a diazonamide will be available (37, 37a).
[0103] The compounds of the present invention have been shown to inhibit mitosis and cellular proliferation as determined using various cell lines, including tumor cell lines such as SK-MEL-5 (a human melanoma cell line), OVCAR 3 (a human adenocarcinoma cell line), and HCT-116 (a human colorectal carcinoma cell line), as described in Examples 5 and 6. Compounds of the present invention, when applied to cells in culture, inhibit proliferation of cells by reducing the number of viable cells in treated versus untreated cultures. Furthermore, the compounds of the present invention have been shown to arrest cell populations in mitosis in a manner similar to known antimitotic agents such as taxol and vinblastine (Example 6). In view of these aforementioned properties, it is contemplated that the compounds of the invention may be used to inhibit mitosis or cell division upon administration to dividing cell populations.
[0104] One aspect of the invention is a method of regulating cell growth and proliferation in normal and malignant cells, comprising the step of administering, to the cells, a compound of the present invention in an amount effective to regulate cell growth and proliferation.
[0105] Another aspect of the present invention is a method of inhibiting growth of proliferating cells comprising the step of administering, to the proliferating cells a compound of the present invention in an amount effective to inhibit growth or mitosis of the proliferating cell.
[0106] In addition, the compounds of the invention are useful in the treatment of diseases in which inhibition of cell growth or proliferation is desired.
[0107] Another aspect of the invention is a method for inhibiting the growth of tumor cells by contacting a tumor cell within a subject with a compound of the present invention under conditions permitting the uptake of said compound by said tumor cell and proliferation of the cell is inhibited. The tumor cell may be derived from a tissue selected from the group consisting of brain, lung, liver, spleen, kidney, lymph node, small intestine, blood, pancreas, colon, stomach, breast, endometrium, prostate, testicle, ovary, skin, head, and neck, esophagus, and bone marrow. The subject is preferably a mammal, more preferably human. In an embodiment, the compound is contained within a liposome. In yet another embodiment, the compound is administered intratumorally, in the tumor vasculature, locally to the tumor, regionally to the tumor, or systemically. In a further embodiment, the method comprises administering a second chemotherapeutic agent to said subject. In a further embodiment, the second chemotherapeutic agent may be cisplatin (CDDP), carboplatin, procarbazine, mechlorethamine, cyclophosphamide, camptothecin, ifosfamide, melphalan, chlorambucil, busulfan, nitrosurea, dactinomycin, daunorubicin, doxorubicin, bleomycin, plicomycin, mitomycin, etoposide (VP16), tamoxifen, raloxifene, estrogen receptor binding agents, taxol, gemcitabien, navelbine, farnesyl-protein transferase inhibitors, transplatinum, 5-fluorouracil, vincristin, vinblastin and methotrexate or any analog or derivative variant of the foregoing. In another embodiment, the method further comprises administering radiation to said subject. In another embodiment, the radiation is delivered local to a cancer site. In yet another embodiment, the radiation is whole body radiation. The radiation may be γ-rays, X-rays, accelerated protons, microwave radiation, UV radiation or the directed delivery of radioisotopes to tumor cells. In another embodiment, the method further comprises administering an anticancer gene to said subject. In an embodiment of the invention, the anticancer gene is a tumor suppressor. In another embodiment of the invention, the anticancer gene is an inhibitor of apoptosis. In another embodiment of the invention, the anticancer gene is an oncogene antisense construct.
[0108] A further aspect of the invention is a method for altering the phenotype of a tumor cell comprising the step of contacting the cell with a compound of the present invention, under conditions permitting the uptake of said compound by said tumor cell. The tumor cell may be derived from a tissue selected from the group consisting of brain, lung, liver, spleen, kidney, lymph node, small intestine, blood, pancreas, colon, stomach, breast, endometrium, prostate, testicle, ovary, skin, head, and neck, esophagus, and bone marrow. In an embodiment of the invention, the phenotype is selected from the group consisting of proliferation, migration, contact inhibition, soft agar growth, cell cycling, invasiveness, tumorigenesis, and metastatic potential. In another embodiment of the invention, the compound may be contained within a liposome.
[0109] Another embodiment of the invention is a method of treating a subject with cancer comprising administering to said subject a compound of the present invention under conditions permitting the uptake of said compound by said cancer cell, wherein proliferation of the cell is inhibited. In an embodiment of the invention, the subject is human.
[0110] Other objects, features and advantages of the present invention will become apparent from the following detailed description. It should be understood, however, that the detailed description and the 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.
[0111] The present invention also provides for physiological compositions comprising the compounds of the present invention. Aqueous physiological compositions of the present invention comprise an effective amount of a compound of the present invention or pharmaceutically acceptable salt thereof, dissolved and/or dispersed in a pharmaceutically acceptable carrier and/or aqueous medium.
[0112] The phrases “physiologically, pharmaceutically and/or pharmacologically acceptable” refer to molecular entities and/or compositions that do not produce an adverse, allergic and/or other untoward reaction when administered to an animal.
[0113] As used herein, “physiologically and/or pharmaceutically acceptable carrier” includes any and/or all solvents, dispersion media, coatings, antibacterial and/or antifungal agents, isotonic and/or absorption delaying agents and/or the like. The use of such media and/or agents for pharmaceutical active substances is well known in the art. Except insofar as any conventional media and/or agent is incompatible with the active ingredient, its use in the therapeutic compositions is contemplated. Supplementary active ingredients can also be incorporated into the compositions. For human administration, preparations should meet sterility, pyrogenicity, general safety and/or purity standards as required by FDA Office of Biologics standards.
[0114] The biological material should be extensively dialyzed to remove undesired small molecular weight molecules and/or lyophilized for more ready formulation into a desired vehicle, where appropriate. The active compounds may generally be formulated for parenteral administration, e.g., formulated for injection via the intravenous, intramuscular, sub-cutaneous, intralesional, and/or even intraperitoneal routes. The preparation of aqueous compositions that contain a therapeutically effective, amount of the compounds of the invention or physiologically acceptable salts thereof as an active component and/or ingredient will be known to those of skill in the art in light of the present disclosure. Typically, such compositions can be prepared as injectables, either as liquid solutions and/or suspensions; solid forms suitable for using to prepare solutions and/or suspensions upon the addition of a liquid prior to injection can also be prepared; and/or the preparations can also be emulsified.
[0115] Pharmaceutical forms suitable for injectable use include sterile aqueous solutions and/or dispersions; formulations including sesame oil, peanut oil and/or aqueous propylene glycol; and/or sterile powders for the extemporaneous preparation of sterile injectable solutions and/or dispersions. In all cases the form must be sterile and/or must be fluid to the extent that easy syringability exists. It must be stable under the conditions of manufacture and/or storage and/or must be preserved against the contaminating action of microorganisms, such as bacteria and/or fungi.
[0116] Solutions of the active compounds as free base and/or physiologically acceptable salts can be prepared in water suitably mixed with a surfactant, such as hydroxypropylcellulose. Dispersions can also be prepared in glycerol, liquid polyethylene glycols, and/or mixtures thereof and/or in oils. Under ordinary conditions of storage and/or use, these preparations contain a preservative to prevent the growth of microorganisms.
[0117] Compounds of the present invention can be formulated into a composition in a neutral and/or salt form. Pharmaceutically acceptable salts, include the acid addition salts and/or which are formed with inorganic acids such as, for example, hydrochloric and/or phosphoric acids, and/or such organic acids as acetic, oxalic, tartaric, mandelic, and/or the like.
[0118] The carrier can also be a solvent and/or dispersion medium containing, for example, water, ethanol, polyol (for example, glycerol, propylene glycol, and/or liquid polyethylene glycol, and/or the like), suitable mixtures thereof, and/or vegetable oils. The proper fluidity can be maintained, for example, by the use of a coating, such as lecithin, by the maintenance of the required particle size in the case of dispersion and/or by the use of surfactants. The prevention of the action of microorganisms can be brought about by various antibacterial and/or antifungal agents, for example, parabens, chlorobutanol, phenol, sorbic acid, thimerosal, and/or the like. In many cases, it will be preferable to include isotonic agents, for example, sugars and/or sodium chloride. Prolonged absorption of the injectable compositions can be brought about by the use in the compositions of agents delaying absorption, for example, aluminum monostearate and/or gelatin.
[0119] Sterile injectable solutions are prepared by incorporating the active compounds in the required amount in the appropriate solvent with various of the other ingredients enumerated above, as required, followed by filtered sterilization. Generally, dispersions are prepared by incorporating the various sterilized active ingredients into a sterile vehicle which contains the basic dispersion medium and/or the required other ingredients from those enumerated above. In the case of sterile powders for the preparation of sterile injectable solutions, the preferred methods of preparation are vacuum-drying and/or freeze-drying techniques which yield a powder of the active ingredient plus any additional desired ingredient from a previously sterile-filtered solution thereof. The preparation of more, and/or highly, concentrated solutions for direct injection is also contemplated, where the use of DMSO as solvent is envisioned to result in extremely rapid penetration, delivering high concentrations of the active agents to a small tumor area.
[0120] Upon formulation, solutions will be administered in a manner compatible with the dosage formulation and/or in such amount as is therapeutically effective. The formulations are easily administered in a variety of dosage forms, such as the type of injectable solutions described above, but drug release capsules and/or the like can also be employed.
[0121] For parenteral administration in an aqueous solution, for example, the solution should be suitably buffered if necessary and/or the liquid diluent first rendered isotonic with sufficient saline and/or glucose. These particular aqueous solutions are especially suitable for intravenous, intramuscular, subcutaneous and/or intraperitoneal administration. In this connection, sterile aqueous media which can be employed will be known to those of skill in the art in light of the present disclosure. For example, one dosage could be dissolved in 1 ml of isotonic NaCl solution and/or either added to 1000 ml of hypodermoclysis fluid and/or injected at the proposed site of infusion, (see for example, “Remington's Pharmaceutical Sciences” 15th Edition, pages 1035-1038 and/or 1570-1580). Some variation in dosage will necessarily occur depending on the condition of the subject being treated. The person responsible for administration will, in any event, determine the appropriate dose for the individual subject.
[0122] The compounds of the present invention may be formulated within a mixture to comprise about 0.0001 to 1.0 milligrams, and/or about 0.001 to 0.1 milligrams, and/or about 0.1 to 1.0 and/or even about 10 milligrams per dose and/or so. Multiple doses can also be administered.
[0123] Various routes of administration are contemplated for various tumor types. For practically any tumor, systemic delivery is contemplated. This will prove especially important for attacking microscopic or metastatic cancer. Where discrete tumor mass may be identified, a variety of direct, local and regional approaches may be taken. For example, the tumor may be directly injected with the compound. A tumor bed may be treated prior to, during or after resection. Following resection, one could deliver the compound by a catheter left in place following surgery. One may utilize the tumor vasculature to introduce the compound into the tumor by injecting a supporting vein or artery. A more distal blood supply route also may be utilized.
[0124] In addition to the compounds formulated for parenteral administration, such as intravenous and/or intramuscular injection, other pharmaceutically acceptable forms include, e.g., tablets and/or other solids for oral administration; liposomal formulations; time release capsules; and/or any other form currently used, including cremes.
[0125] Oral formulations include such normally employed excipients as, for example, pharmaceutical grades of mannitol, lactose, starch, magnesium stearate, sodium saccharine, cellulose, magnesium carbonate and/or the like. These compositions take the form of solutions, suspensions, tablets, pills, capsules, sustained release formulations and/or powders. In certain defined embodiments, oral pharmaceutical compositions will comprise an inert diluent and/or assimilable edible carrier, and/or they may be enclosed in hard and/or soft shell gelatin capsule, and/or they may be compressed into tablets, and/or they may be incorporated directly with the food of the diet. For oral therapeutic administration, the active compounds may be incorporated with excipients and/or used in the form of ingestible tablets, buccal tables, troches, capsules, elixirs, suspensions, syrups, wafers, and/or the like. Such compositions and/or preparations should contain at least 0.1% of active compound. The percentage of the compositions and/or preparations may, of course, be varied and/or may conveniently be between about 2 to about 75% of the weight of the unit, and/or preferably between 25-60%. The amount of active compounds in such therapeutically useful compositions is such that a suitable dosage will be obtained.
[0126] The tablets, troches, pills, capsules and/or the like may also contain the following: a binder, as gum tragacanth, acacia, cornstarch, and/or gelatin; excipients, such as dicalcium phosphate; a disintegrating agent, such as corn starch, potato starch, alginic acid and/or the like; a lubricant, such as magnesium stearate; and/or a sweetening agent, such as sucrose, lactose and/or saccharin may be added and/or a flavoring agent, such as peppermint, oil of wintergreen, and/or cherry flavoring. When the dosage unit form is a capsule, it may contain, in addition to materials of the above type, a liquid carrier. Various other materials may be present as coatings and/or to otherwise modify the physical form of the dosage unit.
[0127] In certain embodiments of the present invention, the use of lipid formulations and/or nanocapsules is contemplated for the introduction of the compounds of the present invention or pharmaceutically acceptable salts thereof into host cells. Lipid formulations and nanocapsules may be prepared by methods well known in the art.
[0128] “Liposome” is a generic term encompassing a variety of single and multilamellar lipid vehicles formed by the generation of enclosed lipid bilayers or aggregates. Liposomes may be characterized as having vesicular structures with a phospholipid bilayer membrane and an inner aqueous medium. Multilamellar liposomes have multiple lipid layers separated by aqueous medium. They form spontaneously when phospholipids are suspended in an excess of aqueous solution. The lipid components undergo self-rearrangement before the formation of closed structures and entrap water and dissolved solutes between the lipid bilayers (Ghosh and Bachhawat, 1991). However, the present invention also encompasses compositions that have different structures in solution than the normal vesicular structure. For example, the lipids may assume a micellar structure or merely exist as nonuniform aggregates of lipid molecules.
[0129] Liposomes within the scope of the present invention can be prepared in accordance with known laboratory techniques. In one preferred embodiment, liposomes are prepared by mixing liposomal lipids, in a solvent in a container, e.g., a glass, pear-shaped flask. The container should have a volume ten-times greater than the volume of the expected suspension of liposomes. Using a rotary evaporator, the solvent is removed at approximately 40° C. under negative pressure. The solvent normally is removed within about 5 min. to 2 hours, depending on the desired volume of the liposomes. The composition can be dried further in a desiccator under vacuum. The dried lipids generally are discarded after about 1 week because of a tendency to deteriorate with time.
[0130] In the alternative, liposomes can be prepared in accordance with other known laboratory procedures: the method of Bangham et al. (1965), the contents of which are incorporated herein by reference; the method of Gregoriadis, as described in DRUG CARRIERS IN BIOLOGY AND MEDICINE, G. Gregoriadis ed. (1979) pp. 287-341, the contents of which are incorporated herein by reference; the method of Deamer and Uster (1983), the contents of which are incorporated by reference; and the reverse-phase evaporation method as described by Szoka and Papahadjopoulos (1978). The aforementioned methods differ in their respective abilities to entrap aqueous material and their respective aqueous space-to-lipid ratios.
[0131] A physiological composition comprising the liposomes will usually include a sterile, pharmaceutically acceptable carrier or diluent, such as water or saline solution.
[0132] The present invention also provides kits comprising the compounds of the present invention or physiologically acceptable salts thereof. Such kits will generally contain, in suitable container means, an acceptable formulation of the compounds of the present invention in a physiologically acceptable formulation.
[0133] In order to increase the effectiveness of the compounds of the present invention, it may be desirable to combine these compositions with other agents effective in the treatment of hyperproliferative disease, such as anti-cancer agents. An “anti-cancer” agent is capable of negatively affecting cancer in a subject, for example, by killing cancer cells, inducing apoptosis in cancer cells, reducing the growth rate of cancer cells, reducing the incidence or number of metastases, reducing tumor size, inhibiting tumor growth, reducing the blood supply to a tumor or cancer cells, promoting an immune response against cancer cells or a tumor, preventing or inhibiting the progression of cancer, or increasing the lifespan of a subject with cancer. More generally, these other compositions would be provided in a combined amount effective to kill or inhibit proliferation of the cell. This process may involve contacting the cells with the compounds of the present invention and other agent(s) at the same time. This may be achieved by contacting the cell with a single composition or pharmacological formulation that includes both agents, or by contacting the cell with two distinct compositions or formulations, at the same or different time, wherein one composition includes the compound and the other includes the second agent(s).
[0134] Cancer therapies may include a variety of combination therapies with both chemical and radiation based treatments. Combination chemotherapies may include, for example, macrocylic lactones, cisplatin (CDDP), carboplatin, procarbazine, mechlorethamine, cyclophosphamide, camptothecin, ifosfamide, melphalan, chlorambucil, busulfan, nitrosurea, dactinomycin, daunorubicin, doxorubicin, bleomycin, plicomycin, mitomycin, etoposide (VP16), tamoxifen, raloxifene, estrogen receptor binding agents, taxol, gemcitabien, navelbine, farnesyl-protein tansferase inhibitors, transplatinum, 5-fluorouracil, vincristin, vinblastin and methotrexate, or any analog or derivative variant of the foregoing.
[0135] The compounds may also be used together with immunotherapy. Immunotherapeutics, generally, rely on the use of immune effector cells and molecules to target and destroy cancer cells. The immune effector may be, for example, an antibody specific for some marker on the surface of a tumor cell. The antibody alone may serve as an effector of therapy or it may recruit other cells to actually effect cell killing. The antibody also may be conjugated to a drug or toxin (chemotherapeutic, radionuclide, ricin A chain, cholera toxin, pertussis toxin, etc.) and serve merely as a targeting agent. Alternatively, the effector may be a lymphocyte carrying a surface molecule that interacts, either directly or indirectly, with a tumor cell target. Various effector cells include cytotoxic T cells and NK cells.
[0136] In yet another embodiment, the compounds of the present invention may be combined with gene therapy in which a therapeutic polynucleotide is administered before, after, or at the same time as the compound of the present invention. Delivery of a vector encoding one of the following gene products will have a combined anti-hyperproliferative effect on target tissues. In the following sections, genes which can be used in gene therapy in conjunction with administration of the compounds will be described. For example, the compounds may be administered together with an expression construct comprising a tumor suppressor gene, such as, but not limited to, the p53 and p16 gene.
[0137] Other genes that may be employed according to the present invention include Rb, APC, DCC, NF-1, NF-2, WT-1, MEN-I, MEN-II, zac1, p73, VHL, MMAC1/PTEN, DBCCR-1, FCC, rsk-3, p27, p27/p16 fusions, p21/p27 fusions, anti-thrombotic genes (e.g., COX-1, TFPI), PGS, Dp, E2F, ras, myc, neu, raf, erb, fms, trk, ret, gsp, hst, abl, E1A, p300, genes involved in angiogenesis (e.g., VEGF, FGF, thrombospondin, BAI-1, GDAIF, or their receptors) and MCC, the Bcl-2 protein family genes, and ICE-like protease genes.
[0138] Furthermore, the compounds of the present invention may be used in combination with surgery.
[0139] It is contemplated that other agents may be used in combination with the present invention to improve the therapeutic efficacy of treatment. These additional agents include immunomodulatory agents, agents that affect the upregulation of cell surface receptors and GAP junctions, cytostatic and differentiation agents, inhibitors of cell adhesion, or agents that increase the sensitivity of the hyperproliferative cells to apoptotic inducers. Immunomodulatory agents include tumor necrosis factor; interferon alpha, beta, and gamma; IL-2 and other cytokines; F42K and other cytokine analogs; or MIP-1, MIP-1beta, MCP-1, RANTES, and other chemokines. It is further contemplated that the upregulation of cell surface receptors or their ligands such as Fas/Fas ligand, DR4 or DR5/TRAIL would potentiate the chemotherapeutic abilities of the present invention by establishment of an autocrine or paracrine effect on hyperproliferative cells. Increases intercellular signaling by elevating the number of GAP junctions would increase the anti-hyperproliferative effects on the neighboring hyperproliferative cell population. In other embodiments, cytostatic or differentiation agents can be used in combination with the present invention to improve the anti-hyperproliferative efficacy of the treatments. Inhibitors of cell adhesion are contemplated to improve the efficacy of the present invention. Examples of cell adhesion inhibitors are focal adhesion kinase (FAKs) inhibitors and Lovastatin. It is further contemplated that other agents that increase the sensitivity of a hyperproliferative cell to apoptosis, such as the antibody c225, could be used in combination with the present invention to improve the treatment efficacy.
[0140] Hormonal therapy may also be used in conjunction with the present invention or in combination with any other cancer therapy previously described. The use of hormones may be employed in the treatment of certain cancers such as breast, prostate, ovarian, or cervical cancer to lower the level or block the effects of certain hormones such as testosterone or estrogen. This treatment is often used in combination with at least one other cancer therapy as a treatment option or to reduce the risk of metastases.
[0141] The invention is further illustrated by the following specific examples which are not intended in any way to limit the scope of the invention.
EXAMPLES
[0142] The following examples are included to demonstrate preferred embodiments of the invention. It should be appreciated by those of skill in the art that the techniques disclosed in the examples which follow represent techniques discovered by the inventor to function well in the practice of the invention, and thus can be considered to constitute preferred modes for its practice. However, those of skill in the art should, in light of the present disclosure, appreciate that many changes can be made in the specific embodiments which are disclosed and still obtain a like or similar result without departing from the concept, spirit and scope of the invention. More specifically, it will be apparent that certain agents which are both chemically and physiologically related may be substituted for the agents described herein while the same or similar results would be achieved. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope and concept of the invention as defined by the appended claims.
Example 1
Synthesis of JL-9 (Formula (III))
[0143] FIG. 2 shows a generic scheme for diazonamide synthesis of JL-9. The macrolactam harboring the central core will be built first. This begins by treating dibutyzirconacene 8 with α-chlorostyrene 6 at a −78° C. for three hours ( FIG. 4 ). The region defined vinyl Zr IV species 8 putatively generated in situ is coupled with bromide 5 ( FIG. 3 ) in a process catalyzed by palladium to afford a 1,1-disubstituted ethylene 9. This is the application of Takahashi's modification of a Negishi coupling neither requires nor benefits from a Zr to Zn transmetalation prior to addition of the electrophile. The protecting groups on 9 are subsequently removed by allowing the reaction mixture to come to room temperature for 1.5 hours to generate phenol 10. 10 is condensed with tyrosine derivative 4 in the presence of DMF and diisopropylamine to afford modified dipeptide 11.
[0144] Referring to FIG. 5 , 11 is exposed to catalytic Pd 0 in the presence of Ag 3 PO 4 at 75° C. for eight hours to produce lactam 13. This pivotal Heck endocyclization is novel in that success appears due to formation of a cyclic Pd II phenoxide (for example, 12 L=2-(di-tert-butylphosphino)biphenyl) prior to carbometalation of the vinylogous acrylonitrile within the catalytic cycle.
[0145] Compound 13 has the content of a diazonamide core and needs only to be oxidatively restructured. After the E-ring phenol is derivatized as its 2-bromoethyl ether, oxidation is achieved by exposure to the complex formed between OsO 4 and (1S,2S)-N,N′-bis(3,3-dimethylbutyl)-cyclohexane-1,2-diamine (14). Decomposition of the incipient Os VI glycolates with H 2 S provides a 93:7 ratio of diasteromeric syn—glycols favoring 15—a particularly gratifying outcome for this stereochemically mis-matched construction. This reaction occurs at −50° C. for four hours. With 15 in hand, its restructuring takes the form of a ring-contracting pinacol rearrangement initiated with dry p-TsOH ( FIG. 5 ) incubated at 95° C. for 40 minutes. The p-TsOH is added in three equal portions at ten minute intervals during the first thirty minutes of the reaction. While efficiency is modest for change, stereochemical communication is near perfect, presumably mediated by phenonium ion 16, as triarylacetaldehyde 17 is produced as a single C10 isomer at room temperature. It should be mentioned that the operations converting 13 to 17 are the only deliberate stereochemical manipulations. The axial asymmetries of the diazonamide polycycle can now be made an artifact of their assembly.
[0146] Alterations of compound 15 are necessary to prepare for incorporation of this additional diazonamide structure ( FIG. 5 ). Following carbamoylation of the C2 amine, reduction of the C10 aldehyde, and degradation of the 2-bromoethyl ether, the resultant E-ring phenol is selectively ortho-brominated to afford 18. The difference in acidity of free nucleophiles present in 18 allows selective re-etherification of the phenol. This product is then exposed to moist Cl 3 CCO 2 H to provide lactone 19 via intramolecular alkoxylation of the C29 nitrile and in situ hydrolysis of the formed imidate.
[0147] An indole segment can be incorporated into structures of type 19 via lactone opening with the dimethlyaluminum amide derived from tryptamine. The product of this reaction is then oxidized with catalytic TPAP and stoichiometric NMO to afford 20. Alternatively, a three step sequence, with an altered timing of events is therefore used to achieve the intended result (19→20) ( FIG. 6 ). Brief photolysis (350 nm) of 20 in dilute dioxane solution then provides a crude C11 hemiacetal that is acylated with Ac 2 O to afford a single diastereomer of acetate 21. Established techniques parlay the β-keto amide segment of this compound into oxazole 22 and position us for completion of diazonamide polycycle.
[0148] Irradiation of degassed solutions of 22 (300 nm-Rayonet, 5×10 −3 M in 3:1 CH 3 CN/H2O) results in loss of HBr and formation of internal arylation product 24. A single regiosomeric biaryl (a-single atropdiastereomer) is isolated from this reaction although there is competing production of uncyclized materials lacking bromine. One interpretation of this Witkop-type cyclization involves intramolecular photo-induced electron transfer from the indole ring to the adjacent bromo arene. Mesolytic elimination of bromide from the resultant radical ion pair 23, biradical collapse, and prototrophy in first formed 4H-indole 24 would give 25. The benefit realized by including Li+ ions into the medium, the inability of 4-methyl-2,6-di(tert-butyl)phenol to inhibit the reaction, and the observation that materials chlorinated at C25 and C27 do not photocyclize similarly are consistent with this simple view.
[0149] To complete the synthesis, compound 25 is chlorinated with N-chlorosuccinimide and treated with Amberlyst-15 acidic resin to initiate dealkylative C11 acetal formation ( FIG. 7 ). The benzyl carbamate of the product formed (27) is hydrogenolyzed and the free amine produced acylated with L-α-hydroxy isovaleric acid using diethylphosphoryl cyanide to provide JL-9 28, the compound of formula (III) ( FIG. 8 ).
[0150] Nuclear magnetic resonance (NMR) spectra were recorded on either a Varian Inova-400 or Mercury-300 magnetic resonance spectrometer. 1 H NMR chemical shifts are given in parts-per-million (δ) downfield from tetramethylsilane using the residual solvent signal (CHCl 3 =δ 7.27, acetone=δ 2.05, methanol=δ 4.87, tetrahydrofuran=δ 1.73) as internal standard. 1 H NMR information is tabulated in the following format: number of protons, multiplicity (s, singlet; d, doublet; t, triplet; q, quartet; m, multiplet, td, triplet of doublet; dt, doublet of triplet), coupling constant(s) (J) in hertz. The prefix app is occasionally applied in cases where the true signal multiplicity was unresolved and br indicates a broad signal.
[0151] JL-9 28: 1 H NMR (400 MHz, CD 3 OD, 25° C.): δ=7.50 (d, J=2.0 Hz, 1H), 7.46 (dd, J=8.4, 0.8 Hz, 1H), 7.36 (appt, J=7.6 Hz, 1H), 7.26 (dd, J=8.4, 2.0 Hz, 1H), 7.21-7.19 (m, 2H), 7.07 (dd, J=7.6, 1.2 Hz, 1H), 6.93 (appt, J=7.6 Hz, 1H), 6.88 (d, J=8.0 Hz, 1H), 6.84 (s, 1H), 4.97 (d, J=6.0 Hz, 1H), 4.61 (dd, J=11.6, 3.2 Hz, 1H), 3.89 (d, J=4.0 Hz, 1H), 3.46 (t, J=12.4 Hz, 1H), 2.80 (dd, J=12.8, 3.2 Hz, 1H), 2.32-2.27 (m, 1H), 2.14-2.09 (m, 1H), 1.09 (d, J=6.8 Hz, 3H), 1.02 (d, J=6.8 Hz, 3H), 0.96 (d, J=6.8 Hz, 3H), 0.92 (d, J=6.8 Hz, 3H). ES-MS: calcd for C 40 H 33 Cl 2 N 5 O 7 [M+H] + : 766.19, found: 766.30; calcd for C 40 H 33 Cl 2 N 5 O 7 [M−H] − : 764.17, found: 764.31; LR-MS (FAB) calcd for C 40 H 33 Cl 2 N 5 O 7 [M+H] + : 766.19, found: 766.35.
[0152] 2: R f =0.72 (35% EtOAc/benzene); [α] D 25 =−108.8° (c=0.32, MeOH); IR (film): v=3281, 2965, 1660, 1651, 1644, 1538, 1479, 1063, 752 cm −1 ; 1H NMR (400 MHz, [D 4 ]MeOH, 25° C.): δ=7.79 (d, J=8.4 Hz, 2H), 7.66 (d, J=8.4 Hz, 2H), 7.52 (s, 1H), 751 (s, 1H), 7.48 (dd, J=0.8, 8.4 Hz, 1H), 7.38 (app t, J=8.4 Hz, 1H), 7.24 (m, 2H), 7.11 (dd,J=1.2, 7.6 Hz, 1H), 6.97 (appt, J=7.6 Hz, 1H), 6.93 (s, 1H), 4.99 (d, J=6.0 Hz, 1H), 4.76 (dd, J=2.8, 12.0 Hz, 1H), 3.60 (app t, J=12.0 Hz, 1H), 2.92 (dd, J=3.2, 12.8 Hz, 1 H), 2.36-2.28 (sym 6-line m, 1H), 1.11 (d, J=6.8 Hz, 3H), 1.01 (d, J=6.8 Hz, 3H); 13 C NMR (75 MHz, [D 4 ]MeOH, 25° C.): δ=174.9, 168.6, 163.4, 159.7, 156.5, 154.8, 152.9, 141.9, 139.9, 136.7, 134.5, 134.4, 133.6, 133.0, 132.7, 130.7, 130.6, 130.6, 130.2, 129.6, 129.2, 128.8, 127.5, 126.4, 125.4, 124.5, 124.17, 124.16, 122.7, 119.5, 112.5, 104.0, 98.0, 63.1, 58.4, 56.6, 37.9, 31.6, 19.5, 18.8; ES-MS: calcd for C 42 H 27 Br 2 Cl 2 N 5 O 6 [M + +H]: 925.98, found: 926.04; calcd for C 42 H 27 Br 2 Cl 2 N 5 O 6 [M−−H]: 923.96, found: 923.96; HR-FAB-MS: calcd for C 42 H 27 Br 2 Cl 2 N 5 O 6 [M++Li]: 931.9865, found: 931.9878.
[0153] 26: R f =0.25 (50% EtOAc/benzene); [α] D 25 =−211.80° (c=O.40,MeOH);IR (film): v=3270, 2966, 1766, 1658, 1651, 1514, 1205, 1048, 754 cm −1 1 H NMR (400 MHz, [D 4 ]MeOH, 25° C.): δ=8.75 (s, 1H), 7.43 (d, J=8.0 Hz, 1H) 7.38-7.30 (m, 6H), 7.15 (d, J=7.6 Hz, 1H), 7.10 (d, J=7.6 Hz, 1H), 6.84-6.75 (m, 4H), 6.54 (d, J=1.2 Hz, 1H), 5.11 (s, 2H), 4.50 (dd, J=2.4, 11.2 Hz, 1H), 4.47 (d, J=8.8 Hz, 1 H), 3.97 (d, J=6.8 Hz, 1H), 3.22 (app t, J=12.8 Hz, 1H), 2.66 (dd, J=2.4, 12.8 Hz, 1H), 2.08-1.98 (m, 2H), 1.84 (s, 3H), 1.07 (d, J=6.4 Hz, 3H), 0.96-0.93 (m, 9H); 13 C NMR (75 MHz, [D 4 ]MeOH, 25° C.): δ=173.5, 172.3, 169.0, 163.8, 157.4, 156.5, 154.1, 154.0, 153.8, 140.9, 137.0, 135.3, 133.5, 132.2, 130.0, 129.1, 128.3, 127.9, 127.8, 127.8, 127.7, 127.1, 126.5, 126.3, 126.0, 124.2, 123.4, 122.8, 122.7, 121.6, 121.3, 117.1, 110.8, 100.7, 97.5, 66.5, 60.7, 59.2, 56.7, 55.2, 37.0, 31.1, 30.2, 19.4, 19.1, 18.4, 18.2, 17.5; ES-MS: calcd for C 50 H 44 Cl 2 N 6 O 10 [M++H]: 959.26, found: 959.25; calcd for C 50 H 44 Cl 2 N 6 O 10 [M−−H] 957.24, found: 957.26.
Example 2
Comparison of JL-9 and Original Diazonamide Structure
[0154] Characteristics of synthesized diazonamide compound, JL-9, were compared to naturally occurring diazonamide. JL-9 was susceptible to handling and its mobility on thin-layer chromatography differed from naturally occurring diazonamide A. Li et al. Angew Chem Int Ed, 2001, 40:4765-4769. Mass spectrometry indicates that late synthetic intermediates begin to decompose through net C10 deformylation almost immediately after unmasking a free C11 hemiacetal. The process completes upon attempted preparative HPLC purification of 1b ( FIG. 1 ) under conditions identical to those used to isolate natural (−)-diazonamide A. In addition, a second degradation pathway available in this series appears as a result of the cleavage of the strained macrolactam ring through diketopiperazine formation that involves the C37 amine and the C12 amide carbonyl. This suggested a misassignment of the C2 amine appendage.
[0155] Spectroscopic data for the heterocyclic cores of diazonamides A and B are nearly identical. So when the crystal structure of a p-bromobenzamide derivative of diazonamide B 2 was reported, the diazonamide A assignment seemed only to require reconciling its exact mass (765.1.998 amu) within the same framework. The high resolution FAB mass spectrum of diazonamide A shows a cluster of six ions between 765 and 770 amu, the relative intensity of which indicates the presence of two chlorine atoms. Heavy-atom analysis confirms that chlorine is the only halogen present. The molecular formula C 40 H 35 N 6 O 6 Cl 2 is consistent with this mass (Δ−0.3 ppm) although it was thought to reflect a desiccated form of the molecule as a result of a C11 hemiacetal that loses water during HRMS analysis. Likewise, the C11 diphenylacetal reported in 2 (see FIG. 1 ) was thought a result of net dehydration occurring during derivatization of diazonamide B with p-bromobenzoyl chloride. Hemiacetal functionality was considered a necessary part of both natural products to accommodate a small vicinal coupling between C11H and an exchangeable, one-proton resonance just over δ=7 in 1 H NMR spectra ([D 6 ]DMSO). The diazonamide A assignment 1b ( FIG. 1 ) was then completed by incorporation of a terminal valine residue which emanates from the C2 amine. In the context of a C11 hemiacetal, this designation does coincide with the high resolution mass measurement but, unfortunately, with little else.
[0156] Acid digests of diazonamide A do not produce valine. Lindquist, N., PhD thesis, University of California San Diego, 1989. 1 H NMR (360 MHz, ([D 6 ]DMSO) indicates the presence of two isopropyl groups in the molecule, but the N7 protons are reported as a sharp, one-proton doublet at δ=5.46. This resonance is, in turn, coupled (5.9 Hz) to the C37 methine hydrogen at δ=3.75. The corresponding C37 methine resonance in synthetic diazonamide 1b appears at δ=3.2 (400 MHz, [D 6 ]DMSO) and is broadened. In a triacetate derivative, the C37 proton shifts downfield to δ=5.11, although it now appears as a doublet rather than the more complex pattern one might expect for a C37 acetamide. Peracetylated diazonamide A shows three methyl singlets at δ=2.87, 2.23, 2.16 in its 1 H NMR spectrum (360 MHz, CDCl 3 ) and two new IR absorbances at 1760 cm −1 and 1725 cm −1 . Moreover, in non-acetylated material, C37 resonates at δ=76.9 (50 MHz, [D4]MeOH), which is considerably downfield from the corresponding carbon atom in a typical valine free-base. As a result, these observations are consistent with the view that the C37 substituent in natural diazonamide A is an alcohol rather than an amine.
[0157] For this to be true, the NH 2 to OH change dictates that a compensatory permutation be made at another position in the structure to rectify the attendant increase by 1 Da in molecular mass. This requires revising the X-ray structure assigned as 2. Notably, the exact mass of diazonamide B is 743.0340 amu. However, the structure proposed for this material 2 has the formula C 40 H 26 N 5 O 6 Cl 2 Br and an [M + +H] —H2O] ion has the calculated mass 744.0416 amu. The formula C 40 H 25 N 6 O 4 Cl 2 Br [M + +H]=743.0576 amu] is more consistent with the observed mass (Δ=2.4 ppm) and this suggests that a protonated nitrogen atom in diazonamide B has been mistaken for oxygen in 2 (see FIG. 1 ).
[0158] C11 hemiacetals in natural diazonamides are not indicated by mass spectrometry. Moreover, synthetic materials with this functional group (namely, 1b) ionize intact, which makes the O2 or O3 assignment suspect. In the structure assigned as 2, the observed C7-O2 bond length (1.371 Å) falls within the range typical for aryl C—O bond distances (1.353-1.409 Å) and deviates by just 1.5σ (σ=standard deviation) from the mean value of 1.385 Å (based upon 36 bonds in 20 related substructures found within the Cambridge Crystallographic Database). However, the C17-O3 bond, likewise expected to be an aryl C—O bond, is measured at 1.433(16) Å. This is 0.048 Å (3σ) longer than the mean and, notably, exceeds the maximal value (1.409 Å) observed for a bond of this type. Atom O3 also displays an unusually large thermal motion for an atom in a rigid group ( FIG. 1 ). The average B-factor (B eq ) in the core (O3 excluded) is 4.8(3) Å 2 while the temperature factor of O3 itself is 7.42 Å 2 , or 8.7σ above the average. This is in comparison to O2 and O3 in the X-ray structure refinement of synthetic diphenyl acetal 28, which are Beq=6.00 and 5.35 Å 2 , respectively. (see FIG. 7 ) This indicates that the O3 assignment should be changed to an element with fewer electrons and a larger covalent radius.
[0159] When taken together, these data are consistent with the electron density assigned as O3 being a protonated nitrogen atom and, by extension, the actual structure of (−)-diazonamide B being C11 diarylaminal 31 ( FIG. 9 ). This change, in combination with an S-configured C37 alcohol, gives 30 as our revised structure of (−)-diazonamide A. 1 H NMR spectra of 28 (JL-9) and its C37 epimer (derived from D-α-hydroxy isovaleric acid) are near identical. C37-S stereochemistry in 30 is based upon relative potencies in cell-based assays. (See Table 2).
[0160] An 1 H/ 15 N-HSQC experiment on natural diazonamide A was performed to support this assignment ( FIG. 10 ). The 1 H/ 15 N-HSQC experiment allows protons attached to nitrogen to be uniquely identified. Kay et al. J Am Chem Soc, 1992, 114:10663-10665. The 1 H/ 15 N-HSQC, 1 H/ 13 C-HSQC, and DQF-COSY experiments were recorded at 25° C. on a 500 MHz Varian Inova spectrophotometer.
[0161] The two dimensional spectrum shown in FIG. 10 indicated four such connectives in the natural product: δ=12.82 (N3H); δ=8.66 (N6H); δ=7.68 (N1H); δ=7.16 (N2H). The proton resonance at δ=7.16 is coupled to C11H (DQF-COSY) and was originally assigned as O7H in 1b. Moreover, the exchangeable one-proton doublet at δ=5.46, first identified as N7H 2 , is not coupled to 15 N, which is consistent with our C37 hydroxyl model.
[0162] The inventors initially considered the possibility that misassignments were made only in the C2 amine side chain. An a-hydroxy amidine congener of 1b was prepared. This material incorporates a C37 carbinol and does have the same net atomic composition as 1b. However, chromatographic and spectroscopic properties of the compound rule it out as a possibility.
Example 3
Synthesis of Naturally Occuring Diazonamide
[0163] Synthesis of compounds of formula (IV) and (V) is disclosed in accordance with the reaction scheme of FIG. 11 . In particular, polyamide 32 may be assembled by standard F-Moc-based peptide synthesis beginning with compounds 38-41. Treatment of 32 with excess (4-5 equivalence) DDQ may oxygenate the 2 indole benzylic positions to provide a diaryl ketone. This product then undergoes a double cyclodehydration when exposed to Ph3PBr2 in dichloromethane solvent. Removal of the allyl protecting groups in the bis(oxazoyl)indole product may then provide phenol 33 ( FIG. 11 ). A 2-electron oxidation of 33 using, for example, an iodine (III) reagent initiates a cyclization between an electron-deficient intermediate and the adjacent indole halo sidechain (as indicated) to afford 34. This substance may be photocyclized to a complete diazonamide skeleton 35 in a manner directly analogous to that used in the synthesis of 25 from 22 (see FIG. 6 ). Chlorination of 35 with n-chlorosuccinimide and cleavage of o-nitrophenylsulphonamide protecting group with a sulfur nucleophile provides 36. This free amine can be acetylated with S-α-hydroisovaleric acid to provide diazonamide A 30.
Example 4
Biosynthetic Origin of Diazonamide Compounds
[0164] The aforementioned studies suggest that diazonamide compounds may be biosynthetically constructed from four natural amino acids ( FIG. 12 ). The polyheterocyclic core may be a derivative of an oxidized, 4,7-linked ditryptophan unit with the macrolactam ring being formed by a net oxidative cycloaddition between tyrosine and tryptophan. Although the oxidative cycloaddition has yet to be identified, the production of dehydrodiconiferyl alcohols during lignan biosynthesis may reveal a plausible analogy. Gang et al. Chem Biol., 1999:6:143-151.
Example 5
Growth Inhibition Activity of Diazonamide Compounds
[0165] MTT assays were performed to demonstrate the cytotoxic effect of JL-9 on SK-MEL-5, a human malignant melanoma cell line. This assay measures cellular viability and proliferation based on the ability of live cells to take up and cleave a tetrazolium salt to generate a colored product. FIG. 13 shows that JL-9 has a potent cytotoxic and growth inhibitory effect on SK-MEL-5. JL-9 significantly inhibits cell proliferation in comparison to JL-10, an inactive analogue. Similar results have been obtained with various tumor cell lines, such as HCT-116, a human colorectal carcinoma, OVCAR-3, a human ovarian adenocarcinoma, 786-0, a human renal cell adenocarcinoma, BSC-1, a kidney epithelial cell line from African green monkey, and CHO-K1, a Chinese hamster ovarian epithelial cell line.
[0166] A growth inhibition study was also conducted using OVCAR-3 (a human ovarian adenocarcinoma) cells. Human ovarian adenocarcinoma OVCAR-3 cells are treated with diazonamide and control compounds for 48 hours and evaluated for cell viability using the Promega CellTiter-Glo™ Assay (Promega, Madison, Wis.). This assay uses luciferase to measure ATP as indicator of metabolically active cells. The results are shown in Table 2 below.
[0167] JL-9 28 is >50-fold more potent than amine JL-10 29 at inhibiting the growth of human ovarian adenocarcinoma OVCAR-3 in vitro, while being equipotent to natural diazonamide A and paclitaxel.
TABLE 2 In Vitro Cytotoxicity Assay Compound GI50 (nM) natural diazonamide 8 JL-9 28 16 JL-9 (epi-C37) 28 191 JL-10 29 845 2 >10,000 paclitaxel 8
Example 6
FACS (Fluorescence Activated Cell Sorting) Analysis
[0168] FACS Analysis was performed on HCT-116 cells to examine the effect of JL-9 on mitosis. 150,000 HCT-116 cells were incubated per well with media into six well tissue culture plates. Cells were allowed to adhere for 16-18 hours. Media containing 0.01% ethanol (vehicle control), 30 nanomolar (nM) taxol, 30 nM vinblastine and 30 nM JL-9 was added to cells and incubated for 12, 24, 36, or 48 hours. At these time points, cells were harvested with 0.25% trypsin 1 mM EDTA, and transferred to 1.5 ml Eppendorf tubes. Cells were pelleted and washed twice with 1× PBS. Cells were then fixed in −20° C. 100% ethanol and stored at 4° C. Cells were pelleted from 100% ethanol, washed once with 1× PBS, and treated with Vindelov's propidium iodide solution (50 ug/ml propidium iodide, 0.01 mM NaCl, 0.1% IPEGAL, 0.01 mg RNase) and 1 mg/ml RNAse for 30 minutes at 37° C. Propidium iodide is a fluorescent marker that binds to nucleotides. It can be used with FACS scan analysis to determine the ploidy of a population of cells. FACS scan analysis was performed using Beckman-Dickinson FACScan instrument. Data was analyzed using Cell Quest software.
[0169] FIG. 14 demonstrates that JL-9 arrests HCT-116 cells in the tetraploid (4n) state in a similar fashion to other anti-mitotic agents, taxol, and vinblastine. This is in contrast to control treated samples which exhibit both diploid and tetraploid populations.
Example 7
Determination of Effect of JL-9 on Cellular Tubulin Cytoskeleton Using Indirect Immunofluorescence
[0170] Immunofluorescence was performed on JL-9, taxol, vinblastine, control-treated OVCAR-3 cells to examine their effects on tubulin cytoskeleton. Cells were grown on 2 cm glass cover slips in tissue culture wells. Media containing JL-9, vinblastine, or taxol was added at various concentrations and incubated for 12 or 23 hours. Hoescht 33343 nuclear dye was added directly to the media (1.5 ug/ml) and incubated at 37° C. for 30 minutes. Coverslips were washed 3× with 1× PBS and fixed for 10 minutes with −20 C 100% methanol. Coverslips were washed 3× with 1× PBS/1% BSA and treated directly with a 1/2000 dilution of anti-α-tubulin antibody (mouse anti-human). Coverslips were washed 3× with 1× PBS/1% BSA and treated with 1/500 dilution of fluorescently conjugated goat anti-mouse secondary antibody (Alexa Fluor 488). Coverslips were washed 3× with 1× PBS/1% BSA and mounted on microscope slides using mounting media (Aqua Poly Mount). Images were obtained using Zeiss Axiovert 100M digital light and confocal microscopy. Our data demonstrate that JL-9 treatment creates aberrant effects on the cytoskeleton and formation of abnormal mitotic spindles.
[0171] Immunofluorescence was also performed on JL-9, JL-10, taxol and vinblastine-treated BSC-1 cells subjected to thymidine block. BCS-1 African Green Monkey kidney cells were treated for 18 hours in culture medium containing 2 mM thymidine and then returned to normal medium containing 100 nM of taxol, vinblastine, JL-10 (control) or JL-9 for 12 hours. During the last 30 minutes, Hoecht's dye was added to 100 nM to stain chromosomes. Cells were fixed in cold methanol and stained with antibody specific for alpha tubulin. Images of the organization of microtubules in spindles were collected with a laser scanning confocal microscope using a single 488 nm excitation wavelength.
[0172] Mitotic figures were frequently found in samples treated with JL-9, taxol or vinblastine. None of the cells are able to construct normal bipolar mitotic spindles. This is in contrast to cells treated with JL-10, which resembled the vehicle controls.
[0173] The present invention is not to be limited in scope by the specific embodiments described herein. Indeed, various modifications of the invention in addition to those described herein will become apparent to those skilled in the art from the foregoing description and accompanying Figures. Such modifications are intended to fall within the scope of the appended claims. Various references are cited herein, the disclosure of which are incorporated by reference in their entireties.
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The application discloses novel synthetic compounds, modeled after unique toxins extracted from the marine invertebrate Diazona angulata useful in the treatment abnormal cell mitosis. The application also discloses novel methods for synthesis of these compounds and methods of using these compounds.
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CROSS-REFERENCED TO RELATED APPLICATIONS
[0001] This application claims the benefit of PPA Ser. No. 60/899,784, filed Feb. 5, 2007 by the present inventor.
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] This invention generally relates to firearms, specifically to manufacturing processes for strengthening firearm barrels to withstand temperatures exceeding 800 degrees Fahrenheit during the course of an extending firing schedule.
[0004] 2. Prior Art
[0005] Barrels for firearms are traditionally manufactured from various allows of steel. Lining barrels with various foreign materials in order to provide resistance to corrosion, increased velocity and long service life has been a routine practice for small arms during the past 100 years.
[0006] 416 stainless steel has been used to prevent corrosion but is generally not as well suited for use as a firearm barrel as compared to the 4140 and 4150 chrome molly steel. 4140 and 4150 are very popular for use in military small arms such as the Colt M16.
[0007] During the United States involvement in Vietnam barrel bore rusting caused weapon malfunctions. 4150 chrome molly steel barrels would rust in the humid environments. Further the small, high pressure projectile which the M16 fired eroded the chamber of the barrel rapidly. A chrome lining was applied to the barrel in order to extend the service life of the weapon.
[0008] Chrome lined barrels present several problems. First it is very difficult to apply the chrome evenly for large production runs. As a result accuracy of the host weapon suffers. Chrome lining does not allow the barrel to operate at temperatures over 800 degrees for any prolonged period of time.
[0009] Other ideals such as composite gun barrels as depicted in U.S. Pat. No. 6,889,464 offers a light weight alternative which cools faster than a standard barrel. Unfortunately the resins used in the construction are not suitable for sustained high rates of fire. Eventually due to high heat the resin will break down rendering the barrel unusable.
[0010] Firearm barrels which are exposed to temperatures exceeding 800 degrees for a prolonged time will loose temper quickly eroding the barrel chamber. This results in the firearm malfunctioning.
[0011] Other linings such as described in U.S. Pat. No. 7,197,986 are not useable with stainless steel barrels. The proposed invention of the above referenced patent does nothing to increase the strength of the barrel at higher temperatures. The coating described is limited to protecting the chamber and rifling of the barrel. When a firearm is being operated for prolong periods of time at high temperatures the temper of the barrels its self is the primary problem to over come.
OBJECTS AND ADVANTAGES
[0012] Accordingly several objects and advantages of the present invention are
(a) To provide a process which will enhanced corrosion resistance to both chrome moly and stainless steel barrels (b) To provide a process which will extended barrel service life by protecting the surface of the chamber and rifling of a firearm barrel (c) To provide a heat treat process which will allow the barrel to maintain its temper at high temperatures (d) To provide a oxidation layer which will minimize friction between the barrel chamber and a spent cartridge (e) To provide a oxidation layer which will reduce friction between the bore and a discharged projectile (f) To provide a process which may be applied to a variety of steel (g) To provide a oxidation layer around the gas port to as to extend the service life of auto loading rifles
[0020] Still further objects and advantages will become apparent from a consideration of the ensuing description and drawings.
SUMMARY
[0021] This invention is in answer to the steady increase of the use of hotter burning gun powder for performance and the full automatic utilization for more rounds per minute. Both characteristics have continued to push the gun barrel life to the limit with regard to hot strength and barrel erosion. Until now, many attempts have been made to improve barrel performance with insufficient success. It is safe to say that gun barrel performance has been one of the primary limits to the increase of gun firepower.
[0022] A new method for increasing gun barrel performance is disclosed herein and is more than simply a gun barrel coating or lubricant. The present invention is a simple but effective method for enhancing the performance of the gun barrel itself and introduces additional benefits noted herein.
[0023] One object of the present invention is the composite hardening of the barrel. The barrel is initially hardened to HRC 50-55 after the chambering and machining process are complete.
[0024] Another object of the present invention is to provide a simple but meaningful method of improving the metal of the gun barrel with a liquid salt dip nitride surface conversion which tempers the barrel steel and leave a black oxide surface layer which is extremely resistance to corrosion. This process does not add significantly to the dimensions of the barrel.
[0025] While the interior and exterior of the barrel are being oxidized through the process of a liquid salt dip those same surfaces are also being heat treated to a HRC 68-72 to a depth of fifteen thousandths of an inch.
[0026] The method I am describing as novel creates a core barrel hardness of HRC 50-55 and a diffusion layer about fifteen thousands deep on the interior surface of the barrel which is HRC 68-72. This diffusion layer will extend the life of the barrel as compared to popular coatings such as chrome lining. As the surface oxidation erodes the bare metal underneath is harder than the metal present under a chrome lining.
[0027] My method is superior to coatings because it is actually changing the property of the barrel steel and is not limited to what types of steel may be processed.
DRAWINGS
[0028] The novel features believed to be characteristic of the invention, together with further advantages thereof, will be better understood from the following description considered in connection with the accompanying drawings in which a preferred embodiment of the present invention is illustrated by way of example. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the invention.
[0029] FIG. 1 is a longitudinal sectional view of various layers of metal which in the preferred embodiment is a firearm barrel;
[0030] FIG. 2 is a sectional side view of the preferred embodiment chamber located on a firearm barrel;
[0031] FIG. 3 is a sectional side view of the muzzle on the preferred embodiment firearm barrel;
[0032] FIG. 4 is a block diagram illustrating one set of steps used in making the extreme duty machine gun barrel.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0033] As used herein, the word “front” or “forward” corresponds to the firing direction of the firearm (i.e., to the right as shown in FIGS. 1 , 2 and 3 ); “rear” or “rearward” or “back” corresponds to the direction opposite the firing direction of the firearm (i.e., to the left as shown in FIGS. 1 , 2 and 3 ); “longitudinal” means the direction along or parallel to the longitudinal axis a of the barrel of the firearm; and “transverse” means a direction perpendicular to the longitudinal direction.
[0034] In FIG. 1 , there is shown a longitudinal sectional view of a composite of harness layers of a firearm barrel 1 , which in the preferred embodiment is a M4 carbine gun barrel having a breech end 5 , a muzzle end 6 , an inner and outer black oxide surface coating 2 , and an diffusion layer 3 . In the preferred embodiment, the firearm barrel 1 is H13 tool steel or other hard refractory material such as for example 4150 carbon steel or a 400 series stainless steel. It has internal walls forming a central longitudinally extending bore 7 which may have rifling on the inside. In the preferred embodiment, the black oxide surface layer 2 comprises all surfaces which are external in that they are in contact with the external environment. The diffusion layer 3 comprises barrel 1 material which begins at a depth of one thousandth from the surface of the firearm barrel 1 . The black oxide surface layer 2 also coats the interior of the gas port 4 .
[0035] In FIGS. 2 & 3 , there is shown a longitudinal sectional view of the firearm barrel 1 chamber 5 and muzzle 6 . Illustrated is the contiguous surface protection afford by the black oxide coating 2 . Also depicted is the diffusion 3 which is surrounded on all sides by the salt nitride layer.
[0036] In FIG. 4 , there is shown a flow diagram of a process 20 for producing the Noveske Rifleworks Machine Gun Barrel 1 which is designed to offer the machine gun user the option to operate the weapon at higher temperatures than normally allowed with the current machine gun barrel options. This is accomplished with the use of our proprietary barrel material, the hardening process, and the final surface conversion process. The barrel 1 is made using H13 tool steel in the softened machinable state. Once the barrel 1 has been machined 10 , the bore is hand lapped using a lead lap 11 impregnated with aluminum oxide particles to orient the land and groove surfaces with the helical twist of the rifling. This process insures that no mechanical abrasion will occur on the projectile as a result of its travel down the bore. This lapping 11 process is also a critical step for the surface conversion process which will be covered later in this description.
[0037] Next, the barrel is chambered 12 , a term which describes the removal of barrel material at the rear which results in the negative of a firearm cartridge. A cartridge is the assembled unit comprised of a case, primer, propellant, and projectile. The barrel 1 now is ready for hardening. The H13 tool steel is hardened to HRC 50-55 13 . Then the barrel 1 is subjected to a unique process which is a liquid salt dip nitride surface conversion 14 which also tempers the hardened barrel 1 . The end result is a barrel 1 with a blackened oxide surface 2 which is extremely resistant to oxidation and other forms of corrosion. Also, the blackened oxide surface 2 is very slick which affects the chamber 5 by improving extraction and affects the bore by reducing friction on the projectile. The nitrided surface extends the serviceable life of the barrel 1 in that it the surface of the barrel material is transformed into a very hard and durable state, about HRC 68-72. This hardened blackened oxide surface 2 will wear slower than a coating, and is not as sensitive to fluxuations in temperature as coatings such as hard chrome. The blackened oxide surface 2 , or nitriding process hardens the surface for about one thousandth of an inch, and also hardens the material under the surface for about fifteen thousandths of an inch. This secondary layer is called the diffusion layer 3 . The diffusion layer 3 offers an extended barrel life over current hard chrome lined barrels in that as the hardened blackened oxide surface 2 layer erodes, the tooth-like portion of the bore, the lands, are still harder in their core than the core of the fore mentioned hard chrome lined barrels. The diffusion layer 3 also offers an improved resistance to corrosion than the worn and exposed barrel material used in the hard chrome lined barrel. The nitrided surface is an improvement over hard chrome in this regard in that it is not a coating, but a transformation to the existing material, (H13). This process may be applied to many types of barrel steel.
[0038] Thus, there has been described a preferred method for the production of my extreme duty machine gun barrel. My method prepares a barrel 1 to operate at temperatures up to 1000 degrees with out fear of the barrel 1 loosing its temper. The bore 7 and chamber 5 of the barrel will resist erosion from the high heat and pressure producing a barrel with superior duty cycle over other barrels which are coated with chrome or manufactured using other currently available methods. My method of machining 1 the lands and grooves of the barrel, heat treating the base barrel material to provide a HRC 50-55 13 , and finally salt nitride dipping 14 the barrel to provide a surface and diffusion layer which is HRC 68-72 and resistant to corrosion may be adapted to work with stainless steel and other tool steels commonly available such as 4140 and 4130 chrome moly. Other embodiments of the present invention, and variations of the embodiment described herein, may be developed without departing from the essential characteristics thereof. Accordingly, the invention should be limited only by the scope of the claims listed below.
CONCLUSION, RAMIFICATIONS, AND SCOPE
[0039] Accordingly the reader will see that, according to the invention, I have provided a barrel which is capable of extended duty cycles were temperatures may exceed 800 degrees Fahrenheit. Further is can bee seen that my process of manufacture and method of production may be applied to a wide variety of metals which are suitable for use as firearms barrel. I have also afforded the user of barrels produced by my method the opportunity to use their firearms for firing schedules which would destroy or significantly reduce the useful life of other currently available barrel.
[0040] While my above drawings and description contain many specificities, these should not be construed as limitations on the scope of the invention, but rather as an exemplification of one preferred embodiment thereof.
[0041] Accordingly, the scope of the invention should be determined not by the embodiments illustrated, but by the appended claims and their legal equivalents.”
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An improved method for producing barrels which need to operate at temperatures exceeding 800 degrees for prolonged periods of time. The method described is ideally suited for barrels which are a part of a crew served weapons, belt feed systems or other fully automatic weapons. My method has limited effect on the accuracy potential of the barrel produced and therefore should not be excluded from use on shoulder fired weapons and precision rifles.
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TECHNICAL FIELD
[0001] The present invention relates to a drip irrigation dripper (hereinafter may simply referred to as a “dripper”) and a drip irrigation apparatus including the dripper, and particularly to a dripper and a drip irrigation apparatus including the dripper which are suitable for growing plants.
BACKGROUND ART
[0002] Conventionally, as means of supplying irrigation liquids such as water or liquid fertilizer to the plants to be grown on the soil in the agricultural land, the plantation or the like, drip irrigation apparatuses that regulate the supply speed of the irrigation liquid have been employed. The use of the drip irrigation apparatus enables the saving of the irrigation liquid and the management of the growth of the plants.
[0003] Such a drip irrigation apparatus includes a dripper for controlling the ejection amount of the irrigation liquid per unit time when ejecting the irrigation liquid having flowed into a flow tube from the water source side (pump side) toward the plants.
[0004] One example of such drip irrigation apparatuses is what is called an on-line dripper. The on-line dripper is used by being inserted into holes bored in a tube wall (side wall) of polyethylene pipe or into the opening of the end portion of a microtube. The on-line dripper is conveniently employed not only in soil culture but also in nutriculture or pot culture when used for greenhouse culture, raising seedling, fruit growing, and the like.
[0005] As such an on-line dripper, a dripper with what is called a differential pressure control mechanism (pressure correction function) being installed is known. The dripper is configured, for example, with a three-component structure in which an elastic film (e.g., silicone rubber film) such as a diaphragm is sandwiched by an inlet side member and an outlet side member (see PTLS 1 and 2, for example).
[0006] The dripper utilizes the operation of the diaphragm (film) in accordance with the liquid pressure of the irrigation liquid having flowed from the inlet of the dripper to control the inflow of the irrigation liquid toward a pressure reduction channel on the downstream side of the inlet and to control the amount of the outflow of the irrigation liquid from the outlet of the dripper after pressure reduction by the pressure reduction channel.
[0007] More specifically, in the dripper, when the inflow liquid pressure of the irrigation liquid toward the inlet is increased to a certain level, the diaphragm that is disposed to shield the pressure reduction channel is deflected by the inflow liquid pressure toward the outlet. Due to the deformation of the diaphragm, the reduction pressure channel is opened, and thus the irrigation liquid flows into the pressure reduction channel. The irrigation liquid having flowed into the pressure reduction channel moves toward the outlet while the pressure of the irrigation liquid is reduced in the pressure reduction channel to flow out of the dripper from the outlet. When the inflow liquid pressure toward the inlet is further increased, the amount of the deflection of the diaphragm toward the outlet becomes larger. In association with the larger amount of the deflection of the diaphragm, the sectional size of the channel at the outlet is reduced, and thus the outflow of the irrigation liquid is regulated.
CITATION LIST
Patent Literature
PTL 1
[0008] U.S. Pat. No. 5,413,282
PTL 2
[0009] U.S. Pat. No. 5,820,029
SUMMARY OF INVENTION
Technical Problem
[0010] However, the dripper has the following three problems.
(First Problem)
[0011] When an error occurs in assembling the above-mentioned three components for the dripper, the assembly error greatly affects the performance of the dripper. Thus, variation occurs in the operation of the diaphragm (film), causing the ejection amount of the irrigation liquid to be unstable.
(Second Problem)
[0012] In the dripper, the material cost is raised when silicone rubber is used for the diaphragm.
(Third Problem)
[0013] The dripper requires a manufacturing process in which the three components are separately manufactured, and thereafter they are further assembled. Therefore, the manufacturing cost is raised.
[0014] In addition, the dripper requires a liquid pressure that is high to a certain degree to open the pressure reduction channel by causing the diaphragm to be elastically deformed. Therefore, when the dripper is used under relatively high liquid pressure with a high pressure pump being employed, the original functions can be performed with no problem. However, when the dripper is used under low liquid pressure, there is a concern that the diaphragm might not be elastically deformed in a proper manner, causing the original functions not to be sufficiently performed.
[0015] The present invention has been achieved taking into consideration the above-mentioned problems. A first object of the present invention is to provide a dripper which makes it possible to stabilize the ejection amount of the irrigation liquid and to further achieve cost reduction by reducing the manufacturing cost, number of components and manufacturing processes, and a drip irrigation apparatus including the dripper.
[0016] In addition, a second object of the present invention is to provide a dripper which makes it possible to properly perform drip irrigation even when the liquid pressure of irrigation liquid is low, and a drip irrigation apparatus including the dripper.
Solution to Problem
[0017] To achieve at least the above-mentioned first object, the present invention provides the following dripper.
[0000] [1] A drip irrigation dripper for controlling an ejection amount of irrigation liquid, having flowed from an inflow part, from an ejection port to eject the irrigation liquid, the drip irrigation dripper including:
[0018] a first member integrally formed of a resin material and composing one part on the inflow part side of the drip irrigation dripper; and
[0019] a second member integrally formed of a resin material and composing the other part on the ejection port side of the drip irrigation dripper, the second member being fixed to the first member,
[0020] wherein
[0021] the first member includes:
[0022] a first plate-like part having a first inner surface to be brought into close contact with the second member and a first outer surface at a side opposite to the first inner surface;
[0023] a first protrusion part being protruded from the first outer surface toward a side opposite to the second member and having the inflow part at a tip portion of the first protrusion part;
[0024] a first guide channel formed from the inflow part to the first inner surface and guiding the irrigation liquid having flowed from the inflow part toward the first inner surface; and
[0025] a pressure reduction channel part for forming, between the first inner surface and the second member, a pressure reduction channel connected continuously to a terminal of an inner surface of the first guide channel and allowing the irrigation liquid having been guided by the first guide channel to flow toward the ejection port while reducing a pressure of the irrigation liquid, and
[0026] the second member includes:
[0027] a second plate-like part having a second inner surface to be brought into close contact with the first inner surface and forming the pressure reduction channel together with the pressure reduction channel part and a second outer surface at a side opposite to the second inner surface;
[0028] a second guide channel formed from a terminal position of the pressure reduction channel at the second inner surface to the ejection port and for guiding the irrigation liquid of which pressure is reduced by the pressure reduction channel to the ejection port; and
[0029] a diaphragm part formed at a terminal of the first guide channel so as to form a part of an inner surface of the second guide channel and being to be deformed toward the second guide channel upon receiving a liquid pressure of the irrigation liquid having been guided by the first guide channel to regulate a width of the second guide channel so as to be smaller as the liquid pressure is increased.
[0000] [2] The drip irrigation dripper according to [1], wherein the diaphragm part includes:
[0030] a dome-shaped center wall part curved so as to be protruded toward the first member;
[0031] a peripheral wall part connected to an outer peripheral end of the center wall part to surround the center wall part and being inclined toward the first member as being outward from the center wall part in a radial direction of the center wall part when viewed in a plan view; and wherein
[0032] a connection part, between the center wall part and the peripheral wall part, is configured to regulate the width of the second guide channel.
[0000] [3] The drip irrigation dripper according to [2], wherein an end edge portion on the connection part side of each of the center wall part and the peripheral wall part has a thinner wall thickness than the connection part and portions other than the end edge portion of the center wall part.
[4] The drip irrigation dripper according to any one of [1] to [3], wherein a starting end of the second guide channel is disposed in the vicinity of the diaphragm part.
[5] The drip irrigation dripper according to any one of [1] to [4], wherein the ejection port opens to the second outer surface.
[6] The drip irrigation dripper according to any one of [1] to [4], wherein the ejection port is formed at a tip portion of a second protrusion part protruded from the second outer surface toward a side opposite to the first member.
[0033] In addition, to achieve at least the above-mentioned second object, the present invention provides the following drip irrigation dripper.
[0000] [7] A drip irrigation dripper for controlling an ejection amount of irrigation liquid, having flowed from an inflow part, from an ejection port to eject the irrigation liquid, the drip irrigation dripper including:
[0034] a plate-like body having a first outer surface on the inflow part side of the drip irrigation dripper and a second outer surface on the ejection port side at a side opposite to the first outer surface;
[0035] a first protrusion part being protruded from the first outer surface toward a side opposite to the second outer surface and having the inflow part at a tip portion of the first protrusion part;
[0036] a first guide channel formed from the inflow part into the plate-like body and guiding the irrigation liquid having flowed from the inflow part into the plate-like body;
[0037] a pressure reduction channel formed so as to be connected to a terminal of the first guide channel to allow the irrigation liquid having been guided by the first guide channel to flow toward the ejection port while reducing a pressure of the irrigation liquid; and
[0038] a second guide channel formed from a position connected to a terminal of the pressure reduction channel inside the plate-like body to the ejection port disposed on the second outer surface side of the drip irrigation dripper and for guiding the irrigation liquid of which pressure is reduced by the pressure reduction channel to the ejection port, wherein
[0039] the inflow part has hydrophobicity and prevents the irrigation liquid having a liquid pressure less than a predetermined liquid pressure from flowing into the inflow part.
[0000] [8] The drip irrigation dripper according to [7], wherein
[0040] the inflow part includes a substrate part that partially shields a starting end of the first guide channel,
[0041] the substrate part includes a plurality of inflow ports extending through the substrate part, and
[0042] at least a surface on a side, of the substrate part, opposite to the first guide channel has hydrophobicity.
[0000] [9] The drip irrigation dripper according to [8], wherein an inner peripheral surface of each of the inflow ports also has hydrophobicity.
[10] The drip irrigation dripper according to [8] or [9], wherein the inflow part comprises a hydrophobic material having hydrophobicity.
[11] The drip irrigation dripper according to [8] or [9], wherein the inflow part includes hydrophobic coating having hydrophobicity.
[12] The drip irrigation dripper according to [10] or [11], wherein the inflow part has, on a hydrophobic surface, an irregular shape that reinforces the hydrophobicity.
[13] The drip irrigation dripper according to any one of [7] to [12], further including a diaphragm part formed at the terminal of the first guide channel so as to form a part of an inner surface of the second guide channel and being to be deformed toward the second guide channel upon receiving the liquid pressure of the irrigation liquid having been guided by the first guide channel, the diaphragm part being for regulating a width of the second guide channel so as to be smaller as the liquid pressure is increased.
[14] The drip irrigation dripper according to [13], including:
[0043] a first member integrally formed of a resin material and composing one part on the inflow part side of the drip irrigation dripper; and
[0044] a second member integrally formed of a resin material and composing the other part on the ejection port side of the drip irrigation dripper, the first member being fixed to the second member,
[0045] wherein
[0046] the first member includes:
[0047] a first plate-like part having a first inner surface to be brought into close contact with the second member and the first outer surface at a side opposite to the first inner surface;
[0048] the first protrusion part;
[0049] the first guide channel disposed from the inflow part to the first inner surface; and a pressure reduction channel part for forming, between the first inner surface and the second member, the pressure reduction channel connected continuously to a terminal of an inner surface of the first guide channel, and
[0050] the second member includes:
[0051] a second plate-like part having a second inner surface that is to be brought into close contact with the first inner surface and that forms the pressure reduction channel together with the pressure reduction channel part, and the second outer surface at a side opposite to the second inner surface;
[0052] the second guide channel disposed from a terminal of the pressure reduction channel part at the second inner surface to the ejection port; and
[0053] the diaphragm part.
[0054] Further, to achieve the above-mentioned first or second object, the present invention provides the following drip irrigation apparatus.
[0000] [15] A drip irrigation apparatus including:
[0055] the drip irrigation dripper according to any one of [1] to [14]; and
[0056] a flow tube through which the irrigation liquid flows,
[0057] wherein
[0058] when the first protrusion part of the drip irrigation dripper is inserted into a tube wall or an opening of the flow tube, the irrigation liquid in the flows tube to flow into a channel of the drip irrigation dripper from the inflow part.
Advantageous Effects of Invention
[0059] With the inventions according to any of [1] to [6], the ejection amount of the irrigation liquid can be stabilized, and in addition cost reduction can be achieved by reducing the manufacturing cost, number of components and manufacturing processes.
[0060] In particular, with the invention according to [1], a dripper excellent in controlling the ejection amount, capable of reducing the pressure of the irrigation liquid using the pressure reduction channel and of regulating the width of the second guide channel using the diaphragm part can be manufactured with less assembly error with only two components of the first member and the second member. Therefore, it is possible to stabilize the ejection amount of the irrigation liquid, and to achieve cost reduction by reducing the manufacturing cost, number of components and manufacturing processes.
[0061] In addition, with the invention according to [2], the diaphragm part can be formed into a suitable shape to be deformed toward a predetermined portion facing the diaphragm part in the inner surface of the second guide channel upon efficiently receiving the liquid pressure of the irrigation liquid before pressure reduction. Therefore, it is possible to regulate the channel width more properly.
[0062] In addition, with the invention according to [3], the rigidity near the connection part to be used for regulating the width of the channel in the diaphragm part is partially weakened, thereby enabling the connection part to be moved more efficiently depending on the liquid pressure. Therefore, it is possible to regulate the channel width more simply and properly.
[0063] In addition, with the invention according to [4], the shape of a metal mold for molding the second member from a resin can be simplified, compared with the case where the starting end of the second guide channel is disposed away from the diaphragm part. Therefore, it is possible to further reduce the manufacturing cost.
[0064] In addition, with the invention according to [5], the configuration of the second member can be simplified. Therefore, it is possible to further reduce the manufacturing cost.
[0065] In addition, with the invention according to [6], it is possible to select a suitable configuration to connect a tube to the ejection port to adjust the ejecting direction.
[0066] In addition, with the inventions according to any of [7] to [14], even when the liquid pressure of the irrigation liquid is low, drip irrigation can be performed properly.
[0067] In particular, with the invention according to [7], the lower limit of the liquid pressure of the irrigation liquid flowing from the inflow part can be controlled so as to be low due to hydrophobicity of the inflow part. Therefore, even when the liquid pressure of the irrigation liquid is low, the irrigation liquid can be properly used for the drip irrigation.
[0068] In addition, with the invention according to [8], a portion, out of the inflow part, to be exposed to the irrigation liquid outside of the dripper has hydrophobicity. Therefore, it is possible to regulate the inflow of the irrigation liquid more properly.
[0069] In addition, with the invention according to [9], capillary action in the inflow port can be surely suppressed. Therefore, it is possible to regulate the inflow of the irrigation liquid more properly.
[0070] In addition, with the invention according to [10], the hydrophobicity of the inflow part can be achieved with a smaller number of components.
[0071] In addition, with the invention according to [11], the hydrophobicity of the inflow part does not depend on the material of the inflow part. Therefore, it is possible to further enhance the freedom in selecting the material of the inflow part.
[0072] In addition, with the invention according to [12], the lower limit of the liquid pressure of the irrigation liquid flowing from the inflow part can also be adjusted to be somewhat higher. Therefore, it is possible to further enhance the freedom in selecting the pressure of the inflow liquid during the use of the dripper under low pressure.
[0073] In addition, with the invention according to [13], even when the dripper is used under high pressure, the flow rate of the irrigation liquid toward the ejection port can be regulated by the diaphragm part. Therefore, it is possible to control the ejection amount of the irrigation liquid more properly. In addition, the diaphragm part does not shield the pressure reduction channel, so as not to be involved in the regulation of the inflow into the pressure reduction channel. Therefore, with the invention according to [13], the diaphragm part does not constitute a cause for raising the lower limit of the liquid pressure to be used toward the high pressure side (i.e., a cause for hindering the drip irrigation using low-pressure irrigation liquid).
[0074] In addition, with the invention according to [14], the dripper excellent in controlling the ejection amount can be manufactured with less assembly error with only two components made of a resin material. Therefore, it is possible to stabilize the ejection amount of the irrigation liquid, and to achieve further cost reduction by reducing the manufacturing cost, number of components and manufacturing processes.
[0075] In addition, with the invention according to [15], it is possible to stabilize the ejection amount of the irrigation liquid, having flowed into the inflow part from the flow tube, from the ejection port, and to achieve cost reduction by reducing the manufacturing cost, number of components and manufacturing processes. Alternatively, with the invention according to [15], even when the liquid pressure of the irrigation liquid flowing through the flow tube is low, it is possible to allow this irrigation liquid to flow into the channel of the dripper to use the irrigation liquid for drip irrigation properly.
BRIEF DESCRIPTION OF DRAWINGS
[0076] FIG. 1 is a perspective bird's-eye view illustrating a dripper according to an embodiment of the present invention;
[0077] FIG. 2 is a transparent bird's-eye view illustrating the dripper;
[0078] FIG. 3 is a perspective upward view of the dripper;
[0079] FIG. 4 is a transparent upward view of the dripper;
[0080] FIG. 5 is a bottom view of a first member in the dripper;
[0081] FIG. 6 is a top view of a second member in the dripper;
[0082] FIG. 7 is a front view of the dripper;
[0083] FIG. 8 is a sectional view of the dripper taken along line A-A in FIG. 7 ;
[0084] FIG. 9 is a sectional view of the dripper taken along line B-B in FIG. 8 ;
[0085] FIG. 10 is a sectional view schematically illustrating a drip irrigation apparatus according to an embodiment of the present invention;
[0086] FIG. 11 is an enlarged sectional view of an inflow part in the dripper;
[0087] FIG. 12 is an enlarged sectional view illustrating one example of means to embody a low-pressure stop filter function of the inflow part;
[0088] FIG. 13 is an enlarged sectional view illustrating another example of means to embody the low-pressure stop filter function of the inflow part;
[0089] FIG. 14A is an enlarged sectional view of the inflow part before the inflow of irrigation liquid, FIG. 14B is an enlarged sectional view of the inflow part when the liquid pressure of irrigation liquid is less than fracture hydraulic pressure, and FIG. 14C is an enlarged sectional view of the inflow part into which irrigation liquid having equal to or more than fracture hydraulic pressure flows;
[0090] FIG. 15 is an enlarged sectional view of a diaphragm part and its periphery in the dripper;
[0091] FIG. 16A is an enlarged sectional view of the diaphragm part and its periphery before the inflow of the irrigation liquid into the dripper, FIG. 16B is an enlarged sectional view of the diaphragm part and its periphery having been deformed upon receiving the liquid pressure of the irrigation liquid having flowed into the dripper, and FIG. 16C is an enlarged sectional view of the diaphragm part and its periphery having been further deformed upon receiving the liquid pressure of the irrigation liquid having flowed into the dripper;
[0092] FIG. 17 is a perspective upward view illustrating a first modification of the dripper according to the present invention;
[0093] FIG. 18 is a perspective upward view illustrating a second modification of the dripper according to the present invention; and
[0094] FIG. 19 is an enlarged sectional view of a diaphragm part and its periphery in a third modification of the dripper according to the present invention.
DESCRIPTION OF EMBODIMENTS
[0095] In the following, embodiments of a dripper according to the present invention and a drip irrigation apparatus including the dripper will be described with reference to FIGS. 1 to 19 .
[0096] FIG. 1 is a perspective bird's-eye view illustrating dripper 1 in the present embodiment. FIG. 2 is a transparent birds-eye view illustrating dripper 1 . FIG. 3 is a perspective upward view of dripper 1 . FIG. 4 is a transparent upward view of dripper 1 . FIG. 5 is a bottom view of first member 2 to be described later in dripper 1 . FIG. 6 is a top view of second member 3 to be described later in dripper 1 . FIG. 7 is a front view of dripper 1 . FIG. 8 is a sectional view of dripper 1 taken along line A-A in FIG. 7 . FIG. 9 is a sectional view of dripper 1 taken along line B-B in FIG. 8 . FIG. 10 is a schematic sectional view illustrating drip irrigation apparatus 4 in the present embodiment.
[0097] As illustrated in FIG. 10 , drip irrigation apparatus 4 is composed of elongated tube 5 as a flow tube in which the irrigation liquid flows, and dripper 1 inserted into tube 5 through through-hole 51 bored in the side wall of tube 5 .
[0098] It is noted that, while not illustrated, dripper 1 may be used by being inserted into the opening of an end portion of the tube.
[0099] Dripper 1 , being inserted into tube 5 in this manner, controls the ejection amount of the irrigation liquid per unit time when the irrigation liquid in tube 5 is ejected to the outside.
[0100] It is noted that, while one dripper 1 and one through-hole 51 are illustrated for convenience in FIG. 10 , actually a plurality of drippers 1 and through-holes 51 are often disposed along the longitudinal direction of tube 5 at a predetermined interval.
[0101] In addition, in FIG. 10 , the right and left sides of the channel in tube 5 correspond to the upstream side and the downstream side, respectively.
[0102] Dripper 1 will be described further in detail. As illustrated in FIGS. 1 to 10 , dripper 1 is formed by fixing first member 2 and second member 3 to each other. Each of first member 2 and second member 3 is integrally formed of a resin material. The method of fixing first member 2 and second member 3 may be joining by means of adhesion using an adhesive, welding, or the like, or alternatively may be pressure joining by means of pressing. In addition, first member 2 and second member 3 may be formed of the same resin material, or alternatively may be formed of different resin materials. Further, as the resin material, an inexpensive resin material such as polypropylene may be employed. Furthermore, each of first member 2 and second member 3 may be integrally molded by injection molding.
[0103] [Specific Configuration of First Member]
[0104] <First Plate-Like Part>
[0105] As illustrated in FIGS. 1 to 5 and FIGS. 7 to 10 , first member 2 has disc-shaped first plate-like part 21 . The shape of first plate-like part 21 is circular in a plan view. However, the shape of the first plate-like part in the present invention does not need to be limited to a disc shape; for example, rectangular or other polygonal plate shapes may be employed.
[0106] First plate-like part 21 has first inner surface (bottom surface in FIGS. 8 and 9 ) 211 to be brought into close contact with second member 3 , and first outer surface (top surface in FIGS. 8 and 9 ) 212 at the side opposite to first inner surface 211 .
[0107] First inner surface 211 and first outer surface 212 are formed so as to be planes disposed parallel to each other across the thickness of first plate-like part 21 .
[0108] As illustrated in FIG. 5 , annular belt-shaped recess 2111 is formed at the center of first inner surface 211 . As illustrated in FIG. 8 , rim part 2112 of first inner surface 211 is protruded toward second member 3 . First plate-like part 21 composes plate-like body 11 (see FIGS. 1 and 8 ) together with second plate-like part 31 to be described later.
[0109] <First Protrusion Part and Inflow Part>
[0110] As illustrated in FIGS. 1 to 4 and FIGS. 7 to 10 , first member 2 has first protrusion part 22 . First protrusion part 22 is protruded from the center portion of first outer surface 212 of first plate-like part 21 toward the side opposite to second member 3 (upward in FIGS. 7 to 9 ).
[0111] The outer peripheral surface of first protrusion part 22 is formed of a cylindrical surface from the base end portion (lower end portion) to the tip portion (upper end portion) in the protrusion direction of first protrusion part 22 , and of a frustum surface formed at the tip side of the cylindrical surface. The frustum surface is a tapered surface formed such that the outer diameter of first protrusion part 22 is gradually decreased toward the tip side. The frustum surface is connected to the cylindrical surface through a plane expanding outwardly in the radial direction from that cylindrical surface. The frustum surface functions as a stopper when dripper 1 is inserted into tube 5 (see FIG. 10 ). However, the outer peripheral surface of the first protrusion part in the present invention does not need to be limited to the cylindrical surface and the frustum surface; a square tube surface, a prismoid surface, or the like may also be employed.
[0112] In addition, first protrusion part 22 is formed into a hollow shape (tubular shape) by the presence of first guide channel 23 to be described later.
[0113] Further, inflow part 221 is formed near the tip portion of first protrusion part 22 . FIG. 11 is an enlarged sectional view of inflow part 221 .
[0114] As illustrated in FIGS. 8 , 9 and 11 , inflow part 221 has substrate part 2211 orthogonal to the longitudinal direction of first protrusion part 22 , and a plurality of inflow ports 2212 extended vertically (in other words, in the longitudinal direction of first protrusion part 22 ) through substrate part 2211 . Inflow port 2212 is a column-shaped pore.
[0115] As illustrated in FIG. 11 , the starting end portion (upper end portion) of first guide channel 23 is partially shielded from the outer space outside of dripper 1 by substrate part 2211 of inflow part 221 , and is partially opened to the outer space through inflow ports 2212 extending through substrate part 2211 .
[0116] It is noted that, while in FIG. 5 each inflow port 2212 is disposed at an intersection of the rectangular lattice, the disposition of the inflow ports in the present invention does not need to be limited to one as in FIG. 5 .
[0117] Inflow part 221 is provided with a low-pressure stop filter function for not allowing irrigation liquid having less than a predetermined pressure (e.g., 0.005 MPa) to flow into the channel of dripper 1 .
[0118] There are several possibilities to be considered for the means to embody the low-pressure stop filter function. For example, when polypropylene is used as a material for dripper 1 , the low-pressure stop filter function can be imparted to inflow part 221 , since polypropylene itself is a high water-repellent (hydrophobic) material with a low surface energy.
[0119] Other than that, as illustrated in FIG. 12 , for example hydrophobic coating C such as fluorine coating by means of a fluorine coating agent is applied to surface 22111 of substrate part 2211 outside of dripper 1 (in other words, at the side opposite to first guide channel 23 to be described later) and, as needed, to the inner peripheral surface 22121 of inflow port 2212 . The hydrophobic coating C reduces the surface energy. In this case, the hydrophobic coating C can impart the low-pressure stop filter function to inflow part 221 locally without depending on the material of dripper 1 .
[0120] In addition, hydrophobicity may be reinforced by, for example, forming an irregular shape on the hydrophobic surface, as needed. The hydrophobic surface may be formed with the above-mentioned material or with the hydrophobic coating. As illustrated in FIG. 13 , the irregular shape may be burr 22122 formed at the upper opening edge of inflow port 2212 , or may be an irregular shape formed by transferring the irregular shape intentionally formed on the transfer surface of a metal mold.
[0121] In addition, it is also possible to optimize the low-pressure stop filter function by adjusting the inner diameter, pitch, number, opening shape and wall thickness of inflow port 2212 , the surface roughness of inflow part 221 , and the like.
[0122] When the liquid pressure of the irrigation liquid in tube 5 is raised to a predetermined pressure (fracture hydraulic pressure), inflow part 221 allows the irrigation liquid to flow into dripper 1 through inflow port 2212 . Here, from the viewpoint of allowing dripper 1 in the present embodiment to favorably function when being used under low pressure, it is desirable to select, as the predetermined pressure, a sufficiently low pressure of about 0.005 MPa exemplified earlier. However, the “predetermined pressure” is embodied (set) depending on the degree of hydrophobicity of inflow part 221 . Accordingly, when imparting hydrophobicity to inflow part 221 , necessary hydrophobicity-causing factors (the above-described material of inflow part 221 , type and film thickness of the hydrophobic coating, surface shape of the hydrophobic surface, and the like) may be selected based on experiment results or the like, taking into consideration the relationship between the hydrophobicity and the predetermined pressure that should be set.
[0123] FIGS. 14A , 14 B and 14 C illustrate specific examples of the operation of inflow part 221 .
[0124] First, as illustrated in FIG. 14A , when the external liquid pressure to which inflow part 221 is exposed is 0 MPa (in other words, there is no irrigation liquid in tube 5 ), the inflow regulation of the irrigation liquid by inflow part 221 is not performed as a matter of course.
[0125] Next, as illustrated in FIG. 14B , when the external liquid pressure is less than 0.005 MPa (the above-mentioned fracture hydraulic pressure), the low-pressure stop filter function works based on the hydrophobicity of inflow part 221 . As a result, the irrigation liquid outside of inflow part 221 (in other words, in tube 5 ) is dammed at outer surface 22111 of substrate part 2211 and at the upper opening end of inflow port 2212 . Therefore, the inflow into first guide channel 23 of dripper 1 is regulated (prevented).
[0126] Next, as illustrated in FIG. 14C , when the external liquid pressure is equal to or more than 0.005 MPa, the external liquid pressure surpasses the hydrophobicity of inflow part 221 . Therefore, the irrigation liquid outside of inflow part 221 flows into first guide channel 23 of dripper 1 from inflow port 2212 .
[0127] As has been described above, when the liquid pressure of the irrigation liquid in tube 5 is raised to the predetermined pressure (fracture hydraulic pressure), inflow part 221 allows the irrigation liquid to flow into dripper 1 through inflow port 2212 .
[0128] <First Guide Channel>
[0129] As illustrated in FIGS. 8 and 9 , first member 2 has first guide channel 23 as the most upstream channel of dripper 1 .
[0130] As illustrated in FIGS. 8 and 9 , first guide channel 23 is formed from inflow part 221 to first inner surface 211 of first plate-like part 21 (in other words, toward the inside of plate-like body 11 ). For example, first guide channel 23 is a hole extending through first protrusion part 22 along the longitudinal direction of first protrusion part 22 .
[0131] First guide channel 23 guides the irrigation liquid having flowed from inflow part 221 toward first inner surface 211 (downward in FIGS. 8 and 9 ).
[0132] It is noted that, while channel inner surface 231 (in other words, inner peripheral surface of first protrusion part 22 defining the shape of first guide channel 23 ) of first guide channel 23 is formed so as to be a cylindrical surface concentric with the outer peripheral surface of first protrusion part 22 , the shape of the channel inner surface in the present invention does not need to be limited to such a shape; for example, a square tube surface, or the like may also be employed.
[0133] <Pressure Reduction Channel>
[0134] As illustrated in FIG. 5 , first member 2 has pressure reduction channel part 213 provided as a recess on first inner surface 211 of first plate-like part 21 .
[0135] As illustrated in FIG. 5 , pressure reduction channel part 213 is composed of groove part 213 connected continuously to the terminal (in other words, downstream end) of channel inner surface 231 of first guide channel 23 .
[0136] As illustrated in FIG. 5 , groove part 213 is formed into a substantially U-shape. That is, groove part 213 is formed in such a shape as to extend outwardly in a serpentine manner in the radial direction of first inner surface 211 from the terminal of channel inner surface 231 of first guide channel 23 , and then to turn back before rim part 2112 of first inner surface 211 to return to the vicinity of the terminal of channel inner surface 231 without serpentine. That is, when first inner surface 211 is viewed in a plan view, groove part 213 includes a zig-zag part being extended along the radial direction of first inner surface 211 , and a turn-back part including a linear portion and being extended from the tip portion of the zig-zag part to a position overlapping the starting end of second guide channel to be described later.
[0137] Pressure reduction channel part 213 forms pressure reduction channel 8 (see FIG. 2 ) together with second member 3 . Pressure reduction channel 8 allows the irrigation liquid having been guided by first guide channel 23 to flow toward ejection port 321 to be described later while reducing the pressure of the irrigation liquid.
[0138] It is noted that the shape of the pressure reduction channel part in the present invention does not need to be limited to the shape illustrated in FIG. 5 as long as pressure reduction channel 8 can be connected to the terminal of first guide channel 23 . In addition, a plurality of pressure reduction channel parts 213 may be provided.
[0139] [Specific Configuration of Second Member]
[0140] <Second Plate-Like Part>
[0141] On the other hand, as illustrated in FIGS. 1 to 4 and FIGS. 6 to 10 , second member 3 has second plate-like part 31 . The shape of second plate-like part 31 is a circular disc-shape being concentric with and having the same diameter as that of first plate-like part 21 in a plan view. However, the shape of the second plate-like part in the present invention does not need to be limited to a disc shape; for example, rectangular or other polygonal plate shapes may be employed.
[0142] Second plate-like part 31 has second inner surface (top surface in FIGS. 8 and 9 ) 311 to be brought into close contact with first inner surface 211 in first plate-like part 21 , and second outer surface (bottom surface in FIGS. 8 and 9 ) 312 at the side opposite to second inner surface 311 .
[0143] Second inner surface 311 and second outer surface 312 are formed so as to be planes disposed parallel to each other across the thickness of second plate-like part 31 .
[0144] It is noted that second inner surface 311 may be joined to first inner surface 211 .
[0145] Rim part 3111 of second inner surface 311 is concaved by the same dimension as the protrusion dimension of rim part 2112 of first inner surface 211 (see FIG. 8 ). It is also possible to use rim parts 3111 and 2112 for positioning first member 2 and second member 3 .
[0146] <Second Protrusion Part and Ejection Port>
[0147] As illustrated in FIGS. 1 to 4 and FIGS. 7 to 10 , second member 3 has second protrusion part 32 . Second protrusion part 32 is protruded from the center portion of second outer surface 312 of second plate-like part 31 toward the side opposite to first member 2 (downward in FIGS. 7 to 9 ).
[0148] The outer peripheral surface of second protrusion part 32 is formed of a cylindrical surface from the base end portion (upper end portion) of second protrusion part 32 to the tip portion (lower end portion) in the protrusion direction of second protrusion part 32 , and of a frustum surface formed at the tip side of that cylindrical surface. The frustum surface is connected to the cylindrical surface through a plane expanding outwardly in the radial direction from that cylindrical surface. However, the outer peripheral surface of the second protrusion part in the present invention does not need to be limited to the cylindrical surface and the frustum surface; a square tube surface, a prismoid surface, or the like may also be employed.
[0149] In addition, second protrusion part 32 is formed into a hollow shape (tubular shape) by the presence of second guide channel 33 to be described later.
[0150] Further, ejection port 321 formed of a circular opening is formed at the tip portion of second protrusion part 32 .
[0151] <Second Guide Channel>
[0152] As illustrated in FIGS. 8 , 9 and 15 , second member 3 has second guide channel 33 .
[0153] As illustrated in FIGS. 8 and 15 , second guide channel 33 is formed from a position, opposed to terminal (in other words, downstream end) 213 E of pressure reduction channel part 213 , on second inner surface 311 of second plate-like part 31 (in other words, inside plate-like body 11 ) to ejection port 321 . For example, second guide channel 33 includes a hole extending through second protrusion part 32 along the longitudinal direction of second protrusion part 32 .
[0154] More specifically, as illustrated in FIG. 15 , second guide channel 33 is composed of starting end channel section (first section) 331 as a starting end portion, width-regulated channel section (second channel) 332 connected to the downstream side of first section 331 , and ejection guide channel section (third section) 333 connected to the downstream side of second section 332 . In first section 331 , the channel inner surface is formed into a rectangular shape. In addition, second section 332 is formed of a relatively narrow space surrounded by bottom surface (hereinafter, referred to as inner bottom surface) 3321 in the channel inner surface formed in second plate-like part 31 and of diaphragm part 34 to be described later. It is noted that inner bottom surface 3321 is continuously connected to inner bottom surface 3311 (see FIG. 15 ) of first section 331 in such a shape as to be in the same plane at the radially inner side. Further, the channel inner surface of third section 333 is formed so as to be a cylindrical surface concentric with first guide channel 23 . The third section in the present invention does not need to be limited to such a configuration, and may be formed to have a square tube surface, or the like, for example.
[0155] In addition, in second guide channel 33 , first section 331 is designed to be opposed to terminal 8 E (see FIG. 15 ) of pressure reduction channel 8 so as to bring first inner surface 211 and second inner surface 311 into close contact with each other, thereby allowing second guide channel 33 to communicate with pressure reduction channel 8 .
[0156] Second guide channel 33 guides the irrigation liquid after pressure reduction by pressure reduction channel 8 to ejection port 321 .
[0157] <Diaphragm Part>
[0158] Furthermore, as illustrated in FIGS. 8 to 10 and 15 , second member 3 has diaphragm part 34 at a position corresponding to the terminal of first guide channel 23 on second inner surface 311 of second plate-like part 31 .
[0159] Diaphragm part 34 is formed so as to separate first guide channel 23 and second guide channel 33 from each other except communication through pressure reduction channel 8 . That is, first guide channel 23 and third section 333 are separated from each other by diaphragm part 34 , and communicate with each other through pressure reduction channel 8 , first section 331 and second section 332 .
[0160] Further, diaphragm part 34 forms a part of the channel inner surface of second guide channel 33 , and, as described above, forms second section 332 together with inner bottom surface 3321 .
[0161] Diaphragm part 34 receives the liquid pressure of the irrigation liquid having been guided by first guide channel 23 . That irrigation liquid is led to pressure reduction channel 8 .
[0162] In addition, diaphragm part 34 is deformed toward inner bottom surface 3321 (i.e., a portion facing diaphragm part 34 in the channel inner surface of second guide channel 33 ) by the liquid pressure of the irrigation liquid. Diaphragm part 34 is deformed such that the width of the channel of second section 332 (i.e., the width of the channel of second guide channel 33 at a position where diaphragm part 34 is deformed) becomes smaller, as that liquid pressure is increased.
[0163] More specifically, as illustrated in FIG. 15 , diaphragm part 34 has dome-shaped center wall part 341 curved so as to be protruded toward first member 2 , and peripheral wall part 342 connected to the outer peripheral end of center wall part 341 to surround center wall part 341 . Peripheral wall part 342 is inclined toward first member 2 as being outward from center wall part 341 in the radial direction (radial direction of center wall part 341 when viewed in a plan view). That is, peripheral wall part 342 is formed in such a shape as to be gradually expanded toward inflow part 221 . Peripheral wall part 342 is connected to the inner rim of the lower end of first guide channel 23 by the close contact between first member 2 and second member 3 .
[0164] In addition, one portion 3431 in the circumferential direction (see FIG. 15 ), out of connection part 343 between center wall part 341 and peripheral wall part 342 , is disposed at a position near inner bottom surface 3321 so as to face inner bottom surface 3321 from above in FIG. 15 . For example, diaphragm part 34 is disposed such that the surface of portion 3431 is a plane orthogonal to a direction in which diaphragm part 34 is deformed (longitudinal direction of first guide channel 23 ).
[0165] Portion (hereinafter, referred to as “channel width-regulating portion” or “fourth portion”) 3431 is a part of connection part 343 , and regulates the width of the channel of second section 332 .
[0166] It is noted that portions near connection part 343 at each of center wall part 341 and peripheral wall part 342 (end edge portion of center wall part 341 and end edge portion of peripheral wall part 342 ) are desirably formed to be thinner, compared with connection part 343 and portions other than the portion near connection part 343 at center wall part 341 . For example, each of center wall part 341 and peripheral wall part 342 is desirably formed so as to have a thickness being gradually decreased toward connection part 343 .
[0167] As illustrated in FIG. 6 , first section 331 is disposed at a position near the radially outer side of diaphragm part 34 .
[0168] Here, FIGS. 16A , 16 B and 16 C illustrate specific examples of the operation of diaphragm part 34 .
[0169] First, as illustrated in FIG. 16A , when the liquid pressure is 0 MPa, i.e., there is no irrigation liquid in first guide channel 23 , the width regulation of second section 332 by diaphragm part 34 is not performed as a matter of course. That channel width in this case is 0.25 mm. It is noted that, as illustrated in FIG. 16A , the channel width is the shortest distance between fourth portion 3431 of diaphragm part 34 and inner bottom surface 3321 .
[0170] Next, as illustrated in FIG. 16B , when the liquid pressure is equal to or more than 0.005 MPa (the above-mentioned fracture hydraulic pressure) and less than 0.05 MPa, diaphragm part 34 is deformed by the liquid pressure of the irrigation liquid in first guide channel 23 . Therefore, fourth portion 3431 moves toward (downward) inner bottom surface 3321 . Thus, the channel width is regulated to 0.15 mm.
[0171] Next, as illustrated in FIG. 16C , when the liquid pressure is equal to or more than 0.05 MPa and equal to or less than 0.1 MPa, diaphragm part 34 is deformed further compared with the state illustrated in FIG. 16B . Therefore, fourth portion 3431 moves further toward inner bottom surface 3321 . Thus, the channel width is regulated to 0.1 mm.
[0172] [Operation and Effect of Present Embodiment].
[0173] According to the present embodiment, the irrigation liquid in tube 5 having reached the predetermined pressure flows into dripper 1 through inflow port 2212 of inflow part 221 .
[0174] According to the present embodiment, the lower limit of the liquid pressure of the irrigation liquid flowing into pressure reduction channel part 8 can be controlled to be lower than the conventional case (i.e., the case of shielding the pressure reduction channel using the elasticity of the diaphragm) using hydrophobicity of inflow part 221 . Therefore, even when the liquid pressure of the irrigation liquid outside of dripper 1 is low, that irrigation liquid can be properly used for drip irrigation.
[0175] In addition, at least surface 22111 outside of substrate part 2211 in inflow part 221 is formed so as to have hydrophobicity, thereby allowing a portion exposed to the external liquid pressure in inflow part 221 to have hydrophobicity. Therefore, the inflow of the irrigation liquid into the channel of dripper 1 can be properly controlled.
[0176] Further, when hydrophobicity is imparted to inner peripheral surface 22121 of inflow port 2212 , capillary action in inflow port 2212 can be surely suppressed, making it possible to control the inflow of the irrigation liquid more properly.
[0177] Furthermore, when inflow part 221 is formed of a hydrophobic material, the hydrophobicity of inflow part 221 can be achieved with a smaller number of components.
[0178] In addition, when the hydrophobicity of inflow part 221 is achieved by hydrophobic coating, the hydrophobicity of inflow part 221 does not depend on the material of inflow part 221 , and thus it is possible to further enhance the freedom in selecting the material of inflow part 221 .
[0179] Further, when an irregular shape is formed on the hydrophobic surface of inflow part 221 , the lower limit of the liquid pressure of the irrigation liquid flowing into the channel of dripper 1 can be adjusted to be somewhat higher. Therefore, it is possible to enhance the freedom in selecting the pressure of the inflow liquid during the use of dripper 1 under low pressure.
[0180] Furthermore, diaphragm part 34 provided in dripper 1 makes it possible to properly control the ejection amount of the irrigation liquid even when used under high pressure.
[0181] The irrigation liquid having flowed into dripper 1 reaches the terminal, where diaphragm part 34 is disposed, of first guide channel 23 through first guide channel 23 .
[0182] The irrigation liquid having reached the terminal of first guide channel 23 deforms diaphragm part 34 with its liquid pressure, while being inhibited from moving forward in such a manner as to be dammed by diaphragm part 34 , and as a result is led to pressure reduction channel 8 sideward as an escape.
[0183] The irrigation liquid introduced into pressure reduction channel 8 undergoes pressure reduction due to pressure loss caused by the shape of the channel of pressure reduction channel 8 .
[0184] The irrigation liquid of which pressure is reduced by pressure reduction channel 8 flows into first section 331 in second guide channel 33 connected to terminal 8 E of pressure reduction channel 8 , and then passes through second section 332 .
[0185] At that time, diaphragm part 34 is deformed by the liquid pressure of the irrigation liquid with which first guide channel 23 is filled, such that fourth portion 3431 moves toward inner bottom surface 3321 . Therefore, the width of the channel of second section 332 is decreased by an amount according to the amount of this deformation.
[0186] Accordingly, the flow rate of the irrigation liquid passing through second section 332 (flow rate moving toward third section 333 and ejection port 321 all at once) is regulated by the influence of the regulation on the channel width by diaphragm part 34 .
[0187] Here, two cases will be discussed in which the liquid pressure of the irrigation liquid flowing into dripper 1 is relatively high and is relatively low. The examples of the causes for such two cases include a position at which dripper 1 is attached on tube 5 (whether near to or distant from a pump), performance of the pump itself (whether high-pressure pump or low-pressure pump), and change of the performance of the pump itself over time.
[0188] First, when the pressure of the irrigation liquid is high, the inflow amount of the irrigation liquid into the channel of dripper 1 becomes relatively larger, but at the same time the amount of deformation of diaphragm part 34 becomes relatively larger. Thus, the flow rate of the irrigation liquid to be regulated by diaphragm part 34 also becomes relatively larger. Therefore, the ejection amount of the irrigation liquid from ejection port 321 does not become excessively large.
[0189] On the other hand, when the pressure of the irrigation liquid is low, the inflow amount of the irrigation liquid into the channel of dripper 1 becomes relatively smaller, but at the same time the amount of deformation of diaphragm part 34 becomes relatively smaller. Thus, the flow rate of the irrigation liquid to be regulated by diaphragm part 34 also becomes relatively smaller. Therefore, the ejection amount of the irrigation liquid from ejection port 321 does not become excessively small.
[0190] Thus, the ejection amount of the irrigation liquid from ejection port 321 can be suitably controlled so as to have less variation (such that the variation of that ejection amount is regulated to 5 to 10%, for example), irrespective of the liquid pressure of the irrigation liquid at the time of flowing into dripper 1 .
[0191] In addition, diaphragm part 34 has a structure in which pressure reduction channel 8 is not shielded, unlike the techniques set forth in PTLS 1 and 2, and pressure reduction channel 8 is constantly opened. Therefore, in the present embodiment, the inflow of the irrigation liquid into pressure reduction channel 8 is not regulated. Therefore, the presence of diaphragm part 34 does not constitute a cause for raising the lower limit of the liquid pressure of the irrigation liquid available for drip irrigation toward the high pressure side.
[0192] In addition, diaphragm part 34 is integrally molded with the same resin material as that of second member 3 . Therefore, in the present embodiment, such dripper 1 excellent in controlling the ejection amount of the irrigation liquid can be manufactured at a low cost and with less processes with only two components of first member 2 and second member 3 made of a resin material. In particular, there are quite large advantages in terms of costs and manufacturing efficiency when compared with the case of assembling a diaphragm made of an expensive material such as silicone rubber as an individual component.
[0193] In addition, since diaphragm part 34 is assembled into second member 3 as an integrally molded product, malfunction of diaphragm part 34 due to assembly error is less likely to occur, contributing to the stabilization of the ejection amount of the irrigation liquid.
[0194] Further, diaphragm part 34 is capable of regulating the channel width properly and efficiently by utilizing the pressure difference between the irrigation liquid in pressure reduction channel 8 after pressure reduction by pressure reduction channel 8 and the irrigation liquid in first guide channel 23 to which diaphragm part 34 is exposed. That is, the reduced liquid pressure of the irrigation liquid in second section 332 is sufficiently low. Therefore, that liquid pressure does not hinder the deformation operation of diaphragm part 34 by the irrigation liquid in first guide channel 23 having a relatively high pressure.
[0195] Furthermore, first section 331 of second guide channel 33 is disposed near diaphragm part 34 . Therefore, compared with the case where first section 331 is disposed away from diaphragm part 34 , the shape of a metal mold in which second member 3 is molded with resin can be simplified, and thus the manufacturing cost can be further reduced.
[0196] In addition, diaphragm part 34 is deflected so as to cancel the curvature toward first guide channel 23 utilizing the elasticity of the resin material to expand outwardly in the radial direction upon receiving the liquid pressure at center wall part 341 from first guide channel 23 side. At the same time, peripheral wall part 342 is rotated about a contact point where peripheral wall part 342 intersects with second plate-like part 31 as a rotation axis. Therefore, fourth portion 3431 can be smoothly displaced toward inner bottom surface 3321 of second section 332 .
[0197] Thus, diaphragm part 34 is formed into a suitable shape to be deformed toward inner bottom surface 3321 upon efficiently receiving the liquid pressure of the irrigation liquid in first guide channel 23 . Accordingly, the channel width can be regulated more properly. Such an effect can be further enhanced by forming a portion near fourth portion 3431 in diaphragm part 34 to be thinner. It is noted that the channel width may be regulated more stably by forming fourth portion 3431 to be further thicker.
[0198] As has been described above, according to the present embodiment, the dripper includes at least a pipe for penetrating the tube wall of the tube through which the irrigation liquid is supplied, a flange part extending outwardly from the outer periphery of that pipe, a partition wall that closes the inside of that pipe in that flange part, and a bypass channel that is formed inside the flange part and allows communication between two portions, of the pipe, partitioned by the partition wall, and that bypass channel includes a pressure reduction channel for reducing the pressure of the irrigation liquid flowing through the bypass channel. In addition, the dripper is composed of the above-mentioned first member and second member that divide the pipe part and flange part into two portions, and the partition wall is integrally formed with either of first member or second member.
[0199] In addition, when at least the partition wall is a diaphragm part that moves in such a direction so as to close the inside of the pipe or the bypass channel upon receiving the pressure of the irrigation liquid having flowed into the pipe, it is possible to provide a dripper enabling the ejection amount of the irrigation liquid to be stabilized, and cost reduction to be achieved by reducing the manufacturing cost, number of components and manufacturing processes, and a drip irrigation apparatus including the dripper. In this case, the above-mentioned low pressure stop filter function does not need to be provided at the inflow port disposed at the end of the pipe disposed in the tube. However, the dripper further including the above-mentioned low pressure stop filter function is more effective from the viewpoint of stabilizing the drop of the irrigation liquid when the liquid pressure of the irrigation liquid is low.
[0200] In addition, when at least the inflow port has the low pressure stop filter function, it is possible to provide a dripper enabling drip irrigation to be properly performed even when the liquid pressure of the irrigation liquid is low, and a drip irrigation apparatus including the dripper. In this case, the partition wall does not need to have the above-mentioned function of the diaphragm part. However, the partition wall being the diaphragm part is more effective from the viewpoint of stabilizing the drop of the irrigation liquid when the liquid pressure of the irrigation liquid fluctuates higher.
[0201] It is noted that the present invention is not limited to the above-described embodiment, and the above-described embodiment may be modified in various manners as long as the feature of the present invention is provided.
[0202] [Modification].
[0203] As illustrated in FIG. 17 , the dimension of second protrusion part 32 in the protrusion direction may be shorter, for example.
[0204] Alternatively, as illustrated in FIG. 18 , second protrusion part 32 itself does not need to be provided. In this case, ejection port 3121 can be formed on second outer surface 312 .
[0205] Alternatively, as illustrated in FIG. 19 , the end portion (upper end portion in FIG. 19 ) of diaphragm part 34 on first member 2 side may be extended to such a position as to abut recess 2111 . In this case, opening 3421 for allowing the inflow of the irrigation liquid into pressure reduction channel 8 can be formed on peripheral wall part 342 of diaphragm part 34 .
[0206] The disclosures of Japanese Patent Applications No. 2012-196149 filed on Sep. 6, 2012, and No. 2012-216574 filed on Sep. 28, 2012 including the specification, drawings and abstract are incorporated herein by reference in their entirety.
INDUSTRIAL APPLICABILITY
[0207] The dripper according to the present invention is capable of dropping a stable amount of irrigation liquid without depending on the liquid pressure of the irrigation liquid. In addition, such dripper can be formed by the joining of two injection-molded products. Therefore, it is possible to manufacture the dripper at a low cost and in a large amount. Accordingly, it is expected that the dripper and drip irrigation apparatus according to the present invention are utilized not only in drip irrigation but also in various industries where stable dropwise addition of liquid is demanded.
REFERENCE SIGNS LIST
[0000]
1 Dripper
2 First member
21 First plate-like part
211 First inner surface
212 First outer surface
213 Pressure reduction channel part
22 First protrusion part
221 Inflow part
23 First guide channel
3 Second member
31 Second plate-like part
311 Second inner surface
312 Second outer surface
321 Ejection port
33 Second guide channel
34 Diaphragm part
8 Pressure reduction channel
11 Plate-like body
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A dripper obtained by incorporating together a first member and second member, which are both resin moldings. The first member is on the side into which an irrigating solution flows, and the second member is on the side from which the irrigating solution is discharged. The dripper has an inflow part having a low-pressure stop filter function, and/or a diaphragm part for narrowing a flow path by elevating the hydraulic pressure of the irrigating solution. The dripper makes it possible to stabilize the amount of irrigating solution discharged, irrespective of the hydraulic pressure of the irrigating solution, and also makes it possible to reduce costs.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to woven sheeting material and in particular to plainwoven sheeting material for institutional use and to a method of making the same.
2. Prior Art Statement
It is known in the art to provide woven sheeting material, such as, plainwoven sheeting material for institutional use wherein such institutions include hospitals, nursing homes, rest homes, and the like. However, the sheeting material proposed previously for institutional use is made in what is referred to as a balanced weave utilizing substantially the same number of warps and wefts in each unit of surface area, such as a square inch, for example, of the sheeting material. Further, the sheeting material proposed previously for institutional use employs a blend of natural material and synthetic material in both the warps and wefts thereof whereby with the usual blend of natural and synthetic material defining each warp or weft there are generally equal quantities or considerably more synthetic material than natural material in the previously proposed sheeting material whereby such previously proposed sheeting material has certain deficiencies which will now be described.
The provision of sheeting material having substantial quantities of synthetic materials therein, such as a polyester, results in a material in which stains are very difficult to remove. This phenomenon is due to the fact that a synthetic material is basically oleophylic and thereby has a tendency to attract oils, such as body oils emitted from the body of a patient, for example.
There is also a tendency for sheeting material having substantial quantities of synthetic materials to become dull and unattractive after about 100 institutional laundry cycles, where a laundry cycle comprises washing, drying, ironing and possibly steam sterilization of a particular sheeting material. Even though such sheeting material is usable after 100 of such cycles there is a tendency to discard such sheeting material because of its poor appearance.
Sheeting material which has been proposed previously for institutional use often is provided with a chemical no-iron surface treatment or finish. Such a treatment tends to degrade cotton fibers of the sheeting material and further tends to make the removal of stains, particularly oleophylic stains, even more difficult.
SUMMARY OF THE INVENTION
This invention provides an improved woven sheeting material having warps and wefts wherein such sheeting material overcomes the above-mentioned deficiencies.
In accordance with one embodiment of this invention each of the warps is made of a blend of a natural material and a synthetic material and each of the wefts is made substantially entirely of the said natural material.
In accordance with another embodiment of this invention a plainwoven sheeting material for institutional use is provided which has warps and wefts and is free of surface treatment to thereby require ironing thereof; and, each of the warps of such sheeting material is made of a blend of cotton and polyester and each of the wefts is made of cotton.
Accordingly, it is an object of this invention to provide an improved sheeting material of the character mentioned.
Another object of this invention is to provide an improved plainwoven sheeting material for institutional use of the character mentioned.
Another object of this invention is to provide an improved method of making a sheeting material of the character mentioned.
Other features, objects, uses, and advantages of this invention are apparent from a reading of this description which proceeds with reference to the accompanying drawing forming a part thereof.
BRIEF DESCRIPTION OF THE DRAWING
The accompanying drawing shows present preferred embodiments of this invention, in which
FIG. 1 is an isometric view with the central portion thereof broken away illustrating one exemplary embodiment of the sheeting material of this invention,
FIG. 2 is an enlarged fragmentary plan view particularly illustrating the warps and wefts of the sheeting material of FIG. 1; and
FIG. 3 is a view taken essentially on the line 3--3 of FIG. 2.
DETAILED DESCRIPTION
Reference is now made to FIG. 1 of the drawings which illustrates one exemplary embodiment of the sheeting material of this invention which is designated generally by the reference numeral 10. The sheeting material 10 is a plainwoven material particularly adapted for institutional use and has warps 11 extending in one direction along such sheeting material in substantially parallel relation and has wefts 12 extending in parallel relation in another direction which in this example is perpendicular to the direction of the warps and as is known in the art for a plainwoven material.
The sheeting material 10 is free of surface treatment and thereby requires ironing. This requirement for ironing in institutional sheeting material is particularly desirable because it tends to reduce pilferage.
Most previously proposed institutional sheeting materials are made in a so-called balanced weave, i.e., the same number of warps and wefts per square inch. However, in the sheeting material 10 the number of warps 11 in a unit area, such as a square inch thereof, is greater than the number of wefts 12 and the total number of warps and wefts in any square inch thereof is generally of the order of 190. This reference to generally of the order of 190 is intended to indicate that between 185 and 200 warps and wefts per square inch are provided. In one particular example, 192 warps and wefts per square inch were provided with 110 of this number being warps and 82 being wefts.
As previously mentioned, each of the warps 11 is made of a blend of natural material and synthetic material. Preferably each of the warps 11 consists of from 40% natural material and 60% synthetic material to 60% natural material and 40% synthetic material. In one specific example of the sheeting material 10 the warps consisted of a blend of 50% natural material and 50% synthetic material.
The natural material of the warps and wefts is preferably cotton and defines approximately 70% by weight of the sheeting material 10 thereby providing a light weight, high moisture absorbency, and softness in such sheeting material. In one example cotton constituted 72% by weight of the sheeting material 10.
The sheeting material 10 is woven such that the cotton of the warps 11 and wefts 12 also defines approximately 80% of the surface area of such sheeting material, and it will be appreciated that with this large amount of cotton defining the surface area there is a minimum tendency for pilling by the loose or broken ends of the synthetic material.
Although any suitable synthetic material may be used to define the warps 11 of the sheeting material 10, such synthetic material is preferably polyester. The preferred natural material used in the warps 11 and wefts 12 is cotton and preferably is in the form of a long staple combed cotton. In a particular example of the sheeting material each warp 11 consisted of 50% cotton and 50% polyester.
Although the natural material comprising the warps and wefts in the exemplary material 10 is described as being preferably cotton, it will be appreciated that other natural materials may be utilized. For example, in applications where expense is not of paramount importance wool, silk, and the like may be utilized. Likewise synthetic materials other than polyester may be utilized provided that the selected synthetic material is easy to blend with the natural material which is being utilized and such selected synthetic material is also easy to weave as a plain weave.
The sheeting material 10 has comparatively higher tensile strength in the warp direction than in the weft direction. This is due to the utilization of polyester in the warps which has a comparatively high tensile strength.
It will also be appreciated that with the provision of the sheeting material 10 having approximately 70% by weight of cotton and a surface area made of approximately 80% cotton, as previously mentioned, the advantages of cotton are preeminent. In particular, cotton provides its well known luxurious feel and touch and greater comfort than sheeting material made with large amounts of synthetic material. It is also comparatively easier to remove stains from cotton. In addition, the utilization of substantial amounts of cotton in the sheeting material 10 enables the provision of such sheeting material for institutional use in colors which retain their brightness.
The utilization of a natural material, such as cotton, to define generally of the order of 70% by weight of the sheeting material 10 enables such sheeting material to be subjected to numerous laundry cycles without destroying what is often referred to as the brightness and cleanliness of such sheeting material. In comparing sheeting material 10 with previously proposed sheeting materials which utilize substantial amounts of synthetic materials, such as polyester, it was found that such previously proposed sheeting materials became dull and their brightness was greatly diminished after about 100 institutional laundry cycles, as previously defined. However, the sheeting material 10 retains its bright clean appearance after 150 institutional laundry cycles and in some instances after as many as 200 such cycles.
The sheeting material 10 is made with its exposed surfaces free of special treatment or finish. In this manner chemicals which tend to degrade and weaken the fibers and/or filaments defining the warps 11 and wefts 12 and which also tend to retain stains thereon are avoided.
It will also be appreciated that the sheeting material 10 with substantial amounts of cotton comprising the same lends itself to the provision of colored selvages for instant identification of size and product. In this context it will be recognized that the reference to sheeting material means bed sheets, whether flat or contoured; pillowcases, so-called draw sheets, or products for hospital surgical procedures made from this sheeting.
Throughout this disclosure reference has been made to warps 11 and wefts 12 of the sheeting material 10. However, it is to be understood that warps 11 means warp threads or yarns and wefts 12 means weft, i.e., fill, threads or yarns and as is known in the art.
While present exemplary embodiments of this invention, and methods of practicing the same, have been illustrated and described, it will be recognized that this invention may be otherwise variously embodied and practiced within the scope of the following claims.
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A woven sheeting material and method of making same are provided wherein such sheeting material has warps and wefts and each of the warps is made of a blend of a natural material and a synthetic material and each of the wefts is made substantially entirely of the natural material.
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BACKGROUND
1. Field of the Invention
The present invention relates generally to railroad car truck brake systems, and more specifically, an adjustable brake beam.
2. Description of Related Art
Railroad car truck brake beams are well known in the art and provide a viable means of stopping a train. In FIG. 1 , a conventional brake beam system 101 is shown. System 101 depicts a rectilinear compression member 103 , a rectilinear tension member 129 , strut 117 with means for connecting said tension member 129 and said compression member 103 , brake heads 131 and 133 with recesses so that said tension member 129 and said compression member 103 may be partially located therein.
As depicted in FIG. 1 , a brake beam system 101 is supported on guides 127 and 109 located adjacent to the wheels 105 and 123 . A lever (not shown) inserted within the slot 121 applies force in the direction of arrows 113 and 115 . When force is applied in the direction of arrow 113 , the beam 103 moves in the direction arrow 113 so that brake shoes 125 and 107 contact wheels 123 and 105 , respectively.
As is known to those skilled in the art, because of the substantial speeds at which railroad cars travel and the heavy loads they carry, large braking forces are required to be transferred to the wheels through the brake beam assemblies during their operation. These forces, and random vibrations borne through the truck structure to the brake beams, create stresses in numerous areas.
The rails 109 and 127 contain recessed, parallel side pockets with an internal liner (not shown in FIG. 1 but discussed in more detail herein) which allow the beam 103 to move by sliding in directions 113 and 115 . The brake heads 131 and 133 contain protrusions 135 and 137 , respectively, which are commonly known as end extensions. The end extensions 135 and 137 are tapered by design and are sized to fit into the side pockets of the rails 109 and 127 . It is notable that the end extensions 135 and 137 are non-adjustably integral to the brake heads 131 and 133 , respectively, since the brake heads (with end extensions) are manufactured as a “one piece” casting. As depicted in FIG. 1 , each brake beam system 101 contains a right hand and left hand brake head.
When the brake beam 103 is engaged such that the brake shoes 125 and 107 contact the wheels 123 and 105 , the resultant friction force is transmitted through the brake beam system 101 through end extensions 135 and 137 to the fixed rails 127 and 109 . Due to tolerance stack-up and loose regulatory standards, the end extensions 135 and 137 loosely fit in the side pockets of the rails 127 and 109 causing them to become diagonally constrained when the brake beam is engaged. Simply put, the end extensions 135 and 137 contact the side pockets via two-point contact; one point on the upper trailing edge of the side pocket and another point on the lower leading edge of the side pocket.
The inherent sloppy fit of the tapered end extensions 135 and 137 to the side pockets of the rails 127 and 109 allows the brake beam to move until the end extensions become diagonally constrained. This allowable, inherent movement causes misalignment between brake shoes 107 and 125 and wheels 105 and 123 resulting in uneven brake shoe wear. This uneven shoe wear; commonly referred to as shoe taper, can occur on new railcars during the first deployment of use. This is viewed as a disadvantage of conventional brake beam systems.
Although great strides have been made in the area of brake beam system, many shortcomings remain.
DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of the embodiments of the present application are set forth in the appended claims. However, the embodiments themselves, as well as a preferred mode of use, and further objectives and advantages thereof, will best be understood by reference to the following detailed description when read in conjunction with the accompanying drawings, wherein:
FIG. 1 is a top view of a conventional brake beam system;
FIG. 2 is an oblique view of an adjustable brake beam system in accordance with a preferred embodiment of the present application;
FIGS. 3, 4 , & 5 are oblique views of the adjustable brake beam system of FIG. 2 ;
FIG. 6 is a top view of the adjustable brake beam system of FIG. 2 ;
FIG. 7 is an oblique view of the tension member of the adjustable brake beam system of FIG. 2 ;
FIG. 8 is an oblique view of the compression member of the adjustable brake beam system of FIG. 2 ;
FIG. 9 is an oblique view of the strut of the adjustable brake beam system of FIG. 2 ;
FIGS. 10 & 11 are oblique views of the brake head of the adjustable brake beam system of FIG. 2 ;
FIGS. 12 & 13 are oblique views of the adjustable adapter of the adjustable brake beam system of FIG. 2 ;
FIGS. 14 & 15 are oblique views of the installation of the adjustable brake beam system of FIG. 2 ;
FIGS. 16A, 16B, and 16C are oblique views of the installation of the adjustable brake beam system of FIG. 2 ;
FIG. 17 is an oblique view of a non-adjustable brake beam system in accordance with an alternate embodiment of the present application;
FIGS. 18 & 19 are oblique views of the non-adjustable brake beam system of FIG. 17 .
FIG. 20 is an oblique, exploded view of the non-adjustable brake beam system of FIG. 17 . and
FIGS. 21 & 22 are oblique views of the non-adjustable adapter of the non-adjustable brake beam system of FIG. 17 .
While the system and method of use of the present application is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular embodiment disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present application as defined by the appended claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Illustrative embodiments of the system and method of use of the present application are provided below. It will of course be appreciated that in the development of any actual embodiment, numerous implementation-specific decisions will be made to achieve the developer's specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.
The system and method of use in accordance with the present application overcomes one or more of the above-discussed problems commonly associated with conventional brake beam systems. Specifically, the system of the present application provides a new and useful adjustable brake beam which will allow the user to eliminate pre-mature brake shoe taper through the use of a unique, adjustable fit up method. These and other unique features of the system and method of use are discussed below and illustrated in the accompanying drawings.
The system and method of use will be understood, both as to its structure and operation, from the accompanying drawings, taken in conjunction with the accompanying description. Several embodiments of the system are presented herein. It should be understood that various components, parts, and features of the different embodiments may be combined together and/or interchanged with one another, all of which are within the scope of the present application, even though not all variations and particular embodiments are shown in the drawings. It should also be understood that the mixing and matching of features, elements, and/or functions between various embodiments is expressly contemplated herein so that one of ordinary skill in the art would appreciate from this disclosure that the features, elements, and/or functions of one embodiment may be incorporated into another embodiment as appropriate, unless described otherwise.
The preferred embodiment herein described is not intended to be exhaustive or to limit the invention to the precise form disclosed. It is chosen and described to explain the principles of the invention and its application and practical use to enable others skilled in the art to follow its teachings.
Referring now to the drawings wherein like reference characters identify corresponding or similar elements throughout the several views, FIG. 2 depicts an adjustable brake beam system in accordance with a preferred embodiment of the present application. It will be appreciated that the adjustable brake beam system 201 overcomes one or more of the above-listed problems commonly associated with conventional brake beam systems.
In a preferred embodiment, system 201 includes a compression member 203 , tension member 205 , strut 207 , brake heads 209 & 215 , and adjustable adapters 211 & 217 with cams 213 & 219 . Each of the said components contain unique features in regards to functionality of system 201 which will be discussed further herein.
Referring to FIG. 3 , an oblique view of system 201 is given which depicts adjustablility features of the exemplary embodiment. In this embodiment, the end extension of the brake head is made up of two pieces; a non-adjustable protrusion 303 which is integral to the brake head 215 and an adjustable cam 219 which is pivotably adjustable in arrow direction 301 . The adjustable adapter 217 provides a bore for the cam 219 to rotate inside of as well a mechanical means of retaining the cam 219 . As depicted in FIG. 3 , the cam includes a key 305 which rotates in a radial slot on the adjustable adapter 217 which, in turn, provides a finite angle rotation for the cam 219 . It is appreciated that though FIG. 3 only depicts the right hand side of the brake beam 201 , the aforementioned features are duplicated in a mirror fashion on the left hand side of system 201 in brake head 209 , adjustable cam 213 , and adjustable adapter 211 .
Referring now to FIG. 4 , another oblique view of system 201 is given. The brake head 215 & 209 , strut 207 , tension member 205 , and compression member 203 is more clearly indicated in FIG. 4 .
Referring now to FIG. 5 , an exploded, oblique view of system 201 is given which the brake head 215 not shown for clarity. FIG. 5 depicts the method of fastening the components of system 201 . The tension member 205 is mechanically fastened to the adjustable adapter 217 and compression member 203 through fasteners 505 and 507 . The brake head 215 (not shown) is attached to the brake beam system 201 using one or more fasteners 501 , 503 , 509 , and 511 . The adjustable cam 219 is inserted into the adjustable adapter 217 and retained using one or more fasteners 513 .
Referring now to FIG. 6 , a top view of system 201 is shown. The practical use of the adjustable brake beam system 201 in the field requires compliance to the governing authority's standards. Therefore, dimensions 601 , 603 , 605 , and 607 are in accordance with the Association of American Railroads' “Manual of Standards and Recommended Practices”, Section D, Trucks and Truck Details, Standard S-345-79, “Application Tolerances for Brake Beams, Hangerless Types”.
Referring now to FIG. 7 , an oblique view of the tension member 205 of system 201 is given. Because of its unique geometry and construction, it is especially suited for use in the adjustable brake beam system 201 . As depicted, the tension member 205 is formed from a substantially “rectangular” cross-sectional shape. The center of the tension member contains a bend 701 which forms to a uniquely contoured slot in the strut 207 . The tension member 205 also contains one or more transitions 703 in which the cross-section becomes flatter and wider. The holes 705 provide a measure of mounting for fasteners 505 and 507 . One or more formed, angled vertical surfaces 707 are included which aid in transmitting the loads into the adjustable adapters 217 and 211 .
Referring now to FIG. 8 , an oblique view of the compression member 203 of system 201 is given. Because of its unique geometry and construction, it is especially suited for use in the adjustable brake beam system 201 . The compression member 203 is “U” shaped in cross-section and contains several unique features. A center hole 801 is a provision for the mounting of the strut 207 . One or more lightening holes 805 are included to decrease the overall weight of the compression member 203 . Additionally, the compression member 203 includes one or more mounting holes 803 which are a provision for mounting fasteners 501 and 509 . One or more cutouts 807 provide clearance for the adjustable adapters 217 and 211 and to protrude through the backside of the compression member 203 . Finally, one or more chamfers 809 are included which provide clearance for fasteners 503 and 511 as well as a weld seam for permanent fastening of the adjustable adapters 217 and 211 to the compression member 203 .
Referring now to FIG. 9 , an oblique view of the strut 207 of system 201 is given. The strut 207 is generally cylindrical in shape and provides a means for the pin (not shown) to transmit the braking force through the adjustable brake beam system 201 . The strut 207 contains a pin hole 901 whose centerline is normal to the centerline of the strut 207 . One end of the strut 207 contains a protrusion with one or more mounting holes 903 . Another end of the strut 207 contains uniquely contoured slots 905 and 907 which are sized and oriented to match and fit the bend contour 701 of the tension member 205 .
Referring now to FIGS. 10 & 11 , oblique views of the brake head 209 of system 201 are shown. It is appreciated that brake head 215 of system 201 contains identically mirrored features to that of brake head 209 depicted in FIGS. 10 & 11 . The brake head 209 contains one or more brake shoe (not shown) mounting surfaces 1003 , 1005 , 1007 , and 1009 which form an arc. The radius of the arc, as well as all of the other critical dimensions of the brake heads 209 and 215 are in accordance with pages Standard S-371-81, “LIMITING CONTOUR OF BRAKE HEADS FOR HANGERLESS TYPE BRAKE BEAMS”. The brake head 209 also contains a non-adjustable protrusion 1001 which is commonly referred to as end extension. The end extension 1001 is stiffened by gusset 1101 which is given in FIG. 11 . A protruding male and female clevis 1103 and 1107 , respectively, provide a mounting provision of the brake head 209 to the adjustable brake beam system 201 using holes 1105 and 1109 , respectively. One or more stiffening gussets 1111 are included on brake head 209 to aid in transmitting the braking forces through the brake head 209 into the brake beam system 201 .
Referring now to FIGS. 12 & 13 , oblique views of the adjustable adapter 217 of system 201 are shown. It is appreciated that adjustable adapter 211 of system 201 contains identically mirrored features to that of adjustable adapter 217 depicted in FIGS. 12 & 13 . The adjustable adapter 217 is uniquely shaped to provide multiple functions in its use on system 201 . The adjustable adapter 217 provides a means of mechanically attaching the compression member 203 to the tension member 205 . The tension member hole 705 aligns with hole 1213 while the angled flat surface 1201 provides a mating surface for the tension member 205 end. Holes 1205 and 1209 provide a mounting means for fasteners 501 , 503 , 509 , and 511 . The female clevis 1203 fits precisely on the male clevis 1105 of the brake head 209 . Finally, the hole 1213 and counter-bore surface 1215 provide clearance for mounting fasteners 505 and 507 , respectively.
Additionally, the adjustable adapter 217 provides a housing and retention for the adjustable cam 219 which is depicted by cylinder 1207 . The radial slot 1217 provides a means of finite rotary adjustability of the cam 219 while weld slot 1219 provides a means of permanent welding after mechanical fit up during installation. One or more weld arm 1211 are also included which provide another means of welding the adjustable adapter to the compression member 203 .
Referring now to FIGS. 14 & 15 , oblique views of the system 201 are shown depicting its installation on an existing railroad car truck. Railroad side frame 1401 and 1413 contain side pockets 1403 with replaceable liner 1405 . The adjustable cam 213 and brake head 209 end extension 1001 fits into the recessed side pocket 1403 and liner 1405 . The brake shoe 1415 is installed on the arched surfaces of the brake head 209 and is arched to match the outer contour of the wheel 1409 secured to a shaft 1407 rotatably attached to the body of the frame 1401 .
Referring now to FIGS. 16A, 16B & 16C , oblique views of the system 201 are shown depicting its installation on an existing railroad car truck. In FIG. 16A , the adjustable brake beam system 201 is inserted in the side pocket in arrow direction 1601 with the adjustable cam 213 oriented as depicted. In FIG. 16B , brake head 209 and brake shoe 1415 are aligned to the wheel 1409 before the adjustable cam is rotated in arrow direction 301 so that the adjustable brake beam system 201 is diagonally constrained. As previously mentioned, two-point contact takes place in the side pockets 1403 in order constrain the brake beam system 201 and resist the braking forces. System 201 allows the user to match the brake head 209 to the wheel 1409 while diagonally constraining its two-piece end extension; namely, the adjustable cam 213 and brake head end extension 1001 in the side pocket 1403 . This will allow the user to greatly reduce and/or eliminate shoe taper and premature shoe wear. This is viewed as an advantage of the system of the present application.
As depicted in FIG. 16C , once the adjustable cam 213 is rotated until the upper trailing edge makes contact with the side pocket 1403 , a permanent weld is made in slot 1219 which locks the orientation of cam 213 relative to the adjustable adapter 211 .
Referring now to FIG. 17 , an exploded view of system 1701 is respectively shown in accordance with alternative embodiment of the present application. System 1701 is substantially similar in function to system 201 and it is contemplated interchanging the features of the different types of the systems discussed herein.
In an alternative embodiment, system 1701 includes a compression member 1703 , tension member 1705 , strut 1707 , brake heads 1709 & 1715 , and non-adjustable adapters 1711 & 1713 . In this embodiment, the non-adjustable adapters 1711 and 1713 end extension is pre-sized to fit the railroad car truck side pocket prior to installation.
In FIG. 18 , an oblique view of system 1701 is given which shows how the end extension of the non-adjustable adapter 1713 appears.
Referring now to FIG. 19 , another oblique view of system 1701 is given. The brake head 1715 & 1709 , strut 1707 , tension member 1705 , and compression member 1703 is more clearly indicated in FIG. 19 .
Referring now to FIG. 20 , an exploded, oblique view of system 1701 is given showing is method of assembly. System 1701 's method of assembly is substantially similar to that of system 201 .
Referring now to FIGS. 21 & 22 , oblique views of the non-adjustable adapter 1713 of system 1701 is given. It is appreciated that adjustable adapter 1713 of system 1701 contains identically mirrored features to that of non-adjustable adapter 1711 depicted in FIG. 17 . The non-adjustable adapter 1713 is uniquely shaped to provide multiple functions in its use on system 1701 . The non-adjustable adapter provides a means of mechanically attaching the compression member 1703 to the tension member 1705 . The tension member hole aligns with hole 2113 while the angled flat surface 2101 provides a mating surface for the tension member 1705 end. Holes 2105 and 2109 provide a mounting means for mechanical fasteners. The female clevis 2103 fits precisely on the male clevis of the brake head 1709 . Finally, the hole 2113 and counter-bore surface 2115 provide clearance for mechanical fasteners, respectively.
Additionally, the non-adjustable adapter 1713 provides a machinable surface 2115 on the end extension protrusion 2107 . The machinable surface 1713 will be precisely contoured per the geometry of the truck side pockets based on the governing authority standards. This is viewed as an advantage of system 1701 of the present application.
The particular embodiments disclosed above are illustrative only, as the embodiments may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. It is therefore evident that the particular embodiments disclosed above may be altered or modified, and all such variations are considered within the scope and spirit of the application. Accordingly, the protection sought herein is as set forth in the description. Although the present embodiments are shown above, they are not limited to just these embodiments, but are amenable to various changes and modifications without departing from the spirit thereof.
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An adjustable brake system for a railroad truck wheel frame. The system includes an elongated body secured to a railroad truck and rotatably secured to a plurality of wheels, the elongated body having a brake side pocket positioned near a wheel of the plurality of wheels; a compression bar and an extension bar extending from a first side of the elongated body to a second side of the elongated body; a strut positioned between the compression bar and the extension bar; a brake head rigidly secured to the compression bar; a protrusion extending from the brake head and configured to engage within the brake side pocket; and a cam rotatably attached to the compression bar and configured to engage within the brake side pocket.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to methods of combusting high molecular weight liquid hydrocarbon fuels by co-firing with a more combustible supplemental fuel. More particularly, this invention presents a method and device that effectively combusts heavy hydrocarbon fuel oils by injecting them through a zone of combusting hydrogen where the oil is finely dispersed, partially vaporized and ignited. Since the method presented utilizes a relatively small amount of hydrogen fuel, a low-volume hydrogen source such as the electrolysis of water can be used to generate the required rates of hydrogen. Combustion of heavy oils using hydrogen generated from the electrolysis of water presents a significant achievement over present methods and devices which combust heavy fuel oils by co-firing with large amounts of natural gas. Using the combusting hydrogen to disperse the fuel oil provides the requisite degree of atomization without the need for compressed non-combustible gases, such as steam or air. When used with vegetable oils, the combustion method and device presented herein offers an economical alternative to producing heat energy using only renewable energy sources.
2. The Relevant Technology
Because high-molecular weight, or heavy liquid fuel oils are of such low volatility, a significant amount of heat and mechanical energy must be input to render these fuels into a readily combustible state. Typically, a heavy oil must be heated from ambient temperature to its flash point with even more heat applied to vaporize some of the oil molecules prior to combustion. Co-firing the heavy oil with a readily combustible gas is well known as an effective method of providing the heat load necessary to render the oil to a readily combustible state. Natural gas is presently the most common co-firing fuel since it is highly combustible and often the least costly supplemental fuel source. Natural gas is, however, a non-renewable energy source that may not readily available in some areas and may be subject to other competing domestic and industrial uses.
A majority of present burner designs employ various means of preheating, atomizing and mixing the heavy oil with the hot flue gases from the combusting co-firing fuel to improve heat transfer. Fuel atomization increases the exposed surface area of the liquid fuel, which increases the rate of vaporization. Three primary means are employed for atomizing the liquid fuel: 1) liquid feed nozzles, 2) high-pressure steam or air-assisted jetting, or 3) rotating cups. Examples of these atomizing methods include Pressure Jet Atomizers and, Steam or Air Assisted Jet Atomizers and Low pressure Air Atomizers. The Pressure Jet Atomizer utilizes high oil feed pressure to atomize the fuel into a spray of finely dispersed droplets. The fuel oil is fed into a swirl chamber by means of tangential ports in the main atomizer body. An air core is set up due to the vortex formed in the swirl chamber, which results in the fuel leaving the final orifice as a thin annular film. The angular and axial velocity of this film causes the fuel to develop into a hollow cone as it discharges from the orifice. One major problem with these types of burners is that the atomizer has a distorted spray angle as the fuel flow rates are reduced, which often results in fuel/flame impingement on the furnace walls.
The External-mix Steam Atomizer or Steam-assisted Pressure Jet Atomizer type burners are designed to make full use of pressure jet atomization at high firing rates and blast atomization at low firing rates. The external-mix style employs an atomizer with a pressure jet tip, around which is provided a steam supply channel. The steam exits this annular passage way through a gap at an angle and swirl that substantially matches the oil-spray cone angle. Since the fuel oil and steam are not pre-mixed, the output is unaffected by slight variations in the steam pressure. An alternate method is the internal-mix steam atomizer, which is comprised of two concentric tubes, a one-piece nozzle and a sealing nut. The steam is supplied through the center tube and the fuel oil through the outer tube. The outlet of the center steam tube has a number of discharge nozzles arranged on a pitch circle such that each oil bore meets a corresponding steam bore in a point of intersection. At the steam exits these nozzles, it mixes with the oil forming an emulsion of oil and steam at high pressure. The expansion of this mixture as it issues from the final orifice produces a spray of finely atomized oil.
The Rotary Cup atomizer employs a cup-shaped member that rotates at high speeds (around 5000 RPM) by an electric motor and belt drive. The fuel oil flows at low pressure into the conical spinning cup where it distributes uniformly on the inner surface and is spun off the cup rim as a very fine oil film. A primary air fan discharges air concentrically around the cup, striking the oil film at high velocity and atomizing it into tiny droplets. The rotary cup burner has good turn down ratio and is relatively insensitive to contaminants in the fuel oil. The Low-Pressure Air Atomizer employs a principle is similar to that of the rotary-cup-atomizing, but the liquid fuel is forced to rotate in a fixed cup by means of a forcefully rotating primary airflow.
Although the aforementioned burners are typically designed to combust lighter fuel oils, such as diesel fuel, they must be modified to combust heavier fuel oils. Typical modifications include equipping the combustion chamber or the area around the oil filming/atomizing device with a plurality of ports where a natural gas can be fed to the combustion zone. The natural gas is ignited first and the oil flow is started once a stable gas flame is established. As the molecular weight of the fuel oil increases, the amount of natural gas required to completely combust the oil also increases. Although natural gas is presently the most common co-firing fuel, the amount required to thoroughly combust a heavy oil can be substantial.
Hydrogen is generally known to be an improved co-firing fuel primarily because its heat of combustion and adiabatic flame temperature are much higher than methane, the primary constituent of natural gas (61,100 btu/ft3 versus 23,879 btu/lb on a gross basis, 3,861° F. versus 3,371° F.). For a typical direct co-firing burner, more than 2.5 times as much natural gas would be theoretically required to produce the same amount of heat as a given mass of combusting hydrogen. Also, hydrogen is further preferred over natural gas because it can be generated from renewable energy resources and its combustion product, water vapor, is more friendly to the environment. However, simply replacing natural gas with hydrogen is not generally feasible because even 2.5 times less gas rate would still constitute a significant hydrogen demand for a standard industrial-sized burner and methods do not presently exist that can economically generate and store large volumes of hydrogen for such an application.
Although the potential benefits of using hydrogen as a co-firing fuel are generally known, the practical difficulties of handling and combusting hydrogen have largely prevented the development of useful combustion devices employing hydrogen as a co-firing fuel. Hydrogen's extreme combustibility makes its generation, storage and handling expensive and potentially dangerous. Secondly, hydrogen's flame velocity is more than 8 times as fast as a typical heavy fuel oil flame velocity. This characteristic makes co-firing by conventional burners largely ineffective because the hydrogen burn rate substantially outpaces the fuel oil burn rate and the flame propagation may not be stable without a large excess of hydrogen.
SUMMARY AND OBJECTIVE OF THE INVENTION
The inventors understood that effective utilization of hydrogen as a co-firing fuel for heavy fuel oils would require a novel combustion method that could accommodate the special characteristics of combusting hydrogen and use relatively small quantities. The inventors felt that the favorable properties of hydrogen, i.e. high combustion heat and rapid flame velocity, could be harnessed to combust a class of liquid fuels, which are abundantly available and renewable but are not economically combusted using present methods or devices. Also, by reducing the volume of hydrogen required, a relatively simple method such as the electrolysis of water, could be used to generate the hydrogen “on-demand,” eliminating the need for complex hydrogen generation and storage methods that might otherwise be required. Although the heavy oil fuels preferred by the inventors for this application are raw vegetable oils, the concept and application can be usefully applied to a broad range of other combustible liquid fuels.
It is the objective of this combustion method and device to provide an economical option to the production of heat energy completely from renewable fuels, such as bio-fuel oils and hydrogen, where the value of the heat energy produced exceeds the sum costs of the fuels, equipment, and power input to produce that heat energy.
It is still a further objective of this combustion method and device to provide an effective means of combusting these heavy oil fuels utilizing hydrogen generated “on demand” by the electrolysis of water such that no ancillary equipment for separation, compression or storage of hydrogen is required and safety is maintained by minimizing the volume of hydrogen staged within the system.
DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a three-dimensional view of the combustion method presented by the inventors where the simulated, conically-shaped zone of combusting hydrogen is established by the rotating shaft and the heavy oil fuel is injected into the base of this cone. A simplified representation of the hydroxy and fuel oil combustion zones is shown to demonstrate the mechanics of the combustion as anticipated by the inventors.
FIG. 2 shows a similar three-dimensional arrangement and configuration in FIG. 1 where the critical geometric design angles of these feeding tubes are identified.
FIG. 3 shows a third three-dimensional arrangement of the hydroxy gas feeding tubes, the forward coolant staging chamber, the middle hydroxy gas staging chamber, and the rear fuel oil staging chamber.
FIG. 4 shows a side view of the assembled burner developed by the inventors to carry out this combustion method.
FIG. 5 shows a side view of one of the staging chambers.
FIG. 6 shows a side view of one of the spacer plates located on either side of the middle hydroxy gas staging chamber.
FIG. 7 shows a side view of one of the cap flanges located on the forward and rear ends of the staging chamber section of the burner.
FIG. 8 shows a side view of the staging chamber section of the burner where the location of the internal mechanical seals are shown
DETAILED DESCRIPTION
The graphic representation shown in FIG. 1 depicts the basic features of the combustion method and device developed by the inventors. The basic principle involves the use of a small quantity of combusting hydrogen to blast atomize and ignite the heavy oil fuel. Small hydrogen flames are established by igniting hydrogen gas as it exits a plurality of feeding tubes 20 and 21 . As the shaft 12 is rotated about axis Z at sufficiently high speeds, the hydrogen flames at the tips of the feeding tubes form a near continuous zone of combusting hydrogen 10 as shown in the figure as a conical spheroid. The liquid primary fuel travels through tube 13 along the axis of rotation Z and is first atomized into the base of the hydrogen combustion zone 10 .
In continued reference to FIG. 1 , in zone 11 a , the atomized primary fuel oil exiting the rotating shaft 12 is sensibly heated by the intense radiant and convective heat emanating from the hydrogen combustion zone 10 . As the primary fuel oil fuel enters zone 10 , the contact with the combusting hydrogen gases vaporizes and ignites some portion of the primary fuel. Any remaining atomized oil droplets that are not vaporized are sheared into an extremely fine micro-dispersion by the intense turbulence created in zone 10 by the combustion and rotation of the hydrogen flames. The dispersed primary fuel leaving zone 10 is comprised of mostly partially heated micro-dispersed oil droplets surround by a lesser amount of combusting, vaporized primary fuel. Zone 11 b depicts the downstream zone where the heat generated by the combusting primary fuel is used to complete the remaining vaporization required to combust all of the primary fuel. This method produces a primary fuel flame extending several feet away from the hydrogen combustion zone 10 , which allows for most of the primary fuel combustion to take place without interference by the hydrogen combustion.
Using hydrogen flame turbulence as a second stage blast atomizing means overcomes two significant problems encountered with combustion of heavy fuel oils. First, the method produces a significantly smaller liquid fuel droplet size in the combustion zone than is achievable by typical atomizing nozzles or orifices, without the need for preheating the fuel or injecting compressed air or steam. Secondly, it partially vaporizes a small quantity of the fuel oil and disperses that vapor throughout the primary fuel/air mixture so that once ignited, the heat of the combusting fuel oil vapor is more efficiently utilized to further vaporize any remaining liquid fuel.
An additional feature of this combustion method is the continuous ignition of the vaporized portion of the primary fuel oil by high-speed rotation of the hydrogen flames. As the atomized primary fuel travels past the tips of the hydroxy gas tubes 20 and 21 , any vaporized primary fuel must first be ignited. This ignition occurs as one of the rotating hydrogen flames fronts extending outwardly from the tips of the hydroxy gas tubes contacts the vaporized primary fuel. Experimentation showed that as the rotational speed of the rigid shaft dropped below the forward flame velocity of the hydrogen, the primary fuel's combustion efficiency began to decrease, resulting in smoking of the flame. This is thought to be due to the decrease in coverage of the hydrogen flames in the area above the feeding tubes. At rotational speeds less than the forward flame velocity of the hydrogen, some of the primary fuel appears to pass through zone 10 without contacting a hydrogen flame front, thus decreasing dispersion, vaporization and ignition efficiency of the primary fuel. This theory is supported by additional experiments that showed increasing the rotational speed above the forward flame velocity of the hydrogen did not provide any increase in combustion efficiency or primary fuel flame stability. The inventor's chose a standard speed achievable by readily available motors that produced a rotational speed of the hydrogen flames greater than 8.0 feet per second. For the size burner tested by the inventors, 400 liters per hour of hydroxy gas were required to effectively burn 25 gallons per hour of cottonseed oil.
Oxygen to support the combustion of hydrogen in zone 10 is best supplied by pre-mixing the hydrogen and oxygen prior to entering the feed tubes 20 and 21 . This is most easily done by using the electrolysis of water as the hydrogen source since the “hydroxy” gas produced is already in the proper stoichiometric proportion for combustion. Oxygen to support the combustion of the heavy oil is supplied by ambient air, which can be drafted into zone 11 b by an external air fan. One drawback to the use of hydrogen as a co-firing fuel is that the high flame temperature of combusting hydrogen can oxidize nitrogen present in the draft air and create NOx emissions that are undesirable. By using hydrogen and oxygen from electrolysis, ambient air is not necessary to fuel the hydrogen's combustion. Thus, since nitrogen gases are virtually non-existent in the hydrogen combustion zone, very little if any NOx is generated from the high-temperature hydrogen combustion zone.
The shapes and combustion zone interactions depicted in Figures are greatly simplified for purposes of disclosing the underlying principals involved with this combustion method. Variations in the heavy oil fuel properties, air draft rate, fuel atomization, fuel feed rate and orientation of the burner will result in distortions of these shapes. Also, these shapes are not in reality smooth conical shapes but rather zones of somewhat conical proportions where the peak of the combustion events occur. In an alternate embodiment of this combustion method, multiple zones of combusting hydrogen can be established downstream of zone 10 along the axis of rotation to provide additional heat energy heat to ensure efficient combustion of even heavier fuels. Such multiple-staged hydroxy combustion zones can be created by additional hydroxy feeding tubes projecting outwardly from the rotating shaft or by surrounding the rigid shaft 12 with a second shaft, rotating in an opposite direction along the same axis.
To accomplish this combustion method, the inventors had to overcome several issues relating to the transport of the hydroxy gas from the electrolytic cell where it is generated into the rotating shaft 12 and through to the tips of the tubes 20 and 21 where the hydrogen combustion occurs. First, hydroxy gas is extremely combustible and will auto-ignite at relatively low pressures when heated. Radiant and convective heat from the combustion zones 10 and 11 will tend to heat the burner components near the combustion area. To prevent thermal-induced auto-ignition before the hydroxy gas reaches the tips of the tubes, the inventors were required to keep the feed gas pressure as low as possible. However, when the shaft 12 is rotated, centrifugal forces act to prevent molecules from entering the feeding tubes. Also, since oxygen has a higher molecular weight than hydrogen, the centrifuge effect created by the rotating shaft tends to move oxygen molecules away from the axis of rotation relative to the hydrogen, which causes separation of the hydrogen and oxygen molecules inside the feeding tubes.
As best shown in FIG. 2 , each feeding tube can be broken down into three subsections, an inlet channel 23 , a shaft channel 24 , and an outlet channel 25 . When the shaft 12 is rotated, a centrifugal force develops radially outward from the axis of rotation, which acts as a resistance to flow of hydroxy gas into the inlet channel 23 . This resistance can be overcome by either increasing the feed gas staging pressure at point Pi or decreasing the pressure at point Po, where the feeding tube inlet channel 23 and the shaft channel 24 intersect. The inventors chose to lower the pressure at point Po because the hydroxy gas is safer to handle at low pressures. The pressure at point Po was lowered by angling the shaft channel 24 an angle beta relative to the axis of rotation Z. By angling the shaft channel 24 , the centrifugal force developed under rotational tends to move the hydroxy gas molecules away from point Po, which results in a decrease in gas pressure at Po. Therefore, a sufficient capillary force created by pressure differential (Pi−Po) to induce flow through the inlet channel 23 can occur without significantly increasing the pressure Pi and increasing the auto-ignition potential of the upstream hydroxy feed gas.
The rotation of the shaft 12 at sufficiently high speeds created a second problem of separation of the hydrogen and oxygen molecules inside the shaft chamber 24 . This separation tends to destabilize the flames at the tips of the tubes because the hydrogen and oxygen are not adequately mixed before entering the combustion area. The inventors overcame this problem by inducing mixing turbulence inside the outlet channel 25 just prior to exiting into the combustion zone. This mixing turbulence results from the change in flow direction relative to the axis of the shaft channel 24 as represented by the outlet tip angle gamma. A stable hydrogen flame was found to be produced with an angle gamma of 40-50 degrees. Angles greater than this resulted in increased hydrogen and fuel oil flame-outs (i.e., loss of ignition) and ineffective envelopment of the fuel oil in the zone of combusting hydrogen.
The inventors' preferred means of creating the oil feeding tube 13 , the inlet channel 23 , and the shaft channel 24 as shown in FIG. 2 was to machine these channels as void spaces in a solid metal shaft 12 . The outlet channel 25 is manufactured from metal tubing of the same bore diameter and is threaded on one end for connecting to the shaft. The diameter of these circular void spaces and tubing will vary depending on the thermal rating of the burner. The entrance to the hydroxy gas feeding tubes occurs at circular openings 26 , which open to the outer surface of the metal shaft 12 . The fuel oil enters the shaft to the oil feeding tube 13 at opening 27 .
As best seen in FIG. 3 , a plurality of cylindrical staging chambers are formed around the shaft 12 to contain the various gases and liquids associated with the burner's operation. In the embodiment presented in FIG. 3 , there is a forward coolant staging chamber 31 , a middle hydroxy gas staging chamber 32 , and a rear fuel oil staging chamber 33 . Each of these staging chambers provides a sealed compartment where the fluids can surround the rotating shaft such that the inlet openings 26 and 27 to the feeding tubes are always exposed to the staged fuels to maintain constant flow. The chambers also provide a fixed volume whose pressure can be controlled to regulate the flow of the fuels into the burner tip area. The forward coolant staging chamber 31 is a multipurpose chamber that is primarily used to shield the hydroxy storage chamber 32 from the radiant and convective heat emanating from the combustion zone. This heat can be removed by circulating a cooling fluid through the chamber, circulating the liquid oil fuel through the chamber prior to entering the rear fuel oil staging chamber 33 , or circulating a mixture of the liquid fuel and water. In an alternate embodiment, the forward chamber can be used as a third material feeding stage, which could either have a separate inlet hole connecting to the liquid fuel shaft or could have its own feeding tube, or a plurality of tubes, discharging the contents of the forward chamber into the combustion zones separately.
Although the inventors' preferred embodiment utilizes three staging chambers, for liquid fuel, hydroxy gas and cooling fluid, more chambers could be added to accommodate a range of other materials to be injected into the combustion zone, such as environmental wastes or additives to control smoking, and others. The shaft length can be extended as necessary to accommodate the additional staging chambers. Multiple feeding tubes can also be bored into the shaft to provide transport conduits for the contents of these additional chambers.
FIG. 4 best shows the complete device made by the inventors to effectively carry-out this combustion method. It is comprised of a AC motor 40 that is coupled to the rigid metal shaft 12 via a gear reducer 41 . In an alternate embodiment, the gear reducer is omitted and the motor is directly coupled to the rigid shaft. This embodiment may be used where the rotational speed of the motor is sufficient to provide a stable hydrogen flame. A flexible coupling 42 is installed to facilitate alignment of the motor and shaft. The motor 40 is connected to the main body of the burner by a plurality of metal spacers 43 that are threaded on each end for receiving a fastening bolt. One end of these metal spacers is attached to the gear reducer 41 while the other end is connected to a rear bearing holder bracket assembly 44 . The rear bearing holder bracket assembly is comprised of two square-shaped metal flanges 44 a and 44 b that are attached together by welding to each end of a plurality of short metal spacers 44 c . The forward flange face 44 b is drilled to receive a plurality of fasteners that connect the bracket holder assembly 44 to the rear chamber mating flange 45 . A square shaped cut-out is made in the center of the forward flange face to accommodate the mechanical seal flange 55 . A separate plurality of holes are drilled and tapped into the rear flange face 44 a to receive retaining bolts for a rear bearing assembly 46 . A short section of the end of rigid shaft 12 connecting to the motor coupling is machined back to a slightly smaller diameter than the main shaft diameter so that the shaft cannot slip through the rear bearing 46 when assembled. The forward face of the forward flange 44 b has a raised disk face extending axially from the centerline of the flange that matches a recess machined into the rear face of the rear cap flange 45 .
The rear fuel oil staging chamber 33 , the middle hydroxy staging chamber 32 , and the forward cooling fluid staging chamber 32 are each comprised of forward and rear circular mating flanges welded on the ends of a center tube. FIGS. 5 shows a side view of one of these staging chambers comprised of the circular mating flanges 65 and 66 , and the center tube 67 . These mating flanges 65 and 66 are circular shaped metal disks with an inner recess of diameter d 2 machined slightly larger than the inside diameter of the center tube to a depth approximately one-half of the flange thickness t. A plurality of bolt holes 63 are drilled along an outer bolt diameter d 3 for receiving a plurality of bolts which fasten one chamber to another. The flange thickness t is that necessary to provide a sufficiently rigid body that can withstand the pressures inside the chamber and can maintain planar shape during the machining process. The number of bolt holes can match any ANSI bolt pattern sufficient to withstand the pressures inside the chamber and ensure adequate sealing. Each staging chamber can be defined as an annular void space around the shaft 12 . The length of each chamber's center tube L marks the axial bounds of the chamber while the diameter of the center tube d 1 marks the radial bounds of each chamber. These axial and radial bounds are limited only by the dimensions necessary to accommodate internal mechanical seals around the rotating shaft inside the forward and rear staging chambers. Each chamber tube has a inlet port for receiving the fuel streams. The forward coolant staging chamber has two ports so that the oil fuel/water mixture can be circulated through the chamber before entering the rear fuel oil staging chamber.
Referring back to FIG. 4 , in between the mating flanges of the forward and rear staging chambers and the mating flanges of the middle hydroxy staging chamber are two spacer plates, 47 and 48 . FIG. 6 shows a side view of one of these spacer plates with a inner face 73 facing into the either the forward or rear chamber and an outer face 74 facing into the middle hydroxy staging chamber. Each spacer plate is comprised of a circular metal disk with a plurality of bolt holes 70 drilled about an outer bolt diameter equivalent to the bolt diameter of the chamber mating flanges. The spacer plates have an inner hole d 4 machined slightly larger than the outer diameter of the sleeve of the mechanical seal, which fits around the central diameter of the rigid shaft 12 . On either side of the inner hole, a pair of studs 71 are welded into the body of the spacer plate to match the fastener slots on the internal mechanical seals. A raised face 72 is machined into each side of the space ring to match with the recess of diameter d 2 in FIG. 5 . The machined raised face and matching recess ensure very precise alignment of the chambers, spacer plates and internal mechanical seals around the rigid shaft 12 .
Referring back to FIG. 4 , two cap flanges 45 and 49 are used to seal the outer sides of the front and rear chambers. FIG. 7 shows a side view of one of these cap flanges. Each cap flange is comprised of a circular metal disk with an inner face 81 facing into the either the forward or rear chambers and an outer face 82 that mates to the forward or rear bearing bracket assembly. A plurality of bolt holes 80 are drilled about an outer bolt diameter equivalent to the bolt diameter of the chamber mating flanges. The cap flanges have an inner hole d 4 machined slightly larger than the outer diameter of the sleeve of the mechanical seal, which fits around the central diameter of the rigid shaft 12 . Into the inner face 81 , on either side of the inner hole d 4 , a pair of bolt holes 83 are drilled and tapped into the body of the cap flange to receive the retaining bolts for the mechanical seal. A raised face 84 is machined into the inner face 1 to match with the recess of the chamber mating flanges at diameter d 2 in FIG. 6 . A circular recess 85 is machined into the outer face 82 for mating with the raised face on the forward or rear bearing bracket assembly.
FIG. 8 shows a side view of the rigid shaft 12 surrounded by the three staging chambers 33 , 32 and 31 . The location of the internal mechanical seals 97 are shown bolted to and projecting away from the spacer plates 47 and 48 and the cap flanges 45 and 49 . The mechanical seals are of a single bellows type commonly used in centrifugal pumps and minimize leakage of fluids from either the forward or rear staging chambers into the middle hydroxy staging chamber. Access to the retaining bolts is through the inlet ports to the chambers. In an alternate embodiment, the middle hydroxy staging chamber can be made substantially square with one of the sides comprising of a removable panel. This embodiment provides an alternate access means to tighten the retaining bolts for the mechanical seals.
Referring back to FIG. 4 , a second forward bearing assembly 50 identical to the rear bearing assembly 46 is provided near the burner tip end to ensure alignment once the burner becomes heated. A forward bearing bracket assembly 52 is provided to secure the forward bearing around the shaft 12 . A short section of the flame end of rigid shaft 12 connecting to the burner tip flange 53 is machined back to a slightly smaller diameter than the main shaft diameter so that the shaft cannot slip through the forward bearings 50 and 51 . The rear face of the forward bearing bracket assembly also has a raised disk face extending axially from the centerline of the flange that matches a recess machined into the outer face of the forward cap flange 49 and a cut-out to accommodate the flange of the mechanical seal 51 . A circular metal burner tip flange 53 is secured by plurality of fasteners to the end of the rigid shaft 12 . This burner tip flange provides a removable part that can be easily modified to accommodate different combustion configurations which may be required to adapt the burner to other fuel types. The hydroxy gas outlet channels 25 are connected to the face of the burner tip flange and are oriented so that the exit points toward the axis of rotation. A standard-type spray atomizing nozzle 54 is connected to the face of the burner tip flange along the center axis for spraying the fuel oil into the zone of combusting hydrogen. This atomizing nozzle can be easily removed to accommodate a variety of fuel types and a variety of spray patterns to optimize combustion for a given fuel type.
In continued reference to FIG. 4 , two ports 55 and 56 are provided into the coolant staging chamber for circulating a fluid. One hydroxy gas inlet port 57 is provided for connection to a hydrogen or hydroxy gas fuel source. A fourth port 58 is provided in the rear fuel staging chamber for connecting to a pressurized liquid fuel source.
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A method and device for combustion of liquid fuels is presented which uses a plurality of rotating hydrogen flames to blast atomize and ignite a mechanically dispersed stream of the liquid fuel. This combustion method and device are particularly suited for heavy oil fuels, such as vegetable oils, which are not well burned using conventional burner technologies. This combustion method involves establishing a zone of combusting hydrogen and projecting a mechanically atomized dispersion of the liquid fuel into and through this zone of combusting hydrogen. The combusting hydrogen partially vaporizes and ignites the liquid fuel while the intense turbulence of the hydrogen combustion zone further disperses any remaining liquid fuel droplets. Once ignited and dispersed, the fuel oil continues to burn as it moves away from the hydrogen combustion zone. Since only a small amount of combusting hydrogen is utilized, the hydrogen can be generated by the electrolysis of water, which produces a 2:1 molar ratio of hydrogen and oxygen, or hydroxy, gas.
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This is a continuation of application Ser. No. 07/467,022, filed Jan. 18, 1989, which was abandoned upon the filing hereof.
BACKGROUND OF THE INVENTION
The instant invention relates to a process for piecing yarn on an open-end spinning device in which a fiber feeding device is turned on and whereby the produced fiber stream is deflected on its way to a fiber collection surface, and is removed until the actual piecing process is initiated, through the backfeeding of the yarn; whereupon the fiber stream is again deflected in synchronization with this backfeeding and is conveyed to the fiber collection surface. The invention also relates as well to a device to carry out the process.
A process of this type as well as a device to carry it out are known from the international patent application WO 86/01235, corresponding to U.S. Pat. No. 4,676,059. By means of this known process and device, it is intended to prevent the fibers which have suffered during the stoppage before the piecing process, from being guided into the spinning device, and to ensure that only fibers of perfect quality enter the spinning rotor. It has, however, been found to be extremely difficult to adapt yarn draw-off to the arrival of fibers, which takes effect suddenly in the spinning device after release of fiber feeding, so that the piecing joint deviates considerably in thickness from the normal yarn thickness. In order to remedy this disadvantage, it has been proposed, according to the above-mentioned patent application, to control the switch-over of the previously removed fiber stream gradually, so that the fiber stream becomes effective only gradually in the spinning device. However, a control device which is complicated, and must also be controlled with the utmost precision is required for this. It has also been shown that in practice, satisfactory results cannot be achieved in this way.
SUMMARY OF THE INVENTION
It is, therefore, the object of the instant invention to provide a process and a device which makes it possible, in a much simpler manner, to tie the fiber draw-off speed to the beginning of the fiber feeding action in the spinning device.
This object is attained with a process in which the deflection of the fiber stream back to the collection surface occurs before said fiber stream, started by the fiber feeding device being switched off, reaches its full strength. In this manner, the first fibers which may have suffered from having been interlaced or ground off are first removed. Since the fiber tuft found in the fiber feeding device is combed out more or less vigorously depending on the stoppage time, it always takes a certain time, depending on this stoppage, until the fiber stream has again reached its full strength, as during production. This fact is utilized, according to the invention, in that the deflection of the fiber stream is terminated, and the supply of fiber to the collection surface is started before the fiber stream regains its full strength. The fiber stream now entering the spinning device is, therefore, considerably thinner than during production and increases only gradually. It is, therefore, much easier to draw off the yarn from the spinning device at a speed adjusted to this decrease of the fiber stream. As a result, an unobtrusive piecing joint is obtained.
In an advantageous embodiment of the process according to the invention, the suction is switched off after switching on the fiber feeding even before the fiber stream (which starts up again as a result of the fiber feeding device being switched on) reaches its full strength, and the speed of the yarn draw-off is adapted to the increase of the fiber stream. In this manner, easy control of the fiber stream is possible for the piecing process.
Since the increase of the fiber stream depends, essentially, on the stoppage time of the fiber feeding device before the piecing process, yarn draw-off is controlled as a function of the combed-out state of the fiber tuft in an advantageous further development of the process according to the invention. Provisions are appropriately made in this case in order to control the acceleration of the fiber draw-off as a function of the combed-out state of the fiber tuft so that when the fiber tuft is greatly impaired, the yarn draw-off speed is accelerated more slowly than when it is less impaired. By taking into account the combed-out state of the fiber tuft in accelerating the yarn draw-off speed, optimal adaptation of the yarn draw-off, to the extent to which fiber feeding into the spinning device becomes effective, is achieved.
Adjustment to the stoppage time of the fiber feeding device and thereby, to the impairment of the fiber tuft, can also take place according to the invention in addition to, or instead of, the control of the yarn draw-off in that yarn draw-off begins later in case of great impairment of the fiber tuft than when the impairment is slighter.
It has been shown to be advantageous to ascertain the combed-out state of the fiber tuft and to control the onset and/or the speed of yarn draw-off as a function of the ascertained state of the fiber tuft.
The combed-out state of the fiber tuft can be ascertained by different methods, but it has been shown to be especially advantageous to derive the combed-out state of the fiber tuft from the stoppage time of the fiber sliver while the opening device runs, before fiber feeding to the fiber collection surface has been turned on. In this way, a simple time clock is sufficient to ascertain the combed-out state.
In order to carry out the process according to the invention, the invention provides for a device of this type to be equipped with control means which act upon the mechanism for the deflection of the fiber stream in such manner that the fiber stream reaches the fiber collection surface as a function of yarn back-feeding before the fiber stream has reached its full operating strength after switching on of the fiber feeding device. Such a device makes it possible to obtain improved piecing joints.
In a preferred embodiment of the invention, the control device for the suction device contains an adjustable time control element which determines the time interval between switching on the fiber feeding device and the switching off of the suction device. This time control element is started up at the moment when the fiber feeding device is switched on, and is set to the time which must expire before the suction device is switched off.
In an advantageous embodiment of the invention, the time control element is connected to a device which ascertains the combed-out state of the fiber tuft at the moment of piecing and determines the time interval as a function of this combed-out state.
The process, according to the invention, is very simple and can also be realized in a simple manner after construction by making minor changes in the normal control device for piecing. Neither are complicated control devices with narrow tolerances necessary to achieve adaptation of the yarn draw-off acceleration to the increase of the fiber stream in the spinning device The process, according to the invention, and the device, according to the invention, can be applied to the widest range of processes and devices of this type (e.g., British Pat. No. 1,170,869, which corresponds to U.S. Pat. No. 3,521,440; German Patent Application No. 1,901,442, which corresponds to British Patent No. 1,296,461; German Patent Application No. 1,932,009, which corresponds to British Patent No. 1,228,534; German Patent Application No. 3,104,444, which corresponds to U.S. Pat. No. 4,384,451; and German Patent Application No. 3,118,382, which corresponds to U.S. Pat. No. 4,497,166).
BRIEF DESCRIPTION OF THE DRAWINGS
The invention shall be explained in greater detail below through drawings in which:
FIG. 1 shows a diagram with the customary piecing switch-over of fiber stream and yarn draw-off;
FIG. 2 shows a diagram with the switch-over of the fiber stream according to the invention and with yarn draw-off adapted thereto;
FIG. 3 shows a diagram with the curve for fiber feeding and the curve for yarn draw-off during piecing following a stoppage of prolonged duration; and
FIG. 4 shows a spinning station of an open-end spinning machine, in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
The device to carry out the process shall first be described through FIG. 4 to the extent required in order to explain the goal to be achieved and the new process.
FIG. 4 shows, in its left half, a schematic representation of a spinning station 10 of an open-end spinning machine 1. The spinning station 10 is provided with an open-end spinning device 11 and with a winding mechanism 12.
Each open-end spinning device 11 is equipped with a fiber feeding device 110 to feed a fiber sliver 2 to an opening device 116. The fiber feeding device 110 (in the embodiment shown) consists of a delivery roller 111 and of a feeding tray 112 interacting elastically with it. The feeding tray 112 is mounted so as to be capable of swiveling on an axle 113 and is pressed elastically against the delivery roller 111 by means of a spring 114. The delivery roller 111 is driven via a controllable coupling 115 by a central drive (not shown).
The opening device 116, in the embodiment shown in FIG. 4, is designed essentially in the form of an opening roller placed in a housing 117. From it, a fiber feeding channel 118 extends towards a spinning element 13 which, in the embodiment shown, is made in form of a spinning rotor. The spinning element 13 is driven or braked in the conventional manner. In the embodiment shown, the spinning element 13, in form of a spinning rotor, is provided with a shaft 130 against which a tangential belt 131 is applied and which can be lifted off from it. The spinning element 13 is located in housing 132 which is provided with a suction opening 133 connected via a controllable valve 134 and a suction circuit 135 to a source of negative pressure which is not shown here.
To guide the yarn 20, which is to be drawn off from the spinning element 13, a yarn draw-off pipe 119 is provided. Draw-off is effected by means of a pair of draw-off rollers 14 consisting of a driven draw-off roller 140 and of a draw-off roller 141 in elastic contact with it and driven by it. For this purpose, the draw-off roller 141 is mounted on a swivel arm 142.
On its way from the open-end spinning device 11 to the pair of draw-off rollers 14, yarn 20 is monitored by a yarn monitor 15.
The yarn 20 is wound up on the winding mechanism 12 which is provided with a driven winding roller 120 for that purpose. The winding mechanism 12 is also equipped with a pair of pivoting bobbin arms 121 which hold a rotatable bobbin 122 between them. The bobbin 122 lies on the winding roller 120 during the undisturbed spinning process and is, therefore, driven by it. The yarn 20, to be wound up on the bobbin 122, is inserted into a traversing yarn guide 123, moving back and forth alongside the bobbin 122 and thus ensuring even distribution of the yarn 20 on the bobbin 122.
The yarn monitor 15, the coupling 115 and the valve 134 are connected, for control, to a computer unit or control device 3 via circuits 30, 31 and 32. Control device 3 contains a time measuring element 33 which measures the time from the moment of stopping the fiber feeding device 110 to the beginning of the piecing process. More details shall be described further below.
A service unit 4 is capable of traveling alongside the open-end spinning machine with a plurality of identical spinning stations 10. The service unit 4 also contains a control device 40 which is connected, for control, to the computer unit or control device 3 via a circuit 407 to control the piecing process. The control device 40 is also connected via a circuit 400 to the swivel drive 410 of a swivel arm 41 which is provided, at its free end, with an auxiliary drive roller 411. The auxiliary drive roller 411 is driven by a drive motor 412 which is also connected, for control, with the control device 40 via a circuit 401.
Swivel arms 42 mounted on the service unit 4 can be advanced to the bobbin arms 121 of mechanism 12 and are capable of swiveling, their swivel drive 420 is connected for control via a circuit 402 to the control unit 40.
A lift-off device 43 can be advanced to the draw-off roller 141 of the pair of draw-off rollers 14. This lift-off device is provided with a swivel arm 430 capable of working together with the swivel arm 142 of the draw-off roller 141. For this purpose, the swivel arm 430 is connected to a swivel drive 431 and to a lifting drive 432, said drives being connected, in turn, for control, via circuits 403 or 404 to the control unit 40.
The service unit 4 is also equipped with a yarn disposal device 44 with a driving device 440, controlled via a circuit 405 from the control unit 40, as seen in more detail in U.S. Pat. No. 4,438,624, which is incorporated herein by reference.
The outlet 50 of a suction channel 5 opens into the housing 117 of the opening device 116 in the open-end spinning machine 1 (arrow P, as seen, indicates the direction of fiber movement) after the outlet of the fiber feeding channel 118, whereby the end of said suction channel 5, which is furthest from the opening device 116, can be closed by a butterfly valve 51. A suction channel 450 of an aspiration device 45 of the service unit 4 can be advanced to the suction channel 5 of the open-end spinning device 1. This suction channel 450 is connected via a valve 451 to a negative-pressure source 452. The valve 451 is, in turn, connected for control via a circuit 406 to the control device 40 which contains a time control element 46.
During normal spinning operation, the fiber sliver 2 is conveyed by means of the fiber feeding device 110 to the opening device 116, which opens the fiber sliver 2 into fibers which are fed to the fiber collection surface 136 of the spinning element 13 and are deposited there. The end of the yarn 20, which is in the process of being drawn off, is linked to this fiber accumulation which, in the spinning rotor of the embodiment shown as an example, constitutes a fiber ring and the yarn end incorporates the fibers into its end due to the rotation which it is imparted by the rotation of the spinning rotor, while the yarn 20 is drawn off by the draw-off rollers 14 from the open-end spinning device 11. The bobbin 122 lies in a known manner on the winding roller 120 during the spinning process and winds up the yarn 20 while the yarn guide 123 distributes the yarn on the bobbin 122 with a shot effect.
Referring now to FIGS. 1, 2, and 3, which illustrate diagrammatically the fiber flow through the apparatus of FIG. 4. In these figures, the lines of each of the diagrams have the following meanings:
______________________________________Symbol Meaning______________________________________Full line = Fiber flow pathHorizontal line t = Process time lineFull line below line t = Fiber flow into the auxiliary suction channel 5Full line above line t = Fiber flow into the spinning elementBroken line above line t = Yarn withdrawalVertical broken lines = Reference time lines for t.sub.2, t.sub.3, etc.100% above line t = Full fiber flow into spinning element100% below line t = Full fiber flow into auxiliary suction channel 5______________________________________
Before explaining the new piecing process, the present, conventional piecing process shall be reviewed through FIG. 1. For the sake of clarity, the rotor speed, which is controlled in the conventional manner, has not been represented on the drawing.
The fiber flow F F , which is effective in the spinning element 13, has been shown on the vertical axis of the diagram by a full line going up. The yarn draw-off A G has also been shown by means of a broken line going up. The fiber flow F F , which is fed into the suction channel 5 and, therefore, does not reach the spinning element 13, has been represented by a full line F F going down.
The time t is entered on the horizontal time line. At the point in time t O , the piecing program is started. At the point in time t 1 , the fiber feeding device 110 begins to run so that the fiber flow F F starts up again. Since the forward fiber sliver end, constituting a fiber tuft, which continues to be presented to the opening device 116 has been combed out to a greater or lesser extent during the prior stoppage time so that said fiber tuft is not considerably thinner than during normal production, the fiber tuft must first be advanced over a certain distance until a fiber tuft which is identical to one during production can again be presented to the opening device 116. It is also necessary for the fibers presented to the opening device 116 fill the clothing of the opening device 116 and be conveyed by it. A certain amount of time is necessary for this, and for that reason the run-up curve of the fiber flow F F is more or less steep.
According to FIG. 1, the fiber flow F F has reached 100%, i.e., its full strength at the point in time t 2 . At any chosen point in time t 3 after the full fiber flow F F has been reached, the latter is switched over in known processes, so that 100% of the fibers go to the fiber collection surface 136 of the spinning element 13 as of point in time t 4 .
Synchronized in time with the release of the fiber flow F F , a yarn end is fed back into the spinning rotor or to another spinning element 13 during the time period t 5 so that it may combine with the fibers arriving there. In synchronization with the point in time t 3 , possibly coincidentally with it or slightly earlier or later, yarn draw-off A G then begins and runs up with acceleration to its production speed (100%). As shown in FIG. 1, a certain amount of time is required for this step. The run-up time of the yarn draw-off A G can be shortened only when the yarn drawoff A G is not effected by means of roller 122 but by means of the pair of draw-off rollers 14. In that case, an excess of yarn which must be buffer-stored appears between the pair of draw-off rollers 14 and the bobbin 122, and it must be used up again once the bobbin 122 has reached its full speed.
To avoid such storage, another process is provided according to FIG. 2. As with the process according to FIG. 1, the fiber flow F F first goes into the suction channel 5 as of point in time t 1 and is taken away via the suction channel 45, so that no fibers reach the fiber collection surface 136 of the spinning element 13. In contrast to the old, known process according to FIG. 1, however, the renewed deflection of the fiber flow F F and its transportation to the fiber collection surface 136 of the spinning element 13 occurs long before the point in time t 2 is reached, so that as of point in time t 4 , which comes before the point in time t 2 , all the fibers reach the spinning element 13. The switch-over of the fiber flow F F and its transportation to the spinning element 13 thus takes place during the run-up of the fiber flow F F , i.e., before the fiber stream or fiber flow F F released as a result of the fiber feeding device 110 having been switched on has reached its full production strength. The end of yarn 20 which has been prepared in the customary manner is back-fed during the period t 5 to the fiber collection surface 136 of the spinning element 13. The yarn draw-off A G begins at that time. Since the run-up curve of the fiber flow F F is considerably flatter with the new process according to FIG. 2 than with the known process according to FIG. 1, the run-up of the speed of the yarn draw-off A G is easy to control and to adapt to the run-up curve of the fiber flow F F , so that the run-up of the yarn draw-off A G deviates only insignificantly from the run-up curve of the fiber flow F F . This means that the piecing joint now deviates only insignificantly from the normal yarn thickness, and thereby from the desired thickness. This appears clear from FIGS. 1 and 2. While the excess of fibers is quite considerable according to FIG. 1 (see shaded triangle A), so that a comparatively voluminous and thereby noticeable thick spot is produced in the area of the piecing joint of the newly pieced yarn 20, the process according to FIG. 2 produces, first of all, an unobtrusive thick spot (see shaded triangle B) and also an equally unobtrusive thin spot (see shaded triangle C) in the yarn 20. As can be seen clearly from a comparison between the triangles B and C and the triangle A, the triangles B and C are considerably smaller than triangle A, signifying that the degree to which the yarn thickness deviates from the desired value is considerably smaller with a process according to FIG. 2 than with the known process according to FIG. 1.
FIG. 3 shows the new piecing process after a lengthy stoppage of the spinning station. Because of the continued running of the opening device 116, even after stoppage of the fiber feeding device 110, the fiber tuft continues to be impaired, a process which can result from combing out or from partial grinding of the fibers of the fiber tuft, depending on the design of the fiber feeding device 110. The longer time during which the opening roller has this effect, corresponding to this longer stoppage time, also causes the fiber tuft to be further impaired, so that it takes longer before the fiber sliver 2 can be opened in a normal fashion by the opening device 116 once the fiber feeding device 110 has been switched back on. The interval between the times t O and t 1 is, therefore, greater according to FIG. 3 than in the case illustrated by FIG. 2.
As shown in FIG. 3, the yarn draw-off A G can also contain a varying acceleration to adapt to the run-up curve of the fiber flow F F . Thus, the yarn draw-off is, for instance, accelerated between the points in time t 4 and t 6 (phase A G ') to a maximum, until the yarn draw-off speed has reached, expressed in percentages of its production speed, the same value as the fiber flow F F . The yarn draw-off speed is then accelerated less (phase A G "), so that the fiber flow F F and the yarn draw-off A G reach full value (100%) essentially at the same time.
As shown in FIG. 3, only small deviations occur between the fiber flow F F and the yarn draw-off A G , whereby the thick spots represented by the shaded triangles D and F and the thin spots represented by the shaded triangles E and G are negligibly minimal.
Following this outline of the principle of the new process, it shall be further explained through the device the design of which has already been described.
If a yarn breakage occurs, this is signaled by the yarn monitor 15 to the control device 3 which actuates the time measuring element 33. At the same time, the coupling 115 of the fiber feeding device 110 is actuated and stops the delivery roller 111 and thereby stops the feeding of the fiber sliver 2 to the opening device 116. In a manner not shown here, the bobbin 122 is also lifted off the winding roller 120 so that the end of the yarn 20 cannot be wound onto the bobbin surface by the continuously running bobbin 122. Furthermore, the spinning element 13 is stopped in a conventional manner. The opening device 116, however, continues to run without interruption.
After a certain time span, the service unit 4 arrives at this spinning station 10 where the yarn 20 broke. For this, the service unit 4 can be summoned to this spinning station by a known calling device (not shown); however, the service unit 4 can also patrol continuously alongside a defined number of spinning stations and thus, arrive at the spinning station 10 which is affected by a yarn breakage. When the service unit 4 has reached the spinning station 10 in question, its control device 40 scans the control device 3 via a circuit 407 and learns in this way whether service is required or not at the spinning station 10 in question. The control device 3 is designed so that it only transmits that information to the service unit 4 which concerns the spinning station 10, where the service unit 4 is present at that time.
When the service unit 4 is at a spinning station 10 needing to be serviced, the service unit 4 stops. The bobbin arms 121 are supported in the manner already described by the swivel arms 42 against the bobbin lifting device on the machine side. Furthermore, the auxiliary drive roller 411 is advanced to the bobbin 122. The suction channel 450 of the service unit 4 is, furthermore, advanced to the suction channel 5 on the machine side. Furthermore, the draw-off roller 141 is lifted off the driven draw-off roller 140 by means of the lift-off device 43, and the yarn 20 is drawn off in the normal way from the bobbin 122 which has been lifted off the winding roller 120, and is back-fed into the yarn draw-off pipe 119. The yarn is thereby laid across the yarn ejection device 44 and is held there.
During that time the spinning element 13 is cleaned in a known manner. The fibers and dirt particles taken from the spinning element 13 are removed through the suction channel 133 by means of the negative spinning pressure applied as always in the housing 132.
After the cleaning of the spinning element 13, the valve 134 for the negative spinning pressure is closed and the valve 451 for the suction channel 450 is reopened. Furthermore, the spinning element 13, which had been stopped until now, is again released and now runs up to is production speed or to a predetermined piecing speed. The piecing program can be written so that piecing is carried out either at a constant speed of the spinning element 13 or during its run-up curve. If piecing is carried out at a reduced but constant rotor speed, the spinning rotor is preferably brought up to its production speed in such manner that its run-up curve is essentially synchronized with those of the fiber flow F F and of the yarn draw-off A G or is extensively adapted to same.
At the beginning of the piecing program, i.e., at the beginning of the task undertaken by the service unit 4 at the spinning station 10 in question, the control device 3 transmits an impulse to the time measuring element 33 which has thus recorded the stoppage time of the fiber feeding device 110, from the moment of yarn breakage to the beginning of the piecing process, with the opening device 116 continuing to run uninterruptedly. The fiber feeding device 110 is then switched back on through actuation of the coupling 115. The fiber sliver 2 is thereby again fed to the opening device 116, but is again sucked away from it and out of the housing 117 by the negative pressure source 452 taking effect. At the point in time t 3 , which is determined by the control device 3 as a function of the stoppage time recorded by the time measuring element 33, the valves 134 and 451 are now actuated, so that no negative pressure prevails, any longer, in the suction channel 5, while negative spinning pressure is applied, instead, once more in housing 132 via suction circuit 135. The fibers entering the housing 117 of the opening device 116 are thus sucked through the fiber feeding channel 118 to the spinning element 13 where they are deposited in a known manner on the collection surface 136.
The point in time t 3 which is determined by the control device 3 and at which the negative pressure is switched on at the suction circuit 135, is selected so that the fiber flow F F has not yet reached its full strength. The control means mentioned (control device 3, valves 134, 451) are used to act upon the mechanism (aspiration opening 133, suction channel 5) for the deflection of the fiber flow F F in such manner that said fiber flow F F reaches the fiber collection surface 136 as a function of the yarn back-feeding. As mentioned earlier, this switch-over is effected in such manner that the fiber flow F F or fiber stream has not yet reached its full production strength after switching on of the fiber feeding device 110.
In the control device 3, storage is carried out (depending on fiber material, staple fiber length, design of the fiber feeding device 110, etc.) as the fiber flow F F increases during corresponding stoppage periods. In this way, yarn draw-off A G can also be controlled as a function of this curve, and can be adapted to the increase of the fiber flow F F . The yarn draw-off A G is switched on by the control device 3 via control device 40 of the service unit 4 at the point in time t 3 when the fiber flow F F becomes effective in the spinning element 13, or shortly before, or shortly after this point in time t 3 , and is accelerated in accordance with the curve indicated by control device 3. This acceleration can be controlled in a linear manner or according to any desired curve, depending on the run-up curve of the fiber flow F F which has been entered into the control device 3. In that case, control is effected by means of the auxiliary drive roller 411. However, it is also possible to control the yarn draw-off curve by means of the draw-off roller 141 by controlling the contact pressure of the draw-off roller 141 by means of the lift-off device 43. Since the fiber tuft is combed out more during a long stoppage of the open-end spinning device 11 than during a short one, this is taken into account in the control of yarn draw-off A G which is, therefore, controlled as a function of the combed-out state of the fiber tuft. For this reason the combed-out state of the fiber tuft is first ascertained. The yarn draw-off A G is then controlled as a function of this state in such manner that the yarn draw-off speed is accelerated more slowly when the fiber tuft has been greatly impaired (long stoppage of the open-end spinning device 11) than when it has been impaired to a lesser extent. In addition, or instead, the yarn draw-off A G can also begin earlier (little impairment) or later (great impairment) depending on the impairment of the fiber tuft.
The fiber flow F F has reached its full strength at the point in time t 2 . Thus, the pressure roller 141 can again be pressed against the driven draw-off roller 140 after this point in time t 2 by means of the lift-off device 43, and the draw-off of yarn 20 from the spinning device 11 can be effected by means of the draw-off device 14. The bobbin 122 can now be lowered on the winding roller 120, whereupon the auxiliary drive roller 411 is lifted off from the bobbin 122.
If desired, the acceleration of the spinning element 13 can also be controlled as a function of the run-up of the fiber flow F F .
The described process and also the described device can be varied in many ways, for example, by replacing individual characteristics by equivalents or through other combinations thereof. Thus, it is not necessary to design the spinning element 13 in form of a spinning rotor, but other open-end spinning elements, e.g., friction spinning rollers, etc., can be used here. Neither is it necessary to provide a separate negative-pressure source 452 on the service unit 4, but the suction channel 450 can also be connected in a known manner to a negative-pressure source to which the suction circuit 135 is connected, on the machine.
It is also possible to drive the drive roller 140 via a controllable slippage coupling (not shown) from a drive shaft and to control it as a function of the effective slippage of the yarn draw-off A G .
As an alternative of the time measuring element 33 in the open-end spinning machine 1, it is also possible to provide a setting key 460 for the time control element 46 on the service unit in order to manually set the time t 1 . This can be done as a function of various factors (state of the fiber tuft, fiber material, staple fiber length, distance from the nip between delivery roller 111 and feeding tray 112, or other counter-element interacting with the delivery roller 111, to the operating zone of the opening device 117, etc.)
Neither is it necessary to derive the state of the fiber tuft from the stoppage time of the fiber sliver 2 (while possible taking into account other factors), but it can absolutely be determined in some other way, e.g., optically, by measuring the air resistance, etc., in case that this might prove desirable.
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A yarn piecing device and process for an open-end spinning machine wherein opened fiber is fed to a fiber collection surface in a pneumatic stream. The stream of fibers is shifted from the fiber collection surface when a broken or missing yarn is detected and the fiber feed to an opening device is interrupted. After the yarn is back-fed to the collection surface, the fiber feed to the opening device is restarted and the pneumatic stream of fibers is shifted back to the fiber collection surface before the fiber density in the pneumatic stream attains its production strength density.
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This invention relates to a hand tool, and more particularly to a magnetic screwdriver having a handle provided with a cavity, for storing and retaining a plurality of bit drivers, with a removable cap. The invention further provides another extra, short screwdriver tool which is readily adapted to be finger held and used as a finger tip sized adjustment screwdriver.
BACKGROUND OF THE INVENTION
In numerous industrial applications where various equipment and machinery are employed, mechanics or other personnel responsible for the control and maintenance of such machines and apparatus or equipment are in constant need of small screwdrivers for making slight adjustments to the machines, sometimes in tight areas or quarters. While the mechanics may not have a tool chest handy, they invariably have a large or big screwdriver in their rear pocket or belt accessory, but they do not normally have a small finger tip-sized adjustment screwdriver tool which is generally of the type required for use in such situations where machines require small adjustments.
SUMMARY OF THE INVENTION
In accordance with the invention, there is provided a hand tool, such as in the plurality of tool bits, and a removable cap; and the cap has a recess with means for securely holding and driving a tool bit placed in said recess so as to form an extra, small-independent, stubby-like adjustment screwdriver as a separate specialized second screwdriver. In a further application of the invention, the recess is a blind, hexagonal-shaped hole with a bottom from mutually cooperative association with hexagonal-shaped tool bit.
A further improvement of the invention is provided where the cap is provided with threaded means on a neck area of said cap; and the recess is further provided with a protuberance adjacent to the bottom of the hexagonal shaped hole for securely retaining in place a tool bit inserted into the hexagonal shaped hole. Other features and improvements of the invention will be more particularly described herein with reference to the following specification when taken with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of our improved plastic cap for use with a hand tool, such as a magnetic screwdriver which is provided with a bit cavity and removal rear cap;
FIG. 2 is a perspective view of the improved cap showing a polygonal aperture, such as a hexagonal recess-bore hole for use with a tool bit, such as a screwdriver bit;
FIG. 3 is a typical cross sectional view of the improved cap showing the hexagon recess bore hole;
FIG. 4 is an alternate embodiment of the improved cap of FIGS. 1-3, but showing in perspective a metal insert with dual recessed ends, one end for creating a full magnetic hand tool, such as the magnetic screwdriver, and the other or back end for employing a drive element, such as a 1/4 inch square driver or Allen wrench in the case of employing a hexagonal recess and mating driver;
FIG. 5 is a perspective view opposite to that of FIG. 4, but showing the hexagonal drive recess without the Phillips screwdriver bit;
FIG. 6 is a side elevational view, partly in section showing the metal insert, magnet element and tool bit in the alternate form of the improved plastic cap;
FIG. 7 is another alternative construction similar to that of FIGS. 4-6, shown in cross sectional view, and broken away, but where the improved plastic cap is provided with special or shortened thread means enabling the improved cap when threaded into the handle cavity to be rotatively locked in place due to the shortened threaded means being driven past the inner mating cavity thread means, thereby permitting the locked cap to spin about the disengaged juxtaposed thread means; and
FIG. 8 is a disassembled view in cross section of the improved cap shown in FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In all of the embodiments of the improved cap of the invention, it should be recognized that their elements or features are "interchangeable" or can be used in any one embodiment. Thus, for example, the locking thread means of FIGS. 7-8 can be used with the embodiments of FIGS. 1-6, or the improved cap of FIGS. 1-3 may be used with a locking thread means to mate with the tool handle of FIGS. 7-8. Also, like numerals or prime reference numbers refer to similarly constructed elements.
Referring now to the drawings, and in particular to FIGS. 1-3, there is shown a hand tool, such as a screwdriver 10, having a handle 12 with a cavity 13, a cap 14, elongated shank 16, preferably hexagonal in section, which is suitably secured to the handle 12, and suitable hexagonal driver sleeve 18 secured to the elongated shank 16. The recess 20 in the hexagonal driver sleeve 18 is provided with a magnet 22 for holding or retaining in place a typical hexagonal tool bit (not shown) thereat, but shown by the reference numeral 24 in the cavity 26 of the handle 12. The handle 12 may be of any desired shape, such as round, polygonal, square, etc., and may also be suitably provided with gripping means or grooves-ribs 28, similar to those shown diagrammatically on the cap 14, is best seen in FIGS. 1 and 2.
The cap 14 may also be provided with a small protuberance 30 near the bottom 32 of the hexagonal recess 34 for gripping and retaining the tool bit 24 in place in the cap 14. Such protuberance 30 may be suitably molded integrally with the plastic cap 14. This construction thus provides a conventional type of hand tool/screwdriver having a tool bit cavity and removable cap with a second small, stubby or finger tip sized adjustment screwdriver. Such small tool is generally required by mechanics who maintain and control various apparatus and machinery where one must periodically adjust one or more control screws or other fine adjustment elements of a machine.
As best shown in FIGS. 4-6, there is an alternate cap 33 embodying a metal insert 36 having a dual recess area with a magnet 38 disposed and suitably held in a generally midpoint area of the sleeve-like insert 36. The magnet 38 securely holds the tool bit 24 in place in the front hexagonal recessed area 40. A back end recessed area is suitably of square shape 42 for mating with a conventional 1/4 inch square drive element (not shown). Other suitable drive recesses, such as conventional hexagonal recesses for mating with Allen wrenches may also be employed in the practice of the invention. Other tool driver means, with or without an extension, such as a small, non-electrical ratchet wrench, may also be used. As in the case of FIGS. 1-3, threads 44 shown in both embodiments, are used to secure the removable caps 14 or 33 to the handle 12. Groove-ribs 28 shown on the caps 14 and 33 of the embodiments of FIGS. 1-6 may also be matched on the gripping portion of the handle 12.
In FIGS. 7 and 8, a modified cap 33' is shown with the cap 33' having a neck area 46 and thread means in the form of partial threads 48, preferably three, suitably disposed uniformly, in the 120° zones about the neck diameter such that for initiating or removing the cap's thread means from like mating threads in the tool handle, the cap 33' will go on or come off in about two-thirds of a revolution. Thus, while the cap 33' can easily be threaded to the handle 12', outward axial pressure must be applied to the cap 33' (see reference arrow in FIG. 8) in order to commence thread engagement between the partial thread means 48 of the cap and handle. As can be appreciated from the thread construction, once the cap threads 48 are rotated past the mating recess thread means, the cap is rotatively locked in place to the handle 12'. Only when the cap 33' is pulled axially outwardly and rotated will the mating thread means engage for removal of the cap 33' from the handle 12'. Preferably, a three start thread is employed, although other like thread means could be employed (two, four or more thread means, depending upon the tool size or cap diameter). Alternatively, multiple "bayonet type" locking means could be used to fixedly lock the cap in place to the handle, in lieu of the "spinning" cap modification.
Although the present invention has been described in some detail by way of illustration and example for purposes of clarity and understanding, it will, of course be understood that various changes and modifications may be made in the form, details and arrangements of the parts without departing from the scope of the invention as set forth in the following claims.
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A hand tool in the form of a magnetic screwdriver, having a handle provided with a cavity for storing a plurality of tool bits, and a removable cap, and the cap has a recess with means for securely holding and driving a tool bit placed in said recess so as to form an extra, small-independent, stubby-like adjustment screwdriver as a separate specialized second screwdriver.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims the benefit of the filing date of U.S. Provisional Patent Application No. 60/172,531, filed Dec. 17, 1999.
FIELD OF THE INVENTION
[0002] The present invention relates to a press device having an extended nip intended for pressing a running paper or paperboard web. More specifically, the invention relates to a shoe press of the type which comprises a support which supports a press shoe adjacent to a counter roll or another backing member in such a way that the press shoe and the backing member form an extended nip therebetween, and which also comprises a hydraulic or pneumatic arrangement for urging the press shoe toward the backing member in order to apply a pressure on the web passing through the nip.
[0003] The press device according to the invention particularly advantageously can be utilized for wet-pressing of moist paper or paperboard webs, but also for calendering or other finishing of dried paper or paperboard. The press device according to the invention can also be utilized for fiber webs other than paper and paperboard.
BACKGROUND OF THE INVENTION
[0004] Shoe press devices, i.e. presses having an extended nip, have been employed for many years when manufacturing different paper and paperboard grades, primarily for wet-pressing in order to increase the dryness of the web, but also for calendering and other finishing in order to improve surface properties or other physical properties of the web.
[0005] As a result of their longer nips, shoe press devices provide a number of advantages in comparison to conventional roll presses, such as a higher dryness at the same nip pressure, or the ability to press at a lower at nip pressure while maintaining the same dryness, which is more gentle to the sheet.
[0006] U.S. Pat. No. 4,917,768 discloses a shoe press device in which the press shoe is supported via tubular sleeves rigidly affixed to and spaced apart on a support in a direction across the machine direction. The sleeves are received in cylindrical recesses in the press shoe in order to allow the press shoe to move toward or away from a counter roll such that the nip pressure can be varied. The disclosed shoe press comprises hydraulic jacks upstream and downstream of the sleeves for forcing the press shoe against the counter roll and for pivoting the shoe about an axis that extends in the cross-machine direction in order to vary the nip pressure in the machine direction. The sleeves fit somewhat loosely in the recesses in the shoe, and a resilient seal encircles each sleeve for sealing the interface between the sleeve and the recess. Accordingly, the press shoe of the shoe press disclosed in U.S. Pat. No. 4,917,768 is capable of pivoting relative to the support for varying the nip pressure in the machine direction.
[0007] However, it has been found that such shoe presses can be associated with certain problems. One such problem originates from the thermal expansion of the press shoe, which is a result of the heat generated by friction against the belt that runs over the press shoe and carries the paper or paperboard web through the press and by the hot hydraulic fluid which for different reasons is circulated through the shoe. The thermal expansion of the press shoe results in an elongation of the shoe in the cross-machine direction, which creates bending tensions in the support and hydraulic arrangement of the press shoe, which of course is undesirable.
[0008] In EP 0 933 471, corresponding to U.S. Pat. No. 6,083,352, the disclosure of which is incorporated herein by reference, a shoe press is disclosed which reduces the problems originating from the thermal expansion of the press shoe, since it has the ability to tolerate relatively large elongations of the press shoe across the machine direction, and also other deformations of the press shoe. The disclosed shoe press comprises a press shoe extending in the cross-machine direction along the entire width of a web running through the press, and a plurality of articulated hydraulic loading cylinders supported by a support and spaced apart along the shoe. The loading cylinders define working chambers which are pressurizable by hydraulic fluid, so as to enable the cylinders to urge the press shoe away from the support and toward a counter roll or other backing member for applying pressure to the web being carried through the nip defined between the shoe and the backing member. Each loading cylinder comprises a piston member disposed within a cylinder member. Either the piston or the cylinder comprises a two-part member having a first member fixed relative the press shoe and a second member fixed relative to the support, while the remaining piston or cylinder comprises a coupler.
[0009] In a preferred embodiment of the shoe press according to EP 0 933 471, the two-part member consists of first and second cylinders, while the coupler comprises a piston which is slidably received in the two cylinders. In an alternative preferred embodiment the two-part member instead comprises first and second pistons, while the coupler comprises a cylinder which surrounds both pistons.
[0010] The coupler of the shoe press disclosed in EP 0 933 471 sealingly engages at least one of the members, so that the first member is urged away from the second member in a loading direction when pressurizing the working chamber to cause the press shoe to be urged towards the backing member. In order to enable the loading cylinders to accommodate elongation of the press shoe across the machine direction, each coupler engages the respective first and second members at seals which enable the coupler to pivot relative to the first and second members about axes parallel to the machine direction. Accordingly, the press shoe is free to expand thermally in the cross-machine direction without causing bending of any piston and/or cylinder members of the loading cylinders.
[0011] Since the press shoe of the shoe press disclosed in EP 0 933 471 also can move or pivot in the machine direction relative to the support, the shoe press includes a stopping means which restricts the movement of the shoe forward in the machine direction.
[0012] In order to control the conditions in the nip of a shoe press, such as the pressure profile through the nip, it is usually desirable to be able to move the press shoe forward or backwards in the machine direction in order to be able to influence the pressure profile through the nip so that the nip pressure is highest in the beginning and lower in the end of the nip, or vice versa. When performing such a regulation of the pressure profile through the nip, the press shoe, in principle, will follow an arc-shaped path having its center at the central axis of the counter roll. This may result in a skewness in the machine direction between the parts included in the loading cylinders, i.e. between piston and cylinders or between pistons and cylinder. Such a skewness can generate forces both on the cylinder and on the shoe, which forces are directed in the machine direction or against the machine direction, depending on the direction of the skewness. If the skewness of the connecting member in a direction away from a possible stopping means (shoe support) is large enough, these forces may exceed the force directed towards the support, resulting in instability. If the connecting member is tilted in a direction toward the shoe support, forces which are directed toward the shoe support are generated, which increases the stresses on the shoe support.
[0013] Also in case a paper lump or the like unintentionally enters the nip, similar skewnesses can be generated and cause stresses on a shoe support.
SUMMARY OF THE INVENTION
[0014] Accordingly, the present invention provides a press device having an extended nip for pressing a running paper or paperboard web in which the press shoe unintentionally or intentionally can be tilted/pivoted around an imaginary axis across the machine direction with minimum skewness between the parts included in the loading cylinders, and without generating any excessively large forces directed towards a possible shoe support or the press shoe becoming unstable if the forces are directed against the machine direction (away from a possible shoe support).
[0015] In accordance with one preferred embodiment of the invention, a press device comprises a press shoe aligned across the machine direction and arranged for forming an extended nip in cooperation with a backing member for passage of the web therethrough, a support which movably supports the press shoe such that the shoe is movable toward and away from the backing member via a plurality of loading cylinders spaced apart along the press shoe for enabling application of pressure on the web during pressing. Each of the loading cylinders comprises a first cylinder member fixed on the press shoe, a second cylinder member fixed on the support, and a connecting member slidably engaged with and extending between the first and second cylinder members. The connecting member and the first cylinder member are slidable in relation to each other with a first length of stroke L 1 , and the connecting member and the second cylinder member are slidable in relation to each other with a second length of stroke L 2 . The connecting member has a length L 3 in a direction corresponding to that along which the connecting member is slidable in relation to the first and second cylinder members. In accordance with the invention, the first length of stroke L 1 is smaller than the second length of stroke L 2 .
[0016] Preferably, the first length of stroke L 1 is less than half of the second length of stroke L 2 . Furthermore, it is preferred that the length L 3 of the connecting member be larger than both the first length of stroke Li and the second length of stroke L 2 . In one embodiment, the length L 3 of the connecting member is larger than the sum of the first length of stroke L 1 and the second length of stroke L 2 .
[0017] In accordance with a preferred embodiment of the invention, the connecting member sealingly engages the first and second cylinder members by contacting seals arranged between the connecting member and each of the cylinder members so as to form at least one working chamber within which pressure of a pressurizing medium can be increased in order to cause a lengthening of the loading cylinder or reduced in order to cause a shortening of the loading cylinder, and in such a way that a central axis C 1 of the first cylinder member and a central axis C 3 of the connecting member can be tilted to an angle relative to each other and relative to a central axis C 2 of the second cylinder member as a result of a tilting of the press shoe during pressing. The lengths of stroke L 1 and L 2 , the connecting member length L 3 , and geometrical positions of the contacting seals are such as to minimize an angle A 2 between the central axis C 3 of the connecting member and the central axis C 2 of the second cylinder member during the tilting of the press shoe.
[0018] The press device in accordance with the invention preferably also includes at least one stopping member arranged on at least one of the first cylinder member and the connecting member so as to limit a maximum value of the first length of stroke L 1 .
[0019] Further objects of the present invention will become apparent from the following description, while the features enabling the further objects to be achieved are defined in the dependent claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] In the following, the invention will be described in greater detail with reference to the attached drawings, in which
[0021] [0021]FIG. 1A shows a schematic sectional view seen across the machine direction of a shoe press device with its press shoe in a first position, intended to generate a substantially symmetrical pressure curve through the nip,
[0022] [0022]FIG. 1B shows the shoe press device in FIG. 1A with its press shoe intentionally moved into a second position, intended to displace the pressure maximum of the pressure curve toward the end of the nip in comparison to when the press shoe is in the first position shown in FIG. 1A,
[0023] [0023]FIG. 2A shows a similar view as in FIG. 1A, but of a press device having an extended nip according to a preferred embodiment of the invention with its press shoe in a first position similar to the first position in FIG. 1A,
[0024] [0024]FIG. 2B shows the press device according to the invention in FIG. 2A, but now with its press shoe intentionally moved into a second position similar to the second position in FIG. 1B,
[0025] [0025]FIG. 3 schematically shows the motion pattern of the cylinder members and the coupling member belonging to a loading cylinder of a shoe press device when lengthening the loading cylinder with its first cylinder member tilted to a certain angle, and
[0026] [0026]FIG. 4 schematically shows the motion pattern of the cylinder members and the connecting member belonging to a loading cylinder of a press device according to the invention when lengthening the loading cylinder with the first cylinder member tilted to the same angle as in FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
[0027] The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. 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 will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.
[0028] For comparison, the attached FIGS. 1A and 1B show two different schematic sectional views, seen across the machine direction MD, of a shoe press device which will be discussed further in the following description.
[0029] In FIGS. 2A and 2B, similar views as in FIGS. 1A and 1B are shown, but of a press device having an extended nip according to a preferred embodiment of the invention.
[0030] The press device according to the invention is intended for pressing a running paper or paperboard web, and comprises a press shoe 101 aligned across the machine direction MD and arranged for forming an extended nip 103 in cooperation with a backing member 102 for passage of the web 104 during pressing.
[0031] The press device further comprises a support 105 which supports the press shoe in a movable way in a direction toward the backing member, via a plurality of loading cylinders 106 spaced apart along the press shoe 101 for enabling application of pressure on the web during pressing.
[0032] Each of the loading cylinders 106 comprises a first cylinder member 107 having a first cylinder end 108 which is attached to or integrated in the press shoe 101 , and a second cylinder member 109 having a second cylinder end 110 which is attached to or integrated in the support 105 .
[0033] The expression “cylinder member”, as used herein, should be understood as a functional part of the loading cylinder, which can be of a hydraulic or pneumatic type. Examples of such “cylinder members” comprise internally or externally substantially cylindrical sleeves which are open in at least one end, substantially cylindrical solid bodies or pistons, or substantially cylindrical recesses in the press shoe or in the support.
[0034] The first and second cylinder members 107 , 109 are slidably connected by a connecting member 111 , wherein the connecting member 111 and the first cylinder member 107 are movable in relation to each other with a first length of stroke L 1 , while the connecting member 111 and the second cylinder member 109 are movable in relation to each other with a second length of stroke L 2 , and the connecting member has a third length L 3 .
[0035] The expression “length of stroke”, as used herein, should be understood as the maximum length of a cylinder member available for sliding displacement of a second, cooperating member in relation to said cylinder member.
[0036] According to the invention and in the preferred embodiment, the first length of stroke L 1 is smaller than the second length of stroke L 2 .
[0037] In a particularly preferred embodiment of the press device according to the invention, the first length of stroke L 1 is less than half of the second length of stroke L 2 .
[0038] In another advantageous embodiment, the third length L 3 is larger than both the first L 1 and the second L 2 length of stroke, wherein the third length L 3 particularly advantageously is larger than the sum of the first L 1 and the second L 2 lengths of stroke.
[0039] In still another advantageous embodiment of the press device according to the invention, the connecting member 111 slidably connects the first 107 and the second 109 cylinder members in a sealed way by means of contacting seals 112 , 113 in order to form at least one working chamber 114 within which the pressure of a pressurizing medium, such as hydraulic oil or pressurized air, can be reduced in order to generate a shortening or increased in order to generate a lengthening of the loading cylinder 106 . Thereby, the connection is arranged in such a way that a central axis C 1 of the first cylinder member 107 and a central axis C 3 of the connecting member 111 can be tilted to an angle in relation to each other and to a central axis C 2 of the second 109 cylinder member during an intentional or unintentional tilting of the press shoe 101 during pressing of the web. In this embodiment, the first L 1 and second L 2 lengths of stroke, the third length L 3 , and the geometrical positions of the contacting seals 112 , 113 are adapted in order to minimize the angle A 2 between the central axis C 3 of the connecting member and the central axis C 2 of the second cylinder member during the tilting.
[0040] The tilting of the press shoe can be either intentional or unintentional. The seals 112 , 113 can advantageously be of the type disclosed in the above-discussed EP 0 933 471 corresponding to U.S. Pat. No. 6,083,352, which has been incorporated herein by reference. As will become evident from the following description, the connecting member can also have different geometrical shapes.
[0041] In still another advantageous embodiment of the press device according to the invention, particularly illustrated in FIG. 2B, a shoe support 115 is fixated to the support for receiving forces in the machine direction MD exerted by the press shoe 101 in contact with the shoe support during a pressing operation. In this embodiment, one or several stopping members 116 are arranged on the first cylinder member 107 and/or on the connecting member 111 , in order to restrict a maximum value of the first length of stroke L 1 , and thereby ensure a very low angle A 2 between the central axes C 3 and C 2 . In the press device illustrated in FIGS. 2A and 2B, the stopping members 116 are constituted by a ring, screwed on the open end of the first cylinder member 107 , and having a slightly smaller inside diameter than the diameter of the first cylinder member, wherein the ring 116 is intended to cooperate with the protruding seal 112 enclosing the connecting member 111 . However, it is also conceivable in other embodiments of the shoe press device according to the invention for the stopping members to have another suitable design. In connection with this embodiment, it should be noted that the shoe press device illustrated in FIGS. 1A and B lacks stopping members for restricting the maximum value of its corresponding length of stroke 11 .
[0042] In still another advantageous embodiment of the press device according to the invention, the first cylinder member 107 comprises an open third cylinder end 116 opposite the above-mentioned first cylinder end 108 , while the second cylinder member 109 comprises an open fourth cylinder end 117 opposite the above-mentioned second cylinder end 110 .
[0043] In this embodiment, the third 116 and fourth cylinder ends 117 encircle a respective end of the connecting member 111 in order to form the working chamber 114 or several working chambers. Thereby, the connecting member 111 advantageously can be a substantially cylindrical sleeve, the interior of which constitutes a part of the working chamber 114 , as illustrated in FIGS. 2A and 2B. In an alternative embodiment (not shown in the drawings), the connecting member instead is constituted of a solid, substantially cylindrical body, at each end of which a working chamber is formed, wherein one or several passages advantageously but not necessarily can be arranged between the two ends for pressure connection between the formed working chambers.
[0044] In still another alternative embodiment (not shown) of the shoe press device according to the invention, each of the first and second cylinder members is a solid, substantially cylindrical body one end of which is enclosed by the connecting member in order to form the working chamber. Thereby, the sealing means should be arranged on the connecting member in order to make it possible to minimize its tilting/skewness in accordance with the invention.
[0045] It is particularly advantageous in accordance with the invention for the backing member 102 to be a rotatable counter roll, and the press device advantageously includes a flexible belt 118 arranged in an endless loop for running between the press shoe 101 and the paper or paperboard web 104 during pressing. Thereby, the flexible belt preferably has the shape of a sleeve.
[0046] The press device having an extended nip according to the invention preferably is intended for wet-pressing, or for calendering a paper or paperboard web.
[0047] In the following, some of the advantages that can be achieved in the practice of the present invention will be illustrated through an example.
[0048] [0048]FIG. 1A shows a shoe press device with its press shoe in a first position, intended to generate a substantially symmetrical pressure curve through the nip.
[0049] [0049]FIG. 1B shows the shoe press device in FIG. 1A, but now with its press shoe intentionally moved into a second position, which is intended to displace the pressure maximum of the pressure curve towards the end of the nip in comparison to when the press shoe is in the first position shown in FIG. 1A. As is evident from FIGS. 1A and 1B, the first length of stroke 11 of the illustrated shoe press device is larger than the second length of stroke 12 .
[0050] Accordingly, the intentional displacement of the press shoe 1 into the second position shown in FIG. 1B is intended to displace the pressure maximum of the pressure curve towards the end of the nip, whereby the press shoe 1 and, consequently, the central axis c 1 of the first cylinder member 7 associated therewith, will be tilted forwards in the machine direction MD to an angle al in relation to the central axis c 2 of the second cylinder member 9 . In this regard, it should be noted that the angles shown in the drawings, for reasons of clarity, have been exaggerated.
[0051] A large tilting of the connecting member (piston) 11 in the direction towards the shoe support 15 results in the shoe support 15 being subjected to large stresses during the pressing, since a force component is generated which will press against the first cylinder member 7 and, together with other forces directed forwards in the machine direction MD, will press the press shoe 1 against the shoe support 15 .
[0052] [0052]FIGS. 2A and 2B instead illustrate a press device having an extended nip according to a preferred embodiment of the invention. FIG. 2A shows the press device with its press shoe in a first position similar to the first position in FIG. 1A, while FIG. 2B shows the press device with its press shoe intentionally moved into a second position similar to the second position in FIG. 1B.
[0053] In FIG. 2B, the press shoe 101 has been intentionally tilted approximately as much as the press shoe 1 in FIG. 1B in order to make it possible to obtain a higher nip pressure in the end of the nip than in its beginning. Accordingly, the angle Al between the central axis C 1 of the first cylinder member 107 and the central axis C 2 of the second cylinder member 109 is approximately as large as the angle al in FIG. 1B. As a result of the different parts of the loading cylinder 106 being arranged in accordance with the invention, the angle A 2 between the central axis C 3 of the connecting member 111 and the central axis C 2 of the second cylinder member 109 now becomes significantly smaller than the corresponding angle a 2 between the central axes c 2 and c 3 in FIG. 1B. Starting from the examples above, it should be evident to the skilled person that the minimization, i.e., reduction or even elimination, of the angle A 2 which is achieved by means of the present invention reduces or even eliminates the force components in the machine direction MD, originating from pressurization of the working chamber 114 , which are exercised by the press shoe 101 on the shoe support 118 .
[0054] [0054]FIG. 3 schematically shows the motion pattern of the cylinder members 7 ′, 9 ′ and the connecting member 11 belonging to a loading cylinder 6 ′ of a shoe press device when lengthening the loading cylinder with its first cylinder member tilted to a certain angle.
[0055] In contrast, FIG. 4 schematically shows the motion pattern of the cylinder members 107 ′, 109 ′ and the connecting member 111 ′ belonging to a loading cylinder 106 ′ of a press device according to the invention when lengthening the loading cylinder with the first cylinder member tilted to the same angle as in FIG. 3.
[0056] As is evident from FIG. 4, the press device according to the present invention enables the connecting member 111 to move substantially linearly and in parallel to the lengthening direction of the loading cylinder 106 , when lengthening (or shortening) the loading cylinder 106 ′. This minimizes the stresses on a possible shoe support.
[0057] During the lengthening (or shortening) of a loading cylinder 6 ′ of the shoe press device shown in FIG. 3, the connecting member 1 F instead will be tilted with different angles in relation to the lengthening direction of the loading cylinder 6 ′ depending on how far the lengthening or shortening course has proceeded. This can generate very large stresses on a possible shoe support, or result in the press shoe becoming unstable in case the forces are directed towards the machine direction (backward in the machine direction). Furthermore, the frictional force between the press shoe and the shoe support will vary in a direction across the machine direction, depending on the larger deflection of the support (beam) in the middle (and resulting larger skewness of the piston). This can cause cross-machine variations in the machine-directional pressure curve of the shoe press.
[0058] The mechanical and hydraulic, alternatively pneumatic, components which are in included in the shoe press device according to the invention have not been described in any greater detail herein, since such components should be well-known to the skilled person and also are disclosed and discussed in the above-mentioned EP 0 933 471.
[0059] Furthermore, it should be noted that the paper web 104 preferably is carried through the nip 103 by one or several water receiving machine clothings, such as one or several press felts.
[0060] Many modifications and other embodiments of the invention 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.
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An extended-nip press device comprises a press shoe extending in a cross-machine direction and a support for supporting the press shoe. Between the shoe and the support are arranged a plurality of loading cylinders for moving the shoe toward a backing member such as a counter roll to apply pressure to a fibrous web passing through the nip between the shoe and counter roll. Each loading cylinder comprises a first cylinder member fixed on the shoe and a second cylinder member fixed on the support, and a connecting member that slidably engages both cylinder members. The connecting member can slide relative to the first cylinder member with a first stroke length L 1 that is smaller than the stroke length L 2 between the connecting member and the second cylinder member. Accordingly, the connecting member can remain essentially aligned along the lengthening direction of the loading cylinder.
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[0001] This application claims the benefit of provisional application serial number 60/229,680 filed Sep. 1, 2000, the complete disclosure of which is hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to oil well production. More particularly, the invention relates to methods for optimizing oil well production.
[0004] 2. State of the Art
[0005] The crude oil which has accumulated in subterranean reservoirs is recovered or “produced” through one or more wells drilled into the reservoir. Initial production of the crude oil is accomplished by “primary recovery” techniques wherein only the natural forces present in the reservoir are utilized to produce the oil. However upon depletion of these natural forces and the termination of primary recovery, a large portion of the crude oil remains trapped within the reservoir. Also many reservoirs lack sufficient natural forces to be produced by primary methods from the very beginning. Recognition of these facts has led to the development and use of many enhanced oil recovery techniques. Most of these techniques involve injection of at least one fluid into the reservoir to force oil towards and into a production well.
[0006] Typically, one or more production wells will be driven by several injector wells arranged in a pattern around the production well(s). Water is injected through the injector wells in order to force oil in the “pay zone” of the reservoir towards and up through the production well. It is important that the water be injected carefully so that it forces the oil toward the production well but does not prematurely reach the production well before all or most of the oil has been produced. Generally, once water reaches the production well, production stops. Over the years, many have attempted to calculate the optimal pumping rates for injector wells and production wells in order to extract the most oil from a reservoir.
[0007] An oil reservoir can be characterized locally using well logs and more globally using seismic data. However, there is considerable uncertainty as to its detailed description in terms of geometry and geological parameters (e.g. porosity, rock permeabilities, etc.). In addition, the market value of oil can vary dramatically and so financial factors may be important in determining how production should proceed in order to obtain the maximum value from the reservoir.
[0008] As early as 1958, a linear programming model was proposed by Lee, A. S. and Aronovsky, J. S. in “A Linear Programming Model for Scheduling Crude Oil Production,” J. Pet. Tech. Trans. A.I.M.E. 213, pp. 51-54. More recently, in 1974, the optimum number and placement of wells has been calculated using mixed integer programming. See, Rosenwald, G. W. and Green, D. W., “A Method for Determining the Optimum Location of Wells in a Reservoir Using Mixed Integer Programming,” Society of Petroleum Engineers of AIME Journal, Vol. 14, No. 1, Feb. 1974, p 44-54. In the 1980s work was done regarding the optimum injection policy for surfactants. This work maximized the difference between gross revenue and the cost of chemicals in a one-dimensional situation but with a sophisticated set of equations simulating multiphase flow in a porous medium. See, Fathi, Z. and Ramirez, W. F., “Use of Optimal Control Theory for Computing Optimal Injection Policies for Enhanced Oil Recovery,” Automatica 22, pp. 33-42 (1984) and Ramirez, W. F., “Applications of Optimal Control Theory to Enhanced Oil Recovery,” Elsevier, Amsterdam (1987). Most recently, in the 1990s, the Pontryagin Maximum Principle for Autonomous Time Optimal Control Problems and Constrained Controls has been applied to optimize oil recovery. See, Sudaryanto, B., “Optimization of Displacement Efficiency of Oil Recovery in Porous Media Using Optimal Control Theory,” Ph.D. Dissertation, University of Southern California, Los Angeles (1998) and Sudaryanto, B. and Yortsos, Y. C., “Optimization of Displacement Efficiency Using Optimal Control Theory”, European Conference on the Mathematics of Oil Recovery, Peebles, Scotland (1998). Because of the linear dependence of the Hamiltonian on the control variables, if the variables are constrained to lie between upper and lower bounds, the Pontryagin Maximum Principle implies that optimal controls display a “bang-bang behavior”, i.e. each control variable staying at one bound or the other. This leads to an efficient algorithm.
[0009] All of these approaches to optimizing oil recovery are subject to various uncertainties. Some of these uncertainties include the accuracy of the mathematical model used, the accuracy and completeness of the data, financial market fluctuations, the possibility that new information will affect present measurements, and the possibility that new technology will affect the collection and/or interpretation of data. Choosing a course of action will invariably involve some risk.
SUMMARY OF THE INVENTION
[0010] It is therefore an object of the invention to provide methods for optimizing oil recovery from an oil reservoir.
[0011] It is also an object of the invention to provide methods for optimizing oil recovery from an oil reservoir which takes into account both deterministic and stochastic factors.
[0012] It is another object of the invention to provide methods for optimizing oil recovery from an oil reservoir which account for downside risk.
[0013] It is still another object of the invention to provide methods for optimizing oil recovery from an oil reservoir which takes into account both financial as well as physical parameters.
[0014] In accord with these objects which will be discussed in detail below, the methods of the present invention include the application of portfolio management theory to associate levels of risk with Net Present Values (NPV) of the amount of oil expected to be extracted from the reservoir. Using the methods of the invention, production parameters such as pumping rates can be chosen to maximize NPV without exceeding a given level of risk, or, for a given level of risk, the NPV can be maximized with a 90% confidence level.
[0015] More particularly, the methods of the invention include first deriving semi-analytical results for a model of the reservoir. This involves setting up a forward problem and the corresponding deterministic problem. Certain simplifying assumptions are made regarding viscosity, permeability, the oil-water interface, the initial areal extent of the oil, the shape of the oil patch and its location relative to the production well. With these assumptions, the motion of the oil-water interface is derived under the influence of oil production at a central well and water injection at neighboring wells. The flow rates (pumping rates) are constrained by positive lower and upper bounds determined by the well and formation structures. The amount of oil extracted, or its NPV is optimized under the assumption that production stops when water breaks through at the producer well. According to the methods of the invention, flow rates do not change continuously. A time interval is split into a small number of subintervals during which flow rates are constant. Optimizing flow rates according to the invention is an optimization of a function of several variables (the flow rates in all the time intervals) rather than a classical control problem contemplated by the Pontryagin Maximum Principle. The solution exhibits a “bang bang behavior” with each control variable staying mainly at one bound or the other.
[0016] After considering this deterministic problem, a probabilistic description is created by assuming that the precise areal extent of the remaining oil is not known. An uncertainty such as this is affected by one or more numerical parameters which are referred to herein as uncertainty parameters. By appropriate averaging over multiple realizations, forming expectations by numerical integration, the expected NPV is maximized for a set of flow rates and a risk aversion constant. The probability distribution of the NPV and its uncertainty (i.e. the variance given the values of the control variables which optimize the mean) are also calculated. The results are then represented as probability distribution curves for the NPV and for total production (given that the flow rates are chosen to optimize the expected NPV). The probability distributions of the financial outcomes can then be calculated from the probability distributions describing the uncertain reservoir parameters. Efficient frontiers (similar to those described in Markowitz's theory of portfolio management) are then calculated by optimizing the linear combinations of the expected NPV and its standard (or semi-) deviation. Each point on the efficient frontier corresponds to a set of flow rates which will produce a maximum expected NPV with a given risk.
[0017] An iterative process for carrying out the invention includes the following steps.
[0018] (a) Choose a risk aversion constant K.
[0019] (b) Choose a set of flow rates.
[0020] (c) For each of certain chosen values of the uncertainty parameters, calculate and store an objective function (e.g. NPV).
[0021] (d) Calculate the mean and variance of the objective function set obtained in step (c) to obtain an objective function F(K) of the risk aversion constant, F(K) being a linear combination of semi-variance and mean NPV.
[0022] (e) repeat steps (b) through (d) until an optimal F(K) is found for the risk aversion constant K,
[0023] (f) when the optimal F(K) is found for the risk aversion constant K, store the means and variances calculated in step (d),
[0024] (g) repeat steps (a) through (f) for each risk aversion constant, and
[0025] (h) generate an efficient frontier based on the set of means and variances stored in step (f).
[0026] Additional objects and advantages of the invention will become apparent to those skilled in the art upon reference to the detailed description taken in conjunction with the provided figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] [0027]FIG. 1 is a schematic plan view of a five-spot well pattern showing the position of the oil-water interface and the flow rates at four intervals;
[0028] [0028]FIG. 2 is a graph illustrating the probability of NPV for two sets of parameters;
[0029] [0029]FIG. 3 is a graph illustrating the probability of obtaining percentage yields for two sets of parameters;
[0030] [0030]FIG. 4 is a graph illustrating the probability of obtaining volume of oil for two sets of parameters;
[0031] [0031]FIG. 5 is a graph illustrating the efficient frontier for NPV based on standard deviation;
[0032] [0032]FIG. 6 is a graph illustrating the efficient frontier for NPV based on semi-deviation;
[0033] [0033]FIG. 7 is a graph illustrating the efficient frontier for NPV based on standard deviation for three sets of parameters;
[0034] [0034]FIG. 8 is a graph illustrating the 95% confidence level for NPV corresponding to the efficient frontiers in FIG. 7, assuming NPV is normally distributed; and
[0035] [0035]FIG. 9 is a flow chart illustrating an iterative process according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] Referring now to FIG. 1, the methods of the invention include first deriving semi-analytical results for a model of the reservoir, making several assumptions. FIG. 1 illustrates an “inverted five-spot” pattern of wells in a reservoir with a producer well 1 in the center of a square defined by four injector wells 2 - 5 . The model assumes that the initial oil-water interface is a circle with its center offset from the location of the producer well. The motion of the oil-water interface is illustrated at the end of four time intervals by the irregularly shaped lines inside the circle surrounding the production well. FIG. 1 also illustrates the assumed flow rates (pumping rates) of the five wells over the four time periods as compared to the upper and lower bounds of the flow rates. As seen in FIG. 1, the flow rates of wells 3 and 5 remain constant, with well 3 remaining high and well 5 remaining low. The flow rate of well 2 starts high, drops, goes high again, and drops slightly during the last interval. The flow rate of well 4 starts low, rises slightly twice, and then drops. The flow rate of the production well 1 stays the same for the first two intervals, drops, and then rises. During each time interval a permeable layer drapes an anticline and contains the water-driven, asymmetrically-shaped, pay zone containing oil. For purposes of this model, the oil and water are considered to have the same viscosity and the permeable layer is considered to have uniform thickness, porosity and permeability. The layer is considered to be so thin and flat that it is treated as horizontal and two-dimensional for the fluid flow calculations. The oil-water interface is considered to be sharp enough to be represented by a curve bounding the pay zone. In order to determine the NPV of the oil in the pay zone, it is necessary to determine the rate of production over time, the expected price of oil in the future and the discount rate. The first step in this calculation is to determine the movement of the oil-water interface based on the flow rates of the wells.
[0037] For a uniform isotropic medium, Darcy's law states that v==(κ/μ)∇(p−ρgz) where g is the acceleration due to gravity, z is the vertical ordinate increasing downward, ρ and μ are density and viscosity common to the oil and water, κ is the permeability of the porous rock, and p is fluid pressure. Assuming incompressibility of the fluids and constancy of κ and μ with Darcy's law leads to Laplace's equation for the velocity potential ψ (v=∇ψ), which is related to pressure p and depth z by ψ=(κ/μ) (ρgz−p).
[0038] If attention is limited to two dimensions, as mentioned above, v and ψ are independent of z in the thin permeable layer of constant vertical thickness h and the vertical component v 3 of velocity v is zero. With these assumptions ψ and v (v 1 , v 2 ) can be written as functions of horizontal location x, y, and time t. It is further assumed that the oil and water are contained in a circular region C, having radius a, whose boundary will supply a water drive of constant hydraulic head.
[0039] The flow regime may be calculated very simply using the complex quantities w=x+iy and w k =x k +iy k for k=1,. . . , N, where the wells are located at horizontal positions w k with flux q k volume per unit time. It is assumed that q k >0 for a producer well and q k <0 for an injector well. Applying the Cauchy-Riemann equations, the complex velocity {overscore (v)}=v 1 −iv 2 is given by Equation (1) where q=(q 1 , . . . q N ) is the vector of flow rates and thereis an image well at {overscore (w)} k , the point inverse to w k in the circle C.
v _ ( w , q ) = 1 2 π h ∑ k = 1 N q k ( 1 w - w k - 1 w - w _ k ) ( 1 )
[0040] Once the q k are chosen, each fluid particle moves along a trajectory w(t) satisfying Equation (2) where φ is the porosity,
w . = 1 φ v _ ( w , q ) _ ( 2 )
[0041] Equation (2) represents a system of ordinary differential equations to be solved, one for each particle forming a discretization of the oil-water interface.
[0042] The flux functions q k (t) are regarded as control parameters. For producing wells q k >0, for injectors q k <0. In practive, the producer will penetrate the oil and an injector will penetrate the water outside the oil region. The pay-off function to be maximized is the discounted expected value of the oil produced over the lifetime of the producing well minus the expected discounted costs involved in operating the producer and injectors.
[0043] If it is assumed that well 1 is the single producer and wells 2 through N are injectors. The rate of production of oil at (future) time t is q 1 (t) and the present value of all oil produced is expressed as
J pr ≡ ∫ 0 t f e - bt r 1 ( t ) q 1 ( t ) t ( 3 )
[0044] where r 1 (t) is the expected price of oil per barrel at time t, t f is the terminal time (the time at which water reaches the producer well) and b is the discount rate. If r(t) is set for all t to 1 and b is set to 0, then J reduces to the quantity of oil produced. It is also worth noting that if the expected price of oil rises at the discount rate b, then the product e −bt r pr (t) remains constant. This is equivalent to, but has a different interpretation than, considering the NPV to be a financial derivative of the oil price. The terminal time t f is actually the first time water reaches some circle of small radius δ centered on the producer. This is regarded for argument's sake as the well radius. It is some small radius within which it is not safe to allow water. Similar considerations apply to the injectors and an expression J ini similar to Equation (4) is obtained. Assuming that r k (t) (k=2, . . . N) is the cost to inject a unit volume of water into well k, and that r 2 =r 3 =. . . =r N ≠r 1 , the total payoff is expressed as
J ≡ J pr - J inj = ∑ K = 1 N ∫ 0 t f e - bt r k ( t ) q k ( t ) t ( 4 )
[0045] where the sign of q k corrects for the difference between costs of the injector wells and the gain of the producer well.
[0046] The next step in the determination is to maximize J subject to the dynamics of the oil-water interface. Because of the simplifying assumptions made above, the oil-water interface w(t,θ) may be regarded as a parametized closed contour of fluid particles in the w=x+iy plane which moves according to the velocity field of Equations (1) and (2) with initial values w(0,θ)=w 0 (θ) where w=w 0 (θ) is the equation of the oil-water interface at t=0 in parametric form. The terminal time t f can then be expressed as a function of the q k by
t f =sup{t|∀θ|w ( t ,θ)|≧δ} (5)
[0047] Numerically, θ will be discretized as θ 1 , θ 2 , . . . θ N , and the system of ordinary differential equations obtained by considering all of these values of θ simultaneously will be solved.
[0048] It is assumed that the q k are stepwise constant functions of t but vary with k. Then J is differentiable with respect to the q k except for those values of q k for which there is more than one value of i for which |w(t f , θ i )=δ. That is when more than one fluid particle arrives simultaneously at the distance δ from the producer.
[0049] The optimization problem may now be expressed as Expression (6), the maximization of J(q) over q subject to various constraints including the equations of interface motion, the initial location of the interface particles, and the bounds on well flow rates, i.e. Equations (7) and (8) and Inequality (9).
max q ( · ) J ( q ) ( 6 ) w ( t , θ ) t = f [ w ( t , θ ) , q ( t ) ] ( 7 )
w (0)= w 0 (8)
v lb ≦q ( t )≦ v ub (9)
[0050] Referring once again to FIG. 1, the time interval (0, t f ) has been divided into four equal subintervals. The position of the oil-water interface at the end of each interval is shown by the irregularly shaped heavy lines surrounding the producer well 1 . The lighter lines flowing towards the producer well represent particle paths for some fluid particles on the oil-water interface. As shown in FIG. 1, three “fingers” of water approach the well simultaneously. The number of fingers is related to the number of injector wells, but the relationship is not simple. Because the pumping rates of some of the wells are against their bounds in several time intervals, the number of degrees of freedom in the controls is reduced. If the flow rates are not optimized as described thus far, one “finger” will approach the producer first and water will enter the well before the maximum amount of oil has been produced.
[0051] The optimization thus far does not account for uncertainties. There are uncertainties regarding the accuracy of the assumptions made about the reservoir even when using a sophisticated reservoir simulator rather than the oversimplified model given by way of example, above. Further, there are financial uncertainties such as the volatility of the price of oil and prevailing interest rates. Under extreme circumstances, e.g. a fixed oil price and interest rate, one could maximize profit with arbitrage. That is, one could short sell oil, deposit the proceeds in an interest bearing account, then buy the oil back later and pocket the interest. In reality, oil price is stochastic and the NPV should be treated as a derivative of the oil price since it is explicitly tied to the oil price.
[0052] One way to solve for NPV when oil price volatility is introduced is to use a binomial lattice such as that described by Luenberger, D. G., Investment Science, Oxford University Press, New York (1998). In such a lattice (or tree) there are exactly two branches leaving each node. The leftmost node corresponds to the initial oil price S. The next two vertical (“child”) nodes represent the two possibilities at time Δt that the oil price will either go up to Su≡uS or down to S d ≡dS, where u=Re σ{square root}{square root over (Δt)} and d=Re −σ{square root}{square root over (Δt)} . Here σ is the volatility and R≡e bΔt is the risk-free discount factor. The binomial lattice process is used to build a tree of oil prices until time t f . Requiring no arbitrage, one can calculate the value of any derivative of the oil price at each node of the lattice working backward in time as in a dynamic programming problem. Taking into account the production in the interval Δt, a certain combination of the oil asset S and its derivative J at the parent node will have equal values at each child node, and the “no arbitrage” condition requires that this risk-free combination earn the risk-free rate of interest as set out in Equations (10) and (11) where J is the NPV at the parent node and J i are the NPVs at the child nodes combined with the new contributions from the production within the interval Δt.
V u −αS u =V d −αS d =R ( J−αS ) (10) V i = J i + Δ t ( S i q 1 + ∑ k = 2 N r k q k ) , i = u , d ( 11 )
[0053] It will be appreciated that S in Equations (10 and (11) corresponds to r in previous equations and the sign convention discussed above applies to these equations as well.
[0054] Solving Equation (10) for α and J yields: J≡(p u V u +p d V d )/R, where P u ≡(R−d)/(u−d) and P d ≡(u−R)/(u−d) are the so-called “risk-neutral probabilities”. It should be noted that p u S u +p d S d =RS. From the above and Equation (11), the NPV J at a given node of the lattice can be expressed by means of Equation (10) as.
J = 1 R [ p u J u + p d J d + Δ t ( RSq 1 + ∑ k = 2 N r k q k ) ] ( 12 )
[0055] As mentioned above, the complete solution process involves applying Equation (12) at each node running backwards from the most future child node to the present parent node to obtain the NPV corresponding to the initially set oil price. Equation (12) is similar to a financial derivative called a “forward contract” in each subinterval of the lattice. This calculation assumes that oil production is uninterrupted no matter how much the oil price drops. However if the expression in parentheses in Equation (12) becomes negative, it means that the cost of water injection outweighs the income from oil production. In that case, one could calculate the NPV based on the option not to produce during that time interval where production is unprofitable. This calculation is accomplished by adding the expression in parentheses only when it is positive and not producing when it is negative.
[0056] The foregoing discussion of uncertainty calculations concerns financial uncertainties. As mentioned above, there are also uncertainties regarding the reservoir. As a simple example, it is assumed that the initial radius of a circular oil patch is random with a known probability distribution. Taking nine realizations of the radius, equally spaced in probability, the expected values are formed by replacing integrals over the probability space with sums of quantities over the nine radii. In order to simplify computations for this example, it is assumed that the values q k are constant in time, i.e. there is only one time interval, unlike the step function of q k described earlier. This simplification allows the computations to be run backwards from the final radius δ around the producer and consider when the various fluid particles reach the nine realizations of the circular boundary of the oil. This obviates the need for running the computations forward nine times for each iteration during optimization. The time t f is the same in the forward and backward computations. For each set of q k , k=1, . . . , N, there are nine events corresponding to the first crossing of each of the nine circles by one of the fluid particles. Each event defines a t f and a corresponding index of the fluid particle which first reaches the corresponding circle. For each of the nine realizations, the NPV (or other objective function) is calculated and the mean value of the nine results is also calculated. As a final step, the optimal values of the q k are used to make forward calculations of the nine realizations and the resulting evolution of the oil-water interface is plotted. In view of the foregoing, those skilled in the art will appreciate that, in the backward integration, it is easy to compute other quantities of interest such as the total volume of oil produced and the variances of other quantities.
[0057] FIGS. 2 - 4 were obtained by optimizing the NPV in two cases. The upper plot in each figure uses quantities q k which are optimal when the interest rate and the cost of pumping water are both zero and the price of oil is $10/bbl. Thus, the NPV is directly related to the volume of oil produced. The lower plot in each figure uses quantities q k which are optimal when the interest rate is 15%/yr and the cost of pumping water is $1/bbl.
[0058] [0058]FIG. 2 plots the probability on the vertical axis of obtaining at least the NPV on the horizontal axis. Using the same values q k , FIG. 3 plots the probability on the vertical axis of obtaining at least the yield (ratio of oil produced to total oil in reservoir) on the horizontal axis as a percentage; and FIG. 4 plots the probability on the vertical axis of obtaining at least the total production on the horizontal axis. Although these functions take uncertainty into account, they do not take into account the downside risk of choosing a particular set of values q k .
[0059] According to the methods of the invention, theories of portfolio management have been applied to the problems discussed thus far. In particular, the invention utilizes aspects of Markowitz's modern portfolio theory. See, Markowitz, H. M., “Portfolio Selection”, 1959, Reprinted 1997 Blackwell, Cambridge, Mass. and Oxford, UK.
[0060] According to the invention, the standard deviation σ sand mean α of an objective function F are used in conjunction with a risk aversion constant λ in order to optimize F for each λ. In the case of a linear combination, for example, Equation (13) is maximized for each value of λ where 0<λ<1.
F λ =(1−λ)μ−λσ (13)
[0061] If λ=0, the solution will be the maximum mean regardless of the risk or the standard deviation. If λ=1, the solution will be the minimum risk regardless of the mean. If the maximum of F λ is denoted F λ max , then the F λ of Equation (13) for each possible set of values of the control will be less than or equal to F λ max and the possible values of σ and μ must lie in the convex set formed by the intersection of half-planes defined by Equation (14).
F λ max ≧(1−λ)μ−λσ (14)
[0062] Equation (14) is represented in FIG. 5 where F is the NPV. The vertical axis of FIG. 5 represents expected mean NPV and the horizontal axis represents the minimum risk associated with the expected NPV. The solution of Equation (14) includes the set of points above the dark line (the intersection of half-planes) as well as the dark line itself. The set of points above the line include all of the sets of q k which satisfy Equation (14). The dark line is the “efficient frontier” which is the optimal solution for maximizing NPV for a given risk or minimizing risk for a given NPV. The data used to construct FIG. 5 are taken from the four injector, one producer example given above where the actual volume of oil initially in place is uncertain and there is a requirement that no water be produced at the producer well. Each point in the efficient frontier corresponds to a unique λ via the multi-well flow rate schedule that optimizes F λ . That schedule then determines the corresponding point (μ λ ,σ λ ) on the efficient frontier. Thus, the efficient frontier can be thought of simply as the locus of F λ , i.e., the set of all points (μ λ ,σ λ ) whose location is determined by the flow rates that optimize F λ .
[0063] In order to substantially eliminate the downside risk, the efficient frontier can be refined by using the one-sided semi-deviation rather than the standard deviation. The semi-deviation σ − is defined by
(σ − ) 2= E {[min( F −μ,0)] 2} (15)
[0064] where E{ } represents the expected value of the expression in the braces.
[0065] The efficient frontier based on the semi-deviation is illustrated in FIG. 6.
[0066] Other examples of efficient frontiers are illustrated in FIG. 7 which shows the efficient frontiers for three different treatments of the oil price.
[0067] [0067]FIG. 8 illustrates the 95% confidence level for the efficient frontiers of FIG. 7 assuming that the NPV is normally distributed.
[0068] The efficient frontier can also be modified by redefining the risk constant as 0≦K<∞ and defining F K as
F K =μ−Kσ (16)
[0069] In this case K takes on a more significant meaning than λ. For example, if some quantity X (e.g. NPV, total oil produced, etc.) results from a process with uncertainties, X will have a probability density function inherited from the uncertainty of the underlying process. Assuming that X has a probability distribution with a mean μ and a variance σ 2 , using these values, and assuming that F K of Equation (16) is optimized, it is possible to compute the probability that X>F K . Another way of stating this is to say with what confidence (in percent) can one be certain that X will be greater than F K . From probability theory, this probability can be expressed as
P ( X>F K )≡1 −P ( X≦F K )=n/100 (17)
[0070] Equation (17) is equivalent to Equation (18) where Φ is the normalized distribution function for X.
1 - Φ ( F K - μ σ ) = 1 - Φ ( - K ) = n 100 ( 18 )
[0071] For distributions having the property Φ(−z)=1−Φ(z) for all z, including z with densities symmetric about the mean, Equation (18) can be reduced to
Φ ( K ) = n 100 ( 19 )
[0072] Using the inverse distribution function to solve for K in Equation (18), the general case, yields Equation (20) and solving for Equation (19), for symmetrical distributions, yields Equation (21).
K = - Φ - 1 ( 1 - n 100 ) ( 20 ) K = Φ - 1 ( n 100 ) ( 21 )
[0073] Substituting for F K yields Equation (22) for the general case and Equation (23) for symmetric distributions.
F K = μ + σ Φ - 1 ( 1 - n 100 ) ( 22 ) F K = μ - σ Φ - 1 ( n 100 ) ( 23 )
[0074] In applied statistics, −Φ −1 (1−n/100) is called the upper n-percentile and Equations (22) and (23) correspond to Equation (16). Thus, one may interpret Equation (20) as the upper n-percentile of the value F K that is, with the probability of n/100 that X will be greater than F K .
[0075] The methods described thus far can be generalized to include various combinations of statistical parameters other than linear equations. Parameters other than the mean can be used to search for an optimum. For example, the median or the mode (for discrete-valued forecast distributions where distinct values might occur more than once during the simulation) may be used as the measure of central tendency. Further, instead of the standard deviation, the variance, the range minimum, or the low end percentile could be used as alternative measures of risk or uncertainty.
[0076] Turning now to FIG. 9, an iterative process for carrying out the invention includes the following steps: At 10 , a risk aversion constant K is chosen. At 12 , a set of flow rates is chosen. At 14 , a value or values for all uncertainty parameters is chosen. At 16 , an objective function is calculated and stored. Then, at 18 , a determination is made as to whether there are more uncertainty parameter values to be considered. If there are, steps 14 and 16 are repeated for each value of the uncertainty parameters until it is determined at 18 that there are no more uncertainty parameter values to be considered. When there are no more uncertainty parameter values for this set of flow rates, the mean and variance of the objective function set obtained in step 16 are calculated to obtain an objective function F K of the risk aversion constant and flow rates. It is then determined at 22 whether the function F K is optimal. If it is not optimal steps 12 through 22 are repeated until the optimal F K is found at 22 . When the optimal F K is found for the risk aversion constant K, the means and variances calculated in step 20 are stored at 24 . A determination is made at 26 whether there are more risk aversion constants. If there are, steps 10 through 24 are repeated for each risk aversion constant. When it is determined at 26 that there are no more risk aversion constants, an efficient frontier is generated at 28 based on the set of means and variances stored at step 24 .
[0077] There have been described and illustrated herein several embodiments of methods for optimization of oil well production with deference to reservoir and financial uncertainty. While particular embodiments of the invention have been described, it is not intended that the invention be limited thereto, as it is intended that the invention be as broad in scope as the art will allow and that the specification be read likewise. Thus, while particular objective functions (i.e. NPV and production quantity) have been disclosed, it will be appreciated that other objective functions could be utilized. Also, while specific uncertainty parameters (i.e. radius of the oil patch, cost of oil, and interest rate) have been shown, it will be recognized that other types of uncertainty parameters could be used. Furthermore, additional parameters could be used, including the number of wells taking into account the cost of drilling each well. The use of an exploration well could be used to better determine the probability distribution of the location of the oil. Also, those skilled in the art will appreciate that the optimization methods of the invention may be applicable to stochastic processes other than oil well production. It will therefore be appreciated by those skilled in the art that yet other modifications could be made to the provided invention without deviating from its spirit and scope as so claimed.
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Methods for optimization of oil well production with deference to reservoir and financial uncertainty include the application of portfolio management theory to associate levels of risk with Net Present Values (NPV) of the amount of oil expected to be extracted from the reservoir. Using the methods of the invention, production parameters such as pumping rates can be chosen to maximize NPV without exceeding a given level of risk, or, for a given level of risk, the minimum guaranteed NPV can be predicted to a 90% probability. An iterative process of generating efficient frontiers for objective functions such as NPV is provided.
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REFERENCE TO PRIORITY RELATED APPLICATION
[0001] This patent application claims priority under 35 U.S.C. § 119 to Korean Patent Application 2005-55906 filed on Jun. 27, 2005, the entire contents of which are hereby incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to integrated circuit memory devices and, more particularly, to flash memory devices and methods of operating flash memory devices
BACKGROUND OF THE INVENTION
[0003] Flash memory devices are a type of nonvolatile semiconductor memory device. Flash memory devices are regarded as being highly adaptable to large storage capacities and high-frequency operation in applications requiring large-capacity storage devices and coded memories for mobile apparatuses. Flash memory devices are generally classified into NAND and NOR types by the logical pattern of the cell array. The memory cell array of the NOR-type flash memory device is structured such that a plurality of memory cells are arranged as being connected to a single bitline in parallel. In contrast, the NAND-type flash memory device has a memory cell array in which a plurality of memory cells are connected in series from a single bitline. The NOR-type flash memory devices are widely used in applications requiring high-frequency operations because they are operable with high speed in programming and reading operations, relative to the NAND-type flash memory devices. Data values within the flash memory device are defined by the threshold voltages of the memory cells, in which programming operations are carried out by changing the cell threshold voltages. It is now conventional to regulate the cell threshold voltages by the ISPP scheme during programming operations.
[0004] FIG. 1 illustrates the pulses of programming and verifying voltages applied to a wordline of a memory cell during a programming operation with the ISPP scheme in a general flash memory. As shown in FIG. 1 , in a typical cycle of the ISPP scheme, a unit step of incrementing a program voltage is confined to a ΔV value and a unit verifying time is fixed to Δt. Such fixed ranges for the program voltage step and the unit verifying time are contrary to achieving narrow distribution profiles of cell threshold voltages in multi-level cell (MLC) arrangements. In detail, the fixed range of the incremental program voltage step raises the probability of shifting cell threshold-voltage distribution profiles upward from a verifying voltage Vveri, after the programming operation for those memory cells that have threshold voltages near to the verifying voltage Vveri. This effect arises when the incremental step of the program voltage is excessively high to inject the appropriate amount of hot electrons into a floating gate. The threshold-voltage distribution profiles of memory cells can be improved as the program voltage step becomes lower. However, a too low level of the program voltage step causes the threshold voltages to be reduced in shifting width so much and the number of programming loops to increase thereby, resulting in a longer overall programming time. While a reduction of the program voltage step is effective in improving the threshold-voltage distribution profiles of memory cells, it is inevitable that this method causes a loss in operating speed. To the contrary, an increase in the program voltage step would incur a heavy loss against the threshold-voltage distribution profiles, but it accelerates a programming speed.
[0005] The problems due to the fixed verifying time are generated when the threshold voltages of memory cells are close in value to the verifying voltage Vveri. In general, sense amplifiers employed in the flash memory devices detect and amplify drain voltages discharged while the verifying voltage is being applied to wordline. If a threshold voltage of memory cell is higher than the verifying voltage Vveri, the memory cell is detected as an off-cell. However, if a threshold voltage of a memory cell is lower than the verifying voltage Vveri, the memory cell is detected as an on-cell. However, when there is only a small difference between a cell threshold voltage and the verifying voltage, (i.e., when the threshold voltage is positioned around an intermediate level between the on-cell and off-cell) a sensing time interval may need to become substantial to obtain accurate verification of the program state of a cell. If a memory cell undergoes an insufficiently long verification operation, then it may be judged as a passed cell even though its threshold voltage is at a relatively low “fail” level. As will be understood by those skilled in the art, the use of a verification operation having an insufficiently long verification time interval may cause “failed” cells to appear as “passed” cells and thereby increase a width of a threshold-voltage distribution profile.
SUMMARY OF THE INVENTION
[0006] Nonvolatile memory devices according to embodiments of the present invention support programming and verify operations that improve threshold-voltage distribution within programmed memory cells. This improvement is achieved by reducing a magnitude of the programming voltage steps and increasing a duration of the verify operations once at least one of the plurality of memory cells undergoing programming has been verified as a “passed” memory cell. According to some of these embodiments, the nonvolatile memory device includes an array of nonvolatile memory cells and a control circuit, which is electrically coupled to the array of nonvolatile memory cells. The control circuit, which may include a plurality of functional circuit elements, is configured to perform a plurality of memory programming operations (P) by driving a selected word line in the array with a first stair step sequence of program voltages having first step height (e.g., ΔV 1 ) and then, in response to verifying that at least one of the memory cells coupled to the selected word line is a passed memory cell, driving the selected word line with a second stair step sequence of program voltages having a second step height (e.g., ΔV 2 ) lower than the first step height. The control circuit may also be configured to perform a plurality of memory verify operations (V), which are interleaved in time with the plurality of memory programming operations.
[0007] According to aspects of these embodiments, a first plurality of memory verify operations are associated with the first stair step sequence of program voltages and a second plurality of memory verify operations are associated with the second stair step sequence of program voltages. In order to support a narrowing of the threshold-voltage distribution within the programmed memory cells, a first duration (t 1 ) of the first plurality of memory verify operations is less than a second duration (t 2 ) of the second plurality of memory verify operations. Moreover, a first interleaved sequence of program and verify operations associated with the first stair step sequence of program voltages commences with a program operation and terminates with a verify operation having the first duration (t 1 ) and a second interleaved sequence of program and verify operations associated with the second stair step sequence of program voltages commences with a verify operation having the second duration (t 2 ). Thus, two immediately consecutive verify operations of different duration are performed during an interval when at least one memory cell is verified as a passed memory cell.
[0008] The control circuit according to embodiments of the invention may include a row decoder electrically coupled to a plurality of word lines in the array and a voltage generator electrically coupled to the row decoder. The voltage generator is responsive to a voltage control signal (V_CONT). A program controller is also provided within the control circuit. The program controller is configured to switch the voltage control signal (V_CONT) from a first logic state to a second logic state in response to a first pass signal (e.g., SPF) and is further configured to switch the voltage control signal from the second logic state to the first logic state in response to a last pass signal (e.g., MPF). This control circuit also includes a sense amplifier and a pass/fail detector electrically coupled to an output of the sense amplifier. The pass/fail detector is configured to generate the first and last pass signals and the sense amplifier is responsive to a sense amplifier enable signal generated by the program controller. In particular, the pass/fail detector may include a first pass detector having OR logic therein that generates the first pass signal SPF and a last pass detector having AND logic therein that generates the last pass signal MPF.
BRIEF DESCRIPTION OF THE FIGURES
[0009] Non-limiting and non-exhaustive embodiments of the present invention will be described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various figures unless otherwise specified. In the figures.
[0010] FIG. 1 is a diagram showing variations of voltage levels versus time during programming and verifying operations by an ISPP scheme in a conventional flash memory device;
[0011] FIG. 2 is a block diagram illustrating a memory device that performs programming and verifies operations according to embodiments of the present invention;
[0012] FIG. 3 is a block diagram illustrating a functional structure of a pass/fail detector shown in FIG. 2 ;
[0013] FIG. 4 is a timing diagram illustrating sensing operations performed by the memory device of FIG. 2 ;
[0014] FIG. 5A is a circuit diagram illustrating a bias condition in a verifying operation for a NOR-type memory cell;
[0015] FIG. 5B is a diagram illustrating relative positions of threshold and verifying voltages for a unit memory cell;
[0016] FIG. 5C is a graphic diagram illustrating features of verifying processes in accordance with variations of threshold voltages along the drain voltage and verifying time in memory cells;
[0017] FIG. 6 is a flow chart illustrating programming operations performed by embodiments of the present invention;
[0018] FIG. 7 is a diagram illustrating variations of wordline voltages versus time by an adaptive ISPP scheme in accordance with embodiments of the invention; and
[0019] FIG. 8 is a diagram showing improved distribution profiles of threshold voltages by the programming scheme according to embodiments of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0020] The present invention now will be described more fully herein with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like reference numerals refer to like elements throughout and signal lines and signals thereon may be referred to by the same reference characters.
[0021] FIG. 2 is a block diagram illustrating a functional structure for a programming operation in a flash memory according to an embodiment of the present invention. The flash memory device includes a memory cell array 20 coupled to a row decoder and a column selector, a voltage generator 10 supplying a program voltage Vpgm and a verifying voltage Vveri to a wordline of memory cells, a writing driver 30 setting bitline voltages of memory cell to be programmed in a programming operation, a sense amplifier 40 detecting channel currents of memory cells in verifying steps, a pass/fail detector 50 checking up pass states with at least one memory cell and with all the memory cells, and a program controller 60 regulating the program voltage and sensing time therein. With such an organization, the programming operation is carried out using a first mode that repeats a cycle with a larger incremental step range ΔV 1 and a shorter verifying time t 1 , and a second mode that repeats a cycle with a smaller incremental step range ΔV 2 and a longer verifying time t 2 . These functional elements that are shown in FIG. 2 as being coupled (directly or indirectly) to the cell array 20 collectively define a memory content circuit.
[0022] The voltage generator 10 generates voltages for the programming and verifying operations (e.g., V WL , V BL , and so forth), which are supplied to the wordline and the writing driver 30 . The voltage V WL applied to a wordline includes the program voltage Vpgm, which is applied to a wordline while programming memory cells, and the verifying voltage Vveri that is applied to a wordline while verifying memory cells. The voltages used for programming the flash memory device are applied to wordlines in the ISPP scheme so as to shift up threshold voltages of memory cells over the verfying voltage Vveri. The ISPP scheme is conducted by repeating a loop in which stepping-up program-voltage pulses of Vpgm are applied to the wordline and then the verifying voltage Vveri is applied next thereto. The voltage generator 10 is designed to supply program-voltage pulses to wordlines in variable stepping-up ranges, which differs from the uniform ranges shown in FIG. 1 . Further, the bitline voltage V BL for activating a selected bitline during the programming operation is also generated in sync with the program voltage Vpgm.
[0023] The memory cell array 20 includes a plurality of memory cells arranged in a NOR logical pattern, being connected with the row and column devices. The memory cells described herein are referred as being operable with the characteristics of NOR-type flash memory cells.
[0024] The writing driver block 30 activates bitlines of selected memory cells at a point of applying the program voltage Vpgm to a wordline of the selected memory cell. During the programming operation, the writing driver block 30 transfers the bitline voltage V BL to the bitlines from the voltage generator 10 in response to a bitline-enabling signal BLEN provided from the program controller 60 . While applying the program voltage Vpgm to the wordline, the writing driver block 30 controls a drain side of the selected memory cell on a level of the bitline voltage V BL (e.g., 5V) so as to induce the injection of hot electrons into a floating gate electrode of the memory cell.
[0025] The sense amplifier block 40 is connected to both the writing driver block 30 and the bitlines of memory cells, detecting cell states during reading and verifying operations. The sense amplifier block 40 includes a plurality of sense amplifiers, which are coupled to corresponding bitlines in the cell array 20 . During the reading operation, a read voltage Vread is applied to a selected wordline of memory cells and the sense amplifiers of the block 40 detect data in accordance with pass or fail states of the memory cells. In the verifying operation, the verifying voltage is applied to a selected wordline and the sense amplifiers of the block 40 detect pass or fail states of the memory cells in response to a sense-enabling signal SAEN. The verifying time is controlled in response to the sense-enabling signal SAEN that is applied to the sense amplifier block 40 from the program controller 60 .
[0026] The pass/fail detector 50 outputs first and last pass signals, SPF and MPF, in response to monitoring detection results of the sense amplifier block 40 . In a general case, a pass signal is generated to the program controller 60 only when all memory cells are detected as being in pass states even if there are inputs of pass-informing signals or data from sense amplifiers. In contrast, the flash memory device of the present invention includes circuitry for detecting a point at which at least one memory cell has been verified as being passed. When this occurs, the first pass signal SPF goes to a high level and the program controller 60 identifies that there is one or more memory cell passed in the ISPP loop. The last pass signal MPF goes to high level only when all the memory cells, which have been programmed, are detected as being passed by the sense amplifiers. The structures and operations of the pass/fail detector 50 will be further described in detail with reference to FIG. 3 .
[0027] The program controller 60 monitors and regulates conditions of the programming voltages and detecting operations with the aforementioned components. The program controller 60 regulates the voltage generator 10 using a voltage control signal V_CONT. This regulation causes a transfer of the program voltage by the ISPP scheme with the larger incremental step range ΔV 1 to a selected wordline in the first programming mode. In addition, the program controller 60 , while the program voltage Vpgm of pulse is being applied to the selected wordline, controls the writing driver block 30 to activate the bitline-enabling signal BLEN in sync with the pulses of the program voltage Vpgm. In a step of verifying a programmed result after applying the program voltage pulses Vpgm, the program controller 60 outputs the sense-enabling signal SAEN for the time t 1 , regulating a verifying time by the sense amplifier block 40 . If there is a receipt of the first pass signal SPF, which goes to a high level when at least a memory cell is detected as being passed during the period of the first programming mode, the program controller 60 changes operation to the second programming mode that is characterized with the smaller incremental step range ΔV 2 and the longer verifying time t 2 .
[0028] Here, in the second programming mode, it is required that a verifying operation occur over a longer verifying time t 2 that supports accurate detection of whether the corresponding memory cells are being in the pass states, for memory cells detected as being passed during the first programming mode. Thus, when the first pass signal SPF goes to a high level, the program controller 60 activates the sense-enabling signal SAEN during the time t 2 to conduct a re-verifying operation for the first passed cells, at the beginning of the second programming mode. After this re-verify operation, in a step of applying the program voltage pulse Vpgm, the voltage generator 10 is controlled to supply the program voltage Vpgm with the smaller incremental step range ΔV 2 to the selected wordline. The second programming mode is terminated when all of the memory cells are detected as being completely programmed after the generation of the first passed cells. After completing the programming operation for all of the memory cells to be programmed, the pass/fail detector 50 detects the completion of the programming operation and sends the last pass signal MPF to the program controller 60 . The program controller 60 terminates the program operation cycle in response to the last pass signal MPF. The program controller may be comprised of a timer to output an alternative one of the first and second verifying times.
[0029] As such, the programming operation is carried out by way of the first programming mode with repeated high-frequency programming/verifying loops and the second programming mode with repeated high-resolution programming/verifying loops, using the functional components shown in FIG. 2 . The second programming mode begins in response to detecting at least one passed memory cell by the first programming mode. While the first programming mode is terminated with the verifying operation, the second programming mode begins with resuming the verifying operation that is carried out in the larger verifying time so as to correctly check out whether the memory cells are conditioned in the pass states. The reason for conducting the verifying operation of the second programming mode subsequent to the verifying operation at the end of the first programming mode will be described in detail with reference to FIG. 5 .
[0030] FIG. 3 is a block diagram illustrating a functional structure of the pass/fail detector 50 shown in FIG. 2 . Referring to FIG. 3 , the pass/fail detector 50 is comprised of first and last pass detectors, 51 and 52 , inputting cell detection results from the sense amplifiers of the block 40 . The first pass detector 51 generates and supplies the first pass signal SPF to the program controller 60 when there is at least one memory cell detected as being passed. For instance, if the pass state corresponds to when an output of the sense amplifier block 40 is logically ‘1’, the first pass detector 51 has the same input/output characteristics as an OR logic gate. If there is detected at least a single passed memory cell (i.e., at least one of the lines SA 1 , SA 2 , . . . SAn is a logical “1”), the first pass signal SPF goes to high level and is transferred to the program controller 60 .
[0031] The last pass detector 52 generates and applies the last pass signal MPF to the program controller 60 when all of the memory cells are detected as being passed. The last pass detector 52 may be formed of an AND logic gate, outputting the last pass signal MPF at a high level only when all the memory cells are detected as being passed and outputs of the sense amplifiers are all logically “1”. If all the memory cells are completely programmed and all the sense amplifier output signals indicate the pass states, the last pass signal MPF will go to a high level and be transferred to the program controller 60 .
[0032] Thus, the pass/fail detector 50 provides circuitry for switching the operation to the second programming mode in response to generating the first pass signal SPF and terminating the whole programming operation in response to generating the last pass signal MPF.
[0033] FIG. 4 is a timing diagram illustrating the sensing operation by means of the components shown in FIG. 2 , which are regulated by the program controller 60 . Referring to FIG. 4 , a turning point between the first and second programming modes is a point when the first pass signal SPF rises up to high level. In the first programming mode, it can be seen that the turning point corresponds to the time period t 1 for which the sense-enabling signal SAEN is set to a high level to activate the sense amplifier block 40 . In this description, the high-level period of the sense-enabling signal SAEN is also referred to as a verifying time for detecting a pass state of a memory cell by the sense amplifier. The bitline-enabling signal BLEN is logically the reverse to the sense-enabling signal SAEN. When the bitline-enabling signal BLEN is set to a high level, it is the programming period for which the program voltage pulse Vpgm is being applied to a selected wordline. The incremental range of the program voltage in the first programming mode is the larger incremental step range ΔV 1 . When it detects a first passed cell while the first programming mode is being conducted with programming and verifying cycles by the ISPP scheme, the first pass signal SPF goes to a high level to turn the operation into the second programming mode. As aforementioned with reference to FIG. 2 , the second programming mode begins with the operation for correctly detecting the first passed cells. In other words, the second programming mode begins with the verifying operation for the longer verifying time t 2 that permits precise verification for the already passed memory cells, and does not begin immediately with a programming operation subsequent to the last verifying time t 1 of the first programming mode. Such subsequent verifying operations over the first and second programming modes are provided to prevent miss-detection of a programmed memory cell due to an insufficient verifying time although the programmed memory cell has a threshold voltage lower than the verifying voltage Vveri. Namely, subsequent to the verifying operation of the first programming mode, the second programming mode verifies the first passed cells in the longer verifying time t 2 that is sufficiently extended more than the time t 1 . If the first passed cell is detected as a failed one through the verifying operation at the beginning of the second programming mode, the memory cell will be excluded from the next programming operation. For this, the second programming mode begins with a verifying operation. And, the second programming mode is terminated in response to the last pass signal MPF of high level by normal completion of program for all the memory cells.
[0034] As such, the program controller 60 enables the high-frequency (high-speed) programming operation in the first programming mode, and the second programming mode, after the generation of at least one first passed cells, with the smaller incremental step range ΔV 2 and the longer verifying time t 2 , in sequence. Therefore, embodiment of the present invention are able to effectively restrain the upper and lower distribution profiles of threshold voltages after completing the whole programming operation by means of the organization for adaptively changing the incremental range of the program voltage step and the verifying time in accordance with the generation of the first passed cells.
[0035] FIGS. 5A, 5B , and 5 C explain reasons for carrying out the verifying operation with the longer verifying time t 2 at the beginning of the second programming mode after the detection (or generation) of the first passed cell (or cells) by the first programming mode as shown in FIG. 4 . FIG. 5A is a circuit diagram illustrating a bias condition in the verifying operation for a NOR-type memory cell. Referring to FIG. 5A , in the NOR-type memory cell programmed in a predetermined threshold voltage Vth, the source electrode S is grounded to a reference voltage while the drain electrode D is precharged in a voltage Vdrain offered by the sense amplifier. The control gate G is supplied with the verifying voltage Vveri through the wordline thereof so as to find the pass state. The sense amplifier compares the drain voltage Vdrain with the reference voltage to detect whether the memory cell is being held in an “on” state or an “off” state in response to application of the verifying voltage Vveri.
[0036] Now, it will be described about the benefit of conducting the sequential verifying operations while switching from the first programming mode to the second programming mode. FIG. 5B is a diagram illustrating positions of threshold and verifying voltages for a unit memory cell. From FIG. 5B , it is possible to find the positions of a first threshold voltage Vth 1 sufficiently lower than the verifying voltage Vveri, a second threshold voltage Vth 2 lower than the verifying voltage Vveri but near thereto, and a third threshold voltage Vth 3 sufficiently higher than the verifying voltage Vveri. The first and second threshold voltages, Vth 1 and Vth 2 , which are lower than the verifying voltage Vveri, correspond to an on-state cell, while the third threshold voltage Vth 3 , which is higher than the verifying voltage Vveri, corresponds to an off-state cell.
[0037] FIG. SC is a graphic diagram illustrating features of verifying processes in accordance with variations of threshold voltages (along the drain voltage) and verifying time in memory cells. Referring to FIG. 5C , in the case of the first and third threshold voltages Vth 1 and Vth 3 with sufficient intervals from the verifying voltage Vveri, it is possible to correctly detect a cell state regardless of the verifying time t 1 or t 2 . But, in the case of the second threshold voltage Vth 2 , which is approximately equal to the verifying voltage Vveri, the cell state would be detected as passed if the short verifying time t 1 was used or failed if the longer verifying time was used. This anomaly may result in miss-verification due to the insufficient verifying time although a cell threshold voltage is still lower than the verifying voltage Vveri. Since a memory cell once detected as being passed is excluded from the next programming cycle, it results in extension of the lower threshold-voltage distribution profile to a level below the verifying voltage Vveri.
[0038] Thus, embodiments of the invention include a first programming mode where the verifying operation is conducted in a shorter verifying time t 1 , and the second programming mode resumes the verifying operation for the passed cells in the longer verifying time t 2 .
[0039] FIG. 6 is a flow chart illustrating a programming procedure by an adaptive ISPP scheme in accordance with embodiments of the invention. During the beginning of the adaptive ISPP programming operation, the wordlines of the memory cells are supplied with the program voltage pulse with the larger incremental step range ΔV 1 (i.e., a first program voltage), in order to shift the threshold voltages up near to the verifying voltage (step S 10 ), which is the first programming mode. Next, a first verifying step S 20 is carried out for the shorter verifying time t 1 (i.e., a first verifying time), after once applying the program voltage pulse. If there is no passed cell after the first verifying step, the procedure returns to the step S 10 of programming with a voltage pulse in the larger incremental step range ΔV 1 . However, if there is at least one passed cell after the first verifying step, then operations pass from step S 30 to step S 40 where the second programming mode begins.
[0040] The second programming mode initially verifies the first passed cells in the longer verifying time t 2 that is sufficiently extended more than the time t 1 , S 40 . If the first passed cell is detected as a failed one through the verifying operation at the beginning of the second programming mode, the memory cell should not be excluded in the next programming operation.
[0041] The second programming mode begins with re-verifying the first passed cell with the second verifying time t 2 (step S 40 ). And, it continues to detect whether all the memory cells are being passed until the last pass signal MPF is applied to the program controller 60 shown FIG. 2 (step S 50 ). If all the memory cells are detected as not being passed entirely, it repeats the steps of programming the memory cells in the program voltage pulse with the incremental step range ΔV 2 smaller than ΔV 1 used in the first programming mode (S 60 ) and verifying the programmed memory cells in the second verifying time t 2 (S 40 ). The steps S 40 through S 60 are a programming and verifying loop that corresponds to the second programming mode. If there is an input of the last pass signal MPF at the program controller 60 , indicating that all the memory cells are detected as being passed during the second programming mode, the whole programming procedure according to the adaptive ISPP scheme is terminated.
[0042] Accordingly, the adaptive ISPP scheme including the aforementioned steps is able to quickly shift threshold voltages of the memory cells close to the verifying voltage Vveni by means of the program voltage with the larger incremental step range ΔV 1 and the shorter verifying time t 1 . Further, after the generation of the first passed cell, the second programming mode is carried out to accomplish the high-resolution programming result, responding to the first pass signal SPF, by means of the program voltage with the smaller incremental step range ΔV 2 and the longer verifying time t 2 . Especially, the second programming mode is controlled to start, after detecting at least a passed cell through the first programming mode, with the verifying operation in the time t 2 that extends longer than the former verifying time t 1 .
[0043] FIG. 7 is a diagram illustrating variations of wordline voltages versus time by the adaptive ISPP scheme in accordance with embodiments of the invention, showing stepping-up pulses of the program voltage and variable verifying times. In FIG. 7 , the hatched portions denote the program voltage pulses and the others denote pulses of the verifying voltage. The first programming mode is the period where the program voltage pulse with the larger incremental step range ΔV 1 and the verifying voltage pulse for the shorter verifying time t 1 are alternately applied to the wordlines of the memory cells prior to the generation (or detection) of the first passed cell. After detecting at least the first passed cell, operations switch to the second programming mode in which the program voltage pulse with the smaller incremental step range ΔV 2 and the verifying voltage pulse for the longer verifying time t 2 are alternately applied to the wordlines of the memory cells. The turning point changing from the first programming mode to the second programming mode corresponds to the last verifying operation of the first programming mode, at which the first passed cell is detected at least, as noticed by the broken line shown in FIG. 7 . Then, after the generation of the first passed cell, the second programming mode performs a first verifying operation with the verifying time t 2 that is sufficient 1 y longer than the verifying time t 1 of the first programming mode. Thereafter, in the second programming inode, the programming and verifying loop is repeated using the program voltage pulses with the smaller incremental step range ΔV 2 and the longer verifying time t 2 , until all of the memory cells are completely programmed.
[0044] FIG. 8 graphically shows an improved distribution profile of threshold voltages by the programming scheme according to the invention, compared to the conventional one 200 with the present profile 210 by the adaptive ISPP scheme of the invention. From FIG. 8 , it can be seen that the cell threshold-voltage distribution profile 210 by the invention is configured to be more tightly constrained in width compared with the conventional distribution profile 200 .
[0045] The improvement on the lower side of the present distribution profile, ΔV low , results from the process of accurately detecting the cell states by re-verifying the passed cells for the extended verifying time (i.e., the longer verifying time t 2 ), after the generation of the first passed cell. On the other hand, The improvement on the upper side of the present distribution profile, ΔV up , is obtained because the memory cells are restricted in the higher range of threshold voltage by conducting the high-resolution programming operation with the smaller incremental step range ΔV 2 after the generation of the first passed cell.
[0046] With the aforementioned organizations and operating steps for programming and verifying, the cell threshold-voltage distribution profile after programming is remarkably improved relative to the conventional distribution profile. The invention may be applicable to other types of flash memory devices, besides the NOR-type flash memory device.
[0047] The programming operations performed by embodiments of the invention area able to restrain the upper and lower threshold-voltage distribution profiles that result from programming operations. Thus, embodiments of the invention may be used in memory devices that require narrow threshold-voltage characteristics, such as multi-level cells.
[0048] In the drawings and specification there have been disclosed typical preferred embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being set forth in the following claims.
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Nonvolatile memory devices support programming and verify operations that improve threshold-voltage distribution within programmed memory cells. This improvement is achieved by reducing a magnitude of the programming voltage steps and increasing a duration of the verify operations once at least one of the plurality of memory cells undergoing programming has been verified as a “passed” memory cell. The nonvolatile memory device includes an array of nonvolatile memory cells and a control circuit, which is electrically coupled to the array of nonvolatile memory cells. The control circuit is configured to perform a plurality of memory programming operations (P) by driving a selected word line in the array with a first stair step sequence of program voltages having first step height (e.g., ΔV 1 ) and then, in response to verifying that at least one of the memory cells coupled to the selected word line is a passed memory cell, driving the selected word line with a second stair step sequence of program voltages having a second step height (e.g., ΔV 2 ) lower than the first step height.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention is broadly concerned with improved dryer apparatus and drying methods which maximize dryer efficiency and product exist moisture control, notwithstanding the occurrence of upset conditions such as differences in input air temperature and/or humidity, or the moisture content of incoming product to be dried. More particularly, the invention is concerned with such methods and apparatus wherein the adiabatic saturation ratio (ASR) and the temperature of the output air stream from the dryer are maintained at predetermined, substantially constant levels during drying; such ASR and output air temperature maintenance involves determination of the temperature and humidity of the output air stream and adjustment of recycle and exhaust portions of the output air stream and energy input to the dryer, to maintain the ASR and output air stream temperature.
[0003] 2. Description of the Prior Art
[0004] A variety of continuous dryers have been proposed in the past for drying of agricultural products or processed pellets (e.g., feed pellets). Such dryers include rotary drum dryers, single or multiple-stage conveyor dryers, and staged, vertical, cascade-type dryers. In all such dryers, an initially wet product is contacted with an incoming heated air stream in order to reduce the moisture level of the product; as a consequence, the dryers emit a cooled, moisture-laden output air stream.
[0005] Regardless of the type of dryer selected for a particular application, operators are always interested in maximizing drying efficiency, i.e., obtaining the maximum drying effect per pound of fuel consumed. A variety of control systems have been suggested in the past for this purpose. See, e.g., U.S. Pat. Nos. 1,564,566, 2,448,144, 4,513,759, 5,950,325, 5,347,727 and 6,085,443; Zagorzycki, Automatic Humidity Control of Dryers; Chemical Engineering Progress , April 1983, and Miller, Drying as a Unit Operation in the Processing of Ready-to-Eat Breakfast Cereals:I. Basic Principles and Drying as a Unit Operation in the Processing of Ready-to-Eat Breakfast Cereals:II. Selecting a Dryer; Cereal Foods World, 33:267-277 (1988). However, the problem of maintaining maximum dryer efficiency while controlling product exit moisture, during the course of a dryer run, which commonly may experience upsets, has not heretofore been satisfactorily resolved.
[0006] A known drying parameter is the adiabatic saturation ratio of an air stream, typically the exhaust air stream from a dryer. The ASR is the ratio of air moisture in a given air stream, divided by the saturated air moisture at the same enthalpy. It is usually expressed as a percent, even though referred to as a ratio. An equivalent definition of ASR is the degree of saturation of an air stream when holding enthalpy constant. The humidity ratio for the air stream is divided by the humidity ratio at the intersection of the total enthalpy curve with the saturation curve, using appropriate psychrometric data.
SUMMARY OF THE INVENTION
[0007] The present invention overcomes the problems outlined above and provides greatly improved drying methods and apparatus which are capable of maintaining high dryer efficiency notwithstanding the occurrence of upsets. Broadly speaking, the drying methods of the invention involve provision of a stream of input air having initial temperature and humidity levels, heating such input air stream to a desired temperature and contacting the heated air stream with an initially wet product in a drying zone to give a dried product and an output air stream. Control of the process is obtained by determining the temperature and humidity of the output air stream on a continuous basis, and using such information to maintain the adiabatic saturation ratio and the temperature of the output air stream at predetermined, substantially constant levels during the drying process, notwithstanding changes in one or more dryer parameters such as input air temperature and/or humidity levels, initially wet product moisture level and combinations thereof. In practice, maintenance of the adiabatic saturation ratio involves recycling a first portion of the output air stream back to the input air stream for mixing therewith, and exhausting a second portion of the output air stream to the atmosphere, in response to the determination of output air stream temperature and humidity. Additionally, the control typically involves adjusting the energy input to the dryer; in most cases, such energy input adjustment includes regulation of the temperature of the heated input air stream, but other energy inputs to the dryer, if any, may also be regulated.
[0008] The invention is applicable to virtually all types of convection dryers where a wet product and a heated air stream are contacted for drying purposes. This includes but is not limited to rotary, conveyor, cascade-type, fluid bed and counterflow dryers. To this end, the dryers may incorporate indirect or direct heating of the input air stream; in the latter case, the effects of direct combustion must of course be taken into consideration.
[0009] In preferred practice, the dryer is equipped with an exhaust fan/damper unit which serves to draw output air from the drying zone. The control apparatus is coupled with the damper so as to continually adjust as necessary the relative proportions of the output air stream which are recycled and exhausted to the atmosphere. Alternately, in lieu of an exhaust fan/damper unit, a variable speed exhaust fan can be employed. Conventional programmable logic controllers are used in such preferred systems to regulate dryer operation so as to maintain substantially constant ASR and output air stream temperatures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 is a schematic representation of a preferred dryer in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0011] Turning now to the drawing, a dryer 10 in accordance with the invention broadly includes a dryer body 12 adapted to receive and dry initially wet product, with an input air heater assembly 14 , output air handling assembly 16 and control assembly 18 coupled to the dryer body.
[0012] The dryer body 12 is schematically illustrated in the Figure, and includes a wet product inlet 20 and a dried product outlet 22 , as well as a heated air input line 26 and an air output line 28 . It will be understood that the body 12 can take the form of a wide variety of known dryers, such as rotary drum dryers, single or multiple-stage conveyor dryers or staged, vertical cascade-type dryers such as those disclosed in pending U.S. patent application Ser. No. 09/543,596 filed Apr. 5, 2000, incorporated by reference herein. In each case, the body 12 defines an internal drying zone 30 designed for contacting a heated input air stream and initially wet product.
[0013] The input air heater assembly 14 includes a heater 32 having a fuel inlet line 34 coupled thereto, the latter being controlled by valve 36 . In addition, the assembly 14 includes an ambient air intake 38 and input line 40 for delivering a stream of input air to the heater 32 . The overall assembly further includes a recirculation fan 42 coupled with heater output 43 and line 26 as shown. A temperature sensor 44 is operatively coupled with line 26 . The heater 32 in the embodiment shown is an indirect heater, but if desired a direct heater could be used.
[0014] The output air handling assembly 16 includes an exhaust fan/damper unit 46 made up of a conventional exhaust fan together with a selectively movable damper. The line 28 extends from dryer body 12 to the inlet of the unit 46 , and has temperature and humidity sensors 48 , 50 coupled thereto. Finally, a recycle line 52 is coupled between the lines 28 and 40 for purposes to be explained.
[0015] The control assembly 18 includes a humidity controller 54 with an input line 56 from sensor 50 , and an output line 58 to exhaust fan/damper unit 46 . Also, the assembly has a temperature controller 60 with an input line 62 from sensor 48 and an output line 64 leading to valve 36 . A programmable logic controller 66 is operatively coupled to the controllers 54 and 60 via lines 68 and 70 . Finally, a line 72 extends between temperature sensor 44 and PLC 66 .
[0016] In the use of dryer 10 , a stream of input air having input temperature and humidity levels is generated at intake 38 and passed through input line 40 to heater 32 . At the same time, fuel is directed through inlet line 34 to the heater. Combustion within the heater 32 serves to heat the input air stream to a desired temperature. The fan 42 draws the heated input air stream through lines 43 and 26 in order to deliver such air to dryer 12 . The temperature of the heated input air stream is measured by sensor 44 . Initially wet product is delivered to the dryer via input 20 and, within the drying zone 30 the initially wet product is dried, leaving by way of output 22 . The output air stream from the dryer body 12 is conveyed by means of exhaust fan/damper unit 46 through line 28 , with the temperature and humidity thereof being determined by sensors 48 and 50 . Depending upon the position of the damper within unit 46 (or alternately the speed of the exhaust fan), first and second portions of the output air stream are recycled through line 52 and exhausted to the atmosphere. The recycled output air is mixed with the input air stream and reheated in heater 32 .
[0017] During operation of the dryer 10 as described, the control assembly 18 comes into play in order to maintain the adiabatic saturation ratio (ASR) and the temperature of the output air stream at predetermined, substantially constant levels. This result obtains notwithstanding dryer system upsets such as caused by changes in a parameter selected from the group consisting of the temperature and/or humidity of the input air at intake 38 , the initially wet product moisture level (which can occur by a wetter starting product or an increase in the flow rate of wet product through dryer body 12 ), and combinations thereof. In particular, the control assembly 18 preferably serves to maintain the ASR within the range of about ±2 ASR percentage points (e.g., if the predetermined ASR is 90%, the maintenance should be from about 88% to 92%); more preferably, this range should be about ±0.5 ASR percentage points. In the case of output air temperature, the assembly 18 should maintain the temperature within the range of from about ±10% of the predetermined temperature, more preferably from about ±2%.
[0018] Assuming a constant ASR, T 6 controls the moisture level of the dried product. Thus, an increase in T 6 will lower the dried product moisture and vice-versa. In practice, an operator will initially experimentally determine the value of T 6 that gives the desired product moisture content, and thus T 6 will then become the set point value.
[0019] The control assembly 18 performs these functions by two primary system adjustments, namely an adjustment of the exhaust fan/damper unit 46 to alter the relative proportions of the output air stream which are recycled via line 52 and exhausted to the atmosphere, and adjusting the energy input to the dryer by controlling fuel to the heater 32 using valve 36 . The connection between sensor 44 and PLC 66 is a protective measure; if the sensor 44 detects an unacceptably high or low temperature, the PLC will shut down the entire system or permit the operator to lower the temperature through operation of valve 3 6 .
[0020] For example, if the dryer 10 is operating in steady state conditions and the water content of the product to be dried is lowered (or a lower flow rate of the moist product occurs), the assembly 18 would typically reduce the heat input to the system by adjusting valve 36 , and also adjust exhaust fan/damper unit 46 so as to exhaust to the atmosphere a smaller proportion of the output air stream (which therefore increases the proportion of the output air stream recycled through line 52 ). Such adjustments are carried out until the predetermined ASR and output air stream temperatures are again substantially returned to their predetermined levels. Alternately, if the water content of the incoming product is increased (or a higher flow rate occurs), more heat would be added and a greater proportion of the output air stream would be exhausted to the atmosphere.
[0021] Control of the ASR and output air stream temperature leads to greater dryer efficiencies. Generally speaking, for most dryers the predetermined ASR level should be in the range of from about 80-95%, more preferably from about 88-92%. Of course the output air stream temperature is extremely variable, depending upon the type of product being dried and desired final product moisture levels.
[0022] As explained above, ASR is a description of the extent of saturation of air, and is directly related to overall energy efficiency (a higher ASR means a higher energy efficiency). As the output air is exhausted from the dryer it will lose heat in the ducting. This is an undesirable condition. Therefore, the operator will set the ASR low enough to avoid condensation in the dryer ducting during normal operating conditions, but otherwise as high as possible in order to maximize dryer efficiency. The advantage of using ASR as a primary control variable stems from the fact that dryer efficiency will remain essentially constant as long as the ASR is unchanged, regardless of what other variables may change.
[0023] The following hypothetical examples set forth exemplary dryer operating conditions at steady state and these operating conditions after four different types of system upsets have been accommodated and the dryer is again at steady state. It is to be understood, however, that these examples are provided by way of illustration and nothing therein should be taken as a limitation upon the overall scope of the invention.
EXAMPLE
[0024] The following Table 1 sets forth a series of computer-generated mass and energy balances for a dryer in accordance with the invention and as depicted in FIG. 1. In all of the upset cases 1-5 the mass and energy balances are taken after the control assembly 18 has reacted to the upset and returned the dryer to steady state conditions. In this Example, the ASR is selected as 90%, and the output air stream temperature measured by the sensor 48 (position 6) is 80° C. In FIG. 1, the boxed numerals and letters refer to the discrete positions within the dryer system, whereas the legends T 4 , T 6 and W 6 refer to sensors as described previously.
[0025] In particular, the initial or start case is varied by lowering the moisture content of the incoming product from 0.23 to 0.22 kg H 2 0/kg product (Case 1); the moisture content of the incoming product is raised from 0.23 to 0.24 kg H 2 0/kg product (Case 2); the temperature of the input air stream at intake 38 is elevated from 21° to 35° C. (Case 3); the absolute humidity of the input air stream at intake 38 is elevated from 0.0080 to 0.0170 kg H 2 0/kg air (Case 4); and the moisture content of the incoming product is raised from 0.23 to 0.24 kg H 2 O/kg product, together with elevation of the temperature and absolute humidity of the input air stream at intake 38 to 35° C. and 0.0170 kg H 2 O/kg air, respectively (Case 5).
[0026] As can be seen from Table 1, in each case the control assembly 18 serves to return the dryer to the desired 90% ASR, 80° C. output air stream temperature by appropriate adjustment of the heat input to the system via heater 32 and/or the ratio of exhausted to recycled output air from the dryer body 12 . Thus, in Case 1, the adjustment results in changes in the calculated values for GDP 1 , GDP 2 , GP 2 , CP 1 , GWP 1 , GPW 2 , HP 1 , HP 2 , GD 6 , C 6 , GW 6 , GW 2 , GD 2 , H 6 , H 2 , Q, Eff, GD 2 , W 4 , GD 4 , GD 5 , H 5 , H 4 , T 4 , and V 4 . This stems from the fact that, in returning to the steady state condition with predetermined ASR and output air stream temperatures, less input heat is delivered to heater 32 (position Q) resulting in a lower temperature T 4 (position 4).
[0027] In a similar fashion, the remaining upset cases can be analyzed to ascertain the alterations effected by the control assembly 18 , as set forth in Table 1.
TABLE 1 MASS & ENERGY BALANCES CASE 1 CASE 2 CASE 3 INITIAL less more hotter CASE 4 CASE 5 start water water amb wetter amb combination GIVEN (either outside variables or control variables) GP1 kg/hr 12,000 12,000 12,000 12,000 12,000 12,000 WP1 kg/kg 0.23 0.22 0.24 0.23 0.23 0.24 WP2 kg/kg 0.09 0.09 0.09 0.09 0.09 0.09 TP1 ° C. 80 80 80 80 80 80 TP2 ° C. 75 75 75 75 75 75 T2 ° C. 21 21 21 35 21 35 W2 kg/kg 0.0080 0.0080 0.0080 0.0080 0.0170 0.0170 T6 ° C. 80 80 80 80 80 80 ASR 90% 90% 90% 90% 90% 90% Z4 m/s 0.63 0.63 0.63 0.63 0.63 0.63 AB m 2 52 52 52 52 52 52 C&R kcal/hr 80,000 80,000 80,000 70,000 80,000 70,000 CALCULATED W6 = f(ASR,T6) kg/kg 0.1075 0.1075 0.1075 0.1075 0.1075 0.1075 GDP1 = GP1*(1-WP1) kg/hr 9,240 9,360 9,120 9,240 9,240 9,120 GDP2 = GDP1 kg/hr 9,240 9,360 9,120 9,240 9,240 9,120 GP2 = GDP2/(1-WP2) kg/hr 10,154 10,286 10,022 10,154 10,154 10,022 CP1 = f(WP1) kcal/° C./- 0.846 0.844 0.848 0.846 0.846 0.848 kg CP2 = f(WP2) kcal/° C./- 0.818 0.818 0.818 0.818 0.818 0.818 kg GWP1 = GP1 − GPD1 kg/hr 2,760 2,640 2,880 2,760 2,760 2,880 GPW2 = GP2 − GPD2 kg/hr 914 926 902 914 914 902 HP1 = GP1*CP1*TP1 kcal/hr 812,160 810,240 814,080 812,160 812,160 814,080 HP2 = GP2*CP2*TP2 kcal/hr 622,938 631,029 614,848 622,938 622,938 614,848 C4 = Z4*AB m 3 /s 32.5 32.5 32.5 32.5 32.5 32.5 h2 = 0.241*T2 + W2* kcal/kg 9.85 9.85 9.85 13.27 15 23 18.72 (−589 + 0 45*T2) V2 = f(T2,W2) m 3 /kg 0.830 0.830 0.830 0.881 0 853 0.893 V6 = f(T6,W6) ft 2 /lb 0.999 0.999 0.999 0.999 0.999 0.999 h6 = 0.241*T6 + W6* kcal/kg 86 47 86.47 86.47 86.47 6.47 86.47 (−589 + 0.45*t6) GD6 = (GPW1 − kg/hr 18,554 17,229 19,880 18,554 20,399 21,857 GPW2)/(W6 − W2) CS = V6*GD6/3600 ft 2 /min 5.15 4.78 5.52 5.15 5 66 6.07 GW6 = W6*GD6 kg/hr 1,995 1,852 2,137 1,995 2,193 2,350 GW2 = GW6 + GPW1 − kg/hr 148 138 159 347 148 372 GPW2 GD2 = GD6 kg/hr 18,554 17,229 19,880 16,554 20,399 21,857 H6 = GD6*h6 kcal/hr 1,604,345 1,489,749 1,718,941 1,604,345 1,763,893 1,889,885 H2 = GD2*h2 kcal/hr 182,734 169,682 195,786 246,271 310,779 409,063 Q = HP2 − HP1 + H6 − H2 kcal/hr 1,232,389 1,140,856 1,323,923 1,168,852 1,263,892 1,281,591 Eff = Q/(GPW1 − GPW2) kcal/kg 668 665 669 633 685 648 T5 = T6 ° C. 80 80 80 80 80 80 W5 = W6*GD6 kg/kg 0 1075 0.1075 0.1075 0.1075 0.1075 0.1075 h5 = h6 kcal/kg 86.47 86.47 86.47 86.47 86.47 86.47 W7 = W6*GD6 kg/kg 0.1075 0.1075 0.1075 0.1075 0 1075 0 1075 GD2 = GD6 kg/hr 18,554 17,229 19,880 18,554 20,399 21,857 T7 = T6 ° C. 80 80 80 80 80 80 Assume W4 1 kg/kg 0.0877 0.0892 0.0861 0.0877 0.0877 0.0861 GD4 = (GPW1 − GPW2)/(W5 − kg/hr 93,146 93,677 92,431 93,240 93,240 92,431 W4) GD5 = GD4 kg/hr 93,146 93,677 92,431 93,240 93,240 92,431 H5 = GD5*h5 kcal/hr 8,054,102 8,100,000 7,992,272 8,062,238 8,062,238 7,992,272 H4 = H5 + HP2 − HP1 kcal/hr 7,864,881 7,920,789 7,793,040 7,873,016 7,873,016 7,793,040 T4 = (H4/GD4- ° C. 116.9 113.9 120.1 116.9 116.9 120.1 589*W4)/(0.241 + 0.4 5*W4) V4 = f(T4,W4) m 3 /kg 1.256 1.249 1.264 1.256 1.256 1.264 C4 = V4*GD4/3600 m 3 /s 32.5 32.5 32.5 32.5 32.5 32.5 less heat more heat less heat more heat more heat less exh more exh same exh more exh more exh lower temp higher same same temp higher temp temp temp same eff same eff better eff worse eff worse eff 1 W4 is ascertained by trial and error, until C4 calculated as Z4*AB = C4 calculated as V4*GD4/3600 VARIABLE Description AB Area of product bed [m 2 ] ASR Adiabatic saturation ratio (see explanation below) C Volumetric air flow [m 3 /s] CP Specific heat of product (kcal/° C./kg] C&R Convection & radiation losses (kcal/hr) Eff Energy efficiency (kcal/kg water evaporated) GD Mass flow of dry air [kg/hr] GP Total mass flow of product [kg/hr] GDP Mass flow of bone dry product [kg/hr] GWP Mass flow of water portion of product [kg/hr] GW Mass flow of water vapor in air [kg/hr] h Specific enthalpy of moist air above ° C. [kcal/kg/° C.] H Total enthalpy of moist air above 0° C. [kcal/hr] Q Total heat added to dryer [kcal/hr] T Temperature of air (dry bulb) [° C.] TP Temperature of product [° C.] W Absolute humidity (mass of water vapor per unit mass of dry air) [kg/kg] WP Moisture content of product (wet basis) [kg/kg] V Specific volume of moist air [m 3 /kg] Z Air velocity through bed [m/s]
[0028] [0028] VARIABLE Description AB Area of product bed [m 2 ] ASR Adiabatic saturation ratio (see explanation below) C Volumetric air flow [m 3 /s] CP Specific heat of product (kcal/° C./kg] C&R Convection & radiation losses (kcal/hr) Eff Energy efficiency (kcal/kg water evaporated) GD Mass flow of dry air [kg/hr] GP Total mass flow of product [kg/hr] GDP Mass flow of bone dry product [kg/hr] GWP Mass flow of water portion of product [kg/hr] GW Mass flow of water vapor in air [kg/hr] h Specific enthalpy of moist air above ° C. [kcal/kg/° C.] H Total enthalpy of moist air above 0° C. [kcal/hr] Q Total heat added to dryer [kcal/hr] T Temperature of air (dry bulb) [° C.] TP Temperature of product [° C.] W Absolute humidity (mass of water vapor per unit mass of dry air) [kg/kg] WP Moisture content of product (wet basis) [kg/kg] V Specific volume of moist air [m 3 /kg] Z Air velocity through bed [m/s]
[0029] As indicated, a goal of the invention is to achieve maximum possible dryer efficiency while controlling product exit moisture. In general, this obtains when the predetermined ASR is from about 80-95%, more preferably from about 88-92%. Table 2 below illustrates hypothetical, computer-generated dryer conditions and efficiencies at selected ASR's (88, 90, 92, 94%) and output air stream temperatures T 6 (150-210° C.), where the table symbols are explained in the legend below. A review of Table 2 confirms that as the ASR is increased, the energy efficiency improves. Moreover, when the ASR is held constant, the efficiency (EFF) varies only slightly with large changes in exhaust air stream temperature (T 6 ). Moreover, efficiencies (Eff) vary slightly with exhaust air stream temperatures (T 6 ), but vary more significantly with small ASR changes.
TABLE 2 T6 Ts6 V6 h6 hs6 dew pt T2 GD6 delta GP Q Eff to dew WBD ASR ° F. ° F. W6 ft 3 /lb Btu/lb Btu/lb ° F. ° F. W2 lb/hr lb/hr Btu/hr Btu/hr Btu/hr ° F. 94% 210 153.30 0.23224 23.12 318.97 299.37 151.48 70 0.0078 15,792 3.216 3,956,750 1,230 309,528 57 200 149.70 0.20566 22.07 284.91 268.14 147.85 70 0.0078 17,920 3,216 3,971,186 1,235 300,515 50 190 145.78 0.18060 21.08 252.85 238.60 143.91 70 0.0078 20,527 3,216 3,989,679 1,241 292,517 44 180 141.48 0.15697 20.15 222.64 210.64 139.60 70 0.0078 23,793 3,216 4,013,601 1,248 285,511 39 170 136.77 0.13489 19.27 194.40 184.38 134.89 70 0.0078 27,946 3,216 4,043,853 1,257 280,018 33 160 131.67 0.11467 18.46 168.48 160.19 129.79 70 0.0078 33,261 3,216 4,079,883 1,269 275,736 28 150 126.10 0 09613 17.71 144.64 137.84 124.23 70 0.0078 40,284 3,216 4,124,049 1,282 273,932 24 92% 210 147.55 0.18744 21.92 267.20 246.88 145.07 70 0.0078 19,801 3,216 4,108,510 1,278 402,352 62 200 144.15 0.16764 21.06 241.15 223.48 141.66 70 0.0078 22,261 3,216 4,123,755 1,282 393,361 56 190 140.43 0 14857 20.24 216.13 200.87 137.93 70 0.0078 25,289 3,216 4,144,073 1,289 385,914 50 180 136.37 0.13040 19.46 192.30 179.22 133.87 70 0.0078 29,055 3,216 4,169,937 1,297 380,036 44 170 131.98 0.11340 18.73 169.96 158.86 129.49 70 0 0078 33,756 3,216 4,200,716 1,306 374,695 38 160 127.21 0.09751 18.03 149.04 139.70 124.73 70 0.0078 39,770 3,216 4,237,956 1,318 371,451 33 150 122.03 0.08281 17.38 129.60 121.82 119.55 70 0.0078 47,613 3,216 4,282,192 1,332 370,427 28 90% 210 142.92 0.15761 21.11 232.72 211.80 139.79 70 0.0078 23,828 3,216 4,260,977 1,325 498,481 67 200 139.32 0.14006 20.33 209.41 190.96 136.14 70 0.0078 27,008 3,216 4,290,561 1,334 498,304 61 190 135.96 0.12496 19.63 189.06 172.99 132.59 70 0.0078 30,505 3,216 4,313,198 1,341 490,220 54 180 131.92 0.11059 18.95 169.68 155.69 128.75 70 0.0078 34,792 3,216 4,340,383 1,350 486,738 48 170 127.75 0.09692 18 31 151.21 139.19 124.60 70 0.0078 40,159 3,216 4,373,583 1,360 482,717 42 160 123.25 0 08409 17.70 133.84 123 59 120.10 70 0.0078 46,956 3,216 4,412,475 1,372 481,295 37 150 118.38 0.07213 17.12 117.54 108.90 115.29 70 0.0078 55,744 3,216 4,457,652 1,386 481,625 32 88% 210 138.67 0.13412 16.98 205.58 184.09 134.83 70 0.0078 28,372 3,216 4,433,011 1,378 609,713 71 200 135.48 0.12109 19 93 187.58 168.51 131.64 70 0.0078 31,650 3,216 4,453,682 1,385 603,571 65 190 132.04 0.10854 19.20 170.23 153.43 128.21 70 0.0078 35,614 3,216 4,478,840 1,393 598,314 58 180 128.33 0.09650 18.59 153 59 138.89 124.52 70 0.0078 40,477 3,216 4,509,272 1,402 595,006 52 170 124.35 0.08512 18.01 137.80 125.04 120.54 70 0.0078 46,471 3,216 4,543,981 1,413 592,973 46 160 120.04 0 07431 17.45 122.75 111.79 116.29 70 0.0078 54,076 3,216 4,585,408 1,426 592,673 40 150 115.40 0.06419 16 92 108.59 99.25 111.72 70 0.0078 63,850 3,216 4,632,583 1,440 596,361 35
[0030] [0030] VARIABLE Description ASR Adiabatic saturation ratio delta GP Mass of water evaporated from product [lb/hr] dew pt dew point (temperature of saturated air) [° F.] Eff Energy efficiency (Btu/lb water evaporated) GD Mass flow of dry air [lb/hr] h Specific enthalpy of moist air above 0° F. [Btu/lb/° F.] H Total enthalpy of moist air above 0° F. [Btul/hr] hs Saturation enthalpy of moist air above 0° F. [Btu/lb/° F.] T Temperature of air (dry bulb) [° F.] to dew Energy removed from air to lower it to dew point [Btu/hr] Ts Saturation temperature of air (wet bulb) [° F.] V Specific volume of moist air [lb 3 /lb] W Absolute humidity (mass of water vapor per unit mass of dry air) [lb/lb] WBD Wet Buld Depression (dry bulb-wet bulb) [° F .]
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An improved dryer ( 10 ) and drying methods are provided which increase overall dryer efficiency by maintaining substantially constant output air stream adiabatic saturation ratio and temperature values during the course of drying, notwithstanding the occurrence of upset conditions. The dryer ( 10 ) includes a dryer body ( 12 ), an input air heater assembly ( 14 ) including an air heater ( 32 ), and a control assembly ( 18 ). The dryer body ( 12 ) has a drying zone ( 30 ), with product inputs and outputs ( 20, 22 ) as well as an input ( 26 ) for a heated air stream and an output ( 28 ) for the cooled, moisture-laden output air stream. The dryer control assembly ( 18 ) includes temperature and humidity sensors ( 48, 50 ) coupled to controllers ( 54, 60 ) and a PLC ( 66 ). The controller ( 54 ) is coupled with an exhaust fan/damper unit ( 46 ) while controller ( 60 ) is connected with a fuel valve ( 36 ). In operation, the temperature and humidity of the output air stream are continuously measured by the sensors ( 48, 50 ), and the controllers ( 54, 60, 66 ) are operable to adjust the exhaust fan/damper unit ( 46 ) to regulate the relative proportion of output air exhausted to the atmosphere and recycled via conduit ( 52 ) for mixing with the input air stream, and also regulate the energy input to the dryer. Maintaining a substantially constant output air stream adiabatic saturation ratio and temperature allows dryer operation at significantly higher efficiencies as compared with prior systems.
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This is a continuation-in-part of application Ser. No. 07/691,572, filed Apr. 25. 1991, now U.S. Pat. No. 5,242,633.
FIELD OF THE INVENTION
This invention relates to the production of organic fibers. More particularly, it relates to the production of fine organic fibers by means of a rotary process.
BACKGROUND OF THE INVENTION
There is an increasing demand for organic polymer or thermoplastic fibers of small diameter, often referred to as microfibers, for a variety of uses, such as, for example, in the manufacture of filter media or sorbent material. A preferred method of producing such fibers is by a rotary process whereby molten polymer is fed to a spinning disc containing a myriad of small holes through which the material flows by reason of centrifugal force. The rotary method not only enables large quantities of fiber to be produced at a rapid rate, but permits the physical parameters of the fibers to be more readily controlled.
The specific type of rotary process employed can vary a great deal. As one example, apparatus ms described in U.S. Pat. No. 4,937,020 which utilizes a rotating nozzle head to which molten polymer is introduced under preliminary pressure, and the resulting fibers are additionally drawn by gas streams exiting the nozzle head in the vicinity of the nozzle holes. The nozzle head includes separate passages through which molten polymer and gases flow, each passage including axial and radial components. In addition, heating coils are included for controlling the temperature of the melt at the exit holes. Because the process essentially takes place entirely within the nozzle head, the nozzle head and its various components must be manufactured to extremely demanding tolerances. Thus the cost of the process equipment would tend to be high and the maintenance of the equipment would be difficult.
It would be preferable to utilize a process made up of individual components which are more economical to produce and maintain, yet which enable organic polymer fibers of various parameters to be readily produced at high rates. Further, it would be desirable to be able to produce organic polymer fibers in much the same way as microfibers of glass are produced, to take advantage of proven procedures for manufacturing fibers from molten material at high production rates. Moreover, the equipment employed in the manufacture of glass microfibers is relatively simple in design and is not dependent on self-contained nozzle constructions such as that described in the above-mentioned patent.
Unfortunately, it is not possible to produce satisfactory fibers by simply running molten polymer through rotary fiber glass equipment. A basic reason for this is that the design of equipment used to produce glass microfibers is determined to a large extent by the temperature and physical characteristics of the molten glass. Because the temperature and specific gravity of molten glass are considerably higher than the temperature and specific gravity of molten polymers, the equipment and process parameters used in glass microfiber production cannot be used to produce organic polymer fibers.
It is therefore an object of the invention to provide simplified equipment for the production of organic polymer fibers, utilizing the principles where possible of the basic rotary method of manufacturing glass microfibers.
It will be understood that although the following description refers to the manufacture of fibers primarily from molten organic polymer or thermoplastic resin, the term "organic polymer" is sometimes used to refer to both types of materials. Where appropriate, this term may also be interpreted as including thermosetting resins as well, as explained more fully in the specification.
BRIEF SUMMARY OF THE INVENTION
In accordance with the invention, a fiberizing disc is connected to a shaft mounted for axial rotation, the disc including a bottom wall, a circular sidewall extending upwardly from the bottom wall, and an upper flange extending inwardly from the upper end of the sidewall. Molten organic material is introduced into the rotating disc by means of a nozzle located between the bottom wall, the sidewall and a plane extending through the upper end of the sidewall parallel to the bottom wall. By uniformly heating the interior of the disc to maintain the material in a molten state, the molten material is centrifugally forced through fiberizing holes in the sidewall of the disc. In a preferred arrangement, the nozzle is placed as close to the bottom wall and the sidewall as possible. Generally, this would place the nozzle in the range of about 1/2 inch to 11/2 inches from the bottom wall, and in the range of about 1/2 inch to 3 inches from the sidewall. Preferably, the nozzle is directed generally outwardly at an angle to both the bottom wall and the sidewall, whereby molten material discharged from the nozzle has both downward and sideward components of direction.
This construction, as explained in more detail hereinafter, permits the rapid production of organic fibers by a method generally similar to the proven rotary fiberizing methods of manufacturing glass fibers, even though the material in question is quite different in character from glass.
The basic disc structure and other features of the apparatus may be modified in a number of ways to provide further benefits. A bottom flange may be provided so as to extend from the sidewall beyond the bottom wall, to form with the bottom wall an enclosure which can be used to house insulation material or a bottom heater for assisting to control the temperature within the disc. Instead of the conventional form of disc, an annular disc may be used. With either type of disc design, the disc may be heated by means of induction heating.
An improved gas fired heater is also provided for heating the interior of the disc, wherein a gas burner and inspirating nozzle are located above the disc. Means are provided for introducing a cooling gas, usually ambient air, into the mixing nozzle to reduce the temperature of the discharge from the burner, which prevents or minimizes oxidation and degradation of the polymer or thermoplastic melt.
Means are also provided for altering the normal flow of the stream of fibers exiting from the disc in order to better control the deposition of the fibers. In one arrangement the air ring conventionally supplied for directing compressed air in a downward direction has been modified to permit the air to be selectively directed from various points of the ring. In another arrangement means are provided for outwardly diverting downward movement of fibers exiting from the disc so as to cause the fibers to be more uniformly deposited on a moving collection surface beneath the disc. The diverting means employed may comprise a blast of compressed air or a structure which physically moves the falling fibers from the central portion of the moving collection surface to the side portions.
It is also desirable to heat the molten material in the transfer tube used to deliver the material to the nozzle in order to maintain the temperature of the flowing molten material within a predetermined range for optimum fiberization.
These features as well as other features and aspects of the invention, and the various benefits thereof, will be apparent from the more detailed description of the preferred embodiments which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified side elevation of the apparatus used in producing organic polymer fibers by means of the present invention;
FIG. 2 is an enlarged side elevation of the fiberizing disc, shown partly in section, and associated equipment included within the circle 2 of FIG. 1;
FIG. 2A is a further enlarged view of a portion of the fiberizing disc, illustrating a modified hole arrangement wherein different size holes are used in various patterns;
FIG. 2B is a further enlarged view of a modified burner which may be used instead of the burner shown in FIG. 2;
FIG. 3 is a longitudinal sectional view of a modified form of fiberizing disc;
FIG. 4 is a longitudinal sectional view of another modified form of fiberizing disc;
FIG. 5 is a plan view of a further embodiment of a fiberizing disc;
FIG. 6 s a longitudinal sectional view taken on line 6--6 of FIG. 5;
FIG. 7 is a pictorial view of a modified air ring for use in the process of the invention;
FIG. 8 is a pictorial view of another modified form of air ring;
FIG. 9 is a longitudinal sectional view of the fiberizing disc and conveyor taken through a plane at right angles to the conveyor, showing means for distributing fibers uniformly across the width of the moving conveyor;
FIG. 10 is a side elevation of another means for distributing fibers uniformly across the width of the moving conveyor; and
FIG. 11 is an end elevation of the fiber distributing means of FIG. 10.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a hopper 10 containing polymer granules or powder communicates with extruder 12, enabling the granules to be fed to the extruder where they are melted by means of heaters and conveyed to a rotating screw. Neither the heater nor the screw are shown, since their construction details are not part of the invention. Both items, however, are well known components of extruder systems and are familiar to those knowledgeable in the fiberizing art. A transfer tube 14 connected to the outlet of the extruder 12 receives the flow of melted polymer through a suitable valve 15, such as a high temperature needle valve. A gear pump 16 can be used to provide required back pressure for the extruder and to ensure regulated flow of polymer to the disc. The transfer tube 14 is heated by an electrical resistance heater and monitored using a thermocouple 18 in order to maintain the temperature of the molten polymer within a narrow range, such as within 5° F. of the desired temperature of the flowing polymer. It will be understood that although the details of the transfer tube are not shown, the heated transfer tube will be insulated to prevent the escape of heat, thereby aiding in the control of the polymer temperature. A thermocouple 20 may also be provided to monitor the desired temperature of the polymer as it is flows into the transfer hose nozzle 22.
The nozzle 22 is positioned to deliver molten polymer to disc 24, and a heater 26 is mounted adjacent the disc. The disc is mounted on rotating shaft 28 for movement therewith. An air ring 30 mounted above the rotating disc 24 directs compressed air downwardly so that fibers F exiting from holes 32 in the sidewall of the disc are both attenuated and caused to move in a stream down to the moving conveyor 34. The conveyor is porous, typically in the form of a tightly woven chain, so that a stationary suction box 36 beneath the conveyor causes the fibers to collect on the conveyor. The fibers thus build up to form a layer or mat M of a thickness determined by the rate of movement of the conveyor and the quantity of fibers produced by the rotating disc.
The broad process described thus far is similar in principle to the broad process of producing glass microfibers by the rotary process. Certain specific features of the present invention, however, are quite different from the glass fiber process. As mentioned above, the temperature of molten glass is higher than the temperature of molten polymer. The temperature of molten glass in a rotary process typically is in the range of 1500° F. to 3000° F., while the temperature of molten polymer in the process of the invention typically is in the range of 150° F. to 850° F., depending upon the particular polymer employed. The specific gravity and the viscosity of molten glass are also quite different from those of molten polymer. For example, the specific gravity of molten glass is in the range of 2.2 to 2.7, while the specific gravity of molten polymer used in the invention is typically in the range of 0.9 to 1.9. The ranges of temperature and specific gravity given for molten polymers also apply to thermoplastic and thermosetting resins. Discs of greater diameter than those utilized in glass fiber manufacture can be used since material strength limitations in discs caused by the higher operating temperatures of a glass fiber process no longer apply. Thus, instead of having to use discs ranging in diameter from 12 inches to 24 inches, discs can safely have a diameter in the range of 3 inches to 48 inches, enabling greater throughput and improved fiber quality.
The ability to employ larger discs is a benefit from another aspect. Because of the wide melt range of the various polymers and resins which may be formed into fibers, a wider hole separation may be required than in discs designed to operate with glass. Thus the minimum spacing between the holes 32 of the disc, better shown in FIG. 2, is 0.010 inch to 0.150 inch. As to the hole diameter itself, this may range from 0.003 inch to 0.080 inch. This compares directly with the hole size of discs utilized in the manufacture of glass fibers.
As illustrated in FIG. 2A, the disc 24 may be provided with holes of varying size in order to simultaneously produce fibers of different diameter to reduce size variations or to compensate for the disc sidewall temperature profile. To illustrate, the holes 32 are shown as being relatively small, the holes 33 as being somewhat larger, and the holes 35 as being larger still. Although the various hole sizes have been shown as being the same within each horizontal row, the distribution of hole sizes may obviously be varied within each row in any desired manner in order to produce the desired form or pattern of fiber distribution. Although the modified disc of FIG. 2A is disclosed in connection with the manufacture of organic fibers, it will be appreciated that fiberizing discs containing holes of varying size could also have utility in the manufacture of inorganic fibers.
In the manufacture of glass fibers the specific gravity of molten glass allows it to be delivered to a rotating disc with only minor concern about retaining it in the disc prior to being centrifugally forced through the holes in the disc sidewall. Thus, molten glass is delivered in a stream to a convenient location on the bottom wall of a disc, and it flows relatively smoothly toward the sidewall. Because the specific gravity of molten polymer material is significantly lower, as pointed out above, molten polymer may tend to be randomly distributed against the sidewall 40 and bounce out of the rotating disc. This results from the fact that air currents generated in the process tend to move the molten stream as it is delivered to the disc and the spinning disc itself tends to pull the stream in the direction of rotation. In addition, relatively high viscosity molten polymer does not flow easily toward the sidewall of the disc and at times tends to be flung about in gobs. In order to combat these tendencies of the molten material to behave in a manner contrary to the behavior of molten glass in a rotary fiberization process, it has been found necessary to deliver the material to the disc through the transfer hose delivery nozzle 22. By positioning the nozzle close to the bottom wall and sidewall of the disc, the length of the molten polymer stream and the distance it must be moved toward the sidewall are both reduced. It has been found that the nozzle preferably should be spaced as close to the bottom wall as possible, typically a distance in the range of about 1/2 inch to 11/2 inches, and as close to the sidewall as possible, typically a distance in the range of about 1/2 inch to 3 inches. This minimizes the problems described above. In addition, the nozzle is preferably curved as shown in FIG. 2 so that the stream discharged from the nozzle has both horizontal and vertical components of direction. The molten polymer is thereby further aided in its movement toward the sidewall.
The sidewall and top flange of the disc are also designed to optimally receive molten polymer. As best shown in FIG. 2, a relatively wide top flange 38 is provided to prevent molten polymer from bouncing or splashing out of the disc. The width of the top flange should be about 1/2 inch for a disc having a diameter of 3 inches and about 6 inches for a disc with a diameter of 48 inches, with the width varying accordingly for discs of intermediate diameters. The sidewall 40 is higher than is normal in a glass fiber manufacturing disc, ranging from about 1 inch to 6 inches in height. This is also for the purpose of containing the polymer melt as it is introduced into the rotating disc. As illustrated, the bottom wall 41 is connected to the lowermost edge of the sidewall 40 and is provided with a central opening through which the shaft 28 extends. The disc may be held in place by any suitable means, such as by the nut 43 engaging the threaded end of the shaft. A flat washer 45 typically is provided between the nut 43 and the bottom wall 41 of the disc.
Because the temperature of the molten material is lower than that of molten glass, it is not necessary to provide as much heat to the disc in order to maintain the material in a molten state. One or more gas burners located inside the rotary fiberizing disc, as is done in the manufacture of glass fibers, would tend to provide too much heat and make it difficult to control the temperature. Excessive heat may also degrade the polymer. In accordance with the invention, one or more gas burners are provided outside the disc, the burners being of a design to provide heat at a lower temperature than a conventional gas burner is able to do.
As shown in FIG. 2, a gas pipe 42 is connected to a gas burner nozzle 44, delivering an air/gas combustible mixture in a manner well known in the burner art. The burner nozzle 44 is mounted in a nozzle holder 46 which fixes the position of the burner nozzle and directs the gas flame from the burner nozzle into a mixing nozzle assembly 48. The nozzle holder 46 is attached to the mixing nozzle 48 by spaced straps or struts 50, so that the mixing nozzle is spaced from the nozzle holder 46. An alternate arrangement is shown in FIG. 2B, wherein the burner nozzle 44 is mounted in an outwardly flared nozzle holder 47 which also functions as a mixing nozzle. A series of relatively large openings 49, such as one inch diameter holes, is provided throughout the circumference of the nozzle holder 47. Either arrangement allows ambient air to be inspirated into the mixing nozzle, as indicated by the flow arrows 52, due to the suction developed at the mixing nozzle inlet. The mixing of ambient air with the gas flame results in the discharge of hot air into the disc which is significantly cooler than the original gas flame. The reduced temperature of the air stream provides sufficient heat to maintain the polymer in a molten state without thermal degradation or ignition of the polymer. The temperature within the disc is controlled by regulating the volume and the air/gas ratio of the air/gas mixture delivered to the burner nozzle 44. If desired, in order to further guard against oxidation of the polymer inside the disc, an inert gas may be mixed with, or may wholly replace, the inspirated air entering the mixing nozzles 48 or 47.
Referring now to FIG. 3, wherein like reference numerals to those used in connection with previous drawing figures refer to similar elements, a modified fiberizing disc 54 is comprised of a bottom wall 41 and top flange 38 similar to the bottom wall and top flange of the disc shown in FIG. 2. This disc, however, includes a bottom flange 56 which extends downwardly from the sidewall 40 beneath the bottom wall 41. High temperature insulation 58, such as refractory fiber sold by Manville Corporation under the name "Cerachrome", is attached to the bottom flange 56 in order to insulate the bottom wall 41 to prevent heat loss through the bottom wall. Such an arrangement is not necessary in all cases and would be used only if heat loss from the disc is excessive or if difficulty is encountered in controlling the temperature of the molten polymer in the disc or the temperature profile of the bottom of the disc and the disc sidewall.
If it is found that a top-heating gas burner does not provide sufficiently uniform heating of the disc, even with the use of insulation, it may be decided to heat the bottom of the disc as well. Since this would help achieve a more uniform disc temperature profile, improvement of product quality can be expected. One arrangement for heating the bottom wall of a fiberizing disc is shown in FIG. 4, wherein the rotary shaft 60 is hollow and is connected to the bottom wall 41 by a nut 43 in the manner described in connection with the shaft 28 of FIG. 2. A stationary gas and air delivery pipe 62 extends through the hollow shaft 60 down below the bottom wall 41 to a bottom burner manifold 64. Gas flow is divided by the manifold to one or more gas burner nozzles 66, and the resulting flames impinge on the bottom wall, heating the bottom of the disc. The amount of heat provided can be controlled by regulating the volume and ratio of the air/gas mixture delivered to the burner nozzles 66. In order to prevent fiber accumulation on the burners and manifold a protective shroud 68, which may be mounted by any suitable means, not shown, is provided to enclose the manifold. The size of the shroud is such that it lies inside the stream of fiber directed downward by the blast of air from the air ring 30, and thus does not interfere with the fiber stream. Induction and electric heating can also be used to maintain the proper disc temperature.
Another modified form of fiberizing disc is shown in FIGS. 5 and 6. In this embodiment a rotary shaft 70, which may be hollow to eliminate unnecessary mass, is connected by spokes 72 to an annular disc 74. The disc 74 is comprised of a sidewall 76 containing holes 78, and upper and lower walls 80 and 82, each of which preferably connect with spaced vertically arranged flanges 84 and 86, respectively. As shown in FIG. 6, induction heater 88 is provided to heat the outside of the disc. Since the annular disc requires the application of less heat than for a conventionally shaped disc of the same diameter, only the outside of the disc need be heated. Further, this design permits the polymer to be introduced into the disc by the transfer hose nozzle 22 near the sidewall of the disc, thus requiring only a minimum amount of time for the material to be processed into a fiber. Although the increased diameter allows for more force to be applied to the molten polymer as it is processed into fiber, the disc is lighter in weight than a conventional disc of similar diameter. This embodiment is designed to be used where a large size disc is needed in order to provide increased capacity on a single fiber production unit.
The air ring 30 shown in the drawing described thus far includes nozzles 31 which, as best illustrated in FIG. 2, are connected to the air ring in a fixed direction so as to provide a downwardly directed air blast spaced radially outwardly from the fiberizing disc. Although not illustrated, the air ring could be provided with specially contoured fixed holes instead of the nozzles. In either case, the fiber distribution resulting from this conventional arrangement is thus fixed, as is the size of the resulting mat built up on the moving conveyor beneath the fiberizing disc. In order to have more control over fiber distribution and mat size, the air ring of FIG. 7 can be used instead. This air ring is comprised of individual segments 90, each of which contains a nozzle 92. Each segment is hollow or contains a conduit through which air can flow, and each is rotatably or otherwise adjustably mounted on short connecting rods or shafts 94. An air line 96 may be connected to each segment 90 so as to deliver air under predetermined pressure to each of the segments, and each segment may be rotated relative to the adjacent short shafts 94. In this way each nozzle can be set to a desired angle to control the size of the mat and the fiber distribution in the mat. In addition, the air pressure to each of the nozzles can be regulated to aid in fiber attenuation and distribution.
As shown in FIG. 8, a modified version of the segmented air ring of FIG. 7 comprises longer segments 98, each of which includes a plurality of nozzles 100. Air lines 102 are connected to each segment 98 to supply compressed air to the nozzles 100. Each segment 98 is rotatably mounted on short shafts or rods 94, as in the embodiment of FIG. 7. The same benefits are derived from this design as discussed in connection with the air ring of FIG. 7, except that the design does not allow as much control of individual air nozzles. In many cases, however, the benefits derived from this arrangement are entirely adequate and the more complex air ring of FIG. 7 is not necessary. The use of segmented air rings would also have utility in the manufacture of inorganic fibers by means of a centrifugal spinning process.
In order to produce a fibrous blanket of specific width, thickness and density, it may be necessary to modify the fiber column discharging from the fiberizing disc so that it provides evenly distributed coverage of fiber on the moving collection belt below the disc. During normal operation of the process the fiber column forms a tight distinct column of entangled fibers in the vortex below the fiberizing disc. The vortex is formed as a result of the spinning motion of the disc, the area of low pressure formed below the disc and the vertical stream of air from the air ring. In accordance with the arrangement of FIG. 9, in order to change the direction of the falling fibers the bottom wall 41 of the disc is provided with an opening through which a hollow rotating shaft 104 extends. The tubular shaft 104 is attached to the bottom wall 41 at the opening, as by nut 105, so that the disc 24 rotates with the shaft. Extending axially through the tubular shaft 104 is a smaller diameter stationary hollow shaft 106 which carries a spray nozzle 108 on the lower end. The spray nozzle 108 is a nozzle which is capable of spraying a 360° fan of compressed air at 0° to 90° to the shaft 106 and is readily commercially available. Thus it provides a flow of compressed air generally perpendicular or less to the fiber flow. This action moves the fibers in an outward direction, thereby modifying the shape of the fiber column and eliminating the low pressure area which normally helps to hold the fiber column together.
This is illustrated in FIG. 9 wherein the fibers F forming the column normally produced by the fiberizing disc 24 are outwardly diverted by the horizontal stream of compressed air A issuing from the spray nozzle 108. The new direction taken by the fibers allows the fibers to collect more evenly in the cross-machine direction on the moving collection chain or belt 34 and more accurately establishes the width of the resulting mat M.
Another method of better distributing fibers across the width of the moving collection belt is illustrated in FIGS. 10 and 11. In this arrangement an open-ended sheath or cone 110 is provided beneath the fiberizing disc 24 so that the fiber column or stream F generated by the fiberizing disc 24 is directed down into the cone. Shafts 112 extend from the upstream and downstream sides parallel to the movement of the conveyor 34. The shafts are supported for rotation in bearings 114 carried by hangers 116 supported from above by support structure, not shown. Suitable means are provided for rotating the shafts 112 through a small arc, such as 45° or less in each direction. For purpose of illustration, a spur gear 118 driven by motor 120 engages spur gear 122 mounted on the shaft 112. Operation of the motor in alternate opposite directions causes the shafts 112 to rotate in opposite directions in their bearings, resulting in the cone having a pivoting motion through the designated arc. This is shown better in FIG. 11, where the lateral extent of the pivoting movement of the cone is indicated in broken lines. The lateral extent of the mat M is thereby controlled.
The operation of the apparatus is carried out in a continuous manner, with each component of the apparatus functioning as explained above. It will be appreciated, however, that at the beginning of a production run, it will be necessary to clear the transfer tube 14 of any polymer or thermoplastic resin which may have remained inside from the last use and which have hardened. Referring back to FIG. 1, by heating the tube to a temperature higher than the melting point of the material for a sufficient length of time, and then opening the valve 17 which controls flow of compressed air through the line 19, compressed air is delivered into the tube. The compressed air purges any molten material in the tube, which is indicated by a steady flow of air from the nozzle 22. Of course the shut-off valve 16 would be closed during the purging operation. At the end of a run, the shut-off valve 16 is closed again and the valve 17 opened, allowing air to be delivered to the transfer tube to purge molten material remaining in the hose from the production run.
When forming fibers from thermosetting material, it should be possible to simply supply the material to the disc at the desired temperature directly from the source of heated resin. No extruder would be necessary.
It is known that organic fibers produced from polymer or thermoplastic and thermosetting resins are comprised of a blend of crystalline and amorphous structures, and that organic fibers made by a rotary process normally possess a greater amount of the crystalline phase than the amorphous phase. It has been found, however, that the fibers produced by the process of the invention are more amorphous than crystalline. It is believed that this is caused by the rapid cooling of the hot fibers experienced when they are contacted almost immediately after exiting the fiberizing disc by the stream of cooling and attenuating air from the air ring, thus precluding the extensive formation of crystals. The cooling is so rapid that molten fibers which exit the fiberizing disc at elevated temperatures in the ranges discussed and which are contacted a fraction of a second later by ambient air from the air ring can be grasped by an operator as they are falling at a point only one or two feet from the disc without injury or discomfort. X-ray diffraction of polypropylene fibers formed by the method of the invention has shown that the amorphous structure of the fibers is substantially greater than the crystalline structure, with the amount of the amorphous phase typically being at least 60% to 70% of the total fiber structure. This is of practical significance in view of the fact that the amorphous phase has a higher solubility than the crystalline phase, thus making the fibers of the invention more biodegradable.
It will now be appreciated that the apparatus described is designed to enable a rotary fiberizing process of the type used in the manufacture of glass fibers to be employed in the production of organic polymer and resin materials. The equipment can readily be commercially obtained or fabricated in accordance with known design criteria for the manufacture of fibers by the rotary or centrifugal spinning process.
It should also be apparent that the invention is not necessarily limited to all the specific details described in connection with the preferred embodiments, but that changes to certain features of the preferred embodiments which do not alter the overall basic function and concept of the invention may be made without departing from the spirit and scope of the invention, as defined in the claims.
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Apparatus for producing organic fibers by means of a centrifugal spinning process. The fiberizing disc and the molten material introduction nozzle are designed to prevent the molten material from escaping the disc prior to being fiberized. The heater for heating the material in the disc is designed to accommodate the lower melt temperature of the material to be fiberized. Also, means are provided for diverting the flow of fibers from the disc to cause the fibers to be more precisely or uniformly deposited. The fibers are substantially immediately cooled upon exiting the fiberizing disc, resulting in a fiber structure that is at least about 60% amorphous.
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BACKGROUND
Field of the Invention
This invention relates to a device for diagnosing disease and use thereof.
Background of the Invention
Many animals have heightened senses relative to humans. In fact, humans have used the relatively enhanced ability to see, hear, and smell of animals to perform tasks for hundreds of years. In particular, dogs have been used for their enhanced sense of smell to assist in tasks that include hunting, protecting livestock from predators, searching for specific humans, and detecting illegal substances. More recently, evidence has been reported that dogs have predicted seizures before they happened and identified cancer. Other organisms, including rats, mice, and insects show behavior that suggests they can identify a diseased organism.
It is unclear what substances animals smell when they identify disease. Furthermore, studies show that a variety of biological substances collected from a diseased human emit substances that animals distinguish from those of healthy humans. Reports of animals identifying disease include those in which the animal evaluated feces, urine, blood, and exhaled breath. Each of these biological substances emit volatile organic compounds (VOCs). It is likely that the biological samples the animals identify as those from a diseased human emit a plurality of different VOCs. It may be this combination that the animal perceives as the scent of disease. By smelling the combination of molecules that collectively identify disease, the animal may be able to diagnose with more sensitivity and specificity than available laboratory assays. Part of the reason the animal's sense of smell may be a more accurate diagnostic tool may be that laboratory assays often detect a single molecule. In contrast, an accurate diagnosis may best be obtained by detecting the simultaneous presence of multiple VOCs.
BRIEF SUMMARY OF THE INVENTION
Some diseases do not present with symptoms until the disease has done significant damage. Consequently, these diseases often go undiagnosed until later in the disease process. In addition, there is no reliable diagnostic test for some diseases. A diagnostic medical device and method of its use is needed that is convenient to use, even at home. In particular, such a device is needed for diseases that do not have a reliable diagnostic test available.
As an answer to these problems, we disclose a medical toilet that includes a scent dispenser. The scent dispenser may be positioned on a side of the medical toilet and is in communication with the toilet bowl within the medical toilet. The scent dispenser comprises a conduit through which air from within the toilet bowl may travel to the environment outside the medical toilet. When bodily waste from the user is deposited into the toilet bowl, the bodily waste emits volatile organic compounds (VOCs). Mechanisms within the medical toilet direct the air within the toilet bowl toward and through the scent dispenser. An animal is positioned outside the medical toilet in the vicinity of the scent dispenser. According to the invention, the animal has been trained to differentiate the scent of VOCs that emit from bodily waste that was collected from a user with a defined disease from that collected from a user that is not afflicted with the defined disease. The animal performs an act which signals to an observer that the animal has perceived the scent of VOCs associated with the disease. In doing so, the user receives a diagnosis that indicates that the user may require additional health care.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a medical toilet with an embodiment of the scent dispenser.
FIG. 2 is a flow chart illustrating a method of using the medical toilet of FIG. 1 comprising a trained animal.
FIG. 3A is a schematic drawing of an embodiment of the medical toilet.
FIG. 3B is a schematic drawing of an embodiment of the medical toilet.
FIG. 3C is a schematic drawing of an embodiment of the medical toilet.
FIG. 4 is a schematic drawing of an embodiment of a scent dispenser and blower.
FIG. 5A is a perspective view of an embodiment of the scent dispenser.
FIG. 5B is a schematic drawing of a side view of the embodiment of the scent dispenser of FIG. 5A on an embodiment of the medical toilet.
FIG. 5C is a side view of an embodiment of the scent dispenser.
FIG. 6A is a canister containing insects, the canister being a part of an embodiment of the scent dispenser in accordance with an embodiment of the invention.
FIG. 6B is a perspective view of a medical toilet with the canister of FIG. 6A mounted on the toilet.
FIG. 7 is a flow chart illustrating a method of using the medical toilet of FIG. 6B with the canister of FIG. 6A mounted on it.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
Toilet, as used herein, means a device that may be used to collect one or more biological waste products of a user.
User, as used herein, means a human or animal that deposits bodily waste into an embodiment of the toilet disclosed herein.
Bodily waste, as used herein, means any one or combination of urine, feces, vomit, sputum, blood, seminal fluid, tears, nasal mucus, gastrointestinal tract mucus, urogenital tract mucus, saliva, exhaled breath, or sweat from the body of a user.
Animal, as used herein, means non-human members of kingdom Animalia, including vertebrates, invertebrates, insects, and marine organisms.
Disease, as used herein, means any disorder of structure or function in the body or a human or animal, whether or not the disorder presents with signs or symptoms. As used herein, the term disease includes non-infectious disorders and disorders caused by physical injury.
Diseases that may be diagnosed according to the methods disclosed herein and using the medical toilet disclosed herein include, but are not limited to, colon adenoma, colon carcinoma, colon adenocarcinoma, colorectal adenoma, colorectal carcinoma, colorectal adenocarcinoma, bladder carcinoma, bladder adenocarcinoma, liver adenoma, liver carcinoma, liver adenocarcinoma, esophageal adenoma, esophageal carcinoma, esophageal adenocarcinoma, stomach adenoma, stomach carcinoma, stomach adenocarcinoma, pancreatic adenoma, pancreatic carcinoma, pancreatic adenocarcinoma, lung cancer, mouth cancer, throat cancer, inflammatory bowel disease, urinary tract infection, gastric ulcer, diabetes, hyperglycemia, hypoglycemia, impending seizure, and impending migraine.
While this invention is susceptible of embodiment in many different forms, there are shown in the drawings, which will herein be described in detail, several specific embodiments with the understanding that the present disclosure is to be considered as an exemplification of the principals of the invention and is not intended to limit the invention to the illustrated embodiments.
Disclosed herein is a medical toilet, which comprises a medical device used to diagnose disease in a user. The toilet differs from those used simply to collect and dispose of urine and feces at least because it includes a scent dispenser. The scent dispenser acts as a conduit through which volatile organic compounds (VOCs) may travel from the environment inside of the toilet, for example, the toilet bowl, to the environment outside the toilet, for example, the room air.
In some embodiments, the medical toilet comprises a blower which functions to move air surrounding the bodily waste that a user has deposited into the medical toilet, along with the VOCs contained therein, toward the scent dispenser. The blower may comprise a fan, air pump, or other device known in the art which may move air in a defined direction. In some embodiments, the blower is positioned within the toilet bowl approximately opposite the toilet bowl from the scent dispenser. This configuration results in the blower creating an air current that moves air within the toilet bowl from a point approximately opposite the scent dispenser, over and around the biological waste which is positioned between the blower and the scent dispenser, and through the scent dispenser into the environment outside of the medical toilet.
In another embodiment, the blower is located on the same side of the toilet bowl as the scent dispenser. Rather than create positive pressure to push air away from the blower and toward the scent dispenser, the blower of this embodiment creates negative pressure and pulls or sucks air toward the scent dispenser. Thus, the air surrounding the biological waste that within the toilet bowl, along with the VOCs contained therein, is pulled toward the scent dispenser. The air and VOCs then travel through the scent dispenser and into the environment outside the toilet.
Some embodiments may comprise a length of tubing in connection with the scent dispenser. A user may exhale into a first end of the tubing, thus transferring the user's breath to the scent dispenser.
The scent dispenser may comprise of an opening on the side of the medical toilet. FIG. 1 illustrates an embodiment in which the medical toilet 100 appears much like a traditional toilet with a seat 120 , lid 125 , and tank 105 . However, FIG. 1 further illustrates an embodiment of a scent dispenser on toilet 100 which comprises a frame 110 surrounding a screen 115 . Frame 110 may be constructed of a variety of materials including, but not limited to, one or more of metal, porcelain, rubber or rubberized materials, plastics that comprise of any of a variety of polymers and copolymers known in the art, glass, silicone, and ceramic. Frame 110 may be constructed of any of a variety of materials that are water resistant so as to not be damaged by exposure to toilet water. Frame 110 may include a gasket constructed of one or more of rubber, rubberized material, plastics that comprise of any of a variety of polymers and copolymers known in the art, or other materials known to prevent liquid leakage.
Frame 110 surrounds screen 115 which may be constructed of a porous material through which air and accompanying VOCs may travel. Screen 115 may be constructed from one or more of metal, rubber or rubberized materials, plastics that comprise of any of a variety of polymers and copolymers known in the art, and filter paper.
For use in diagnosis of disease, an animal is positioned near the toilet and a user deposits bodily waste into the toilet bowl. The blower is activated through mechanisms known in the art which include the use of motion sensors which would cause a signal to be transmitted to the blower when biological waste passes by the sensor. Alternatively, the user, or possibly even the animal, may turn the blower on or off by pressing a button or flipping a switch.
The user deposits bodily waste into the toilet through actions which include urinating or defecating into the toilet, vomiting into the toilet, coughing up sputum into the toilet, and depositing mucus into the toilet. A user may deposit nasal mucus and sputum into the toilet by coughing or blowing the user's nose into a tissue and tossing the tissue into the toilet.
An animal may be trained to sniff the scent dispenser in response to a command or signal which the user gives the animal when the user desires the animal to assess the presence of disease in the user. Alternatively, the animal may simply be trained that the scent dispense is something that the animal should sniff and do so when placed in the proximity of the toilet. Furthermore, the animal may be an insect that is placed in a container. The container may be attached to or placed in the vicinity of the scent dispenser avoiding any need to train the animal to approach the scent dispenser.
The animal must also be trained to identify a disease by the smell of bodily waste collected from a user who has that disease and to differentiate this from scents emitted by bodily waste collected from users who do not have the disease. Furthermore, the animal must be trained to perform a behavior that functions as a signal to the user that the animal has detected the scent of disease in the user's bodily waste. Methods of training an animal to identify a sample of bodily waste that was obtained from a diseased organism as well as methods to train the animal to provide a signal to communicate upon perceiving a particular scent are known in the art and within the scope of the methods disclosed herein.
FIG. 2 is a flow chart that illustrates an embodiment of a method of using the medical toilet disclosed herein. In this embodiment, the animal is first trained to identify bodily waste collected from a user and differentiate whether the user is afflicted with a particular disease or not. The animal is trained to perform a defined act upon perceiving the scent associated with the disease. Next the animal is trained to sniff the scent dispenser on command. The animal is now ready to participate in diagnosis of a user. Not that in some embodiments, the step of, training to sniff the scent dispenser on command may not be necessary. The animal is then brought to the medical toilet and a user's bodily waste is deposited into the toilet. The animal is given the command to sniff the scent dispenser after which the animal may perform the defined act that indicates the animal's perception of the scent associated with the disease. If the animal does not perceive the scent associated with the disease, it will not perform the defined act. Finally, the animal's response may be reported to a health care provider.
FIG. 3A illustrates one embodiment of the medical toilet, a scent dispenser, and its use with an animal. In this embodiment, the animal is a dog, although the animal may be another species. Toilet bowl 350 is drawn schematically as a rectangle. Bodily waste sample 310 is schematically represented by an elliptical shape. Bodily waste sample 310 is positioned between blower 315 and scent dispenser 305 . When blower 315 is actuated, air moves from blower 315 toward scent dispenser 305 as indicated by the solid arrows. This arrangement results in VOCs 325 emitted from biological waste sample 310 being driven, along with the air, toward scent dispenser 305 . VOCs 325 travel through scent dispenser 305 to the environment outside the toilet. There, animal 320 may perceive the scent of VOCs 325 .
FIG. 3B illustrates another embodiment of the medical toilet, scent dispenser 305 , and its use with animal 320 . In this embodiment, the medical toilet comprises receptacle 340 . While receptacle 340 is illustrated as a cup, it may contain solid material such as feces. In one embodiment, receptacle 340 contain toilet water or another solvent to at least partially dissolve solid waste and release VOCs 325 from within the solid mass. As with the embodiment of FIG. 3A , blower 315 moves air in the direction illustrated by the solid arrows, over the top of receptacle 340 , and through scent dispenser 305 . Animal 320 then sniffs VOCs 325 to determine if they contain the disease scent.
FIG. 3C illustrates another embodiment of the medical toilet, scent dispenser 305 , and its use with animal 320 . In this embodiment, the medical toilet comprises J-tube 330 . J-tube 330 is bent with a lower end and an upper end. In this embodiment, the lower end of J-tube 330 is positioned below the surface of toilet water 335 . The upper end of J-tube 330 is positioned above the surface of toilet water 335 . Bodily waste is deposited into toilet bowl 350 and some or all of the bodily waste is dissolved in toilet water 335 . At least some of the dissolved bodily waste enters the lower end of J-tube 330 . Through capillary action, the dissolved bodily waste moves through the bottom of J-tube 330 and up through the upper end of J-tube 330 . The fluid movement occurs according to the following capillary action formula:
h =(2γθ)/(μ gr )
where h is the height the bodily waste solution moves up the upper end of J-tube 330 , γ is the liquid-air surface tension (force/unit length), θ is the contact angle, ρ is the density of the liquid (mass/volume), g is the local acceleration due to gravity (length/divided by the square of time), and r is the radius of J-tube 330 .
The diameter of J-tube 330 may be within the range that, according to the capillary action formula, that brings the bodily waste solution to a level that allows VOCs 325 to be drawn out by the air current generated by blower 315 and moved toward scent dispenser 305 . Once VOCs 325 travel through scent dispense 305 , animal 320 may perceive their scent.
FIG. 4 illustrates an embodiment of the medical toilet that comprises blower 405 . In contrast to blower 315 of FIGS. 3A, 3B, and 3C , blower 405 is positioned within toilet bowl 350 adjacent scent dispenser 305 . More specifically, blower 405 is positioned between scent dispenser 305 and VOCs 325 that have been emitted from bodily waste. In contrast to blower 315 , blower 405 creates negative pressure. Consequently, blower 405 pulls air toward scent dispenser 305 instead of pushing air.
FIG. 5A illustrates an embodiment of a scent dispenser. Sniff dispenser 500 comprises a porous material 505 surrounded by frame 510 . Porous material 505 may comprise of a screen with holes of a size that allow VOCs to escape from behind screen 505 but protect blotting sheet 515 from damage that might occur, for example, from the animal's nose touching blotting sheet 515 .
Frame 510 surrounds the perimeter of porous material 505 and may be constructed from metal, porcelain, rubber or rubberized materials, plastics that comprise of any of a variety of polymers and copolymers known in the art, glass, silicone, and ceramic. Frame 510 may be constructed of any of a variety of materials that are water resistant so as to not be damaged by exposure to toilet water. Frame 510 may include a gasket constructed of one or more of rubber, rubberized material, plastics that comprise of any of a variety of polymers and copolymers known in the art, or other materials known to prevent liquid leakage.
FIG. 5A further illustrates blotting sheet 515 . Frame 520 surrounds the perimeter of blotting sheet 515 . Blotting sheet 515 may comprise of any absorbent material, including but not limited to, paper, cotton, polyester, hemp, bamboo, modal fabric, and polyamide. As one of skill in the art will readily understand, any material that absorbs liquid and allows VOCs to escape from the material may be used to manufacture blotting sheet 515 .
Frame 510 may be constructed to receive and hold frame 520 , frame 520 being in combination with blotting sheet 515 , such that blotting sheet 515 is positioned behind porous material 505 . In one embodiment, frames 510 and 520 are constructed so that frame 520 is a cassette that slides laterally to a position within frame 510 fits within frame 510 . FIG. 5B provides a side view of frame 520 positioned within frame 510 in an embodiment of a medical toilet in accordance with the disclosed invention.
Blotting sheet 515 may be positioned within the medical toilet, such that toilet water or other solvent comes in physical contact with at least a part of blotting sheet 515 when a user has deposited bodily waste into the toilet. Alternatively, blotting sheet 515 may be positioned such that liquid bodily waste comes directly in physical contact with blotting sheet 515 without being diluted by solvent. For example, the user's urine stream may come in contact with blotting sheet 515 .
In either scenario, blotting sheet 515 wicks the solution or liquid bodily waste so that it is spread across blotting sheet 515 . VOCs evaporate into the environment outside the toilet, traveling through porous material 505 . The animal is then able to smell the VOCs to assess them for the disease scent.
FIG. 5B illustrates yet another embodiment of the invention which incorporates the scent dispenser of FIG. 5A . In addition, the embodiment of FIG. 5B comprises a receptacle 525 which is in connection with pipe 530 . Similar to receptacle 340 of FIG. 3B , receptacle 525 is positioned to receive bodily waste which the user deposits through the hole in seat 120 . Receptacle 525 may be above or below the surface of the toilet water. In embodiments in which receptacle 525 is positioned below the surface of the toilet water, bodily waste, including solid waste, may be dissolved by the toilet water. Alternatively, other solvents may be present in receptacle 525 which may dissolve solid waste.
The bodily waste, which may or may not be dissolved in a solvent, travels through pipe 530 toward the scent dispenser. Blotting sheet 515 extends from frame 520 such that it is in contact with the interior of the end of pipe 530 . The liquid bodily waste or bodily waste solution is wicked up into and throughout blotting sheet 515 . VOCs evaporate from blotting sheet 515 , travel through porous material 505 , and into the environment outside of the medical toilet. The animal is then able to smell the VOCs to assess them for the disease scent.
FIG. 5C is another embodiment of a scent dispenser according to the disclosed invention. Concentrator 540 is a cone-shaped embodiment of a scent dispenser which funnels VOCs 325 into a smaller space. VOCs 325 emerge from the smaller end of concentrator 325 . VOCs 325 move in the direction of the solid arrows shown in FIG. 5C . The volume of room air occupied by the VOCs 325 is smaller so the animal receives a more concentrated gas stream. One or more of the blowers disclosed herein may be used to provide force to move VOCs 325 through concentrator 540 .
While FIGS. 3A, 3B, and 3C illustrate a dog, FIG. 6A illustrates an embodiment in which insects 615 identify the scent associated with bodily waste collected from a diseased user. FIG. 6A illustrates container 605 which may be a canister or other enclosure that will contain live insects. One end of container 605 includes attachment device 610 which functions similar to frame 510 of FIG. 5A . Attachment device 610 may include a porous material that covers the end of container 605 and allows VOCs 325 to enter container 605 . Insects 615 smell VOCs 325 as they enter container 605 . Like the embodiment in which the animal comprises a dog, insects 615 have been trained to differentiate between the scent of bodily waste from a user that is afflicted with a defined disease from bodily waste from a user that is not afflicted with the disease. Also, insects 615 respond by performing a defined act that signals to an observer when insects 615 have perceived the scent associated with the disease.
FIG. 6B illustrates the container 605 of FIG. 6A as it appears when attached to toilet 620 which is an embodiment of the medical toilet disclosed herein. Similar to other embodiments of the scent dispenser, container 605 attaches to toilet 620 on a side of toilet 620 . Container 605 is in communication with the toilet bowl of toilet 620 .
FIG. 7 is a flow chart that illustrates an embodiment of a method in which container 605 and insects 615 may be used in accordance with the disclosed invention. Insects 605 may be trained to perform a defined act when they are exposed to the scent of bodily waste that was collected from a user afflicted with a defined disease. The defined act may comprise of one or more of vibrating, extending a proboscis, increased movement, emitting a sound whether or not the sound is audible by the human ear. One of skill in the art will understand that other insect behaviors may indicate perception of the disease scent by insects 615 .
While specific embodiments have been illustrated and described above, it is to be understood that the disclosure provided is not limited to the precise configuration, steps, and components disclosed. Various modifications, changes, and variations apparent to those of skill in the art may be made in the arrangement, operation, and details of the methods and systems disclosed, with the aid of the present disclosure.
Without further elaboration, it is believed that one skilled in the art can use the preceding description to utilize the present disclosure to its fullest extent. The examples and embodiments disclosed herein are to be construed as merely illustrative and exemplary and not a limitation of the scope of the present disclosure in any way. It will be apparent to those having skill in the art that changes may be made to the details of the above-described embodiments without departing from the underlying principles of the disclosure herein.
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Many diseases are difficult to diagnose or present with no symptoms that would suggest that medical diagnosis is needed until significant bodily damage has occurred. We disclose a medical toilet that may be used to diagnose disease. The toilet comprises a conduit through which volatile organic compounds travel from the toilet bowl to the environment outside the toilet. The invention includes methods that comprise the steps of training an animal to identify the scent of bodily waste collected from a user that is afflicted with a defined disease. A user's bodily waste is deposited into the medical toilet and the animal is then exposed to the volatile organic compounds traveling through the conduit on the medical toilet. The animal performs an act that signals that the animal has perceived the smell associated with the disease. Thus, we disclose a novel device for diagnosing disease and methods of user thereof.
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RELATED APPLICATIONS
This application claims priority to provisional patent application U.S. Ser. No. 61/513,055 filed Jul. 29, 2011, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to hydrocracking or hydroprocessing systems and processes that employ ebullated-bed reactors.
2. Description of Related Art
Common objectives of hydrocracking or hydroprocessing operations are to remove impurities such as sulfur, nitrogen and/or metals, particularly in residue feedstocks, and cracking the heavy feed into lower molecular weight hydrocarbons having lower boiling points to obtain transportation fuels such as gasoline and diesel. The reactions that occur in hydrocracking/hydroprocessing operations include hydrodesulfurization (HDS), carbon residue reduction (CRR), nitrogen removal (HDN), and cracking.
In a refinery, it is desirable to minimize the down-time for replacement or regeneration of catalyst. Further, process economics generally require a versatile system capable of handling feed streams of varying contaminants levels such as sulfur, nitrogen, metals and/or organometallic compounds, such as those found in a vacuum gas oils, deasphalted oils and residues.
There are three common reactor types used in the refining industry: fixed, ebullated, and moving bed. The decision to utilize a particular type of reactor is based on a number of criteria including the characteristics of the feedstock, desired conversion percentage, flexibility, run length, and requisite product quality.
The ebullated-bed reactor was developed to overcome plugging problems commonly associated with fixed-bed reactors during processing of relatively heavy feedstocks and as the conversion requirements increases, e.g., for vacuum residue. In an ebullated-bed reactor, the catalyst is in an expanded bed, thereby countering plugging problems associated with fixed-bed reactors. The fluidized nature of the catalyst in an ebullated-bed reactor also allows for on-line catalyst replacement of a small portion of the bed. This results in a high net bed activity which does not vary with time.
Fixed-bed technologies have considerable problems in treating particularly heavy charges containing relatively high quantity of heteroatoms, metals and asphaltenes, as these contaminants cause the rapid deactivation of the catalyst and plugging of the reactor. Multiple fixed-bed reactors connected in series can be used to achieve a relatively high conversion of heavy feedstocks boiling above 370° C., but such designs require high capital investment and, for certain feedstocks, commercially impractical, e.g. catalysts replacement every 3-4 months.
Therefore, to treat these heavy charges, ebullated-bed reactors were developed and are in operation worldwide. These reactors have numerous advantages in performance and efficiency, particularly with heavy crudes. Early ebullated-bed processes and systems are described by Johanson in U.S. Pat. Nos. 2,987,465 and 3,197,288, both of which are incorporated herein by reference.
In general, an ebullated-bed reactor includes concurrently flowing streams of liquids, solids and gas through a vertically-oriented cylindrical vessel containing catalyst. The catalyst is placed in motion in the liquid and has a gross volume dispersed through the liquid medium that is greater than the volume of the catalyst mass when stationary. Ebullated-bed reactors are incorporated in various refinery operations, including processes for the upgrading of heavy liquid hydrocarbons and the conversion of coal to synthetic oils.
Typically, a liquid hydrocarbon phase and a gaseous hydrogen phase are passed upwardly through the bed of catalyst particles at a rate such that the particles are forced into motion as the fluids pass upwardly through the bed. The catalyst bed expansion level is, at least in part, determined by the bottoms recycle liquid flow rate, which is controlled by an ebullating-bed pump. During steady-state operation (i.e., the ebullated-bed state), the bulk of the catalyst does not rise above a certain level in the reactor which is predetermined during reactor design. This level is established to prevent the catalyst particles from leaving the reactor or to interfere with the efficient operation of the cyclones that are installed inside the reactors to separate carried-over catalyst particles from the gas-liquid mixture. More catalyst can be loaded into the reactor initially because of no gas hold-up and liquid viscosity. These design criteria are well within the routine skill in the art. A substantial portion of the product vapors and liquids pass through the upper level of the catalyst particles into a substantially catalyst-free zone and are removed proximate to the upper portion of the reactor.
Substantial amounts of hydrogen gas and light hydrocarbon vapors rise through the reaction zone into the catalyst-free zone. Liquid is recycled to the bottom of the reactor and removed from the reactor as net product from this catalyst-free zone. A certain portion of the vapor is separated from the liquid recycle stream before being passed through the recycle conduit drawn by suction of ebullating pump. However, gases or vapors present in the bottoms recycle stream materially decrease the capacity of the recycle pump. The presence of vapors also reduces the liquid residence time in the reactor and limit hydrogen partial pressure.
Certain reactors employed in the catalytic hydrocracking process with an ebullated-bed of catalyst particles are designed with a central vertical recycle conduit which serves as the downflow conduit, or downcomer, for recycling liquid from the catalyst-free zone above the ebullated catalyst bed to the suction of a recycle pump to re-circulate the liquid through the catalytic reaction zone.
FIG. 1 schematically illustrates a system and apparatus 100 of the prior art in which liquid is recycled internally with a recycle downflow conduit. Apparatus 100 includes an ebullated-bed reactor 160 and an ebullating pump 164 . Ebullated-bed reactor 160 includes an inlet 130 for receiving a mixture of hydrogen gas and feedstock and an outlet 166 for discharging product effluent. Ebullating pump 164 is in fluid communication with the ebullated-bed reactor 160 and includes an inlet 162 for receiving effluent recycled from ebullated-bed reactor 160 and an outlet 163 for discharging the recycled effluent at an increased pressure.
In the practice of system 100 , a mixture of hydrogen gas and feedstock is introduced into the ebullated-bed reactor 160 via inlet 130 for reaction that includes conversion of the feedstock into lower molecular weight hydrocarbons. Liquid reaction effluent continuously flows down in the downflow conduit located inside ebullated-bed reactor 160 , and is recycled back to the ebullated-bed reactor 160 at elevated pressure using ebullating pump 164 . Product effluent is recovered via outlet 166 .
Alternatively, the recycle liquid can be obtained from a vapor separator located downstream of the reactor or obtained from an atmospheric stripper bottoms stream. The recycling of liquid serves to ebullate and stabilize the catalyst bed, and maintain temperature uniformity through the reactor.
FIG. 2 schematically illustrates a system and apparatus 200 with an external recycle system that includes an ebullated-bed reactor 260 , an ebullating pump 264 and a high-pressure separator 280 . Ebullated-bed reactor 260 includes an inlet 230 for introducing a mixture of hydrogen gas and feedstock and an outlet 266 for discharging product effluent. High-pressure separator 280 includes an inlet in fluid communication with outlet 266 for receiving product effluent, an outlet 282 for discharging a gas product stream and an outlet 284 for discharging a liquid stream. Ebullating pump 264 includes an inlet 262 in fluid communication with outlet of high-pressure separator for receiving at least a portion of the liquid stream, and an outlet 263 for discharging recycling stream at elevated pressure.
In the practice of system 200 , a mixture of hydrogen gas and feedstock is introduced into the ebullated-bed reactor 260 via inlet 230 for reaction which includes the conversion of the feedstock into lower molecular weight hydrocarbons. Reaction effluent is conveyed to the high-pressure separator 280 to obtain a gas stream 282 and a liquid stream 284 . At least a portion of the liquid stream 284 is recycled as stream 288 to the ebullated-bed reactor 260 via ebullating pump 264 . The remaining portion of the stream 284 can be recovered as product stream 286 or subjected to further refinery processes.
Catalyst bed expansion is an important factor in the ebullated-bed reactor. In the process, the expansion of the bed is controlled by the recycle pump speed. Certain systems include a bed characterized by a number of bed level detectors and one or more additional detectors for determining abnormally high bed (interface) level. The interface level is detected, for instance, by a density detector including a radiation source at an interior point within the reactor and/or a detection source in the reactor wall.
Although ebullated-bed processes are generally used for conversion of heavier vacuum residue feedstocks, they can also be used to clean or treat a lower boiling point vacuum gas oil feedstock. Advantages of ebullated-bed processes include product quality and rate uniformity, reduced downtime and lower capital investment.
The volume and length-to-diameter ratio are known to be factors in ebullated-bed reactor design that impact the catalyst load. For a given volume reactor, the greater the length-to-diameter ratio, the more catalyst that can be introduced into the reactor.
Gas and liquid hold-up rates are important process characteristics that contribute to the system performance. High gas hold-up rates result in decreased liquid residence time which lowers process performance. The gas hold-up rate in an ebullated-bed reactor can be as high as 40%.
Although there are numerous types of ebullated-bed reactor designs, the problems exists of providing a more efficient and effective ebullated-bed reactor process and achieving improved reactor performance that eliminates or minimizes gas hold-up in the recycle system and its adverse effect on the recycle pump.
SUMMARY OF THE INVENTION
The above problems are addressed and further advantages are provided by the system and process for processing feedstocks in an ebullated-bed hydroprocessing reactor in which hydrogen gas is dissolved in the combined fresh and recycled liquid feedstock by mixing and/or diffusion upstream of the reactor inlet, flashing the mixture and recovering undissolved hydrogen and any light components, following which the feed containing dissolved hydrogen is charged to an ebullated-bed hydroprocessing reactor. The problem of gas hold-up that is typical of ebullated-bed reactors of traditional design is minimized.
The invention is thus directed to a process for conversion of a liquid hydrocarbon feedstock into lower molecular weight hydrocarbon compounds in an ebullated-bed reactor, the process comprising:
mixing the fresh and recycled liquid hydrocarbon feedstock and an excess of hydrogen gas in a mixing zone to dissolve a portion of the hydrogen gas in the liquid hydrocarbon feedstock to produce a hydrogen-enriched liquid hydrocarbon feedstock; conveying the hydrogen-enriched liquid hydrocarbon feedstock and excess hydrogen to a flashing zone in which at least a portion of undissolved hydrogen gas is flashed; passing the hydrogen-enriched liquid hydrocarbon feedstock from the flashing zone to a feed inlet of the ebullated-bed reactor for reaction including conversion of the feedstock into lower molecular weight hydrocarbons; recovering the converted lower weight hydrocarbon products from a substantially catalyst-free region of the ebullated-bed reactor; and recycling the unconverted fed for mixing with fresh feedstock for reprocessing.
The process and system of the invention solves the problems related to gas hold-up and those associated with reduced efficiency of the recycle pump due to the presence of gas in the recycle stream that are typically encountered in ebullated-bed hydroprocessing reactors of the prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in further detail below and with reference to the attached drawings in which the same or similar elements are referred to by the same number, and where:
FIG. 1 is a schematic diagram of a conventional ebullated-bed reactor of the prior art with internal recycle;
FIG. 2 is a schematic diagram of a conventional ebullated-bed reactor of the prior art with external recycle;
FIGS. 3A-3C are schematic diagrams of ebullated-bed processes with internal recycle and a straight recycle system ( FIG. 3A ), a combined recycle and feedstock hydrogen addition system ( FIG. 3B ) and a feedstock hydrogen addition system combined with a recycle separation system ( FIG. 3C ); and
FIGS. 4A-4C are schematic diagrams of ebullated-bed processes with external recycle and a straight recycle system ( FIG. 4A ), a combined recycle and feedstock hydrogen addition system ( FIG. 4B ) and a feedstock hydrogen addition system combined with a recycle separation system ( FIG. 4C ).
DETAILED DESCRIPTION OF THE INVENTION
In accordance with the process of the invention, a substantial portion of the hydrogen gas required for hydroprocessing/hydrocracking reactions is dissolved in the liquid feedstock. A hydrogen distributor apparatus is utilized to treat the feedstock upstream of the ebullated-bed reactor to dissolve at least a substantial portion of the requisite reaction hydrogen gas into the liquid feedstock to produce a combined feed/hydrogen stream as the ebullated-bed reactor influent.
In the practice of the process of the invention, the ebullated-bed reactor gas hold-up is less than 40 V % of the total liquid volume passing through the reactor, and preferably less than 10 V %, and most preferably less than 1 V % of the liquid volume.
Also in the practice of the process of the invention, the ebullated-bed recycle stream contains less than 10 V % of vapors, preferably less than 1.0 V %, and most preferably less than 0.1 V % of vapors.
FIGS. 3A-3C depict internal-recycle type ebullated-bed reactor apparatus adapted for receiving a charge 320 including at least a substantial portion of the requisite hydrogen in solution with the feedstock.
The apparatus for the process generally includes a hydrogen distributor 314 , a flash vessel 322 , an ebullated-bed reactor vessel 360 , and one or more pumps 364 a , 364 b and 364 c.
A feedstock stream 310 is mixed with an excess of hydrogen gas 312 in a distributor vessel 314 to dissolve a desired quantity of hydrogen in the liquid and produce a hydrogen-enriched liquid hydrocarbon feedstock. The hydrogen gas stream 312 includes fresh hydrogen 316 and recycled hydrogen 318 .
In certain embodiments, a column is used as a hydrogen distributor vessel in which hydrogen gas is injected at one or more locations, at least one of which is toward the bottom of the column. The liquid feedstock can be fed from the bottom or top of the column. Hydrogen gas is injected through hydrogen distributors into the column for intimate mixing to promote saturation of the feedstock with dissolved hydrogen.
Combined stream 320 , which includes hydrogen-enriched feedstock and excess hydrogen gas, is conveyed to the flashing zone 322 in which excess hydrogen and other gases (e.g., light feedstock fractions) are flashed off as stream 324 . A portion of stream 324 is recycled as stream 318 with the fresh hydrogen feed 316 . The remaining portion of the flashed gases is discharged from the system as a bleed stream 326 , which can be distributed or collected for other refinery and/or petrochemical applications (not shown).
The hydrogen-enriched hydrocarbon feedstock stream 330 which contains the dissolved hydrogen is fed to an ebullated-bed reactor 360 for hydroprocessing reactions. The reactor effluents product stream 366 is discharged from the ebullated-bed reactor and fed into one or more separation vessels (not shown) for product recovery.
Alternatively, the product stream 366 can be conveyed to one or more downstream ebullated-bed reactor systems, which can include one or more of the associated unit operations described herein, e.g., upstream flashing vessel, downstream flashing vessel, and/or one or more additional hydrogen distributor apparatus.
The embodiments of FIGS. 3A , 3 B and 3 C can be implemented individually or in various combinations with the feedstock hydrogen addition system. An ebullated-bed process with a straight recycle system is depicted in FIG. 3A . An ebullated-bed process with a combined recycle and feedstock hydrogen addition system is depicted in FIG. 3B . An ebullated-bed process with a feedstock hydrogen addition system combined with a recycle separation system is depicted in FIG. 3C .
In particular, referring to FIG. 3A , hydrogen-enriched hydrocarbon feedstock 330 from flashing vessel 322 is charged to the ebullated-bed reactor 360 . In the internal-recycle type ebullated-bed reactor, liquid recycle effluent 362 a is drawn through the downcomer conduit in fluid communication with the catalyst-free zone above the catalyst bed by draw force of an ebullated pump 364 a . The recycle stream 363 a from ebullated pump 364 a is returned to the catalyst bed, with the fluid pressure causing catalyst bed expansion.
Referring to FIG. 3B , internal recycle effluent 362 b is passed to hydrogen gas distributor 314 and combined with the feedstock stream 310 for hydrogen saturation. The combined hydrogen-saturated stream 330 is conveyed to the ebullated-bed reactor with the fluid pressure imparted by ebullating-bed pump 364 b causing bed expansion of the catalyst.
Referring to FIG. 3C , hydrogen-enriched hydrocarbon feedstock 330 from flashing vessel 322 is charged to the ebullated-bed reactor 360 . Internal recycle effluent 362 c is passed through a separator vessel 370 with optional hydrogen incorporation via stream 378 . Separator bottoms 374 are passed through an ebullating pump 364 c and a recycle stream 363 c is returned to ebullated-bed reactor 360 . The fluid pressure imparted to recycle stream 363 c by ebullating pump 364 c causes catalyst bed expansion. A portion of separator tops 372 including recycle hydrogen and light gases is bled from the system, and a portion 376 is recycled and mixed with recycle effluent 362 c along with optional make-up hydrogen via stream 378 .
In another embodiment depicted in FIGS. 4A-4C , external-recycle type ebullated-bed reactors are adapted to receive a charge 420 including at least a substantial portion of the requisite hydrogen in solution with the feedstock.
The apparatus for the process generally includes a hydrogen distributor 414 , a flash vessel 422 , an ebullated-bed reactor vessel 460 , a recycle separation vessel 480 , and one or more ebullating pumps 464 a , 464 b and 464 c.
A feedstock stream 410 is mixed with hydrogen gas 412 in a distributor vessel 414 to dissolve a suitable quantity of hydrogen in liquid mixture and produce a hydrogen-enriched liquid hydrocarbon feedstock. The hydrogen gas stream 412 includes fresh hydrogen 416 and recycled hydrogen 418 .
In certain embodiments, a column is used as a hydrogen distributor vessel, in which hydrogen gas is injected at one or more locations, at least one of which toward the bottom of the column. The liquid feedstock can be fed from the bottom or top of the column. Hydrogen gas is injected through hydrogen distributors into the column for adequate mixing to promote formation of a feedstock containing dissolved hydrogen.
Combined stream 420 , which includes hydrogen-enriched feedstock and excess hydrogen gas, is conveyed to the flashing zone 422 in which excess hydrogen and other gases, e.g., light feedstock fractions, are flashed off as stream 424 . A portion of stream 424 is recycled as stream 418 with the fresh hydrogen feed 416 . The remaining portion of the flashed gases is discharged from the system as a bleed stream 426 , which can be distributed or collected for other refinery and/or petrochemical applications (not shown).
The hydrogen-enriched hydrocarbon feedstock stream 430 which contains a suitable quantity of dissolved hydrogen is fed to the ebullated-bed reactor 460 for hydroprocessing reactions.
The ebullated-bed reactor effluents product stream 466 is sent to a recycle separation vessel 480 to flash-off the gas products stream 482 and recover a liquid products stream 484 , a portion of which is recycled. A portion 486 of the liquid products stream is drawn-off from the process and passed to one or more separation vessels (not shown) for product recovery. Alternatively, the product stream 486 can be conveyed to one or more downstream ebullated-bed reactor systems, which can include one or more of the associated unit operations shown herein, e.g., upstream flashing vessel, downstream flashing vessel, and/or one or more additional hydrogen distributor apparatus.
The various embodiments of FIGS. 4A , 4 B and 4 C can be implemented individually or in various combinations with the feedstock hydrogen addition system. An ebullated-bed process with a straight recycle system is depicted in FIG. 4A . An ebullated-bed process with a combined recycle and feedstock hydrogen addition system is depicted in FIG. 4B . An ebullated-bed process with a feedstock hydrogen addition system combined with a recycle separation system is depicted in FIG. 4C .
In particular, referring to FIG. 4A , hydrogen-enriched hydrocarbon feedstock 430 from flashing vessel 422 is charged to the ebullated-bed reactor 460 . In the external-recycle type ebullated-bed reactor, the effluent stream 466 is separated into a product fraction 482 and a liquid fraction 484 in the recycle separation vessel 480 . A portion 488 a of the liquid products stream 484 serves as the external recycle stream 463 a that is charged to the bottom of reactor vessel 460 through an ebullating pump 464 a , with the fluid pressure causing catalyst bed expansion.
Referring to FIG. 4B , hydrogen-enriched hydrocarbon feedstock 430 from flashing vessel 422 is charged to the ebullated-bed reactor 460 . External recycle effluent 478 b is passed to hydrogen gas distributor 414 and combined with the feedstock stream 410 for hydrogen saturation. The combined hydrogen-saturated stream 430 is conveyed to the ebullated-bed reactor with the fluid pressure imparted by ebullating pump 464 b causing catalyst bed expansion.
Referring to FIG. 4C , hydrogen-enriched hydrocarbon feedstock 430 from flashing vessel 422 is charged to the ebullated-bed reactor 460 . External recycle effluent 488 c is passed through a separator vessel 470 with optional hydrogen incorporation via stream 478 . Separator bottoms 474 are passed through an ebullating pump 464 c and a recycle stream 463 c is returned to ebullated-bed reactor 460 . The fluid pressure imparted to recycle stream 463 c by ebullating pump 464 c causes catalyst bed expansion. A portion of separator tops 472 including recycle hydrogen and light gases is bled from the system, and a portion 476 is recycled and mixed with recycle effluent 488 c along with optional make-up hydrogen via stream 478 .
In general, the operating conditions for the ebullated-bed reactor include a temperature in the range of from 350° C. to 500° C., in certain embodiments from 400° C. to 450° C.; a pressure in the range of from 50 to 300 Kg/cm 2 , in certain embodiments from 100 to 250 Kg/cm 2 , and in further embodiments from 150 to 200 Kg/cm 2 ; and a recycle-to-feedstock ratio in the range of from 1:1 to 40:1, in certain embodiments from 1:1 to 20:1.
For the saturation of the feedstock, a hydrogen feed rate of up to about 10,000 standard cubic feet per barrel (SCFB) of feed, in certain embodiments from 500 to 10,000 SCFB, and in further embodiments from 1,500 to 5,000 SCFB is used, the rate being determined by the nature and characteristics of the feedstock.
According to the process and system of the invention, by using a hydrogen-enriched hydrocarbon feedstock which contains at least a substantial portion of the requisite hydrogen for hydroprocessing reactions (in certain embodiments a substantially single-phase combined feed and hydrogen stream) as the feed through the ebullated catalyst bed reactor, problems associated with ebullated pump apparatus related to excess gas in the recycle are alleviated.
Operation of the ebullated-bed reactor is optimized as at least a substantial portion of the hydrogen necessary for hydroprocessing reactions is dissolved in the liquid phase with the feedstream. In certain embodiments, a substantially two-phase system of catalyst and liquid is provided to minimize the reactor volume requirements, increase catalyst loading and liquid volume, and reduce the gas hold-up rate.
Since excess hydrogen gas in the system is minimized or substantially eliminated, the recycle stream and therefore the recycle liquid will have a reduced gas phase compared to conventional ebullated-bed hydroprocessing systems, thereby increasing the efficiency of ebullated-bed recycle pump and minimizing the need for ebullating pumps designed to handle a substantial gas phase. Further, the reduced levels of excess hydrogen will minimize the likelihood of gas hold-up, and reactor volume can be used more effectively, e.g., in certain embodiments an effective reactor volume increase of up to about 40%.
One feature of ebullated-bed reactors is that catalyst addition/withdrawal occurs on a regular basis, and in certain operations, on a continuous or semi-continuous basis without interrupting the reactor's operation. Any catalyst deactivation caused by a possible lack of hydrogen as compared to conventional systems without incorporation of hydrogen in solution with the liquid feedstock is at least partially offset by the regular partial replacement of catalyst. The ebullated-bed reactor cycle length is therefore set by the refiner's inspection and turnaround schedule, not by catalyst activity.
The ebullated-bed reactors operate at constant temperature, whereas the fixed-bed reactors operate over wide a temperature range. Pressure drop is relatively low in the ebullated-bed reactor as a result of ebullation.
Back-mixing characteristics of the ebullated-bed reactor process provides enhanced reactant dispersing and results in a near-isothermal bed conditions. Reaction temperature is controlled by the temperature of the feed, which results in isothermal temperature operation across the reactor. This eliminates the requirement for a hydrogen gas quench in the reactor. Isothermal operation (no quench requirement) in the ebullated-bed process will increase the feedstock processing flexibility, and relatively heavier feedstock can be process in the ebullated-bed reactors according to the present system and process.
Example
A vacuum residue derived from Arabian heavy crude oil, the characteristics of which are given in Table 1, was hydrocracked in a single-stage ebullated-bed reactor at 440° C., 150 bars of hydrogen partial pressure, 0.3 liters of oil per liters of reactor volume and with 0.8 kg of catalyst per tons of vacuum residue. The total hydrogen gas rate is set at four times the rate at which hydrogen is consumed in the process. The ebullated-bed reactor was operated at a recycle-to-feedstock ratio of 10:1.
TABLE 1
Composition
Property
Unit
Value
Density
Kg/L
1.04
Sulfur
W %
5.3
Nitrogen
ppmw
4000
CCR
W %
25
1050° C.+
W %
91
The total material balance for the process which is configured as shown in FIG. 3B is given in Table 2.
TABLE 2
Stream
Component
310
316
312
320
324
326
318
330
366
362b
Hydrogen
93
381
381
288
0
288
93
H 2 S
510
NH 3
30
CH 4
85
C 2 H 6
86
C 3 H 8
150
C 4 H 10
120
C 5 -180
810
180° C.-240° C.
537
240° C.-370° C.
1,634
370° C.-520° C.
900
900
900
2,340
520° C.+
9,100
48,000
48,000
38,900
Total
10,000
93
381
49,281
288
0
288
48,993
6,302
38,900
The total conversion of the hydrocarbons boiling above 520° C. was 61 W % and 92 W % of hydrodesulfurization was achieved in the process. Since hydrogen was dissolved in the feedstock, the gas phase hydrogen was eliminated in the ebullated-bed reactor which resulted in a savings of 30-40 V % of the reactor space that was previously required for gas hold-up in the three phase system of the prior art.
The method and system of the present invention have been described above and in the attached drawings; however, modifications will be apparent to those of ordinary skill in the art and the scope of protection for the invention is to be defined by the claims that follow.
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An improved system and method for processing feedstocks in an ebullated-bed hydroprocessing reactor is provided in which hydrogen gas is dissolved in the fresh and recycled liquid feedstock by mixing and/or diffusion of an excess of hydrogen, followed by flashing of the undissolved hydrogen upstream of the reactor inlet, introduction of the feed containing dissolved hydrogen into the ebullated-bed hydroprocessing reactor whereby the dissolved hydrogen eliminates or minimizes the prior art problems of gas hold-up and reduced operational efficiency of the recycle pump due to the presence of excess gas in the recycle stream when hydrogen gas was introduced as a separate phase into the reactor.
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The application claim priority as a divisional application of U.S. patent application Ser. No. 12/823,410 (published as U.S. Patent Application Pub. No. 2011-0315384), which is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
This invention relates generally to the art of making and using oilfield treatment gels. More particularly it relates to gelled foam fluids made of polymer and methods of using such fluids in a well from which oil and/or gas can be produced.
BACKGROUND
The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
Water control problems are ubiquitous in oil and gas reservoirs and they have many forms. One difficult problem is that of shutting off fractures or fissures in carbonate reservoirs without impacting the hydrocarbon production. The fissure or fracture tends to dominate flow to a producing well compared to the matrix flow. Commonly, the flow of hydrocarbons may move from the matrix into the fractures and from the fractures into one or more main fractures that intersect the wellbore. Because of the huge flow potential in a sizable opening, any fluid solution must be rather large in volume and able to resist extrusion after the treatment has finished and the well is placed on production. A further complication is the reservoir may contain a range of fissures, fractures and vugs, all of which have the potential to flow. Vugs have both flow potential and large storage capacity, while the capacity of fissures and fractures depend upon the width and the cementation. Since these features cannot be easily mapped, the volumes and geometry of the features are not known, leading to difficulties in designing a plugging treatment.
A similar problem has been encountered in drilling applications where lost circulation zones exist. These features tend to capture the expensive drilling fluid and must be plugged prior to continuing the drilling process. Cementing pipe in hole is subject to these features as well, and poor cementing can result because the cement is diluted by underground rivers or the fluid loss is so high that the cement cannot be propagated throughout the area requiring cement.
Various solutions exist for combating these problems and they generally are referred to as lost circulation material (LCM), lost circulation pills, plugs, gels, cement plugs, formation damage plugs, solids laden plugs, bentonite plugs, fiber plugs, etc. Some solutions include pumping water reactive materials in a non-aqueous fluid (clays and especially bentonite, organic polymers, cement) that tend to set when water is encountered; aqueous fluids that set into stiff gels (crosslinked-water soluble organic polymers, inorganic monomers that gel such as silicates and aluminum compounds, organic monomers that polymerize in situ); non-aqueous fluids such as resins; slurries of solids in aqueous or non-aqueous carrier fluids that plug indiscriminately such as walnut shells, diatomaceous earth or silica flour; and non-compatible waters which precipitate upon meeting in the reservoir.
Polymer gels have been widely used for conformance control of naturally fissured/fractured reservoirs. For an overview of existing polymer compositions, reference is made to the U.S. Pat. Nos. 5,486,312 and 5,203,834 which also list a number of patents and other sources related to gel-forming polymers.
Some of these solutions have been foamed with gas to plug a larger volume with the same amount of chemicals. Foams are often stabilized with polymers which restrict the drainage of the foam boundaries or plateau borders. Foamable gel compositions are described for example in the U.S. Pat. Nos. 5,105,884, 5,203,834, and 5,513,705, wherein the polymer content is reduced at constant volume of the composition.
The typical components of a foamable gel composition are (a) a solvent, (b) a crosslinkable polymer, (c) a crosslinking agent capable of crosslinking the polymer, (d) a surfactant to reduce the surface tension between the solvent and the gas, and (e) the foaming gas, itself.
A new gelled foam having enhanced properties of foam stability is proposed herewith.
SUMMARY
In a first aspect, a composition is disclosed. The composition is for use in a wellbore and consists essentially of a solvent, a surfactant, a foaming gas and a foam enhancer, wherein the foam enhancer by its own increases the viscosity of the composition and the stability of the foam. Also, the composition can be a gel composition for use in a wellbore comprising a solvent, a surfactant, a foaming gas, a foam enhancer, a crosslinkable polymer, and a crosslinking agent capable of crosslinking the polymer, wherein the foam enhancer increases the foam half-life of the gel composition compared to the gel composition without the foam enhancer.
In a second aspect, a method is disclosed. The method comprises injecting into a wellbore, a composition consisting essentially of a solvent, a surfactant, a foaming gas and a foam enhancer; and allowing viscosity of the composition to increase.
In a third aspect, the method comprises injecting into a wellbore, a composition comprising a solvent, a surfactant, a foaming gas, a foam enhancer, a crosslinkable polymer, and a crosslinking agent capable of crosslinking the polymer, wherein the foam enhancer increases the foam half-life of the gel composition compared to the gel composition without the foam enhancer; and allowing viscosity of the composition to increase and form a gel.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing rheology of foam composition according to the invention versus time.
DETAILED DESCRIPTION
At the outset, it should be noted that in the development of any actual embodiments, numerous implementation-specific decisions must be made to achieve the developer's specific goals, such as compliance with system and business related constraints, which can vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time consuming but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.
The description and examples are presented solely for the purpose of illustrating embodiments of the invention and should not be construed as a limitation to the scope and applicability of the invention. In the summary of the invention and this detailed description, each numerical value should be read once as modified by the term “about” (unless already expressly so modified), and then read again as not so modified unless otherwise indicated in context. Also, in the summary of the invention and this detailed description, it should be understood that a concentration range listed or described as being useful, suitable, or the like, is intended that any and every concentration within the range, including the end points, is to be considered as having been stated. For example, “a range of from 1 to 10” is to be read as indicating each and every possible number along the continuum between about 1 and about 10. Thus, even if specific data points within the range, or even no data points within the range, are explicitly identified or refer to only a few specific, it is to be understood that inventors appreciate and understand that any and all data points within the range are to be considered to have been specified, and that inventors possession of the entire range and all points within the range disclosed and enabled the entire range and all points within the range.
As used herewith the term “gel” means a substance selected from the group consisting of (a) colloids in which the dispersed phase has combined with the continuous phase to produce a viscous, jelly-like product, (b) crosslinked polymers, and (c) mixtures thereof.
According to a first embodiment, the gel composition is a composition made from: a solvent, a surfactant also called a foaming agent, a foaming gas and a foam enhancer.
The solvent may be any liquid in which the crosslinkable polymer and crosslinking agent can be dissolved, mixed, suspended or otherwise dispersed to facilitate gel formation. The solvent may be an aqueous liquid such as fresh water or a brine.
Surfactant is used to reduce the surface tension between the solvent and the foaming gas. The surfactants may be water-soluble and have sufficient foaming ability to enable the composition, when traversed by a gas, to foam and, upon curing, form a foamed gel. Typically, the surfactant is used in a concentration of up to about 10, about 0.01 to about 5, about 0.05 to about 3, or about 0.1 to about 2 weight percent.
The surfactant may be substantially any conventional anionic, cationic or nonionic surfactant. Anionic, cationic and nonionic surfactants are well known in general and are commercially available. Preferred foaming agents include those that have good foam formation and stability as measured by half-life. An additional feature is to continue to foam in the presence of hydrocarbons, which are known defoamers. Betaines, mixture of ammonium C6-C10 alcohol/ethoxysulfate 2-Butoxyethanol (EGMBE)/Ethanol and amphoterics such as amphoteric alkyl amine surfactant are good foamers.
Exemplary surfactants include, but are not limited to, alkyl polyethylene oxide sulfates, alkyl alkylolamine sulfates, modified ether alcohol sulfate sodium salt, sodium lauryl sulfate, perfluoroalkanoic acids and salts having about 3 to about 24 carbon atoms per molecule (e.g., perfluorooctanoic acid, perfluoropropanoic acid, and perfluorononanoic acid), modified fatty alkylolamides, polyoxyethylene alkyl aryl ethers, octylphenoxyethanol, ethanolated alkyl guanidine-amine complexes, condensation of hydrogenated tallow amide and ethylene oxide, ethylene cyclomido 1-lauryl, 2-hydroxy, ethylene sodium alcoholate, methylene sodium carboxylate, alkyl arylsulfonates, sodium alkyl naphthalene sulfonate, sodium hydrocarbon sulfonates, petroleum sulfonates, sodium linear alkyl aryl sulfonates, alpha olefin sulfonates, condensation product of propylene oxide with ethylene oxide, sodium salt of sulfated fatty alcohols, octylphenoxy polyethoxy ethanol, sorbitan monolaurate, sorbitan monopalmitate, sorbitan trioleate, polyoxyethylene sorbitan tristearate, polyoxyethylene sorbitan tristearate, polyoxyethylene sorbitan monooleate, dioctyl sodium sulfosuccinate, modified phthalic glycerol alkyl resin, octylphenoxy polyethoxy ethanol, acetylphenoxy polyethoxy ethanol, dimethyl didodecenyl ammonium chloride, methyl trioctenyl ammonium iodide, trimethyl decenyl ammonium chloride, and dibutyl dihexadecenyl ammonium chloride.
In one embodiment the gel composition comprises a surfactant made of alcohol ether sulfates (AES). Alcohol ether sulfates provide a good foaming performance in acid brines with a broad range of ionic strength and hardness. They allow the liquid phase of the foam to form a strong and robust gel under acid conditions.
The foaming gas is usually a noncondensable gas. Exemplary noncondensable gases include air, oxygen, hydrogen, noble gases (helium, neon, argon, krypton, xenon, and radon), natural gas, hydrocarbon gases (e.g., methane, ethane), nitrogen, and carbon dioxide. Nitrogen and carbon dioxide are typically readily available in the oil field. Steam could be used for treating high temperature wells; however, the steam may condense and collapse the foam.
The amount of gas injected (when measured at the temperature and pressure conditions in the subterranean formation being treated) is generally about 1 to about 99 volume percent based upon the total volume of treatment fluids injected into the subterranean formation (i.e., the sum of the volume of injected gas plus the volume of injected foamable, gel-forming composition). According to one embodiment, the amount of gas injected is about 20 to about 98, and more preferably about 40 to about 95, volume percent based upon the total volume of injected treatment fluids. Foam enhancers are generally formed from water soluble polymers but can also be other organic extenders. Polymers have been used as they increase viscosity in the liquid borders and minimize drainage of the films which lead to bubble collapse. Especially good foam extenders include polymers which have a yield stress behavior at low shear rate such as xanthan and diutan. Other polymers include guar and guar derivatives, welan gum, locust bean gum, polyacrylamides and copolymers containing monomers of acrylamide, acrylic acid, sodium AMPS and vinyl pyrrolidone. Examples include polysaccharides such as substituted galactomannans, such as guar gums, high-molecular weight polysaccharides composed of mannose and galactose sugars, or guar derivatives such as hydroxypropyl guar (HPG), carboxymethylhydroxypropyl guar (CMHPG) and carboxymethyl guar (CMG), hydrophobically modified guars, guar-containing compounds, and synthetic polymers. Cellulose derivatives are also used in an embodiment, such as hydroxyethylcellulose (HEC) or hydroxypropylcellulose (HPC), carboxymethylhydroxyethylcellulose (CMHEC) and carboxymethycellulose (CMC). Xanthan, diutan, and scleroglucan, three biopolymers, have been shown to have excellent foaming enhancement properties.
According to a second embodiment, the gel composition further comprises a crosslinkable polymer, and a crosslinking agent capable of crosslinking the polymer. The result is a permanent gelation of the foam structure. According a third embodiment, the gel composition further comprises a delay agent to allow delayed crosslinking.
A crosslinked polymer is generally formed by reacting or contacting proper proportions of the crosslinkable polymer with the crosslinking agent. However, the gel-forming composition need only contain either the crosslinkable polymer or the crosslinking agent. When the crosslinkable polymer or crosslinking agent is omitted from the composition, the omitted material is usually introduced into the subterranean formation as a separate slug, either before, after, or simultaneously with the introduction of the gel-forming composition. The composition may comprise at least the crosslinkable polymer or monomers capable of polymerizing to form a crosslinkable polymer (e.g. acrylamide, vinyl acetate, acrylic acid, vinyl alcohol, methacrylamide, sodium AMPS, ethylene oxide, propylene oxide, and vinyl pyrrolidone). In another embodiment, the composition comprises both (a) the crosslinking agent and (b) either (i) the crosslinkable polymer or (ii) the polymerizable monomers capable of forming a crosslinkable polymer.
Typically, the crosslinkable polymer is water soluble. Common classes of water soluble crosslinkable polymers include polyvinyl polymers, polymethacrylamides, cellulose ethers, polysaccharides, lignosulfonates, ammonium salts thereof, alkali metal salts thereof, as well as alkaline earth salts of lignosulfonates. Specific examples of typical water soluble polymers are acrylic acid-acrylamide copolymers, acrylic acid-methacrylamide copolymers, polyacrylamides, partially hydrolyzed polyacrylamides, partially hydrolyzed polymethacrylamides, polyvinyl alcohol, polyvinyl pyrrolidone, polyalkyleneoxides, carboxycelluloses, carboxyalkylhydroxyethyl celluloses, hydroxyethylcellulose, galactomannans (e.g., guar gum), substituted galactomannans (e.g., hydroxypropyl guar), heteropolysaccharides obtained by the fermentation of starch-derived sugar (e.g., xanthan gum), and ammonium and alkali metal salts thereof. Other water soluble crosslinkable polymers include hydroxypropyl guar, partially hydrolyzed polyacrylamides, xanthan gum, polyvinyl alcohol, and the ammonium and alkali metal salts thereof.
The crosslinkable polymers are typically synthetic polymers for long term stability but could include biological polymers as well with a biocide.
The crosslinkable polymer is available in several forms such as a water solution or broth, a gel log solution, a dried powder, and a hydrocarbon emulsion or dispersion. As is well known to those skilled in the art, different types of equipment are employed to handle these different forms of crosslinkable polymers.
With respect to the crosslinking agents, these agents are organic and inorganic compounds well known to those skilled in the art. Exemplary organic crosslinking agents include, but are not limited to, aldehydes, dialdehydes, phenols, substituted phenols, and ethers. Phenol, phenyl acetate, resorcinol, glutaraldehyde, catechol, hydroquinone, gallic acid, pyrogallol, phloroglucinol, formaldehyde, and divinylether are some of the more typical organic crosslinking agents. The organic crosslinker can also take the form of a polymer such as polyalkyleneimines such as polyethyleneimine or polyalkylenepolyamines such as polyethylenepolyamines and polypropylenepolyamines as disclosed in U.S. Pat. Nos. 4,773,481 and 6,192,986 incorporated by reference herewith. Typical inorganic crosslinking agents are polyvalent metals, chelated polyvalent metals, and compounds capable of yielding polyvalent metals. Some of the more common inorganic crosslinking agents include chromium salts, aluminates, gallates, dichromates, titanium chelates, aluminum citrate, chromium citrate, chromium acetate, and chromium propionate.
Suitable delay agents vary with the type of polymer and crosslinker employed. Some examples include organic complexing agents such as lactic acid, malonic acid and maleic acids for the metals, ammonium and carbonates salts for the amines, precursors that generate active crosslinkers such as trioxane, hexamethylenetetramine, acetic acid trimer, dioxane, etc.
According to a fourth embodiment, the gel composition further comprises a gelling accelerator or activator.
In some cases the temperature of application is lower than desired to promote crosslinking of the polymer. For example, below about 93° C., hexamethylenetetramine does not thermally degrade into the active crosslinking species quickly enough. In such cases, application of acid to the mixture can force the decomposition of the hexamethylenetetramine and begin the crosslinking reaction and subsequent gelation. However, in some application, as for example in carbonate rocks, some or all of the acid can be lost in reactions with the rock.
The gelling accelerator can be an encapsulated acid to prevent reaction with the rock until the fluid has been placed. The capsule then releases the acid, so most of the acid will be available for interaction with the delayed crosslinker rather than being spent on the rock during flow through the fracture, fissure or fault. Suitable acids include encapsulated acids or acidic salts that reduce pH upon dissolution. Some examples include acetic acid, acetic anhydride, formic acid, hydrochloric acid, fumaric acid, ammonium bisulfite, sodium bisulfate, potassium bisulfate, ammonium sulfate, etc. The chemicals can be encapsulated by various means including sprayed on coatings, fluidized bed coating, pan coating, coating formed by interfacial polymerization, organic coatings used for drug and vitamin delivery such as lipids, etc.
The gelling accelerator can be embodied in or as part of the foaming gas. The gas can be a binary foam defined as a mixture of nitrogen and carbon dioxide. Since carbon dioxide is an acidic gas that interacts with the aqueous medium, the acid functionality can be used to alter the gelation time of the organic crosslinked gel. The crosslinker precursor, hexamethylenetetramine, breaks down into the active crosslinker at a rate that is dependent upon temperature and/or pH. At lower temperatures below about 93° C., the breakdown can be accelerated by applying an acid. Increasing acidic strength speeds up the breakdown and thus, the gelation of the system by crosslinking of the gel. By adjustment of the carbon dioxide content in the gas phase, the gelation time of the foamed gel mixture can be controlled. Since the amount of carbon dioxide available for pH adjustment depends upon the equilibrium conditions of the application (temperature, pressure and partial pressure of carbon dioxide), the design will involve equations of state for prediction of the pH and the subsequent gelation time.
For higher temperature applications, the use of both temperature and pH can accelerate gelation. One example is adding polylactic acid (PLA) solids to the composition. This chemical is largely inert until a certain temperature is reached, at which time the PLA decomposes to provide lactic acid that accelerates the gelation. A similar effect could be achieved by using encapsulated acid or acidic salts that have a capsule wall that does not release until a higher temperature is achieved.
In a fifth embodiment, the gel composition further comprises a gelling enhancer.
The gelling enhancer can be a colloidal solid. Examples include fly ash, silica, fumed silica, titanium dioxide, natural solids such as clays, synthetic clays, talc, calcium carbonate, latexes, nanocarbons, and minerals such as boehmite (Bohmite), carbon black, graphite, etc. Other gelling enhancers for fracture plugging can include solids as fine silica flour, ground nut shells, diatomaceous earth, ground seashells, calcium carbonate, fibers and other minerals. Fibers can be used as synthetic fibers e.g. Kevlar fibers or metal fibers e.g. cast iron fibers.
In a sixth embodiment, the gel composition further comprises a swellable polymer to trap oil and/or water.
If used for removing water, swellable polymers include super absorber polymers based on crosslinked polyacrylates.
If used for trapping oil, swellable polymers include EPDM, EPM, SBR, butyl rubber, neoprene rubber, silicone rubber, and ethylene vinyl acrylate.
Optionally, the liquid components are mixed at the surface and foaming gas is added on the fly just before the combined streams enter the wellbore. Other potential options are to apply some of the gas and liquid phases in separate streams which meet partway or near the bottom of the well. Foam generators are an option for delivering optimal foam properties. The composition gels are compatible with other fluids or material as for example hydrocarbons such as mineral oil, proppants or additives normally found in well stimulation. Current embodiments can be used in various applications including temporary plugs of a formation, kill plugs, or multiple fracturing steps for treating subterranean formations having a plurality of zones of differing permeabilities. However, the primary target is plugging of fractures, fissures and faults within subterranean reservoirs accessed via a wellbore.
To facilitate a better understanding of some embodiments, the following examples of embodiments are given. In no way should the following examples be read to limit, or define, the scope of the embodiments described herewith.
EXAMPLES
Series of experiments were conducted to demonstrate properties of compositions and methods as disclosed above.
In the following tests, various compositions were examined for the ability to foam, the foam volume, foam stability as measured by half-life and foam quality. The half-life is the time for 50 mL to separate and drain from the foam using a loaded volume of 100 mL of liquid. Foam volume is the volume of foam immediately after foaming energy is stopped. The time for the half-life is started at this time as well. Foam quality is the gaseous content of the foam. As can be seen in Table 1, the addition of the foam enhancer vastly improved the foam half-life, but decreased the foam volume and quality. Use of higher molecular weight substituted polyacrylamide polymer (3 million Daltons) lowered the foam volume versus acrylamide sodium acrylate copolymer (0.5 million Daltons). As the gel time might be 2-4 hours, an extender is needed to maintain the foam after pumping is stopped and before the gelation begins.
The polymers were fully hydrated in water prior to adding the other components. Next, 100 mL of the solution was added to a graduated beaker and foamed by operating a Silverson mixer at 4000 rpm for three minutes. A separate study of mixing speed confirmed that 4000 rpm provides the most foam volume and does not shear degrade the polymer viscosity. The foam volume was recorded and the stop watch started after the beaker was removed from the mixer. The acrylamide sodium acrylate copolymer solutions also included 0.21 wt % of hexamethylenetetramine and 0.21 vol % of acetic acid. The substituted polyacrylamide solution also contained 0.2 wt % hexamethylenetetramine, 0.18 vol % phenyl acetate and 0.3 vol % acetic acid. A separate sample of the formulations was heated in capped bottles to 100° C. and good gels were formed, showing none of the components were incompatible. The samples with acrylamide sodium acrylate copolymer and substituted polyacrylamide with guar were stiff and did not move when the bottle was inverted. However, the sample with substituted polyacrylamide alone formed a tonguing gel that extended several inches from the bottle top upon inversion. It was found that cocamidopropyl Betaine/isopropanol/2-Butoxyethanol (EGMBE) mixture was insensitive to oil contamination whereas foams prepared with the other foamers would collapse with oil contamination.
TABLE 1
Fluid
Foam
Foam Half-life,
composition
Polymer
Foaming agent
Foam enhancer
Volume, mL
minutes
Foam Quality, %
A
3.1%
0.5 vol % ammonium
650
15
84.6
acrylamide
C6-C10 alcohol
sodium
ethoxysulfate/ethanol/2-
acrylate
Butoxyethanol (EGMBE)
copolymer
mixture
B
3.1%
1 vol % ammonium C6-C10
1000
17
90
acrylamide
alcohol
sodium
ethoxysulfate/ethanol/2-
acrylate
Butoxyethanol (EGMBE)
copolymer
mixture
C
3.1%
2 vol % ammonium C6-C10
1220
16.1
91.8
acrylamide
alcohol
sodium
ethoxysulfate/ethanol/2-
acrylate
Butoxyethanol (EGMBE)
copolymer
mixture
D
3.1%
0.5 vol % ammonium
0.24% guar
375
82.5
73.3
acrylamide
C6-C10 alcohol
sodium
ethoxysulfate/ethanol/2-
acrylate
Butoxyethanol (EGMBE)
copolymer
mixture
E
3.1%
2 vol % dicoco dimethyl
0.24% guar
200
55
50.0
acrylamide
ammonium
sodium
chloride/ethanol mixture
acrylate
copolymer
F
3.1%
5 vol % dicoco dimethyl
0.24% guar
300
171
66.6
acrylamide
ammonium
sodium
chloride/ethanol mixture
acrylate
copolymer
G
3.1%
10 vol % dicoco dimethyl
0.24% guar
300
125
66.6
acrylamide
ammonium
sodium
chloride/ethanol mixture
acrylate
copolymer
H
3.1%
10 vol % dicoco dimethyl
0.24% guar
350
85
71.4
acrylamide
ammonium
sodium
chloride/ethanol mixture +
acrylate
1 vol % 2-
copolymer
butoxyethanol (EGMBE)
I
1% substituted
0.5 vol % ammonium
720
36.7
86
polyacrylamide
C6-C10 alcohol
ethoxysulfate/ethanol/2-
Butoxyethanol (EGMBE)
mixture
J
1% substituted
0.5 vol % ammonium C6-C10
0.24% guar
475
100
78.9
polyacrylamide
alcohol
ethoxysulfate/ethanol/2-
Butoxyethanol (EGMBE)
mixture
K
3.1%
1.0 vol %
0.7 wt %
—
>5 hours
74.0
acrylamide
cocamidopropyl
diutan
sodium
Betaine/isopropanol/2-
acrylate
Butoxyethanol (EGMBE)
copolymer
mixture
The fluid composition K in the above table was evaluated further in a circulating foam loop at 100° C. using nitrogen. The hexamethylenetetramine was not included to prevent gelation during the test. The foam was formulated at a quality of 72%. A constant shear rate of 100 s −1 was maintained throughout the test except for three shear ramps where the shear rate was reduced to 75, 50 25 and then increased to 50, 75 and 100 s −1 . Table 2 shows the calculated power law parameters, for the foam versus elapsed time, and includes the R 2 or goodness of fit parameter. Clearly the foam maintains its viscosity and its shear thinning properties with only minor changes over the test time of 3.5 hours. The rheology trace is included in FIG. 1 . Pictures of the foam segregated in a view cell (data not shown) show that some coarsening of the foam is evident, but the foam has no drainage over the 3.5 hour test time.
TABLE 2
Elapsed Time,
Temperature,
hr:min:sec
° C.
n′
K′, lbf-s n′ /ft 2
R 2
1:14:32
100.3
0.435
0.0120
0.977
2:28:36
101.2
0.449
0.0974
0.987
3:25:40
101.3
0.456
0.0888
0.992
The fluid composition K was further augmented with 5 vol % of silicate solution (colloidal silica solution). This formulation showed nearly identical properties to the fluid composition K except the gel was visibly stronger and the foamed volume was enhanced. Picture of the formulation (data not shown) shows a stronger gel when put upside down.
The particular embodiments disclosed above are illustrative only, as the invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details herein shown, other than as described in the claims below. It is therefore evident that the particular embodiments disclosed above may be altered or modified and all such variations are considered within the scope of the embodiments described herewith. Accordingly, the protection sought herein is as set forth in the claims below.
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The invention provides a method made of steps of injecting into a wellbore, a composition comprising a solvent, a surfactant, a foaming gas, a foam enhancer, a crosslinkable polymer, and a crosslinking agent capable of crosslinking the polymer, wherein the foam enhancer increases the foam half-life of the gel composition compared to the gel composition without the foam enhancer; and allowing viscosity of the composition to increase and form a gel.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 61/334,203 filed on May 13, 2010. U.S. Provisional Application No. 61/334,203 is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
The present invention generally relates to a firearm training aid, and more particularly this invention relates to a firearm barrel that is configured for use with a blank cartridge and a light emitting training device to operatively simulate live fire training. This invention also relates to a system for registering “hits” during dry-fire exercises and/or gaming with a handheld firearm.
BACKGROUND
A cartridge, also called a round, generally packages a bullet, propellant (e.g., smokeless powder or gunpowder) and primer into a single metallic case precisely made to fit the firing chamber of a firearm. The primer, typically, is a small charge of an impact-sensitive chemical that may be located at the center of the case head (centerfire ammunition) or at its rim (rimfire ammunition). In use, the cartridge case seals a firing chamber in all directions except down the bore, A firing pin strikes the primer, igniting it. A jet of burning gas from the primer ignites the powder. Gases from the burning powder (deflagration) expand the case to seal it against the chamber wall. The projectile is then pushed down the barrel in the direction that has least resistance to this pressure. After the projectile leaves the barrel, the pressure drops, allowing the cartridge case to contract slightly, easing its removal from the chamber.
A blank is a charged cartridge that does not contain a projectile. To contain the propellant, the opening where the projectile would be is crimped shut or sealed with some material that disperses rapidly on leaving the barrel. A blank cartridge is discussed in U.S. Pat. No. 5,359,937, which is incorporated herein by reference.
A light emitting cartridge typically shines a collimated pulse of coherent electromagnetic radiation on a target when a gun loaded with the cartridge is fired. A light emitting cartridge is discussed in U.S. Pat. No. 5,685,106, which is incorporated herein by reference.
Dry fire training—repeated drawing, aiming and firing without ammunition—is a practical and convenient way to improve and/or maintain shooting techniques. The practice is limited, however, by the fact that the bullet impact point is a mere assumption; thus the trainees and/or trainers are limited in their ability to evaluate the trainees' performance or/and improve their skills. Furthermore, there has long existed the need for an apparatus and system whereby a single or multiple user, or trainer and trainee can readily practice using a firearm without placing themselves or others at risk of accidental discharge of the firearm while still maintaining the ability to recognize the “hits.” This safety imperative coincides with an added desire to limit the financial burden related to the wear and tear on a firearm, including cost of ammunition and use of adequate facilities brought about by live fire training.
These considerations have proven to be especially relevant to law-enforcement and military personnel, who require a high degree of firearm practice and proficiency. In such situations, “Force on Force” drills pose a heightened risk to users, as the muzzle of firearm points toward other users, increasing the likelihood of accidental and potentially fatal discharge. It is well documented that Training Officers (TOO have been injured or fatally wounded due to several loading/unloading, procedures, such that a live round reaches the chamber of a firearm without the fellow officer being able to discern that he is facing a loaded weapon.
Accordingly, a need exists for a firearm training system that addresses these concerns and maintains the overall benefit of live fire training.
SUMMARY
Hence, the present invention is directed to a firearm barrel that houses a light emitting device for use in a laser training system, as well as a firing chamber that accommodates blanks for simulating physical conditions associated with live fire training.
One aspect of the present invention is directed to a training barrel having a central axis for housing alight emitting insert which includes an elongate member having a first end, a second end, and a first internal surface extending from the first end through the elongate member to the second end. The first internal surface may include a first segment abutting the first end which defines a first volume having a first cross sectional area perpendicular to the central axis. The first internal surface also may include a second segment adjacent the first segment which defines a second volume having a second cross sectional area perpendicular to the central axis, the second cross sectional area being less than the first cross sectional area. The first internal surface may include a third segment proximate the second segment which defines a third volume having a third cross sectional area perpendicular to the central axis, the third cross sectional area being greater than the second cross sectional area. Additionally, the first internal surface may include a fourth segment situated between the third segment and the second end which defines a fourth volume having a fourth cross sectional area perpendicular to the central axis, the fourth cross sectional area being less than the third cross sectional area.
The elongate member may be separable into a proximal part and a distal part, and the first, second, and third segments may be disposed in the proximal part and the fourth segment may be disposed in the distal part. The proximal part may include a first screw thread, and the distal part may include a second screw thread such that the second screw thread and the first screw thread mate to secure the distal part to the proximal part. The first screw thread may be proximate the third segment and the second screw thread may be proximate the fourth segment. In addition, the proximal part may further include an exterior surface and a second interior surface which extends from the exterior surface to the first screw thread. The distal part may include a third interior surface which extends toward the first interior surface from the second screw thread. A fastening element may be disposed in the second and third interior surfaces.
Also, the third segment may be configured and dimensioned to receive a light emitting insert, and the fourth and second segments may be configured and dimensioned to secure a light emitting insert in the third segment. Moreover, the first segment may be configured and dimensioned to receive a source of compressed gas. For instance, the first segment may be configured and dimensioned to receive a blank cartridge.
The elongate member may further include a fifth segment disposed between the fourth segment and the third segment which defines a fifth volume having a fifth cross sectional area perpendicular to the central axis, the fifth cross sectional area being greater than the fourth cross sectional area. The fifth segment may be located in the distal pan.
The elongate member may further include a sixth segment disposed between the fourth segment and the second end which defines a sixth volume having a sixth cross sectional area perpendicular to the central axis, the sixth cross sectional area being greater than the fourth cross sectional area. The second segment may include a vent in fluid communication with the sixth segment.
The first segment may have circular cylindrical shape and the diameter of the first cross sectional area may be between approximately 0.1 inches and 0.5 inches. The distance between the first and second end may be between approximately 3 inches and 6 inches, and the elongate member may be formed from an alloy. The elongate member may be a drop in replacement part for a handgun.
DESCRIPTION OF THE DRAWINGS
In the accompanying drawings, which form part of this specification and are to be read in conjunction therewith and in which like reference numerals are used to indicate like parts in the various views:
FIG. 1 is a front view of an exemplary embodiment of the firearm training barrel of the present invention;
FIG. 2 is ail exploded view of the firearm training barrel of FIG. 1 from a top rear perspective;
FIG. 3 is a side view of an illustrative light emitting device that may be disposed within the firearm training barrel of FIG. 1 ;
FIG. 4 is a cross-sectional view of the proximal part of the firearm training barrel of FIG. 1 ;
FIG. 5 is a cross-sectional view of the distal part of the firearm training barrel of FIG. 1 ;
FIG. 6 is a cross-sectional view of the proximal part along line 6 - 6 in FIG. 4 .
FIG. 7 is a cross-sectional view of the proximal part along line 7 - 7 in FIG. 4 .
FIG. 8 is a schematic of the light emitting device of FIG. 3 disposed within the proximal and distal parts of the firearm training barrel of FIG. 1 ;
FIG. 9 is left side view of the firearm training barrel of FIG. 1 ;
FIG. 10 is right side view of the firearm training barrel of FIG. 1 ;
FIG. 11 is an exploded view of the light emitting cartridge of FIG. 3 ;
FIG. 12 is a partially exploded view of the light emitting cartridge of FIG. 11 with an accessory.
FIG. 13 is a partial sectional view of the distal part of FIG. 2 .
DESCRIPTION
FIGS. 1 and 2 illustrate a substitute firearm barrel (or training barrel) 10 that is configured to receive projectile-less munitions (or blank cartridges) and exchangeable light emitting munitions (or light emitting cartridges). The training barrel may be used as a conversion barrel for a service weapon in order to simulate live tire training. The training barrel 10 preferably has an outline (or profile) which matches that of the service weapon barrel, so as to provide a drop-in replacement part for the original firearm barrel. In accordance with the embodiment disclosed in FIG. 1 , the training barrel may be a modified 9 mm Simunition® conversion barrel for a Glock Model 19 pistol. The training barrel, however, may be formed from any durable, high strength material suitable for this application. For example, the training barrel may be formed from an alloy, such as a chromium-molybdenum steel (e.g., SAE, Grade 4140) or stainless steel (e.g., SAE, Type 416).
As shown in FIG. 2 , the training barrel 10 may include a proximal part 12 and a removable distal part 14 that may be screwed into the proximal part. Additionally, the distal part 14 may be secured to the proximal part 12 by a fastener 16 . For instance, the fastener 16 may be a headless screw that is inserted into threads 18 and 20 , until it is level with (or below) the exterior surface of the proximal part 12 . In another embodiment, the threaded portion 20 of the distal part 14 may be replaced with a smooth bore or groove.
Referring to FIG. 3 , alight emitting munition (or light emitting cartridge) 24 may be inserted into the training barrel 10 . The tight emitting cartridge may have cylindrical shape and include an actuator 26 and a light emitting mechanism 28 . Internally, the light emitting mechanism may further include a laser source and electric driver circuitry (not shown).
As shown in FIG. 11 , the light emitting cartridge 24 may include a first casing 30 , a second casing 32 , a securing mechanism 34 , a complementary securing mechanism 36 , an illuminator 38 and lens 40 which emit and focuses a first wavelength of light and a second wavelength of light 44 , a power supply 46 , a battery 48 , 50 , 52 , a securing ring 54 , a control circuit bias 56 , a spring 58 , a firing pad 60 , a bell-shaped absorbent material 62 , a conductive pin 64 , a control circuit 66 , an accessory attachment element 68 , and an accessory indicator 70 . The light emitting cartridge of FIG. 11 is disclosed in commonly owned, co-pending U.S. patent application Ser. No. 13/008,234, entitled “Dry Fire Training Device,” filed on Jan. 18, 2011, U.S. patent application Ser. No. 13/008,234 is incorporated herein in its entirety. Although the first and second casing may be shaped like a cartridge, the light emitting insert may take any suitable form provided that it may be securely held within the training barrel so as to prevent the insert from separating from the training barrel during use. Additionally, the bell shaped absorbent material and conductive pin may be replaced with a vibration sensor (e.g. a multiple axis accelerometer) cooperates with the control circuit to recognize the discharge of a blank cartridge and actuate the light emitting insert.
Referring back to FIG. 3 , the light emitting mechanism 28 may emit a pulse of light in the form of a laser beam 68 , in response to mechanical pressure applied to the actuator 26 . The light pulse may be of a predetermined nature, which can be adjusted by the electric driver circuitry. In one embodiment, the light emitting mechanism 28 may emit generally monochromatic “red” light and have a dominant wavelength between approximately 610 nm and 760 nm. For instance, the light emitting mechanism may include a laser diode that emits light at approximately 635 nm or 650 nm. Additionally, the case (or exterior surface) of the light emitting cartridge 24 may include an abrupt gradation 70 and a tapered gradation 72 for fixing the case between by mating gradations (or portions) formed in the proximal part 12 and the removable distal part 14 .
FIG. 4 is a cross-sectional view of the proximal part 12 . In its proximal end (the end that is closer to the striker of the firearm), the proximal part 12 includes a chamber 74 , into which a blank cartridge (not shown) that matches the caliber of the firearm barrel is inserted. The chamber 74 may have a sidewall 76 . A first annular groove 78 , formed in the distal end of the proximal part 12 , may be adapted to receive the actuator 26 of the light emitting munitions 24 . The first annular groove may be situated between two sidewall segments 90 , 92 which differ in internal dimension. The distal end of the proximal part 12 also may include an inner circumferential thread 80 for receiving a mating thread on the distal part 14 . A perpendicular thread 82 may be formed in the wall of the proximal part 12 , so as to receive a fastener, such as a headless screw 16 . One or more passages 84 a may be formed in the wall of proximal part 12 , so as to provide a passageway for hot gases and polluting particles to discharge.
Referring to FIGS. 5 and 13 a second annular groove 86 , adapted to receive the lighting end (or light emitting end) 28 of the light emitting cartridge (or light emitting insert) 24 , may be formed in the proximal end of the distal part 14 . The second annular groove may be situated between two sidewalls segments 94 , 96 which differ in internal dimension. The proximal end of the distal part 14 also may include an outer circumferential thread 88 that is to be received in mating thread 80 of the proximal part 12 . Discharge passages 84 b (or vents) may be formed in the wall of distal part 14 , so as to allow excess hot gases and polluting particles to continue discharging from the barrel.
A perpendicular thread (or groove) 20 may be formed in the wall of the distal part 14 , so as to receive the tip of the headless screw 16 and to lock distal part 14 to the proximal part 12 . As shown in FIG. 6 , discharge passages 84 a in the wall of proximal part 12 are aligned with the discharge passages 84 b in the wall of distal part 14 so as provide a continuous passageway for venting the barrel. In another embodiment, the discharge passages may be directed into two longitudinal openings in the barrel of the pistol. For instance, the longitudinal openings may be arranged in a “V-position” on the upper portion of the barrel as in a Glock “C” compensator pistol. In another embodiment, the discharge passages may include multiple ports which exit the barrel. In yet another embodiment, the training barrel may be implemented for use in an Airsoft weapon or toy in which the weapon or toy creates (or supplies) the increase in barrel pressure required to actuate the light emitting device, eliminating the need for a blank cartridge in applications where smoke or ejection of cartridge cases may not be desired.
FIG. 6 is a cross-sectional view of an assembled training barrel 10 with a light emitting cartridge 24 disposed between the proximal part 12 and the distal part 14 . In this embodiment, the light emitting cartridge 24 is disposed in the first annular groove 78 and the distal part 14 is screwed to the proximal part 12 so as to fix the light emitting cartridge 24 within the barrel 10 while positioning and holding the central axis of the light emitting cartridge in alignment with the central axis of the barrel. Accordingly, the case of the light emitting cartridge 24 may be securely centered within the bore 98 by the first annular groove 78 and the second annular groove 86 .
Referring to FIG. 12 , a retaining pipe 100 may be connected to the light emitting cartridge 24 . In addition, the retaining pipe 100 may end with an attachment element 102 (e.g., a screw thread) that accommodates a mating reversible beveled fastener 104 . An extension 106 may be added to lengthen the retaining pipe. In another embodiment, the retaining pipe 100 may be integral to the light emitting cartridge 24 . In general, the retaining pipe 24 is long enough to protrude out of the front end of the barrel such that the beveled fastener 104 can be attached to the retaining pipe 100 , and tightened against the muzzle. In this manner, the beveled fastener 104 may advance down the retaining pipe to center and secure the light emitting cartridge 24 securely against the distal part 14 . The retaining pipe assembly 114 also may shield the light emitting mechanism 28 of cartridge 24 from hot gases and particulates from the blank cartridge discharge.
Additionally, O-rings 108 may be placed on the retaining pipe 100 in order to prevent contact between the barrel sidewall near the muzzle and the deployed retaining pipe 100 . One O-ring 112 may be positioned at the end of the retaining pipe 100 . This O-ring 112 may prevent the threaded connection between retaining pipe 100 and the light emitting cartridge 24 from seizing due to operational vibrations during use.
In use, a blank cartridge (for example, a SecuriBlank® cartridge from Simunition®) is placed in the chamber 74 of the training barrel 10 that has been assembled into an operative firearm. The user aims the firearm and pulls the trigger. The blank cartridge is fired, and the resulting pressure inside the barrel 116 activates the actuator 26 of the light emitting cartridge 24 . In response, the light emitting cartridge 24 emits a red laser pulse 68 which may register as a user “hit” in a training aid system or gaining system, while maintaining the perception of live firing (noise, smoke and recoil). The hot gases and any particles from the used blank cartridge are discharged from the training barrel 10 via the passages 84 a , 84 b , which may be configured to adjust the recoil power, cycling and loading of the weapon.
While it is apparent that the illustrative embodiments of the invention disclosed herein fulfill the objectives of the present invention, it is appreciated that numerous modifications and other embodiments may be devised by those skilled in the art. Additionally, feature(s) and/or element(s) from any embodiment may be used singly or in combination with other embodiment(s). Therefore, it will be understood that the appended claims are intended to cover all such modifications and embodiments, which would come within the spirit and scope of the present invention.
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A training barrel having a central axis for housing a light emitting insert which includes an elongate member having a first end, a second end, and a first internal surface. The first internal surface extends from the first end to the second end. The internal surface includes a first segment which defines a first volume having a first cross sectional area perpendicular to the central axis, a second segment adjacent the first segment which defines a second volume having a second cross sectional area perpendicular to the central axis, and a third segment proximate the second segment which defines a third volume having a third cross sectional area perpendicular to the central axis, the third cross sectional area being greater than the second cross sectional area. The third segment may be configured and dimensioned to receive a light emitting insert and the first segment may be configured and dimensioned to receive a blank cartridge.
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FIELD OF THE INVENTION
[0001] The present invention generally relates to a steam distributor for applying steam to a paper sheet moving along its side wherein one or more sealable slots located along the cross direction of the distributor permits easy access to the internal compartments or chambers for cleaning and maintenance.
BACKGROUND OF THE INVENTION
[0002] The steam heating of a paper sheet is widely practiced in papermaking. The increase in sheet temperature that results provides increased drainage rates for the water thus reducing the amount of water to be evaporated in the drier section. Water drainage is improved by the application of steam principally because the heating of the sheet reduces the viscosity of the water, thus increasing the ability of the water to flow. Most of the heat transfer takes place when the steam condenses in the sheet. The condensation of the steam transforms the latent heat of the steam to sensible heat in the water contained by the sheet.
[0003] A particular advantage of the steam heating of the paper sheet is that the amount of steam applied may be varied across the width of the sheet along the cross machine direction so that the cross machine moisture profile of the sheet may be modified. This is usually carried out to ensure that the moisture profile at the reel is uniform. Apparatus are well known in the papermaking art that can sense the moisture profile of a sheet of paper. If such an apparatus is positioned over the paper sheet, downstream of a steam distributor able to control the moisture profile, then after measuring the water profile in the sheet, steam can be applied in varying amounts on a selective basis across the sheet, thus achieving the required uniform moisture profile at the reel.
[0004] It is known to divide a steam distributor into compartments and to control the supply of steam to each compartment, thus controlling the moisture profile of the sheet. Unfortunately, with prior art designs, fiber and dirt tend to accumulate within the compartments and over time, the debris penetrates into the internal structures and interfere with steam flow. The steam distributor must be disassembled in order to clean the internal components; this requires that the entire screen covering the steam distributor be moved.
SUMMARY OF THE INVENTION
[0005] The present invention is based in part on the development of a steam distributor that preferably includes multiple steam discharge chambers or compartments that are separated by spaced-apart partitions or baffle panels. Steam exits each compartment through perforations in a perforated steam discharge screen plate that is permanently secured, e.g., welded, onto adjacent partition panels. The steam distributor also includes one or more resealable access slots or channels through which debris that is trapped within the internal of the compartments can be readily removed.
[0006] In one embodiment, the invention is directed to an apparatus to distribute steam to a moving sheet, the apparatus having a leading edge and a trailing edge relative to the moving sheet, the apparatus includes:
(a) a steam distribution header; and (b) a housing defining at least one steam discharge chamber that is covered with a perforated screen plate, wherein each discharge chamber is in fluid communication with the steam distribution header and the at least one control chamber has at least one sealable access slot.
[0009] In another embodiment, the invention is directed to an apparatus to distribute steam to a moving sheet, the apparatus having a leading edge and a trailing edge relative to the moving sheet, the apparatus includes:
(a) a steam distribution header; (b) housing comprising a plurality of partition panels that are spaced apart along the length of the apparatus to form a plurality of steam discharge chambers that are covered with one or more perforated screen plates, wherein each discharge chamber is in fluid communication with the steam distribution header through a conduit that has an inlet in the steam distribution header and an outlet in a discharge chamber and wherein, each discharge chamber includes a lower wall that defines a sealable access slot; and (c) means for controlling the flow of steam from the steam distribution header to each discharge chamber.
[0013] Typically, each discharge chamber has an associated access slot that is located adjacent to the outer, lower portion of the discharge chamber where debris tends to congregate. The dimensions of each access slot are preferably relatively small as compared to that of the discharge chamber. Upon removal of a cleanout bar or other resealable implement that covers the access slot, the internal parts of the discharge chamber the can be cleaned of debris, dirt, and other contaminants with high pressure water that is delivered by a spray wand configured to fit through the slot. This reduces the likelihood of damage to the steam distribution apparatus since the fragile screen plates are not removed and handled. The perimeter of each access slot can be lined with a gasket to provide additional protection against steam leakage. And to facilitate precise alignment of a sealable cleanout bar over the access slot, the housing adjacent the access slot and the cleanout bar itself can have matching apertures for visual alignment. These matching apertures can accommodate dowel pins which help secure the cleanout bar to the steam distributor body.
[0014] Furthermore, since the discharge screen plates are permanently secured onto the partitions that separate the discharge chambers, the screen plates are an integral part of the body structure of the steam distributor. This design further prevents the thin screen plates from being twisted or otherwise damaged. Preferably, the screen plates are welded onto the partitions so that under certain abnormal operating conditions such as steam overpressure within the discharge chambers, screen plate damage is significantly reduced because of the integral design.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1A is a perspective view of a steam distribution apparatus;
[0016] FIGS. 1B and 1C are enlarged views of the discharge screen plate in the steam distributor apparatus;
[0017] FIG. 2 is a perspective view of a compartment in the steam distributor apparatus;
[0018] FIG. 3 is a cross sectional view of the compartment;
[0019] FIG. 4A is another perspective view of a compartment;
[0020] FIG. 4B illustrates an actuator;
[0021] FIG. 5 is a cross sectional view of a front portion of the discharge compartment adjacent the discharge screen plate with the cleanout bar removed; and
[0022] FIG. 6 is a cross sectional view of a front portion of the discharge compartment adjacent the discharge screen plate with the cleanout bar attached during normal operating conditions.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0023] FIG. 1A illustrates the overall assembly of a steam distribution apparatus or steam shower 10 which includes an elongated housing 12 that is enclosed by end plates located at opposite ends. The length of the apparatus typically corresponds to the width of the sheet or web to which steam is to be applied. For papermaking operations the length can range, for instance, up to about 30 feet (9.1 meters). An external source of steam is connected to the steam distribution apparatus and excess steam in the form of condensate is removed through a drain 16 which is located on the side of end plate 14 . The contour of the front screen panel or plate 18 preferably matches the external shape of the product to which steam is being supplied. The concave-shaped curvature of front screen panel 18 is particularly suited for apply steam to a roll of material. The front screen panel can also have a planar configuration to match the straight run of a moving sheet.
[0024] As further described herein, the steam distributor apparatus 10 is separated into a plurality of steam discharge chambers or compartments along the length of the apparatus 10 so that profiling of the steam application can be accomplished. For example, the amount of steam that enters into the individual chambers can be controlled in response variations in measured properties of the sheet along its cross direction.
[0025] FIGS. 1B and 1C show the arrangement of the steam outlets or perforations 20 that are formed across the entire length of the front screen panel 18 . Typically, the outlets 20 are arranged in a plurality of rows 22 , 24 , and 26 , for instance. The individual outlets 20 can be circular or have non-circular configurations. The number and size of the outlets are designed to achieve the desired steam flow rate and velocity. The size of the outlets 20 should be sufficiently small to minimize the amount of fibers and other debris from the sheet of material being heated that enters into the discharge chambers. Nevertheless, in operation, as steam is applied through the perforations 20 onto a moving sheet of paper, for stance, the front screen plate 18 can come into contact with the sheet. As a result, fiber and dirt will clog the perforations 20 and accumulate inside the housing 12 as well.
[0026] FIG. 2 shows a partially disassembled exposed portion of the housing 30 of the steam distributor apparatus. The housing 30 encloses a steam distribution header 36 which is connected to at least one source of steam (not shown). Header 36 runs the length of the steam distribution apparatus. The header 36 is flanked by an interior wall 60 and an exterior wall 62 . The inner enclosure 34 shields the pneumatic actuators 32 with a removable cover that is secured by the hand tightened screws 64 . A plurality of baffles or partition panels 40 , that are laterally spaced apart are secured to the exterior wall 62 thereby creating a number of steam discharge chambers or compartments once the front screen panel segment 31 is secured to the forward part of the housing.
[0027] Each pneumatic actuator 32 is operatively connected to a pipe 42 which has an inlet end located within the header 36 and an outlet end that is located in a discharge chamber. In this embodiment, the inlet end of the pipe 42 is partially covered by a sleeve 44 . A piston is attached to the actuator 32 by a connecting rod to regulate the inlet into pipe 42 and thus control the steam flow between the header 36 and the control chamber. Pneumatic actuators for regulating steam flow in a steam distribution apparatus are described in U.S. Pat. No. 4,398,355 to Dove and U.S. Pat. No. 4,351,700 to Dove, which are incorporated herein by reference.
[0028] In operation, as shown in FIGS. 3 and 4 A, high pressure steam that is supplied to the header 36 is drawn into the pipe 42 through the annular opening between the pipe 42 and the sleeve 44 . The amount of steam drawn is controlled by the actuator 32 which is connected to a pneumatic supply 35 which tunes or regulates the actuator by pressurizing a diaphragm that is on top of a piston that is located inside the actuator 32 . The piston is connected to a measuring plug that moves inside the sleeve 44 to control the amount of steam that goes into each discharge chamber. Steam from the pipe 42 initially enters into a discharge chamber 66 through the pipe outlet 68 . The high velocity steam is dispersed within the discharge chamber 66 before exiting through the perforations of the front panel screen segment 31 and contacting a continuous moving sheet 33 located in front of the perforations. By monitoring and controlling the steam flow into each of the discharge chambers, the steam profile that is injected onto the sheet along its cross direction can be continuously regulated. The steam profile as measured along the length of the steam distribution apparatus can be uniform or non-uniform so that the sheet or web of material can be exposed to a steam curtain having different amounts of steam in the cross direction.
[0029] As shown in FIG. 2 , the front screen panel segment 31 has a concaved exterior contour; as is apparent, the individual perforations in the panel segment 31 are not shown. A backing bar 98 is secured to the lower end of the laterally spaced baffles 40 . The front screen panel segment 31 is welded onto a portion of the backing bar 98 as well as onto the baffles 40 . In this fashion, the front screen panel segment 31 forms the front perforated wall of the steam discharge chambers. The front of the backing bar 98 also defines a series of dowel pins 84 that helps align the cleanout bar 48 as it is secured with screws 50 to the body of the steam distribution apparatus as further described herein. When it is necessary to clean the steam discharge chambers between the baffles 40 , it is only necessary to remove the cleaning bar 48 to gain access to the discharge chambers through access slots that are located at the lower end of each discharge chamber.
[0030] The baffles 40 and front screen panel segment 31 are preferably welded onto the body of the housing as shown in FIG. 4A . By welding the inner side of the segment 31 to the baffles 40 , steam does not leak from one discharge chamber to an adjacent one. Gaskets can be employed to further reduce leakage. As is apparent, the number of front screen panel segments 31 required to cover a steam distribution apparatus will depend on the total cross directional length of the steam distribution apparatus and the cross directional length of each panel segment 31 .
[0031] FIG. 5 shows a steam discharge chamber 70 that is covered by perforated screen plate 72 and that is welded onto the baffles (not shown) and onto body 76 of the steam distributor apparatus. In this embodiment, the perforated screen plate 72 is configured as a slightly curved two-sided panel. The discharge chamber 70 is partitioned from the header by the header exterior wall 74 . The body 76 and the header exterior wall 74 both extend the entire length of the steam distribution apparatus and provide structural support for the baffles and the perforated screen plate 72 . The lower end of screen plate 72 can be positioned between the projection of body 76 and a continuous backing bar 98 which provides additional support for the screen plate 72 . The backing bar 98 serves as a holding plate for the cleanout bar 78 .
[0032] In the lower part of the body 110 of the steam shower there is a series of fixed inserts with threaded holes. The access slot 80 can be sealed with a detachable cleanout bar 78 . Each access slot 80 is typically 1.5 in. (3.8 cm) to 2 in. (5.1 cm) wide as measured in the machine direction and 3 in. (7.6 cm) to 6 in. (15.2 cm) long as measured in the cross direction. With the bar 78 removed, the discharge chamber 70 can be cleaned. As is apparent, locating the access slot 80 in the lower part 110 substantially underneath the screen plate 72 creates an unobstructed path to maneuver a spray wand into the access slot 80 for cleaning the internal parts of the discharge chamber and for cleaning the inner surface of the screen plate 72 . Moreover, the debris inside the discharge chamber should accumulate near the access slot 80 for easy removal. When the steam distribution apparatus is equipped with a plurality of access slots along its length, it is necessary to removed only selected bars to gain access to certain discharge chambers that require maintenance. To insure a tight seal, a polymeric gasket can be positioned around the opening of the access slot 80 . To facilitate alignment of the cleanout bar 78 over the access slot 80 , the “L” shaped cleanout bar 78 can include an aperture 82 which can be visually aligned to a corresponding dowel pin 84 that is located on the bottom side of the screen plate 72 . Once the aperture 82 and dowel pin 84 are aligned, the cleanout bar 78 can be fully mounted to the steam shower body 110 using bolts 86 thereby sealing the bottom portion of the control chamber 70 (shown in FIG. 6 )
[0033] In operation, as shown in FIG. 6 , the cleanout bar 78 is fastened to the lower wall 110 of the discharge chamber 70 with bolts 86 . High pressure steam from the header is discharged through the nozzle of a pipe 90 and into the discharge chamber 70 . Preferably, a target plate 92 which serves as a baffle, is positioned to disperse the high velocity steam uniformly throughout the discharge chamber 70 before the steam permeates through the perforations in the screen plate 72 . In this fashion, there is uniform steam distribution from the leading edge 104 to the trailing edge 106 of the steam distribution apparatus as the sheet of material moves across the screen plate 72 in the machine direction (MD). Condensate that forms on the bottom of the discharge chamber 70 seeps through a drain hole 94 and out through a condensate drain 38 .
[0034] The foregoing has described the principles, preferred embodiments and modes of operation of the present invention. However, the invention should not be construed as being limited to the particular embodiments discussed. Thus, the above-described embodiments should be regarded as illustrative rather than restrictive, and it should be appreciated that variations may be made in those embodiments by workers skilled in the art without departing from the scope of the present invention as defined by the following claims.
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Employment of one or more resealable access slots in a steam distributor apparatus affords easy access to the internal chambers of the apparatus for cleaning and maintenance. The access slots can be located on the lower walls of the steam discharge chambers where debris tend to aggregate during operation of the apparatus. The apparatus can have multiple discharge chambers that are separated by spaced-apart partitions or baffle panels. Steam that is supplied from a steam header to each chamber exits each chamber through perforations of a discharge screen plate that is permanently secured onto adjacent partition panels. Actuators can regulate the steam flow from the steam header to the individual discharge chambers thereby creating a steam curtain with uniform or non-uniform cross direction profiles as desired.
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This is a division of application Ser. No. 07/943,495, filed Sep. 11, 1992, and now U.S. Pat. No. 5,272,893.
BACKGROUND OF THE INVENTION
This invention relates generally to the treatment of textile materials, and more particularly, to a novel and improved method and apparatus for the treatment of textile materials in enzyme baths.
PRIOR ART
Enzymes have been developed to produce specialized treatment of textile materials. For example, it is possible with some enzymes, to simulate the effect previously achieved with stonewashing.
In prior stonewashing systems, the textiles are tumbled in a bath containing stones. During the tumbling of the textiles, such as blue denim jeans, the material is given a worn look, and the fabric is greatly softened. The tumbling stones cause damage to the machine carrying out the process, and means must be provided to separate the stone fragments from the textiles at the completion of the operation.
The cellulase enzyme, because it attacks the molecular structure of the textile, can achieve the stonewashed effect without requiring the use of stones and without the damaging effect produced by the stones.
Other enzymes have been developed and will be developed to perform specialized functions for the treatment of textiles. For example, enzymes for laundry purposes can be targeted to attack fatty materials which constitute many stains. Other enzymes may be targeted to attack the proteinaceous materials of stains such as blood. Most enzymes, however, tend to require very close temperature and pH control for effective performance.
For example, the cellulase enzyme used to simulate the stonewashing effect functions with greatest efficiency within a predetermined narrow temperature range, such as 50° C. to 60° C. If the temperature of the bath drops below such range, the rate of operation of the enzyme decreases, or even ceases, requiring substantial additional time to obtain the required result. On the other hand, if the temperature exceeds a temperature limit slightly above such predetermined range, the enzyme becomes denatured and ceases to function.
In the past, it is believed that cellulase enzymes have been used to simulate the stonewashed effect by introducing into a machine a bath containing the enzyme at a temperature within the predetermined narrow temperature range. While the processing of the textiles within such bath continues, the temperature of the bath decreases due to the transfer of heat to the environment. Consequently, the optimum rate of operation of the enzyme does not continue, and the rate of the enzyme's operation deteriorates. Consequently, longer cycle times are required to achieve the desired result.
It has been observed that the pH of a bath or solution has a similar effect on the performance of enzymes contained therein. For example, a cellulase enzyme used in stonewashing, known as an acid cellulase, operates in a bath having an optimum pH of approximately pH=4.8. A pH substantially out of this range, e.g., ±0.5 pH, will have a deleterious effect on stonewashing performance, reducing efficiency by about 20%. As with excessive heat, if the pH of the enzyme bath becomes too low, the enzyme will be denatured, while a pH too high will chemically destroy the enzyme.
In stonewashing applications, the indigo dye used in blue denim material is released into the bath during the stonewashing operation. This dye causes the bath pH to change with time, requiring addition of chemicals to maintain the desired, predetermined pH value. As a further consequence of the change in bath pH due to the released indigo, the indigo may actually backstain, or re-dye the material.
Such limitations as the relatively narrow temperature and pH range limits discussed above have severely limited the utility of employing enzymes in the textile industry by reducing substantially the efficiency of such processes. Such limitations have increased the cost and time required by these processes, and so have thus limited their practicality.
SUMMARY OF THE INVENTION
In accordance with the present invention, a novel and improved method and apparatus are provided for the treatment of textile materials within enzyme baths. In accordance with one important aspect of this invention, the treatment is performed while the temperature of the enzyme bath is maintained within the optimum temperature range. This is accomplished, however, without exceeding the known, predetermined temperature limit, so the enzyme is not denatured. Further, in accordance with this invention, the pH of the bath is maintained within the optimum pH range. It has been established that with the present invention, the cycle time required to obtain the desired stonewashed obtained effect can be reduced by approximately one-half. The results will be consistent and predictable from batch to batch.
The illustrated machine for processing the textile materials includes an outer shell, which forms the container for the bath. The textile material is treated within the bath. Located within the outer shell is a rotating drum in which the textile materials are placed.
A heat exchanger is located within the shell and is operated so as to automatically maintain the predetermined temperature of the bath within very close limits, such as plus or minus 0.5° C. (approximately equal to ±1° F.). The heat exchanger, in the illustrated embodiment, is connected to a source of heat at a temperature which is close to the predetermined temperature range. Further, the heat exchanger is supplied with heat and operated so that the surface temperature of the heat exchanger, which is in contact with the enzyme bath, does not reach the temperature limit above which the enzyme is denatured.
In addition, the machine includes means for accurately establishing the pH of the bath and for automatically maintaining such pH within the desired range.
In addition, in the illustrated embodiment, the shell is constructed to minimize locations where enzymes, having a high specific gravity, might collect. This ensures that the entire enzyme charge is available to perform the required function. In addition, agitator means are provided between the drum and the shell to ensure that the enzymes being used are uniformly distributed throughout the entire bath.
These and other aspects of this invention are illustrated in the accompanying drawings and more fully described in the following specification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the outer cylindrical shell or casing of the textile treating machine.
FIG. 2 is a perspective view of an embodiment of the heat exchangers and the sump and drain system.
FIG. 3 is a perspective view of the inner cylindrical drum of the textile treating machine.
FIG. 4 is a perspective view of a partially assembled embodiment of the machine.
FIG. 5 is a perspective view of a finished, assembled textile treating machine, with its main access door open.
FIG. 6 is a schematic diagram of the automatic pH and temperature monitoring and control system.
FIG. 7 is a graph of temperature against activity for a typical cellulase enzyme, showing the effect of temperature on enzymic activity.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring initially to FIG. 1, the subject textile treating machine 10 includes a stationary, cylindrical shell 12 having a generally horizontal axis adapted to contain a fluid enzyme bath. The shell 12 has a shell inner surface 11 and a shell outer surface 13. The machine is mounted upon standards 14 provided with conventional bearing members 16 and a suitable motor (not shown) for providing driving rotation of cylindrical drum 26 illustrated in FIG. 3. The shell includes heat exchanger elements 20 for providing heat and maintaining the bath temperature to a preselected range and a drain 22 disposed within a slightly recessed sump 24, most clearly shown in FIG. 2. Heat exchanger element constitutes part of the shell inner surface 11. As shown in FIG. 2, the heat exchanger elements 20 are designed to extend along the shell inner surface wall. Both the upper and lower ends of the heat exchanger are open so that portions of the bath behind the heat exchanger cannot become entrapped. The entire shell is structured so as to prevent occurrence of "dead" volume, such as pockets or voids, where enzymes might collect or be entrapped. The heat exchanger 20 may be of the tube or plate type. Further to avoid entrapment of enzymes, the sump 24 is shallow, covering a large area of the shell inner wall as compared to the depth of the sump.
The heat exchanger elements 20 may be either rigidly or removably mounted to the shell inner wall. U.S. patent application Ser. No. 07/954,973, filed Sep. 30, 1992, which is commonly assigned with the present application, is directed towards such removable heat exchanger elements.
As shown in more detail in FIG. 3, the apparatus into which the textile materials are placed is a cylindrical drum 26. The drum 26 is horizontally mounted along its axis of rotation, by which the drum is journaled at a first, closed end to bearing members 16 and a second bearing (not shown) for rotation within the outer shell during the processing of textile materials. The rotation provides both continuous mixing and agitation of the bath, and tumbling of the textile materials together with the bath used in the process. A motor (not shown) provides the rotational driving force for this agitation, mixing and tumbling. Continuous mixing and agitation of the bath is preferred, particularly when the enzymes have a high specific gravity and/or when they have limited solubility in the liquid medium employed, which is usually water. Many enzymes do not actually dissolve in water, forming instead a suspension or a colloidal suspension in the bath, which is subject to settling on standing. In such cases continuous agitation insures an even distribution of the enzymes throughout the bath.
Cylindrical drum 26 has a drum outer surface 27 and a drum inner surface 29. As shown in PIG. 3, the drum outer surface 27 is equipped with external, radially outwardly extending vanes or ribs 28 in order to provide the necessary mixing action or agitation of the bath in the zone between the drum 26 and shell 12. The drum inner surface 29 is likewise equipped with internal, radially inwardly extending vanes or breaker ribs 32 for providing agitation of the bath and the textile materials within the interior zone of the drum. The external vanes 28 are sized and mounted to allow only a small clearance between the external vanes 28 and the shell inner surface 11. The cylindrical wall of the drum 26 is penetrated by a plurality of perforations 34 which provide for the bath mixing, agitation, and exchange between the inside and outside zones of the drum. The perforations allow fluid communication between the interior zone of the drum and the zone outside the drum but within the shell, and thereby provide uniform distribution of the enzymes in the fluid or liquid medium of the bath.
The cylindrical drum 26 also includes at a second end a drum access opening 30 at drum end face panel 25 to enable solid materials, including the textile materials to be treated, to be received by the cylindrical drum 26 during processing of textile materials. The drum access opening 30 is disposed axially at the opposite end of the cylindrical drum from the bearing mount at bearing member 16 at the closed end of the cylindrical drum. When the inner, cylindrical drum 26 is operably mounted within the cylindrical shell 12, the drum access opening 30 aligns with the main access opening 60, (FIG. 5).
Any suitable enzyme bath or other liquid additive used for processing the textile materials may be added by suitable means such as inflow pipes 36. The flow into the shell from such inflow means may be disposed either above or below the expected liquid level within the drum. Preferably shell 12 includes both such inflow means, since some agents are better added below the water line and others are preferably added above the water line. The bath is combined with the textile materials to be treated by the mixing and agitating action of the drum.
As best shown in FIG. 4, the shell outer surface 13 of shell 12 preferably is covered by a layer of insulation 38. The most preferred type of insulation is closed cell polyurethane foam insulation, which substantially reduces heat losses.
As shown in detail in FIGS. 4 and 5, shell 12 is mounted between and supported by end panels 40 and 42. The open end 15 of the outer shell 12 is covered and sealed by cylindrical shell end face panel 58, having flanged or other connection to the end 15 and having an access door 62 attached to the cylindrical shell end face panel 58 by hinges and having sealing means 64 and locking means 66. Enclosing cabinet 70 is formed by the combination of end panels 40 and 42 with a top panel and two side walls 68.
An electronic control panel 72, for controlling or presetting process parameters, such as bath temperature and pH, is accessibly mounted on the enclosing cabinet 70. The apparatus thus subject to control, such as pumps, sensors, and the like, may be conveniently mounted below the outer shell 12 and within enclosing cabinet 70, as generally shown in FIG. 4. Preferably, the system comprising the heat exchanger 20 should be connected via insulated piping to an insulated holding tank equipped with heating means, as a measure to conserve both water and energy.
FIG. 6 is a schematic diagram of the automatic monitoring and control system, for such process parameters as pH and temperature. As shown, a sample of the bath is withdrawn, via a connection 81 to the shell drain 22 or sump 24, passed through a filter 82 and pumped by a pump 83 into a sealed sensing chamber 84. FIG. 6 shows only probes for pH 86 and temperature 87, but other parameters may also be monitored and controlled. Following analysis, the sample is either discharged to drain or returned to the interior of the outer shell through the passage 88. The apparatus presently in use is either the Optima Elite or the Optima Prism (both manufactured by Softrol Systems, Inc., Acworth, Ga., and available from Washex Machinery Company, Wichita Falls, Tex.). Both are capable of analyzing and providing feedback information for a total of four parameters, for which automatic controls may also be provided if necessary. Samples may be obtained and analyzed continuously or as frequently as necessary. The signal thus obtained is transmitted to electronic control panel 72, which activates appropriate portions of the system in order to make necessary adjustments to the bath, or to alert the operator to make manual adjustments. The sensing chamber is further adapted to be flushed with clean water or with suitable standardizing reagents.
In the event the controls establish that the temperature of the bath has dropped below the desired temperature the control panel 72 initiates operation of a pump 91 which pumps heated water from a source of heated water 92 to the heat exchanger 20. Similarly if the controller has established that correction of the bath pH is required, the pump 93 operates to introduce acid or base from source 94 or 95 (respectively) to the shell 12.
FIG. 7 is a graphical plot illustrating the effect of temperature on enzyme activity for a typical cellulase enzyme. Enzyme activity plotted against treatment bath temperature reveals the substantial effect played by temperature on such activity. FIG. 7 shows that, a change of temperature, whether an increase or a decrease from an optimum value, causes a substantial decrease in enzyme activity.
In the illustrated embodiment of this process, the bath is comprised of an enzyme, preferably a cellulase enzyme, and more preferably an acid cellulase enzyme in a fluid such as water. The preferred embodiment further comprises the use of hot water as the heat source for adjusting the temperature of the bath, the hot water being passed through heat exchanger 20. The hot water is passed through the heat exchanger 20 in response to control signals generated at electronic control panel 72 from detector signals arising from the automatic pH and temperature monitoring and control system such as that diagrammed in FIG. 6.
The temperature of the hot water should preferably be no more than approximately 12° C. or 20° F. above the preselected temperature of the bath. The hot water at the preselected temperature is supplied from a source which includes a heat source capable of responding to control by the control system herein described. Such a low temperature differential is provided to avoid the denaturing the enzyme in the bath in the vicinity of the heat exchanger. If a hotter source of heat is used, denaturation of the enzyme in the vicinity of the heat exchanger may occur. The heat flux between the heat exchange medium and the enzyme bath is thus kept low, and avoids unnecessary thermal enzyme degradation.
The preselected, preferred temperature of use of the enzyme bath is in the range of 48°-66° C. This preselected temperature is preferentially controlled to within ±0.5° C. (equal to approximately ±1° F.) by the control system shown schematically in FIG. 6. If the temperature exceeds an upper limit temperature the enzyme will be denatured, and if the temperature is allowed to drop significantly below this preferred range, the enzyme becomes increasingly dormant as the temperature falls.
The preferred pH of an acid cellulase enzyme bath is approximately pH =4.8, and should preferably be maintained to within ±0.1 pH unit by the control system shown schematically in FIG. 6. The preferred pH of a neutral cellulase enzyme both is approximately pH=6-7. In both enzyme systems, excessive fluctuation in the pH value will result in denaturation or deactivation of the enzyme.
At least four types of enzymes are used in laundry applications, including stonewashing. Proteases, such as Esperase® (available from Novo Nordisk) assist in the removal of protein-based stains, such as those from blood and various food products. Lipases, such as Lipolase™ (Novo Nordisk) are used to aid the removal of fat-containing stains such as from food and cosmetics. Amylases, such as Teramyl® (Novo Nordisk) are used to remove residues of starchy foods such as mashed potatoes or porridge. Cellulases, such as Celluzyme® (Novo Nordisk) are used for color brightening, fabric softening, stonewashing and removal of particulate soil. Other enzymes, particularly synthetic enzymes, are in used in the textile industry in relation to dyeing of fabrics.
In the stonewashing industry two types of enzymes are presently in use, acid cellulase and neutral cellulase enzymes. Acid cellulases are less expensive, and therefore preferable economically, but are more difficult to use effectively due to the narrow pH and temperature ranges in which they operate efficiently. Acid cellulase baths should be closely monitored to maintain, preferably, a maximum temperature range of approximately ±0.5° C. (±1° F.), and a maximum pH range of approximately ±0.1 pH unit.
Neutral cellulases are more operationally forgiving than acid cellulases, but they are approximately 40% more expensive.
Synthetic enzymes are very similar to the cellulase enzymes with respect to the degree of pH and temperature control required for processing as described herein.
The enzyme bath maintenance system described herein will control the precise temperature and pH requirements of the enzyme process. Temperature levels are maintained by indirect heating with internal plate coils or pipe coils. These coils may either be rigidly attached to the shell structure or be removable for easier service or maintenance. In the case of removable coils, the apparatus is capable of operation with one of the coils removed, which will eliminate downtime if repairs make a coil unavailable. The preferred heating medium is hot water.
The presently disclosed apparatus has been designed for and is preferably used with enzyme-based systems for treating textile materials. For instance, since enzymes have a high specific gravity and are generally not completely dissolved in an aqueous bath system, they sink or tend to settle out. The enzymes thus tend to collect or to become entrapped in the sump and other low or embedded locations or voids. To overcome this problem, the drum outer surface 27 has been equipped with vanes for agitating the enzymes and preventing their settlement or entrapment in such locations. As a second instance, due to the need of enzymes to be used in a thermally stable and controlled environment, the outer shell of the apparatus has been equipped with thermal insulation, specifically closed cell polyurethane insulation, in order to help maintain a steady, controlled temperature.
The invention has been described hereinabove with particular reference to achieving, in textile materials, a stonewashed effect by the use of an enzyme bath, in particular the use of cellulase enzymes on denim-type fabrics. It is to be understood, however, that reference to stonewashing of denim-type fabrics is not to be construed as an indication that the broader aspects of the invention are so limited, but that the disclosure is intended to include other fabrics, and further to include other processes such as cleaning, laundering, and dyeing of such fabrics, with or without the use of enzymes. The apparatus and method herein described and claimed further are applicable to and are specifically intended to include tunnel-type machines for the treatment of textile materials.
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An enzyme bath maintenance system is provided for use in such textile treating fields as stonewashing, laundry, cleaning and dyeing, including the use of enzymes as the active agent, in which the enzymes are utilized within narrowly controlled ranges of pH and temperature. As a means for providing heat for controlling the temperature, a heat exchanger in which the heat source is hot water at a temperature not more than 12° C. higher than that of the desired temperature, is disposed within the apparatus. The heat exchanger and the apparatus as a whole are designed to avoid pockets which allow the enzyme to become entrapped therein. The apparatus further includes automated means for detecting, monitoring and reporting bath parameters such as pH and temperature, with output for manual or automatic control thereof, and means for agitating the enzyme bath to maintain uniform distribution of the enzyme.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a drive force control method for a four-wheel drive vehicle.
[0003] 2. Description of the Related Art
[0004] In the case of turning a corner having a small turning radius in a four-wheel drive mode of a four-wheel drive vehicle in a low to medium vehicle speed range, a difference in rotational speed due to a difference in turning radius is generated between the front and rear wheels of the vehicle, causing a tight corner braking phenomenon. As the prior art for eliminating such a tight corner braking phenomenon, front and rear wheels driving devices are disclosed in Japanese Patent Publication Nos. 7-61779 and 7-64219.
[0005] The front and rear wheels driving devices disclosed in these publications have such a structure that a speed increasing device is provided between main drive wheels and auxiliary drive wheels to thereby adjust an average rotational speed of the auxiliary drive wheels to an average rotational speed of the main drive wheels. This speed increasing device includes a lockup clutch and a speed increasing clutch, which are selectively switched between ON and OFF states to thereby obtain a lockup condition or same speed condition where the average rotational speed of the main drive wheels and the average rotational speed of the auxiliary drive wheels are substantially equal to each other or an increasing speed condition where the average rotational speed of the auxiliary drive wheels is greater than the average rotational speed of the main drive wheels.
[0006] Particularly in the front and rear wheels driving device disclosed in Japanese Patent Publication No. 7-61779, a torque distribution ratio between right and left rear wheels are controlled according to a vehicle speed and a steering angle so that the rear wheel torque is larger than the front wheel torque and the turning outer wheel torque is larger than the turning inner wheel torque. In this front and rear wheels driving device, the auxiliary drive wheels are increased in rotational speed by the speed increasing device in turning a corner having a small turning radius in the four-wheel drive mode, thereby preventing the tight corner braking phenomenon.
[0007] The object of distributing a drive force between right and left wheels in turning is to give a larger drive force to the outer wheel as compared with the inner wheel, thereby generating a turning moment to suppress understeer occurring at acceleration during turning. However, the expectable effect of the drive force distribution between right and left wheels may vary according to a vehicle speed. For example, there is a tendency to desire stabilization of a vehicle body rather than improvement in maneuverability by giving a large turning moment at high vehicle speeds. However, minute control of the drive force distribution between right and left wheels according to a vehicle speed is not sufficiently disclosed in the above publications.
[0008] By distributing a driving/braking force generated by an engine in a four-wheel drive vehicle between front wheels and rear wheels, the load on each wheel can be controlled to maximize the utilization of tire performance. Particularly at acceleration of a two-wheel drive vehicle, a drive force so large as to cause skid of the wheels is generated. It is therefore very effective to make the two-wheel drive vehicle into a four-wheel drive vehicle.
[0009] In also taking a turning performance into consideration, the performance can be improved by changing the drive force distribution ratio between front and rear wheels so that the drive force distributed to the rear wheels is greater than that to the front wheels. However, when a vehicle speed is increased, a drive force and an engine brake force generated by a vehicle body are decreased in general, so that the effect of changing the drive force distribution ratio between front and rear wheels is small. Changing the torque distribution ratio of rear wheels to front wheels according to a vehicle speed, accelerator opening, transmission shift position, etc. is not sufficiently described in the above publications.
SUMMARY OF THE INVENTION
[0010] It is therefore an object of the present invention to provide a drive force control method for a four-wheel drive vehicle which can accurately control a drive force distribution ratio between right and left front wheels or between right and left rear wheels.
[0011] It is another object of the present invention to provide a drive force control method for a four-wheel drive vehicle which can accurately control a drive force distribution ratio between front wheels and rear wheels according to a vehicle speed, accelerator opening, transmission shift position, etc.
[0012] In accordance with a first aspect of the present invention, there is provided a drive force control method for a four-wheel drive vehicle having main drive wheels connected to a driving source, auxiliary drive wheels whose drive torque is adjustable, and a mechanism capable of adjusting a torque distribution ratio between said main drive wheels and said auxiliary drive wheels so that the torque distribution ratio of said auxiliary drive wheels to said main drive wheels is increased in turning and also capable of adjusting a torque distribution ratio between said right and left auxiliary drive wheels in turning, said drive force control method including the steps of detecting a vehicle speed; and gradually decreasing the torque distribution ratio of a turning outer wheel as one of said right and left auxiliary drive wheels to a turning inner wheel as the other with an increase in said vehicle speed.
[0013] The object of distributing a drive force between right and left wheels in turning is to give a larger drive force to the outer wheel as compared with the inner wheel, thereby generating a turning moment to suppress understeer occurring at acceleration during turning. However, the expectable effect of the drive force distribution between right and left wheels may vary according to a vehicle speed. For example, there is a tendency to desire stabilization of a vehicle body rather than improvement in maneuverability by giving a large turning moment at high vehicle speeds.
[0014] According to the first aspect of the present invention, the torque distribution ratio of the turning outer wheel to the turning inner wheel is gradually decreased with an increase in vehicle speed. Accordingly, torque steps or the like can be eliminated to reduce vibrations, noise, shock, etc.
[0015] In accordance with a second aspect of the present invention, said drive force control method further includes the step of decreasing the torque distribution ratio of said turning outer wheel to said turning inner wheel in a low-speed position or a high-speed position as a transmission shift position.
[0016] When the transmission shift position is a low-speed position or a high-speed position, the necessity to improve the turning performance is lowered and constant control is therefore sufficient. According to the second aspect of the present invention, the torque distribution ratio of the turning outer wheel to the turning inner wheel is decreased when the transmission shift position is a low-speed position or a high-speed position. Accordingly, undue changes in input to the differential device for the auxiliary drive wheels can be reduced to thereby suppress the generation of noise, shock, and vibrations.
[0017] In general, the maneuverability of a vehicle as in forward running is not desired in reverse running. Therefore, drive force distribution control between right and left wheels similar to that in forward running is not desired. In particular, it is not necessary to improve the turning performance in reverse running, and constant control is therefore sufficient.
[0018] In accordance with a third aspect of the present invention, said drive force control method further comprises the step of decreasing the torque distribution ratio of said turning outer wheel to said turning inner wheel in reverse running.
[0019] Since the torque distribution ratio of the turning outer wheel to the turning inner wheel is decreased in reverse running, undue changes in input to the differential device for the auxiliary drive wheels can be reduced to thereby suppress the generation of noise, shock, and vibrations.
[0020] In accordance with a fourth aspect of the present invention, said drive force control method further includes the step of decreasing the torque distribution ratio of said turning outer wheel to said turning inner wheel with a decrease in temperature of hydraulic fluid for a differential device for the auxiliary drive wheels.
[0021] When the temperature of hydraulic fluid for the differential device for the auxiliary drive wheels is low, there arises a problem such that an actual output from the mechanism in response to a control command may delay because of an increase in viscosity of the fluid. According to the fourth aspect of the present invention, the torque distribution ratio of the turning outer wheel to the turning inner wheel is decreased with a decrease in temperature of hydraulic fluid for the differential device for the auxiliary drive wheels. Accordingly, a degradation in performance due to a decrease in temperature of the hydraulic fluid can be minimized.
[0022] In accordance with a 5th aspect of the present invention, there is provided a drive force control method for a four-wheel drive vehicle having main drive wheels connected to a driving source, auxiliary drive wheels whose drive torque is adjustable, and a mechanism capable of adjusting a torque distribution ratio between said main drive wheels and said auxiliary drive wheels so that the torque distribution ratio of said auxiliary drive wheels to said main drive wheels is increased in turning, said drive force control method including the steps of detecting a vehicle speed; and gradually decreasing the torque distribution ratio of said auxiliary drive wheels to said main drive wheels with an increase in said vehicle speed.
[0023] When a vehicle speed is increased, a drive force and an engine brake force generated by a vehicle body are decreased in general, so that the effect of changing the drive force distribution ratio between main drive wheels and auxiliary drive wheels is small. According to the 5th aspect of the present invention, the torque distribution ratio of the auxiliary drive wheels to the main drive wheels is gradually decreased with an increase in vehicle speed. Accordingly, torque steps or the like can be eliminated to reduce vibrations, noise, and shock.
[0024] In accordance with a 6 th aspect of the present invention, said drive force control method further includes the step of increasing the torque distribution ratio of said auxiliary drive wheels to said main drive wheels with an increase in accelerator opening.
[0025] At acceleration, the vertical load on the auxiliary drive wheels is increased by the influence of a longitudinal acceleration, causing an increase in performance of the auxiliary drive wheels. According to the 6th aspect of the present invention, the torque distribution ratio of the auxiliary drive wheels to the main drive wheels is effectively increased at acceleration. The operator's intention to accelerate the vehicle can be detected earliest by detecting an accelerator opening. Accordingly, by changing the torque distribution ratio between the main drive wheels and the auxiliary drive wheels according to an accelerator opening, quick-response control can be performed.
[0026] In accordance with a 7th aspect of the present the invention, said drive force control method further includes the step of decreasing the torque distribution ratio of said auxiliary drive wheels to said main drive wheels in a low-speed position or a high-speed position as a transmission shift position.
[0027] When the transmission shift position is a low-speed position or a high-speed position, the necessity to improve the turning performance is lowered and constant control is therefore sufficient. According to the 7th aspect of the present invention, the torque distribution ratio of the auxiliary drive wheels to the main drive wheels is decreased when the transmission shift position is a low-speed position or a high-speed position. Accordingly, undue changes in input to the differential device for the auxiliary drive wheels can be reduced to thereby reduce noise, shock, and vibrations.
[0028] In accordance with an 8th aspect of the present the invention, said drive force control method further includes the step of decreasing the torque distribution ratio of said auxiliary drive wheels to said main drive wheels in reverse running.
[0029] In general, the maneuverability of a vehicle as in forward running is not desired in reverse running. Therefore, drive force distribution control between main drive wheels and auxiliary drive wheels similar to that in forward running is not desired. In particular, it is not necessary to improve the turning performance in reverse running, and constant control is therefore sufficient. According to the 8 th aspect of the present invention, the torque distribution ratio of the auxiliary drive wheels to the main drive wheels is decreased in reverse running. Accordingly, undue changes in input to the differential device for the auxiliary drive wheels can be reduced to thereby suppress the generation of noise, shock, and vibrations.
[0030] In accordance with a 9th aspect of the present the invention, said drive force control method further includes the step of decreasing the torque distribution ratio of said auxiliary drive wheels to said main drive wheels with a decrease in temperature of hydraulic fluid for a differential device for auxiliary drive wheels.
[0031] When the temperature of hydraulic fluid for the differential device for the auxiliary drive wheels is low, there arises a problem such that an actual output from the mechanism in response to a control command may delay because of an increase in viscosity of the fluid. According to the 9th aspect of the present invention, the torque distribution ratio of the auxiliary drive wheels to the main drive wheels is decreased with a decrease in temperature of hydraulic fluid for the differential device for the auxiliary drive wheels. Accordingly, a degradation in performance due to a decrease in temperature of the hydraulic fluid can be minimized.
[0032] The above and other objects, features and advantages of the present invention and the manner of realizing them will become more apparent, and the invention itself will best be understood from a study of the following description and appended claims with reference to the attached drawings showing some preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] FIG. 1 is a schematic diagram showing a power transmitting system for a four-wheel drive vehicle to which the drive force control method of the present invention is applicable;
[0034] FIG. 2 is a sectional view of a speed increasing device (speed changing device) and a rear differential device;
[0035] FIG. 3 is a diagram showing the locus of each wheel during turning of the vehicle;
[0036] FIG. 4A is a diagram showing the transmission of power to the rear wheels during straight running at acceleration;
[0037] FIG. 4B is a diagram showing the transmission of power to the rear wheels during turning at acceleration;
[0038] FIG. 5 is a block diagram of a control system according to a preferred embodiment of the present invention;
[0039] FIG. 6 is a graph showing the relation between lateral G and torque distribution ratios of the outer wheel and the rear wheels;
[0040] FIG. 7 is a flowchart showing the processing of calculating a drive force distribution ratio between the front and rear wheels and a drive force distribution ratio between the right and left rear wheels in the preferred embodiment of the present invention;
[0041] FIG. 8 is a graph showing the relation between estimated slip angle and torque reducing amounts to the outer wheel and the rear wheels;
[0042] FIG. 9 is a flowchart showing the detection of a running condition;
[0043] FIG. 10 is a flowchart showing the calculation of a target rear wheel torque;
[0044] FIG. 11 is a flowchart showing 4 WD control according to the target rear wheel torque;
[0045] FIG. 12 is a graph showing the relation between vehicle speed and torque distribution to the rear wheels;
[0046] FIG. 13 is a graph showing the relation between accelerator opening and torque distribution to the rear wheels;
[0047] FIG. 14 is a graph showing the relation between shift position and torque distribution to the rear wheels;
[0048] FIG. 15 is a graph showing the relation between rear differential oil temperature and torque distribution to the rear wheels;
[0049] FIG. 16 is a flowchart showing the processing of calculating a target rear outer wheel torque;
[0050] FIG. 17 is a graph showing the relation between vehicle speed and torque distribution to the rear outer wheel;
[0051] FIG. 18 is a graph showing the relation between shift position and torque distribution to the rear outer wheel;
[0052] FIG. 19 is a graph showing the relation between rear differential oil temperature and torque distribution to the rear outer wheel;
[0053] FIG. 20 is a flowchart showing the processing of controlling the change from a lockup condition to a speed increase condition;
[0054] FIG. 21 is a flowchart showing the processing of controlling the change from a speed increase condition to a lockup condition;
[0055] FIG. 22 is a flowchart showing the processing of stabilizing the behavior of the vehicle in an unstable condition of the vehicle;
[0056] FIG. 23 is a graph showing the relation between shift position and permission/inhibition of the speed increase;
[0057] FIG. 24 is a flowchart showing the control in an engine brake condition;
[0058] FIG. 25 is a flowchart showing the control during braking; and
[0059] FIG. 26 is a flowchart showing the processing of permitting the speed increase condition after low-speed running.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0060] Referring to FIG. 1 , there is shown a schematic diagram of a power transmitting system for a four-wheel drive vehicle having a speed increasing device (speed changing device) 10 based on a front-engine front-drive (FF) vehicle. As shown in FIG. 1 , the power transmitting system for the four-wheel drive vehicle mainly includes a front differential device 6 to which the power of an engine 2 located at a front portion of the vehicle is transmitted from an output shaft 4 a of a transmission 4 , a speed increasing device (speed changing device) 10 to which the power from the front differential device 6 is transmitted through a propeller shaft 8 , and a rear differential device 12 to which the power from the speed increasing device 10 is transmitted.
[0061] The front differential device 6 has a structure well known in the art, and the power from the output shaft 4 a of the transmission 4 is transmitted through a plurality of gears 14 and output shafts 16 and 18 in a differential case 6 a to left and right front wheel drive shafts 20 and 22 , thereby driving front wheels. As will be hereinafter described, the rear differential device 12 includes a pair of planetary gear sets and a pair of electromagnetic actuators for controlling the engagement of multiplate clutch mechanisms. The electromagnetic actuators are controlled to transmit the power to left and right rear wheel drive shafts 24 and 26 , thereby driving rear wheels.
[0062] FIG. 2 is a sectional view of the speed increasing device 10 and the rear differential device 12 located downstream of the speed increasing device 10 . The speed increasing device 10 includes an input shaft 30 rotatably mounted in a casing 28 and an output shaft (hypoid pinion shaft) 32 . The speed increasing device 10 further includes an oil pump subassembly 34 , a planetary carrier subassembly 38 , a lockup clutch 40 , and a speed increasing clutch (speed increasing brake) 42 .
[0063] When the lockup clutch 40 is engaged, the rotation of the input shaft 30 is directly transmitted to the output shaft 32 without changes in rotational speed. On the other hand, when the lockup clutch 40 is disengaged and the speed increasing clutch 42 is engaged, the rotation of the input shaft 30 is transmitted to the output shaft 32 with the rotational speed being increased by a predetermined amount. A detailed structure of the speed increasing device 10 is disclosed in Japanese Patent Application NO. 2002-278836 previously filed by the present applicant. The rear differential device 12 located downstream of the speed increasing device 10 has a hypoid pinion gear 44 formed at the rear end of the hypoid pinion shaft 32 . The hypoid pinion gear 44 is in mesh with a hypoid ring gear 48 , and the power from the hypoid ring gear 48 is input to the ring gears of a pair of left and right planetary gear sets 50 A and 50 B.
[0064] The sun gears of the planetary gear sets 50 A and 50 B are rotatably mounted on a left rear axle 24 and a right rear axle 26 , respectively. The planetary carriers of the planetary gear sets 50 A and 50 B are fixed to the left rear axle 24 and the right rear axle 26 , respectively. In each of the planetary gear sets 50 A and 50 B, the planetary gear carried by the planetary carrier is in mesh with the sun gear and the ring gear. The left and right planetary gear sets 50 A and 50 B are connected to a pair of left and right clutch mechanism (brake mechanisms) 51 provided to variably control the torque of the respective sun gears. Each clutch mechanism 51 includes a wet multiplate clutch (brake) 52 and an electromagnetic actuator 56 for operating the multiplate clutch 52 .
[0065] The clutch plates of each wet multiplate clutch 52 are fixed to a casing 54 , and the clutch discs of each wet multiplate clutch 52 are fixed to the sun gear of each of the planetary gear sets 50 A and 50 B. Each electromagnetic actuator 56 is composed of a core (yoke) 58 , an exciting coil 60 inserted in the core 58 , an armature 62 , and a piston 64 connected to the armature 62 . When a current is passed through the exciting coil 60 , the armature 62 is attracted to the core 58 by the coil 60 to thereby generate a thrust. Accordingly, the piston 64 integrally connected to the armature 62 pushes the multiplate clutch 52 to thereby generate a clutch torque.
[0066] Accordingly, the sun gears of the planetary gear sets 50 A and 50 B are fixed to the casing 54 , and the drive force of the hypoid pinion shaft 32 is transmitted through the ring gears, the planet gears, and the planetary carriers of the planetary gear sets 50 A and 50 B to the left and right rear axles 24 and 26 . By making variable the currents to be passed through the left and right exciting coils 60 , the output torques to the left and right rear axles 24 and 26 can be variably controlled.
[0067] When the lockup clutch 40 of the speed increasing device 10 is engaged and the left and right exciting coils 60 of the rear differential device 12 are off, the left and right clutch mechanisms 51 are disengaged and the sun gears of the planetary gear sets 50 A and 50 B therefore idly rotate about the left and right rear axles 24 and 26 . Accordingly, the drive force (torque) of the hypoid pinion shaft 32 is not transmitted to the left and right rear axles 24 and 26 . In this case, the rear wheels idly rotate and the drive force from the engine is fully transmitted to the front wheels, so that this four-wheel drive vehicle runs in a two-wheel drive mode.
[0068] When predetermined amounts of currents are passed through the left and right exciting coils 60 to completely engage the left and right multiplate clutches 52 through the pistons 64 , the sun gears of the planetary gear sets 50 A and 50 B are fixed to the casing 54 . Accordingly, the drive force of the input shaft 30 is uniformly divided by the planetary gear sets 50 A and 50 B and transmitted to the left and right rear axles 24 and 26 . As a result, this four-wheel drive vehicle runs in a four-wheel drive mode.
[0069] In the case of turning a corner having a small turning radius in the four-wheel drive mode in a medium vehicle speed range, the lockup clutch 40 is disengaged and the speed increasing clutch 42 is engaged. Accordingly, the rotational speed of the output shaft 32 is increased over that of the input shaft 30 . The speed increasing rate is about 5%, for example. In such a case that the vehicle is turned in the condition where the rotational speed of the output shaft 32 is increased over that of the input shaft 30 , the rear wheel on the turning outside can be rotated faster than the front wheel on the same side, so that the drive force can be transmitted to the rear wheel on the turning outside, and the turning performance in the medium vehicle speed range can be improved.
[0070] The loci of the front wheels and the rear wheels during turning of the vehicle will now be described with reference to FIG. 3 . Reference numeral 66 denotes the center of turning, reference numerals 68 L and 68 R denote the left and right front wheels, respectively, and reference numerals 70 L and 70 R denote the left and right rear wheels, respectively. It is assumed that the vehicle is turned counterclockwise about the center 66 . Reference numeral 72 denotes the locus of the front inner wheel 68 L, reference numeral 74 denotes the locus of the front outer wheel 68 R, and reference numeral 76 denotes the average locus of the front wheels. Reference numeral 78 denotes the average locus of the rear wheels in the engaged condition of the lockup clutch 40 , and reference numeral 80 denotes the locus of the rear outer wheel 70 R in the engaged condition of the lockup clutch 40 .
[0071] In the case of turning at high lateral G as shown in FIG. 3 , the slip angle of the rear wheels becomes larger (the cornering force becomes larger), so that the locus 80 of the rear outer wheel 70 R is larger in radius than the average locus of the rear wheels 78 in the engaged condition of the lockup clutch 40 , and the drive force (torque) is not transmitted to the rear outer wheel 70 R. In the four-wheel drive vehicle according to the present invention, the speed increasing clutch 42 of the speed increasing device 10 is engaged in this case, thereby increasing the rotational speed of the output shaft 32 by about 5% over the rotational speed of the input shaft 30 . Accordingly, the drive force (torque) can be transmitted to the rear outer wheel 70 R. Reference numeral 82 denotes the locus of the rear outer wheel 70 R in the engaged condition of the speed increasing clutch 42 .
[0072] Operation modes of the drive force control method according to the present invention are shown in Tables 1A and 1B.
TABLE 1A Forward Straight Left turn Left turn Straight (LSD) (lockup) (speed increase) Accelera- Decelera- Accelera- Decelera- Accelera- Decelera- Accelera- Decelera- Element Mode tion tion tion tion tion tion tion tion 1 Speed — — — — — — on on increasing clutch 2 Lockup on on on on on on — — clutch 3 Left Medium Small Large Small Small Small Small Small clutch 4 Right Medium Small Large Small Large Small Large Small clutch
[0073]
TABLE 1B
Reverse
Straight
Straight
(LSD)
Accelera-
Decelera-
Accelera-
Decelera-
Element
Mode
tion
tion
tion
tion
1
Speed
—
—
—
—
increasing
clutch
2
Lockup
on
on
on
on
clutch
3
Left
Medium
Small
Large
Small
clutch
4
Right
Medium
Small
Large
Small
clutch
In the case of right turn, the magnitudes in the element (3) and the magnitudes in the element (4) are interchanged.
Conditions for turning (lockup):
The vehicle speed is less than 30 km/h or greater than 120 km/h. The lateral G is less than 0.075 G.
[0078] Conditions for turning (speed increase):
The vehicle speed is 30 to 120 km/h, and the lateral G is not less than 0.075 G.
[0080] Small: 0 to 40 kgfm Medium: 40 to 80 kgfm Large: 80 to 110 kgfm
[0081] In Tables 1A and 1B, “Small”, “Medium”, and “Large” indicate the magnitudes of the engaging force of each clutch. “Small” means 0 to 40 kgfm, “Medium” means 40 to 80 kgfm, and “Large” means 80 to 110 kgfm. In the case that the vehicle speed is less than 30 km/h or greater than 120 km/h during turning, the lockup clutch 40 is engaged. Further, also in the case that the lateral G is less than 0.075 G, the lockup clutch 40 is engaged.
[0082] In the case that the vehicle speed is 30 to 120 km/h and the lateral G is not less than 0.075 G during turning, the speed increasing clutch 42 is engaged, so that torque transmission to the rear outer wheel is allowed. While the engaging forces of the left and right clutches 52 during left turning are shown in Table 1, the magnitudes of the engaging force of the left clutch 52 may be interchanged with the magnitudes of the engaging force of the right clutch 52 in the case of right turning.
[0083] FIG. 4A shows the condition where the lockup clutch 40 is engaged at acceleration during straight running. In this condition, the torque is transmitted uniformly to the left and right rear axles 24 and 26 . In FIGS. 4A and 4B , torque transmission paths are shown by bold lines. FIG. 4B shows the condition where the speed increasing clutch 42 is engaged at acceleration during left turning. In this condition, the engaging force of the right clutch 52 is controlled to become larger than the engaging force of the left clutch 52 , thereby increasing the torque distribution to the right rear axle 26 .
[0084] While the operational conditions shown in Tables 1A and 1B are the general outlines of the drive force control method according to the present invention, the drive force control method will now be described in detail.
[0085] FIG. 5 is a block diagram of a control system according to the present invention. This control system has a feed-forward control section 84 , a feedback control section 86 , and a speed increase control section 88 . Engine torque and transmission gear position are input into a block 90 in the feed-forward control section 84 to calculate a tire drive force. A vehicle speed detected by a vehicle speed sensor 92 and a steering angle detected by a steering angle sensor 94 are input into a block 96 to calculate an estimated lateral acceleration (estimated lateral G).
[0086] A lateral acceleration (lateral G) detected by a lateral acceleration sensor (lateral G sensor) 98 is input into a block 100 to determine a lateral acceleration (lateral G). The lateral G output from the block 100 is corrected by the estimated lateral G output from the block 96 to obtain a control lateral G signal. This correction is made by averaging the lateral G signal and the estimated lateral G signal, for example. The control lateral G signal is input into an outer wheel decision block 102 to determine which of the right and left rear wheels is an outer wheel. The control lateral G signal is also input into a block 104 to calculate a torque distribution ratio between the front and rear wheels, and is also input into a block 106 to calculate a torque distribution ratio between the right and left wheels.
[0087] An outer wheel signal from the outer wheel decision block 102 , a rear wheel distribution ratio signal from the block 104 , and a rear outer wheel distribution ratio signal from the block 106 are input into a block 108 to obtain a torque distribution ratio between the rear outer wheel and the rear inner wheel. The vehicle speed detected by the vehicle speed sensor 92 , the steering angle detected by the steering angle sensor 94 , the lateral G detected by the lateral G sensor 98 , and a yaw rate detected by a yaw rate sensor 110 are input into a vehicle model block 112 in the feedback control section 86 to calculate a slip angle of the vehicle. Further, a slip angle threshold is calculated by a block 114 according to the vehicle speed detected by the vehicle speed sensor 92 and the lateral G detected by the lateral G sensor 98 .
[0088] A rear wheel torque reducing amount is obtained by a block 116 according to a difference between the slip angle and the slip angle threshold, and an outer wheel torque reducing amount is obtained by a block 118 according to this difference. In other words, if the slip angle of the vehicle is greater than a predetermined value, it is determined that the vehicle is in an unstable condition, and the rear wheel distributed torque and the outer wheel distributed torque are reduced to eliminate this unstable condition. A left rear wheel torque command value is generated by a block 120 according to the drive torque calculated by the block 90 , the left rear wheel torque from the block 108 , the rear wheel torque reducing amount from the block 116 , and the outer wheel torque reducing amount from the block 118 , and the left electromagnetic actuator 56 is controlled by a left clutch control section 122 according to the left rear wheel torque command value generated above.
[0089] Similarly, a right rear wheel torque command value is generated by a block 124 according to the drive torque calculated by the block 90 , the right rear wheel torque from the block 108 , the rear wheel torque reducing amount from the block 116 , and the outer wheel torque reducing amount from the block 118 , and the right electromagnetic actuator 56 is controlled by a right clutch control section 126 according to the right rear wheel torque command value generated above.
[0090] A speed increase threshold is calculated by a block 128 in the speed increase control section 88 according to the vehicle speed detected by the vehicle speed sensor 92 . The estimated lateral G calculated by the block 96 and the speed increase threshold calculated by the block 128 are compared with each other, and it is determined by a block 130 that a speed increasing condition is to be provided when the estimated lateral G is greater than the speed increase threshold, whereas the lockup condition is to be provided when the estimated lateral G is not greater than the speed increase threshold. A speed increase signal or a lockup signal from the block 130 is input into a speed increasing device control section 132 to control the speed increase/lockup of the speed increasing device 10 .
[0091] The drive force control method of the present invention will now be described in detail. When the vehicle is accelerated during turning, the vertical loads on the inner wheels and the front wheels are reduced by the influence of lateral and longitudinal accelerations acting on the vehicle body. Further, since the front wheels are steered for turning, a lateral force acting on the front wheels is greater than that acting on the rear wheels. The greater the vertical load, the greater the drive force that can be generated by each tire. Therefore, the load on the tire of each front wheel is greater than the load on the tire of each rear wheel during turning at acceleration, and the load on the tire of each inner wheel is greater than the load on the tire of each outer wheel during turning at acceleration.
[0092] The load on each tire depends on the degree of turning (the magnitude of lateral G) and the magnitude of acceleration. Owing to this tendency, understeer occurs in the vehicle during turning at acceleration, and the running locus of the vehicle is deviated to the outside of turn. As a result, the acceleration performance during turning is limited. It is effective to make the load on each tire uniform in improving this acceleration performance. According to the drive force control method of the present invention, the torque distribution ratio between the front and rear wheels is controlled so that the rear wheel torque is increased with an increase in lateral acceleration (lateral G), and the torque distribution ratio between the right and left wheels is controlled so that the outer wheel torque is increased with an increase in lateral G as shown in FIG. 6 . Thus, the rear wheel torque distribution ratio and the outer wheel torque distribution ratio are increased with an increase in lateral G. Accordingly, understeer occurring during turning at acceleration can be suppressed to thereby allow stable acceleration.
[0093] The torque distribution between the front and rear wheels and the torque distribution between the right and left rear wheels will now be described in detail with reference to the flowchart shown in FIG. 7 . In step 10 (shown by “S 10 ” in FIG. 7 ), the lateral G signal from the lateral G sensor 98 is detected. In step 11 , the estimated lateral G is calculated according to the steering angle detected by the steering angle sensor 94 and the vehicle speed detected by the vehicle speed sensor 92 . In step 12 , the lateral G signal is corrected by the estimated lateral G signal to calculate the control lateral G. This correction is performed by averaging the lateral G signal and the estimated lateral G signal, for example.
[0094] The use of an output signal from a lateral G sensor as the lateral G signal is most general. However, it is known that the output from the lateral G sensor delays from a turning operation by the operator. Further, an actuator for performing the torque distribution generally has delay characteristics. Accordingly, if only the output signal from the lateral G sensor is used, control delay occurs. To suppress such control delay, the estimated lateral G is calculated according to the steering angle and the vehicle speed detected and the output signal from the lateral G sensor is corrected by the estimated lateral G signal obtained above according to this preferred embodiment. Since the steering angle is a turning operation itself by the operator, the estimated lateral G signal can be generated earlier than the output signal from the lateral G sensor. As a result, a control command can be early output to thereby allow quick-response control.
[0095] After calculating the control lateral G in step 12 , the program proceeds to step 13 to calculate the rear wheel torque and the outer wheel torque according to the control lateral G. In step 14 , it is determined whether or not the vehicle is in an unstable condition. For example, in the case that the slip angle of the vehicle is greater than a predetermined value or the change rate of the slip angle is greater than a predetermined value, it is determined that the vehicle is in an unstable condition. These predetermined values may be changed according to the condition of a road surface. For example, the smaller the coefficient of friction (μ) between a road surface and each tire, the smaller the predetermined values to be set. Accordingly, the unstable condition can be detected earlier and more accurately.
[0096] If the unstable condition of the vehicle is detected, the program proceeds to step 15 to obtain a rear wheel torque reducing amount and an outer wheel torque reducing amount and to correct the rear wheel torque and the outer wheel torque according to these reducing amounts, respectively. The rear wheel torque reducing amount and the outer wheel torque reducing amount are increased with an increase in estimated slip angle as shown in FIG. 8 . In other words, the unstable condition of the vehicle is corrected in step 15 by making the torque distribution ratio between the front and rear wheels greater on the front wheel side and making the torque distribution ratio between the right and left wheels smaller on the outer wheel side.
[0097] If the unstable condition of the vehicle is not determined in step 14 or after the rear wheel torque and the outer wheel torque are corrected in the unstable condition of the vehicle in step 15 , the program proceeds to step 16 to calculate an actuator control value according to the rear wheel torque and the outer wheel torque. This actuator control value includes control values for the right and left electromagnetic actuators 56 and control values for the lockup clutch 40 and the speed increasing clutch 42 of the speed increasing device 10 . In step 17 , the right and left electromagnetic actuators 56 are controlled and whether the speed increasing device 10 is to become a lockup condition or a speed increasing condition is controlled according to the above control values. The degree of this speed increase is set so that the rotational speed of the output shaft 32 becomes greater by about 5% than the rotational speed of the input shaft 30 , for example.
[0098] A control method for drive force (torque) distribution between the front and rear wheels of the four-wheel drive vehicle will now be described with reference to the flowcharts shown in FIGS. 9 to 11 . Running condition detection processing will now be described with reference to the flowchart shown in FIG. 9 . In step 20 , a turning condition is detected. More specifically, the lateral G signal detected by the lateral G sensor 98 is corrected by the estimated lateral G calculated according to the vehicle speed and the steering angle to calculate the control lateral G.
[0099] In step 21 , a vehicle speed is detected from the signal from the vehicle speed sensor 92 . In step 22 , an accelerator opening is detected. In step 23 , a transmission shift position is detected. In step 24 , a transmission reverse range is detected. In step 25 , a 4 WD oil temperature, or an oil temperature of the rear differential device 12 is detected. Target rear wheel torque calculation processing will now be described with reference to the flowchart shown in FIG. 10 . In step 30 , a rear wheel torque according to the turning condition is calculated. In step 31 , a rear wheel torque correction amount K 1 according to the vehicle speed is calculated. In this preferred embodiment, the torque distribution to the rear wheels is decreased with an increase in the vehicle speed by using the correction amount K 1 as shown in FIG. 12 .
[0100] In step 32 , a rear wheel torque correction amount K 2 according to the accelerator opening is calculated. In this preferred embodiment, the torque distribution to the rear wheels is increased with an increase in the accelerator opening by using the correction amount K 2 as shown in FIG. 13 . In step 33 , a rear wheel torque correction amount K 3 according to the transmission shift position is calculated. In this preferred embodiment, the torque distribution to the rear wheels is decreased by using the correction amount K 3 in the case that the transmission shift position is a low-speed position or a high-speed position as shown in FIG. 14 .
[0101] In step 34 , a rear wheel torque correction amount K 4 according to the reverse range is calculated. In this preferred embodiment, the torque distribution to the rear wheels is decreased by using the correction amount K 4 in the case of reverse running. In step 35 , a rear wheel torque correction amount K 5 according to the 4 WD oil temperature, or the oil temperature of the rear differential device 12 is calculated. In this preferred embodiment, the torque distribution to the rear wheels is decreased with a decrease in the oil temperature of the rear differential device 12 by using the correction amount K 5 as shown in FIG. 15 .
[0102] In step 36 , the rear wheel torque calculated in step 30 is corrected according to the correction amounts K 1 , K 2 , K 3 , K 4 , and K 5 to thereby calculate a target rear wheel torque. In step 40 of the flowchart showing 4 WD control in FIG. 11 , an actuator control value is calculated according to the target rear wheel torque. In step 41 , the actuator is controlled according to the actuator control value calculated above. More specifically, the degree of engagement of the right and left electromagnetic actuators 56 is controlled according to the control value to thereby control the torque distribution ratio between the front and rear wheels.
[0103] Target rear outer wheel torque calculation processing will now be described with reference to the flowchart shown in FIG. 16 . In step 50 , a rear outer wheel torque according to the turning condition is calculated. This turning condition is determined according to the lateral G. In step 51 , a rear outer wheel torque correction amount K 6 according to the vehicle speed is calculated. In this preferred embodiment, the torque distribution to the rear outer wheel is decreased with an increase in the vehicle speed by using the correction amount K 6 as shown in FIG. 17 .
[0104] In step 52 , a rear outer wheel torque correction amount K 7 according to the transmission shift position is calculated. In this preferred embodiment, the torque distribution to the rear outer wheel is decreased by using the correction amount K 7 in the case that the transmission shift position is a low-speed position or a high-speed position as shown in FIG. 18 . In step 53 , a rear outer wheel torque correction amount K 8 according to the reverse range is calculated. In this preferred embodiment, the torque distribution to the rear outer wheel is decreased by using the correction amount K 8 in the case of reverse running.
[0105] In step 54 , a rear outer wheel torque correction amount K 9 according to the 4 WD oil temperature, or the oil temperature of the rear differential device 12 is calculated. In this preferred embodiment, the torque distribution to the rear outer wheel is decreased with a decrease in temperature of hydraulic fluid for the rear differential device 12 by using the correction amount K 9 as shown in FIG. 19 . In step 55 , the rear outer wheel torque calculated in step 50 is corrected according to the correction amounts K 6 , K 7 , K 8 , and K 9 to thereby calculate a target rear outer wheel torque.
[0106] Further, as in step 40 of the flowchart shown in FIG. 11 , an actuator control value is next calculated according to the target rear outer wheel torque calculated above, and as in step 41 in FIG. 11 , the degree of engagement of the right and left electromagnetic actuators 56 are controlled according to the control value calculated above. The lockup/speed increase control for the speed increasing device 10 will now be described. The object of the lockup/speed increase control for the speed increasing device 10 is to operate the speed increasing device 10 so that the outer wheel can be driven during turning.
[0107] Accordingly, the lateral G signal is used to quickly and accurately determine the turning condition. In a straight running condition of the vehicle, the lateral G is zero. Accordingly, by using a small value as a lateral G threshold, the speed increasing device 10 can be controlled to an increasing speed condition immediately after the vehicle starts turning. For example, when the lateral G signal for the vehicle exceeds the lateral G threshold according to the vehicle speed, the lockup condition or same speed condition of the speed increasing device 10 is changed to the increasing speed condition. As a result, the speed increasing can be performed before largely driving the outer wheel to thereby ensure a condition where the outer wheel can be driven. Accordingly, a larger drive force can be applied to the outer wheel as compared with the inner wheel, thereby improving the turning performance.
[0108] Further, by using the estimated lateral G signal calculated according to the steering angle and the vehicle speed as the lateral G signal, the lateral G signal can be obtained more quickly during the process of transition from the straight running condition to the turning condition. The steering angle is an input itself from the operator, and a delay of motion of the vehicle is added to the actual generation of lateral G. In compensating for the drawbacks of a lateral G sensor, it is also effective to partially correct the output signal from the lateral G sensor by using the estimated lateral G signal or to use the average of the lateral G signal and the estimated lateral G signal.
[0109] A speed increase command is generated after the decision of turning. If the speed increasing device 10 is operated immediately according to the speed increase command, the controller is influenced by the noise included in the signal, and a speed increase stop command is generated every time the turning direction changes as in slalom running, causing an increase in frequency of operation of the speed increasing device 10 . In order to minimize the noise, shock, etc. due to the operation of the speed increasing device and reduce the frequency of operation of the speed increasing device with a reduced size and weight, the speed increasing device 10 is controlled so that the command to the speed increasing device 10 is not immediately executed, but the command is continued for about one second, for example, prior to performing the actual operation of the device 10 .
[0110] This control will now be described with reference to the flowcharts shown in FIGS. 20 and 21 . FIG. 20 shows the flowchart of change control from the lockup condition (same speed condition) to the increasing speed condition. In step 60 , it is determined whether or not a speed increase command is ON. If the speed increase command is ON, the program proceeds to step 61 to start time measurement by a timer. In step 62 , it is determined whether or not the measured time T is greater than a predetermined value T 0 .
[0111] If T>T 0 in step 62 , the program proceeds to step 64 to determine the speed increasing operation. Then, the lockup clutch 40 of the speed increasing device 10 is disengaged and the speed increasing clutch 42 is engaged. If the measured time T is less than or equal to the predetermined value T 0 in step 62 , the program proceeds to step 63 to determine whether or not the speed increase command is OFF. If the speed increase command is not OFF, the determination of step 62 is executed again, whereas if the speed increase command is OFF, the determination of step 60 is executed again.
[0112] Change control from the increasing speed condition to the lockup condition will now be described with reference to the flowchart shown in FIG. 21 . In step 70 , it is determined whether or not a lockup command is ON. If the lockup command is ON, the program proceeds to step 71 to start time measurement by a timer. In step 72 , it is determined whether or not the measured time T is greater than a predetermined value T 0 . If T>T 0 in step 72 , the program proceeds to step 74 to determine the lockup operation. Then, the speed increasing clutch 42 of the speed increasing device 10 is disengaged, and the lockup clutch 40 is engaged.
[0113] If the measured time T is less than or equal to the predetermined value T 0 in step 72 , the program proceeds to step 73 to determine whether or not the lockup command is OFF. If the lockup command is not OFF, the determination of step 72 is executed again, whereas if the lockup command is OFF, the determination of step 70 is executed again. The object of this speed increase control is to improve the maneuverability of the vehicle by driving the outer wheel more than the inner wheel. When the vehicle becomes an unstable condition, there is a case that any particular improvement in the maneuverability is not desired under any circumstances such as counter steer running.
[0114] For example, when the slip angle of the vehicle body becomes greater than a predetermined value or when counter steer such that the steering angle and the lateral G are different in sign is detected, the speed increase control is inhibited. Accordingly, outer wheel driving that may invite a further degradation in behavior can be avoided to thereby allow the stabilization of behavior. Such behavior stabilization control will now be described with reference to the flowchart shown in FIG. 22 . In step 80 , it is determined whether or not counter steer is detected. If the counter steer is detected, the program proceeds to step 82 to generate a lockup command, thereby engaging the lockup clutch 40 of the speed increasing device 10 .
[0115] If the counter steer is not detected in step 80 , the program proceeds to step 81 to determine whether or not the slip angle β of the vehicle body is greater than a slip angle threshold β 0 . If the slip angle β is greater than the threshold β 0 , it is determined that the behavior of the vehicle is unstable, and the program proceeds to step 82 to generate the lockup command, thereby engaging the lockup clutch 40 of the speed increasing device 10 to stabilize the behavior. In such circumstances that an improvement in driving stability is not desired or that a large effect cannot be obtained by the outer wheel driving as control, the speed increase control is inhibited to thereby allow a reduction in torque to be input into the speed increasing device 10 and a reduction in frequency of operation of the device 10 . Accordingly, this is effective in reducing the weight of the device 10 and in improving the durability of the device 10 .
[0116] For example, when the shift position is a first-speed position or a fifth-speed position, the speed increase control is inhibited as shown in FIG. 23 . That is, when the shift position is a first-speed position, a very large torque is generated. However, since the vehicle speed at the first-speed position is low, the effect by the outer wheel driving cannot be so obtained. Conversely, when the shift position is a fifth-speed position, the vehicle speed is too high and there is a danger that the vehicle is excessively turned. Therefore, the speed increase control is inhibited also in this case. In addition, when the shift position is in a reverse position, an improvement in driving stability cannot be expected and the speed increase control is therefore inhibited.
[0117] Further, in an engine brake condition or during braking where the drive force cannot be transmitted to the outer wheel, the speed increase control is also inhibited to thereby allow a reduction in torque to be input into the speed increasing device 10 and a reduction in frequency of operation of the device 10 . Accordingly, the weight of the device 10 can be reduced and the durability of the device 10 can be improved. Further, by controlling the speed increasing device 10 into the lockup condition in the engine brake condition or during braking, a braking force can be applied to the outer wheel, and this is effective also in suppressing oversteer occurring in braking during turning.
[0118] Such control in the engine brake condition or during braking will now be described with reference to the flowcharts shown in FIGS. 24 and 25 . FIG. 24 shows the flowchart of control in the engine brake condition. In step 90 , it is determined whether or not the drive torque is negative, that is, whether or not the vehicle is in the engine brake condition. If the vehicle is in the engine brake condition, the program proceeds to step 91 to generate a lockup command, thereby disengaging the speed increasing clutch 42 of the speed increasing device 10 and engaging the lockup clutch 40 .
[0119] FIG. 25 shows the flowchart of control during braking. In step 100 , it is determined whether or not the vehicle is being braked by the operator. If the vehicle is being braked by the operator, the program proceeds to step 101 to generate a lockup command, thereby disengaging the speed increasing clutch 42 of the speed increasing device 10 and engaging the lockup clutch 40 . In the case that the operation of the speed increasing device 10 is relied on the oil pressure of a pump driven by an axle, there is a possibility that an oil pressure required for the speed increasing cannot be obtained at certain low vehicle speeds. If the control is relied on only the lateral G threshold, a speed increase command is undesirably generated in the stage where a sufficient oil pressure is not obtained, causing a possibility of adverse effects on the speed increasing clutch 42 .
[0120] Further, when the vehicle speed becomes a value at which a sufficient oil pressure can be obtained, the lockup condition is shifted to the increasing speed condition. Accordingly, even during turning at this vehicle speed or higher, the lockup condition is changed to the increasing speed condition. To avoid possible instability of the behavior of the vehicle because of the above control, the change to the increasing speed condition is inhibited until the vehicle runs straight at a given vehicle speed (V 1 ) or more during low-speed running at a given vehicle speed (V 0 ) or less. Accordingly, the speed increase control at the vehicle speed V 0 or less can be avoided. Further, a rapid change to the increasing speed condition during turning can also be prevented.
[0121] This control will now be described with reference to the flowchart shown in FIG. 26 . In step 110 , it is determined whether or not the vehicle speed V is less than the given vehicle speed V 0 . If the vehicle speed V is less than the given vehicle speed V 0 , the program proceeds to step 111 to inhibit the change to the increasing speed condition. Thereafter, the vehicle continues to run. In step 112 , it is determined whether or not the vehicle speed V is greater than V 1 which is greater than V 0 and the lateral G is less than G 0 . If the answer in step 112 is YES, the program proceeds to step 113 to permit the change to the increasing speed condition. The value G 0 in step 112 is set to about 0.1 G. Further, the determination in step 112 is to determine whether or not the vehicle is running straight at a vehicle speed greater than V 1 .
[0122] While the present invention is applied to a four-wheel drive vehicle based on a FF vehicle in the above preferred embodiment, the control method of the present invention is also applicable to a vehicle such that the power from a driving power source such as an engine is directly transmitted to the rear wheels, that the transmission of the power to the right and left rear wheels can be controlled by a clutch or the like, and that the power can also be transmitted to the front wheels by a clutch or the like. Further, the vehicle may be of such a type that the rear wheels are normally increased in rotational speed.
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A drive force control method for a four-wheel drive vehicle having front wheels as main drive wheels always connected to a driving source, rear wheels as auxiliary drive wheels whose drive torque is adjustable, and a mechanism capable of adjusting a torque distribution ratio between the front wheels and the rear wheels so that the torque distribution ratio of the rear wheels to the front wheels is increased in turning and also capable of adjusting a torque distribution ratio between the right and left rear wheels in turning. The drive force control method includes the steps of detecting a vehicle speed, and gently decreasing the torque distribution ratio of a turning outer wheel to a turning inner wheel with an increase in the vehicle speed. When the transmission shift position is a low-speed position or a high-speed position or the vehicle is in reverse running, the torque distribution ratio of the turning outer wheel to the turning inner wheel is decreased.
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FIELD
The disclosure relates to adapting an elevator system for use by handicapped persons.
BACKGROUND
It is known that an elevator system having an elevator cabin transports users between floors of a building. To this end, the floors and/or the elevator cabin is/are provided with call input apparatuses which the users can use to make call inputs. On the basis of the call inputs, an elevator controller actuates an elevator drive for the elevator cabin and a door drive for the elevator cabin such that the users can enter the elevator cabin and are transported by the elevator cabin between floors of the building.
To provide for equality of users with handicaps, European standard 81-70 prescribes a handicapped persons pushbutton for the call input. Pushing the handicapped persons pushbutton puts the elevator system into a special mode of operation. In this special mode of operation, elevator doors on the floors and/or elevator cabins are open and/or closed more slowly and users with handicaps are provided with feedback from the call input by means of visual and/or audible signals.
The document US 2002/0191819 A1 describes a way of detecting elevator users using a wheelchair. This involves taking images of elevator users in the space in front of an elevator system and using the position of the face to infer a wheelchair user.
The document US 2004/0022439 A1 describes a method for distinguishing between people who are able to walk and people using a wheelchair. Images are used to ascertain a 3D model of a recorded person and to determine whether or not the person is a person with a wheelchair.
The document JP 2002211833 discloses a method for verifying a wheelchair user when the latter has pushed a special key on an elevator control unit. Pushing the special key indicates to the elevator system that the passenger is a wheelchair user. When the special key has been pushed, the person who has pushed the switch has an image taken by means of a camera, and it is verified whether the person is actually a wheelchair user.
The document JP 11268879 describes how disabled people are detected by means of two cameras as soon as they push a switch on an elevator control unit and how the elevator system executes the elevator journey in a special mode when a disabled person has been detected.
The document U.S. Pat. No. 5,192,836 describes how the elevator which executes a journey requested by a disabled person is selected from a group of elevators. In order to indicate that the person requesting the elevator journey is a disabled person, the requesting person pushes an additional key on the control unit of the elevator system.
The document U.S. Pat. No. 5,323,470 describes a method for tracking the face of a patient in real time using cameras so that a patient can be fed by a robot.
The document US 2006/0011419 A1 discloses how an elevator control unit has an arrangement of switching keys with an optical sensor which are able to be activated contactlessly.
The document U.S. Pat. No. 6,161,655 describes an elevator control switch which can be operated contactlessly. Infrared radiation is emitted by the switch. If a potential passenger keeps his hand in front of the elevator control switch, the infrared radiation is reflected and hence the switch is activated.
The specification EP1598298A1 shows an elevator system having a call input apparatus in the elevator cabin. The call input apparatus has a touch screen, which touch screen is not compliant with EN81-70, since it does not have a handicapped persons pushbutton. As a solution which is compliant with EN81-70, EP 1598298A1 discloses adding a handicapped persons pushbutton to the touch screen. A top side of the handicapped persons pushbutton is clearly recognizable to visually handicapped persons by virtue of Braille characters with a relief height of at least 0.8 mm. Pushing the handicapped persons pushbutton with a pushing force of between 2.5 N and 5.0 N operates an area of the screen below the handicapped persons pushbutton and generates a cabin call.
SUMMARY
In at least some embodiments disclosed herein, the elevator system can be put into a handicapped persons mode of operation while largely avoiding touching operator control elements and in which call inputs are also possible while largely avoiding touching operator control elements.
In further embodiments, at least one sensor detects at least one change of position by a user as at least one signal and at least one reference signal; the signal is compared with the reference signal; if at least one predefined comparison result is achieved then at least one signal state change is produced; and the elevator system is at least to some extent put into a handicapped persons mode of operation when the reference state change has been produced.
At least some embodiments are based on the insight that the user can produce a signal state change interactively and contactlessly solely by changing his position, which signal state change transfers the elevator system from a normal mode to a handicapped persons mode of operation. “Change of position” by the user is understood to mean any type of movement and/or rest by the user, which movement and/or rest can be detected as a signal and a reference signal by the sensor. The extent of the movement and/or rest can vary within the range of prescribed physical and/or time-based limits. Hence, a signal and a reference signal from a user are detected and the handicapped user can thereby express his desire to be moved by the elevator system in a handicapped persons mode of operation; he is therefore more easily able to take part in social life, to make social contacts, to train and do further studies and to undertake gainful employment.
Possibly, the reference signal is detected at a time before or after the signal. Possibly, a predefined comparison result is achieved if the detected signal matches the reference signal. Possibly, a predefined comparison result is achieved if the detected signal does not match the reference signal.
This can mean that a change of position by the user is detected by explicit signals. For each unit of time, a signal or reference signal is detected. There are multiple options in this context. By way of example, a user is detected by the sensor with a positive signal; the detected positive signal is compared with a detected negative signal as a reference signal. If these two successively detected signals do not match, a signal state change is produced. Alternatively, it is possible for a user resting in front of the sensor for a certain period of time to be detected as a series of negative signals. In this case, the detected series of negative signals is compared with a previously detected series of negative signals as a reference signal, and a match between the series of signals produces a signal state change. This can mean that only such a change of position by the user is used as a predefined comparison result for the signal and the reference signal, which change of position conveys the actual desire by the user. Such a change of position by the user is understood widely and can be learned intuitively.
Possibly, the signal and the reference signal are transmitted from the sensor to at least one apparatus, which apparatus is a destination call controller and/or elevator controller and/or call input apparatus; the apparatus compares whether the signal matches the reference signal; if the signal does match the reference signal then the signal state change is produced or if the signal does not match the reference signal then the signal state change is produced.
This can mean that the signal comparison and the production of the signal state change can be performed at a plurality of locations of the elevator system or by different apparatuses in the elevator system, which prompts a high level of flexibility for the implementation of the method.
Possibly, the elevator system is at least to some extent put into the handicapped persons mode of operation by the apparatus for a predetermined period of time when the signal state change has been produced. Possibly, the elevator system is at least to some extent put into the handicapped persons mode of operation by the apparatus for a predetermined period of time until at least one call from the user has been handled completely when the signal state change has been produced. Possibly, the elevator system is at least to some extent put into the handicapped persons mode of operation by the apparatus for a predetermined period of time until at least one call from the user has been handled completely when the signal state change has been produced.
This can mean that once the elevator system has been put into the handicapped persons mode of operation, the handicapped user can generate a call which is handled by the elevator system in the handicapped persons mode of operation. The change by the elevator system to the handicapped persons mode of operation can take place in part, i.e. only a portion of the elevator system is put into the handicapped persons mode of operation. First, in some embodiments, only one call input apparatus and/or only one elevator cabin can be put into the handicapped persons mode of operation. It is also possible for different portions of the elevator system to be put into the handicapped persons mode of operation at different times. Thus, first a call input apparatus and then an elevator cabin can be put into the handicapped persons mode of operation. By way of example, the call input apparatus is put into the handicapped persons mode of operation until a call has been input, and the elevator cabin assigned to the call is put into the handicapped persons mode of operation until the call has been handled completely. It is also possible for different portions of the elevator system to be put into the handicapped persons mode of operation for particular periods of time only. By way of example, an elevator cabin is put into the handicapped persons mode of operation only specifically while a cabin door is closing, and in this context an elevator door is closed with a particularly long delay and/or is closed particularly slowly after the passenger has entered the elevator cabin; in the rest of the period in which the passenger is traveling, the elevator cabin is not in the handicapped persons mode of operation.
Possibly, the signal state change produced indicates that a user can move and/or orient himself only using at least one facility specific to disabled persons. Possibly, the signal state change produced indicates that a user can move and/or orient himself only using at least one facility specific to disabled persons; which facility specific to disabled persons is a wheelchair and/or a hospital bed on castors and/or a crutch and/or a hearing aid and/or a visual aid and/or a white stick and/or a guide dog and/or an accompanying user.
This can mean that the handicapped user can indicate that he can move and/or orient himself in a building and hence also in the elevator system only using a facility specific to disabled persons.
Possibly, the signal state change produced indicates that a user can move and/or orient himself only using at least one facility specific to disabled persons; and that for a user with at least one facility specific to disabled persons, at least one elevator door is closed with a particularly long delay and/or is closed particularly slowly.
This can mean that the user who can move and/or orient himself only using at least one facility specific to disabled persons has sufficient time to enter and/or leave the elevator cabin.
Possibly, the signal state change produced indicates that a user can move and/or orient himself only using at least one facility specific to disabled persons; and that for a user with at least one facility specific to disabled persons, at least one elevator cabin is stopped on a floor with a particular degree of precision.
This can mean that the user who can move and/or orient himself only using at least one facility specific to disabled persons can enter and/or leave the elevator cabin on a level path.
Possibly, the signal state change produced indicates that a user can move and/or orient himself only using at least one facility specific to disabled persons; and that a user with at least one facility specific to disabled persons is allocated a particularly large amount of space in at least one elevator cabin.
This can mean that the user who can move and/or orient himself only using at least one facility specific to disabled persons has a large amount of space for his facility specific to disabled persons.
Possibly, the signal state change produced indicates that a user can move only using at least one facility specific to disabled persons; and that a user with at least one facility specific to disabled persons is transported by at least one elevator cabin from a call input floor to a destination floor.
This can mean that the user who can move using at least one facility specific to disabled persons is conveyed directly from the call input floor and therefore does not have to take any additional routes to a starting floor.
Possibly, the signal state change produced indicates that a user can move only using at least one facility specific to personal protection. Possibly, the signal state change produced indicates that a user can move only using at least one facility specific to personal protection; which facility specific to personal protection is a physical safe area and/or a time-based safe area and/or a bodyguard.
This can mean that even when a user in need of protection, i.e. a user with a potential safety threat, is conveyed by means of the elevator cabin in the building, it can be possible to ensure personal protection for the user against attacks from third parties.
Possibly, the signal state change produced indicates that a user can move only using at least one facility specific to personal protection; and that a user with at least one facility specific to personal protection is allocated a particularly large amount of space in at least one elevator cabin.
This can mean that the user who can move only using at least one facility specific to personal protection has a large amount of space for his facility specific to personal protection.
Possibly, the signal state change produced indicates that a user can move only using at least one facility specific to personal protection; and that a user with at least one facility specific to personal protection is transported by at least one elevator cabin from a call input floor directly to a destination floor.
This can mean that the user who can move using at least one facility specific to personal protection is conveyed to the desired destination floor directly and therefore quickly.
Possibly, the change of position by the user is detected when the user positions himself in at least one detection range of the sensor. Possibly, the change of position by the user is detected when the user leaves at least one detection range of the sensor. Possibly, the change of position by the user is detected when the user positions himself close to at least one call input apparatus.
This can mean that the user needs to position himself in the detection range of the sensor. He can position himself inside or outside of the detection range of the sensor and effect a change of position. This bounding of the location at which a change of position by the user is detected as a signal can result in further, even greater clarity for the transmission of the desire by the user to be moved by the elevator system in the handicapped persons mode of operation. Within the context of the present disclosure, close to a call input apparatus then means that the user is positioned less than approximately ten meters, perhaps less than one meter, perhaps a few centimeters, away from the call input apparatus.
Possibly, the change of position by the user is detected by the sensor automatically.
This can mean that the signal can be detected automatically when the user can be detected by the sensor. The user can initiate sensor detection contactlessly, solely by changing position.
Possibly, the detection range of the sensor is less than approximately ten meters, perhaps less than one meter.
This can mean that a sensor with a very reduced detection range can be used to detect the desire by the user to put the elevator system into a handicapped persons mode of operation.
Possibly, the sensor is a motion sensor and/or a load sensor and/or a radio sensor. Possibly, the motion sensor is a camera and/or a photosensor and/or an ultrasonic sensor or an infrared sensor and/or a microphone and/or a noise level sensor. Possibly, the load sensor is a weighing unit. Possibly, the radio sensor is a transmission/reception unit for at least one radio field.
This can mean that it is possible to use a multiplicity of known and proven sensors in order to detect the desire by the user to be moved by the elevator system in the handicapped persons mode of operation.
Possibly, the change of position by the user is detected by at least one motion sensor as a signal; the detected signal is compared with a reference signal detected at a previous time; and if the detected signal does not match the reference signal, the signal state change is produced. Possibly, the change of position by the user is detected by at least one load sensor as a signal; the detected signal is compared with a reference signal detected at a previous time; and if the detected signal does not match the reference signal then the signal state change is produced. Possibly, the change of position by the user is detected by at least one radio sensor as a signal; the detected signal is compared with a reference signal detected at a previous time; and if the detected signal matches the reference signal then the signal state change is produced.
This can mean that the different working of different sensors means that different signal state changes are also produced in order to put the elevator system into the handicapped persons mode of operation.
Possibly, at least one data communication between the radio sensor and at least one mobile communication unit carried by the user is activated within a particular detection range of at least one radio field; and a change of position by the mobile communication unit carried by the user is detected by the radio sensor as at least one signal. Possibly, at least one data communication between the radio sensor and at least one mobile communication unit carried by the user is activated within a particular detection range of at least one radio field; the mobile communication unit sends at least one code to the radio sensor; and the code is detected by the radio sensor as at least one signal. Possibly, the mobile communication unit used is a mobile telephone and/or an RFID card. Possibly, the radio field used is a short-range radio field; the detection range of the short-range radio field is less than approximately ten meters, or less than one meter.
This can mean that merely a change of position by a mobile communication unit in everyday use can be detected as a desire by the user to put the elevator system into a handicapped persons mode of operation. Surprisingly, this is because it is merely possible to use the change of position by the mobile communication unit in order to detect with a high level of certainty the desire by the user to put the elevator system into a handicapped persons mode of operation.
Possibly, at least one data communication between the radio sensor and at least one mobile communication unit carried by the user is activated within a particular detection range of at least one radio field; the mobile communication unit sends at least one code to the radio sensor; the code is detected by the radio sensor as at least one signal; the signal is transmitted from the radio sensor to the destination call controller and/or elevator controller; and the destination call controller and/or elevator controller ascertains at least one call allocation for the transmitted signal.
This can mean that the signal detected by the radio sensor is also accompanied by the transmission of a code for call allocation to the destination call controller and/or elevator controller.
Possibly, the sensor transmits the detected signal to at least one call input apparatus. Possibly, the sensor transmits the detected signal to at least one call input apparatus, which call input apparatus is close to the user whose change of position has been detected as a signal, and at least one input/output unit of the call input apparatus is used to output at least one functional descriptor. Possibly, the sensor transmits the detected signal to at least one call input apparatus, which call input apparatus is close to the user whose change of position has been detected as a signal, and at least one input/output unit of the call input apparatus is used to output a plurality of functional descriptors. Possibly, the sensor transmits the detected signal to at least one call input apparatus, which call input apparatus is close to the user whose change of position has been detected as a signal, and at least one input/output unit of the call input apparatus is used to output a plurality of functional descriptors in at least one predetermined chronology. Possibly, the sensor transmits the detected signal to at least one call input apparatus, which call input apparatus is close to the user whose change of position has been detected as a signal, and at least one input/output unit of the call input apparatus is used to output a plurality of functional descriptors in at least one predetermined order.
This can mean that one or more functional descriptors are output to the user on an input/output unit automatically, without the user having to do anything further, when a signal has been detected and transmitted to the call input apparatus.
Possibly, at least one input/output unit of at least one call input apparatus, which call input apparatus is close to the user whose change of position has been detected as a signal, is used to output at least one functional descriptor to the user when a signal state change has been produced. Possibly, the functional descriptor indicates that the user can move and/or orient himself in the building only using a facility specific to disabled persons. Possibly, the facility specific to disabled persons is a wheelchair and/or a hospital bed on castors and/or a crutch and/or a hearing aid and/or a visual aid and/or a white stick and/or a guide dog and/or an accompanying passenger.
This can mean that a disabled user can indicate which facility specific to disabled persons he intends to use to move and/or orient himself in a building and hence also in the elevator system.
Possibly, at least one input/output unit of at least one call input apparatus, which call input apparatus is close to the user whose change of position has been detected as a signal, is used to output at least one functional descriptor to the user when a signal state change has been produced; and the functional descriptor indicates that the user can move only using a facility specific to personal protection. Possibly, the facility specific to personal protection is a physical safe area and/or a time-based safe area and/or a bodyguard.
This can mean that a user with a potential safety threat can indicate which facility specific to personal protection he intends to use to be moved by the elevator system.
Possibly, at least one input/output unit of at least one call input apparatus, which call input apparatus is close to the user whose change of position has been detected as a signal, is used to output at least one functional descriptor to the user when a signal state change has been produced; and the functional descriptor indicates that the user desires at least one user-specific communication language, the user being able to select between a plurality of communication languages.
This can mean that the user can indicate his preferred communication language.
Possibly, at least one input/output unit of at least one call input apparatus, which call input apparatus is close to the user whose change of position has been detected as a signal, is used to output at least one functional descriptor to the user when a signal state change has been produced; and the functional descriptor indicates that the user desires to make at least one interactive assistance for using the elevator system, the user being able to select between a plurality of assistances.
This can mean that the user is provided with interactive assistance when using the elevator system.
Possibly, at least one input/output unit of at least one call input apparatus, which call input apparatus is close to the user whose change of position has been detected as a signal, is used to output at least one functional descriptor to the user when a signal state change has been produced; and the functional descriptor indicates that the user desires to make at least one destination call, the user being able to select between a plurality of destination floors.
This can mean that the user can confirm between a plurality of destination floors and that a user who has difficulty walking selects that destination floor which he can leave as easily as possible, for example.
Possibly, at least one input/output unit of at least one call input apparatus, which call input apparatus is close to the user whose change of position has been detected as a signal, is used to output at least one functional descriptor to the user when a signal state change has been produced; and the functional descriptor indicates that the user desires to make at least one floor call, the user being able to select between a plurality of starting floors.
This can mean that the user does not necessarily have to begin his journey from the call input floor, but rather can select a starting floor which is convenient to him. By way of example, a user with difficulty walking will select a starting floor which is as easy to reach as possible.
Possibly, at least one input/output unit of at least one call input apparatus, which call input apparatus is close to the user whose change of position has been detected as a signal, is used to output at least one functional descriptor to the user when a signal state change has been produced; and the functional descriptor indicates that the user desires to make at least one cabin call; the user being able to select between a plurality of destination floors.
This can mean that the user in the elevator cabin can make a cabin call of his choice.
Possibly, at least one input/output unit of at least one call input apparatus, which call input apparatus is close to the user whose change of position has been detected as a signal, is used to output at least one functional descriptor to the user when a signal state change has been produced; and that the functional descriptor indicates that the user desires at least one user-specific elevator cabin, the user being able to select between a plurality of elevator cabins.
This can mean that the user can confirm between a plurality of possible elevator cabins in order to get to his destination floor. By way of example, the user wishes a panorama cabin with a nice view or an express cabin for the fastest possible journey.
Possibly, at least one input/output unit of at least one call input apparatus, which call input apparatus is close to the user whose change of position has been detected as a signal, is used to output a plurality of functional descriptors when a signal state change has been produced. Possibly, in the unhandicapped operating state, the sensor detects at least one change of position by the user as a further signal; a comparison is performed to determine whether the further signal matches a recently detected signal, wherein the recently detected signal is the signal or reference signal; if at least one predefined comparison result is achieved then at least one further signal state change is produced; and the call input apparatus marks at least one output functional descriptor for the further signal state change that has been produced. Possibly, in the unhandicapped operating state, the sensor detects at least one change of position by the user as a further signal and a further reference signal; a comparison is performed to determine whether the further signal matches the further reference signal; if at least one predefined comparison result is achieved then at least one further signal state change is produced; and the call input apparatus marks at least one output functional descriptor when the further signal state change has been produced.
This can mean that the user can mark one of a plurality of output functional descriptors contactlessly by means of a simple change of position. Such marking can be hygienic, since the user does not need to touch the call input apparatus and it is therefore less likely for any diseases and/or pathogens to be transmitted.
Possibly, at least one input/output unit of at least one call input apparatus, which call input apparatus is close to the user whose change of position has been detected as a signal, is used to output a plurality of functional descriptors when a signal state change has been produced. Possibly, in the unhandicapped operating state, the sensor detects at least one change of position by the user as yet a further signal; a comparison is performed to determine whether the yet further signal matches a recently detected signal, wherein the recently detected signal is the signal or the reference signal or a further signal or a further reference signal; if at least one predefined comparison result is achieved then at least one yet further signal state change is produced; and the call input apparatus confirms at least one output functional descriptor when the yet further signal state change has been produced. Possibly, in the unhandicapped operating state, the sensor detects at least one change of position by the user as yet a further signal and as yet a further reference signal; a comparison is performed to determine whether the yet further signal matches the yet further reference signal; if at least one predefined comparison result is achieved then at least one yet further signal state change is produced; and the call input apparatus confirms at least one output functional descriptor when the yet further signal state change has been produced.
This can mean that the user can confirm an output functional descriptor contactlessly by means of a simple change of position. Such confirmation can be hygienic, since the user does not need to touch the call input apparatus and it is therefore less likely for diseases and/or pathogens to be transmitted.
Possibly, at least one input/output unit of at least one call input apparatus, which call input apparatus is close to the user whose change of position has been detected as a signal, is used to output a plurality of functional descriptors when a signal state change has been produced; and operation of at least one area of the input/output unit marks at least one output functional descriptor. Possibly, at least one input/output unit of at least one call input apparatus is used to output a plurality of functional descriptors when a signal state change has been produced; and operation of at least one area of the input/output unit confirms at least one output functional descriptor.
This can mean that a user is alternatively also able to activate an output functional descriptor on the input/output unit in order to mark and/or confirm the functional descriptor.
Possibly, the marked and/or confirmed functional descriptor is transmitted from the call input apparatus to the destination call controller and/or elevator controller; and the user is moved by the destination call controller and/or elevator controller for the transmitted functional descriptor using the elevator system in the handicapped persons mode of operation.
This can mean that the user can put an elevator system into a handicapped persons mode of operation totally contactlessly, solely by changing position, and is then moved by the elevator system in the handicapped persons mode of operation.
Further embodiments comprise an elevator system for carrying out a method for catering for the use of the elevator system by handicapped persons. To this end, at least one sensor detects at least one change of position by a user as at least one signal and at least one reference signal; the elevator system compares the signal with the reference signal; and if at least one predefined comparison result is achieved then the elevator system produces at least one signal state change; and the elevator system at least to some extent changes to a handicapped persons mode of operation when the reference state change has been produced.
This can mean that an elevator system is rendered capable of changing from a normal mode to a handicapped persons mode of operation by a signal and a reference signal which have been detected by a sensor as a result of a change of position by a user.
Moreover, the aforementioned object is achieved by proposing a method for upgrading an elevator system having at least one destination call controller and/or elevator controller for carrying out the method for catering for the use of the elevator system by handicapped persons. To this end, at least one sensor is installed for the purpose of detecting at least one change of position by a user as at least one signal and at least one reference signal; at least one signal line and/or radio field for transmitting the signal and reference signal detected by the sensor is installed between the sensor and the elevator system; at least one computer program means is loaded into at least one processor in the elevator system; the computer program means compares the signal with the reference signal; if at least one predefined comparison result is achieved then the computer program means produces at least one signal state change; and the elevator system is at least to some extent put into a handicapped persons mode of operation by the computer program means when the signal state change has been produced.
This can mean that an existing elevator system can be upgraded merely by installing a sensor and a signal line and/or a radio field for the destination call control and/or elevator control in order to allow a user, when a computer program means has been loaded into at least one processor in the destination call controller and/or elevator controller, to generate a signal state change and to put the elevator system into a handicapped persons mode of operation merely by changing positions.
Possibly, a computer program product comprises at least one computer program means which is suitable for implementing the method for catering for the use of an elevator system by handicapped persons by executing at least one method step when the computer program means is loaded into at least one processor in at least one call input apparatus and/or in at least one destination call controller and/or in at least one elevator controller and/or into at least one sensor. Possibly, the computer-readable data memory comprises such a computer program product.
This can mean that an elevator system is rendered capable, by loading the computer program means, of putting the elevator system into a handicapped persons mode of operation when a signal detected by a sensor has been transmitted which, in comparison with a reference signal, results in the production of a signal state change.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments of the disclosed technologies will be explained in detail with reference to the figures, in which, in some cases schematically:
FIG. 1 shows a first exemplary embodiment of an elevator system having a sensor and a call input apparatus as shown in one of FIGS. 3 to 13 ;
FIG. 2 shows a second exemplary embodiment of an elevator system having a sensor and a call input apparatus as shown in one of FIGS. 3 to 13 ;
FIG. 3 shows a view of a portion of a first exemplary embodiment of sensors in the form of a radio sensor and of a motion sensor and also of a first exemplary embodiment of a call input apparatus;
FIG. 4 shows a view of a portion of a second exemplary embodiment of sensors in the form of a motion sensor and of a load sensor and also of a second exemplary embodiment of a call input apparatus;
FIG. 5 shows a view of a portion of a third exemplary embodiment of a sensor in the form of a radio sensor and of a third exemplary embodiment of a call input apparatus, wherein a user changes position in order to change the elevator system to a handicapped persons mode of operation;
FIG. 6 shows a view of the portion of the third exemplary embodiment of a sensor and of a call input apparatus shown in FIG. 5 , wherein a user changes position in order to mark a functional descriptor;
FIG. 7 shows a view of the portion of the third exemplary embodiment of a sensor and of a call input apparatus shown in FIG. 5 or 6 , wherein a user changes position in order to confirm a functional descriptor;
FIG. 8 shows a view of a portion of a fourth exemplary embodiment of a sensor in the form of a motion sensor and a fourth exemplary embodiment of a call input apparatus, wherein a user changes position in order to change the elevator system to a handicapped persons mode of operation;
FIG. 9 shows a view of a portion of the fourth exemplary embodiment of sensors and of a call input apparatus shown in FIG. 8 , wherein a user changes position in order to mark a functional descriptor;
FIG. 10 shows a view of the portion of the fourth exemplary embodiment of sensors and of a call input apparatus shown in FIG. 8 or 9 , wherein a user changes position in order to confirm a functional descriptor;
FIG. 11 shows a view of a portion of a fifth exemplary embodiment of sensors in the form of a motion sensor and of a load sensor and also a fifth exemplary embodiment of a call input apparatus, wherein a user changes position in order to change the elevator system to a handicapped persons mode of operation;
FIG. 12 shows a view of the portion of the fifth exemplary embodiment of sensors and of a call input apparatus as shown in FIG. 11 , wherein a user changes position in order to mark a functional descriptor;
FIG. 13 shows a view of the portion of the fifth exemplary embodiment of sensors and of a call input apparatus as shown in FIGS. 11 or 12 , wherein a user changes position in order to confirm a functional descriptor; and
FIG. 14 illustrates and embodiment elevator controller.
DETAILED DESCRIPTION
FIGS. 1 and 2 show two exemplary embodiments of an elevator system 100 in a building. The building has a relatively large number of floors S 1 to S 3 which are served by at least one elevator cabin 6 , 6 ′. On each floor S 1 to S 3 , a user can enter and/or leave the elevator cabin 6 , 6 ′ via at least one elevator door 11 , 11 ′, 12 , 12 ′. In at least one elevator shaft S 4 , S 4 ′, the elevator cabin 6 , 6 ′ is connected to at least one counterweight 7 , 7 ′ by means of at least one supporting means 8 , 8 ′. To move the elevator cabin 6 , 6 ′ and the counterweight 7 , 7 ′, the supporting means 8 , 8 ′ is set in motion by at least one elevator drive 10 , 10 ′ in frictionally engaged fashion. Normally, at least one door drive 9 , 9 ′ is arranged on the elevator cabin 6 , 6 ′ and activates the elevator door 11 , 11 ′, 12 , 12 ′. In the case of the elevator door 11 , 11 ′, 12 , 12 ′, a distinction is drawn between a floor door 11 , 11 ′ which is arranged on each floor S 1 to S 3 and a cabin door 12 , 12 ′ of the elevator cabin 6 , 6 ′. During a floor stop, the cabin door 12 , 12 ′ can be operatively connected to the floor door 11 , 11 ′ by means of mechanical coupling such that the cabin door 12 , 12 ′ and the floor door 11 , 11 ′ are opened and closed simultaneously. FIG. 1 shows two elevator cabins 6 , 6 ′ arranged in two elevator shafts S 4 , S 4 ′. FIG. 2 shows one elevator cabin 6 arranged in one elevator shaft S 4 . With knowledge of the present disclosure, a person skilled in the art can implement an elevator system 100 having more than three served floors S 1 to S 3 and/or having more than one elevator cabin 6 , 6 ′ per elevator shaft S 4 , S 4 ′ and/or having a hydraulic drive and/or having an elevator drive on the elevator cabin and/or on the counterweight and naturally also an elevator system 100 without a counterweight.
At least one elevator controller 5 , 5 ′ in the elevator system 100 has at least one processor and at least one computer-readable data memory. From the computer-readable data memory, at least one computer program means is loaded into the processor and executed. The computer program means actuates the elevator drive 10 , 10 ′ and the door drive 9 , 9 ′. At least one housing for the elevator controller 5 , 5 ′ contains at least one adapter for at least one radio field 21 and/or at least one adapter for at least one signal line 3 , 3 ′ and also at least one electrical power supply.
At least one call input apparatus 1 , 1 ′ in the elevator system 100 is arranged close to a floor door 11 , 11 ′ and/or in an elevator cabin 6 . FIGS. 1 to 13 show a plurality of exemplary embodiments of a call input apparatus 1 , 1 ′. The call input apparatus 1 , 1 ′ is mounted on a building wall in the region of the floor door or is located in an isolated fashion in the region of the floor door for floors S 1 to S 3 . At least one housing for the call input apparatus 1 , 1 ′ contains at least one adapter for a signal line 2 and/or at least one adapter for at least one radio field 21 , at least one input/output unit 13 in the form of a touch screen 13 ′ and/or a keypad 13 ″, at least one tone generator 15 and at least one electrical power supply. The input/output unit 13 comprises a touch screen 13 ′ of rectangular and/or circularly symmetric diameter. By way of example, the touch screen 13 ′ has a diameter of five centimeters and a thickness of between two and ten millimeters. By way of example, the display comprises glass or impact-resistant plastic such as polyurethane, polypropylene, polyethylene, etc. A front side of the touch screen 13 ′ is highly visible to the user and, by way of example, comprises glass or impact-resistant plastic such as polyurethane, polypropylene, polyethylene. Several operating principles for touch screens 13 ′ are known, such as a resistive touch screen, a capacitive touch screen, an optical touch screen, etc., in which touch prompts the alteration of an electromagnetic field or a beam of light. Instead of a touch screen, the input/output unit 13 may also have a simple screen and/or luminous displays. The keypad 13 ″ has a plurality of mechanical keys, which keys have permanently assigned elevator functions. By way of example, the keypad 13 ″ is a decimal keypad for the input of floor descriptors such as “ 5 ” or “ 16 ”. By way of example, the tone generator 15 is a loudspeaker for the output of spoken alphanumeric character strings and/or spoken sentences. The sound pressure of the tone generator 15 can be adjusted in the range between 30 dB and 120 dB, and the frequency band extends from 10 Hz to 25 kHz. The call input apparatus 1 , 1 ′ has at least one processor 30 and at least one computer-readable data memory (CRM) 31 . From the computer-readable data memory, at least one computer program means is loaded into the processor and executed. The processor of the call input apparatus 1 , 1 ′ can have a plurality of computer program means loaded into it which operate independently of one another and/or together with one another. The computer program means actuates the adapter and/or the input/output unit 13 and/or the tone generator 15 .
At least one sensor 17 , 18 , 19 in the elevator system 100 detects at least one area of the building. The sensor 17 , 18 , 19 is arranged in the proximity of a call input apparatus 1 , 1 ′. FIG. 1 shows a first sensor 17 arranged in the housing of a first call input apparatus 1 , while a further sensor 17 is arranged above a further call input apparatus 1 ′. FIG. 2 shows a sensor 17 arranged at the side next to a call input apparatus 1 . FIG. 3 shows two sensors 17 and 19 arranged in the housing of a call input apparatus 1 , 1 ′. FIG. 4 shows a first sensor 18 arranged in front of a call input apparatus 1 , 1 ′, while a further sensor 17 is arranged above the floor doors 11 , 11 ′. FIGS. 5 to 7 show a first sensor 19 arranged in the housing of a call input apparatus 1 , 1 ′. FIGS. 8 to 10 show a first sensor 17 arranged above a call input apparatus 1 , 1 ′. FIGS. 11 to 13 show a first sensor 17 arranged in the housing of a call input apparatus 1 , 1 ′, while a further sensor 18 is arranged in front of the call input apparatus 1 , 1 ′. The sensor 17 , 18 , 19 is a motion sensor 17 and/or a load sensor 18 and/or a radio sensor 19 . The motion sensor 17 is a camera and/or a photosensor and/or an ultrasonic sensor and/or an infrared sensor and/or a microphone and/or a noise level sensor. The load sensor 18 is a weighing unit. The radio sensor 19 is a transmission/reception unit for at least one radio field 21 . The sensor 17 , 18 , 19 has at least one processor, at least one computer-readable data memory, at least one adapter for a signal line 2 and/or at least one adapter for at least one radio field 21 and at least one electrical power supply. From the computer-readable data memory, at least one communication computer program means is loaded into the processor and executed. The communication computer program means controls the communication between the sensor 17 , 18 , 19 and at least one call input apparatus 1 , 1 ′ and/or destination call controller 4 and/or elevator controller 5 , 5 ′. The text below explains embodiments of a sensor 17 , 18 , 19 by way of example:
The camera has at least one optical lens and at least one digital image sensor. The digital image sensor is a charged coupled device (CCD) sensor or a complementary metal oxide semiconductor (CMOS) sensor, for example. The camera captures images in the spectrum of visible light. The camera can capture still images or moving images at a frequency of 0 to 30 frames per second. From a computer-readable data memory in the camera, at least one computer program means is loaded into a processor in the camera and executed. The computer program means controls the operation of the camera, stores and loads still images, compares still images with one another and can produce at least one signal state change as a comparison result. The camera has an exemplary resolution of two Mpixels and an exemplary sensitivity of two lux. The camera has a motor-operated zoom lens and can thus alter the focal length of the lens automatically or under remote control. It is thus possible to capture objects at different distances in image sections with different levels of detail. The camera has a motor-operated tripod so as to alter the orientation of the lens automatically or under remote control. By way of example, the camera pivots or rotates. The camera is provided with an illumination device and can thus illuminate an object that is to be captured when ambient light is poor or it is dark. The photosensor operates on the basis of the photoelectric effect and is a photodiode or a phototransistor, for example. The photosensor measures the brightness in the range between 10 lux and 1500 lux, for example, and a resolution of ±one percent. The ultrasonic sensor operates on the basis of echo time measurement and to this end uses an excited diaphragm, for example. When the ultrasound waves emitted by the diaphragm hit an object, they are reflected and the reflected ultrasound waves are detected. The delay between the emitted ultrasound waves and the detected reflected ultrasound waves is used to ascertain a distance between the diaphragm and the object. The ultrasonic sensor detects movements at an exemplary resolution of one millimeter. The infrared sensor contactlessly detects radiated heat in an exemplary temperature measurement range between −30° C. and +500° C. at a resolution of ±one percent. The infrared sensor provides thermal images of the radiated heat emitted by passengers. The microphone is a sound transducer which converts airborne sound into electrical voltage changes. The characteristic sensitivity of the microphone is between five mV/Pa and 100 mV/Pa, for example, and detects a sound pressure level of between 30 dB and 130 dB at an exemplary resolution of one dB. The noise level sensor detects intensities and noise levels. Intensities are detected at an exemplary resolution of between 10 −3 μWm 2 and 10 +4 μWm 2 ; the noise level is detected in an exemplary range of between 30 dB and 110 dB at an exemplary resolution of 0.1 dB. The weighing unit is a load mat, for example, which detects the weight of a user standing on it in kilograms. Such load mats exist in different dimensions. For example, a load mat has a rectangular base area of 0.5 square meters and a thickness of two centimeters and detects a weight in the range between one kilogram and 200 kilograms. The transmission/reception unit has at least one processor, at least one computer-readable data memory, at least one adapter for a signal line 2 and at least one electrical power supply. From the computer-readable data memory, at least one communication computer program means is loaded into the processor and executed. The communication computer program means controls the communication between the transmission/reception unit in the radio field 21 and at least one mobile communication unit 20 carried by the user. FIG. 3 shows this communication represented by curved triple circular segments. In this case, a plurality of embodiments are possible: In a first embodiment, the mobile communication unit 20 is a radiofrequency identification (RFID) card carried by the user, for example, having at least one coil, at least one data memory and at least one processor. The radio frequency used by the transmission/reception unit is 125 kHz, 13.56 MHz, 2.45 GHz, etc., for example. The mobile communication unit 20 uses its coil to inductively receive power from the electromagnetic field of the transmission/reception unit and is thus activated with power. The power activation is effected automatically as soon as the mobile communication unit 20 is in the reception range of the electromagnetic field of between a few centimeters and one meter from the transmission/reception unit. As soon as the mobile communication unit 20 has been activated with power, the processor reads at least one code stored in the data memory, which code is sent via the coil to the transmission/reception unit. The power activation of the mobile communication unit 20 and the sending of the code to the transmission/reception unit are effected contactlessly. In a second embodiment, the mobile communication unit 20 is a mobile telephone and/or a computer carried by the user, for example. The mobile appliance has at least one processor and at least one computer-readable data memory and at least one electrical power supply. From the computer-readable data memory, at least one communication computer program means is loaded into the processor and executed. The communication computer program means controls the communication of the mobile communication unit 20 in the radio field 21 . For the communication in the radio field 21 , known local radio networks with a reception range of up to 300 meters such as Bluetooth (IEEE 802.15.1), ZigBee (IEEE 802.15.4) or WiFi (IEEE 802.11), can be used at a frequency of 800/900 MHz or 2.46 GHz, for example. The radio field 21 allows bidirectional communication on the basis of known and proven network protocols such as the Transmission Control Protocol/Internet Protocol (TCP/IP) or Internet Packet Exchange (IPX). As soon as the mobile communication unit 20 is in the radio field 21 , the processor reads a code stored in the data memory, which code is sent to the transmission/reception unit.
At least one destination call controller 4 in the elevator system 100 has at least one processor, at least one computer-readable data memory, at least one adapter for a signal line 2 and at least one electrical power supply. According to FIG. 1 , the destination call controller 4 is a standalone electronic unit in at least one dedicated housing, which is positioned on floor S 3 , for example. The destination call controller 4 may also be an electronic plug-in unit, for example in the form of a printed circuit board, which printed circuit board is arranged in the housing of a call input apparatus 1 , 1 ′ and/or an elevator controller 5 , 5 ′.
The call input apparatus 1 , 1 ′, the sensor 17 , 18 , 19 and the destination call controller 4 and/or the elevator controller 5 , 5 ′ communicate bidirectionally via a signal line 2 such as a Universal Serial Bus (USB), Local Operating Network (LON), Modbus, Ethernet, etc. The signal line 2 is therefore a bus system. This signal line 2 is used to perform a communication on the basis of a known protocol. According to FIG. 1 , two respective call input apparatuses 1 , 1 ′ and two respective sensors 19 per floor S 1 to S 3 are communicatively connected to the destination call controller 4 via a signal line 2 . The signal line 2 is shown by dotted lines in FIG. 1 . Instead of a cabled signal line 2 between the sensor 17 , 18 , 19 and the destination call controller 4 and/or elevator controller 5 , a person skilled in the art can naturally also provide a radio field 21 such as Bluetooth, ZigBee or WiFi. According to FIG. 2 , a respective call input apparatus 1 and a sensor 17 per floor S 1 to S 3 are communicatively connected to an elevator controller 5 via a radio field 21 . Each communication subscriber is explicitly identifiable by means of an address for an adapter for the signal line 2 and/or the radio field 21 . The radio field 21 is shown by curved triple circular segments in FIG. 2 . The destination call controller 4 and the elevator controller 5 , 5 ′ communicate bidirectionally via a signal line 3 , 3 ′. According to FIG. 1 , the destination call controller 4 is communicatively connected to an elevator controller 5 , 5 ′ by means of a respective signal line 3 , 3 ′. The communication subscribers at the ends of the permanently activated signal lines 3 , 3 ′ are explicitly identifiable. The signal line 3 , 3 ′ is also shown by dotted lines in FIG. 1 . Given knowledge of the present disclosure, a person skilled in the art can combine the exemplary embodiments of an elevator system 100 as shown in FIGS. 1 and 2 with one another, for example such that a call input apparatus 1 , 1 ′ and/or a sensor 17 , 18 , 19 is communicatively connected to a plurality of elevator controllers 5 , 5 ′ by means of a radio field 21 and/or that a destination call controller 4 is communicatively connected to just one elevator controller 5 , 5 ′ by means of a signal line 3 , 3 ′.
The user can make a call by selecting a functional descriptor 16 , 16 ′, 16 ″ which is output on the input/output unit 13 of the call input apparatus 1 , 1 ′. The selection can be made by simply marking and/or by confirming a marked functional descriptor 16 , 16 ′, 16 ″. According to FIG. 1 , the call input apparatus 1 , 1 ′ transmits the call which has been made to the destination call controller 4 as a destination call via the signal line 2 . According to FIG. 2 , the call input apparatus 1 transmits the call which has been made to the elevator controller 5 as a floor call and/or as a cabin call via the radio field 21 . As shown in FIGS. 3 and 5 to 10 , the user can also send a code from the mobile communication unit 20 to a radio sensor 19 in a call input apparatus 1 , 1 ′, which code is received by the radio sensor 19 and transmitted to the destination call controller 4 and/or elevator controller 5 , 5 ′. The code may be a call which is desired by the user and/or may be a user identification, wherein the destination call controller 4 and/or elevator controller 5 , 5 ′ associate at least one predefined call with a transmitted user identification, which predefined call is stored in the computer-readable data memory in the destination call controller 4 and/or elevator controller 5 , 5 ′. The code transmitted to the destination call controller 4 and/or elevator controller 5 , 5 ′ is therefore handled by the destination call controller 4 and/or elevator controller 5 , 5 ′ like a call which has been made.
The call may be a floor call or cabin call or destination call. In the case of a floor call, FIG. 2 shows that first of all an elevator cabin 6 is moved to the floor of the call input apparatus 1 , which call input apparatus 1 has been used to make the floor call, or, if the floor call has been transmitted as a code, an elevator cabin 6 , 6 ′ is first of all moved to the floor of the radio sensor 19 , which radio sensor 19 received the code. This floor is called the call input floor. Only after the user on the call input floor has entered the elevator cabin 6 is—as shown in FIG. 2 —a cabin call to a destination floor made on a call input apparatus 1 in the elevator cabin 6 , and the elevator cabin 6 moved to this destination floor. This cabin call can also be transmitted to the elevator controller 5 , 5 ′ as a code. The elevator controller 5 , 5 ′ ascertains at least one respective call association for the floor call and for the cabin call. In the case of a destination call, the call input floor and a destination floor which is desired by the user are denoted, which means that there is no longer a need for a cabin call. Hence, the destination call controller 4 already knows the destination floor and can therefore optimize not only the approach to the call input floor but also the approach to the destination floor. The destination call controller 4 ascertains at least one call association for a destination call. The call association denotes a journey with at least one elevator cabin 6 , 6 ′ from a starting floor to a destination floor with the shortest possible waiting time and/or the shortest possible destination time. The starting floor does not have to match the call input floor. The destination floor also does not have to match the destination floor which the user desires on the basis of the destination call. When the call association is assigned to the elevator cabin 6 , 6 ′, at least one starting call signal and at least one destination call signal are produced and are transmitted to the adapter for the elevator controller 5 , 5 ′ of this elevator cabin 6 , 6 ′ via the signal line 3 , 3 ′.
Producing at least one signal state change puts the elevator system into an unhandicapped mode of operation. In the handicapped persons mode of operation, a user is transported by the elevator system 100 unhandicapped in the building. The handicap may be a disability of the user and/or a potential safety threat for the user. In the simplest case, the signal state change indicates in binary fashion whether or not the user is disabled and/or whether or not the user's safety is threatened.
The signal state change can be used to provide a detailed indication of the nature of the disability, such as walking disability, visual disability, hearing disability. The disability may be a physical disability and/or a mental disability. Thus, the user can move and/or orient himself in a building only using at least one facility specific to disabled persons. Examples of a facility specific to disabled persons are a wheelchair, a hospital bed on castors, a crutch, a hearing aid, a visual aid, a white stick, a guide dog, etc. It may also be that a severely disabled user can move only using at least one accompanying user. By way of example, an accompanying user pushes the wheelchair of the severely disabled user or makes a call input for the severely disabled user.
It is also possible to use the signal state change to indicate whether the handicapped user requires passive personal protection and/or active personal protection. For example, the user can move in a building only using at least one facility specific to personal protection. Examples of a facility specific to personal protection are a physical safe area and/or a time-based safe area and/or a bodyguard. By way of example, a physical safe area and/or a time-based safe area with as few other users as possible is/are produced for the handicapped user in the elevator cabin 6 , 6 ′. To this end, other users can be transported by the elevator cabin 6 , 6 ′ at earlier and/or later times. It may also be that a user with an acute safety threat is accompanied in the elevator cabin 6 , 6 ′ by at least one bodyguard.
Accordingly, in the special mode of operation, the call input apparatus 1 , 1 ′ and/or the elevator door 11 , 11 ′, 12 , 12 ′ and/or the elevator cabin 6 , 6 ′ is/are actuated as follows:
For a user with a facility specific to disabled persons, the elevator door 11 , 11 ′, 12 , 12 ′ is closed with a particularly long delay and it is closed particularly slowly. Whereas, in the normal mode of operation, an elevator door 11 , 11 ′, 12 , 12 ′ closes after a delay of between two and twenty seconds and the elevator door 11 , 11 ′, 12 , 12 ′ requires around two seconds for the closing operation, the delay and the closing operation are between 10% and 50% more for a user with a facility specific to disabled persons. For a user with a facility specific to disabled persons, the elevator cabin 6 , 6 ′ is stopped with a particular level of precision on floors S 1 to S 3 . Whereas, in the normal mode of operation, the level difference between a floor of the elevator cabin 6 , 6 ′ and a threshold of the floor door 11 , 11 ′ may be more than ten millimeters, a maximum level difference between the floor of the elevator cabin 6 , 6 ′ and the threshold of the floor door 11 , 11 ′ of +/− ten millimeters is prescribed pursuant to EN81-70 for a user with a facility specific to disabled persons. A user with a facility specific to disabled persons and/or specific to personal protection is allocated a particularly large amount of space in an elevator cabin 6 , 6 ′. Whereas, in the normal mode of operation, an elevator cabin 6 , 6 ′ with a 450 kg payload can take up to six users, this elevator cabin 6 , 6 ′ with a 450 kg payload is assigned to a single user with a facility specific to disabled persons and/or specific to personal protection. Similarly, an elevator cabin 6 , 6 ′ with a 630 kg payload, which can take up to eight users in the normal mode of operation, is assigned one user with a facility specific to disabled persons and an accompanying user and/or one user with a safety threat and a bodyguard. A user with a facility specific to disabled persons is transported by the elevator cabin 6 , 6 ′ from the call input floor to the destination floor. Whereas the elevator cabin 6 , 6 ′ inserts one or more intermediate stops and/or change stops in the normal mode of operation, a user with a facility specific to disabled persons is transported from the call input floor to the desired destination floor, so that he does not have to take any additional routes to reach a starting floor. A user with a facility specific to personal protection is transported by the elevator cabin 6 , 6 ′ from the call input floor directly to the destination floor. Whereas the elevator cabin 6 , 6 ′ inserts one or more intermediate stops and/or change stops in the normal mode of operation, a user with a facility specific to personal protection is transported from the call input floor to the desired destination floor without any intermediate stops and/or change stops.
In order to implement the handicapped persons mode of operation, the user can be provided with at least one functional descriptor 16 , 16 ′, 16 ″ which is output via the input/output unit 13 and/or the tone generator 15 . The surface of the input/output unit 13 which is visible to the user has at least one functional descriptor 16 , 16 ′, 16 ″. The functional descriptors 16 , 16 ′, 16 ″ are pictograms and/or alphanumeric character strings. The functional descriptors 16 , 16 ′, 16 ″ are produced by at least one luminous element such as a liquid crystal display (LCD), light emitting display (LED) and/or organic light emitting display (OLED), etc. Each luminous element can be activated by the computer program means, and the number, size, color and shape of the functional descriptors 16 , 16 ′, 16 ″ are freely programmable. The functional descriptor 16 , 16 ′, 16 ″ may also be a “blank area”, i.e. a uniform area of the touch screen 13 ′ which currently has no specific characterization. FIG. 3 shows fourteen functional descriptors 16 , 16 ′ arranged on the input/output unit 13 . FIGS. 5 to 13 show three functional descriptors 16 , 16 ′ 16 ″ arranged on the input/output unit 13 .
The functional descriptor 16 , 16 ′, 16 ″ indicates at least one option of the handicapped persons mode of operation which is executed by the elevator controller 4 and/or the destination call controller 5 , 5 ′. The user is moved for the transmitted functional descriptor 16 , 16 ′ 16 ,″ with the elevator system 100 in the handicapped persons mode of operation. In this context, a functional descriptor 16 , 16 ′, 16 ″ indicates at least one of the following options:
that the user can move and/or orient himself only using a facility specific to disabled persons; which facility specific to disabled persons is a wheelchair; which facility specific to disabled persons is a hospital bed on castors; which facility specific to disabled persons is a crutch; which facility specific to disabled persons is a hearing aid; which facility specific to disabled persons is a visual aid; which facility specific to disabled persons is a white stick; which facility specific to disabled persons is a guide dog; which facility specific to disabled persons is an accompanying passenger; that the user can move only using a facility specific to personal protection; which facility specific to personal protection is a physical safe area; which facility specific to personal protection is a time-based safe area; which facility specific to personal protection is a bodyguard; that the user desires at least one user-specific communication language, the user being able to confirm between a plurality of communication languages; that the user desires at least one interactive assistance for using the elevator system, the user being able to confirm between a plurality of assistances; that the user wishes to make at least one destination call, the user being able to confirm between a plurality of destination floors; that the user wishes to make at least one floor call, the user being able to confirm between a plurality of starting floors; that the user wishes to make at least one cabin call, the user being able to confirm between a plurality of destination floors; that the user desires at least one user-specific elevator cabin 6 , 6 ′, the user being able to confirm between a plurality of elevator cabins 6 , 6 ′.
In the handicapped persons mode of operation, functional descriptors 16 , 16 ′, 16 ″ are output visually on the input/output unit 13 and are output audibly by the tone generator 15 . By way of example, in the handicapped persons mode of operation, a selection between a plurality of destination floors is output visually on the input/output unit 13 as particularly large pictograms and/or alphanumeric character strings such as “1”, “2” or “library”, “Meier's office” and are voiced with audible clarity and distinctly by the tone generator 15 .
The user can mark and/or confirm a descriptor 16 , 16 ′, 16 ″ which has been output. The term “mark” is understood to mean selection of one of a plurality of functional descriptors 16 , 16 ′, 16 ″. The term “confirm” is understood to mean confirmation of such a selection of a functional descriptor 16 , 16 ′, 16 ″. The user can perform this “marking” and “confirmation” in several ways:
By touching the touch screen 13 ′ in the area of a currently output functional descriptor 16 , 16 ′, 16 ″, the user operates the input/output unit 13 and can mark and/or confirm a functional descriptor 16 , 16 ′, 16 ″ which has been output. By touching the keypad 13 ″, the user operates the input/output unit 13 and can mark and/or confirm a functional descriptor 16 , 16 ′, 16 ″ which has been output. By detecting a further signal, a functional descriptor 16 , 16 ′, 16 ″ is marked. By detecting yet a further signal, a functional descriptor 16 , 16 ′, 16 ″ is confirmed. To this end, the user performs at least one further change of position and/or at least yet a further change of position which is detected by the sensor 17 , 18 , 19 as a further signal and/or as yet a further signal and, as a comparison result, produces a further signal state change and/or yet a further signal state change.
The production of the further signal state change and/or of the yet further signal state change is illustrated by way of example with reference to FIGS. 5 to 13 and described as follows:
In FIG. 5 , a user approaches a sensor 19 in the form of a transmission/reception unit, which transmission/reception unit communicates with a mobile communication unit 20 in the right hand of the user in the radio field 21 . The transmission/reception unit is arranged in the housing of a call input apparatus 1 , 1 ′. As soon as the user has approached the transmission/reception unit to such an extent that the mobile communication unit 20 is in the detection range of the transmission/reception unit, the mobile communication unit 20 sends a code to the transmission/reception unit. This change of position by the user is denoted by a leftward pointing horizontal arrow. The transmission/reception unit detects the sent code as a signal and transmits it via the signal line 2 shown in FIG. 1 to the destination call controller 4 or via the radio field 21 shown in FIG. 2 to the elevator controller 5 . There, the transmitted signal is compared with at least one reference signal. If there is a match, the comparison result produced is a signal state change. The elevator system 100 is to some extent put into an unhandicapped mode of operation for the signal state change. As a result, a plurality of functional descriptors 16 , 16 ′, 16 ″ are output to the user on the touch screen 13 ′ schematically in the form of rectangles. The topmost output functional descriptor 16 is premarked by the call input apparatus 1 , 1 ′ by virtue of the rectangle being half filled. In FIG. 6 , the user marks one of the output functional descriptors 16 , 16 ′, 16 ″. The output functional descriptors 16 , 16 ′, 16 ″ are automatically premarked in the order in which they are output while communication is taking place between the transmission/reception unit and the mobile communication unit 20 . The call input apparatus 1 , 1 ′ first of all premarks the topmost functional descriptor 16 , then the second functional descriptor 16 ′ from the top, then the third functional descriptor 16 ″ from the top. The period of time after which the call input apparatus 1 , 1 ′ skips from one output functional descriptor 16 , 16 ′, 16 ″ to the next is freely settable and is between two and ten seconds, for example. By raising the right hand, the mobile communication unit 20 is taken out of the detection range of the transmission/reception unit and the communication between the transmission/reception unit and the mobile communication unit 20 is interrupted. This change of position by the user is denoted by an upward pointing vertical arrow. The transmission/reception unit detects the termination of communication with the mobile communication unit 20 as a further signal. The further signal from the transmission/reception unit is transmitted to the call input apparatus 1 , 1 ′. There, the transmitted further signal is compared with a reference signal. The reference signal used is the previously detected code of the mobile communication unit 20 in FIG. 5 . If the further signal from the transmission/reception unit does not match the reference signal, a further signal state change is produced as a comparison result for the further signal from the transmission/reception unit, and the currently premarked second functional descriptor 16 ′ from the top in FIG. 6 is marked completely for the further signal state change. In FIG. 7 , the user confirms a completely marked functional descriptor 16 , 16 ′, 16 ″. By lowering the right hand, the mobile communication unit 20 is taken back into the detection range of the transmission/reception unit and the communication between the transmission/reception unit and the mobile communication unit 20 is set up again. This change of position by the user is denoted by a downward pointing vertical arrow. The transmission/reception unit detects that the communication with the mobile communication unit 20 has been set up again as yet a further signal. The further signal from the transmission/reception unit is transmitted to the call input apparatus 1 , 1 ′. The transmitted yet further signal is compared with a reference signal. The reference signal used is the previously detected code from the mobile communication unit 20 in FIG. 5 . If the yet further signal from the transmission/reception unit matches the reference signal, yet a further signal state change is produced as a comparison result for the yet further signal from the transmission/reception unit, and the currently completely marked functional descriptor 16 ′ is confirmed for the yet further signal state change. This confirmation of the second functional descriptor 16 ′ from the top is shown in FIG. 7 by virtue of the rectangle being completely filled. In FIG. 8 , a user approaches a sensor 17 in the form of a camera. This change of position by the user is denoted by a leftward pointing horizontal arrow. The camera is arranged close to a call input apparatus 1 , 1 ′ and captures an area in front of the call input apparatus 1 , 1 ′. The camera captures the change of position by the user as still images. The still images are compared with one another in the camera. As soon as the user remains stationary in the capture range of the camera for several seconds, a signal state change is produced. The camera transmits the signal state change via the signal line 2 shown in FIG. 1 to the destination call controller 4 or via the radio field 21 shown in FIG. 2 to the elevator controller 5 . The elevator system 100 is to some extent put into an unhandicapped mode of operation for the signal stage change. As a result, a plurality of functional descriptors 16 , 16 ′, 16 ″ are output to the user on the touch screen 13 ′ schematically in the form of rectangles. The topmost output functional descriptor 16 is premarked by the call input apparatus 1 , 1 ′ by virtue of the rectangle being half filled. In FIG. 9 , the user marks one of the output functional descriptors 16 , 16 ′, 16 ″. The output functional descriptors 16 , 16 ′, 16 ″ are automatically premarked in the order in which they are output while the user does not change position with his left hand. The call input apparatus 1 , 1 ′ first of all premarks the topmost functional descriptor 16 , then the second functional descriptor 16 ′ from the top, then the third functional descriptor 16 ″ from the top. The period of time after which the call input apparatus 1 , 1 ′ skips from an output functional descriptor 16 , 16 ′, 16 ″ to the next is freely settable and is between two and ten seconds, for example. Raising of the left hand of the user is detected in the capture range of the camera as a further signal. This change of position by the user is denoted by an upward pointing curved arrow. The captured still images are compared with one another in the camera. The still image with the raised left hand is compared with the still image in which the user remained stationary in the capture range of the camera, and which produced the prior signal state change, as a reference signal. The nonmatch between the further signal and the reference signal produces a further signal state change as a comparison result. The further signal stage change is transmitted from the camera via the signal line 2 shown in FIG. 1 via the radio field 21 shown in FIG. 2 to the call input apparatus 1 , 1 ′, and the currently premarked second functional descriptor 16 ′ from the top shown in FIG. 9 is marked completely for the further signal state change. In FIG. 10 , the user selects a completely marked functional descriptor 16 , 16 ′, 16 ″. The user leaves the capture range of the camera, which is detected by the camera as yet a further signal. This change of position by the user is denoted by a rightward pointing horizontal arrow. The captured still images are compared with one another in the camera. The reference signal used is the previously captured still image of the user shown in FIG. 8 . If the yet further signal does not match this reference signal, yet a further signal state change is produced for the yet further signal as a comparison result. The yet further signal state change is transmitted from the camera via the signal line 2 shown in FIG. 1 or via the radio field 21 shown in FIG. 2 to the call input apparatus 1 , 1 ′, and the currently completely marked functional descriptor 16 ′ is confirmed for the yet further signal state change. This confirmation of the second functional descriptor 16 ′ from the top is shown by virtue of the rectangle being filled completely in FIG. 10 . In FIG. 11 , a user approaches a sensor 18 in the form of a weighing unit. This change of position by the user is denoted by a leftward pointing horizontal arrow. The weighing unit is arranged in front of a call input apparatus 1 , 1 ′. As soon as the user steps on to the weighing unit, the weighing unit detects the change of position by the user as a weight and produces a signal therefor. This detected signal is transmitted via the signal line 2 shown in FIG. 1 to the destination call controller 4 or via a radio field 21 shown in FIG. 2 to the elevator controller 5 . There, the transmitted signal is compared with a reference signal. As soon as the user remains in the capture range of the weighing unit for several seconds, i.e. is stationary on the weighing unit, a signal state change is produced. The elevator system 100 is to some extent put into an unhandicapped mode of operation for the signal state change. As a result, a plurality of functional descriptors 16 , 16 ′, 16 ″ are output to the user on the touch screen 13 ′ schematically in the form of rectangles. The topmost output functional descriptor 16 is premarked by the call input apparatus 1 , 1 ′ by virtue of the rectangle being half filled. In FIG. 12 , the user marks one of the output functional descriptors 16 , 16 ′, 16 ″. To this end, the call input apparatus 1 , 1 ′ has at least one sensor 17 in the form of a microphone. The output functional descriptors 16 , 16 ′, 16 ″ are automatically premarked in the order in which they are output while the user does not change position. The call input apparatus 1 , 1 ′ first of all premarks the topmost functional descriptor 16 , then the second functional descriptor 16 ′ from the top, then the third functional descriptor 16 ″ from the top. The period of time after which the call input apparatus 1 , 1 ′ skips from one output functional descriptor 16 , 16 ′, 16 ″ to the next is freely settable and is between two and ten seconds, for example. A spoken command from the user such as “YES” is detected in the capture range of the microphone as a further signal. The microphone captures the change of position by the user as airborne sound. This change of position by the user is denoted by a speech bubble. The further signal from the microphone is transmitted to the call input apparatus 1 , 1 ′. There, the transmitted further signal is compared with a reference signal. If the further signal from the microphone matches the reference signal, a further signal state change is produced for the further signal from the microphone as a comparison result, and the currently premarked second functional descriptor 16 ′ from the top in FIG. 12 is marked completely for the further signal state change. In FIG. 13 , the user selects a completely marked functional descriptor 16 , 16 ′, 16 ″. The user leaves the capture range of the weighing unit, which is detected by the weighing unit as yet a further signal. This change of position by the user is denoted by a rightward pointing horizontal arrow. The yet further signal from the weighing unit is transmitted to the call input apparatus 1 , 1 ′. There, the transmitted yet further signal is compared with a reference signal. The reference signal used is the previously detected weight of the user in FIG. 11 . If the yet further signal from the weighing unit does not match the reference signal, yet a further signal state change is produced for the yet further signal from the weighing unit as a comparison result, and the currently completely marked functional descriptor 16 ′ is confirmed for the yet further signal state change. This confirmation of the second functional descriptor 16 ′ from the top is shown by virtue of the rectangle being filled completely in FIG. 13 .
Given knowledge of the present disclosure, a person skilled in the art has diverse options for varying the method steps shown, which variations cannot all be shown purely for economic reasons. Thus, confirmation of a functional descriptor 16 , 16 ′, 16 ″ can be practical but is not absolutely necessary in order to carry out the method for catering for the use of the elevator system 100 by handicapped persons. In principle, marking of a functional descriptor 16 , 16 ′, 16 ″ is sufficient. The call input apparatus 1 , 1 ′ transmits the marked and/or confirmed functional descriptor 16 , 16 ′, 16 ″ via the signal line 2 shown in FIG. 1 to the destination call controller 4 or via a radio field 21 shown in FIG. 2 to the elevator controller 5 . There, the option linked to the functional descriptor 16 , 16 ′, 16 ″ is executed. It is also possible for a functional descriptor 16 , 16 ′, 16 ″ to be marked and confirmed coincidentally in one method step. It is thus possible to produce both a further signal state change and yet a further signal state change by leaving the capture range of the camera shown in FIG. 10 or by leaving the capture range of the weighing unit shown in FIG. 13 . In this case, the method step of raising the left hand shown in FIG. 9 or the method step of the spoken command shown in FIG. 12 is not necessary. The user thus merely needs to enter the capture range of the camera or of the weighing unit for several seconds and then leave it again in order to carry out the method for catering for the use of the elevator system 100 by handicapped persons.
Having illustrated and described the principles of the disclosed technologies, it will be apparent to those skilled in the art that the disclosed embodiments can be modified in arrangement and detail without departing from such principles. In view of the many possible embodiments to which the principles of the disclosed technologies can be applied, it should be recognized that the illustrated embodiments are only examples of the technologies and should not be taken as limiting the scope of the invention. Rather, the scope of the invention is defined by the following claims and their equivalents. I therefore claim as my invention all that comes within the scope and spirit of these claims.
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A method for enabling the use of an elevator system by disabled persons includes detecting at least one position change of a user using at least one sensor, said position change being in the form of at least one signal and at least one reference signal. The signal is then compared to the reference signal. At lease one signal status change is generated when at least one predefined comparison result is fulfilled. For the generated signal state change, the elevator system is at least partially brought to an operating mode enabling the use thereof by disabled persons.
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This application is a continuation of international application number PCT/AT 01/00234 filed Jul. 12, 2001.
The invention relates to a method for re-profiling by peripheral milling at least one running surface of a rail, preferably the convex portion of the rail head cross-profile of a rail, especially a railway rail, which convex portion exhibits the running surface.
It is known to re-profile worn rails by peripheral milling, i.e. to provide them with a new profile. For that purpose, the rail head was machined by peripheral milling. In order to somewhat control the costs of a milling cutter, it is known to equip the milling cutter with turning plates mounted to holding devices in turn inserted in recesses in the milling cutter body. In doing so, the turning plates being on a level of the peripheral milling cutter each generate a milling track oriented in the longitudinal direction of the rail. However, for lack of space, the number of turning plates to be attached is limited with peripheral milling cutters of that kind. Therefore, by peripheral milling it was only possible to provide a small number of tracks lying next to each other in the longitudinal direction of the rail and being applied to the rail head by the turning plates. Thereby, a large corrugation is created, and it was necessary to subject the rail head to a smoothing process following upon milling. It is known to equip a peripheral milling cutter for that purpose with a plurality of blades exhibiting the entire desired profile. The plurality of blades is necessary in so far as they ensure that only slight differences in depth occur in the longitudinal direction of the rail. Here, it is disadvantageous that the hollows and points generated by such kind of smoothing extend across the entire cross section that is machined. That causes noise and vibrations when being passed over as well as a decrease in lifetime.
The invention aims at avoiding those drawbacks and difficulties and has as its object to provide a method of the initially described kind as well as a rail-profile milling cutter for carrying out the method, by means of which it is possible to achieve a minor corrugation both in the longitudinal direction of the rails and in the cross-profile which complies with the regulations of the railway operators or the railway corporations. The present invention employs a milling operation that—for less stringent regulation requirements, such as for slower speeds of the railway—may suffice alone. To meet more stringent requirements, such as for faster speeds of the railway, an optionally subsequent grinding operation may be employed.
In a method of the initially described kind that object is achieved in that, in order to produce the desired profile by a single peripheral milling operation, more than five, preferably nine, milling tracks lying next to each other in the longitudinal direction of the rail are formed and that, in the following, optionally a grinding operation of at least the running surface, preferably the convex portion of the rail head cross-profile, which convex portion exhibits the running surface, is carried out.
Preferred variants are characterized in the subordinate claims.
As mentioned above, for railways having greater requirements such as, faster traveling speeds, the milling operation, according to the invention, is followed by a grinding operation. Thus, in order to decrease or level the corrugation running in the longitudinal direction of the tracks and, optionally, in order to flatten or level the polygonal line (cross-section), respectively, the milled rail is ground, preferably immediately following upon milling taking place in the same run. The axis of the grinding wheel and a plane perpendicular to the longitudinal direction of the rail includes an angle deviating from 0°. Preferred variants for said grinding are described in the following detailed description of the invention.
A rail-profile milling cutter according to the invention is provided for milling at least one running surface of a rail, especially a railway rail, preferably for milling the convex portion of a rail head cross-profile of a rail. The rail-profile milling cutter is a sandwich milling cutter configured with a plurality of wheels each of which is provided with turning plates at the periphery of the wheels.
Advantageous embodiments are described below
A device for carrying out the method according to the invention is characterized by
a means for generating a relative motion between the rail and the milling cutter as well as the optionally existing grinding wheel,
a driving means for the milling cutter as well as a driving means for the grinding wheel in case a grinding wheel is provided,
a milling cutter formed of a plurality of wheels provided with turning plates at the periphery,
a positioning of the axis of the grinding wheel in a direction deviating from a plane perpendicular to the longitudinal direction of the rail.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following, the invention is explained in more detail by way of two exemplary embodiments with reference to the drawings, wherein
FIG. 1 shows a side view of a device for carrying out the method according to the invention and
FIG. 2 shows a schematic top view along the arrow II of FIG. 1 .
FIG. 3 shows a variant of the device for carrying out the method according to the invention.
FIG. 4 shows the cross section of a railway rail in various conditions of the rail.
FIG. 5 shows the engagement of the grinding wheel on a railway rail seen in cross section, in accordance with the method according to the invention.
The rail-profile milling cutter according to the invention is shown in FIGS. 6 to 8 , with FIG. 6 illustrating a partial section through the milling cutter in the assembled state,
FIG. 7 illustrating the individual parts of the milling cutter in an exploded view, and
FIG. 8 being a side view of a wheel of the milling cutter along the arrow VIII of FIG. 7 .
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 4, the cross section of a rail 1 is illustrated in various conditions. The rail head 3 situated on the stem of a rail 2 is provided with a convex cross-sectional portion 5 exhibiting the running surface 4 on which the track wheel of a rail vehicle runs, which cross-sectional portion, in its new condition, is illustrated by line A. Due to wear, that convex portion 5 of the cross section of the rail head 3 receives the shape as illustrated by line B. As soon as rail 1 has reached that condition or even earlier, as in accordance with high-speed rails, rail 1 is subjected to finishing so that the convex portion 5 of the rail head 3 , at least, however, the running surface 4 , regains its original condition, i.e. the original cross-sectional shape—as illustrated by line C—with the best possible approximation in accuracy. Thereby, certain tolerances in the range of from 1 to 3 decimillimeters are to be observed according to the regulations of a railway operator or a railway corporation or a supraregional standard such as cen DRAFT pr EN 13674-1. In doing so, it is essential that the guiding surface 6 of the rail 1 and the running surface 4 are finished.
As can be seen in FIG. 4, a relatively large amount of material has to be removed according to the wear of the rail, which has to be done as fast and inexpensively as possible in case of laid rails so as to impede the railway traffic as little as possible.
FIGS. 1 and 2 illustrate a device according to the invention which is arranged in a stationary position and past which the rail 1 to be machined is moved. FIG. 3 illustrates a device according to the invention which is incorporated in a movable facility such as a locomotive engine so that it is feasible to machine rails which already have been laid by means of said device. In that case, the device according to the invention exists in duplicate so that both the left-hand and the right-hand rails can be finished in one passage. Parts and devices of the stationary facility and the movable device which are mutually identical are marked by identical numerals.
Reference numeral 7 denotes a milling unit the rail-profile miffing cutter 8 of which is configured as a peripheral miffing cutter and is described in greater detail hereinafter. The milling cutter 8 can be driven via a driving motor 9 and a gear 10 whereby the direction of rotation is chosen such that the rail 1 is machined by the cut-down milling method. Immediately adjacent to the milling unit 7 , a grinding unit 11 is provided, the grinding wheel 12 of which can be driven by means of a driving gear 13 , preferably also in the direction of rotation of the milling cutter 8 so that down-grinding of the rail 1 is effected. The grinding wheel 12 is equipped with a system for regulating the depth of grinding 14 so that it is feasible to continuously readjust the grinding wheel 12 to the rail 1 , according to its wear. The Said system for regulating the depth of grinding 14 comprises a measuring system for measuring the continuously decreasing diameter of the periphery of the grinding wheel 12 ; it can also make use of measuring data gained from measuring an angular moment of a driving component.
Just upon their emergence, both the milling chips and the grinding chips as well as the grinding dust are removed via the vacuum means 15 and 16 .
Just in front of the milling unit 7 and just behind the grinding unit 11 , guides 17 for the rail 1 are provided in each case, against which guides the rail 1 can be pressed by means of support rolls 18 , whereby it is possible to press at least the running surface 4 of the rail 1 , preferably the crown of the rail head 3 . Furthermore, lateral guiding rolls 19 engaging the rail head 3 on both sides are provided along the device, whereby the lateral guiding rolls 19 fitting closely to the side of the guiding surface 6 of the rail 1 are fixed in their positions. The rail is pressed against the fixed lateral guiding rolls 19 by the lateral guiding rolls 19 fitting closely to the opposite side, whereby the rail 1 assumes an exact position opposite the milling unit and the grinding unit.
Between the milling unit 7 and the grinding unit 11 , a further guide 20 is provided, which is equipped with a damping device in order to eliminate any vibrations of the rail 1 caused by the milling cutter.
As can be seen in particular in FIG. 2, the axis 21 of the grinding wheel is inclined by an angle α against a plane 22 perpendicular to the longitudinal direction of the rail, which angle is greater than 0, preferably ranging between 1 and 20° C., depending on the respective condition of the rail 1 prior to grinding. If the rail head 3 has a cross section which, due to milling, approaches the ideal cross section, already before grinding, or if the rail 1 , in its new condition, is still provided with a roller skin, the angle α suitably ranges between 5 and 12°, ideally amounting to 8°. However, if the previous state of the cross section has been adjusted to the ideal cross-profile in a less exact manner, f.i., if it has been roughed down only crudely, a smaller angle α, preferably ranging between 1 and 6° C., is suitable for securing an optimal chip removal volume with a long service life of the grinding wheel.
In its new condition, the grinding wheel 12 has already been pre-profiled, i.e., it exhibits a profile which roughly mates rail 1 . For an exact manufacture of said counterprofile, it is advantageous to provide a sharpening means 23 with a grinding stone 24 which can be pressed against the periphery of the grinding wheel 12 . Said grinding stone has exactly the desired profile which is to be produced and it also includes angle α together with the grinding wheel. Before grinding of the first rail 1 is started, said grinding stone 24 is pressed against the grinding wheel 12 until the grinding wheel has adopted its profile. While rail 1 is ground, the grinding stone 24 can be lifted from the grinding wheel 12 , since the grinding wheel profiles itself at the pre-profile, i.e., at the milled rail-head area or the rail-head surface still provided with the roller skin, respectively. During machining of a rail head 3 , the grinding stone may optionally be fitted to the grinding wheel 12 for temporary sharpening.
Rail 1 may also be used for the adjustment of a profile which exactly mates the grinding wheel 12 provided that it has been milled with sufficient accuracy or still has the roller skin.
If, as in the illustrated exemplary embodiment, a milled rail-head surface is ground, the profiled grinding wheel 12 only has the most important task of smoothing the waves generated by the milling cutter 8 and of creating an image of traverse grinding.
By inclining the grinding wheel 12 according to the invention, particularly good conditions of engagement as well as a strong smoothing effect occur. The engagement of the inclined grinding wheel 12 is illustrated in FIG. 5 . It is apparent that the inclination creates an advantageous engagement angle, in particular at the point where the convex portion 5 of the rail head 3 meets the side faces 25 of the rail head 3 . Those favourable conditions of engagement allow also in those places a sufficiently extensive removal of material with a very good thermal behaviour being provided so that, on the ground surface, burning cannot occur. Furthermore, a very good service life of the grinding wheel 12 is thereby created.
It can be advantageous if the axis 21 of the grinding wheel 12 is also inclined against the rail's longitudinal central plane of symmetry 26 by an angle β which may have a size of between 1 and 20°.
If different rail profiles are to be machined by means of the device according to the invention, the axis 21 of the grinding wheel 12 may suitably be arranged so as to be adjustable on the device.
According to the embodiment illustrated in FIG. 3, the milling unit 7 and the grinding unit 11 are incorporated in a rail-milling line 27 . By means of actuators 28 , the milling cutter 8 and the grinding wheel 12 are moved approximately vertically against the rail 1 until the guides 17 and 20 rest on the rail head 3 . A lateral movement of the grinding unit 11 and the milling unit 7 toward the guiding surface 6 until the lateral guiding rolls 19 rest on the rail head 3 is possible as well.
The rail-profile milling cutter 8 according to the invention is constructed as a sandwich milling cutter, i.e., it is comprised of wheels 30 each of which is shaped as a ring wheel. As will be described hereinafter, those ring wheels 30 each support a plurality of turning plates 31 . These are made of hard metals, ceramics or similar materials. As can be seen in FIG. 6, the ring wheels 30 are fastened to a milling cutter core 32 by means of a screw connection 33 and are centered against each other by means of several centering pins 34 and are secured against each other by means of further screws 35 .
According to the illustrated exemplary embodiment, nine ring wheels 30 are provided, whereby the two external ring wheels 30 support quadruple turning plates the cutting edges of which are of an arcuated shape and serve for milling, i.e. creating a milling track, close to the guiding surface 6 . At the outer periphery 36 , the ring wheels 30 arranged between the external ring wheels 30 are provided with humps 37 surpassing the outer periphery 36 and manufactured in one piece with the ring wheels 30 . Said humps 37 form seats for the quadruple turning plates 31 , which, however, exhibit straight cutting edges. Due to the humps 37 provided at the ring wheels 30 , spacious chip bags 38 are formed between the turning plates 31 .
All turning plates 31 are fastened to the ring wheels 30 preferably by means of screw connections, clamping joints might be used as well. Each of the cutting edges of the turning plates 31 of the ring wheels 30 arranged between the external ring wheels 30 surpasses with its cutting edge the side faces of the ring wheel 30 to which it is fastened. The turning plates 31 of adjacent ring wheels 30 , which turning plates are arranged on the ring wheels 30 , are arranged so as to be peripherally offset so that, with respect to the periphery, the turning plates 31 of the neighbouring ring wheel end up lying between the turning plates 31 of the first ring wheel 30 .
By means of the sandwich milling cutter 8 according to the invention, it is possible to mill a great number of milling tracks—even more than nine—extending in the longitudinal direction of the rail 1 onto the rail head 3 , whereby it is feasible to achieve an extremely great accuracy of the milled cross-profile, i.e., an extremely close approximation to the ideal cross-profile of the rail head 3 . For certain requirements, the rail heads 3 re-profiled by means of the milling cutter 8 according to the invention and/or the milling method according to the invention are sufficient without subsequent grinding being necessary, f.i., for travelling speeds which are not too high. For greater requirements, the milled tracks are subjected to a grinding operation such as described above.
The essential advantage of the grinding method according to the invention lies in the plurality of adjacent milling tracks which can be milled onto the rail head 3 in a single working process. Particularly advantageously, the milling method according to the invention is combined with the grinding method according to the invention, whereby it is feasible to achieve an extensive removal of material also in case of extremely worn rails as well as a surface which, because of the milling method according to the invention, corresponds to the desired rail profile already to a large extent and which requires only minor grinding, i.e., grinding involving the removal of relatively little material, if any.
In doing so, it is possible to combine milling and grinding in a single operating process, thereby manufacturing a running surface or a machined portion of the rail head, respectively, fulfilling the greatest requirements in terms of running qualities, lifetime and avoidance of noise.
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The invention relates to a method for re-profiling the running surface of a rail, preferably the convex portion of the rail head cross-profile of a rail, especially a railway rail, by peripheral milling. The aim of the invention is to obtain a profile that meets the requirements and has few corrugations. To this end, for producing the profile in a single peripheral grinding step, more than five, preferably nine milling tracks are produced that are oriented in parallel to the longitudinal direction of the rail. Optionally, the running surface, preferably the convex portion of the rail head cross-profile including the running surface is ground afterwards.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a conductive material used for a resistor and a sensor, which is enhanced its mechanical strength while maintaining a stable resistance ratio.
2. Description of the Related Art
Conventionally, conductive materials have been used in a gas sensor for flammable gas such as carbon monoxide and butane, which conducts the detection of the gas on the basis of a change in resistance while heating a catalyst by resistance heating. Further, in a thermistor and an oxygen sensor using a solid electrolyte, a lead for a sensor of gas such as carbon monoxide and nitrogen oxide, and a lead for a semiconductor gas sensor, conductive materials have been used, which are required to have a stable resistance at high temperatures and have enhanced mechanical strength by a solid solution such as Pt or a Pt—Rh alloy. Such conductive materials are not remarkably oxidized even in the atmosphere at high temperatures and have stable corrosion resistance.
Conductive materials to be used for the above-mentioned purposes are required to have excellent corrosion resistance and stable resistance at the temperature to be used. Such conductive materials are used in the form of a wire rod, a thin film produced by vapor deposition or sputtering, and a film obtained by printing and heating a paste or the like. In particular, when the conductive material is used as a wire rod, it is required to have mechanical strength at a certain level or higher. Further, depending upon the purpose, the conductive material is used as a wire rod with a diameter of 50 μm or less, which is required to have satisfactory workability, as well as corrosion resistance, heat resistance, and oxidation resistance. In order to satisfy those requests, Pt and a Pt—Rh alloy are used.
However, Pt has low mechanical strength, and in the case where Pt is heated in a high-temperature during the process, crystal grains become coarse. When bending is performed during the process, the crystal grains are broken from a grain boundary.
The mechanical strength may be enhanced by adding Rh or the like to Pt. However, due to the difference in vapor pressures, the composition change is occurred to vary a resistance. Thus, there is a problem that it cannot be used for the purpose in which the change in resistance is considered to be important.
In addition, Elements to be added are limited to those which are unlikely to be oxidized, and an element such as Rh which is more expensive than Pt needs to be used.
Further, in the case of enhancing the solid solution, Rh has a small effect of suppressing the coarsening of crystal grains. In the case where Rh is exposed to high temperatures of 1,500° C. or higher during the process, Rh is coarsened to an extent about the same as Pt and may be broken from the grain boundary.
Therefore, a material in which an oxide or the like is dispersed is used. However, it is difficult to form an extra fine wire of 50 μm or less from the material, and there are such problems that the material has ductility smaller than that of Pt and a Pt alloy, and the like.
SUMMARY OF THE INVENTION
The inventors of the present invention have conducted intensive studies in order to solve the above conventional problems, and hence have found a conductive material comprising: Pt; 400 to 10,000 ppm of Sr contained therein; and an inevitable impurity as the balance, wherein an intermetallic compound phase formed of Pt and Sr is dispersed and precipitated in Pt.
Note that when the addition amount of Sr is less than 400 ppm, Pt and Sr are not precipitated sufficiently as an intermetallic compound, and the mechanical strength becomes weak. Further, when the addition amount of Sr exceeds 10,000 ppm, the workability is decreased, and cracks and ruptures are caused during the process, with the result that an extra fine wire (with a diameter of 50 μm or less) cannot be formed. Then, in the present invention, the addition amount of Sr is set to be 400 to 10,000 ppm.
The conductive material of the present invention has a stable resistance ratio and high mechanical strength at high temperatures, suppresses the coarsening of crystal grains, and is excellent in workability. Further, the conductive material of the present invention has oxidation resistance and corrosion resistance, and the surface thereof is not to be covered with an oxide film even when exposed to a high temperature of 1,500° C. or higher.
The conductive material can be used in, for example: a resistance wire using a temperature coefficient; and a lead wire required to have a stable resistance at high temperatures in an oxygen sensor or the like.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows surface analysis results by EPMA in Example 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, the present invention is described by way of specific examples.
Table 1 shows a component composition of each of samples of Examples 1 to 4, Comparative Examples 1 and 2, and Conventional Examples 1 and 2. Pt and a Pt alloy with elements shown in Table 1 were melted in an argon gas atmosphere, and cast in a mold to obtain ingots, and then each ingot was forged and stretched. The workability, mechanical strength, and resistance ratio thereof were investigated.
Table 2 shows the investigation results of the workability and the mechanical strength.
TABLE 1
Sr (ppm)
Rh (mass %)
Pt (mass %)
Example 1
600
—
bal.
Example 2
1,200
—
bal.
Example 3
3,000
—
bal.
Example 4
6,500
—
bal.
Comparative Example 1
61
—
bal.
Comparative Example 2
11,500
—
bal.
Conventional Example 1
—
—
bal.
Conventional Example 2
—
13
bal.
TABLE 2
Possibility
Tensile Strength
Tensile Strength
of Working
(MPa) at
(MPa) at High-Temp.
at φ30 μm
Room Temp. * 1
[600° C.]
Example 1
Possible
161
66.7
Example 2
Possible
167
75.8
Example 3
Possible
253
118
Example 4
Possible
245
126
Comparative
Possible
131
46.8
Example 1
Comparative
Impossible
—
—
Example 2
Conventional
Possible
127
36.4
Example 1
Conventional
Possible
239
107
Example 2
* 1 Test after heat treatment at 1,550° C. for one hour.
Test Sample: wire rod of φ0.3 mm × L50 mm
As shown in Table 2, stretching of a drawn wire of φ30 μm is possible in any of Examples 1 to 4. Further, compared with Pt in Conventional Example 1, the tensile strength in each Example is 1.3 times or more at room temperature, and is twice or more at 600° C. Thus each Example has sufficient tensile strength. Further, when Sr is 3,000 ppm or more (Examples 3 and 4), the tensile strength equal to or more than that of a PtRh alloy in Conventional Example 2 is obtained.
In order to confirm the stability of a resistance ratio R 100 /R 0 (=Resistance at 100° C./Resistance at 0° C., abbreviated hereinafter), Examples 1 to 4 were heat-treated in the atmosphere at 600° C. for 500 hours, and the change rate in a resistance ratio before and after the heat treatment was investigated. The change rate of the resistance ratio was calculated from Expression 1.
Change rate of a resistance ratio (%)=[(Resistance ratio* 2 BEFORE heat treatment −Resistance ratio AFTER heat treatment)/Resistance ratio BEFORE heat treatment]×100 Expression 1:
*2: Conditions before heat treatment:
φ0.3 mm×1,000 mm wire;
Measurement after heat treatment at 1,100° C. for 1 hour.
Table 3 shows the results.
TABLE 3
Change Rate of Resistance Ratio
at 600° c. for 500 Hours
Example 1
−0.01
Example 2
−0.01
Example 3
−0.01
Example 4
−0.02
The temperature of 600° C. is high for the temperature range to be used in a sensor; however, no large change in resistance ratio was found even by a heat treatment for 500 hours, and thus, satisfactory results were obtained.
In the case of using a conductive material as a wire rod, the conductive material is likely to be broken along a crystal grain boundary when the crystal grain diameter is coarse. Thus, the crystal grain is required to be fine. The average crystal grain diameter of the samples in Table 1 after the heat treatment at 1550° C. for one hour was investigated. The diameter of each of the samples was set to be φ0.3 mm. Expression 2 shows how to calculate an average crystal grain diameter.
D= 2 ×[A /[Π(μ 1 +(μ 2 /2))]] 0.5 Expression 2:
D: Average crystal grain diameter
A: Measurement area
μ 1 : Number of crystal grains that are not in contact with the measurement end present in a measurement area
μ 2 : Number of crystal grains that are in contact with the measurement end present in a measurement area
Table 4 shows the results.
TABLE 4
Average Crystal Grain Diameter (μm)
Example 1
65
Example 2
50
Example 3
15
Example 4
15
Comparative Example 1
105
Conventional Example 1
150
Conventional Example 2
150
As shown in Table 4, in any of Examples 1 to 4, the average crystal grain diameter after the heat treatment was less than 100 μm. Thus, the effect of suppressing the coarsening of crystal grains was recognized. In Comparative Example 1, although the coarsening of crystal grains was suppressed compared with Conventional Examples, such an effect as that in Examples was not obtained. In Conventional Examples 1 and 2, the crystal grains were coarsened irrespective of the presence/absence of Rh, and the grain boundary passing through the wire was present depending upon the observation portion.
The peak other than that of Pt was investigated by X-ray diffraction, and the presence of a precipitate was confirmed. Table 5 shows the results.
TABLE 5
Example 1
Peaks of Pt 5 Sr and the like confirmed
in addition to Pt
Example 2
Peaks of Pt 5 Sr and the like confirmed
in addition to Pt
Example 3
Peaks of Pt 5 Sr and the like confirmed
in addition to Pt
Example 4
Peaks of Pt 5 Sr and the like confirmed
in addition to Pt
Comparative Example 1
No peak confirmed except for Pt
In Examples 1 to 4, the peak of an intermetallic compound such as Pt 5 Sr was confirmed in addition to Pt, and thus, the presence of a precipitated phase was confirmed. In Comparative Example 1, no peak was confirmed except for Pt.
FIG. 1 shows a surface analysis results by EPMA in Example 3. As shown in FIG. 1 , Sr precipitates of about 1 μm and about several hundred nm were confirmed in the surface analysis of Sr.
The present invention described above is formed of a Pt alloy in which 400 to 10,000 ppm of Sr is contained in Pt, and an intermetallic compound phase composed of Pt and Sr is dispersed and precipitated in Pt. Thus, a conductive material used in a resistance wire, a sensor, and the like, which uses a temperature coefficient of a stable resistance ratio, can be provided.
The application of the conductive material of the present invention is not particularly limited, and the conductive material can be used as the material for the conductor which constitutes, for example, the following heaters, resistance temperature detectors, and leads.
(1) heater
(2) resistance temperature detector
(3) resistance temperature detector and heater for a sensor of carbon monoxide and flammable gas
(4) lead for a thermistor
(5) lead for a solid electrolyte gas sensor
(6) lead for a semiconductor gas sensor
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Provided is a conductive material to be used for a resistor and a sensor, which is enhanced its mechanical strength while maintaining a stable resistance ratio. In the conductive material used for the resistor and the sensor, 400 to 10,000 ppm of Sr is contained in Pt, and the balance is an inevitable impurity. An intermetallic compound phase formed of Pt and Sr is precipitated and dispersed in Pt.
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PRIORITY CLAIM
[0001] This utility application claims priority to U.S. Provisional Application No. 61/755,889, filed Jan. 23, 2013.
TECHNICAL FIELD
[0002] The present disclosure relates to a method for manufacturing open cavity plastic packages for integrated circuits (ICs), in particular, using a cover over the IC die during the encapsulation process to provide a plastic package with an open cavity to allow the device to act as a sensing device.
BACKGROUND
[0003] Integrated circuits (ICs) may include sensors for a variety of reasons. For example, ICs may comprise moisture-sensitive sensors to detect liquid or humidity. Manufacturers may include a moisture-sensitive sensor to determine whether an IC has been damaged by immersion in water, so as to know whether a customer returning an IC is entitled to a replacement of the IC under warranty. Other ICs include sensors that are part of the functionality of the IC. For example, ICs have sensors to detect: radio frequency identification, temperature, ambient light, mechanical shock, liquid immersion, humidity, CO 2 , O 2 , pH, and ethylene. These IC chips may be used to monitor these ambient conditions.
[0004] Integrated circuit devices that operate as sensors may require a specific opening in the package to be able to act as an environmental sensing device. Conventional sensing devices use tape assist in the mold operation to create a cavity in the package. That technology is expensive and there are problems associated with it, in particular, damage to the sensor area (for example, die surface scratches, puncture marks in the sensor area or resin bleed from the molding operation). These problems continue to be the major issues with the tape assist art. Thus, a need exists for a plastic package for use as a housing for an integrated circuit device with an opening providing for a sensing area, wherein the sensing area must be free of resin bleed from the molding operation and must be free of damage.
SUMMARY
[0005] According to various embodiments, a spring-loaded solution is provided to resolve all those issues addressed above and make the process of manufacturing of an environmental sensing device even less expensive. According to an embodiment, a retractable spring loaded pin is provided in the mold to create an open cavity molded package. The open cavity concept is used to expose a certain sensor area to the environment (for example, a specific top area of an integrated circuit die). It is important that, during the manufacturing process, the sensor area is not scratched, punctured, nor covered with any resin residue from the mold operation. According to various embodiments, all those issues are resolved, and the sensor device can be economically produced.
[0006] According to various embodiments, a cavity or hole is created in a plastic package such that there will be no resin bleed from mold flash nor can there be any damage to the sensor area. To achieve these objects, a retractable spring-loaded pin or pins are used within the mold to create the cavity (for example, in a top half of a mold). The spring-loaded pins actually retracts back when the mold is closed and thus protect the sensor area on the silicon die from being covered by mold compound.
[0007] One aspect of the invention provides a method for manufacturing open cavity integrated circuit packages, the method comprising: placing a wire-bound integrated circuit in a mold; forcing a pin to contact a die of the wire-bound integrated circuit by applying a force between the pin and the mold; injecting plastic into the mold; allowing the plastic to set around the integrated circuit to form a package having an open cavity defined by the pin; and removing the open cavity integrated circuit package from the mold.
[0008] According to another aspect of the invention, there is provided a mold for forming a package for an integrated circuit sensor device, comprising: a bottom part for supporting an integrated circuit die; and a top part that is operable to be placed on top of said bottom part to form a cavity into which a plastic material can be injected to form the package, wherein the top part of the mold comprises a spring loaded pin arrangement comprising a cover that covers a sensor area on the integrated circuit die and provides for an opening when the plastic material is injected.
[0009] Still another aspect of the invention provides a process of manufacturing a sensor device comprising: placing an integrated circuit die on a support placed on a bottom part of a mold; wire-bonding the integrated circuit die; placing a top part of a mold on top of said bottom part to form a cavity for a package, wherein the top part of the mold comprises a spring-loaded pin arrangement comprising a cover that covers a sensor area on the integrated circuit die; and injecting plastic material into the mold formed by the top and bottom part, wherein the cover provides for an opening in the package formed by said injected plastic material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIGS. 1A and 1B illustrate a cross-sectional side view and a top view of an open cavity plastic IC package 10 made by the process of the present invention;
[0011] FIG. 1C illustrates a cross-sectional side view of the IC package 10 of FIGS. 1A and 1B in a mold 105 ;
[0012] FIG. 2 illustrates a cross-sectional side view of an IC package in a mold of the present invention;
[0013] FIG. 3 shows a two-part mold according to various embodiments;
[0014] FIG. 4A shows the manufacturing process in the form of a flow chart for an IC package of the present invention;
[0015] FIG. 4B illustrates an IC at the end of the die attach sub-process;
[0016] FIG. 4C illustrates an IC at the end of the wire bonder sub-process;
[0017] FIG. 4D illustrates an IC at the end of the molding sub-process;
[0018] FIGS. 5A-5C show top, side, and bottom views of an IC package 10 of an environmental sensor using a TQFN package;
[0019] FIGS. 6A and 6B show a lead frame and a top mold cavity design for an array of sensor device; and
[0020] FIGS. 7A and 7B show an exemplary embodiment of the spring-loaded pin arrangement according to various embodiments.
DETAILED DESCRIPTION OF INVENTION
[0021] FIGS. 1A and 1B illustrate a cross-sectional side view and a top view of an open cavity plastic IC package 10 made by the process of the present invention. The open cavity plastic IC package 10 has a die 140 positioned on a lead frame 130 . Bond wires 135 extend from the die 140 to the lead frame 130 . The IC package 10 is covered with a plastic encapsulant 145 , which provides a sensor port or an open cavity 147 for a sensor on the die 140 to have access to the ambient conditions in which the IC package 10 may be placed.
[0022] FIG. 1C illustrates a cross-sectional side view of the IC package 10 of FIGS. 1A and 1B in a mold 105 . During the manufacturing process, encapsulant in the form of a molding compound is pumped into the mold to cover the interconnects or bond wires. The mold 105 comprises two half-shell molds: a top part of the mold 110 and a bottom part of the mold 120 . The top part 110 of the mold has a pin 160 that contacts the upper surface of the die 140 when the mold is assembled on the lead frame 130 . The pin 160 prevents the plastic encapsulant from forming a cover in the area above the die 140 so that an open cavity 147 may be formed.
[0023] FIG. 2 illustrates a cross-sectional side view of an IC package in a mold of the present invention. The top part 110 of the mold 105 comprises a pin 160 . The pin 160 has a pin head 163 , which contacts the die 140 . The pin 160 also has a force element 161 and an anchor element 162 . The anchor element 162 holds the pin 160 in the top part 110 of the mold 105 . The force element 161 is connected at one end to the anchor element 162 and at the other end to the pin head 163 . The force element 162 pushes the pin head 163 away from the anchor element 162 toward the die 140 . The force element may take any form known to persons of skill in the art, such as a spring, a piston, an elastic rod, a magnetic rod, etc., wherein it has the capacity to force the position of the pin head 163 toward the die 140 . To provide more uniform contact between the pin head 163 and the die 140 , the pin head 163 may be flexibly or pivotably attached to the force element 161 . A flexible or pivotable attachment may allow the pin head 163 to adjust its contact face to align with the die 140 . This alignment may be particularly beneficial where the die is thicker on one side and relatively thinner on another side, or if the die is not perfectly bonded to the lead frame so as to be the same height at all points.
[0024] As IC dies may vary in thickness, the force element works beyond its means to protect the sensor area. Conventional manufacturing devices use a fixed pin and a high-temperature tape to protect the sensor area and form the open cavity. However, because fixed pins may apply different contact pressures to IC dies, depending on the IC die thicknesses, plastic encapsulate or resin may bleed or flow into the open cavity where the sensor is to be positioned or is positioned on the IC die. Further, use of a fixed pin and high-temperature tape may require additional process steps to remove the high-temperature tape. During the removal process, the sensor is further exposed and could be damaged. This conventional process uses a very expensive high-temperature tape to cover the sensor area during encapsulation and then an additional process to remove the high temperature tape from the open cavity either manually or using vacuum. These extra steps add to the unit cost. Also, additional process steps have their own process issues, i.e., they may scratch the sensor or cause resin to bleed into the open cavity over the sensor.
[0025] The force or spring-loaded concept according to various embodiments of the invention has been proven not to cause any damage to the sensor area. The technology according to various embodiments utilizes a spring-loaded pin similar to a spring-loaded pogo pin technology only present in equipment handlers for piece part testing (for example, to provide electrical connection of a test device with bond pads on a silicon die).
[0026] According to an embodiment, a spring load pogo or pin is used in the transfer molding process to create an opening in plastic packages such as in a Thin Quad Flat No Lead package. A similar concept can be applied to any other plastic package that is used in, for example, a gas or pressure sensor application that requires an opening to expose a sensor area of the device.
[0027] Using a spring-loaded bin a mold (for example in the top half of a mold), provides an economically sound process without causing any sort of damage to the sensor areas. The spring loaded cavity package furthermore will not cause any damage during the transfer molding process.
[0028] FIG. 3 shows a two-part mold according to various embodiments. The bottom part 120 of the mold provides support for a die 140 , which may be placed on a lead frame 130 . The top part 110 includes the spring-molded pin arrangement 190 , wherein a pin 160 supporting a cover 150 provides for a cover of the sensor area that may be arranged in the center of the die 140 on the lead frame 130 . The spring can be arranged inside a spring housing 170 and extends the cover 150 into or beyond the hollow space 100 when the top part 110 of the mold is not placed on the bottom part 120 as shown in FIG. 3 . Once the top part 110 of the mold is placed onto the bottom part 120 , the spring-loaded pin 160 is pushed back by the die 140 . An additional opening 180 can be provided to retract the cover 150 . The extension length is designed such that the cover portion 150 of the spring loaded pin arrangement 190 will form an opening in the housing. The spring-loaded pin arrangement 190 further provides for automatic adjustment depending on the thickness of the die 140 . Thus, a single top mold part 110 can be used with various die thicknesses. Once the mold is closed by putting the top part 110 of the mold on top of the bottom part 120 , plastic can be injected into the hollow space 100 to encompass and seal the die 140 within the housing and at the same time form the opening in the top portion of the housing. Retracting the top part of the mold leaves the sensing device package completed without damage to the sensor area.
[0029] FIG. 4A shows the manufacturing process in the form of a flow chart for an IC package of the present invention, wherein the process comprises three sub-processes: die attach, wire bonder, and molding. For the die attach sub-process, a supply of wafers 410 is brought into the process for inspection 411 . The wafers are then mounted 412 and sawed 413 . Dies are then attached 422 to the lead frames. A machine, such as an ASM AD898 may be used, wherein the machine may have an automatic wafer handling system with water cassette elevator for up to 8-inch wafers. Such a machine may be capable of handling die sizes from 0.25 mm×0.25 mm to 25.4 mm×25.4 mm. The machine may also apply a bond force of 30-2000 g and provide multi-grey levels PRS. FIG. 4B illustrates an IC at the end of the die attach sub-process.
[0030] Referring again to FIG. 4A , for the wire bonder sub-process, a supply of lead frames 420 is brought into the process for inspection 421 . Bond wires are then made to bond 423 the dies to the lead frames. A step called 3 rd Optical QA 424 is then performed. This sub-process creates wire-bound integrated circuits. A machine such as an ASM Eagle-60 or equivalent may be used. The wire size may be 15 um to 50.8 um Au. The maximum length of the wires may be 8 mm. The bonding speed may be 60+ ms for 2 mm wire. The bond placement accuracy may be ±3.0 um. The bonding area may be 54 mm×65 mm. FIG. 4C illustrates an IC at the end of the wire bonder sub-process.
[0031] Referring again to FIG. 4A , for the molding sub-process, a supply of compound 430 is brought into the process for inspection 431 . The wafers are then molded 432 to form the IC packages. The wafers are then marked 433 . A saw singulation step 434 is then performed to separate the IC packages. A visual inspection 435 is performed, and the ICs are then packed and shipped 436 . An ASAHI Cosmo-T machine may be used for the molding sub-process. The mold temperature may be 180° C.±5° C. The transfer pressure may be 35 kgf. The clamp tonnage may be 45 ton. The in-mold cure time may be 90 seconds. FIG. 4D illustrates an IC at the end of the molding sub-process.
[0032] Materials known to persons of skill in the art may be used to manufacture the ICs. For example, the lead frame may be μPPF 0.2 mm thick, wherein the pad size may be 2.90 mm×2.90 mm and the exposed pad size may be 2.60 mm×2.60 mm. The die-attached epoxy may be Sumitomo CRM1076NS. Gold wire may be used having a diameter of MKE 0.8 mils. A mold compound may be Sumitomo G770HCD, wherein the pellet size may be 14×6.0 g.
[0033] FIGS. 5A-5C show top, side, and bottom views of an IC package 10 of an environmental sensor using a TQFN package. The depth of the open cavity 147 may be about 0.35 mm±0.05, and the diameter of the open cavity 147 may be about 1 mm, for a package that is about 4 mm square. The lead frame 130 is visible from the side and bottom, as shown in FIGS. 5B and 5C , respectively.
[0034] FIGS. 6A and 6B show a lead frame and a top mold cavity design for an array of sensor devices, wherein FIG. 6A is a top view of the entire array 605 , and FIG. 6B is a cross-sectional side view of a portion of the array 605 . The exemplary top mold cavity design has four panels 610 , wherein each panel 610 is a 10×12 a for an array 610 having a total of 480 ICs. Each panel 610 has a lead frame 130 with an array of dies 140 , wherein a pin 160 is used relative to each die 140 to form an open cavity for a sensor on the die. According to one embodiment, the array 605 may be a TQFN top mold cavity design for TQFN 4×4 pressure sensor.
[0035] FIGS. 7A and 7B show an exemplary embodiment of the spring-loaded pin arrangement according to various embodiments. FIG. 7A is a side view of a spring-molded pin arrangement 190 . The spring-molded pin arrangement 190 comprises a spring housing 170 , a pin 160 , and a cover 150 . FIG. 7B is an end view of the cover 150 . The cover 150 has an annular contact face 151 that allows the cover 150 to make more uniform contact with the die 140 (see FIG. 3 ) to prevent flashing of the plastic encapsulant into the open cavity 147 (see FIG. 1A ). The outside diameter of the cover 150 may be about 1.2 mm, and the inside diameter of the conical recess in the cover 150 may be about 1.0 mm, so that the annular contact face 151 may be about 0.1 mm wide. The spring-molded pin arrangement 190 may be constructed of material sufficient to endure exposure to plastic encapsulant heated to at least 300° C. The force of the spring inside the spring housing 170 may be about 80-120 g.
[0036] In alternative embodiments of the invention, a plurality of open cavities may be formed on a single IC. To form a plurality of open cavities, a plurality of covers 150 or pin heads 163 may be applied to a single IC during a molding sub-process. Where a plurality of pins are independently forced against the die, the independent application of force may ensure that the plastic encapsulant is unable to enter any of the open cavities because the plurality of pins are each able to make a firm contact with the die. Alternatively, a single cover 150 or pin head 163 may be applied to a single IC during a molding sub-process, but the single cover 150 or pin head 163 comprises a plurality of contact faces 151 . In the embodiment illustrated in FIG. 7B , the contact face 151 is annular, but in alternatively embodiments, the contact face may be any shape or configuration and may comprise a plurality of contact faces. A plurality of open cavities 147 may be useful where a plurality of sensors are attached to a single IC.
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A method for manufacturing open cavity integrated circuit packages, the method comprising: placing a wire-bound integrated circuit in a mold; forcing a pin to contact a die of the wire-bound integrated circuit by applying a force between the pin and the mold; injecting plastic into the mold; allowing the plastic to set around the integrated circuit to form a package having an open cavity defined by the pin; and removing the open cavity integrated circuit package from the mold. A mold for forming a package for an integrated circuit sensor device, comprising: a bottom part for supporting an integrated circuit die; a top part that is operable to be placed on top of said bottom part to form a cavity into which a plastic material can be injected to form the package, wherein the top part of the mold comprises a spring-loaded pin arrangement comprising a cover that covers a sensor area on the integrated circuit die and provides for an opening when the plastic material is injected.
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FIELD OF THE INVENTION
The present invention relates to a method of separating a fibre suspension containing undesirable, relatively small particles by a filter device, which comprises a hollow filter body with a wall of filter material, and a container in which the filter body is situated. The invention also relates to a device for separating a fibre suspension.
BACKGROUND OF THE INVENTION
In known filter devices of this kind the fibre suspension to be separated is supplied to the container, such that the filter body is at least partly immersed in the suspension. The hydrostatic pressure in the fibre suspension in the container forces a fine fraction of the fibre suspension through the part of the wall of filter material of the filter body which is immersed in the fibre suspension, so that fibres are deposited and form a layer of fibres on the filter material. The formed layer of fibres constitutes in itself a filter medium, which is substantially tighter than the filter material of the filter body and which merely allows water from the fibre suspension in the container to pass through.
A filter device for thickening fibre suspensions is known from U.S. Pat. No. 4,138,338, which discloses a disc filter with an inlet tank for a fibre suspension to be thickened. From the inlet tank fibre suspension flows directly into a container, in which the discs are immersed in fibre suspension. To increase the dewatering capacity of the disc filter a number of spray members is arranged to spray liquid, for instance a quantity of the fibre suspension to be thickened, onto the disc walls of filter material which are immersed in the fibre suspension in the container, so that creation of tight fibre layers on the walls is prevented.
The known filter devices, as described above, are not suited for the separation of undesired relatively small particles from fibre suspensions, since most of such small particles would be trapped by the created tight layer of fibres deposited on the filter material or by thickened fibre suspension during the separation. Consequently, in practice such known filter devices usually have only been used for thickening of fibre suspensions, i.e. mere dewatering of the latter. Conventionally, undesired relatively small particles are therefore initially separated from the fibre suspensions by other kinds of separation devices, for instance by flotation plants. Subsequently, the fibre suspensions thus cleaned can be dewatered, for instance by known filter devices of the kind described above.
When producing paper from waste paper pulp the undesired relatively small particles are substantially composed of printing ink. They are separated from the waste paper pulp to avoid greyness of the produced paper. Hitherto, the profitability of producing paper from such a waste paper pulp has been poor. However, the authorities tend to tighten up the requirements on paper manufacturers to produce some paper from waste paper pulp, in order to provide a reduction of the paper waste and a saving of raw wood material.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a new separation method, which reduces the costs for cleaning and dewatering fibre suspensions, preferably fibre suspensions created from waste paper pulp. A further object of the present invention is to provide a new device for accomplishing the new separation method.
These objects are obtained by a method of the kind initially stated, which is characterized by spraying the entire fibre suspension to be separated in the form of at least one liquid jet onto said wall of filter material to force a fine fraction of the suspension containing most of said undesired particles through said wall of filter material into the hollow filter body, thereby leaving a coarse fraction of the fibre suspension mainly containing fibres in the container outside the filter body; providing relative displacement between the liquid jet and the filter material; dewatering said coarse fraction of the fibre suspension through the wall of filter material; and discharging said dewatered coarse fraction from the container.
The advantage gained is that in one and the same filter device the fibre suspension is separated from undesired particles and dewatered, which means significant savings in costs as compared to the conventional method utilizing two separate devices for the separation of the undesired particles and the dewatering of the fibre suspension, respectively. By spraying the fibre suspension to be separated against said wall of filter material the sprayed elongated fibres of relatively large specific surface are rapidly retarded by the frictional drag between them and the surrounding medium (air or liquid), whereas undesired relatively small particles of relatively small specific surface substantially maintain their velocity, and thereby penetrate said wall of filter material. Said rapid retardation of the fibres has the advantage that the fibres do not press into and clog the screen passages of the filter material.
The invention also relates to a device for separating a fibre suspension containing undesired, relatively small particles, comprising a hollow filter body with a wall of filter material, a container, in which the filter body is situated, means for supplying fibre suspension to be separated, spray means arranged to spray fibre suspension onto the wall of filter material of the filter body, and means for providing relative displacement between the spray means and the wall of filter material. The new separation device is primarily characterized in that said supplying means is arranged to supply the fibre suspension to be separated solely by means of said spray means, said spray means being adapted to spray the fibre suspension onto the wall of the filter body to force a fine fraction of the fibre suspension containing most of said undesired relatively small particles through said wall of filter material into the hollow filter body and leave a pool of a coarse fraction of the fibre suspension mainly containing fibres in the container outside the filter body, said coarse fraction of the fibre suspension being dewatered through said wall of filter material during operation, and in that means is provided for discharging said dewatered coarse fraction from the container.
Preferably, said displacement means are adapted to displace the wall of filter material of the filter body alternately up and down through the surface of said pool of coarse fraction, said spray means being arranged to spray fibre suspension onto the part of the wall of filter material which is above said pool of coarse fraction. By this the advantage is gained that the fibre suspension can be sprayed under a low frictional drag through a medium of air, whereby a relatively larger share of the liquid content of the fibre suspension can be passed directly through the filter material as compared to spraying of the fibre suspension through said pool of coarse fraction.
Advantageously, said spray means is arranged to spray fibre suspension onto the part of the wall of filter material which is in said pool of coarse fraction. By this the relatively tight fibre layer formed is continuously removed from the filter material during operation by means of the liquid jet from the spray means, which has the advantage that the coarse fraction of fibre suspension in the container is more efficiently dewatered through the filter material, since-the filter material will be at least partly devoid of tight fibre layers during operation.
Suitably, said spray means is arranged to spray fibre suspension onto the part of the wall of filter material which moves downwards in said pool of coarse fraction during operation and which consequently has only been covered with a relatively thin layer of fibres. Said spray means is advantageously arranged to spray fibre suspension on a zone of said downwards moving part of the wall of filter material situated in the vicinity of the surface of said pool of coarse fraction. At said zone the created fibre layer is very thin and is readily dissolved by the sprayed fibre suspension.
Preferably, said displacement means are arranged to rotate the filter body around a horizontal axis for revolving displacement of the wall of filter material up and down through the surface of said pool of coarse fraction. In this way, the filter material can readily be continuously cleaned at a position of the filter body above said pool of coarse fraction.
The filter body may for instance be constituted by a horizontal rotary drum with a circumferential wall of filter material or by at least one vertical annular rotary disc with two side walls of filter material spaced from each other.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained more closely in the following with reference to the accompanying drawings, in which
FIG. 1 schematically shows a drum filter according to an embodiment of the device according to the invention.
FIG. 2 shows a section along the line II--II of FIG. 1,
FIG. 3 shows a modification of the embodiment shown in FIG. 2,
FIG. 4 shows a section along the line IV--IV of FIG. 3,
FIG. 5 schematically shows a disc filter according to another embodiment of the device according to the invention,
FIG. 6 shows a part of a section along the line VI--VI of FIG. 5,
FIG. 7 shows a sectional view along the line VII--VII of FIG. 5, and
FIG. 8 shows a modification of a spray nozzle.
DETAILED DESCRIPTION OF THE INVENTION
The drum filter shown in FIG. 1 comprises a hollow filter body in the form of a horizontal drum 1 with a circular circumferential wall 2 of filter material. The drum 1 is rotatably journalled in a container 3. During operation the drum 1 is partly immersed in a pool of a created coarse fraction of a fibre suspension in the container 3. A drive motor 4 is in drivable engagement with the drum 1 via a gear wheel 5 for rotating the drum 1 around its central axis. (The direction of rotation of the drum 1 is indicated by an arrow in FIG. 1).
The fibre suspension to be separated is supplied to the drum filter by means of a spray member 6, which is above said pool of coarse fraction in the container 3 descending the side of the circumferential wall 2, and two spray members 7 and 8, which are situated in said pool of coarse fraction. The spray members 6-8 include supply pipes 9-11, respectively, for fibre suspension to be separated, which extend axially along the circumferential wall 2 of the drum 1 (FIG. 2). Each supply pipe 9-11 is provided with a plurality of spray nozzles 12 (here eight), which are directed against the circumferential wall 2. As an alternative each supply pipe 9-11 may be provided with only two spray nozzles 13, each spray nozzle 13 having an elongated outlet opening (FIG. 3 and 4). The spray member 7 is adapted to spray fibre suspension on a zone 14 at the descending side of the circumferential wall 2 at a small distance from the surface of the coarse fraction.
Above the spray member 6 there is a device 15 for the removal of built up layers of fibres from the circumferential wall 2. The removal device 15 is adapted to transfer removed fibre layers to a trough 16, which is provided with a conveyor screw 17.
The interior of the drum 1 forms a filtrate chamber 18, which is connected to a device not shown for discharging fine fraction formed during the operation from the drum filter.
Between the removal device 15 and the spray member 6 there is a spray member 19 for cleaning the filter material of the circumferential wall 2 by means of cleansing liquid, for instance water.
The drum filter according to FIG. 1 is operated in the following way:
All the fibre suspension to be separated, for instance a fibre suspension produced from waste paper pulp and containing about 0.5% fibres, undesired small particles consisting substantially of printing ink, and water, is sprayed in the form of liquid jets by means of the spray members 6-8 onto the circumferential wall 2 of filter material during rotation of the drum 1 by the drive motor 4, the fibre suspension being separated into a fine fraction, which passes through the circumferential wall 2 into the filtrate chamber 8 and which substantially contains undesired particles and water, and a coarse fraction of the fibre suspension, which is received in the container 3 and which substantially contains fibres and water. By the hydrostatic pressure in the pool of coarse fraction formed in the container 3 water is forced from said pool through the circumferential wall 2 of filter material into the filtrate chamber 18, whereby fibres are deposited on the circumferential wall creating a layer of fibre pulp on it. This layer is rapidly created on the circumferential wall 2 when the wall goes down into the pool of coarse fraction and will be thicker and thicker during the displacement of the circumferential wall 2 through said pool. The layer of fibre pulp on the circumferential wall 2 along the zone 14 is however not yet very thick and can easily be removed by the jets of suspension from the spray member 7. When the circumferential wall 2 has passed the jets of suspension from the spray member 7 there is once more created on the circumferential, wall 2 a layer of fibre pulp, which in turn is easily removed by the jets of suspension from the spray member 8. Thus, the descending side of the circumferential wall 2 in the pool of coarse fraction is substantially free from a thick, tight layer of fibre pulp, with the result that the pool of coarse fraction is efficiently dewatered through the circumferential wall 2 at the sinking side of the latter.
On the rising side of the circumferential wall 2 a thick layer of fibre pulp is created, which follows the circumferential wall out of the pool of coarse fraction to the removal device 15. This removes the fibre pulp from the circumferential wall 2 and transfers the fibre pulp to the trough 16, whereafter the conveyor screw 17 discharges the fibre pulp from the drum filter. The part of the circumferential wall 2 which has just been freed from fibre pulp by the removal device 15, is cleansed by means of the spray member 1, whereafter the operation described above is repeated.
The drum filter according to FIG. 1 can be operated so that the obtained fibre pulp will have a consistency of about 8-12%. However, if a lower consistency of the fibre pulp of about 3-4% would be acceptable the removal device 15 can be replaced by an overflow in the container 3 for the coarse fraction of fibre suspension at the rising side of the circumferential wall 2. In this case further spray members for fibre suspension to be separated may be arranged along the drum 2 above the pool of coarse fraction, which would increase the capacity of the drum filter.
The disc filter shown in FIG. 5 comprises a plurality of vertical annular, hollow discs 20 with walls 21 of filter material. The discs 20 are, via a hollow shaft 22, rotatably journalled coaxially with each other in a container 23. During operation the discs are partly immersed in a pool of coarse fraction formed in the container 23. A drive motor 24 is in drivable engagement with the shaft 22 via a gear wheel 25 for rotating the discs 20 about the shaft 22. (The rotational direction of the discs 22 is indicated by an arrow in FIG. 5).
Fibre suspension to be separated is supplied to the disc filter by means of a spray member 26, which is situated above said pool of coarse fraction in the container 23 at the descending sides of the discs 22 and two spray members 27 and 28, which are situated in said pool of coarse fraction. The spray members 26-28 include supply pipes 29-31, respectively, for fibre suspension to be separated, which extend axially along the discs 2. Each supply pipe 29-31 is connected to a number of distribution pipes 32 which extend radially along the side walls 21 of the discs 20. Each distribution pipe 32 is provided with spray nozzles 33 for spraying fibre suspension onto an adjacent side wall 21 (FIG. 6). Each of the distribution pipes 32 which extends between two adjacent discs 20 has nine spray nozzles 33 for spraying the side wall 21 of one of the discs and nine spray nozzles 33 for spraying the adjacent side wall 21 of the other disc 20 (FIG. 7).
The interior of the discs 20 communicates with the interior of the shaft 22 which forms a filtrate chamber 34 connected to a device, not shown, for discharging created fine fraction from the disc filter.
By means of drop legs connected to the interior of the discs 20 the disc filter, can be operated so that the fibre pulp obtained will have a fibre consistency of about 8-12 %, whereby the concentrated fibre pulp may be removed from the side walls of the discs above said pool of coarse fraction by means of a removal device well known in the art of filtration and not shown in the drawing. In this case each disc 20 is divided, for instance, into twelve chambers 35, which are connected in sequence to each drop leg via axial pipes 36 during rotation of the disc. As an alternative the disc filter can be operated without drop legs, so that the fibre pulp obtained will have a fibre consistency of only about 3-4%. In this case, the fibre pulp can be removed directly from the container 23 via an overflow.
The operation of the disc filter is analogous to that of the drum filter and, consequently, should be clear from the description above of the operation of the drum filter.
In case spray nozzles 12, 33 with passages of relatively small cross-sectional areas must be used, a risk of clogging the spray nozzles 12, 33 with fibre pulp might arise, for instance at sudden pressure drops in the passages of the spray nozzles 12, 33 during operation. In this case each spray nozzle 12, 33 may advantageously be formed with an increasing cross-sectional area towards the opening (FIG. 8), whereby a clogging or plug of fibre pulp can easier be forced through the nozzle when the operational pressure is restored after a pressure drop.
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A fibre suspension is separated by a filter device having a hollow filter body (1) with a wall (2) of filter material, and a container (3). The entire fibre suspension to be separated is sprayed in the form of at least one liquid jet onto said wall (2) to force a fine fraction of the suspension containing most of said undesired particles through said wall of filter material into the hollow filter body, thereby leaving a created coarse fraction of the fibre suspension mainly containing fibres in the container outside the filter body. Relative displacement between the liquid jet and the filter material is provided. Said created coarse fraction is dewatered through the wall of filter material, and said dewatered coarse fraction is discharged from the container.
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BACKGROUND OF THE INVENTION
The invention relates to a heat-sealable barrier laminate structure which produces an oxygen impermeable, leak free container. More particularly, this invention relates to barrier laminate structures which are comprised of specific high strength polymer resin layers which effectively prevent heat activation pinholes, cuts or cracking of oxygen barrier layers caused during scoring and especially during folding and heat sealing of the laminate in package formation.
The invention as disclosed and claimed herein is closely related to pending application Ser. Nos. 191,987; 191,988 now U.S. Pat. No. 4,888,222; Ser. No. 191,989 now U.S. Pat. No. 4,880,701; Ser. No. 191,992 and 191,337 now U.S. Pat. No. 4,859,513, all owned by the Assignee. Also, application Ser. Nos. 354,591 and 354,571 two additional applications have been concurrently filed and are related. Thirdly, structures for paperboard containers using heat-sealable polymer resins and containing various oxygen barrier materials are disclosed in U.S. Pat. Nos. 3,972,467; 4,698,246; 4,701,360; 4,789,575 and 4,806,399, all owned by the Assignee.
Heat-sealable low density polyethylenes are well known to be components of current paperboard food and/or non-food packages which provide little barrier to the transmission of oxygen. Pinholes, cuts, score line cracks or channels, existent in conventional packaging and cartons, create additional leakage sites. It is well known that impermeable materials such as aluminum foil, polar brittle materials such as: polyacrylonitriles,polyvinylidenechlorides, polyvinyl chlorides, etc., provide varying degrees of barrier to the transfer of oxygen. However, all these materials lack the requisite strength at high rates of deformation, namely stress cracking resistance during scoring, package formation and distribution abuse to provide a resultant oxygen impermeable and airtight structure. In addition, leakage through the uncaulked channels of the carton in the top, bottom and side seam have likewise resulted in poor whole carton oxygen barrier properties.
The existing commercial structures for a paperboard carton for liquid and solid, food and non-food, products have utilized an easily heat-sealable barrier laminate composed of a paperboard substrate and a foil oxygen barrier layer, both being sandwiched between two thick layers of low density polyethylene (LDPE). The LDPE is a relatively inexpensive heat-sealable moisture barrier material. The conventional structure falters in that the foil layer which acts as the barrier to the transmission of oxygen in and out of the carton cracks during blank conversion, carton formation, and package distribution stages.
Bending and folding occurring during the formation of a gable "type" top, flat "type" top, or other folded, heat-sealed top closure, and a fin-sealed, or other conventional folded bottom puts excessive amounts of local stress on the thin foil and/or other oxygen barrier layer and, as typically results, cracks and pinholes appear.
To date, there have been no economically attractive commercially available paperboard packages which consistently approach the oxygen impermeability of glass or metal containers. The object of the present invention is to produce an oxygen impermeable, leak free container and/or laminate structure such as a paperboard based package or carton that prevents the transmission of gases therethrough, and in addition, prevents the escape of flavor components or the ingress of contaminates. A further object of the present invention is to produce such a package that is economical on a per-package cost basis, is fundamentally compatible with existing converting machinery and can be formed, filled and sealed at economically high speeds using conventional packaging machine temperatures, pressures and dwell times.
Another object of the present invention is to provide this oxygen impermeable package in a variety of applications including four-ounce to 128-ounce containers, or larger, as required by the packager.
A further object of this invention is to incorporate a functional polymer layer which exhibits high strength, abuse resistance and toughness during converting and carton forming in combination with aluminum foil or other oxygen barrier layers and paper, paperboard or other mechanically stable structural material such that the high-strength layer reduces the stresses incurred by the barrier layers during blank conversion, package formation, and distribution. Additionally, should a penetration of the barrier layer or layers occur, the high-strength layer serves to maintain package integrity at the failure site. The high-strength, heat-resistant layer effectively prevents heat activation pinholes through the product contact layer, even when non-foil barrier layers are used.
SUMMARY OF THE INVENTION
A preferred embodiment of the invention reveals an oxygen impermeable leak free barrier laminate, side-seamed blank and/or container providing a total barrier to the loss of essential food flavor oils or non-food components over an extended product shelf-life as well as an absolute barrier to the transmission of oxygen during the same extended shelf-life period. A preferred embodiment of the laminate structure comprises, from the outer surface to the inner surface, contacting the essential oils, flavors and/or components of food or non-food products: an exterior layer of a low density polyethylene, a mechanically stable structural substrate, such as an unbleached or bleached paper or paperboard material, a corrugated board, a stiff polymer resin material such as high density polyethylene or polypropylene, or multi-ply combinations thereof, a first layer of a caulking polymer resin such as an ionomer type resin (Surlyn®1652), an oxygen barrier material layer such as an aluminum foil layer, a sandwich interior layer of an abuse-resistant polymer such as a polyamide type polymer (nylon 6) surrounded by two additional caulking polymer resin layers such as an ionomer type resin (Surlyn®1652), and a layer of low density polyethylene in contact with the food or non-food product rendering the laminate structure heat-sealable.
The cartons, side-seamed blanks, or containers constructed of the laminate of the present invention enable significant containment of gases in the container as well as preventing any migration of oxygen or contaminants into the package. The present invention has produced a suitable container which has the ultimate barrier properties. It utilizes a laminate which can be heat-sealed easily with its exterior and interior layers being like, non-polar constituents. During the heat-seal processes, the scoring processes, the side-seaming processes, and the folding, forming and filling steps, the particular caulking polymer resins, namely ionomer type resins, ethylene acrylic acid copolymers, ethylene methacrylic acid copolymers, ethylene vinyl acetate copolymers, ethylene methylacrylate copolymers, polyethylene based grafted copolymers and the like, with melt indexes which allow them to flow during the heat-sealing processes (temperatures ranging from 250° F. to 500° F.). The particular selected resins act as a caulking agent to fill the channels produced during formation of the gable, or other type flat top, the fin-sealed, or other conventional type bottom and the skived side seam. Consequently, each of those gap areas is caulked to prevent the leakage of oxygen therethrough. In addition, the selection of the particular abuse-resistant polymer, namely polyamide type polymers, polyester type polymers and ethylene vinyl alcohol copolymers or the like acts to prevent any type of significant deformation damage to the foil or other oxygen barrier layer which would result in a crack or pinhole allowing for the seepage of oxygen therethrough.
The preferred package structures formed from the preferred novel laminates of the present invention not only exhibit these novel oxygen impermeable and/or other high barrier properties, but the novel laminate structures are produced using conventional extrusion and/or coextrusion coating and/or lamination equipment.
The novel laminate structure and materials selected therefor, namely the particular caulking polymer resins and abuse-resistant polymer resins contemplated by the present invention, coupled with oxygen impermeable or high oxygen barrier materials, in various combinations, can be utilized in a variety of food or non-food packaging applications.
In one application, the preferred laminate structure is produced using conventional coextrusion coating equipment.
Secondly, this laminate is printed and forwarded through scoring dies and cutting dies to create flat blanks.
Thirdly, these flat blanks are skived and folded and side-seamed to create the side-seamed blanks. During the heat-sealing step of the side-seam operation, the resins which have been selected for their particular melt flow characteristics, caulk and seal along the seam. Resins which have melt flow indexes ranging from 4.5 to 14.0 are preferred. These side-seamed blanks are then forwarded to the particular customer for further assemblage.
Fourth, these side-seamed blanks are magazine fed into a machine wherein they are opened and placed on a mandrel, wherein sealing of the bottom takes place.
Typically, the bottom folding and sealing is where most of the damage to the interior thin barrier foil layer occurs in conventional cartons. Utilization of a particular strong polymer resin, comprising an abuse-resistant polymer, such as a polyamide type polymer, prevents cracking of the foil layer during the bottom sealing process. The bottom is fully heat-sealed into a flat configuration at which time caulking polymer resins, such as ionomer resins, flow in a caulking manner to seal the bottom. The container or package is then forwarded to the filling step. Next, the top is "prebroken" and filled with the particular product and then top-sealed. Again, much damage is done to the foil or other barrier layer during this top-sealing process of conventional cartons. The utilization of the novel abuse-resistant and caulking polymer resin constituents in the barrier laminate acts to prevent any damage to the foil or non-foil barrier layer and produce a top closure which has been caulked to doubly prevent any transport of oxygen.
The novel barrier laminate produced by the present invention not only exhibits excellent oxygen barrier properties and can be easily constructed, but also meets FDA approval for use in food packaging. The resins heat seal at low temperatures (250° F. to 500° F.) and the structures can be converted and cut on conventional machinery.
Thus, until the advent of the present invention, no suitable oxygen impermeable, leak free containers or packages have been developed which retain the advantages of using mechanically stable structural substrates such as paperboard or the like as the base material and FDA approved heat-sealable barrier layers which are economical and can be produced using conventional coextrusion coating equipment.
The present invention described herein is particularly useful as a coated paperboard structure employed in the packaging of food and non-food products. These types of containers make use of a heat-seal for seaming and closing, and are utilized in the formation of folding boxes, square rectangular cartons or containers, or even cylindrical tubes.
In addition, the novel combinations of caulking polymer resins, abuse-resistant polymers and oxygen impermeable and/or high oxygen barrier materials have other applications as well.
Namely, the combination of high oxygen barrier materials such as ethylene vinyl alcohol copolymers or other brittle oxygen barrier materials coupled with abuse-resistant type polymer resins such as polyamide type polymers or the like, have applications in combination with almost any mechanically stable structural substrate. Particularly, multilayer blow-molded containers incorporating abuse-resistant polymer resins in combination with high oxygen barrier materials is one of the novel applications of this invention.
One specific example of such an application is the utilization of ethylene vinyl alcohol copolymer in combination with a polyamide type polymer mounted on a high density polyethylene structural substrate. The polyamide type polymer acts to protect the brittle ethylene vinyl alcohol copolymer oxygen barrier layer from abuse during shipping and transport of the overall container structure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional elevation of the preferred embodiment of the laminate of the present invention;
FIG. 2 is a cross-sectional elevation of an alternate embodiment of the laminate of the present invention.
FIG. 3 is a cross-sectional elevation of an alternate embodiment of the laminate of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The preferred embodiment of the invention is for an hermetic, oxygen impermeable leak free and/or high oxygen barrier leak free package incorporating a laminate structure as disclosed in FIG. 1. All weights are expressed in pounds per 3,000 square feet. Disclosed is a mechanically stable structural substrate 12 which is most suitably high grade paperboard stock, for example, 100-300 lbs. or higher sized carton board, to which is applied on one side a coating of a low density polyethylene polymer 10 in a coating weight of about 12.0 to 30.0 lbs. Layer 10 is the "gloss" layer which contacts the outer atmosphere. An extrusion coating grade LDPE having a melt flow index ranging from 4.0 to 7.0 is suitable for use herein. On the underside or interior portion of the paperboard substrate 12 is coated thereon a layer of a caulking polymer resin, 14, such as an ionomer type resin (Surlyn®1652), in a coating weight of about 8.0 to 20.0 lbs., and coated on the interior of the caulk is an absolute oxygen impermeable material or a high oxygen barrier material, such as a 0.000275-0.0005 inch layer of aluminum foil having a coating weight of about 12 lbs., 16. Coated onto the foil is a sandwich layer, 23, of an abuse-resistant polymer resin such as a polyamide type polymer (nylon 6), 20, in a coating weight of about 3.0 to 10.0 lbs., sandwiched between two caulking polymer resin layers, 18 and 22, such as an ionomer type resin (Surlyn®1652), in coating weights of about 2 to 6 lbs., and lastly coated onto the sandwich layer, 23, is a second layer of low density polyethylene polymer 24, in a coating weight of about 12.0 to 30.0 lbs. rendering the entire laminate structure heat sealable on conventional heat-seal equipment at conventional heat-seal temperatures (250° F. to 500° F.).
Referring to FIG. 2, an alternate preferred embodiment of the laminate of the present invention is shown. The embodiment adds tie layers around the oxygen barrier material layer to facilitate better adhesion in the structure. In this alternate preferred embodiment, the mechanically stable structural substrate 28, such as a paperboard substrate, having a weight of 100-300 lbs. or higher for a half pint or smaller, pint, quart, half gallon, gallon and multi-layer structures, has extrusion coated on its external surface a 12.0 to 30.0 lb. layer of a low density polyethylene polymer 26. On the internal surface of the mechanically stable structural substrate 28, is applied a first sandwich layer 33, of an oxygen barrier material such as an ethylene vinyl alcohol copolymer, having a coating weight of about 8.0 to 20.0 lbs., 32, sandwiched between two tie layers, 30 and 34, such as a Plexar®175, having coating weights of about 2.0 to 6.0 lbs. each. Coated onto the first sandwich layer 33 is a second sandwich layer 39 comprising an abuse-resistant polymer resin, such as a polyamide-type polymer (nylon 6), 38, having a coating weight of about 3.0 to 10.0 lbs. sandwiched between two caulking polymer resin layers, 36 and 40, having coating weights of about 2.0 to 6.0 lbs. each. Finally, coated thereon, is a 12.0 to 30.0 lb. layer of a low density polyethylene polymer 42 which in combination with layer 26 renders the entire laminate structure heat-sealable.
FIG. 3 is another preferred embodiment of the present invention. A mechanically stable structural substrate such as a paperboard substrate having a weight of 100-300 lbs., or higher, 46, is coated with a 12.0 to 30.0 lb. layer of a low density polyethylene polymer on its exterior 44. On the interior layer of the substrate 46 is coated a five-layer sandwich, 51, having the following laminate structure: A first 2.0 to 6.0 lb. layer of a caulking resin material, such as an ionomer resin (Surlyn®1652), 48, a first 3.0 to 10.0 lb. layer of an abuse-resistant polymer resin, 50, such as a polyamide-type polymer (nylon 6), an oxygen barrier material layer, 52, such as an ethylene vinyl alcohol copolymer, having a coating weight of about 8.0 to 20.0 lbs., a second 3.0 to 10.0 lb. abuse-resistant polymer resin layer, 54, such as a polyamide type polymer (nylon6), and a second 2.0 to 6.0 lb. caulking polymer resin layer such as an ionomer resin (Surlyn®1562). Finally coated thereon is a second 12.0 to 30.0 lb. layer of a low density polyethylene polymer, 58, rendering the entire laminate structure heat-sealable on conventional heat-seal equipment at conventional heat-seal temperatures.
Although specific coating techniques have been described, any appropriate technique for applying the layers onto the mechanically stable structural substrate can be suitably employed, such as extrusion coating, coextrusion coating, extrusion lamination, coextrusion lamination and/or adhesive lamination of single layer and/or multilayer films to the mechanically stable structural substrate to achieve the stated inventions of this patent. The unique effect provided by the oxygen impermeable, leak free packages made from the laminate of the present invention is clearly demonstrated by the following Examples outlined in Table I. The preferred embodiment of the present invention is listed as the "International Paper oxygen impermeable halfgallon" and it utilizes as its mechanically stable structural substrate a 282 lb. layer of paperboard. The preferred structure is compared in Table I to a variety of commercial paperboard based and non-paperboard based containers currently available in the market place and recommended for extended shelf-life applications.
TABLE I__________________________________________________________________________Average Whole Container Oxygen Transmission Rates (OTR) OTR (CC/M.sup.2 /Day) Avg., CC O.sub.2 /Pkg./Day To Fill -Container (75° F., 50% RH, in Air) Volume (ml) Ratio*__________________________________________________________________________INTERNATIONAL PAPER 0.000 0.000(OXYGEN IMPERMEABLEHALF-GALLON)TOPPAN, EP-PAK (1500 ml) 0.005 0.004WITH PLASTIC FITMENTINTERNATIONAL PAPER 0.016 0.2ASEPTIC (250 ml.)TETRA BRIK-PAK (250 ml.) 0.013 0.2CAPRI-SUN POUCH 0.01 0.3(200 ml.)TREESWEET COMPOSITE 0.29 0.4FIBER CAN (1360 ml.)CONOFFAST CUP 0.022 0.4(250 ml.)INTERNATIONAL PAPER 1.11 0.5HOT FILL (2000 ml.)GALLON HDPE 2.75 0.5(BLOW MOLDED BOTTLE)HALF-GALLON HDPE 1.98 1.1(BLOW MOLDED BOTTLE)HYPAPAK (700 ml.) 0.52 1.7HAWAIAN PUNCH COMPOSITE 0.09 2.0CAN (236 ml.)COMBIBLOCK (250 ml.) 0.21 3.2JUICE BOWL COMPOSITE 0.34 4.1CAN (355 ml.)__________________________________________________________________________ *All numbers should be multiplied by 10.sup.-2
It can be seen that the container prepared from a laminate of the present invention provides a complete hermetic barrier to the transport of oxygen.
The specially selected abuse-resistant polymer constituents such as the polyamide type polymers which make up the container are resilient enough to prevent any type of cutting, pinholing, or other damage caused during the converting, carton formation and distribution steps. In addition, the container utilizes ionomer type resins as caulking material for the channels and seams.
The mechanically stable structural substrate may consist of an unbleached or bleached paper or paperboard material, a corrugated type board material, a stiff polymer resin material such as high density polyethylene or polypropylene, and/or multi-ply combinations thereof.
The barrier layer may consist of an aluminum foil, an ethylene vinyl alcohol copolymer, a polyvinyl alcohol polymer, a polyethylene terephthalate, a polybutylene terephthalate, a glycol-modified polyethylene terephthalate, an acid-modified polyethylene terephthalate, a vinylidene chloride copolymer, a polyvinyl chloride polymer, a vinyl chloride copolymer, a polyamide polymer or a polyamide copolymer, or combinations of these materials.
The heat-sealable outer and inner polymer layers may consist of a low density polyethylene polymer, a linear low density polyethylene polymer, a medium density polyethylene polymer and/or blends thereof. The heat-sealable polymer materials contemplated for this invention all possess FDA approval for food contact applications and all have the ability to heat-seal on conventional equipment at conventional heat-seal temperatures (250° F. to 500° F.).
The preferred embodiments of the present invention utilize an aluminum foil layer as the primary absolute oxygen and flavor oil barrier material. All of the above-identified materials could be utilized in all alternate embodiments in place of the foil layer as well as in the preferred embodiment of the invention. The barrier and high strength layers may be applied as film laminations and/or as extrusion coatings.
The invention may be used in materials for all types of blank fed or web fed package forming equipment. The effectiveness of the laminate of the present invention as an oxygen impermeable package structure permits a significant extension of shelf-life of the products packaged in the containers.
The tough, high strength, abuse-resistant type materials can be selected from the following group of polymers: polyamide type polymers such as the preferred Nylon 6, or Nylon 6/66, Nylon 6/12, Nylon 6/9, Nylon 6/10, Nylon 11, Nylon 12; polyethylene terephthalate; polybutylene terephthalate; and ethylene vinyl alcohol copolymers; or other similar tough, high strength polymeric materials which have tensile strengths of 10,000 psi or greater at conventional heat-seal temperatures (250° F. to 500° F.).
In addition, the high strength, low viscosity caulking resins preferred are selected from the following group of polymers: ionomer type resins, such as the preferred zinc or sodium salts of ethylene methacrylic acid (Surlyn®1652 or the like); ethylene acrylic acid copolymers; ethylene methacrylic acid copolymers; ethylene vinyl acetate copolymers; ethylene methylacrylate copolymers, ethylene based graft copolymers; and the like, all exhibiting melt flow indexes ranging from 4.5 to 14.0.
Adhesive tie layers preferred are selected from the following: Plexars® from Quantum Chemical Co., more commonly known in the industry as ethylene based graft copolymers; CXA's® from Dupont, more commonly known in the industry as modified polyethylene resin containing vinyl acetate, acrylate and methacrylate comonomers; Admer's® from Mitsui, more commonly known in the industry as polyethylene copolymer based materials with grafted functional groups, and similar performing tie resins.
Additional abuse-resistant polymers, caulking polymer resins, mechanically stable structural substrates, oxygen barrier materials, and adhesive tie layers which meet the specifications and requirements outlined above could also be utilized to practice the present invention.
This invention provides a means of transforming the economical, high volume, gable top or flat top paperboard or non-paperboard food/non-food carton into an oxygen impermeable, leak free package that can be produced, sold, and filled economically at high production speeds, offering a low-cost hermetic packaging alternative to glass and metal, with the bulk of one embodiment of the package being biodegradable paperboard from a renewable resource.
The novel container has the feature of acting as a stand alone abuse-resistant package for products which when contained in normal packaging are considered to be extremely difficult to contain. Such products include: detergents, synthetic sweeteners, oil products, etc. all of which can be stored in the novel structure embodied by the invention.
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The present invention relates to an improved container for food and non-food products. The container utilizes a novel paperboard barrier laminate structure which maintains an isolated gas environment in the container. The laminate makes use of high strength, heat-resistant and caulking polymer layers which prevent pinholes, cuts, or cracking of the barrier layers during blank conversion, package formation, and package distribution. In addition, the novel polymer resin layers act to caulk the seams and channels present in the carton providing a sealed leak free container.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional of and claims priority to U.S. Pat. No. 8,562,438, entitled, “System and Method for Television-Based Services”, filed on Oct. 26, 2007, which claims priority to U.S. Provisional Application Ser. No. 60/863,105 filed Oct. 26, 2006, entitled “Multiplayer Gaming Infrastructure”, the contents of which are incorporated by reference in their entirety.
BACKGROUND
The present disclosure relates to the provision of interactive services to one or more users over a television distribution system, including interactive gaming services.
Television signal distribution architectures have been developed to provide alternatives to traditional over-the-air broadcasting. For example, since the late 1940's, cable television systems have been used to deliver television signals to subscribers. Cable television systems distribute signals over optical fibers and/or electrical cables, such as coaxial cable. Further, wireless-cable systems have been developed using microwave signals as the distribution medium. Cable television systems permit the distribution of both typical over-the-air content, such as broadcast networks, and specialized content, such as pay channels and video on demand.
In a cable television system, television programming representing a number of individual television channels is coordinated at a headend for distribution to subscribers, such as endpoints within a particular geographic region. All of the endpoints serviced by a headend receive a common signal. Television programming representing a plurality of separate frequency bands is multiplexed onto a single cable. The television signal can be encoded as an analog signal or a digital signal. A set-top box (or “cable television tuner”) at the receiving location, such as a subscriber's home or business, provides access to a single channel of the multiplexed signal. Thus, a single channel included in the cable television signal can be tuned and presented on a corresponding device, such as a television or computer monitor.
Direct broadcast satellite (or “direct-to-home”) television systems also have been developed as an alternative to over-the-air broadcasting. As with cable television, direct broadcast satellite television provides a single, multiplexed signal that is decoded using a set-top box (or “satellite receiver”). The distribution medium between the satellite broadcaster and the set-top box, however, is a radio frequency signal, such as a K u -band transmission.
Until recently, both cable and satellite television distribution systems were limited to receive-only. Because coaxial cables are capable of bi-directional transmission, however, additional services have been merged with cable television systems. For example, voice and data services have been offered over cable television distribution systems. Similarly, the cable television transmission path can serve as a back-channel for information sent from the set-top box to the cable television provider. Typically the bandwidth upstream from a set-top box to a headend is lower than the downstream bandwidth from the headend to the set-top box. Further, satellite television providers also have implemented bi-directional communication capabilities and are offering additional services, such as internet connectivity, in conjunction with the television signal distribution architecture.
SUMMARY
An interactive service involving one or more subscribers (or users) can be provided over a television distribution system. For example, game-play can be initiated from a client device, such as a set-top box included in the television distribution system. Further, execution and coordination of a game instance can be controlled by a server device included in the television distribution system. For example, the server device can be configured to control access to a game, to manage game play, to record game scores, and to facilitate communication and interaction between subscribers participating in one or more game instances. Other interactive services also can be provided over the television distribution system, including shopping, weather forecasts, and chatting.
In order to provide interactive services over a television distribution system, the present inventors recognized the need to permit bi-directional communication over the television distribution system relating to the interactive service between a client device, such as a set-top box, and a server device, such as a game server or server cluster. Further, the present inventors recognized the need to permit authenticating by the server device one or more client device users.
The present inventors also recognized the need for the server device to communicate with a plurality of client devices, which can be configured to communicate using different protocols or message formats. Further, the need to utilize a plurality of server devices within the television distribution system also was recognized. Additionally, the present inventors also recognized the need to utilize a single, global protocol for communication between elements within a server device. The single, global communication protocol also can be used for communication between server devices. Accordingly, the techniques and apparatus described here implement algorithms for providing interactive services over a television distribution system.
In general, in one aspect, the subject matter can be implemented to include receiving input over the television distribution system from a game client indicating an action associated with a game instance, wherein the game client is hosted on a set-top box; determining an updated status of the game instance based on the action; generating a game status message identifying the updated status of the game instance; and transmitting the game status message to the game client.
The subject matter also can be implemented to include transmitting the game status message to a plurality of game clients participating in the game instance. Further, the subject matter can be implemented to include receiving input over the television distribution system from another game client indicating a second action associated with the game instance and determining an updated status of the game instance based on the second action. Additionally, the subject matter can be implemented to include processing the game status message by the game client to generate a current status of the game instance at the set-top box.
In general, in another aspect, the techniques can be implemented as a computer program product, encoded on a computer-readable medium, operable to cause data processing apparatus to perform operations comprising receiving input over a television distribution system from a game client indicating an action associated with a game instance, wherein the game client is hosted on a set-top box included in the television distribution system; determining an updated status of the game instance based on the action; generating a game status message identifying the updated status of the game instance; and transmitting the game status message to the game client.
The subject matter also can be implemented to be operable to cause data processing apparatus to perform operations comprising transmitting the game status message to a plurality of game clients participating in the game instance. The subject matter further can be implemented to be operable to cause data processing apparatus to perform operations comprising receiving input over the television distribution system from another game client indicating a second action associated with the game instance and determining an updated status of the game instance based on the second action. Additionally, the subject matter further can be implemented to be operable to cause data processing apparatus to perform operations comprising processing the game status message by the game client to generate a current status of the game instance at the set-top box.
In general, in another aspect, the subject matter can be implemented as a system including a game client hosted on a set-top box included in a television distribution system; and a server including processor electronics configured to perform operations comprising receiving input over the television distribution system from the game client indicating an action associated with a game instance; determining an updated status of the game instance based on the action; generating a game status message identifying the updated status of the game instance; and transmitting the game status message to the game client.
The subject matter also can be implemented such that the processor electronics are further configured to perform operations comprising transmitting the game status message to a plurality of game clients participating in the game instance. Further, the subject matter can be implemented such that the processor electronics are further configured to perform operations comprising receiving input from another game client indicating a second action associated with the game instance and determining an updated status of the game instance based on the second action. Additionally, the subject matter can be implemented such that the processor electronics are further configured to perform operations comprising processing the game status message by the game client to generate a current status of the game instance.
In general, in another aspect, the subject matter can be implemented as a system including an interactive services client hosted on a set-top box included in a television distribution system; and a server including processor electronics configured to perform operations comprising receiving a request from the interactive services client to participate in an interactive service hosted by the server; verifying that the interactive services client is authorized to participate in the interactive service; and assigning the interactive services client to a process corresponding to the interactive service.
The techniques described in this specification can be implemented to realize one or more of the following advantages. For example, the techniques can be implemented such that one or more client devices can participate in interactive services provided by one or more server devices in a television distribution system. The techniques also can be implemented such that a plurality of client devices, two or more of which are configured to utilize a different communication protocol, can interact over the television distribution system. Additionally, the techniques can be implemented to include utilizing a single, global communication protocol by the one or more server devices included in the television distribution system.
The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features and advantages will be apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an example of a television distribution system.
FIG. 2 shows an example of components included in a set-top box.
FIG. 3 shows an example of a message flow between a set-top box and the messaging layer of a server cluster.
FIG. 4 shows an example of a message flow between a process executing in the server cluster and a set-top box.
FIG. 5 shows an example of a login message flow between a set-top box and a server cluster.
FIG. 6 shows an example message flow relating to the execution of a game instance.
FIG. 7 shows a flowchart for executing an interactive game in a television distribution system.
Like reference symbols indicate like elements throughout the specification and drawings.
DETAILED DESCRIPTION
FIG. 1 shows an example of a television distribution system 100 . The television distribution system 100 can include a plurality of set-top boxes (STBs), such as STBs 110 - 117 . An STB can be utilized to provide access to a channel of a cable television signal, such as a multiplexed signal representing a plurality of separate channels. Further, an STB can be configured to provide access to one or more interactive services, including gaming, chatting, shopping, and information retrieval services. Interactive gaming is presented as an exemplary implementation, but a wide variety of interactive services can be provided over the television distribution system 100 . In an implementation, the television distribution system 100 can be a satellite television system that permits bi-directional communication.
A game player (or “subscriber”) can access one or more interactive games through an STB, such as the STB 110 . For example, the STB 110 can be located at the game player's home or office. Further, the game player can access one or more interactive games through any STB that has been provisioned in the television distribution system 100 . The STB 110 can be connected to one or more display devices, such as a television or monitor. The STB 110 also can be connected to one or more audio output devices, such as speakers or an audio receiver. Further, the STB can be coupled with one or more peripheral devices, such as one or more joysticks, game pads, keyboards, keypads, and/or controllers. Each of the peripheral devices can be coupled with the STB 110 over a wired or wireless interface. Additionally, one or more remote control devices can be used to communicate with the STB 110 .
In an implementation, one or more aspects can differ between the STBs 110 - 117 , including the manufacturer, the operating instructions (or middleware), the configuration, the communications interface, and the hardware, such as the memory and/or the processor. Additionally, the television distribution system 100 can include STBs associated with two or more cable television systems or service providers.
FIG. 2 shows an example of components included in a set-top box, such as the STB 110 . The STB 110 can be configured to execute an operating system 201 that can provide access to one or more interactive services offered by the television distribution system 100 . The operating system 201 also can be configured to control the operations of the STB 110 , including communicating with the television distribution system 100 , providing output to a corresponding display device, and receiving input from a user. In an implementation, the operating system 201 further can be operable to configure the STB 110 as a gaming platform that can execute one or more game clients, such as the game client 202 . Further, the game client 202 can be configured to manage the execution of one or more game instances at the STB 110 , including poker game instances, trivia game instances and billiards game instances. The game client 202 can communicate with a remote game server, such as a server cluster, to execute a game instance. Additionally, the game client 202 can receive input from one or more users relating to playing (or “executing”) a game instance. For example, a user can enter commands through an STB remote control device or other controller.
An STB can be connected to a headend through a bi-directional communication path. A headend can receive input from and provide output to one or more STBs. For example, the STBs 110 - 117 can be connected to the headends 120 - 123 . In the television distribution system 100 , one or more cable television providers operate the headends 120 - 123 to provide television programming and interactive services to corresponding STBs. The STBs associated with a headend receive a common signal from that headend. Further, a headend can be configured to provide connectivity to the internet 130 for one or more associated STBs. In some implementations, the headend can serve as a proxy or router for the one or more STBs connected to the headend.
Additionally, the STBs that are connected to a headend can use any desired communication protocol and message format. For example, the STBs 110 and 111 can communicate with the corresponding headend 120 using any desired communication protocol, such as the Aloha or slotted Aloha protocol. STBs associated with a different headend, such as the headend 121 , can use the same communication protocol and message format as is used in conjunction with the headend 120 or a different communication protocol and/or message format.
Further, the game client 202 running on the STB 110 can communicate with the server cluster 140 . When the game client 202 initiates communication a connection, such as a secure socket layer (SSL) connection, can be established between the headend 120 and the server cluster 140 over the internet 130 . The connection can be made with a connection processor, such as the connection processor 151 , included in the server cluster 140 . When the game client 202 on the STB 110 transmits data, the headend 120 forwards the transmitted data over the connection to the connection processor 151 . Further, the headend 120 can forward the transmitted data using any communication protocol and message format. For example, the headend 120 can translate the data received from the STB 110 into a different communication protocol and/or message format.
The connection processors 151 - 156 are configured to terminate the connections established between the various headends 120 - 123 and the server cluster 140 . In a distributed environment, such as the one shown in the television distribution system 100 , a headend can establish a connection with any available connection processor included in the server cluster 140 , such as one of the connection processors 151 - 156 . In an implementation, a headend also can establish a connection with a plurality of connection processors of the server cluster 140 , such as for different services on the same STB or services associated with different STBs. In another implementation, a headend can establish connections with a plurality of server clusters, such as server clusters offering different interactive services. Upon receiving a message on the connection, the connection processor included in the server cluster 140 forwards the message to a corresponding protocol converter and message router 160 . In some implementations, the protocol converter can be realized in an element separate from the message router.
The protocol converter and message router 160 can be configured to translate the received message from the communication protocol and message format utilized by the STB and/or headend into the communication protocol and message format utilized within the server cluster 140 . For example, a gaming platform of an STB that uses the Flash programming language can transmit one or more XML-based messages to the server cluster 140 through a corresponding headend. The protocol converter and message router 160 , which is associated with the server cluster 140 can translate the XML-based messages received from the headend into a communication protocol and message format utilized within the server cluster 140 . For example, the server cluster 140 can be configured to utilize a single, standard communication protocol and message format (or “cluster protocol”) for all messages routed within the server cluster 140 . Further, the protocol converter and message router 160 can be configured to translate messages from the cluster protocol into a communication protocol and message format that is compatible with an STB to which the message is being sent.
The protocol converter and message router 160 also can be configured to distribute the converted message to one or more processes and/or modules included in the server cluster 140 , such as the login process 170 , the lobby manager 171 , the scoring processor 172 , the advertising module 173 , one or more game processes 174 - 177 , and the database 180 . For example, the protocol converter and message router 160 can pass the converted message to the messaging layer 165 for distribution. In some implementations, the messaging layer 165 can implement the JMS message model. The protocol converter and message router 160 also can be configured to distribute messages to one or more other protocol converters and message routers included in the server cluster 140 , such as the protocol converters and message routers 163 - 165 .
The messaging layer 165 can be configured to distribute messages between elements included in the server cluster 140 , including the protocol converters and message routers, the database 180 , the login process 170 , the lobby manager 171 , the scoring processor 172 , the advertising module 173 , and one or more game processes. Further, the messaging layer 165 can include one or more message channels or message queues through which messages are routed.
In some implementations, the messaging layer 165 can implement a “Publish/Subscribe” model for message distribution to the server cluster 140 elements, including the processes and modules. In the “Publish/Subscribe” model, an element of the server cluster 140 that is configured to communicate with the messaging layer 165 can subscribe to one or more predetermined message types and/or messages including one or more predetermined identifiers. For example, the login process 170 can subscribe to login messages received by the server cluster 140 . Thus, login messages received by the server cluster 140 can be routed by the messaging layer 165 to the login process 170 . For example, a received login message can be inserted into a message queue associated with the login process 170 by the messaging layer 165 . The login process 170 can then retrieve the login message from the message queue for processing. An element included in the server cluster 140 can have one or more associated message queues. A game process also can subscribe to messages from one or more clients that are participating in a game instance associated with the game process.
A process executing in the server cluster 140 also can transmit one or more messages to a target STB. For example, a game process executing on the server cluster 140 can generate a game status message that is to be transmitted to a game client executing on the target STB. The game status message can include an indicator associated with the target STB. Further, the game process can pass the game status message to the messaging layer, where the message can be inserted into a message queue associated with the protocol converter and message router subscribing to messages relating to the target STB. The protocol converter and message router can route the message through an associated connection processor to a network, over which the game status message can be delivered to the headend associated with the target STB. The headend then can insert the game status message into the data signal provided to the subscribing STBs connected to the headend and the message can be retrieved by the target STB.
The login process 170 of the server cluster 140 can uniquely identify a subscriber before permitting the subscriber to participate in an interactive service. For example, before a subscriber can begin a game hosted by the server cluster 140 , the subscriber can be directed to log in, such as by presenting a login screen. In response, the subscriber can submit a login request to the login process 170 through the game client 202 hosted on the STB 110 , such as by supplying a username and password. In some implementations, either or both of the username and password can be stored on the STB 110 . The supplied username and password can be transmitted in one or more messages from the STB 110 to the login process 170 for login and authentication purposes. For example, the username and password can be transmitted through the headend 120 to the internet 130 and then through the connection processor 151 , the protocol converter and message router 160 , and the messaging layer 165 . An alternative communication path using one or more other elements also can be used if available.
Further, the login process 170 can be configured to query corresponding user data from the database 180 in order to perform the login and authentication. The game client 202 also can be configured to utilize a common application programming interface (API) for communication with the login process 170 . The common API can be responsible for transmitting the login information to the login process 170 , verifying the login result, and returning the user identifier to the game client 202 . The user identifier can be utilized to uniquely identify the subscriber while the subscriber's session is active. Once the game client 202 has been authenticated, the user can be given access to one or more menus associated with interactive services available through the server cluster 140 , such as one or more interactive games.
A lobby manager 171 also can be included in the server cluster 140 . The lobby manager 171 can be configured to track the location of the subscriber within a game environment while the game client 202 is connected to the server cluster 140 . For example, a game environment can include one or more virtual lobbies with which a subscriber can be associated, such as a poker lobby. The poker lobby further can be associated with one or more poker game rooms, in which separate poker game instances can be played. Additionally, the game environment can include a lobby associated with one or more other games, such as billiards and checkers. In another implementation, a plurality of lobbies can be associated with a game provided in a game environment. The server cluster 140 can manage one or more game environments. Further, a game environment can be defined that spans a plurality of server clusters. A subscriber can select which environment or server cluster to join, such as by selecting a predefined world or game. Alternatively, a subscriber can be automatically assigned to an environment or server cluster, such as by the headend.
The lobby manager 171 can store the location of one or more subscribers in the database 180 . A subscriber can move between lobbies and/or rooms included in the game environment by issuing one or more commands to the game client 202 . When a subscriber move occurs, the lobby manager 171 can update the database 180 to reflect the subscriber's new location. The lobby manager 171 also can send a notification message announcing the player move to one or more subscribers, such as subscribers associated with the lobby the player left and subscribers associated with the lobby the player joined. Additionally, the lobby manager 171 can send a notification message to one or more other subscribers, such as buddies, who have requested information regarding the location of the subscriber who has changed locations.
A lobby can be utilized to organize a plurality of common game instances or subscriber groupings. A game instance can be created for each “bottom level” room that corresponds to a lobby, based on a set of configuration characteristics. A fixed-room hierarchy can be used, in which game rooms can be generated as needed in accordance with one or more sets of configuration characteristics. Further, dynamic-room creation can be implemented to allow one or more subscribers to create a game instance in accordance with a custom set of configuration characteristics, such as game settings and difficulty parameters. Access to a dynamically created room also can be controlled, such as through invitation or password. Two or more rooms for which the associated configuration characteristics vary can be associated with a common lobby.
In addition, a lobby can be used as a “chat point”, where subscribers can engage in text-based chat sessions with one another. As with games, chat points can be organized by a topic or a subscriber group. A chat system in the server cluster 140 can be configured to allow a subscriber to access a list of pre-programmed text strings, which can be initialized before a chat session is initiated or joined. Further, text can be entered by a subscriber through an on-screen interface generated by the STB. For example, a virtual keyboard can be displayed in which letters, numbers, and special purpose characters are selected through use of a remote control device.
A game process, such as the game processes 174 - 177 , represents a server-side component of a game application. For example, the game process 174 can be a self contained entity that is configured to generate a game state for one or more connected game clients, such as the game client 202 of the STB 110 . In an implementation, the game process 174 can be configured to generate a poker game and can be responsible for determining what cards are dealt to each subscriber (or player) participating in the game, managing the value of the pot, controlling the sequence of the game, and determining which player wins a hand. Further, the game process 174 can interface with the database 180 to save information representing a persistent game state and to register the statistics associated with the players, such as each player's bank. A game process, such as the game process 174 , can be initialized by the lobby manager 171 when a subscriber elects to host a game of a specific type. In another example, a game process can be automatically initialized by the lobby manager 171 , such as when only a predetermined number of available positions remain in the existing game processes.
A scoring processor 172 included in the server cluster 140 permits a game process, such as the game processes 174 - 177 , and/or a game client, such as the game client 202 , to post scoring data. The scoring data can include game specific data and events. Further, the scoring data can be used to rank subscribers who participate in a game environment. In an implementation, the user rankings and associated statistics can be stored in the database 180 . The scoring processor 172 can be configured to track data submitted for one or more games, and can provide current rankings based on the scoring data, such as in response to a game event or a request. A request can be generated by a game client 202 or a game process. For example, a subscriber playing a single player game, such as checkers, can submit the time taken to win a game instance to the scoring processor 172 via a client scoring system API. In another example, the game process associated with a multiplayer game, such as billiards, can post one or more items of user ranking data on behalf of the game participants.
The server cluster 140 also can include an advertising module 173 , which can be configured to manage advertising content. The advertising module 173 also can schedule advertising content for delivery to an STB, such as in response to a game event or at a predetermined interval. In some implementations, an advertisement can comprise a full screen image or full-screen, full-motion video. Further, audio content also can be associated with an advertisement. In some implementations, an advertisement also can be an image or video sequence that occupies a smaller portion of a display or screen, such as a banner embedded in the game space. For example, a sponsor's logo can be displayed on the surface of a poker or pool table. The advertising module 173 can indicate to the game client 202 through one or more messages that a particular advertisement is to be presented at a predetermined time or in response to a predetermined event. In some implementations, the advertising module 173 can be configured to select one or more advertisements for presentation based on a parameter, such as the geographical location of a headend or an STB.
FIG. 3 shows an example of a message flow between an STB, such as the STB 110 , and the messaging layer of a server cluster. The STB can generate a message, such as based on a subscriber input, and transmit 305 the message to the corresponding headend. For example, the STB can transmit the message to the corresponding headend using a socket-based protocol, such as the slotted Aloha protocol. Any communication protocol, however, can be used for communication between the STB and the headend. Upon receiving the message from the STB, the headend can forward 310 the message over a network to a server cluster. The network can be a public network, such as the internet, or a private network, such as a local area network or a wide area network. In an implementation, the headend can communicate with the server cluster over a connection, such as a secure socket layer (SSL) connection. Further, the headend can serve as a router for the one or more STBs connected to the headend.
A connection processor, such as the connection processor 151 , included in the server cluster 140 can be configured to communicate with the headend over the connection. In a distributed network environment, such as the internet, any connection processor included in the server cluster can serve as the connection point for the headend. Further, a connection processor included in the server cluster can communicate with a plurality of headends.
The connection processor receives 315 the message for processing in the server cluster. For example, the connection processor can be configured to receive the message over the connection with the headend and to pass the message to a corresponding protocol converter and message router included in the server cluster, such as the protocol converter and message router 160 . A protocol converter and message router can receive messages from a plurality of connection processors.
The protocol converter and message router can be configured to determine the format of a received message. For example, the protocol converter can determine how the message has been encoded and/or how the message is structured. Further, the protocol converter and message router can determine 320 whether the message is compatible with the cluster protocol utilized within the server cluster. If the message is not compatible with the cluster protocol, the message can be converted 325 into a compatible format by the protocol converter. In some implementations, the protocol converter can be configured to convert a message from any format employed by a participating STB or headend into a format that is compatible with the cluster protocol. If the message is in a compatible format, or once the message has been converted into the cluster protocol, the protocol converter and message router can route 330 the message to one or more subscribing processes. A subscribing process can then access 335 the message for use within the cluster server.
The television distribution system 100 architecture can be scaled to meet the demands of the subscribers. In some implementations, the television distribution system 100 can include one or more server clusters, which can be designated based on geography, subscriber population, or services. Further, a server cluster also can be scaled to meet the demands of subscribers. For example, a plurality of one or more types of elements, such as connection processors, protocol converters and message routers, databases, and processors can be included in the cluster server based on system demand. Additionally, information regarding one or more STBs and headends can be stored in a database included in the server cluster.
FIG. 4 shows an example of a message flow between a process executing in a server cluster of a television distribution system and an STB. A process executing in the server cluster generates a message 405 to an associated game client, such as a message describing the status of a game instance. The message can include an indicator, such as a user identifier, that can be used to deliver (or address) the message. A process executing in the server cluster can be configured to generate messages to one or more associated STBs, such as to manage the execution of a game instance between a plurality of participating subscribers.
The process forwards the message 410 within the server cluster over the messaging layer. For example, the messaging layer can direct the message to one or more message queues that have subscribed to messages relating to the indicator, such as the user identifier, included in the message. In the present example, the message can be inserted into a message queue corresponding to the protocol converter and message router that processes message traffic to the STB with which the indicator is associated. The protocol converter and message router can retrieve the message from the message queue and determine the format 415 associated with the STB to which the message is to be transmitted. Further, the protocol converter and message router can determine whether the message is to be converted 420 . For example, if the message format of the cluster protocol is incompatible with the message format of the STB, the message can be converted to the STB format 425 .
Once the message has been converted to the STB format, or if the message format already is compatible with the message format of the STB, the message can be forwarded to the associated connection processor 430 . Further, the connection processor can transmit the message to the game client hosted on the destination STB 435 , such as over the connection with the headend corresponding to the STB. Thus, one or more processes executing in the cluster server can transmit messages to associated STBs. Additionally, processes executing in the server cluster also can communicate with one another over the messaging layer. For example, a game process can publish a scoring message to the messaging layer. Further, the scoring processor can subscribe to all scoring messages. Thus, the messaging layer can insert the scoring message generated by the game process into a message queue associated with the scoring processor.
FIG. 5 shows an example of a login message flow between an STB and a cluster server. A subscriber can initiate a login process by generating and transmitting a login request message 505 through an STB. For example, the subscriber can tune an STB to a channel in the television distribution system 100 on which an interactive service, such as a game, can be accessed. Tuning an interactive services game channel can cause a game portal application resident on the STB to be launched. Further, a login screen can be displayed to the subscriber by the game portal application. The subscriber can use a control interface, such as a remote control device or coupled controller, to enter authentication information, such as a user name and a personal identification number or password.
The login request message can be transmitted from the requesting STB to the headend over a bi-directional communication path. Further, the headend can route the login request message 510 received from the requesting STB over a communication network, such as the internet, to a corresponding cluster server. In some implementations, the headend can route the login request message to the cluster server over an SSL connection. The login request message can be received at the cluster server by a connection processor, which further can forward the message to an associated protocol converter and message router 515 .
The protocol converter and message router can convert the login request message into a format compatible with the cluster protocol and then route the login request message to the login process over the messaging layer 520 . The protocol converter can be configured to determine the format of the message and can convert between any format utilized by an STB included in the television distribution system 100 and the cluster protocol format. A protocol converter can be updated to include a new conversion routine when an STB with an unsupported protocol or message format is used in the television distribution system 100 . The login process can retrieve the login request message from the messaging layer and can determine whether the subscriber supplying the credentials can be authorized 525 . For example, the login process can compare the supplied credentials with authorization data stored in the database of the server cluster.
If the login process determines that the subscriber can be authorized, an authorization message can be generated and the subscriber can be given access to the interactive services 530 . For example, the login process can assign the subscriber to an initial lobby of the server cluster. If the login process determines that the subscriber cannot be authorized, a rejection message can be generated and the subscriber can be denied access to the interactive services of the server cluster 535 . The login response message generated by the login process can be forwarded to the protocol converter and message router 540 , such as over the messaging layer. For example, an indicator identifying the requesting STB can be included in the login response message generated by the login process. Further, the protocol converter and message router that forwarded the login request can subscribe to any messages corresponding to the requesting STB. Thus, the messaging queue can insert the login response message into a message queue associated with the subscribing protocol converter and message router.
The protocol converter and message router can convert the login response message into a format compatible with the requesting STB and pass the converted message to the associated connection processor for transmission to the headend 545 . For example, the connection processor can transmit the message to the headend over an established connection, such as an SSL connection. The headend can then deliver the login response message to the requesting STB 550 . For example, the headend can insert the login response message into a data stream that is provided to one or more STBs, including the requesting STB. The message can be included in a file carousel, which periodically circulates data to the STBs connected to a headend.
FIG. 6 shows an example message flow relating to the execution of a game instance. A subscriber participating in a game instance can input one or more items of data corresponding to a subscriber event 605 . For example, in a billiards game instance, the subscriber can input data describing the position of a pool cue relative to a cue ball and a measure of force to identify a shot. In a poker game instance, the subscriber can input data indicating an action, such as a call, raise, check, or fold.
Once the subscriber submits data representing an event, the game client on the STB with which the subscriber is interacting can generate one or more game data messages 610 . The one or more game data messages can be forwarded to the headend to which the STB is connected 615 . A game data message can be transmitted from the STB to the headend using any communication protocol supported by the television distribution system. Further, the headend can transmit the one or more game data messages to the cluster server hosting the game process that is controlling the game instance 620 . For example, the headend can serve as a proxy for the STB and can route game data messages over a network to the cluster server.
The one or more game data messages generated by the game client can be received at the cluster server 625 . For example, a connection processor included in the cluster server can receive messages transmitted to the cluster server by one or more headends. Further, the connection processor can forward the received messages to a protocol converter and message router, which can convert a received message into a format compatible with the elements hosted in the cluster server. The protocol converter and message router also can distribute the message to one or more processes executing in the cluster server, including the game process with which the message is associated.
The game process can update the game status based on the game data included in the one or more game data messages 630 . For example, in a billiards game instance, the game process can utilize the shot identified by the game data to calculate the new position of the billiard balls. In a poker game instance, the game process can update the status of the game instance to reflect the subscriber's action. The game process further can be configured to generate a game status message indicating the updated status of the game instance 635 . The game status message can include one or more items of data that can be used by the game logic included in the game client to accurately represent the current state of the game instance.
Additionally, the game process can transmit the game status message to one or more participating subscribers 640 . For example, the game process can pass the game status message to the messaging layer, which can forward the game status message to a protocol converter and message router to be formatted in accordance with the requirements of the intended recipient STBs. The formatted game status messages can then be passed to a connection processor, which can transmit the messages to one or more headends for distribution to the recipient STBs. Upon receipt of a game status message, a game client associated with a participating STB can update the status of the game. Further, the STB can present the updated game status to a subscriber on the associated display. For example, in a billiards game instance, the game client can update the position of the balls based on the most recent shot. In a poker game instance, the game client can update the hand based on the most recent player action.
FIG. 7 shows a flowchart for executing an interactive game in a television distribution system. Initially, input can be received over the television distribution system from a game client indicating an action associated with a game instance, wherein the game client is hosted on a set-top box ( 705 ). An updated status of the game instance can be determined based on the action ( 710 ). Further, a game status message can be generated identifying the updated status of the game instance ( 715 ). Once the game status message has been generated, the game status message can be transmitted to the game client ( 720 ).
Embodiments of the subject matter and the functional operations described in this specification can be implemented in digital electronic circuitry, or in computer software, firmware, or hardware, including the structures disclosed in this specification and their structural equivalents, or in combinations of one or more of them. Embodiments of the subject matter described in this specification can be implemented as one or more computer program products, i.e., one or more modules of computer program instructions encoded on a computer readable medium for execution by, or to control the operation of, data processing apparatus.
The computer readable medium can be a machine-readable storage device, a machine-readable storage substrate, a memory device, a composition of matter effecting a machine-readable propagated signal, or a combination of one or more of them. The term “data processing apparatus” encompasses all apparatus, devices, and machines for processing data, including by way of example a programmable processor, a computer, or multiple processors or computers. The apparatus can include, in addition to hardware, code that creates an execution environment for the computer program in question, e.g., code that constitutes processor firmware, a protocol stack, a database management system, an operating system, or a combination of one or more of them. A propagated signal is an artificially generated signal, e.g., a machine-generated electrical, optical, or electromagnetic signal, that is generated to encode information for transmission to suitable receiver apparatus.
A computer program (also known as a program, software, software application, script, or code) can be written in any form of programming language, including compiled or interpreted languages, and it can be deployed in any form, including as a stand alone program or as a module, component, subroutine, or other unit suitable for use in a computing environment. A computer program does not necessarily correspond to a file in a file system. A program can be stored in a portion of a file that holds other programs or data (e.g., one or more scripts stored in a markup language document), in a single file dedicated to the program in question, or in multiple coordinated files (e.g., files that store one or more modules, sub programs, or portions of code). A computer program can be deployed to be executed on one computer/processing device or on multiple computers/processing devices that are located at one site or distributed across multiple sites and interconnected by a communication network.
A number of implementations have been disclosed herein. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the claims. Accordingly, other implementations are within the scope of the following claims.
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A system, method, and processor-readable media for providing interactive, television-based gaming service, comprising a server cluster including processor electronics configured to send and receive messages and to execute a game, a first set-top box coupled to a first headend managed by a first television service provider, the first set-top box executing a first game client for enabling a first user to play the game executed by the server cluster, a second set-top box coupled to a second headend managed by a second television service provider, the second set-top box executing a second game client for enabling a second user to play the game executed by the server cluster, wherein the server cluster is coupled to the first and second headends via a public network and further configured to enable the first user to play the game with or against the second user.
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CROSS-REFERENCE TO RELATION APPLICATIONS
The present application claims the benefit of U.S. Provisional Application No. 60/247,132, filed Nov. 10, 2000.
FIELD OF INVENTION
The present invention is directed to a method and system for wireless interfacing of electronic devices. More particularly, the present invention implements “BLUETOOTH® wireless technology which permits electronic devices to communicate with other without wired connections. BLUETOOTH® is a specification for a small-form factor, low-cost radio solution providing links between mobile computers, mobile phones and other portable hand-held devices, printers, printers, facsimile machines, copiers and connectivity to the Internet.
BACKGROUND OF THE INVENTION
Electronic devices have traditionally interfaced to other electronic devices through the use of specially designed cables. There are many drawbacks associated with the use of specially designed cables. These drawbacks include: limited mobility of the electronic device, the requirement of specially designed cable connectors that are not universal, the requirement of multiple connectors for each electronic device desired to be interfaced, and workspace obstructions associated with cables connecting to the electronic devices.
The present invention enables users to interface with a wide range of computing and telecommunication devices seamlessly without a cable connecting the devices. As such, the present invention allows for the replacement of the many proprietary cables that connect one device to another with one universal short-range radio link. For instance, BLUETOOTH® devices will replace RS-232, parallel, Universal Serial Bus (USB), and other types of cables with a single, standard wireless connection. Therefore, any BLUETOOTH®-enabled device will be able to communicate with any other BLUETOOTH®-enabled device. For example, a BLUETOOTH®-certified personal digital assistant (PDA) or cellular phone will work with any personal computer equipped with a BLUETOOTH®-enabled card. Printers, PDA's, cellular telephones, desktop computers, fax machines, keyboards, joysticks and virtually any other digital device can be part of the BLUETOOTH® system.
BLUETOOTH® technology does more than just untethering devices by replacing the cables, BLUETOOTH® radio technology provides a universal bridge to existing data networks, a peripheral interface, and a mechanism to form small private ad hoc groupings of connected devices away from fixed network infrastructures.
SUMMARY OF THE INVENTION
In accordance with the present invention, a wireless transmission method and apparatus is disclosed for implementing the steps of transmitting a request packet requesting a response from a second electronic device to a first electronic device and transmitting a response packet from the first electronic device to the second electronic device in response to the request packet. One or more data file packets are transmitted from the second electronic device to the first electronic device. Correct transmission is verified of the at least one data file packet. Transmission of at least a portion of data file packets is verified from an entire input data file, and transmission is terminated upon completion of a predetermined condition.
As will be realized, the invention is capable of other and different embodiments and its several details are capable of modifications in various respects, all without departing from the invention. Accordingly, the drawing and description are to be regarded as illustrative and not restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
The subject application is described with reference to certain figures, including:
FIG. 1 is a diagram of a cable replacement implementation of the system for wireless connection to a document processor according to one embodiment of the subject application;
FIG. 2 is a diagram illustrating a print by reference implementation of the system for wireless connection to a document processor according to one embodiment of the subject application;
FIG. 3 is a diagram illustrating a remote print implementation of the system for wireless connection to a document processor according to one embodiment of the subject application;
FIG. 4 is a diagram illustrating a three-in-one telephone implementation of the system for wireless connection to a document processor according to one embodiment of the subject application;
FIG. 5 is a diagram illustrating an Internet bridge implementation of the system for wireless connection to a document processor according to one embodiment of the subject application;
FIG. 6 is a diagram illustrating an interactive conference implementation of the system for wireless connection to a document processor according to one embodiment of the subject application;
FIG. 7 is a diagram illustrating a wireless headset implementation of the system for wireless connection to a document processor according to one embodiment of the subject application;
FIG. 8 is a diagram illustrating an automatic synchronization implementation of the system for wireless connection to a document processor according to one embodiment of the subject application;
FIG. 9 is a diagram illustrating a wireless cluster print implementation of the system for wireless connection to a document processor according to one embodiment of the subject application;
FIG. 10 is a diagram illustrating a wireless document distribution implementation of the system for wireless connection to a document processor according to one embodiment of the subject application;
FIG. 11 is a diagram illustrating a wireless management implementation of the system for wireless connection to a document processor according to one embodiment of the subject application;
FIG. 12 is a diagram illustrating a wireless gateway implementation of the system for wireless connection to a document processor according to one embodiment of the subject application;
FIG. 13 is a block diagram illustrating an implementation of the system and method for wireless connection to a document processor according to one embodiment of the subject application;
FIG. 14 is a flowchart illustrating an implementation in the system and method for wireless connection to a document processor according to one embodiment of the subject application;
FIG. 15 is a flowchart illustrating port configuration in the system and method for wireless connection to a document processor according to one embodiment of the subject application;
FIG. 16 is a flowchart illustrating an implementation of the system and method for wireless connection to a document processor according to one embodiment of the subject application;
FIG. 17 is a flowchart illustrating client side configuration in the system and method for wireless connection to a document processor according to one embodiment of the subject application;
FIG. 18 is a screen template illustrating a printer configuration page for use in the system and method for wireless connection to a document processor according to one embodiment of the subject application;
FIG. 19 is a screen template illustrating a printer configuration port addition page for use in the system and method for wireless connection to a document processor according to one embodiment of the subject application;
FIG. 20 is a screen template illustrating depicting wireless devices for use in the system and method for wireless connection to a document processor according to one embodiment of the subject application;
FIG. 21 is a screen template illustrating a printer port configuration page for use in the system and method for wireless connection to a document processor according to one embodiment of the subject application;
FIG. 22 is a flowchart illustrating a wireless printing implementation of the system and method for wireless connection to a document processor according to one embodiment of the subject application;
FIG. 23 is a diagram illustrating a URL-printing implementation of the system and method for wireless connection to a document processor according to one embodiment of the subject application;
FIG. 24 is a flowchart diagram illustrating the URL-printing implementation of the system and method for wireless connection to a document processor according to one embodiment of the subject application;
FIG. 25 is a flowchart illustrating the URL-printing implementation of the system and method for wireless connection to a document processor according to one embodiment of the subject application;
FIG. 26 is a flowchart illustrating an implementation of the system and method for wireless connection to a document processor according to one embodiment of the subject application; and
FIG. 27 is a flowchart illustrating an implementation of the system and method for wireless connection to a document processor according to one embodiment of the subject application.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is designed to operate in a noisy radio frequency environment, the BLUETOOTH® enabled radio uses a fast acknowledgment and frequency hopping scheme to make the link robust. Thus, BLUETOOTH® radio modules avoid interference from other signals by hopping to a new frequency after transmitting or receiving a packet. Compared with other systems operating in the same frequency band (ISM band), the BLUETOOTH® radio typically hops faster and uses shorter packets. Accordingly, the BLUETOOTH® radio is more robust than other systems currently available. The shorter packets and faster hopping also limit the impact of domestic and professional microwave ovens. In addition, the use of forward error correction limits the impact of random noise on long-distance links.
The BLUETOOTH® specification is a de facto standard containing the information required to ensure that diverse devices supporting the BLUETOOTH® wireless technology can communicate with each other worldwide. The BLUETOOTH® specification Ver. 1.0. may be located at www.BLUETOOTH®.com and is incorporated by reference as if fully rewritten herein. Volume One of the BLUETOOTH® specification (known as the “Core”) specifies components such as the radio, baseband, link manager, service discovery protocol, transport layer, and interoperability with different communication protocols. Volume Two of the BLUETOOTH® specification (known as the “Profiles”) specifies the protocols and procedures required for different types of BLUETOOTH® applications.
All of BLUETOOTH® system applications consist of four basic parts: a radio (RF section) that receives and transmits data and voice; a baseband or link control unit that processes the transmitted or received data; link management software that manages the transmission; and supporting application software.
The BLUETOOTH® radio is a short-distance, low-power radio that operates in the unlicensed ISM band at approximately 2.4 GHz, using a nominal antenna power of 0 dBm. At 0 dBm, the electronic devices must be within 10 meters (approximately 33 feet) to communicate with each other using the BLUETOOTH® standard. Other ranges are available by increasing the antenna power. For instance, a range of 100 meters may be achieved by using an antenna power of 20 dBm. Data is transmitted at a maximum rate of up to 1 Mbps.
Since the 2.4-GHz frequency is shared by other types of equipment, the BLUETOOTH® specification employs frequency-hopping spread-spectrum techniques to eliminate interference.
The baseband converts received radio signals into a digital format and converts digital or voice data into a format that can be transmitted using a radio signal. The BLUETOOTH® Specification requires that each packet contain information about where it is coming from, what frequency it is using, and where it is going. Packets also contain information on how the data was compressed, the order in which the packets were transmitted, and information used to verify the effectiveness of the transmission. When the data is received it is checked for accuracy, extracted from the packet, reassembled, decompressed, and possibly filtered.
The BLUETOOTH® link is the method of data transmission to be used. The BLUETOOTH® standard supports two link types—synchronous connection-oriented (SCO) links, used primarily for voice communications, and asynchronous connectionless (ACL) links for packet data. Each link type supports sixteen different packet types that are used, depending on the application. Any two devices in a BLUETOOTH® system may use either link type and may change link types during a transmission.
Link manager software runs on a microprocessor and manages the communication between BLUETOOTH® devices. Each BLUETOOTH® device has its own link manager, which discovers other remote link managers, and communicates with them to handle link setup, negotiate features, authenticate QoS, and to encrypt and adjust data rate on link, dynamically.
The link controller is a supervisory function that handles all of the BLUETOOTH® baseband functions and supports the link manager. It sends and receives data, identifies the sending device, performs authentication and ciphering functions, determines what type of frame to use on a slot-by-slot basis, directs how devices will listen for transmissions from other devices, or puts devices into various power-save modes according to BLUETOOTH®-specified procedures. Each packet uses a single 625-μs timeslot, but can be extended to cover up to five slots. BLUETOOTH® supports an asynchronous data channel, three synchronous voice channels at 64 kbps, or simultaneous asynchronous data and synchronous voice channels. The asynchronous channel can support an asymmetric link of 721 kbps in either direction and 57.6 kbps in the return direction, or a 432.6-kbps symmetric link.
The application software is embedded in the device that operates an application over the BLUETOOTH® protocol stack. This software allows the PDA, mobile phone, or keyboard to function properly in relation to the other BLUETOOTH® devices.
The present invention will now be described with reference to the attached figures. It should be understood that the server side of the present implementation would preferably be deployed on GL1010 type servers, but could also be employed on SC-3 or any other type servers, without departing from the invention.
As shown in FIG. 1 , in the Cable Replacement Mode, a BLUETOOTH®-enabled computer uses server drivers and prints as if the electronic device was physically connected to the printer.
In addition, as shown in FIG. 2 , documents may be printed by reference. Typically the documents are prepared and stored to the Web in PDL format (postscript/PCL5), PDF, Word, Excel, or PowerPoint. The SERVER is given the name of the file to print via a BLUETOOTH® connected device. The file is retrieved via the Internet or the Intranet and then is ripped and printed. This is ideal for handheld devices, the sole drawback is that SERVER print driver are required to prepare the files.
FIG. 3 illustrates the remote printing service associated with the present invention. Documents are prepared and stored to the Web in application format—such as Microsoft Word format with the “.doc” extension files. The SERVER driver is given the name of the file to print via a BLUETOOTH® connected device. The file is retrieved via the Internet or the Intranet and printed via an application—such as Microsoft Word®. The benefit of this method or system is that the print drivers are on the SERVER. One drawback associated with this embodiment is that the document may contain fonts not stored on the SERVER.
The following is listing of the applications contemplated by the present invention. Note, the following is by way of example and is not intended to limit the scope of the invention.
Three-in-one telephone: As shown in FIG. 4 , a three-in one telephone is disclosed. At home, the telephone functions as a portable telephone (fixed line charge). When on the move, the telephone functions as mobile telephone (cellular charge). And when the telephone comes within the range of another mobile telephone with built-in BLUETOOTH® technology it functions as a walkie-talkie (no telephony charge).
Internet Bridge: As shown in FIG. 5 , a user may use mobile computer to surf the Internet wherever they are, and regardless if they're cordlessly connected through a mobile telephone (cellular) or through a wire-bound connection (e.g. PSTN, ISDN, LAN, xDSL).
Interactive Conference: As shown in FIG. 6 , in meetings and conferences the user may transfer selected documents instantly with selected participants, and exchange electronic business cards automatically, without any wired connection.
Ultimate Headset: As shown in FIG. 7 , the user may connect its wireless headset to a mobile telephone, mobile computer, or any wired connection to keep the user's hands free for more important tasks when the user is at the office or in the automobile.
Ultimate Synchronizer: As shown in FIG. 8 , the ultimate synchronizer allows the user to automatically synchronize a desktop, mobile computer, notebook (PC-PDA and PC-HPC) and a mobile telephone. For instance, as soon as the user enters his office the address list and calendar in the notebook computer will automatically be updated to agree with the one in the user's desktop or vice versa.
Wireless cluster printing: As shown in FIG. 9 , print jobs are sent to a master printer. The master printer will then distribute the job among available printers using BLUETOOTH® communication. With this implementation, print jobs can be redirected if a device is down due to paper out, or a service problem. Additionally, the device will have dynamic load balancing to achieve the fastest output.
Wireless document distribution: As shown in FIG. 10 , a user walks up to the copier and scans the document. Provides the ability to receive a facsimile and redirect to laptop and PDA. The document is converted to PDF (or other format) and distributed to a laptop or PDA via BLUETOOTH®. One benefit associated with this method is that a user is given the ability to receive incoming facsimiles or documents on a laptop or PDA. A negative result is that transmission of large documents may take a while and client software is required to receive the document.
Wireless management: As shown in FIG. 11 , wireless management allows a device to broadcast events such as a warning message, i.e., paper out, toner low, and error condition (fuser error). Both a laptop and a PDA can be used to configure the device administration. In addition, BLUETOOTH® provides WAP interface for device management. Thus, an administrator may be mobile, that is not confined to a desk, for device management.
Wireless gateway: As shown in FIG. 12 , the wireless gateway allows access to the network from BLUETOOTH® enabled device (laptop, PDA) without the requirement of a LAN connection.
The general operation of a BLUETOOTH® enabled server device will now be discussed.
A BLUETOOTH® enabled server will generally operate in the following manner:
Step No. 1: Wait for signal: If a packet is not received from a client within a predetermined amount of time, the server triggers an expiration error and Step No. 1 is repeated. If a packet is received within the predetermined amount of time, the server sends an “Acknowledgment” (“ACK”) signal and progresses to Step No. 2.
Step No. 2: Wait for data: If a data packet is not received by the server within a predetermined amount of time, the server triggers an expiration error and proceeds to Step No. 6. If a data signal is received, the server progresses to Step No. 3.
Step No. 3: Verify Data: If an error is determined, the server sends an Non-Acknowledgment (“NACK”) signal and returns to Step No. 2 to wait for retransmission of the data. If the data is verified, the server continues on to Step No. 4. The present invention contemplates many methods for verifying correct data transmission, including CHECKSUM calculation.
Step No. 4: Valid Data or EOF Flag: If an end of file (“EOF”) flag is received, the server transmits a confirming EOF string back to the client and progresses to Step No. 6. If valid data is received, the server writes the data to an output file which may reside in memory, a disk storage medium, or any other commonly used storage media. The server then continues on to Step No. 5.
Step No. 5: ACK: Upon receiving valid data and not an EOF flag, the server sends an ACK signal to the client and the server continues on to Step 2 to continue transferring the data file. This method is repeated until the program is properly terminated or upon completion of the data to be transferred.
Step No. 6: Exit: Indicates a user or manufactured defined condition has been completed or signaled and the server terminates the executed algorithm and allows a newly entered command or data signal to be processed.
The operation of a BLUETOOTH® client will now be discussed.
Step No. 1: The client searches into the designated directory for an input file.
Step No. 2: The client sends a first signal, “RURdy” in the DataBuffer format. The DataBuffer format is:
enum DATATYPE {RURdy, file, URL};
MAX = 10240;
#pragma pack(1)
struct DataBuffer {DATATYPE dataType; //type of data being sent
long length;
//length of data
long xsum;
// data checksum value
char data[MAX];
//10KB data block itself
} *DBptr;
#pragma pack
xsum is calculated as: for (index =0; index <DBptr−>length; index++)
xsum+=long (DBptr −>data[index]);
Step No. 3: The client waits for a response from the server, typically either an ACK or NACK. If a NACK is received Step No. 2 is repeated. If an ACK is received, the client progresses on to Step No. 4.
Step No. 4: The client reads the data from the input file.
Step No. 5: The client sets up the DataBuffer and transmits the packet to the server.
Step No. 6: The client then waits for a four character string response, ACK/NACK. If Nack, the client goes to Step 4. If ACK, the client continues on to Step No. 7.
Step No. 7: If the client has reached EOF (Determined from Step No. 4), the client, write datablock contains “FINISH” and is transmitted to the server. The client then proceeds to Step No. 8. If the client has not reached the EOF, the client returns to Step No. 4 and continues the above listed steps until properly terminated.
Step No. 8: The client terminates transmission of data with the server.
BLUETOOTH® Printing
In one particular aspect of the present invention, a BLUETOOTH® Printing system is contemplated to support printing from a PC or other client device to a network controller over a BLUETOOTH® wireless network. A major design goal of the present system is achieve network transparency, i.e. during normal every day usage a user should have no specific awareness of BLUETOOTH® as the communications channel. Rather, to the user, the connection should appear indistinguishable to a direct printer connection to the client device, i.e. a hard-wired serial or USB connection. To facilitate this functionality, the invention includes a port monitor DLL. As shown in FIG. 13 , the present port monitor 100 is incorporated into the Windows Spooler System 102 that is responsible for opening a communications channel between the user-mode print spooler and the kernel-mode port driver. In the preferred embodiment, the kernel mode port driver resides on a separate machine. A BLUETOOTH® Service application, shown in FIG. 13 as TBTSVC 108 , is a program that runs on the network controller to provide the port monitor 100 with an indirect interface to the port driver.
FIG. 13 illustrates the relationship between the port monitor 100 , the TBTSVC 108 the Windows system components 102 , 104 , and BLUETOOTH® software 106 . FIG. 13 also illustrates the flow of data through the BLUETOOTH® system. A print job originates in the Spooler 102 . The Spooler 102 directs the port monitor 100 to open a specified port. For example, a directly-connected printer on a machine's parallel port would be opened by the port monitor 100 using a “CreateFile” function with a file name argument of “LPT1.” The Spooler 102 invokes the port monitor 100 when a printer has been configured to use a port with a name containing a prefix of “TBP”. Once the port is opened, the Spooler 102 sends data to the printer via the port monitor 100 . The port monitor 100 transmits the data to the server using a WriteFile function. When the Spooler 102 has processed all the data it informs the port monitor 100 and the port monitor 100 closes the port and disconnects the virtual COM port connection. A print job operation in the present print monitor 100 deviates from the normal operation in two important respects. First, before opening a port, the print monitor 100 uses the BLUETOOTH® software 106 to establish a connection between a local virtual COM port and a remote virtual COM port on the server. Second, before a port is closed, the print monitor 100 breaks the virtual COM port connection to the server.
On the server, as shown in FIG. 14 , when the system is booted, TBTSVC 108 is automatically executed. It opens a virtual COM port and “listens”, i.e. waits, for data to arrive. When it detects a new print job it opens the local default printer and writes print data to it. When TBTSVC receives an end-of-data packet it closes the local printer and returns to its initial state, i.e. listening for data. The present BLUETOOTH® Printing system is a “client/server” architecture. The port monitor 100 (called “TBTMON”) is the client element of the architecture. The BLUETOOTH® Service application (called “TBTSVC” 108 , an NT service application) is the server element of the architecture. TBTSVC 108 is a passive receiver. It is essentially idle while it is waiting for a connection from a client port monitor 100 . Once the connection is established TBTSVC 108 creates a local print job. It then continues treading data from the connection and writing it to the printer until and end-of-data notification is received. Upon receiving the end-of-data notification TBTSVC 108 closes the print job.
Several requirements influence the direction the design of TBTSVC 108 . TBTSVC 108 is preferably intended to support the Toshiba BLUETOOTH® Card, manufactured by the present assignee. This card is reputed to be the industry leader (at least in terms of market share) and is OEM'ed by Toshiba from Digianswer. A BLUETOOTH® stack is included with the installation of the card's drivers. Digianswer supports a Software Development Kit (SDK) that provides an interface to the BLUETOOTH® stack. This provides third parties with a convenient mechanism to utilize BLUETOOTH® communications. Therefore TBTSVC 108 will utilize the BLUETOOTH® COM interface developed by Digianswer.
TBTSVC 108 needs to be automatically executed when the print server machine is booted. Since the server (preferably a GL1010 server) is preferably running a version Windows NT as its operating system, the objective is achieved by making TBTSVC 108 a service type application. Service applications are notoriously difficult to debug so a special “debug” mode will be implemented. When run in this mode, TBTSVC will omit calling the code that attaches the program to the Service Control Manager (SCM). This will allow the application to exercise most of its startup code, general-purpose routines, and profile handler code while being run in the debugger. It will also allow the service to be run on Windows 9x platforms.
TBTSVC 108 will be implemented in an object-oriented manner, having numerous benefits. One significant benefit in this case is that functionality for HCRP, BPP, and Serial interface support will be completed isolated from one another. The ultimate goal of TBTSVC 108 is to support the simultaneous operation of the BLUETOOTH® Hardcopy Cable Replacement Profile (HCRP) and the Basic Print Profile (BPP). In order to isolate the functionality of the profile handling code from another profile handler each profile handler will preferably be implemented as a separate object type. These object types will derive from a more basic profile handling class that supports methods common to the normal execution of the profile handlers, e.g. “Run” or “Shutdown”.
In accordance with the present invention, a file can be printed to a BLUETOOTH® printer by 1) printing from any application; and 2) selecting a printer driver that has been configured to print to a desired BLUETOOTH® port. If the destination printer assigned to the port is connectable then the file is transmitted to the printer and printed without further ado or user intervention. In this respect, printing to a BLUETOOTH® connected printer is no different than printing to a normal wired printer.
A flowchart for printing to a BLUETOOTH® printer is shown in FIG. 22 . At a first decision block, a determination is made as to whether the device is connectable. If it is not, then a “Configure Port” dialog box is displayed as shown in FIG. 21 , asking the user to select destination device. In this instance, only devices that are currently connectable are displayed. (In ‘Configure Port’ all devices from the Service Discovery Database (SDDB) are displayed, which could include devices that were connectable at another time but are not when the dialog box is displayed.) When data is being sent to the printer, each data packet contains a checksum to insure data integrity. After the print job is completed the receiver sends an acknowledgment message indicating whether the job was received successfully. If it was not, a message displays on the sender indicating there was a problem printing the job.
A BLUETOOTH® device is capable of supporting multiple connections and transfers simultaneously, and applies to both sender and receiver. There can be multiple connections between a single pair of devices, or a device can be connected to several different devices simultaneously. On the sending side each simultaneous connection requires a virtual serial port and a BLUETOOTH® port. For example, supporting three simultaneous connections requires three virtual serial ports and three BLUETOOTH® ports. On the receiving side, the number of simultaneous connections is determined by the number of virtual serial ports that are created. It should be noted that the while the interface itself supports multiple connections, a particular printer controller may or may not want to take advantage of this feature. For a controller that is capable of receiving and spooling multiple print jobs simultaneously this might be a good feature. A controller that does not have spooling capability might want to restrict the number of simultaneous connections to just one, and allow spooling to take place on the client.
The implementation in accordance with the present invention includes the following components: on the client side, port monitor 100 and an installation program; on the server side, NT service. The implementation is preferably based on the BLUETOOTH® Serial Port Profile (SPP). This is one of the profiles that are currently supported the existing BLUETOOTH® documentation and development tools. SPP allows a program to read and write over a BLUETOOTH® virtual serial port as if it were a regular serial port. From the user's perspective there are two aspects to BLUETOOTH® printing: (1) configuring the port to print to a BLUETOOTH® device, and (2) printing to a BLUETOOTH® device. Configuring the port is accomplished through the Control Panel/Printers/Properties menu on Windows. These property sheets allow a port to be added, modified, or deleted.
FIG. 15 shows the flowchart for the port configuration. After a port is properly configured, printing is accomplished the same way as the user prints to any device: that is, by printing from any application program and selecting a printer (actually a printer driver) that is configured for a BLUETOOTH® port. If the port is properly configured then no other actions are required of the user during printing. If the BLUETOOTH® device is not available then a dialog box displays allowing the user to select a BLUETOOTH® device, or cancel the print job. shows the steps of printing to a BLUETOOTH® printer in accordance with the present invention. The invention is preferably supported in any of the Windows family of operating system platforms, but the invention could be modified and adapted for any other type of platform, without departing from the invention.
The SPP enables a BLUETOOTH® virtual serial port to be created that can be accessed through the regular serial port I/O functions (read( ), write( ), open( ), etc.). A virtual serial port is created through the BLUETOOTH® configuration tool. (This is a program provided by BLUETOOTH®.) Once a port is created it is available for reading and writing by any program using the standard serial I/O functions. The SPP is implemented by products from Digianswer (a company that makes an SDK for BLUETOOTH®) as an object that works in conjunction with several other profiles and interfaces also provided by Digianswer. Together the profiles and interfaces provide a number of services and facilities required for BLUETOOTH® devices, beyond serial port emulation. The services include features such as: doing an ‘Inquiry’ to see what devices are available; establishing a BLUETOOTH® link between two devices; and a notification interface allowing the application to be notified when asynchronous BLUETOOTH® events occur.
The steps to configure for BLUETOOTH® printing on the client side are as follows. FIG. 17 is a flowchart showing the steps of the operation. A BLUETOOTH® serial port is created using the BLUETOOTH® configuration tool. A BLUETOOTH® port is created from Printers/Properties/Ports. A connectable BLUETOOTH® device is assigned to the BLUETOOTH® port. A BLUETOOTH® port is assigned to a printer driver. This configuration operation assumes that the printer driver is already installed. If not, that needs to be done using the standard Windows ‘Add Printer’ wizard. The BLUETOOTH® configuration tool in step #1 is a program provided by BLUETOOTH®. A BLUETOOTH® serial port is a system resource that is used internally by the port monitor and the BLUETOOTH® profiles. After the serial port is created no additional configuration for it needs to be done. Steps 2-4 are accomplished through the ‘Ports’ property dialog box in Control Panel/Printers/Properties. That dialog is shown in FIG. 18 , which is a standard printer configuration page displayed by the Windows spooler. There are three configuration functions: “Add Port”, “Delete Port”, and “Configure Port”.
When “Add Port” is clicked, the screen shown in FIG. 19 is displayed. This screen is also displayed by the Windows spooler. The options correspond to the print monitors that have been installed. To create a BLUETOOTH® port, select “Toshiba BLUETOOTH® Monitor” then press “Add Port . . . ”. The screen shown in FIG. 20 is displayed. This screen is displayed by the software of the present invention. Default port name is “TBPx”, where “x” is the next available number for which a Toshiba BLUETOOTH® port doesn't already exist. The screen of FIG. 20 shows all BLUETOOTH® devices that support the BLUETOOTH® SPP, and could include devices not made by the present assignee. The destination printer names displayed are the ‘friendly names’ of all known SPP servers. The list includes all devices from the Service Discovery Data Base (SDDB), which includes all devices that have been connectable either now or in the past.
Even though the “Add Port” procedure is invoked from the properties page for a particular printer, once a port has been created it is a system resource that is available to all printers. When “Configure Port” is pressed the screen shown in FIG. 21 is displayed. This is the same as the screen displayed in “Add Port”, without the port name field. When “Delete Port” is pressed a message box is displayed asking to confirm that the port should be deleted. The only configuration required on the server is to create the virtual serial port, using the BLUETOOTH® configuration tool from BLUETOOTH®. After the ports are configured, the user can print using the BLUETOOTH® SPP-based printing system, as described above.
Sometimes it is desired to send a URL of a file to the printer to print instead of the actual print data. The printer, upon receiving the URL, will go to the Internet to download the file and print. The file can either be in a printable format, postscript, or any other raw application. For raw application data to be printable, the application itself must be installed in the printer controller. The hardware realization is shown in FIG. 23 and a flow chart of the steps is shown in FIG. 24 . Currently, the following applications are supported: Word, Excel, PowerPoint, Acrobat, and HTML. This feature called PrintByReference is extremely useful for printing a pre-stored document on the Internet via a PDA. To print-by-reference, the client connects to the server TopAccess/PrintByReference page and sends a text string of the file URL. The PrintByReference module resides inside the server and consists of two components, the PrintByReference process and PrintByReference COM interface.
PrintByReference process is an executable component that would do the actual file download and print. The file download task use windows WININET API and currently support http servers only. The file print task use windows ShellExecute API to launch the applications printto verb. It is required that the supporting application (i.e. Words, Excel, PowerPoint, and Acrobat) has to be installed in the server. PrintByReference COM interface is a COM object that act as the interface between the TopAccess page and PrintByReference process. This interface allows the client to send the URL to the printer and also retrieve the current print status.
From the foregoing, it should be appreciated that the drawings illustrated herein are shown for the purpose of illustrating a preferred embodiment of the invention only and not for purposes of limiting same. Further, it should be appreciated that the present invention could easily be adapted for other wireless schemes such as in accordance with the IEEE 802.11 standard, and any other type of wireless communication, including radio frequency, microwave, infrared and any other such approach. Moreover, it should be understood that the present invention is suitable for use in connection with such devices, including but not limited to, mobile phones (cellular and digital), smart phones, pagers, messaging devices, personal digital assistants (PDAs), pocket PCs, personal computers (laptops and desktops), TV set top devices, other Internet enabled devices, etc. This list is not exhaustive, and is intended merely to illustrate a preferred embodiment of the present invention, and these and other variations could all be contemplated without departing from the invention.
As described hereinabove, the present invention solves many problems associated with previous type apparatuses. However, it will be appreciated that various changes in the details, materials and arrangements of parts which have been herein described and illustrated in order to explain the nature of the invention may be made by those skilled in the are within the principle and scope of the invention will be expressed in the appended claims.
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The present invention enables users to interface with a wide range of computing and telecommunication devices seamlessly without a cable connecting the devices. As such, the present invention allows for the replacement of the many proprietary cables that connect one device to another with one universal short-range radio link. The typical BLUETOOTH® system consist of four basic components: a radio (RF section) that receives and transmits data and voice; a baseband or link control unit that processes the transmitted or received data; link management software that manages the transmission; and supporting application software. Electronic devices incorporating BLUETOOTH® technology will replace RS-232, parallel, Universal Serial Bus (USB), and other types of cables with a single, standard wireless connection. BLUETOOTH® radio technology will also provide a universal bridge to existing data networks, a peripheral interface, and a mechanism to form small private ad hoc groupings of connected devices away from fixed network infrastructures.
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This is a continuation-in-part application of U.S. application Ser. No. 13/494,877, filed on Jun. 12, 2012, now U.S. Pat. No. 8,852,291, issued on Oct. 7, 2014.
TECHNICAL FIELD
The present invention relates generally to method of making a suspension-type gel cushioned liner to be worn over an amputee's residual limb regardless of the amputation being a leg amputation below-the-knee, BTK, or above-the-knee, ATK, but could also relate to an arm amputation below-the-elbow, BTE, or above-the-elbow, ATE. The gel cushioned liner of the present invention is designed to create suction between the liner and a socket, which suction is enhanced by an annular seal designed to promote a more secure fit of the prosthesis to the residuum of the wearer while greatly reducing, if not eliminating, inhibited blood flow through the residuum caused by the annular seals and the associated manufacturing processes used to create them of current prior art liners rendering such liners uncomfortable.
BACKGROUND
Over the course of the last several decades, various methods of suspending prostheses to the residual limb of an amputee were invented. One in particular involved a docking means that included a distal attachment fabricated into the distal end of an elastomeric interface or liner which was rolled onto the residual limb. After the interface was rolled onto the limb, the distal attachment would engage a locking means built into the socket of the prosthesis thereby locking the prosthesis on the patient's limb. This system became a standard in the industry. Manufacturers began producing these interfaces or liners with a fabric layer on the outer surface of the interface to help increase both the durability and ease of insertion into the sockets.
Further advancements were found in suspending the prostheses to a residual limb by creating an airtight seal between the liner mounted on the residual limb of the patient and the socket of the prosthesis to hold the prosthesis on the limb by suction. In some prostheses, one-way expulsion valves were located proximate to the distal end of the socket to expel any remaining air between the liner and the socket and thus create a more effective suspension of the prosthesis. Other prostheses included an evacuation pumping system attached to the distal end of the socket to evacuate the interstitial area between the liner and socket. When the prosthesis is fitted tightly to the limb, the patient feels more secure and perceives the prosthesis to be lighter. A tightly fitted prosthesis gives the amputee the feeling that the prosthesis is more of an extension to the residual limb, not just an addition. In order to enhance the evacuation of air out of the interstitial area of the prostheses, the interface or liner was lined with a fabric on the outer surface thereof to act as a wicking device for the air to travel through and out of the socket. Historically, the liner would have fabric on the external portion of the liner, and these liners are often produced anywhere from 12 inches in length to 20 inches in length. If a below the knee amputee has a limb 6 inches long from the knee joint, the socket would extend the medial and lateral walls a little more proximal, and because of knee flexion the liner may extend another 2-8 inches above the knee. In order to create a seal with the suspension sleeve, the sleeve must extend beyond the liner an additional 2-3 inches to seal against the skin. The added bulk and additional length increase that are associated with this method of using a suspension sleeve to create this suction suspension are two major factors developers have sought for many years to overcome.
To further enhance and maintain the suction created in suspension liners, annular seals have been incorporated into the liners to act as an elastic band around the residuum of the amputee. One example of such a suspension liner is disclosed in U.S. Pat. No. 6,508,842 to Caspers, incorporated herein by reference. Caspers discloses a suspension liner. As best illustrated in FIG. 18, the suspension liner includes urethane liner 92 having an outer fabric cover 130 with an annular seal 140. As disclosed in col. 13, lines 60 and 61, the annular seal is made from the same material as layer 92. As disclosed in col. 14, lines 1-10, the annular seal 140 may be an extension of liner 92 passing through the fabric cover 130. The Caspers invention is typical of a vacuum pumping type suspension system wherein the annular seal 140 acts as an elastic band around the residuum of the amputee. Another example of this type of suspension liner is disclosed in U.S. Pat. No. 8,034,120 to Egilsson, et al. incorporated herein by reference. Egilsson, et al. disclose a suspension liner 310 as best illustrated in FIGS. 45-47 and disclosed in col. 11, line 44 through col. 14, line 26. As disclosed in column 12, lines 41-43, the embodiment of FIGS. 45-47 is similar to the embodiment of FIGS. 43 and 44. The liner includes two tubular textile sections, a first section 312 and second section 314, defining a continuous profile 324. The Klasson patent (U.S. Pat. No. 4,923,474) is referenced in the Egilsson, et al. patent at col. 5, lines 37-58 as a prior art example of how an outer textile cover is molded to an inner layer of silicone. The Klasson molding technique is applied in the manufacture of the embodiment shown in FIGS. 45-47. The textile sections 312 and 314 (which are comparable to textile sections 212 and 214 of FIGS. 43 and 44) are secured to each other along seam 326. As disclosed in col. 11, lines 49-51, the first material segment 212 of FIGS. 43 and 44 may have stiffness greater than the stiffness of the second material segment 214. This would imply that material segment 312 of FIG. 45 has a greater stiffness than material segment 314. As disclosed in col. 13, lines 44-55, during the molding process, silicone is squeezed through the first material section. As disclosed in col. 13, lines 56-62, the embodiment of FIG. 45 may include a single layer of silicone instead of the double layers 324 and 326 as shown in FIG. 47. Although material segment 312 has a greater stiffness than segment 314, does not necessarily mean that the number of stitches per centimeter is greater in segment 312. Just the opposite is shown. Egilsson et al. also recognize that the profile of the seals is not limited to arcuate or curvilinear, but may be substantially linear as disclosed in col. 12, lines 36-40.
Although the prior art inventions discussed above have benefited amputees by enhancing the suction effect of the liner to the limb of the amputee, they do have certain drawbacks. One major problem associated with such suspension liners is that the annular seals are restricted by the stiffness of the fabrics extending through the seals during the molding process. Such annular seals are limited in deformation and elongation due to the confining embedded fabric and therefore cause the seals to compress the residuum in the adjacent annular region. Horizontal seams stitched across the transverse axis of such prior art to hold different material sections together can also cause compression and discomfort in the residuum. Such prolonged compression actually squeezes the limb thereby inhibiting the flow of blood which leads to irritation not to mention other difficulties especially if the amputee is diabetic, hypertensive, arthritic, etc.
As discussed above, when the prosthesis is fitted tightly to the limb, the patient feels more secure and perceives the prosthesis to be lighter. A tightly fitted prosthesis gives the amputee a more comfortable feeling that the prosthesis is more of an extension to the residual limb, not just an addition. However, the addition of one or several annular seals or seams to the suspension liner inhibiting the flow of blood detracts from such a comfortable feeling especially during the course of a day where the residuum may swell and contract from everyday ambulation.
Maximum comfort is a critical component to the amputee (and consequentially, to their prosthetist) during their search for the correct prosthetic liner. Thus, there is still a need in the art for a prosthetic liner which overcomes the deficiencies of the prior art. As such, the present invention provides a solution to such problems as will be described hereafter.
BRIEF SUMMARY OF THE INVENTION
The method of making the gel liner of the present invention incorporates fabric on its outer surface except in a portion of at least one annular seal that is free of any fabric constrictions, at least, on its outer surface.
By stating that the at least one annular seal is free of any fabric constrictions on its outer surface is intended to mean that there may be fabric embedded or partially embedded within the annular seal. However, the section of fabric embedded or partially embedded within the annular seal is selected, as will be discussed hereinafter, to not inhibit deformation in the radial direction and/or elongation in the axial direction of the annular seal when donning or during normal ambulation of the wearer or during adjustment of the liner in response to discomfort of the liner during ambulation. In other words, by providing the annular seal free of any constricting fabric, as the liner is donned, the amputee will be able to stretch the seal portion of the liner to the extent necessary to allow the flow of blood through the residuum for the proper level of comfort. An important aspect of the present invention is that the annular seal portion is free to elongate in the axial direction as it is deformed in the radial direction. Thus, as the amputee ambulates during the course of a day, the unconstrained annular seal will be able to deform and elongate freely between the residuum and socket, thereby relieving any discomfort that would otherwise be caused by the prior art seals compressing the residuum too tightly inhibiting the flow of blood. Should the wearer experience discomfort due to inhibited blood flow, the liner could easily be adjusted lengthwise by stretching the seal to the extent necessary for maximum comfort without sacrificing the level of suction necessary for the above mentioned tight fit.
While the embodiments illustrated in the parent application included unconstrained annular seals wherein the fabric is either embedded in the gel layer or melted in the gel layer, the present invention also includes embodiments wherein the fabric layer is only partially embedded in the gel layer as will be explained hereinbelow. These embodiments also facilitate the insertion of the donned liner into a socket while maintaining an adequate seal with the socket interior during ambulation.
BRIEF DESCRIPTIONS OF THE DRAWINGS
FIG. 1 is a vertical sectional view of a first embodiment of the prosthetic liner of the present invention with an intermediate annular seal located toward the distal end of the liner having fabric embedded within the annular seal.
FIG. 2 is a vertical sectional view of a second embodiment of the prosthetic liner of the present invention with an intermediate annular seal located toward the distal end of the liner and being free of fabric within the annular seal.
FIG. 3 is a perspective view of a one-piece tubular fabric layer having an intermediate section between distal and proximate sections initially used to manufacture the liners of the first or second embodiments of the present invention.
FIG. 4 is a vertical sectional view of a third embodiment of the prosthetic liner of the present invention with the annular seal located toward the proximal end of the liner.
FIG. 5 is a sectional view of a male/female mold in which the prosthetic liner of the first, second and third embodiments of the present invention can be manufactured.
FIG. 6 is a vertical sectional view of a fourth embodiment of the prosthetic liner of the present invention with an alternative annular seal located toward the distal end of the liner.
FIG. 7 is a vertical sectional view of a fifth embodiment of the prosthetic liner of the present invention with the alternative annular seal located toward the proximal end of the liner.
FIG. 8 is a sectional view of a male/female mold in which the fourth and fifth embodiments of the prosthetic liner with the alternative seal of the present invention can be manufactured.
FIGS. 9 and 9 a are vertical sectional views of a sixth embodiment of the prosthetic liner of the present invention similar to the first embodiment except that the fabric of the intermediate section is partially embedded within the annular seal as illustrated in FIG. 9 a.
FIG. 10 is a perspective view of a one-piece tubular fabric layer of a seventh embodiment of the present invention having only proximal and distal sections and with an optional thickened distal end for a distal insert initially used to manufacture the liner of the present invention.
FIG. 11 is a sectional view of the seventh embodiment of the prosthetic liner of the present invention with the fabric of the proximal section partially embedded within the annular seal as illustrated in FIG. 9 a.
FIG. 12 is a partial sectional view of the distal end of the first through seventh embodiments depicting an encircled distal region in which a distal insert is attached.
FIG. 12 a is an enlarged cross-sectional view of a first embodiment of a distal insert that can be molded in the distal end of any of the liners of the present invention.
FIG. 12 b is an enlarged cross-sectional view of a second embodiment of a distal insert that can be molded in the distal end of any of the liners of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1-4 , first and second embodiments of the liner ( 1 ) of the present invention is made to initially include a one-piece tubular fabric “sock” structure ( 2 ) that includes a closed distal end section ( 8 ), an open proximal end section ( 3 ) and at least one intermediate section ( 7 ). As illustrated in FIG. 1 , the finished liner ( 1 ) made by the molding process of the present invention is designed to have an outer tubular fabric ( 4 ) and ( 5 ) with annular seal ( 12 ) and gel interface ( 13 ) as an integral structure. The outer tubular fabric ( 4 ) and ( 5 ) is made as a one-piece tubular fabric as shown in FIG. 3 . It can be made using a computerized flat-bed knitting machine or any other conventional knitting machinery of the type such as disclosed in U.S. Pat. No. 7,363,778 incorporated herein by reference. The flat-bed knitting style allows the one-piece tube to taper (grow) gradually from distal end to the proximal end and match the exact shape of the standard prosthetic liner. The computerized options allow the stitch cams to be tightened or loosened throughout any portion of the sock structure ( 1 ) depending on how much permeability is desired, and further allows different yarns or other materials such as nylon, meltable nylon, polyester, meltable polyester, meltable polyethylene, meltable polypropylene, Lycra, etc. to be introduced at any point in the knitting process. These type of knitting machines also allow the potential for knitting a much thicker, more tightly knitted fabric portion at any point in the sock and quickly transition to a very loose knit, more flaccid fabric portion or transition to any other desired knitted fabric portion. Referring to FIG. 3 , the one-piece tubular fabric “sock” structure ( 2 ) of the present invention is made by programming the knitting machine to first knit a distal portion ( 5 ) preferably of a mixture of Coolmax® Polyester and stretchable synthetic elastane such as Lycra® selected so as not to permit gel to bleed through the fabric during the molding process as will be discussed hereinafter. The knitting machine may also be programmed to knit the distal portion ( 5 ) with an optional thicker portion ( 6 ) as illustrated in FIG. 3 having a thickness, for example, of (0.05″-0.50″ or about 1.27 mm-12.7 mm) as an optional “reinforced” fabric distal area to reduce pistoning at the distal end of the liner and to allow the incorporation of a distal insert and locking pin thereto should it be desired to manufacture a combination locking liner/suction suspension system. The tubular fabric structure can be made to have roughly the same stretch characteristics as the traditional ALPS Beige Fabric liner, having Longitudinal Stretch of 5%-180%, and Transverse Stretch of 50%-250%. After making the distal portion ( 5 ) of the sock, the knitting machine can be programmed to knit the intermediate portion ( 7 ) which is embedded within the annular seal ( 12 ) by selecting a yarn and stitch per inch combination that is substantially less “stiff” than the distal portion ( 5 ) and proximal portion ( 4 ) so that the intermediate portion ( 7 ) will not substantially constrict the deformation of the annular seal in the radial direction or elongation of the annular seal in the longitudinal and transverse directions when the fibers remain embedded therein as illustrated in FIG. 1 , or will not constrict the deformation of the annular seal in the radial direction or elongation of the annular seal in the longitudinal or transverse directions when the fibers are melted and blended within the annular seal as illustrated in FIG. 2 . Preferably, the knitting machine is programmed to have the intermediate portion ( 7 ) be made of meltable fibers, such as meltable nylon fibers, meltable polyester fibers, meltable polyethylene, meltable polypropylene, etc. that will melt at a predetermined temperature, and with the stitch cams adjusted to have fewer stitches per inch whereby gel would flow freely through the intermediate portion ( 7 ). The meltable fibers will melt and blend with the gel should the temperature of the gel be selected above the melting temperature of the meltable fibers during the molding process as will be discussed hereinbelow. It must be pointed out that in order for this to occur, the meltable fiber is selected to have a melting temperature within the tolerable temperature limits of the gel itself. In other words, the melting temperature of the gel must be lower than the melting temperature of the fibers of the intermediate portion ( 7 ), but could withstand higher temperatures than the melting temperature of the fibers. However, the present invention will perform equally well if the temperature of the gel does not rise above the melting temperature of the fibers of the intermediate portion during the molding process if the fibers selected are of a less stiff (more flexible) yarn and seamlessly knitted in a loose stitch construction than the knit fabric in the upper or lower portions of the invention. The structural integrity of the fibers embedded therein may remain, as illustrated in FIG. 1 , and will permit adequate movement of seal ( 12 ) when deformed between an amputee's stump and the inner surface of a socket but will not add additional constriction due to the combination of the less rigid yarn that is seamlessly knitted in a loose stitch construction to allow uninhibited blood flow. Following the intermediate portion, the knitting machine could be programmed again to seamlessly transition back into a portion similar to the knitting of the distal portion ( 5 ) to complete the sock.
When the tubular sock is completed, the next step in the process is to install it into a molding machine ( 17 ) as illustrated in FIG. 5 . These types of molding machines are conventional as for example, disclosed in U.S. Pat. No. 7,001,563 incorporated herein by reference. The molding machine includes a male core component ( 9 ) and a female component ( 10 ) and annular space ( 11 ) when the two components are mounted together. The knitted sock ( 2 ) is inverted prior to being mounted over the male component ( 9 ). The male component is then inserted into the female component and the system is sealed and ready for insertion of molten gel into space ( 11 ) between the two components. As the gel is inserted, it is adhered to the inner surface (now facing outward) of the fabric layer distal and proximal portions ( 4 ) and ( 5 ) without any bleed-through to the outer surface (now facing inward) of these portions. However, as the molten gel reaches the intermediate portion ( 7 ), it freely extrudes through the fabric interstices to the outer surface thereby encompassing the intermediate fabric portion. As discussed above, if the temperature at which the fibers of the intermediate fabric portion ( 7 ) melt is less than the temperature of the molten gel, the fibers will melt and blend with the gel. If the temperature at which the fibers of the intermediate fabric portion ( 7 ) melt is greater than the temperature of the molten gel, the fibers will be maintained and be embedded within the gel. Thus, after the intermediate fabric portion is engulfed with the molten gel, the fibers will either melt and blend with the molten gel, or be embedded therein, to form a substantially constriction-free seal ( 12 ). When the molded liner is cooled and removed from the molding machine, it is reverted to have the fabric covered portions facing outward. As shown in FIG. 1 or 2 , the resulting seal ( 12 ) has an outer surface coextensive with the outer surfaces of the proximal and distal fabric portions ( 4 ) and ( 5 ). However, the outer surface of the seal ( 12 ) could extend slightly beyond the outer surface of fabrics ( 4 ) and ( 5 ) by modifying the male component ( 9 ) to have a slight recess to allow for a thicker seal. Furthermore, the location of the seal could be adjusted as, for example, illustrated in FIG. 4 closer to the proximal end of the liner by programming the knitting machine accordingly.
Referring to FIGS. 6-8 , fourth and fifth embodiments are illustrated similar to the first embodiment except that it has a raised bead shaped seal ( 14 ) formed by the modified male component ( 15 ) illustrated in FIG. 8 . The male component includes recesses ( 16 ) which receive molten gel during the molding process which, when cooled, results in a constriction-free seal as shown in FIG. 6 or 7 . The male component 15 could also be modified such that the seal ( 14 ) is located towards the proximal end of the liner as illustrated in FIG. 7 .
Referring to FIG. 9 , a sixth embodiment is illustrated similar to the first embodiment of FIG. 1 except that the fabric ( 24 ) of the intermediate section ( 12 ) is only partially embedded in the annular seal as illustrated in FIG. 9 a . The one-piece tubular fabric is knitted in the same manner as in the first embodiment with the exception that during the molding process, the threads of the fabric are coated only on the sides thereof that are not in contact with the male component of the molding machine. This is accomplished by controlling the flow, pressure and temperature of the inserted gel during the molding process such that the gel does not completely engulf the fabric threads but leaves the surface of the threads interfacing with the male component uncoated. Since the threads of the fabric are partially embedded in the gel layer, Applicants have found that this embodiment reduces the tackiness of the outer surface of the annular seal ( 12 ) which facilitates the insertion of the liner into a socket after being donned, but still provides a sufficient seal between the liner and socket.
Referring to FIGS. 10 and 11 , a seventh embodiment of the present invention ( 22 ) is illustrated having a one-piece tubular fabric ( 18 ). The one-piece tubular fabric ( 18 ) does not include an intermediate section. It includes a proximal section ( 19 ) and a distal section ( 20 ) which may have an optional thickened portion ( 21 ) should this embodiment have a distal insert attached thereto. In this embodiment, the entire proximal section ( 25 ) serves as an annular seal. The distal section ( 20 ) and optional distal end ( 21 ) are knitted in the same manner as the distal and optional sections ( 5 ) and ( 6 ) of the embodiment illustrated in FIG. 3 . However, the entire proximal section ( 19 ) is knitted in the same manner as the intermediate section ( 7 ) of the first embodiment illustrated in FIG. 3 of the present invention, i.e., after making the distal portion ( 20 ) of the sock, the knitting machine can be programmed to knit the entire proximal portion ( 19 ) by selecting a yarn and stitch per inch combination that is substantially less “stiff” and will not constrict the deformation or elongation of the annular seal ( 25 ), when the fibers are partially embedded in the gel layer ( 23 ) as illustrated in FIG. 9 a . Another advantage of this embodiment is that twisting of the donned liner within a socket is greatly reduced due to the extent of the annular seal ( 25 ).
The liner made by the process of the present invention provides an easy adjustable molding technique for manufacturing the liner because it starts with a one-piece liner. The gel interface of the preferred embodiment is covered with a tubular knit outer fabric layer except for the annular seal. The length of the annular seal of an intermediate section can be adjusted to approximately 0.5-3.0 inches and can be located anywhere along the length of the liner, or it can comprise the entire proximal section of the liner. Although not limited to any predetermined dimensions, the distal end can be adjusted to approximately 4-8 inches and the proximal section can be adjusted to approximately 10-14 inches. A great advantage of the process of the present invention is that the tubular fabric sock is initially knitted as a one-piece sock which, during the molding process, selectively may remain as a one-piece sock or become a two-piece fabric sock joined by the fabric-free annular seal simply by adjusting the temperature of the molten gel above or below the melting temperature of the fibers of the intermediate portion ( 7 ). This advantage saves manufacturing time by not having to knit separate multiple portions of the liner with different lengths, not having to secure multiple portions of the liner on the male component of the molding machine prior to injection, or not having to sew multiple portions of the liner together before mounting on the male component of the molding machine.
The liners of the present invention comprise a layer of elastomeric material ( 13 or 23 ) preferably of a type compatible with long periods of dynamic wearer contact. Such materials are known in the art and may include the following polymers, as well as gels which comprise them: silicones, polyurethanes; block copolymers such as styrene block copolymers, general non-limiting examples of which may include SEBS-, SEPS-, SEEPS-, SEEBS-, and other type styrene block copolymers. Further non-limiting examples of styrene block copolymers which may be useful in the liner of the present invention include so called “controlled distribution polymers,” such as, for example, those disclosed in U.S. Pat. No. 7,226,484; United States Patent Application Publication No. 20070238835; and United States Patent Application Publication No. 20050008669. Other potentially useful polymers may include certain so-called “crystalline” polymers, such as, for example, polymers disclosed in U.S. Pat. Nos. 5,952,396; 6,420,475 and 6,148,830. The above list is non-limiting, and in general, the list of acceptable polymers and gels includes those known in the art to be useful for the fabrication of prosthetic liners. By the term “gel,” is meant a polymer mixed with a plasticizer, such as mineral oil. An example of current liner using such gel is the “EZ Gel liner, available from Alps South L.L.C.
The unconstricted, low-profile seal designs of the present invention create a complete seal against the interior socket while permitting unconstricted deformation and elongation of the seal resulting in a more comfortable fit to a user. The fully knit fabric covering acts distally as a wick to draw any air inside the prosthesis to the outside of the closed system whether using a socket having a one-way valve in the distal end thereof, or a more elaborate suctioning system. The fabric covering of each embodiment acts both proximally and distally to facilitate ease of donning and doffing the liner.
As discussed above, the layer of cushioning material ( 13 or 23 ) could be a gel copolymer such as that sold by ALPS, silicone or polyurethane. The knitted tubular fabrics act to stabilize and cover the internal gel copolymer/silicone/polyurethane layer which exhibits stretch characteristics of 600%-2000% and a Modulus of 50-500 psi. against the residual limb. It is critical to note that in addition to the proprietary ALPS Gel noted above, many different inner materials could be used, including but not limited to: silicone, thermoplastic elastomers (triblock), copolymer Styrenic gels, and polyurethane gels. The fabrics utilized would likely demonstrate longitudinal stretch characteristics of 5% to 180%, and transverse stretch characteristics of 50% to 250%, and could be between 0.30 mm and 1.5 mm in thickness.
As illustrated in FIGS. 3 , 10 and 12 , the respective embodiments of the present invention can be modified to have thicker portion ( 6 ) or ( 21 ) such that the addition of a distal insert illustrated in FIGS. 12 , 12 a and 12 b can be molded into or onto the distal end of the liner for attaching a locking pin thereto. While the distal inserts of FIGS. 12 a and 12 b are simply shown graphically, they are not intended as limiting the present invention, wherein any well known insert could be employed.
The foregoing relates to the preferred exemplary embodiments of the invention, it being understood that other variants and embodiments thereof are possible within the spirit and scope of the invention, the latter being defined by the appended claims.
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A gel liner made by starting initially with a one-piece knitted tubular sock-shaped fabric having a closed distal end section of gel impermeable knitted fabric and an open proximal end section of gel impermeable knitted fabric and being a gel permeable loosely knitted fabric. Molding the liner to have a gel cushion layer on its interior surface with the gel passing through and partially embedding the yarns of the proximal fabric section with the outermost portions of the yarns free of gel to form at least one annular seal whereby the proximal end section forming a seal not inhibited in deformation and/or elongation by the fabric when the liner is worn thereby reducing or eliminating any twisting or discomfort of the liner during ambulation caused by the annular seal.
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This application claims the benefit of U.S. Provisional Application No. 60/088,988, filed Jun. 11, 1998.
FIELD OF THE INVENTION
The present invention relates to processes for the preparation of macrocyclic molecules containing anti-succinate residues which inhibit metalloproteinases such as aggrecanase, and the production of tumor necrosis factor (TNF). The anti-succinates are formed by an Ireland Claisen rearrangement of a silyl ketene acetal which proceeds with high stereoselectivity. The resultant compounds are then coupled with α-amino acids to give intermediates which can readily be converted to the desired macrocyclic inhibitors.
BACKGROUND
Metalloproteinases (MP) have been implicated as the key enzymes in the destruction of mammalian cartilage and bone. There is evidence that the pathogenesis of such diseases can be modified in a beneficial manner by the administration of MP inhibitors. (Wahl et al. Ann. Rep. Med. Chem. 25, 175-184, AP, San Diego, 1990). Tumor necrosis factor (TNF) is a cell associated cytokine which has been shown to be a primary mediator in humans and in animals, of inflammation, fever, and acute phase responses, similar to those observed during acute infection and shock. There is considerable evidence that blocking the effects of TNF with specific antibodies can be beneficial in a variety of circumstances including autoimmune diseases such as rheumatoid arthritis (Feldman et al, Lancet, 1994, 344, 1105) non-insulin dependent diabetes melitus, (Lohmander L .S. et al. Arthritis Rheum. 36, 1993, 1214-22) and Crohn's disease (Macdonald T. et al. Clin. Exp. Immunol. 81, 1990, 301). PCT International Publication No. WO97/18207 discloses novel macrocycles of formula (I) which act as inhibitors of MMPs, in particular aggrecanase and TNF-C, thereby preventing cartilage loss by inflammatory disorders involving TNF.
Among the most synthetically challenging are the macrocyclic analogs containing a succinate residue in which the 5(R), 6(S) stereochemistry is desired:
The previous synthesis of the 2,3-disubstituted succinate is described in Scheme 1. An acid halide is converted to its oxazolidinone derivative and the auxiliary directs the subsequent alkylation with t-butyl bromoacetate to afford the 5(R) stereocenter. The oxazolidinone group is removed using H 2 O 2 /LiOH. Treatment of the enolate of this acid intermediate with a triflate derivative of a di-alcohol protected at one terminus as the benzyl ether produces a succinate derivate. This intermediate, however, requires epimerization because the alkylation consistently favors the undesired syn product. In order to separate the epimerization products, the acid is esterified and subject to chromatography. Following separation, the acid is hydrolyzed and coupled with a variety of amino acids such as tyrosine or lysine which contain α-side chains amenable to cyclization. The benzyl group is removed by hydrogenation and the resulting alcohol converted to a bromide using carbon tetrabromide and triphenyl phosphine. Macrocyclization of the tyrosine or lysine derivative is accomplished using potassium carbonate in N,N-dimethylformamide. Cyclization of the lysine derivative may also be accomplished with phosgene, leading to a carbamate bridge in the macrocycle. The t-butyl group is deprotected using TFA to give the carboxylic acid, and if desired, the acid is converted to a hydroxamic acid by coupling with hydroxylamine.
The present invention describes a new and useful process for the preparation of these macrocycles, which employs a highly stereoselective Ireland-Claisen rearrangement to form the anti-succinate residue:
Generally, the production of anti-adducts requires either an E olefin and a Z enolate-E silyl ketene acetal or a Z olefin and an E enolate-Z silyl ketene acetal (J. Am. Chem. Soc. 1976, 98, 2868). The Claisen precursor of the present invention can be obtained by reacting an O-protected lithium 4-pentyn-1-ol (or a 4-halopentyne derivative) with an acyl chloride to give a propargylic ketone. Asymmetric reduction of the carbonyl with S-Alpine Borane® followed by hydride reduction of the alkyne yields the desired E-allylic alcohol. Acylation of the alcohol gives the scalemic ester used in the rearrangement.
The Claisen rearrangement proceeds with exceptional diastereoselectivity under the preferred conditions, eliminating the need for chromatography. The silyl ester product of the rearrangement can be isolated or immediately hydrolyzed with hydroxide to give the free acid which is then available for coupling with various α-amino acids. The compound which results from the subsequent manipulation of the chain terminus serves as the macrocyclization precursor.
If a derivative of tyrosine is used as the amino acid, the ring may be cyclized under basic conditions. This cyclization proceeds under the preferred conditions through the use of cesium carbonate in dimethyl sulfoxide and N,N-dimethylformamide. In similiar fashion, if the amino acid is a ω-protected lysine derivative, macrocyclization can be accomplished by reacting an acyclic alcohol and the deprotected amine with phosgene or an equivalent thereof in the presence of an acid scaventger to give a carbamate linkage.
Compounds of formula (IX) or (IX-a) result when amino acids derivatives such as tyrosine or lysine are coupled with the anti-succinate residues formed by a Claien rearrangement, and subsequently cyclized.
These macrocycles are converted to the corresponding carboxylic acids with KMnO 4 in the presence of NaIO 4 , or with ozone. If desired, the resultant acids can be converted to alternative chelators such as hydroxamic acids by activation of the carbonyl and subsequent treatment with hydroxylamine.
Production of the anti-succinate residue (Ib) poses significant synthetic challenges to large scale drug preparation. In order to prepare large quantities of the desired therapeutic agents, an economically viable preparation of the anti-succinate, which is practical for scale-up, is necessary. The present invention obviates the need for epimerization and tedious purification protocols. As a result, the production of these important compounds is more efficient and cost effective.
SUMMARY OF THE INVENTION
The present invention relates generally to processes for the preparation of compounds of the formula:
or salt forms thereof;
wherein:
D is para HO—C 6 H 4 — or P 1 —NR 11 —CH 2 CH 2 CH 2 —;
G is a halogen or —OP;
P is a suitable oxygen protecting group;
p 1 is a suitable nitrogen protecting group;
L is a leaving group selected from the group consisting of: chlorine, bromine, iodine, mesylate and tosylate;
R 1 is selected from the group consisting of:
C 1-5 alkyl substituted with 0-5 R 1a , —(CH 2 ) r —C 3-10 cycloalkyl substituted with 0-5 R 1a , and —(CH 2 ) r -aryl substituted with 0-5 R 1a ;
R 1a is selected independently at each occurrence from the group consisting of:
hydrogen, —CF 3 , —CF 2 CF 3 , —NR 1b R 1c , —Si(R 1d ) 3 , C 1-5 alkyl, C 3-10 cycloalkyl, and aryl substituted with 0-5 R 1e ;
R 1b and R 1c are selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 1d is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 haloalkyl, and aryl substituted with 0-5 R 1e ;
R 1e is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, —(CH 2 ) r —OR 1f , —OH, halo, —NH 2 , and —(CF 2 ) r CF 3 ;
R 1f is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 2 is selected from the group consisting of:
C 1-10 alkyl, C 3-10 cycloalkyl, and —(CH 2 ) r -phenyl substituted with 0-3 R 2a ;
R 2a is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, —(CH 2 ) r —OR 2b , —OH, halo, —NH 2 , and —(CF 2 ) r CF 3 ;
R 2b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 3 is selected from the group consisting of:
—OR 4 , —NR 5 R 6 , —NR 6 (OR 5 ), C 1-5 alkyl substituted with 0-3 R 3a , —(CH 2 ) r -aryl substituted with 0-5 R 3a , and —(CH 2 ) r -heterocyclic substituted with 0-3 R 3a ;
R 3a is selected independently at each occurrence from the group consisting of:
hydrogen, C 1-5 alkyl, halo, hydroxy, —O—(CH 2 ) r —R 3b , —(CH 2 ) r —C(O)R 3b , —(CH 2 ) r —SO 2 NHR 3b , —(CH 2 ) r —C(O)NHR 3b , —(CH 2 ) r —OC(O)R 3b , —(CH 2 ) r —NHSO 2 R 3b , aryl, —(CH 2 ) r —NHC(O)R 3b , and —(CH 2 ) r —C(O)OR 3b ;
R 3b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 4 is selected from the group consisting of:
hydrogen, C 1-10 alkyl, —(CH 2 ) r —C 3-10 cycloalkyl,
—(CH 2 ) r -heterocyclic, and —(CH 2 ) r -aryl substituted with 0-5 R 4a ;
R 4a is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, —(CH 2 ) r —OR 4b , —OH, halo, —NH 2 , and
—(CF 2 ) r CF 3 ;
R 4b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 5 is selected from the group consisting of:
C 1 -C 5 alkyl, —(CH 2 ) r —C 3 -C 10 cycloalkyl, —(CHR 5a Y) n —R 9 , —(CR 7 R 8 ) n —O—C(R 7 R 8 ) r —R 9 , —(CR 7 R 8 ) r —R 9 , and —(CR 7 R 8 ) r CONR 7 R 8 ;
R 5a is selected independently at each occurrence from the group consisting of:
hydrogen, C 1-10 alkyl substituted with 0-3 R 5b , —(CH 2 ) r -aryl substituted with 0-3 R 5b , and
—(CH 2 ) r —O—(CH 2 ) r -aryl substituted with 0-3 R 5b ;
R 5b is selected independently at each occurrence from the group consisting of:
hydrogen, halo, hydroxy, —OR 5c , —NHC(O)CH 3 , -aryl-(CH 2 ) r —NH 2 , -aryl-(CH 2 ) r -aryl, C 1-10 alkyl substituted with 0-3 R 5d , and —(CH 2 ) r -aryl substituted with 0-3 R 5d ;
R 5c is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 5d is selected independently at each occurrence from the group consisting of;
hydrogen, C 1-5 alkyl, —O—(CH 2 ) r —R 5e , —OH, halo, —NHC(O)CH 3 , and —C(O)NH 2 ;
R 5e is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 6 is selected from the group consisting of:
hydrogen, C 1 -C 10 alkyl, —(CH 2 ) r -aryl, —(CH 2 ) r —C(O)R 6a , —(CH 2 ) r -heterocyclic, and phenyl substituted with 0-5 R 6c ;
R 6a is selected independently at each occurrence from the group consisting of;
hydrogen, C 1-5 alkyl, —O—(CH 2 ) r —R 6b , —OH, halo, —NHC(O)CH 3 , and —C(O)NH 2 ;
R 6b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 6c is selected independently at each occurrence from the group consisting of:
halogen, NO 2 , —R 6d , and —O—(CH 2 ) r —R 6d ;
R 6d is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
Alternatively, R 5 and R 6 combine to form a 3 to 8 membered heterocyclic ring containing 1 to 3 additional heteroatoms selected from —O—, —NR 6 —, —S(O)p—, and —C(O)—, optionally fused to a phenyl ring;
R 7 and R 8 may be H or R 5a ;
Alternatively, R 7 and R 8 combine to form 3 to 7 membered heterocyclic ring substituted with 1-3 R 7a , containing 1-3 additional heteroatoms selected from —O—, —S(O)p-, and —NR 6 —, optionally fused to an aryl ring substituted with 0-3 R 7c ;
R 7a is selected independently at each occurrence from the group consisting of:
hydrogen, C 1-5 alkyl, C 3-5 cycloalkyl, hydroxy, halo, —OR 7b , —NHC(O)CH 3 , —C(O)NH 2 , and aryl;
R 7b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
R 7c is selected independently at each occurrence from the group consisting of;
hydrogen, C 1-5 alkyl, C 3-5 cycloalkyl, hydroxy, halo, —O(CH 2 ) r —R 7d , —NHC(O)CH 3 , —C(O)NH 2 , and aryl;
R 7d is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
R 9 is selected from the group consisting of:
hydrogen, C 1-5 alkyl, —C(O)OC 1-5 alkyl, —(CH 2 ) r -aryl substituted with 0-3 R 9a , and a 5 or 6 membered heterocyclic ring containing from 0 to 2 N, O or S(O)p, and substituted with 0-3 R 9a ;
R 9a is selected from the group consisting of:
—OH, —O—(CH 2 ) r —R 9b , —C(O)OR 9b , —NHR 10 and aryl;
R 9b is selected from the group consisting of:
C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
R 10 is independently at each occurrence H or C 1-10 alkyl substituted with 0-3 R 10a ;
R 10a is selected independently at each occurrence from the group consisting of:
hydrogen, C 1-10 alkyl substituted with 0-3 R 10b , and —(CH 2 ) r -aryl substituted with 0-3 R 10b ;
R 10b is selected independently at each occurrence from the group consisting of:
hydrogen, halo, hydroxy, —OR 10c , —NHC(O)CH 3 , —(CH 2 ) r —C(O)NH 2 , -aryl-NH 2 , and —SO 2 NH 2 ;
R 10c is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
R 11 is selected independently at each occurrence from the group consisting of:
hydrogen, C 1 -C 10 alkyl substituted with 0-3 R 11a ; and —(CH 2 ) r -aryl substituted with 0-3 R 11a ;
R 11a is selected independently at each occurrence from the group consisting of:
hydrogen, halo, hydroxy, —OR 11b , —NHC(O)CH 3 , —(CH 2 ) r —C(O)NH 2 , -aryl-NH 2 , and —SO 2 NH 2 ;
R 11b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
n is selected from 1, 2 and 3;
p is selected independently at each occurrence from 0, 1 and 2;
r is selected independently at each occurrence from 0, 1, 2, and 3;
Y is selected from the group consisting of:
—CONR 10 —, —NR 10 CO—, —SO 2 NR 10 —, —NR 10 SO 2 —, and a 5 membered heterocyclic ring; and
z is selected from 1, 2, 3, 4 and 5;
the process comprising:
(1) reducing of a compound of formula (II):
to form a compound of formula (III);
(2) acylating the compound of formula (III) to form a compound of formula (IV);
(3) contacting the compound of formula (IV) with a silylating agent in the presence of a suitable base, to form a compound of formula (IV-a), followed by treatment with hydroxide to form a compound of formula (V);
(4) coupling the compound of formula (V) with a compound of formula (VI):
to form a compound of formula (VII);
(5) deprotecting or activating, if necessary, the compound of formula (VII) to form a compound of formula (VIII) or (VIII-a);
(6) cyclizing a compound of formula (VIII) or (VIII-a) to form a compound of formula (IX) or (IX-a); and
(7) contacting the compound of formula (IX) or (IX-a) with a suitable oxidizing agent to form a compound of the formula (X) or (X-a).
DETAILED DESCRIPTION OF THE INVENTION
In a first embodiment, the present invention describes a process for the preparation of compounds of formula (VII):
or a form thereof;
wherein:
D is para HO—C 6 H 4 — or P 1 —NR 11 —CH 2 CH 2 CH 2 —;
G is a halogen or —OP;
—P is a suitable oxygen protecting group;
P 1 is a suitable nitrogen protecting group;
R 1 is selected from the group consisting of:
C 1-5 alkyl substituted with 0-5 R 1a ,
—(CH 2 ) r —C 3-10 cycloalkyl substituted with 0-5 R 1a , and —(CH 2 ) r -aryl substituted with 0-5 R 1a ;
R 1a is selected independently at each occurrence from the group consisting of:
hydrogen, —CF 3 , —CF 2 CF 3 , —NR 1b R 1c , —Si(R 1d ) 3 , C 1-5 alkyl, C 3-10 cycloalkyl, and aryl substituted with 0-5 R 1e ;
R 1b and R 1c are selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 1d is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 haloalkyl, and aryl substituted with 0-5 R 1e ;
R 1e is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, —(CH 2 ) r —OR 1f , —OH, halo, —NH 2 , and —(CF 2 ) r CF 3 ;
R 1f is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 2 is selected from the group consisting of:
C 1-10 alkyl, C 3-10 cycloalkyl, and —(CH 2 ) r -phenyl substituted with 0-3 R 2a ;
R 2a is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, —(CH 2 ) r —OR 2b , —OH, halo, —NH 2 , and —(CF 2 ) r CF 3 ;
R 2b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 3 is selected from the group consisting of:
—OR 4 , —NR 5 R 6 , —NR 6 (OR 5 ), C 1-5 alkyl substituted with 0-3 R 3a , —(CH 2 ) r -aryl substituted with 0-5 R 3a , and —(CH 2 ) r -heterocyclic substituted with 0-3 R 3a ;
R 3a is selected independently at each occurrence from the group consisting of:
hydrogen, C 1-5 alkyl, halo, hydroxy, —O—(CH 2 ) r —R 3b , —(CH 2 ) r —C(O)R 3b , —(CH 2 ) r —SO 2 NHR 3b , —(CH 2 ) r —C(O)NHR 3b , —(CH 2 ) r —OC(O)R 3b , —(CH 2 ) r —NHSO 2 R 3b , aryl, —(CH 2 ) r —NHC(O)R 3b , and —(CH 2 ) r —C(O)OR 3b ;
R 3b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 4 is selected from the group consisting of:
hydrogen, C 1-10 alkyl, —(CH 2 ) r —C 3-10 cycloalkyl, —(CH 2 ) r -heterocyclic, and —(CH 2 ) r -aryl substituted with 0-5 R 4a ;
R 4a is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, —(CH 2 ) r —OR 4b , —OH, halo, —NH 2 , and —(CF 2 ) r CF 3 ;
R 4b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 5 is selected from the group consisting of:
C 1 -C 5 alkyl, —(CH 2 ) r —C 3 -C 10 cycloalkyl, —(CHR 5a Y) n —R 9 , —(CR 7 R 8 ) n —O—C(R 7 R 8 ) r —R 9 , —(CR 7 R 8 ) r —R 9 , and —(CR 7 R 8 ) r CONR 7 R 8 ;
R 5a is selected independently at each occurrence from the group consisting of:
hydrogen, C 1-10 alkyl substituted with 0-3 R 5b , —(CH 2 ) r -aryl substituted with 0-3 R 5b , and —(CH 2 ) r —O—(CH 2 ) r -aryl substituted with 0-3 R 5b ;
R 5b is selected independently at each occurrence from the group consisting of:
hydrogen, halo, hydroxy, —OR 5c , —NHC(O)CH 3 , -aryl-(CH 2 ) r —NH 2 , -aryl-(CH 2 ) r -aryl, C 1-10 alkyl substituted with 0-3 R 5d , and —(CH 2 ) r -aryl substituted with 0-3 R 5d ;
R 5c is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 5d is selected independently at each occurrence from the group consisting of;
hydrogen, C 1-5 alkyl, —O—(CH 2 ) r —R 5e , —OH, halo, —NHC(O)CH 3 , and —C(O)NH 2 ;
R 5e is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 6 is selected from the group consisting of:
hydrogen, C 1-10 alkyl, —(CH 2 ) r -aryl, —(CH 2 ) r —C(O)R 6a , —(CH 2 ) r -heterocyclic and phenyl substituted with 0-5 R 6c ;
R 6a is selected independently at each occurrence from the group consisting of;
hydrogen, C 1-5 alkyl, —O—(CH 2 ) r —R 6b , —OH, halo, —NHC(O)CH 3 , and —C(O)NH 2 ;
R 6b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 6c is selected independently at each occurrence from the group consisting of:
halogen, NO 2 , —R 6d , and —O—(CH 2 ) r —R 6d ;
R 6d is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
Alternatively, R 5 and R 6 combine to form a 3 to 8 membered heterocyclic ring containing 1 to 3 additional heteroatoms selected from —O—, —NR 6 —, —S(O)p-, and —C(O)—, optionally fused to a phenyl ring;
R 7 and R 8 may be H or R 5a ;
Alternatively, R 7 and R 8 combine to form 3 to 7 membered heterocyclic ring substituted with 1-3 R 7a , containing 1-3 additional heteroatoms selected from —O—, —S(O)p-, and —NR 6 —, optionally fused to an aryl ring substituted with 0-3 R 7c ;
R 7a is selected independently at each occurrence from the group consisting of:
hydrogen, C 1-5 alkyl, C 3-5 cycloalkyl, hydroxy, halo, —OR 7b , —NHC(O)CH 3 , —C(O)NH 2 , and aryl;
R 7b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
R 7c is selected independently at each occurrence from the group consisting of;
hydrogen, C 1-5 alkyl, C 3-5 cycloalkyl, hydroxy, halo, —O(CH 2 ) r —R 7d , —NHC(O)CH 3 , —C(O)NH 2 , and aryl;
R 7d is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
R 9 is selected from the group consisting of: hydrogen, C 1-5 alkyl, —C(O)OC 1-5 alkyl, —(CH 2 ) r -aryl substituted with 0-3 R 9a , and a 5 or 6 membered heterocyclic ring containing from 0 to 2 N, O or S(O)p, and substituted with 0-3 R 9a ;
R 9a is selected from the group consisting of:
—OH, —O—(CH 2 ) r —R 9b , —C(O)OR 9b , NHR 10 and aryl;
R 9b is selected from the group consisting of:
C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
R 10 is independently at each occurrence H or C 1-10 alkyl substituted with 0-3 R 10a ;
R 10a is selected independently at each occurrence from the group consisting of:
hydrogen, C 1-10 alkyl substituted with 0-3 R 10b , and —(CH 2 ) r -aryl substituted with 0-3 R 10b ;
R 10b is selected independently at each occurrence from the group consisting of:
hydrogen, halo, hydroxy, —OR 10c , —NHC(O)CH 3 , —(CH 2 ) r —C(O)NH 2 , -aryl-NH 2 , and —SO 2 NH 2 ;
R 10c is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
R 11 is selected independently at each occurrence from the group consisting of:
hydrogen, C 1 -C 10 alkyl substituted with 0-3 R 11a , and —(CH 2 ) r -aryl substituted with 0-3 R 11a ;
R 11a is selected independently at each occurrence from the group consisting of:
hydrogen, halo, hydroxy, —OR 11b , —NHC(O)CH 3 , —(CH 2 ) r —C(O)NH 2 , -aryl-NH 2 , and —SO 2 NH 2 ;
R 11b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
n is selected from 1, 2 and 3;
p is selected independently at each occurrence from 0, 1 and 2;
r is selected independently at each occurrence from 0, 1, 2, and 3;
Y is selected from the group consisting of: —CONR 10 —, —NR 10 CO—, —SO 2 NR 10 —, —NR 10 SO 2 —, and a 5 membered heterocyclic ring; and
z is selected from 1, 2, 3, 4 and 5;
the process comprising:
contacting a compound of the formula (IV):
wherein the double bond is in the E configuration; with a silylating agent in the presence of a strong base to give a compound of formula (IV-a):
wherein R 12 is selected independently at each occurrence from C 1-6 alkyl and phenyl;
contacting the compound of formula (IV-a) with hydroxide to form a compound of formula (V):
coupling the compound of formula (V) with a compound of formula (VI):
to form a compound of formula (VII), or a salt form thereof.
In a preferred embodiment, the compound of formula (IV) is prepared by the process comprising:
reducing a compound of formula (II):
to form a compound of formula (III):
acylating the compound of formula (III) to form a compound of formula (IV).
In another preferred embodiment, P is tert-butyldimethylsilyl or methoxymethyl;
P 1 is tert-butyloxycarbonyl;
R 1 is C 1-5 alkyl;
R 2 is selected from the group consisting of:
C 1-10 alkyl, C 3-10 cycloalkyl, and —(CH 2 ) r -phenyl;
R 3 is —OR 4 or —NR 5 R 6
R 4 is selected from the group consisting of:
hydrogen, C 1-10 alkyl, —(CH 2 ) r —C 3-10 cycloalkyl, and —(CH 2 ) r -phenyl;
R 5 is selected from the group consisting of:
C 1-5 alkyl, —(CH 2 ) r —C 3-10 cycloalkyl, —CH 2 —CONHR 10 , —CH 2 —C(O)OC 1-5 alkyl, —CH 2 —CONR 7 R 8 , and —(CH 2 ) r -phenyl;
R 6 is selected from hydrogen or C 1 -C 10 alkyl;
R 7 and R 8 form a 6 membered saturated ring containing —O— or —NR 6 —;
R 10 is H or C 1-5 alkyl;
R 11 is selected from the group consisting of:
hydrogen, C 1 -C 10 alkyl, and phenyl;
r is selected from 0, 1, or 2; and
z is 2.
In a more preferred embodiment, the silylating agent is trimethylsilylchloride or t-butyldimethylsilylchloride;
the strong base is lithium diisopropylamide or lithium hexamethyldisilazide; and
coupling comprises contacting a compound of formula (V) with a compound of formula (VI) in the presence of a coupling agent selected from the group consisting of:
dicyclohexylcarbodiimide, carbonyldiimidazole, 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide, O-(1H-benzotriazol-1-yl)-N,N,N′,N′-tetra-methyluronium tetraflouroborate, benzotriazol-1-yl-oxy-tri-pyrrolidinophosphonium hexafluorophosphate and benzotriazol-1-yl-oxy-tris-dimethylamino-phosphonium hexafluorophosphate.
In an even more preferred embodiment,
R 1 is —CH 2 CH(CH 3 ) 2 ;
R 2 is —CH(CH 3 ) 2 ;
R 3 is selected from the group consisting of:
—OC 1-5 alkyl, —NHCH 2 C(O)OC 1-5 alkyl, —NHCH 2 C(O)NR 7 R 8 and —NHCH 2 C(O)NHCH 3 ; and
R 7 and R 8 are taken together to form a morpholine ring.
In a second embodiment, the present invention describes a process for the preparation of a compound of formula (X-a):
or a pharmaceutically acceptable salt form thereof,
wherein:
R 1 is selected from the group consisting of:
C 1-5 alkyl substituted with 0-5 R 1a , —(CH 2 ) r —C 3-10 cycloalkyl substituted with 0-5 R 1a , and —(CH 2 ) r -aryl substituted with 0-5 R 1a ;
R 1a is selected independently at each occurrence from the group consisting of:
hydrogen, —CF 3 , —CF 2 CF 3 , —NR 1b R 1c , —Si(R 1d ) 3 , C 1-5 alkyl, C 3-10 cycloalkyl, and aryl substituted with 0-5 R 1e ;
R 1b and R 1c are selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 1d is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 haloalkyl, and aryl substituted with 0-5 R 1e ;
R 1e is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, —(CH 2 ) r —OR 1f , —OH, halo, —NH 2 , and —(CF 2 ) r CF 3 ;
R 1f is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 3 is selected from the group consisting of:
—OR 4 , —NR 5 R 6 , —NR 6 (OR 5 ), C 1-5 alkyl substituted with 0-3 R 3a , —(CH 2 ) r -aryl substituted with 0-5 R 3a , and —(CH 2 ) r -heterocyclic substituted with 0-3 R 3a ;
R 3a is selected independently at each occurrence from the group consisting of:
hydrogen, C 1-5 alkyl, halo, hydroxy, —O—(CH 2 ) r —R 3b , —(CH 2 ) r —C(O)R 3b , —(CH 2 ) r —SO 2 NHR 3b , —(CH 2 ) r —C(O)NHR 3b , —(CH 2 ) r —OC(O)R 3b , —(CH 2 ) r —NHSO 2 R 3b , aryl, —(CH 2 ) r —NHC(O)R 3b , and —(CH 2 ) r —C(O)OR 3b ;
R 3b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 4 is selected from the group consisting of:
hydrogen, C 1 -C 10 alkyl, —(CH 2 ) r —C 3-10 cycloalkyl, —(CH 2 ) r -heterocyclic, and —(CH 2 ) r -aryl substituted with 0-5 R 4a ;
R 4a is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, —(CH 2 ) r —OR 4b , —OH, halo, —NH 2 , and —(CF 2 ) r CF 3 ;
R 4b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 5 is selected from the group consisting of:
C 1 -C 5 alkyl, —(CH 2 ) r —C 3 -C 10 cycloalkyl, —(CHR 5a Y) n —R 9 , —(CR 7 R 8 ) n —O—C(R 7 R 8 ) r —R 9 , —(CR 7 R 8 ) r —R 9 , and —(CR 7 R 8 ) r CONR 7 R 8 ;
R 5a is selected independently at each occurrence from the group consisting of:
hydrogen, C 1-10 alkyl substituted with 0-3 R 5b , —(CH 2 ) r -aryl substituted with 0-3 R 5b , and —(CH 2 ) r —O—(CH 2 ) r -aryl substituted with 0-3 R 5b ;
R 5b is selected independently at each occurrence from the group consisting of:
hydrogen, halo, hydroxy, —OR 5c , —NHC(O)CH 3 , -aryl-(CH 2 ) r —NH 2 , -aryl-(CH 2 ) r -aryl, C 1-10 alkyl substituted with 0-3 R 5d , and —(CH 2 ) r -aryl substituted with 0-3 R 5d ;
R 5c is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 5d is selected independently at each occurrence from the group consisting of;
hydrogen, C 1-5 alkyl, —O—(CH 2 ) r —R 5e , —OH, halo, —NHC(O)CH 3 , and —C(O)NH 2 ;
R 5e is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 6 is selected from the group consisting of:
hydrogen, C 1 -C 10 alkyl, —(CH 2 ) r -aryl, —(CH 2 ) r —C(O)R 6a , —(CH 2 ) r -heterocyclic and phenyl substituted with 0-5 R 6c ;
R 6a is selected independently at each occurrence from the group consisting of;
hydrogen, C 1-5 alkyl, —O—(CH 2 ) r —R 6b , —OH, halo, —NHC(O)CH 3 , and —C(O)NH 2 ;
R 6b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 6c is selected independently at each occurrence from the group consisting of:
halogen, NO 2 , —R 6d , and —O—(CH 2 ) r —R 6d ;
R 6d is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
Alternatively, R 5 and R 6 combine to form a 3 to 8 membered heterocyclic ring containing 1 to 3 additional heteroatoms selected from —O—, —NR 6 —, —S(O)p—, and —C(O)—, optionally fused to a phenyl ring;
R 7 and R 8 may be H or R 5a ;
Alternatively, R 7 and R 8 combine to form 3 to 7 membered heterocyclic ring substituted with 1-3 R 7a , containing 1-3 additional heteroatoms selected from —O—, —S(O)p-, and —NR 6 —, optionally fused to an aryl ring substituted with 0-3 R 7c ;
R 7a is selected independently at each occurrence from the group consisting of:
hydrogen, C 1-5 alkyl, C 3-5 cycloalkyl, hydroxy, halo, —OR 7b , —NHC(O)CH 3 , —C(O)NH 2 , and aryl;
R 7b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
R 7c is selected independently at each occurrence from the group consisting of;
hydrogen, C 1-5 alkyl, C 3-5 cycloalkyl, hydroxy, halo, —O(CH 2 ) r —R 7d , —NHC(O)CH 3 , —C(O)NH 2 , and aryl;
R 7d is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
R 9 is selected from the group consisting of: hydrogen, C 1-5 alkyl, —C(O)OC 1-5 alkyl, —(CH 2 ) r -aryl substituted with 0-3 R 9a , and a 5 or 6 membered heterocyclic ring containing from 0 to 2 N, O or S(O)p, and substituted with 0-3 R 9a ;
R 9a is selected from the group consisting of:
—OH, —O—(CH 2 ) r —R 9b , —C(O)OR 9b , NHR 10 and aryl;
R 9b is selected from the group consisting of:
C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
R 10 is independently at each occurrence H or C 1-10 alkyl substituted with 0-3 R 10a ;
R 10a is selected independently at each occurrence from the group consisting of:
hydrogen, C 1 -C 10 alkyl substituted with 0-3 R 10b , and —(CH 2 ) r -aryl substituted with 0-3 R 10b ;
R 10b is selected independently at each occurrence from the group consisting of:
hydrogen, halo, hydroxy, —OR 10c , —NHC(O)CH 3 , —(CH 2 ) r —C(O)NH 2 , -aryl-NH 2 , and —SO 2 NH 2 ;
R 10c is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
R 11 is selected independently at each occurrence from the group consisting of:
hydrogen, C 1 -C 10 alkyl substituted with 0-3 R 11a , and —(CH 2 ) r -aryl substituted with 0-3 R 11a ;
R 11a is selected independently at each occurrence from the group consisting of:
hydrogen, halo, hydroxy, —OR 11b , —NHC(O)CH 3 , —(CH 2 ) r —C(O)NH 2 , -aryl-NH 2 , and —SO 2 NH 2 ;
R 11b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
n is selected from 1, 2 and 3;
p is selected independently at each occurrence from 0, 1 and 2;
r is selected independently at each occurrence from 0, 1, 2, and 3;
Y is selected from the group consisting of:
—CONR 10 —, —NR 10 CO—, —SO 2 NR 10 —, —NR 10 SO 2 —, and a 5- membered heterocyclic ring; and
z is selected from 1, 2, 3, 4 and 5;
the process comprising:
cyclizing a compound of formula (VIII-a):
or an acceptable salt form thereof;
wherein:
R 2 is selected from the group consisting of:
C 1-10 alkyl, C 3-10 cycloalkyl, and —(CH 2 ) r -phenyl substituted with 0-3 R 2a ;
R 2a is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, —(CH 2 ) r —OR 2b , —OH, halo, —NH 2 , and —(CF 2 ) r CF 3 ;
R 2b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
to form a compound of formula (IX-a):
contacting the compound of formula (IX-a) with an oxidizing agent to form a compound of formula (X-a) or a pharmaceutically acceptable salt form thereof.
In a preferred embodiment, R 1 is C 1-5 alkyl;
R 2 is selected from the group consisting of:
C 1-10 alkyl, C 3-10 cycloalkyl, and —(CH 2 ) r -phenyl;
R 3 is —OR 4 or —NR 5 R 6
R 4 is selected from the group consisting of:
hydrogen, C 1-10 alkyl, —(CH 2 ) r —C 3-10 cycloalkyl, and —(CH 2 ) r -phenyl;
R 5 is selected from the group consisting of:
C 1-5 alkyl, —(CH 2 ) r —C 3-10 cycloalkyl, —CH 2 —CONHR 10 , —CH 2 —C(O)OC 1-5 alkyl, —CH 2 —CONR 7 R 8 , and —(CH 2 ) r -phenyl;
R 6 is selected from hydrogen or C 1 -C 10 alkyl;
R 7 and R 8 form a 6 membered saturated ring containing —O— or —NR 6 —;
R 10 is H or C 1-5 alkyl;
R 11 is selected from the group consisting of:
hydrogen, C 1 -C 10 alkyl, and phenyl;
r is selected from 0, 1, or 2;
z is 2;
cyclizing comprises contacting the free base of the compound of formula (XII-a) with phosgene or an equivalent thereof in the presence of an acid scavenger; and
the oxidizing agent is KMnO 4 in NaIO 4 or ozone.
In a more preferred embodiment, R 1 is —CH 2 CH(CH 3 ) 2 ;
R 2 is —CH(CH 3 ) 2 ;
R 3 is selected from the group consisting of:
—OC 1-5 alkyl, —NHCH 2 C(O)OC 1-5 alkyl, —NHCH 2 C(O)NR 7 R 8 and —NHCH 2 C(O)NHCH 3 ; and
R 7 and R 8 are taken together to form a morpholine ring;
cyclizing comprises contacting the free base of the compound of formula (XII-a) with phosgene or an equivalent thereof in the presence of an acid scavenger selected from the group consisting of:
triethylamine, diisopropylamine, and pyridine; and the oxidizing agent is ozone.
In an even more preferred embodiment, R 3 is —OCH 3 .
In a third embodiment, the present invention describes a process for the preparation of a compound of formula (X):
or a pharmaceutically acceptable salt form thereof;
wherein:
R 1 is selected from the group consisting of:
C 1-5 alkyl substituted with 0-5 R 1a , —(CH 2 ) r —C 3-10 cycloalkyl substituted with 0-5 R 1a , and —(CH 2 ) r -aryl substituted with 0-5 R 1a ;
R 1a is selected independently at each occurrence from the group consisting of:
hydrogen, —CF 3 , —CF 2 CF 3 , —NR 1b R 1c , —Si(R 1d ) 3 , C 1-5 alkyl, C 3-10 cycloalkyl, and aryl substituted with 0-5 R 1e ;
R 1b and R 1c are selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 1d is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 haloalkyl, and aryl substituted with 0-5 R 1e ;
R 1e is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, —(CH 2 ) r —OR 1f , —OH, halo, —NH 2 , and —(CF 2 ) r CF 3 ;
R 1f is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 3 is selected from the group consisting of:
—OR 4 , —NR 5 R 6 , —NR 6 (OR 5 ), C 1-5 alkyl substituted with 0-3 R 3a , —(CH 2 ) r -aryl substituted with 0-5 R 3a , and —(CH 2 ) r -heterocyclic substituted with 0-3 R 3a ;
R 3a is selected independently at each occurrence from the group consisting of:
hydrogen, C 1-5 alkyl, halo, hydroxy, —O—(CH 2 ) r —R 3b , —(CH 2 ) r —C(O)R 3b , —(CH 2 ) r —SO 2 NHR 3b , —(CH 2 ) r —C(O)NHR 3b , —(CH 2 ) r —OC(O)R 3b , —(CH 2 ) r —NHSO 2 R 3b , aryl, —(CH 2 ) r —NHC(O)R 3b , and —(CH 2 ) r —C(O)OR 3b ;
R 3b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 4 is selected from the group consisting of:
hydrogen, C 1 -C 10 alkyl, —(CH 2 ) r —C 3-10 cycloalkyl, —(CH 2 ) r -heterocyclic, and —(CH 2 ) r -aryl substituted with 0-5 R 4a ;
R 4a is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, —(CH 2 ) r —OR 4b , —OH, halo, —NH 2 , and —(CF 2 ) r CF 3 ;
R 4b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 5 is selected from the group consisting of:
C 1 -C 5 alkyl, —(CH 2 ) r —C 3 -C 10 cycloalkyl, —(CHR 5a Y) n —R 9 , —(CR 7 R 8 ) n —O—C(R 7 R 8 ) r —R 9 , —(CR 7 R 8 ) r —R 9 , and —(CR 7 R 8 ) r CONR 7 R 8 ;
R 5a is selected independently at each occurrence from the group consisting of:
hydrogen, C 1-10 alkyl substituted with 0-3 R 5b , —(CH 2 ) r -aryl substituted with 0-3 R 5b , and —(CH 2 ) r —O—(CH 2 ) r -aryl substituted with 0-3 R 5b ;
R 5b is selected independently at each occurrence from the group consisting of:
hydrogen, halo, hydroxy, —OR 5c , —NHC(O)CH 3 , -aryl-(CH 2 ) r —NH 2 , -aryl-(CH 2 ) r -aryl, C 1-10 alkyl substituted with 0-3 R 5d , and —(CH 2 ) r -aryl substituted with 0-3 R 5d ;
R 5c is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 5d is selected independently at each occurrence from the group consisting of;
hydrogen, C 1-5 alkyl, —O—(CH 2 ) r —R 5e , —OH, halo, —NHC(O)CH 3 , and —C(O)NH 2 ;
R 5e is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 6 is selected from the group consisting of:
hydrogen, C 1 -C 10 alkyl, —(CH 2 ) r -aryl, —(CH 2 ) r —C(O)R 6a , —(CH 2 ) r -heterocyclic and phenyl substituted with 0-5 R 6c ;
R 6a is selected independently at each occurrence from the group consisting of;
hydrogen, C 1-5 alkyl, —O—(CH 2 ) r —R 6b , —OH, halo, —NHC(O)CH 3 , and —C(O)NH 2 ;
R 6b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 6c is selected independently at each occurrence from the group consisting of:
halogen, NO 2 , —R 6d , and —O—(CH 2 ) r —R 6d ;
R 6d is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
Alternatively, R 5 and R 6 combine to form a 3 to 8 membered heterocyclic ring containing 1 to 3 additional heteroatoms selected from —O—, —NR 6 —, —S(O)p-, and —C(O)—, optionally fused to a phenyl ring;
R 7 and R 8 may be H or R 5a ;
Alternatively, R 7 and R 8 combine to form 3 to 7 membered heterocyclic ring substituted with 1-3 R 7a , containing 1-3 additional heteroatoms selected from —O—, —S(O)p-, and —NR 6 —, optionally fused to an aryl ring substituted with 0-3 R 7c ;
R 7a is selected independently at each occurrence from the group consisiting of:
hydrogen, C 1-5 alkyl, C 3-5 cycloalkyl, hydroxy, halo, —OR 7b , —NHC(O)CH 3 , —C(O)NH 2 , and aryl;
R 7b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
R 7c is selected independently at each occurrence from the group consisting of;
hydrogen, C 1-5 alkyl, C 3-5 cycloalkyl, hydroxy, halo, —O(CH 2 ) r —R 7d , —NHC(O)CH 3 , —C(O)NH 2 , and aryl;
R 7d is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
R 9 is selected from the group consisting of: hydrogen, C 1-5 alkyl, —C(O)OC 1-5 alkyl, —(CH 2 ) r -aryl substituted with 0-3 R 9a , and a 5 or 6 membered heterocyclic ring containing from 0 to 2 N, O or S(O)p, and substituted with 0-3 R 9a ;
R 9a is selected from the group consisting of:
—OH, —O—(CH 2 ) r —R 9b , —C(O)OR 9b , NHR 10 and aryl;
R 9b is selected from the group consisting of:
C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
R 10 is independently at each occurrence H or C 1-10 alkyl
substituted with 0-3 R 10a ;
R 10a is selected independently at each occurrence from the group consisting of:
hydrogen, C 1 -C 10 alkyl substituted with 0-3 R 10b , and —(CH 2 ) r -aryl substituted with 0-3 R 10b ;
R 10b is selected independently at each occurrence from the group consisting of:
hydrogen, halo, hydroxy, —OR 10c , —NHC(O)CH 3 , —(CH 2 ) r —C(O)NH 2 , -aryl-NH 2 , and —SO 2 NH 2 ;
R 10c is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
n is selected from 1, 2 and 3;
p is selected independently at each occurrence from 0, 1 and 2;
r is selected independently at each occurrence from 0, 1, 2, and 3;
Y is selected from the group consisting of:
—CONR 10 —, —NR 10 CO—, —SO 2 NR 10 —, —NR 10 SO 2 —, and a 5 membered heterocyclic ring; and
z is selected from 1, 2, 3, 4 and 5;
the process comprising:
cyclizing a compound of formula (VIII):
wherein:
L is a leaving group;
R 2 is selected from the group consisting of:
C 1-10 alkyl, C 3-10 cycloalkyl, and —(CH 2 ) r -phenyl substituted with 0-3 R 2a ;
R 2a is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, —(CH 2 ) r —OR 2b , —OH, halo, —NH 2 , and —(CF 2 ) r CF 3 ;
R 2b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
to give a compound of formula (IX):
contacting the compound of formula (IX) with an oxidizing agent to give a compound of formula (X),
or a pharmaceutically acceptable salt form thereof.
In a preferred embodiment, R 1 is C 1-5 alkyl;
R 2 is selected from the group consisting of:
C 1-10 alkyl, C 3-10 cycloalkyl, and —(CH 2 ) r -phenyl;
R 3 is —OR 4 or —NR 5 R 6
R 4 is selected from the group consisting of:
hydrogen, C 1-10 alkyl, —(CH 2 ) r —C 3-10 cycloalkyl, and —(CH 2 ) r -phenyl;
R 5 is selected from the group consisting of:
C 1-5 alkyl, —(CH 2 ) r —C 3-10 cycloalkyl, —CH 2 —CONHR 10 , —CH 2 —C(O)OC 1-5 alkyl, —CH 2 —CONR 7 R 8 , and —(CH 2 ) r -phenyl;
R 6 is selected from hydrogen or C 1-10 alkyl;
R 7 and R 8 form a 6 membered saturated ring containing —O— or —NR 6 —;
R 10 is H or C 1-5 alkyl;
r is selected from 0, 1, or 2;
z is 2;
the leaving group is selected from the group consisting of: chlorine, bromine, iodine, mesylate and tosylate;
cyclizing comprises contacting a compound of formula (VIII) with a suitable base in a suitable solvent at a suitable temperature; and
the oxidizing agent is KMnO 4 in NaIO 4 or ozone.
In a more preferred embodiment, R 1 is —CH 2 CH(CH 3 ) 2 ;
R 2 is —CH(CH 3 ) 2 ; and,
R 3 is selected from the group consisting of:
—OC 1-5 alkyl, —NHCH 2 C(O)OC 1-5 alkyl, —NHCH 2 C(O)NR 7 R 8 and —NHCH 2 C(O)NHCH 3 ; and
R 7 and R 8 are taken together to form a morpholine ring;
the leaving group is bromine;
cyclizing comprises contacting the free base of a compound of formula (VIII) with cesium carbonate in dimethyl formamide and dimethylsulfoxide at about 70° C. to about 90° C.; and
the oxidizing agent is ozone.
In an even more preferred embodiment, R 3 is —OCH 3 .
In a fourth embodiment, the present invention describes a compound of formula (III):
wherein:
R 2 is —CH(CH 3 ) 2 ;
G is —OCH 2 OCH 3 ; and
z is 2.
In a fifth embodiment, the present invention describes a compound of formula (IV):
wherein:
R 1 is —CH 2 CH(CH 3 ) 2
R 2 is —CH(CH 3 ) 2 ;
G is —OCH 2 OCH 3 ; and
z is 2.
In a sixth embodiment, the present invention describes a compound of formula (IV-a):
wherein:
R 1 is —CH 2 CH(CH 3 ) 2 ;
R 2 is —CH(CH 3 ) 2 ;
R 12 is selected independently at each occurrence from C 1-6 alkyl or phenyl;
G is —OCH 2 OCH 3 or —O-t-butyldimethylsilyl; and
z is 2.
In a more preferred embodiment, the compound of formula (V) is:
In another preferred embodiment, the compound of formula (V) is:
In a seventh embodiment, the present invention describes a compound of formula (V):
wherein:
R 1 is —CH 2 CH(CH 3 ) 2 ;
R 2 is —CH(CH 3 ) 2 ;
G is —OCH 2 OCH 3 or —O-t-butyldimethylsilyl; and
z is 2.
In a more preferred embodiment, the compound of formula (V) is:
or a salt form thereof.
In another preferred embodiment, the compound of formula (V) is:
or a salt form thereof.
In an eighth embodiment, the present invention describes a compound of formula (VII):
or a salt form thereof;
wherein:
D is P 1 —NR 11 —CH 2 CH 2 CH 2 —, or para HO—C 6 H 4 —;
G is —OP or halogen;
P is a suitable oxygen protecting group;
P 1 is a suitable nitrogen protecting group;
P 1 is a suitable nitrogen protecting group;
R 1 is selected from the group consisting of:
C 1-5 alkyl substituted with 0-5 R 1a , —(CH 2 ) r —C 3-10 cycloalkyl substituted with 0-5 R 1a , and —(CH 2 ) r -aryl substituted with 0-5 R 1a ;
R 1a is selected independently at each occurrence from the group consisting of:
hydrogen, —CF 3 , —CF 2 CF 3 , —NR 1b R 1c , —Si(R 1d ) 3 , C 1-5 alkyl, C 3-10 cycloalkyl, and aryl substituted with 0-5 R 1e ;
R 1b and R 1c are selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 1d is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 haloalkyl, and aryl substituted with 0-5 R 1e ;
R 1e is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, —(CH 2 ) r —OR 1f , —OH, halo, —NH 2 , and —(CF 2 ) r CF 3 ;
R 1f is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 2 is selected from the group consisting of:
C 1-10 alkyl, C 3-10 cycloalkyl, and —(CH 2 ) r -phenyl substituted with 0-3 R 2a ;
R 2a is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, —(CH 2 ) r —OR 2b , —OH, halo, —NH 2 , and —(CF 2 ) r CF 3 ;
R 2b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 3 is selected from the group consisting of:
—OR 4 , —NR 5 R 6 , —NR 6 (OR 5 ), C 1-5 alkyl substituted with 0-3 R 3a , —(CH 2 ) r -aryl substituted with 0-5 R 3a , and —(CH 2 ) r -heterocyclic substituted with 0-3 R 3a ;
R 3a is selected independently at each occurrence from the group consisting of:
hydrogen, C 1-5 alkyl, halo, hydroxy, —O—(CH 2 ) r —R 3b , —(CH 2 ) r —C(O)R 3b , —(CH 2 ) r —SO 2 NHR 3b , —(CH 2 ) r —C(O)NHR 3b , —(CH 2 ) r —OC(O)R 3b , —(CH 2 ) r —NHSO 2 R 3b , aryl, —(CH 2 ) r —NHC(O)R 3b , and —(CH 2 ) r —C(O)OR 3b ;
R 3b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 4 is selected from the group consisting of:
hydrogen, C 1 -C 10 alkyl, —(CH 2 ) r —C 3-10 cycloalkyl, —(CH 2 ) r -heterocyclic, and —(CH 2 ) r -aryl substituted with 0-5 R 4a ;
R 4a is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, —(CH 2 ) r —OR 4b , —OH, halo, —NH 2 , and —(CF 2 ) r CF 3 ;
R 4b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 5 is selected from the group consisting of:
C 1 -C 5 alkyl, —(CH 2 ) r —C 3 -C 10 cycloalkyl, —(CHR 5a Y) n —R 9 , —(CR 7 R 8 ) n —O—C(R 7 R 8 ) r —R 9 , —(CR 7 R 8 ) r —R 9 , and —(CR 7 R 8 ) r CONR 7 R 8 ;
R 5a is selected independently at each occurrence from the group consisting of:
hydrogen, C 1-10 alkyl substituted with 0-3 R 5b , —(CH 2 ) r -aryl substituted with 0-3 R 5b , and —(CH 2 ) r —O—(CH 2 ) r -aryl substituted with 0-3 R 5b ;
R 5b is selected independently at each occurrence from the group consisting of:
hydrogen, halo, hydroxy, —OR 5c , —NHC(O)CH 3 , -aryl-(CH 2 ) r —NH 2 , -aryl-(CH 2 ) r -aryl, C 1-10 alkyl substituted with 0-3 R 5d , and —(CH 2 ) r -aryl substituted with 0-3 R 5d ;
R 5c is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 5d is selected independently at each occurrence from the group consisting of;
hydrogen, C 1-5 alkyl, —O—(CH 2 ) r —R 5e , —OH, halo, —NHC(O)CH 3 , and —C(O)NH 2 ;
R 5e is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 6 is selected from the group consisting of:
hydrogen, C 1 -C 10 alkyl, —(CH 2 ) r -aryl, —(CH 2 ) r —C(O)R 6a , —(CH 2 ) r -heterocyclic, and phenyl substituted with 0-5 R 6c ;
R 6a is selected independently at each occurrence from the group consisting of;
hydrogen, C 1-5 alkyl, —O—(CH 2 ) r —R 6b , —OH, halo, —NHC(O)CH 3 , and —C(O)NH 2 ;
R 6b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 6c is selected independently at each occurrence from the group consisting of:
halogen, NO 2 , —R 6d , and —O—(CH 2 ) r —R 6d ;
R 6d is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
Alternatively, R 5 and R 6 combine to form a 3 to 8 membered heterocyclic ring containing 1 to 3 additional heteroatoms selected from —O—, —NR 6 —, —S(O)p—, and —C(O)—, optionally fused to a phenyl ring;
R 7 and R 8 may be H or R 5a ;
Alternatively, R 7 and R 8 combine to form 3 to 7 membered heterocyclic ring substituted with 1-3 R 7a , containing 1-3 additional heteroatoms selected from —O—, —S(O)p-, and —NR 6 —, optionally fused to an aryl ring substituted with 0-3 R 7c ;
R 7a is selected independently at each occurrence from the group consisiting of:
hydrogen, C 1-5 alkyl, C 3-5 cycloalkyl, hydroxy, halo, —OR 7b , —NHC(O)CH 3 , —C(O)NH 2 , and aryl;
R 7b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
R 7c is selected independently at each occurrence from the group consisting of;
hydrogen, C 1-5 alkyl, C 3-5 cycloalkyl, hydroxy, halo, —O(CH 2 ) r —R 7d , —NHC(O)CH 3 , —C(O)NH 2 , and aryl;
R 7d is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
R 9 is selected from the group consisting of: hydrogen, C 1-5 alkyl, —C(O)OC 1-5 alkyl, —(CH 2 ) r -aryl substituted with 0-3 R 9a , and a 5 or 6 membered heterocyclic ring containing from 0 to 2 N, O or S(O)p, and substituted with 0-3 R 9a ;
R 9a is selected from the group consisting of:
—OH, —O—(CH 2 ) r —R 9b , —C(O)OR 9b , —NHR 10 and aryl;
R 9b is selected from the group consisting of:
C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
R 10 is independently at each occurrence H or C 1-10 alkyl substituted with 0-3 R 10a ;
R 10a is selected independently at each occurrence from the group consisting of:
hydrogen, C 1 -C 10 alkyl substituted with 0-3 R 10b , and —(CH 2 ) r -aryl substituted with 0-3 R 10b ;
R 10b is selected independently at each occurrence from the group consisting of:
hydrogen, halo, hydroxy, —OR 10c , —NHC(O)CH 3 , —(CH 2 ) r —C(O)NH 2 , -aryl-NH 2 , and —SO 2 NH 2 ;
R 10c is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
R 11 is selected independently at each occurrence from the group consisting of:
hydrogen, C 1 -C 10 alkyl substituted with 0-3 R 11a , and —(CH 2 ) r -aryl substituted with 0-3 R 11a ;
R 11a is selected independently at each occurrence from the group consisting of:
hydrogen, halo, hydroxy, —OR 11b , —NHC(O)CH 3 , —(CH 2 ) r —C(O)NH 2 , -aryl-NH 2 , and —SO 2 NH 2 ;
R 11b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
n is selected from 1, 2 and 3;
p is selected independently at each occurrence from 0, 1 and 2;
r is selected independently at each occurrence from 0, 1, 2, and 3;
Y is selected from the group consisting of: —CONR 10 —, —NR 10 CO—, —SO 2 NR 10 —, —NR 10 SO 2 —, and a 5 membered heterocyclic ring; and
z is selected from 1, 2, 3, 4 and 5.
In a ninth embodiment, the present invention describes a compound of formula (IX):
or a salt form thereof;
wherein:
P 1 is a suitable nitrogen protecting group;
R 1 is selected from the group consisting of:
C 1-5 alkyl substituted with 0-5 R 1a , —(CH 2 ) r —C 3-10 cycloalkyl substituted with 0-5 R 1a , and —(CH 2 ) r -aryl substituted with 0-5 R 1a ;
R 1a is selected independently at each occurrence from the group consisting of:
hydrogen, —CF 3 , —CF 2 CF 3 , —NR 1b R 1c , —Si(R 1d ) 3 , C 1-5 alkyl, C 3-10 cycloalkyl, and aryl substituted with 0-5 R 1e ;
R 1b and R 1c are selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 1d is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 haloalkyl, and aryl substituted with 0-5 R 1e ;
R 1e is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, (CH 2 ) r —OR 1f , —OH, halo, —NH 2 , and —(CF 2 ) r CF 3 ;
R 1f is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 2 is selected from the group consisting of:
C 1-10 alkyl, C 3-10 cycloalkyl, and —(CH 2 ) r -phenyl substituted with 0-3 R 2a ;
R 2a is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, —(CH 2 ) r —OR 2b , —OH, halo, —NH 2 , and —(CF 2 ) r CF 3 ;
R 2b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 3 is selected from the group consisting of:
—OR 4 , —NR 5 R 6 , —NR 6 (OR 5 ), C 1-5 alkyl substituted with 0-3 R 3a , —(CH 2 ) r -aryl substituted with 0-5 R 3a , and —(CH 2 ) r -heterocyclic substituted with 0-3 R 3a ;
R 3a is selected independently at each occurrence from the group consisting of:
hydrogen, C 1-5 alkyl, halo, hydroxy, —O—(CH 2 ) r —R 3b , —(CH 2 ) r —C(O)R 3b , —(CH 2 ) r —SO 2 NHR 3b , —(CH 2 ) r —C(O)NHR 3b , —(CH 2 ) r —OC(O)R 3b , —(CH 2 ) r —NHSO 2 R 3b , aryl, —(CH 2 ) r —NHC(O)R 3b , and —(CH 2 ) r —C(O)OR 3b ;
R 3b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 4 is selected from the group consisting of:
hydrogen, C 1 -C 10 alkyl, —(CH 2 ) r —C 3-10 cycloalkyl, —(CH 2 ) r -heterocyclic, and —(CH 2 ) r -aryl substituted with 0-5 R 4a ;
R 4a is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, —(CH 2 ) r —OR 4b , —OH, halo, —NH 2 , and —(CF 2 ) r CF 3 ;
R 4b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 5 is selected from the group consisting of:
C 1 -C 5 alkyl, —(CH 2 ) r —C 3 -C 10 cycloalkyl, —(CHR 5a Y) n —R 9 , —(CR 7 R 8 ) n —O—C(R 7 R 8 ) r —R 9 , —(CR 7 R 8 ) r —R 9 , and —(CR 7 R 8 ) r CONR 7 R 8 ;
R 5a is selected independently at each occurrence from the group consisting of:
hydrogen, C 1-10 alkyl substituted with 0-3 R 5b , —(CH 2 ) r -aryl substituted with 0-3 R 5b , and —(CH 2 ) r —O—(CH 2 ) r -aryl substituted with 0-3 R 5b ;
R 5b is selected independently at each occurrence from the group consisting of:
hydrogen, halo, hydroxy, —OR 5c , —NHC(O)CH 3 , -aryl-(CH 2 ) r —NH 2 , -aryl-(CH 2 ) r -aryl, C 1-10 alkyl substituted with 0-3 R 5d , and —(CH 2 ) r -aryl substituted with 0-3 R 5d ;
R 5c is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 5d is selected independently at each occurrence from the group consisting of;
hydrogen, C 1-5 alkyl, —O—(CH 2 ) r —R 5e , —OH, halo, —NHC(O)CH 3 , and —C(O)NH 2 ;
R 5e is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 6 is selected from the group consisting of:
hydrogen, C 1-10 alkyl, —(CH 2 ) r -aryl, —(CH 2 ) r —C(O)R 6a , —(CH 2 ) r -heterocyclic, and phenyl substituted with 0-5 R 6c ;
R 6a is selected independently at each occurrence from the group consisting of;
hydrogen, C 1-5 alkyl, —O—(CH 2 ) r —R 6b , —OH, halo, —NHC(O)CH 3 , and —C(O)NH 2 ;
R 6b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 6c is selected independently at each occurrence from the group consisting of:
halogen, NO 2 , —R 6d , and —O—(CH 2 ) r —R 6d ;
R 6d is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
Alternatively, R 5 and R 6 combine to form a 3 to 8 membered heterocyclic ring containing 1 to 3 additional heteroatoms selected from —O—, —NR 6 —, —S(O)p-, and —C(O)—, optionally fused to a phenyl ring;
R 7 and R 8 may be H or R 5a ;
Alternatively, R 7 and R 8 combine to form 3 to 7 membered heterocyclic ring substituted with 1-3 R 7a , containing 1-3 additional heteroatoms selected from —O—, —S(O)p-, and —NR 6 —, optionally fused to an aryl ring substituted with 0-3 R 7c ;
R 7a is selected independently at each occurrence from the group consisiting of:
hydrogen, C 1-5 alkyl, C 3-5 cycloalkyl, hydroxy, halo, —OR 7b , —NHC(O)CH 3 , —C(O)NH 2 , and aryl;
R 7b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
R 7c is selected independently at each occurrence from the group consisting of;
hydrogen, C 1-5 alkyl, C 3-5 cycloalkyl, hydroxy, halo, —O(CH 2 ) r —R 7d , —NHC(O)CH 3 , —C(O)NH 2 , and aryl;
R 7d is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
R 9 is selected from the group consisting of: hydrogen, C 1-5 alkyl, —C(O)OC 1-5 alkyl, —(CH 2 ) r -aryl substituted with 0-3 R 9a , and a 5 or 6 membered heterocyclic ring containing from 0 to 2 N, O or S(O)p, and substituted with 0-3 R 9a ;
R 9a is selected from the group consisting of: —OH, —O—(CH 2 ) r —R 9b , —C(O)OR 9b , —NHR 10 and aryl;
R 9b is selected from the group consisting of: C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
R 10 is independently at each occurrence H or C 1-10 alkyl substituted with 0-3 R 10a ;
R 10a is selected independently at each occurrence from the group consisting of:
hydrogen, C 1 -C 10 alkyl substituted with 0-3 R 10b , and —(CH 2 ) r -aryl substituted with 0-3 R 10b ;
R 10b is selected independently at each occurrence from the group consisting of:
hydrogen, halo, hydroxy, —OR 10c , —NHC(O)CH 3 , —(CH 2 ) r —C(O)NH 2 , -aryl-NH 2 , and —SO 2 NH 2 ;
R 10c is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
n is selected from 1, 2 and 3;
p is selected independently at each occurrence from 0, 1 and 2;
r is selected independently at each occurrence from 0, 1, 2, and 3;
Y is selected from the group consisting of: —CONR 10 —, —NR 10 CO—, —SO 2 NR 10 —, —NR 10 SO 2 —, and a 5 membered heterocyclic ring; and
z is selected from 1, 2, 3, 4 and 5.
In a preferred embodiment, the compound of formula (IX) is:
In another preferred embodiment, the compound of formula (IX) is:
In another preferred embodiment, the compound of formula (IX) is:
In a tenth embodiment, the present invention describes a compound formula (IX-a):
or a salt form thereof;
wherein:
P 1 is a suitable nitrogen protecting group;
R 1 is selected from the group consisting of:
C 1-5 alkyl substituted with 0-5 R 1a , —(CH 2 ) r —C 3-10 cycloalkyl substituted with 0-5 R 1a , and —(CH 2 ) r -aryl substituted with 0-5 R 1a ;
R 1a is selected independently at each occurrence from the group consisting of:
hydrogen, —CF 3 , —CF 2 CF 3 , —NR 1b R 1c , —Si(R 1d ) 3 , C 1-5 alkyl, C 3-10 cycloalkyl, and aryl substituted with 0-5 R 1e ;
R 1b and R 1c are selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 1d is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 haloalkyl, and aryl substituted with 0-5 R 1e ;
R 1e is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, —(CH 2 ) r —OR 1f , —OH, halo, —NH 2 , and —(CF 2 ) r CF 3 ;
R 1f is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 2 is selected from the group consisting of:
C 1-10 alkyl, C 3-10 cycloalkyl, and —(CH 2 ) r -phenyl substituted with 0-3 R 2a ;
R 2a is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, —(CH 2 ) r —OR 2b , —OH, halo, —NH 2 , and —(CF 2 ) r CF 3 ;
R 2b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 3 is selected from the group consisting of:
—OR 4 , —NR 5 R 6 , —NR 6 (OR 5 ), C 1-5 alkyl substituted with 0-3 R 3a , —(CH 2 ) r -aryl substituted with 0-5 R 3a , and —(CH 2 ) r -heterocyclic substituted with 0-3 R 3a ;
R 3a is selected independently at each occurrence from the group consisting of:
hydrogen, C 1-5 alkyl, halo, hydroxy, —O—(CH 2 ) r —R 3b , —(CH 2 ) r —C(O)R 3b , —(CH 2 ) r —SO 2 NHR 3b , —(CH 2 ) r —C(O)NHR 3b , —(CH 2 ) r —OC(O)R 3b , —(CH 2 ) r —NHSO 2 R 3b , aryl, —(CH 2 ) r —NHC(O)R 3b , and —(CH 2 ) r —C(O)OR 3b ;
R 3b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 4 is selected from the group consisting of:
hydrogen, C 1 -C 10 alkyl, —(CH 2 ) r —C 3-10 cycloalkyl, —(CH 2 ) r -heterocyclic, and —(CH 2 ) r -aryl substituted with 0-5 R 4a ;
R 4a is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, —(CH 2 ) r —OR 4b , —OH, halo, —NH 2 , and —(CF 2 ) r CF 3 ;
R 4b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 5 is selected from the group consisting of:
C 1 -C 5 alkyl, —(CH 2 ) r —C 3 -C 10 cycloalkyl, —(CHR 5a Y) n —R 9 , —(CR 7 R 8 ) n —O—C(R 7 R 8 ) r —R 9 , —(CR 7 R 8 ) r —R 9 , and —(CR 7 R 8 ) r CONR 7 R 8 ;
R 5a is selected independently at each occurrence from the group consisting of:
hydrogen, C 1-10 alkyl substituted with 0-3 R 5b , —(CH 2 ) r -aryl substituted with 0-3 R 5b , and —(CH 2 ) r —O—(CH 2 ) r -aryl substituted with 0-3 R 5b ;
R 5b is selected independently at each occurrence from the group consisting of:
hydrogen, halo, hydroxy, —OR 5c , —NHC(O)CH 3 , -aryl-(CH 2 ) r —NH 2 , -aryl-(CH 2 ) r -aryl, C 1-10 alkyl substituted with 0-3 R 5d , and —(CH 2 ) r -aryl substituted with 0-3 R 5d ;
R 5c is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 5d is selected independently at each occurrence from the group consisting of;
hydrogen, C 1-5 alkyl, —O—(CH 2 ) r —R 5e , —OH, halo, —NHC(O)CH 3 , and —C(O)NH 2 ;
R 5e is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 6 is selected from the group consisting of:
hydrogen, C 1 -C 10 alkyl, —(CH 2 ) r -aryl, —(CH 2 ) r —C(O)R 6a , —(CH 2 ) r -heterocyclic, and phenyl substituted with 0-5 R 6c ;
R 6a is selected independently at each occurrence from the group consisting of;
hydrogen, C 1-5 alkyl, —O—(CH 2 ) r —R 6b , —OH, halo, —NHC(O)CH 3 , and —C(O)NH 2 ;
R 6b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
R 6c is selected independently at each occurrence from the group consisting of:
halogen, NO 2 , —R 6d , and —O—(CH 2 ) r —R 6d ;
R 6d is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 3-5 cycloalkyl and phenyl;
Alternatively, R 5 and R 6 combine to form a 3 to 8 membered heterocyclic ring containing 1 to 3 additional heteroatoms selected from —O—, —NR 6 —, —S(O)p—, and —C(O)—, optionally fused to a phenyl ring;
R 7 and R 8 may be H or R 5a ;
Alternatively, R 7 and R 8 combine to form 3 to 7 membered heterocyclic ring substituted with 1-3 R 7a , containing 1-3 additional heteroatoms selected from —O—, —S(O)p—, and —NR 6 —, optionally fused to an aryl ring substituted with 0-3 R 7c ;
R 7a is selected independently at each occurrence from the group consisiting of:
hydrogen, C 1-5 alkyl, C 3-5 cycloalkyl, hydroxy, halo, —OR 7b , —NHC(O)CH 3 , —C(O)NH 2 , and aryl;
R 7b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
R 7c is selected independently at each occurrence from the group consisting of;
hydrogen, C 1-5 alkyl, C 3-5 cycloalkyl, hydroxy, halo, —O(CH 2 ) r —R 7d , —NHC(O)CH 3 , —C(O)NH 2 , and aryl;
R 7d is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
R 9 is selected from the group consisting of: hydrogen, C 1-5 alkyl, —C(O)OC 1-5 alkyl, —(CH 2 ) r -aryl substituted with 0-3 R 9a , and a 5 or 6 membered heterocyclic ring containing from 0 to 2 N, O or S(O)p, and substituted with 0-3 R 9a ;
R 9a is selected from the group consisting of:
—OH, —O—(CH 2 ) r —R 9b , —C(O)OR 9b , —NHR 10 and aryl;
R 9b is selected from the group consisting of:
C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
R 10 is independently at each occurrence H or C 1-10 alkyl
substituted with 0-3 R 10a ;
R 10a is selected independently at each occurrence from the group consisting of: hydrogen, C 1 -C 10 alkyl substituted with 0-3 R 10b , and —(CH 2 ) r -aryl substituted with 0-3 R 10b ;
R 10b is selected independently at each occurrence from the group consisting of:
hydrogen, halo, hydroxy, —OR 10c , —NHC(O)CH 3 , —(CH 2 ) r —C(O)NH 2 , -aryl-NH 2 , and —SO 2 NH 2 ;
R 10c is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
R 11 is selected independently at each occurrence from the group consisting of:
hydrogen, C 1 -C 10 alkyl substituted with 0-3 R 11a , and —(CH 2 ) r -aryl substituted with 0-3 R 11a ;
R 11a is selected independently at each occurrence from the group consisting of:
hydrogen, halo, hydroxy, —OR 11b , —NHC(O)CH 3 , —(CH 2 ) r —C(O)NH 2 , -aryl-NH 2 , and —SO 2 NH 2 ;
R 11b is selected independently at each occurrence from the group consisting of:
C 1-5 alkyl, C 1-5 cycloalkyl and phenyl;
n is selected from 1, 2 and 3;
p is selected independently at each occurrence from 0, 1 and 2;
r is selected independently at each occurrence from 0, 1, 2, and 3;
Y is selected from the group consisting of: —CONR 10 —, —NR 10 CO—, —SO 2 NR 10 —, —NR 10 SO 2 —, and a 5 membered heterocyclic ring; and
z is selected from 1, 2, 3, 4 and 5.
In a preferred embodiment, the compound of formula (IX-a) is:
In another preferred embodiment, the compound of formula (IX-a) is:
In another preferred embodiment, the compound of formula (IX-a) is:
DEFINITIONS
The reactions of the synthetic methods claimed herein are carried out in suitable solvents which may be readily selected by one of skill in the art of organic synthesis, said suitable solvents generally being any solvent which is substantially nonreactive with the starting materials (reactants), the intermediates, or products at the temperatures at which the reactions are carried out, i.e., temperatures which may range from the solvent's freezing temperature to the solvent's boiling temperature. A given reaction may be carried out in one solvent or a mixture of more than one solvent. Depending on the particular reaction step, suitable solvents for a particular reaction step may be selected.
The following terms and abbreviations are used herein and defined as follows. The abbreviation: “THF” as used herein means tetrahydrofuran, “HPLC” as used herein means high performance liquid chromatograpy, “MOM” as used herein means methoxymethyl, “TBDS” means tert-butyldimethylsilane or tert-butyldimethylsilyl, “LDA” means lithium diisopropylamide, “py” means pyridine, “GC” means gas chromatography, “EE” means enantiomeric excess, “DE” means diastereomeric excess, “DIEA” means N,N-diisopropylethylamine, “BOC” means the protecting group tert-butyloxycarbonyl.
Suitable halogenated solvents include, but are not limited to: carbon tetrachloride, bromodichloromethane, dibromochloromethane, bromoform, chloroform, bromochloromethane, dibromomethane, butyl chloride, dichloromethane, tetrachloroethylene, trichloroethylene, 1,1,1-trichloroethane, 1,1,2-trichloroethane, 1,1-dichloroethane, 2-chloropropane, hexafluorobenzene, 1,2,4-trichlorobenzene, o-dichlorobenzene, chlorobenzene, fluorobenzene, fluorotrichloromethane, chlorotrifluoromethane, bromotrifluoromethane, carbon tetrafluoride, dichlorofluoromethane, chlorodifluoromethane, trifluoromethane, 1,2-dichlorotetrafluorethane and hexafluoroethane.
Suitable ether solvents include, but are not limited to: dimethoxymethane, tetrahydrofuran, 1,3-dioxane, 1,4-dioxane, furan, diethyl ether, ethylene glycol dimethyl ether, ethylene glycol diethyl ether, diethylene glycol dimethyl ether, diethylene glycol diethyl ether, triethylene glycol dimethyl ether, anisole, or t-butyl methyl ether.
Suitable protic solvents include, but are not limited to: water, methanol, ethanol, 2-nitroethanol, 2-fluoroethanol, 2,2,2-trifluoroethanol, ethylene glycol, 1-propanol, 2-propanol, 2-methoxyethanol, 1-butanol, 2-butanol, i-butyl alcohol, t-butyl alcohol, 2-ethoxyethanol, diethylene glycol, 1-, 2-, or 3-pentanol, neo-pentyl alcohol, t-pentyl alcohol, diethylene glycol monomethyl ether, diethylene glycol monoethyl ether, cyclohexanol, benzyl alcohol, phenol, or glycerol.
Suitable aprotic solvents include, but are not limited to: tetrahydrofuran (THF), dimethylformamide (DMF), dimethylacetamide (DMAC), 1,3-dimethyl-3,4,5,6-tetrahydro-2(1H)-pyrimidinone (DMPU), 1,3-dimethyl-2-imidazolidinone (DMI), N-methylpyrrolidinone (NMP), formamide, N-methylacetamide, N-methylformamide, acetonitrile, dimethyl sulfoxide (DMSO), propionitrile, ethyl formate, methyl acetate, hexachloroacetone, acetone, ethyl methyl ketone, ethyl acetate, sulfolane, N,N-dimethylpropionamide, tetramethylurea, nitromethane, nitrobenzene, or hexamethylphosphoramide.
Suitable hydrocarbon solvents include, but are not limited to: benzene, cyclohexane, pentane, hexane, toluene, cycloheptane, methylcyclohexane, heptane, ethylbenzene, m-, o-, or p-xylene, octane, indane, nonane, or naphthalene.
Suitable acids include, but are not limited to: hydrochloric acid, hydrobromic acid, sulfuric acid, phosphoric acid, nitric acid, and those acids referred to as organic acids.
Suitable organic acids include, but are not limited to: formic acid, acetic acid, propionic acid, butanoic acid, methanesulfonic acid, p-toluene sulfonic acid, benzenesulfonic acid, trifluoroacetic acid, propiolic acid, butyric acid, 2-butynoic acid, vinyl acetic acid, pentanoic acid, hexanoic acid, heptanoic acid, octanoic acid, nonanoic acid and decanoic acid.
As used herein, a “suitable acid scavenger” refers to any species known in the art of organic synthesis capable of accepting a proton without reacting with the starting material or product. Examples include but are not limited to tertiary amines such as trimethylamine, triethylamine, N-methylmorpholine, diisopropylethylamine, pyridine, piperidine, and the like.
Suitable bases include, but are not limited to: lithium hydroxide, sodium hydroxide, potassium hydroxide, lithium carbonate, sodium carbonate, and potassium carbonate.
Strong bases include, but are not limited to, alkoxides, metal amides, metal hydrides, metal dialkylamides and arylamines, wherein; alkoxides include lithium, sodium and potassium salts of methyl, ethyl and t-butyl oxides; metal amides include sodium amide, potassium amide and lithium amide; metal hydrides include sodium hydride, potassium hydride and lithium hydride; and metal dialkylamides include sodium and potassium salts of methyl, ethyl, n-propyl, i-propyl, n-butyl, t-butyl, trimethylsilyl and cyclohexyl substituted amides.
The compounds described herein may have asymmetric centers. Unless otherwise indicated, all chiral, diastereomeric and racemic forms are included in the present invention. Many geometric isomers of olefins, C═N double bonds, and the like can also be present in the compounds described herein, and all such stable isomers are contemplated in the present invention. It will be appreciated that compounds of the present invention that contain asymmetrically substituted carbon atoms may be isolated in optically active or racemic forms. Methods on how to prepare optically active forms from optically active starting materials are known in the art, such as by resolution of racemic forms or by synthesis. All chiral, diastereomeric, racemic forms and all geometric isomeric forms of a structure are intended.
The present invention includes all isotopes of atoms occurring in the intermediates or final compounds. Isotopes include those atoms having the same atomic number but different mass numbers. By way of general example and without limitation, isotopes of hydrogen include tritium and deuterium. Isotopes of carbon include C-13 and C-14.
When any variable (for example but not limited to R 1a , R 1b , R 1c , etc.) occurs more than one time in any constituent or in any formula, its definition on each occurrence is independent of its definition at every other occurrence. Thus, for example, if a group is shown to be substituted with 0-3 R 1a′ , then said group may optionally be substituted with up to three R 1a′ and R 1a′ at each occurrence is selected independently from the defined list of possible R 1a ′.
Combinations of substituents and/or variables are permissible only if such combinations result in stable compounds. By stable compound or stable structure it is meant herein a compound that is sufficiently robust to survive isolation to a useful degree of purity from a reaction mixture, and formulation into an efficacious therapeutic agent. Such restrictions to the substituents which are compatible with the reaction conditions will be readily apparent to one skilled in the art and alternate methods must then be used.
The term “substituted”, as used herein, means that any one or more hydrogen on the designated atom is replaced with a selection from the indicated group, provided that the designated atom's normal valency is not exceeded, and that the substitution results in a stable compound.
As used herein, any carbon range such as “C x -C y ” is intended to mean a minimum of “x” carbons and a maximum of “y” carbons representing the total number of carbons in the substituent to which it refers. For example, “C 3 -C 10 alkylcarbonyloxyalkyloxy” could contain one carbon for “alkyl”, one carbon for “carbonyloxy” and one carbon for “alkyloxy” giving a total of three carbons, or a larger number of carbons for each carbon in an alkyl group not to exceed a total of ten carbons.
As used herein, “alkyl” is intended to include both branched and straight-chain saturated aliphatic hydrocarbon groups having the specified number of carbon atoms; for example, C 1 -C 4 alkyl includes methyl, ethyl, n-propyl, i-propyl, n-butyl, i-butyl, s-butyl, and t-butyl; for example C 1 -C 10 alkyl includes C 1 -C 4 alkyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, and isomer thereof.
As used herein, “cycloalkyl” is intended to include saturated ring groups, including mono-, bi-, or poly-cyclic ring systems, such as cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, and adamantyl.
As used herein, “Alkenyl” is intended to include hydrocarbon chains of either a straight or branched configuration and one or more unsaturated carbon-carbon bonds which may occur in any stable point along the chain, such as ethenyl, 1-propenyl, 2-propenyl, 1-butenyl, 2-butenyl, 3-butenyl, 1,3-butadienyl and the like. “Alkynyl” is intended to include hydrocarbon chains of either a straight or branched configuration and one or more triple carbon-carbon bonds which may occur in any stable point along the chain, such as ethynyl, propynyl, butynyl and the like.
“Aryl” is intended to mean phenyl or naphthyl. The term “arylalkyl” represents an aryl group attached through an alkyl bridge; for example C 7 -C 11 arylalkyl can represent benzyl, phenylethyl and the like.
As used herein, “halo” or “halogen” refers to fluoro, chloro, bromo and iodo. Haloalkyl as used herein refers to an alkyl group containing a specified number of carbon atoms substituted with 1-10 halogens.
As used herein, the term “mesylate” is intended to mean —OSO 2 CH 3 . As used herein, the term “tosylate” is intended to mean —OSO 2 —C 6 H 4 —CH 3 , wherein C 6 H 4 is a phenyl group and the methyl group is in the para position.
As used herein, the term “chain terminus” is intended to mean the G group at the end of the alkyl chain in the formula —(CH 2 ) z —G.
As used herein, the term “hydroxide” is intended to mean lithium hydroxide, calcium hydroxide, magnesium hydroxide, sodium hydroxide, or potassium hydroxide.
As used herein, the term “heterocycle”, “heterocyclic” or “heterocyclic ring” is intended to mean a stable 5- to 10-membered monocyclic or bicyclic or 5- to 10-membered bicyclic heterocyclic ring which may be saturated, partially unsaturated, or aromatic, and which consists of carbon atoms and from 1 to 3 heteroatoms independently selected from the group consisting of N, O and S and wherein the nitrogen and sulfur heteroatoms may optionally be oxidized, and the nitrogen may optionally be quaternized, and including any bicyclic group in which any of the above-defined heterocyclic rings is fused to a benzene ring. The heterocyclic ring may be attached to its pendant group at any heteroatom or carbon atom which results in a stable structure. The heterocyclic rings described herein may be substituted on carbon or on a nitrogen atom if the resulting compound is stable. Examples of such heterocycles include, but are not limited to, pyridyl (pyridinyl), pyrimidinyl, furanyl (furyl), thiazolyl, thienyl, pyrrolyl, pyrazolyl, imidazolyl, tetrazolyl, benzofuranyl, benzothiophenyl, indolyl, indolenyl, isoxazolinyl, quinolinyl, isoquinolinyl, benzimidazolyl, piperidinyl, 4-piperidonyl, pyrrolidinyl, 2-pyrrolidonyl, pyrrolinyl, tetrahydrofuranyl, tetrahydroquinolinyl, tetrahydroisoquinolinyl, decahydroquinolinyl or octahydroisoquinolinyl, azocinyl, triazinyl, 6H-1,2,5-thiadiazinyl, 2H,6H-1,5,2-dithiazinyl, thianthrenyl, pyranyl, isobenzofuranyl, chromenyl, xanthenyl, phenoxathiinyl, 2H-pyrrolyl, pyrrolyl, imidazolyl, pyrazolyl, isothiazolyl, isoxazolyl, oxazolyl, pyrazinyl, pyridazinyl, indolizinyl, isoindolyl, 3H-indolyl, 1H-indazolyl, purinyl, 4H-quinolizinyl, phthalazinyl, naphthyridinyl, quinoxalinyl, quinazolinyl, cinnolinyl, pteridinyl, 4aH-carbazole, carbazole, β-carbolinyl, phenanthridinyl, acridinyl, perimidinyl, phenanthrolinyl, phenazinyl, phenarsazinyl, phenothiazinyl, furazanyl, phenoxazinyl, isochromanyl, chromanyl, imidazolidinyl, imidazolinyl, pyrazolidinyl, pyrazolinyl, piperazinyl, indolinyl, isoindolinyl, quinuclidinyl, morpholinyl or oxazolidinyl. Also included are fused ring and spiro compounds containing, for example, the above heterocycles.
As used herein, the term “suitable oxygen protecting group” includes those known in the art of organic synthesis to be temporary functional groups attached to oxygen which render it unreactive to the reagents in question, and can be readily removed to liberate the free oxygen. Examples of oxygen protecting groups include those which protect the oxygen of alcohol group (R—OH) and the oxygen of a carboxyl group (R—(C═O)O—).
Examples of alcohol protecting groups include, but are not limited to, the following: 1) ether types such as tetrahydropyranyl, triphenylmethyl, benzyl, allyl, tetrahydrofuranyl, methoxymethyl (MOM), benzyloxymethyl, p-methoxybenzyloxymethyl, 2-trimethylsilylethoxymethyl (SEM), t-butoxymethyl, methylthiomethyl, 2-methoxyethoxymethyl (MEM), trichloroethoxymethyl, t-butyl, p-methoxybenzyl, t-butyldimethylsilyl (TBDMS), o-nitrobenzyl, p-nitrobenzyl, p-methoxyphenyldiphenylmethyl, triisopropylsilyl, t-butyldiphenylsilyl; 2) ester types such as acetate, formate, mono-chloro, di-chloro, and trichloroacetate, methoxyacetate, triflouroacetate, triphenylmethoxy acetate, phenoxyacetate, pivaloate, adamantoate, benzoate, p-phenyl benzoate, isobutyrate, chlorodiphenylacetate; 3) carbonate types such as methyl, ethyl, 2,2,2-trichloroethyl, isobutyl, vinyl, allyl, p-nitrophenyl, benzyl, p-methoxybenzyl; 4) sulfonate types such as sulfate, methane sulfonate, benzylsulfonate, tosylate.
Examples of carboxyl protecting groups include, but are not limited to, the following: 1) substituted methyl ester type such as methoxymethyl, tetrahydropyranyl, benzyloxymethyl, N-phthalimidomethyl; 2) 2-substituted ethyl ester type such as 2,2,2-trichloroethyl, 2-methylthioethyl, t-butylethyl, cinnamylethyl, benzylethyl, 2-(2′-pyridyl)ethyl; 3) substituted benzyl ester type such as triphenylmethyl, 9-anthrylmethyl, p-nitrobenzyl, 4-picolyl, 2,4,6-trimethylbenzyl; 4) silyl ester type such as trimethylsilyl, t-butyldimethylsilyl, phenyldimethylsilyl; 5) miscellaneous type such as oxazole, orthoester; 6) amides type such as N,N-dimethyl, piperidinyl, pyrrolindinyl; and 7) hydrazide type such as alkylated hydrazides.
As used herein, the term “suitable nitrogen protecting group” includes those known in the art of organic synthesis to be a temporary functional group attached to nitrogen which renders it unreactive to the reagents in question, and can be readily removed to liberate the free nitrogen. Examples of nitrogen protecting groups include those which protect the nitrogen of an amine group (R—NH 2 ) and the nitrogen of an amide group (R—(C═O)NH—).
Examples of amine protecting groups include, but are not limited to, the following: 1) amide types such as formyl, trifluoroacetyl, phthalyl, and p-toluenesulfonyl; 2) aromatic carbamate types such as benzyl (Cbz) and benzyl substituted one or more time with with alkyl, cyano, nitro, chloro, fluoro, bromo, and methoxy; diphenylmethyl, 1-(p-biphenyl)-1-methylethyl, 9-fluorenylmethyl (Fmoc), 2-phenylethyl, and cinnamyl, 3) aliphatic carbamate types such as tert-butyl (Boc), ethyl, diisopropylmethyl, allyl, vinyl, t-amyl, diisopropylmethyl, and isobutyl ; 4) cyclic alkyl carbamate types such as cyclopentyl, cyclohexyl, cyclopropylmethyl, and adamantyl; 5) alkyl types such as triphenylmethyl (trityl) and benzyl; 6) trialkylsilane such as trimethylsilane; and 7) thiol containing types such as phenylthiocarbonyl and dithiasuccinoyl.
Examples of amide protecting groups include, but are limited to the substituted amides such as allyl, methoxymethyl, benzyloxymethyl, t-butyldimethyl-siloxymethyl, methoxy, benzyloxy, t-butyldimethylsilyl, dimethoxybenzyl, and t-butyloxycarbonyl.
Groups which serve as nitrogen and oxygen protecting groups, and the methods employed to add and remove them will be readily understood by one skilled in the art, and are further described in Protective Groups in Organic Synthesis, Greene, 2nd ed., John Wiley & Sons, Inc., N.Y., 1991, the disclosure of which is hereby incorporated by reference.
As used herein, “S-Alpine Borane®” refers to B-isopinocampheyl-9-borabicyclo[3.3.1]nonane.
As used herein, “coupling agents” refers to an agent which is known in the art of organic synthesis capable of reacting in the presence of a carboxylic acid and an amine to produce an amide. Examples of such agents include, but are not limited to dicyclohexylcarbodiimide (DCC), diisopropylcarbodiimide (DIC), carbonyldiimidazole (CDI), 1-(3-dimethylamino propyl)-3-ethylcarbodiimide (EDC), O-(1H-benzo triazol-1-yl)-N,N,N′,N′,-tetramethyluronium tetraflouroborate (TBTU), and benzotriazol-1-yl-oxy-tripyrrolidinophosphonium hexafluorophosphate (PyBOP), (benzotriazolyloxy)tris(di methylamino)phosphonium hexafluorophosphate (BOP) and 2,3-dichloro-5,6-dicyano-1,4-benzoquinone (DDQ).
As used herein, “suitable silylating agent” means any agent which when reacted with an oxygen produces a silyl ester. Examples of such agents include, but are not limited to the flouro, bromo, chloro, iodo and anhydride derivatives of trimethylsilyl, triethylsilyl, triisopropylsilyl, dimethylisopropylsilyl, diethylisopropylsilyl, dimethythexylsilyl, t-butyldimethylsilyl, t-butyldiphenylsilyl, tribenzylsilyl, triphenylsilyl, diphenylmethylsilyl, and t-butylmethoxyphenylsilyl.
As used herein, “leaving group” means any group known in the art of organic synthesis to be displaced in a nucleophilic substitution reaction. These include, but are not limited to halogens, sulfate esters (—SO 2 R), phosphate esters, azides, and the like.
As used herein, “pharmaceutically acceptable salts” refer to derivatives of the disclosed compounds wherein the intermediates or final compound are modified by making acid or base salts of the intermediates or final compounds. Examples of pharmaceutically acceptable salts include, but are not limited to, mineral or organic acid salts of basic residues such as amines; alkali or organic salts of acidic residues such as carboxylic acids; and the like.
The pharmaceutically acceptable salts of the intermediates or final compounds include the conventional non-toxic salts or the quaternary ammonium salts from non-toxic inorganic or organic acids. For example, such conventional non-toxic salts include those derived from inorganic acids such as hydrochloric, hydrobromic, sulfuric, sulfamic, phosphoric, nitric and the like; and the salts prepared from organic acids such as acetic, propionic, succinic, glycolic, stearic, lactic, malic, tartaric, citric, ascorbic, pamoic, maleic, hydroxymaleic, phenylacetic, glutamic, benzoic, salicylic, sulfanilic, 2-acetoxybenzoic, fumaric, toluenesulfonic, methanesulfonic, ethane disulfonic, oxalic, isethionic, and the like.
The pharmaceutically acceptable salts are generally prepared by reacting the free base or acid with stoichiometric amounts or with an excess of the desired salt-forming inorganic or organic acid or base in a suitable solvent or various combinations of solvents.
The pharmaceutically acceptable salts of the acids of the intermediates or final compounds are prepared by combination with an appropriate amount of a base, such as an alkali or alkaline earth metal hydroxide e.g. sodium, potassium, lithium, calcium, or magnesium, or an organic base such as an amine, e.g., dibenzylethylenediamine, trimethylamine, piperidine, pyrrolidine, benzylamine and the like, or a quaternary ammonium hydroxide such as tetramethylammoinum hydroxide and the like.
As discussed above, pharmaceutically acceptable salts of the compounds of the invention can be prepared by reacting the free acid or base forms of these compounds with a stoichiometric amount of the appropriate base or acid, respectively, in water or in an organic solvent, or in a mixture of the two; generally, nonaqueous media like ether, ethyl acetate, ethanol, isopropanol, or acetonitrile are preferred. Lists of suitable salts are found in Remington's Pharmaceutical Sciences, 17th ed., Mack Publishing Company, Easton, Pa., 1985, p. 1418, the disclosure of which is hereby incorporated by reference.
The present invention is contemplated to be practiced on at least a multigram scale, kilogram scale, multi kilogram scale, or industrial scale. Multigram scale, as used herein, is preferably the scale wherein at least one starting material is present in 10 grams or more, more preferably at least 50 grams or more, even more preferably at least 100 grams or more. Multikilogram scale, as used herein, is intended to mean the scale wherein more than one kilogram of at least one starting material is used. Industrial scale as used herein is intended to mean a scale which is other than a laboratory scale and which is sufficient to supply product sufficient for either clinical tests or distribution to consumers.
The methods of the present invention, by way of example and without limitation, may be further understood by reference to Schemes 2-4. Schemes 2-4 provide the general synthesis of compounds of formula (III)-(X). Compound of formula (II) can be prepared by methods described by S. D. Burke, et al. in Tet. Lett. 30, 6299 (89). Compounds of formula (VI) can be prepared by methods described in commonly assigned U.S. application Ser. No. 08/743439, the disclosure of which is hereby incorporated by reference. It is readily understood by one skilled in the art that alcohols and amines can be reacted with various compounds which, when attached to these atoms act as protecting groups. These groups are readily put on and removed by methods described in Protective Groups in Organic Synthesis, Greene, 2nd ed., John Wiley & Sons, Inc., N.Y., 1991. Further, alcohols may be converted to halogens and halogens may be converted to alcohols by methods described in Advanced Organic Chemistry, March, 3rd ed., John Wiley & Sons, Inc., N.Y., 1985, p. 382-384 and 326 respectively, the disclosure of which is hereby incorporated by reference.
SYNTHESIS
In Reaction 1, the propargylic alcohol (II) is reduced to the E-allylic alcohol (III). A vessel is preferably charged with about 10 mL of solvent per gram of reducing agent. While numerous reaction solvents are possible, ethers, cyclic ethers and toluene are preferred. Tetrahydrofuran is most preferred. The solution is preferably cooled to about 0° C. with continuous agitation. The reducing agent is preferably added to the solution after the desired temperature is achieved. While numerous reducing agents are possible, lithium aluminum hydride, Red-Al, diisobutylaluminum hydride, Li—NH 3 and EtNH 2 are preferred. LiAlH 4 is most preferred. Enough reducing agent is added to preferably produce a concentration of about 1.0M in the reaction solvent. The number of equivalents of reducing agent after addition is preferably about 1.0 to about 2.0 equivalents based on 1 equivalent of starting material. More preferred is about 1.2 to about 1.5 equivalents. The temperature is preferably kept below about 10° C. during the addition of the starting material. A solution of the propargylic alcohol, preferably in the reaction solvent, is slowly added to the stirred solution. Preferably, the solution contains 10 mL of solvent per gram of propargyl alcohol and is added to the reaction vessel at about 0° C. After the addition is complete, the reaction is preferably allowed to warm up to about 10° C. to about 30° C. and then preferably heated to about 65° C. to about 70° C. for about 1 hour. If THF is the reaction solvent, the solution is preferably refluxed. Reaction progression is preferably monitored by removing an aliquot of the reaction mixture and quenching it, preferably by the addition of aqueous hydroxide. The reaction is considered complete when an organic extract of the reaction shows no trace of starting material by gas chromatography. The reaction mixture is preferably quenched at about 0° C. to about 10° C. by the careful addition of water. The salts of the residue are removed, preferably by filtering through a Celite pad. The cake is preferably washed with a volatile organic solvent such as an ether, or hydrocarbon of which tert-butyl methyl ether is preferred. The mother liquor is preferably washed once with an aqueous salt solution and dried. Numerous methods of drying are suitable, including the addition of drying agents such as sodium or magnesium sulfate and azeotropic distillation. The addition of magnesium sulfate is preferred followed by filtration. The solvent may be removed, preferably under vacuum to give the desired product. The product may be purified, preferably by vacuum distillation which will be readily understood by one skilled in the art.
In Reaction 2, the allylic alcohol (III) is acylated to give the Claisen precursor E-allyl ester (IV). The allylic alcohol (III) is preferably dissolved in about 5 mL to about 15 mL of the reaction solvent per gram of starting material. Numerous reaction solvents are possible, such as ethers, alkyl cyanides, halogenated and aryl solvents of which acetonitrile, THF, methylene chloride, toluene, diethyl ether, and dimethoxyethane are preferred. Acetonitrile is most preferred. The temperature of the resultant solution is preferably cooled to about 0° C. If R 2 is an aryl group the reaction is preferably cooled to about −78° C. to about −30° C. to avoid a [3,3] sigmatropic rearrangement. About −35° C. to about −45° C. is more preferred. An amine base is preferably added at the reduced temperature. Numerous amine bases may be used, of which pyridine, N-methyl morpholine and triethylamine are preferred. Pyridine is most preferred. The amount of base is preferably about 1.0 to about 2.0 equivalents. More preferred is about 1.2 to about 1.5 equivalents. An acid halide is preferably added dropwise to the solution. The amount of acid halide used is preferably about 1.0 to about 1.5 equivalents. The reaction is preferably warmed to about room temperature and stirred for about 1 to about 10 hours. The reaction is considered complete when the starting material has been completely consumed as evident by gas chromatography. After the reaction is judged complete, the solution is preferably cooled below room temperature and quenched by the addition of a suitable aqueous acid such as hydrochloric acid. The aqueous layer is preferably withdrawn and the non-aqueous layer extracted with additional portions of the aqueous acid. The aqueous layers are preferably combined and extracted with the reaction solvent or if the reaction solvent is water miscible, a suitable organic solvent. Preferred solvents include hydrocarbons, ether, aryls, chlorinated and acetates. All organic extracts are preferably combined, and washed with water, an aqueous base such as sodium bicarbonate and a salt solution such as aqueous sodium chloride. The organic solution is preferably dried and concentrated. Numerous methods of drying are suitable, including the addition of drying agents such as sodium or magnesium sulfate and azeotropic distillation. The addition of magnesium sulfate is preferred followed by filtration. The solvent may be removed under vacuum and the product may be purified, preferably by vacuum distillation to give the desired product which will be readily understood by one skilled in the art.
In Reaction 3, the allylic ester (IV) is converted the silyl ester anti-adduct, which may be isolated or hydrolyzed during work-up to give the corresponding acid (VI). The allylic ester is preferably dissolved in a suitable anhydrous solvent under inert atmosphere to give a molarity of about 0.9 to about 1.1 molar. Preferred solvents include cyclic or acyclic ethers such as diethyl ether, t-butyl methyl ether, tetrahydrofuran and dimethoxyethane, with tetrahydrofuran being most preferred. A suitable silylating agent is preferably dissolved in the solution. Preferred silylating agents include trimethyl silylchloride and t-butyldimethylsilylchloride. The amount of silylating agent is preferably about 1.0 to about 1.2 equivalents based on the allylic ester.
The allylic ester/silylating agent solution is preferably added to a second solution of reaction solvent containing a suitable strong base to form the desired E-enolate which is trapped by the alkylsilylhalide. This order of addition is preferred because it minimizes the degree of self condensation. Alternatively, a solution of the silylating agent may be added to a solution containing the allylic ester and base. While numerous bases may be used, lithium hexamethyldisilazide, lithium diisopropylamide and lithium tetramethyl piperidide (TMP) are preferred. Lithium diisopropylamide is most preferred. The solution preferably contains about 1.0 to about 1.5 equivalents of base based on allylic ester. About 1.1 to about 1.3 is most preferred. The basic solution preferably has a molarity of about 0.2 to about 1.0. The addition is preferably performed at a reduced temperature of about −78° C. to about −60° C. Most preferred is about −78° C. to about −70° C. The addition should be performed over the course of about 30 minutes to about 2 hours depending upon scale, preferably keeping the temperature within the preferred range. The resulting mixture is preferably stirred at a temperature of about −78° C. to about −70° C. for about 15 minutes to about 60 minutes. About 30 minutes to about 45 minutes is preferred. About 5 equivalents to about 8 equivalents of an additive such as such as 1,1,2,2-tetramethylethylene diamine (TMEDA), hexamethylphosphoramide (HMPA), and 1,3-dimethyl-3,4,5,6-tetrahydro-2(1H)-pyrimidinone (DMPU) may be introduced, preferably keeping the reaction below about −60° C., with below about −70° C. being most preferred. The reaction is preferably stirred keeping the temperature within the preferred range preferably for about 1 to about 5 hours. Most preferred is about 2 to about 4 hours, preferably followed by allowing the solution to warm up over about 1 to about 4 hours. The room temperature solution is preferably stirred overnight. More preferably, the reaction stirs about 5 to about 16 hours at room temperature prior to work-up.
The silyl ester may be isolated, if desired. This is preferably accomplished by the addition of a suitable solvent. Such suitable solvents include ethers and hydrocarbons, with hexane being preferred. The resultant solution is preferably extracted with water and an aqueous salt solution such as sodium chloride, and the organic layer preferably dried. Numerous methods of drying are suitable, including the addition of drying agents such as sodium or magnesium sulfate and azeotropic distillation. The addition of magnesium sulfate is preferred followed by filtration. The solvent may be removed, preferably under vacuum. The desired stereochemistry is preferably determined using the isolated silyl ester intermediate. The diastereoselectivity of the reaction preferably produces the preferred diastereomer in a ratio of about 10:1 for the anti:syn stereochemistry, respectively. More preferred is about 15:1 or higher. Most preferred when G is OMOM is about 18:1 or higher. Most preferred when G is OTBDMS is about 30:1 or higher. The preferred method of analysis for determining the chiral purity is gas chromatography. The weight percent yield of the reaction is preferably about 70 to about 99 percent. More preferred is about 80 to about 99 percent.
Alternatively, the reaction may be quenched with water and treated with hydroxide to cleave the silyl ester. The amount of hydroxide is preferably about 1 to about 3 equivalents based on the substrate. More preferred is about 1.5 to about 2.0 equivalents. While numerous hydroxide sources are possible, lithium hydroxide is preferred. The lithium carboxylate is generally soluble in organic solvents, and may be extracted into a suitable organic solvent. Preferably, the reaction solution is concentrated prior to extraction. All organic extracts are preferably combined, and washed with water, an aqueous base such as sodium bicarbonate and a salt solution such as aqueous sodium chloride. The organic solution is preferably dried and concentrated. Numerous methods of drying are suitable, including the addition of drying agents such as sodium or magnesium sulfate and azeotropic distillation. The addition of magnesium sulfate is preferred followed by fitration. The solvent may be removed under vacuum and the product may be purified, preferably by vacuum distillation to give the desired product which will be readily understood by one skilled in the art.
In Reaction 4, the anti-succinic acid adduct (V) is coupled with an amino acid derivative (VI). The free acid anti-succinate adduct from the Claisen rearrangement (V) is preferably dissolved in a suitable solvent. The amount of solvent employed is preferably from about 5 mLs to about 15 mLs per gram of starting material. A wide variety of solvents may be employed including aprotic, ether, halogented, and aryl solvents. Preferred are tetrahydrofuran, acetonitrile and N,N-dimethylformamide. N,N-dimethylformamide is most preferred. The amino acid is preferably dissolved with the starting material. The amount of amino acid is preferably from about 1.0 to about 1.5 equivalents. Most preferred is from about 1.0 to about 1.2 equivalents. An acid scavenger is preferably added to the vessel. While numerous chemical species may act as acid scavengers, tertiary amine bases such as pyridine, N-methyl morpholine, N,N-diisopropylethylamine and triethylamine are preferred. Triethylamine is most preferred. The preferred amount of acid scavenger is from about 1.0 to about 5.0 equivalents. Most preferred is about 2.0 to about 4.0 equivalents. The resultant solution is preferably cooled. The most preferred reaction temperature is about 0° C. to about 5° C. After the desired temperature is achieved, a coupling agent is preferably added to the solution. Many reagents may act as suitable coupling agents for the formation of the amide bond including thlonyl chloride, dicyclohexylcarbodiimide (DCC), carbonyldiimidazole (CDI), 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide (EDC), O-(1H-benzotriazol-1-yl)-N,N,N′,N′,-tetramethyluronium tetraflouroborate (TBTU), benzotriazol-1-yl-oxy-tripyrrolidinophosphonium hexafluorophosphate (PyBOP) and benzotriazol-1-yl-oxy-tris-dimethylamino-phosphonium hexafluorophosphate (BOP). PyBOP and thionyl chloride are most preferred. It will be readily understood by one skilled in the art of organic synthesis that the use of thionyl chloride may be accompanied by an acid scavenger if labile protecting groups are present. Further, the order in which some of the components of a amide forming coupling reaction may be changed without substantially affecting the outcome of the reaction. For example, the base may be added after the coupling agent, or the acid may be first combined with the coupling agent before the addition of the nucleophile.
The reaction is preferably stirred at a reduced temperature for a period of about 1 hour to about 3 hours, then preferably allowed to warm to room temperature and stir for about 1 to about 4 hours. The reaction is considered complete when the starting acid has been been completely consumed, preferably as monitored by thin layer chromatography or NMR. The reaction is preferably diluted with an organic solvent, such as an ether, acetate, chlorinated or aryl solvent of which ethyl acetate is preferred. The organic solution is preferably washed with a suitable acid, with the most preferred being citric acid. The organic solution is preferably further washed with an aqueous base such as sodium bicarbonate and a salt solution such as aqueous sodium chloride. The organic solution is preferably dried and concentrated. Numerous methods of drying are suitable, including the addition of drying agents such as sodium or magnesium sulfate and azeotropic distillation. The addition of sodium sulfate is preferred followed by fitration. The solvent may be removed under vacuum and the product may be purified, preferably by recrystallization in a suitable solvent, the choice of which will be readily understood by one skilled in the art.
In Reaction 5, the coupled product may be deprotected either by liberating the protected oxygen, protected nitrogen, both, or neither depending upon the amino acid and chain terminus chosen. It will be understood by one skilled in the art, that if group G is a halogen, it will be converted to an oxygen only if a carbamate bridge is desired, as in the case of a macrocycle containing a lysine residue. Otherwise, the alkyl terminus is ready to undergo substitution with the phenolic alcohol of tyrosine. The halogen may be converted to an alcohol, preferably through the use of CBr 4 if a carbamate bridge is desired. This conversion will be readily understood by one skilled in the art. If however, the group G is a protected alcohol, conditions appropriate for the removal of the protecting group will be employed, such as the preferred method which is treatment with acid. With similiar reasoning, if lysine is the amino acid, the ω-protected nitrogen may be simultaneously deprotected under appropriate conditions, depending upon the protecting group. The preferred method of deprotection is the use of acid, for example when a butyloxycarbonyl (BOC) group is the nitrogen protector. If the tyrosine derivative is desired, the alcohol may be converted to the halogen by methods known in the art.
The following conditions may be used for the deprotection of alcohols.
Conditions to remove tetrahydropyranyl, triphenylmethyl, tetrahydrofuranyl, methoxymethyl, benzyloxymethyl, p-methoxybenzyloxymethyl, 2-trimethylsilyl ethoxymethyl, t-butoxymethyl, methylthiomethyl, 2-methoxyethoxymethyl, trichloroethoxymethyl, t-butyl, p-methoxyphenyldiphenyl methyl, may include: (a) 1-4M HCl in anhydrous or aqueous methanol, ethanol, isopropanol, tetrahydrofuran, dioxane, or diethyl ether; (b) 1-4M H 2 SO 4 in anhydrous or aqueous methanol, ethanol, isopropanol, tetrahydrofuran, dioxane, or diethyl ether; (c) poly styrene sulfonic acid resin in anhydrous or aqueous methanol, ethanol, isopropanol, tetrahydrofuran, dioxane, or diethyl ether; (d) 10-100% trifluoroacetic acid in dichloromethane; or (e) p-toluenesulfonic acid or camphorsulfonic acid in anhydrous or aqueous methanol, ethanol, isopropanol.
Conditions to remove benzyl, benzyloxymethyl, p-methoxybenzyloxymethyl, p-methoxybenzyl, o-nitrobenzyl, p-nitrobenzyl which employ hydrogenolysis in the presence of 1-17% palladium on carbon, or palladium black may only be used to the extent that they do not effect the integrity of the double bond in structure (VII). Examples of such conditions include the use of pressures in combination with amounts of catalyst sufficient to reduce the double bond which will be readily understood by one skilled in the art. Conditions to remove o-nitrobenzyl group include irradiation of the compound at 320 nm wavelength for 5-60 minutes. These conditions can only be employed to the extent that they do not reduce the double bond in the Claisen product which will be readily understood by one skilled in the art.
Conditions to remove 2-trimethylsilylethoxymethyl, t-butyldimethylsilyl, triisopropylsilyl, t-butyldiphenylsilyl may include: treatment of the compound with tetrabutylammonium fluoride; or hydrogen flouride pyridine complex in THF, DMF or dimethylpropyleneurea.
Conditions to remove allyl may include: isomerization of the allyl ether with [Ir(COD)(Ph 2 MeP) 2 ]PF 6 or (Ph 3 P) 3 RhCl in tetrahydrofuran, diethyl ether or dioxane followed by hydrolysis with aqueous HgCl 2 .
It will be readily understood by one skilled in the art, that certain conditions used to deprotect hydroxy groups, will also be appropriate for the removal of nitrogen protecting groups such as t-butyloxycarbonyl (BOC). These conditions may include (a) 1-4M HCl in anhydrous or aqueous methanol, ethanol, isopropanol, tetrahydrofuran, dioxane, or diethyl ether; (b) 1-4M H 2 SO 4 in anhydrous or aqueous methanol, ethanol, isopropanol, tetrahydrofuran, dioxane, or diethyl ether; (c) polystyrene sulfonic acid resin in anhydrous or aqueous methanol, ethanol, isopropanol, tetrahydrofuran, dioxane, or diethyl ether; (d) 10-100% trifluoroacetic acid in dichloromethane; or (e) p-toluenesulfonic acid or camphorsulfonic acid in anhydrous or aqueous methanol, ethanol, isopropanol. The following non-acidic conditions may be used for the deprotection of nitrogens.
Preferred Nonacidic
Protecting Group, Abbreviation
Removal Conditions
2-trimethylsilylethyl
ZnCl 2 in CH 3 NO 2
carbamate, Teoc
1,1-dimethyl-2,2-dibromoethyl
solvolysis with ethanol
carbamate, DB-t-Boc
1-methyl-1-(4-biphenylyl)ethyl
tetrazole in
carbamate, Bpoc
trifluoroethanol
2-(p-toluenesulfonyl)ethyl
1 M NaOH in alcohol
carbamate
m-nitrophenyl carbamate
photolysis
o-nitrobenzyl carbamate
photolysis
3,5-dimethoxybenzyl carbamate
photolysis
3,4-dimethoxy-6-nitrobenzyl
photolysis
carbamate
N′-p-toluenesulfonylamino-
alcoholysis
carbonyl
phthalimide
CH 3 NH 2 in ethanol
dithiasuccinimide, Dts
mercaptoethanol and Et 3 N
2,5-dimethylpyrrole
ozonolysis
benzyl
Na and NH 3
methanesulfonamide, Ms
lithium aluminum
hydride
In Reaction 6, the compound is cyclized. Two cyclization procedures are possible depending upon the bridging unit desired. If an ether linker is desired, the chain terminus may be a halogen in reactions 1-5. The halogen may also be derived later in the synthesis from an alcohol, which may be deprotected in reaction 5, then converted to either a halogen, or a sulfonate (or phosphate) ester by procedures known in the art. Such procedures for conversion to a halogen include treatment with CBr 4 and PPh 3 in a suitable solvent. Such procedures for conversion of an alcohol to a sulfonate ester include treatment with a halo derivative of the desired sulfonyl group in the presence of an acid scavenger. The other reactive end is either the phenolic alcohol of tyrosine, or the ω-nitrogen of lysine.
The cyclization substrate is preferably dissolved in a suitable solvent. Preferred solvents include N,N-dimethylformamide and dimethylsulfoxide. A base is preferably dissolved in a suitable solvent. Preferred solvents include N,N-dimethylformamide and dimethyl seulfoxide. Most preferred is about a 4:1 mixture of N,N-dimethylformamide and dimethylsulfoxide. The basic solution is preferably heated. Preferred temperatures are about 40° C. to about 80° C. The solution containing the substrate is preferably added to the basic solution. The resultant solution is preferably heated until the starting material is consumed. Preferred temperatures are about 40° C. to about 80° C. More preferred is about 60° C. to about 85° C. Most preferred is 75° C. to about 85° C. The reaction is judged complete when the starting material is consumed, as evident by TLC. The reaction is preferably cooled and quenched with a suitable acid such as sodium bisulfate. The solution is preferably partitioned between the quenching acid and an organic solvent. Preferred organic solvents include aryls, chlorinated hydrocarbons, ethers and acetates. Most preferred is ethyl acetate. The aqueous layer is preferably extracted two to three times with the extraction solvent. The combined organics are then preferably washed two to three times with water and a saturated salt solution such as aqueous sodium chloride. The organic solution is preferably dried and concentrated. Numerous methods of drying are suitable, including the addition of drying agents such as sodium or magnesium sulfate and azeotropic distillation. The addition of sodium sulfate is preferred followed by fitration. The solvent may be removed under vacuum and the product may be purified, preferably by recrystallization in a suitable solvent, the choice of which will be readily understood by one skilled in the art.
If a carbamate linker (—OCONH—) is desired, the chain terminus is preferably an alcohol, deprotected in reaction 5. The chain terminus may also be a halogen through reaction 1-5, converted to an alcohol by procedures known in the art, such as treatment with hydroxide in a suitable solvent system. The other reactive end is the ω-nitrogen of lysine, preferably deprotected in Step 5.
The starting material is preferably dissolved in a suitable solvent. While numerous solvents are possible, ethers are preferred. Tetrahydrofuran is most preferred. The solution is preferably cooled. Preferred temperatures include about −78° C. to about 5° C. Most preferred is about −5° C. to about 5° C. An acid scavenger is preferably added via syringe or dropping funnel. While numerous chemical species may act as acid scavengers, tertiary amine bases such as pyridine, N-methyl morpholine, N,N-diisopropyl ethylamine, and triethylamine are preferred. N,N-diisopropylethylamine is most preferred. The preferred amount of acid scavenger is from about 1.0 to about 5.0 equivalents. Most preferred is about 2.0 to about 4.0 equivalents. A phosgene or phosgene equivalent is preferably added dropwise. The reaction is preferably stirred for about 1 to about 7 hours. More preferred is about 4 to about 6 hours, warming the reaction to room temperature during the last hour after isocyanate formation if evident by TLC. A catalyst is preferably dissolved in the reaction solvent and added. The preferred concentration when all material is added is about 0.3 M to about 0.5 M. Preferred catalysts include, but are not limited to cupric halides and alkyl tin reagents such as dibutyltin dilaurate, which is preferred. The amount of catalyst is preferably about 1 percent to about 10 percent by weight of the starting material. Most preferred is about 4 percent to 6 percent. The reaction is preferably stirred for about 1 to about 5 additional hours. The reaction is considered complete when all starting material has been consumed, as evident by TLC. Product formation may also be evident by HPLC. The reaction is preferably diluted with a water immiscible organic solvent, such as an ether, aryl or acetate. The solution is preferably stirred to achieve the dissolution of any solids, followed by extraction with an acid aqueous medium. Saturated ammonium chloride is preferred. The organics are preferably washed one to two times with water and a salt solution such as aqueous sodium chloride. The organic solution is preferably dried and concentrated. Numerous methods of drying are suitable, including the addition of drying agents such as sodium or magnesium sulfate and azeotropic distillation. The addition of sodium sulfate is preferred followed by fitration. The solvent may be removed under vacuum and the product may be purified, preferably by recrystallization in a suitable solvent, the choice of which will be readily understood by one skilled in the art.
In Reaction 7, the olefin is oxidized to give a carboxylate group. The substrate is preferably taken up in a suitable solvent. While many solvents may be used, alcoholic solvents are preferred. Methanol is most preferred. The solution is preferably cooled. Preferred temperatures are about −78° C. to about 5° C. A suitable oxidizing agent is preferably added. Preferred oxidizing agents include ozone and potassium permanganate in sodium periodate. Ozone is most preferred. Preferably, ozone is bubbled through the solution. The solution preferably turns blue, and is monitored by TLC. The reaction is considered complete when the starting material is consumed. An inert gas is preferably bubbled through the solution to to remove residual ozone. The mixture is preferably concentrated under reduced pressure. The residual material is preferably dissolved in a suitable acid. Suitable acids include organic and mineral acids. Organic acids are preferred. Formic acid is most preferred. The acid addition is preferably followed by the addition of a peracid. Aqueous hydrogen peroxide is preferred. The percent weight of the peroxide solution in water is preferably about 3 percent to 50 percent by weight. Most preferred is about 20 percent to 30 percent. The mixture is preferably stirred for a suitable period of time at room temperature. The amount of time is preferably 1 to 7 hours, or until the starting material is consumed, as evident by TLC. The reaction is preferably quenched by the addition of an aqueous acid at reduced temperature. The preferred acid is sodium bisulfate. The reaction may be tested for peroxide, as is understood in the art. The product may be isolated by extraction with an organic solvent such as aryl, ether or acetate. The organics are preferably washed one to two times with water and a salt solution such as aqueous sodium chloride. The organic solution is preferably dried and concentrated. Numerous methods of drying are suitable, including the addition of drying agents such as sodium or magnesium sulfate and azeotropic distillation. The addition of sodium sulfate is preferred followed by fitration. The solvent may be removed under vacuum and the product may be purified, preferably by recrystallization in a suitable solvent, the choice of which will be readily understood by one skilled in the art.
The present invention may be further exemplified, without limitation, by reference to Schemes 5-6.
The following examples are meant to be illustrative of the present invention. These examples are presented to exemplify the invention, and are not to be construed as limiting the inventors scope.
EXAMPLE 1
Preparation of Allylic Alcohol (III-i)
A 5 L 4-neck-rounded flask was charged with 1600 mL of dry THF and cooled to 0° C. with continuos agitation. To this cooled THF solution was slowly added LiAlH 4 (1100 mL, 1.0 M in THF) to keep the internal temperature below 10° C. A solution of the propargylic alcohol (163 g, 0.815 mols) in THF (60 mL) was slowly added to the stirred solution of LiAlH 4 in THF at 0° C. via additional funnel. The internal temperature was kept below 10° C. After the addition was completed, the reaction was allowed to warm up to 25° C. and then reflux (68° C.) for 1 hour. After that time, an aliquot of the reaction mixture (1 mL) was worked up by addition of NaOH 10% aqueous solution at 0° C. and analyzed by 1 H-NMR showing no trace of starting material. The reaction mixture was quenched at 0° C. by carefully dropping 50 mL of water until the hydrogen evolution was controlled. Then, 102 mL of NaOH 10% aqueous solution added in moderate portions. The aluminum salts residue were filtered through a Celite path and washed with t-butyl-methyl ether (3×150 mL). The mother liquor was washed once with brine and dried over MgSO 4 . After filtration and rotary-evaporation, 150 g of crude material was isolated. Crude material shows a GC trace of 87% purity by GC area. Distillation under reduced pressure, b.p.=90° C. to 93° C./0.8 mmHg. Enatiomeric excess: 92% ee by HPLC. 1 H-NMR (CDCl 3 ): 5.58 (1H, m), 5.44 (1H, dd), 4.56 (2H, s), 3.72 (1H, t), 3.49 (2H, t), 3.31 (3H, s), 2.10 (2H, m), 1.86 (1H, s, broad), 1.64 (3H, m), 0.87 (3H, d), 0.82 ppm (3H, d) 13 C-NMR (CDCl 3 ): 131.8, 96.3, 67.0, 55.0, 33.8, 29.2, 28.8, 18.1 ppm. MS (C.I., NH 3 ): 203 (M+1).
EXAMPLE 2
Preparation of Ketone (IV-i)
In a 2 L 4-neck-rounded flask was dissolved the allylic alcohol (121 g, 0.60 mols) in CH 2 Cl 2 (1.2 L) and cooled to 0° C. with continues agitation, under nitrogen. To this stirred solution was added pyridine (72.79 mL, 0.90 mols) in one portion. 4-Methyl valeryl chloride (121 g, 0.90 mols) was charged into an additional funnel and added to the stirred reaction mixture at 0° C. dropwise. The solution turned yellow during addition. The reaction mixture was allowed to warm slowly to r.t. After 10 h of stirring at r.t. no starting material was shown on TLC (hexane/ethyl acetate:4:1 v/v). The solution was cooled to 0° C. and quenched with 400 mL of HCl (0.5 M). The organic phase was washed three times with HCl (0.5 M, 200 mL). The combined aqueous layers were extracted once with 300 mL of CH 2 Cl 2 . The combined organic layers was subsequently washed once with 300 mL of water, 300 mL NaHCO 3 (sat.) and 400 mL of brine. Finally, the solution was dried over MgSO 4 and rotary evaporated to afford 208 g (112%) of crude allylic ester. The product was purified by reduced pressure distillation. b.p.=125 to 128° C./0.8 mmHg. Enantiomeric excess: 93%ee by HPLC. 1 H-NMR (CDCl 3 ): 5.68 (1H, m), 5.38 (1H, q), 5.00 (1H, t), 4.62 (2H, s), 3.52 (2H, t), 3.34 (3H, s), 2.30 (2H, t), 2.14 (2H, q), 1.83 (1H, m), 1.67 (2H, m), 1.54 (3H, m), 0.92 (6H, dd), 0.89 ppm (6H, dd). 13 C-NMR (CDCl 3 ): 173.2, 134.1, 127.2, 96.3, 79.1, 66.9, 55.0, 33.1, 32.7, 32.0, 29.0, 28.8, 27.6, 22.2, 18.0 ppm. MS (C.I., NH 3 ): 301(M+1).
EXAMPLE 3
Preparation of Silyl Ester (IV-a-i)
To a dry 500 mL 3-neck-round bottom flask equipped with a magnetic stirring bar, nitrogen inlet and outlet under nitrogen atmosphere was charged with 150 mL of dry THF and diisopropylamine (4.36 g, 43.05 mmol, 1.3 equivalent). The solution was cooled to 0° C. with stirring. To this solution, n-butyl lithium (26.9 mL of 1.6 M solution in THF, 43.05 mmol, 1.3 equivalent) was added slowly (in such a rate that internal temperature did not exceed 5° C.). The solution was stirred at 0° C. for 1 hour and then cooled to −78° C. The titled allylic ester (9.95 g, 33.12 mmol) in 35 mL THF solution was added very slowly (in such a rate that internal temperature did not exceed −72° C.) to the LDA solution with vigorous stirring. The reaction mixture was stirred for 45 minutes at −78° C. followed by the addition of TBSCl (5.5 g in 45 ml of THF, 36.4 mmol, 1.1 equivalent) slowly (internal temperature<−72° C.) and then DMPU (25 mL) slowly (internal temperature<−72° C.). The reaction mixture was stirred at −78° C. for 30 minutes, and then gradually warmed from −78° C. to room temperature and stirred at room temperature for 14 hours. The reaction was then quenched with saturated ammonium chloride solution (150 mL) and extracted with hexane (3×150 ml). The combined organic phases were dried with anhydrous magnesium sulfate (10 g). Filtration to filtered magnesium sulfate, and the solvents were removed with rotoevaporate under reduced pressure. The residue was then dried under high vacuum to produce 11.3 g (83% yield). The enantio-selectivity: 93%ee (by GC), diastereoselectivity, anti/syn >30:1 (by NMR). 13 C-NMR (300 MHz, ppm, CDCl3): 17.5, 21.5, 22.2, 22.6, 22.7, 23.7, 25.4, 25.5, 25.6, 26.5, 27.6, 29.7, 31.1, 39.5, 46.0, 50.5, 55.0, 67.7, 96.3, 127.9, 140.4, 176.1. 1 H-NMR (300 MHz, ppm, CDCl3, J=Hz): 0.16 (s, 6H), 0.82 (dd, J=5.7, 5.7, 6H), 0.84, (s, 9H), 0.88 (d, J=23, 6H), 1.09˜1.22 (m, 3H), 1.23˜1.49 (m, 4H), 2.02 (m, 1H), 2.16 (m, 3H), 2.24 (s, 3H), 3.37 (t, J=6.1, 2H), 4.49 (s, 2H), 4.87 (dd, J=15.57, 8.25, 1H), 5.29 (dd, J=15.2, 8.25, 1H).
EXAMPLE 4
Preparation of Silyl Ester (IV-a-ii)
To a dry 500 mL 3-neck-round bottom flask equipped with a magnetic stirring bar, nitrogen inlet and outlet under nitrogen atmosphere was charged with 150 mL of dry THF and diisopropylamine (4.01 g, 39.63 mmol, 1.3 equivalent). The solution was cooled to 0° C. with stirring. To this solution, n-butyl lithium (39.6 mmol, 24.8 mL of 1.6 M solution in THF, 1.3 equivalent) was added slowly (in such a rate that internal temperature did not exceed 5° C.). The solution was stirred at 0° C. for 1 hour and then cooled to −78° C. The titled allylic ester (11.3 g, 30.5 mmol) in 35 mL THF solution was added very slowly (in such a rate that internal temperature did not exceed −72° C.) to the LDA solution with vigorous stirring. The reaction mixture was stirred for 45 minutes at −78° C. followed by the addition of TBSCl (5.05 g in 45 ml of THF, 33.5 mmol, 1.1 equivalent) slowly (internal temperature<−72° C.) and then DMPU (25 mL) slowly (internal temperature<−72° C.). The reaction mixture was stirred at −78° C. for 30 minutes, and then gradually warmed from −78° C. to −20° C. in a period of 5 hours. The reaction was then quenched with saturated ammonium chloride solution (150 mL) and extracted with hexane (3×150 ml). The combined organic phases were dried with anhydrous magnesium sulfate (10 g). Filtration to filtered magnesium sulfate, and the solvents were removed with rotoevaporate under reduced pressure. The residue was then dried under high vacuum to afford the crude product, which was purified by silicon gel chromatography to afford the desired product (12.5 g, 83% yield). The enantioselectivity: 94%ee (by GC), diastereoselectivity, anti/syn >20:1(by NMR). 13 C-NMR (ppm, free acid, CDCl3): 18.3, 21.5, 22.6, 23.6, 25.9, 26.4, 29.2, 30.5, 31.1, 38.8, 45.5, 48.7, 63.1, 127.7, 140.5, 181.7. 1 H-NMR (300 MHz, ppm, CDC 1 3, J=Hz): −0.034 (s, 6H), 0.85 (dd, J=6.5, 6.5, 6H), 0.85, (s, 9H), 0.94 (d, J=22, 6H), 1.15˜1.29 (m, 3H), 1.30˜1.57 (m, 4H), 2.09 (m, 1H), 2.18˜2.32 (m, 3H), 3.53 (t, J=5.3, 2H), 4.95 (dd, J=15.19, 7.79, 1H), 5.29 (dd, J=15.02, 7.79, 1H).
EXAMPLE 5
Preparation of Amide (VII-ii)
To a solution of the acid(2.4 g, 8 mmol) and ω-N-Boc-L-Lysine methyl ester hydrogen chloride salt(2.4 g, 8 mmol) in DMF(30 ml) cooled in an ice water bath was injected triethylamine(6.7 ml, 48 mmol) followed by addition of PyBop(4.70 g, 8 mmol). Stirring was continued at 0° C. for 2 hrs and rt for 3 hrs. The resulting mixture was diluted with EtOAc (150 ml) and then washed with aqueous NaHCO 3 , brine, dried over Na 2 SO 4 . The EtOAc solution was concentrated and the residue was flush chromatographed on silica gel to afford the product as a white solid(3.59 g, 83%). Diastereomeric Excess: >95% by 1 H NMR. 1 H-NMR (CDCl 3 ): 6.04(1H, d), 5.40(1H, dd), 4.96(1H, dd), 4.76(1H, broad), 4.64(1H, m), 4.58(2H, s), 3.76(3H, s), 3.46(2H, m), 3.34(3H, s), 3.08(2H, q), 2.28(1H, m), 1.96-2.16(2H, m), 1.84(1H, m), 1.14-1.68(10, m), 1.46(9H, s), 0.98(6H, d), 0.86(6H, d). MS(ESI): 543(M+1).
EXAMPLE 6
Preparation of Aminoalcohol (VIII-a-i)
To a solution of the amide (3.30 g, 6.10 mmol) in MeOH(36 ml) was added 4N HCl in 1,4-dioxane(12 ml). The resulting solution was stirred at rt for 7 hrs, and then concentrated under reduced pressure to give the aminoalcohol as an amorphous solid(2.60 g, 99%). 1H NMR(DMSO): 8.26(1H, d), 7.98(2H, s), 5.28(1H, dd), 4.90(1H, dd), 4.20(1H, m), 3.58(1H, m), 3.26(2H, t), 2.70(2H, m), 2.24(m, 1H), 2.10(1H, t), 1.82(1H, q), 1.00-1.70(13H, m), 0.92(6H, d), 0.78(3H, d), 0.74(3H, d). MS(ESI): 399(M+1).
EXAMPLE 7
Preparation of Cyclic Carbamate (IX-a-i)
To a suspension of the aminoalcohol HCl salt(560 mg, 1.06 mmol) in THF(100 ml) cooled at −20° C. was added DIEA(0.58 ml). After stirring for 30 min, a solution of triphosgene(116 mg) in THF(10 ml) was injected, followed by the addition of a catalytic amount of dibutyltin dilaurate(5 mol%). The mixture was stirred at −20° C. for 5 hrs and then at rt overnight. After concentration, the solid residue was washed with hexane and further purified by flush chromatography using CH 2 Cl 2 and MeOH as the eluent to afford the desired cyclic carbamate as a white solid(405 mg, 74%). 1H NMR(CDCl 3 ): 5.90(1H, d), 5.34(1H, dd), 4.80(1H, dd), 4.80(2H, m), 4.40(1H, t), 3.78(1H, m), 3.68(3H, s), 3.38(1H, m), 2.94(1H, m), 2.20(2H, m), 1.80-2.04(3H, m), 0.94-1.60(10H, m), 0.90(6H, d), 0.88(3H, d), 0.86(3H, d). MS(ESI): 425(M+1).
EXAMPLE 9
Preparation of Cyclophene (IX-i)
The phenol alcohol (530 mg, 1.22 mmol) and CBr 4 (810 mg, 2.44 mmol) were mixed in THF (12 ml) and cooled with an ice water bath. To this solution was added a solution of PPh3(640 mg, 2.44 mmol) in THF(10 ml). The reaction mixture was stirred at rt overnight. After removal of THF, the residue chromatographed on silica gel using a mixture of EtOAc and Hexane as the eluent to afford the desired bromide as an amorphous solid(540 mg, 89%).
To a suspension of Cs 2 CO 3 (720 mg, 2.2 mmol) in DMF(13.2 ml) and DMSO(4.4 ml) heated at 60° C. was added a solution of the bromide(420 mg, 0.85 mmol) in DMF (6.5 ml). After addition, stirring was continued at 80° C. for 30 mins. The mixture was cooled down to to 0° C. with an ice-water bath and neutralized with citric acid. After removal of DMF and DMSO under reduced pressure, the residue was extracted with EtOAc and the EtOAc solution washed with NaHCO 3 , brine, then dried. Chromatography after concentration on silica gel using a mixture of EtOAc and Hexane as the eluent gave a white solid(240 mg, 68%). 1 H NMR(CDCl 3 ): 7.26(1H, d), 7.08(1H, d), 6.94(2H, s), 5.30(2H, m), 4.98(1H, m), 4.64(1H, dd), 4.20(1H, dd), 3.86(1H, m), 3.76(3H, s), 3.70(1H, dd), 2.60(1H, t), 2.24(1H, m), 1.86(1H, m), 1.58(3H, m), 1.00-1.40(5H, m), 0.986(6H, d), 0.86(3H, d), 0.76(3H, d). MS(ESI), 416(M+1).
EXAMPLE 10
Preparation of Cyclic Carbamate Diacid Monomethyl Ester (X-a-i)
A solution of the cyclic carbamate (35 mg, 0.083 mmol) in methanol (5 ml) was cooled in an acetone-dry-ice bath. Into this solution was bubbled a O 3 -O 2 flow. When the solution turned slightly blue, it was concentrated under reduced pressure. The residue thus obtained was dissolved in 4 ml of formic acid, followed by addition of 2 ml of 30% H2O2. The mixture was stirred at rt for 3 hrs. 1.8 g of sodium hydrobissulfite was added in portion. After addition, the reaction mixture was further stirred at rt for 30 mins (At this time peroxide test should be negative). After concentration, the residue was washed thoroughly with EtOAc and CH 2 Cl 2 . Concentration of the organic solution afforded a solid, which was further purified by plug-filtration. 26 mg of the product was obtained. 1H NMR(DMSO): 7.98(1H, d), 6.36(1H, s), 4.40(1H, m), 4.14(1H, m), 3.92(1H, d), 3.60 (3H, s), 3.04(2H, m), 2.50(1H, m), 2.20(1H, m), 1.30-1.80(13H, m), 0.88(3H, d), 0.82(3H, d). MS(ESI): 405(M+1).
Analyticla Methods
GC Test Method (Achiral)
For general analysis of reaction and products (Steps 1-3):
Chromatographic Conditions
Column: J & W DB-17, 15 m×0.53 mm I.D., 1.0 um thick film thickness or equivalent
Injector Temp.: 150° C.
Detector Temp.: 280° C.
Inlet Pressure: 2.8 psi
Inlet Flow: 4 ml/min
Stop time: 37.5 min
Split Flow: splitless
Oven Temperature Program
Oven Initial Temp: 35° C. Time: 5 min
Oven Program Rate: 15° C./min
Oven Temperature: 240° C. Time: 2 min
Oven Program Rate: 10° C./min
Oven Temperature: 270° C. Time: 7 min
Sample Preparation
one drop of reaction mixture dissolved in ACN
Approximate Retention Times
Example 1: Propargyl-OH (II): 13.4 min Allyl-OH (III): 13.2 min
Example 2: Allyl-ester (IV): 15.9 min
Example 3: Claisen-silyl-ester (V): 15.5 min
GC Test Method (chiral)
For the determination of silyl ester diastereomers following the Claisen rearrangement (step 3):
Chromatographic Conditions
Column: J & W DB-17, 15 m×0.53 mm I.D., 1.0 um thick film thickness or equivalent
Injector Temp.: 150° C.
Detector Temp.: 280° C.
Inlet Pressure: 2.8 psi
Inlet Flow: 4 ml/min
Stop time: 28.0 min
Split Flow: splitless
Oven Temperature Program
Oven Initial Temp: 150° C. Time: 5 min
Oven Program: 2° C./min→170° C. Time: 3 min
Oven Program: 10° C./min→270° C.
Sample Preparation
one drop of sample in acetonitrile
Approximate Retention Times
Examples 3 and 4: Anti (silyl-ester): 15.1 min Syn (sylyl-ester): 15.6 min
HPLC Method (Chiral)
Assay of Allyl Ester of step 1:
Chromatographic Conditions
Column: Chiracel AD, 25 cm×4.6 mm i.d.
Mobile Phase: 99% acetonitrile/1% isopropanol
Flow rate: 1.0 mL/min
Oven Temperature: 5° C.
Injection volume: 5 uL
Detection: 205 nm
Stop time: 10 min
Post time: 3 min
Sample Preparation
Sample Prep.: Dissolve sample into acetonitrile (eluent) and adjust concentration to approximately 1 mg/ml. The sample concentration may be adjusted to ensure the proper quantitation.
Retention Times
Example 1: S enantiomer: 3.7 min R enantiomer: 4.0 min
HPLC Method (Achiral)
General method for monitoring of reactions and products of steps 4-7:
Column: 25 cm×4.6 mm id. Ultracarb 5 C8 (Phenomenex)
Mobile Phase: A: 0.1% trifluoroacetic acid in HPLC grade water B: 0.1% trifluoroacetic acid in HPLC grade acetonitrile
Gradient:
t = 0 min
60% A 40% B
t = 5 min
60% A 40% B
t = 10 min
60% A 40% B
t = 15 min
55% A 45% B
t = 20 min
50% A 50% B
t = 25 min
0% A 100% B
t = 30 min
0% A 100% B
Flow Rate: 1.0 mL/min
Injection Volume: 5 microliters
Stop Time: 30 minutes
Oven Temp.: ambient
Detector: UV (220 nm)
Sample Prep.: Dissolve 25 mg of sample (dry solids weight) into the eluent and adjust concentration to approximately 1 mg/ml. Reaction aliquot (1-5 drops) may also be dissolved in eluent for monitoring reaction progression. The sample concentration may be adjusted to ensure the proper quantitation.
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The present invention is directed to a process for the preparation of a compound of formula (X-a):
or a pharmaceutically acceptable salt form thereof, wherein:
R 1 is selected from the group consisting of:
C 1-5 alkyl substituted with 0-5 R 1a , —(CH 2 ) r —C 3-10 cycloalkyl substituted with 0-5 R 1a , and —(CH 2 ) r -aryl substituted with 0-5 R 1a .
Compounds of Formula (X-a) are macrocyclic molecules containing anti-succinate residues which inhibit metalloproteinases such as aggrecanase, and the production of tumor necrosis factor (TNF). The anti-succinates are formed by an Ireland Claisen rearrangement of a silyl ketene acetal which proceeds with high stereoselectivity.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of my copending U.S. application Ser. No. 888,744, filed Mar. 21, 1978.
BACKGROUND OF THE INVENTION
The present invention relates to novel piperidinyldithiocarbonic acid derivatives that are free of undesired degradation products which have been regarded as a potential source of environmental hazard to mammalian species, including man.
Dithiocarbamates and dithiocarbonates are well known in the art and have been used for diverse purposes. They are not widely accepted because of the impurities in the products which are deleterious to human, animals and plants. A major objection to the products of the prior art is that they are carcinogenic and a hazard to the environment. Therefore, there is a need to overcome the disadvantages of the prior art products and render them more useful for their intended usage.
The process of preparing dithiocarbamates and dithiocarbonates by prior art methods are dangerous and hazardous, resulting in the formation of side reaction products. The process creates a physical hazard and danger to the workers producing the dithiocarbamates and dithiocarbonates. Therefore, there is a need to overcome the hazardous formation of dithiocarbamates as well as the production of compounds that create environmental problems.
According to prior art methods, it was not possible to react a dithiocarbonate compound with compounds containing both sulfur and chlorine, e.g., thionyl chloride and sulfuryl chloride, because said compounds readily decomposed when placed in water. Although U.S. Pat. Nos. 1,798,588, 2,414,014, 3,116,328 and 3,193,580 teach the use of thionyl chloride and sulfuryl chloride as being capable of reacting with dithiocarbamates in water, the prior art recognizes that said thionyl chloride and sulfuryl chloride will decompose in water and thus cause the basic dithiocarbamic acid to precipitate. See, e.g.:
Comptes rendus hebdomadaires des seances de l'academie des sciences 62,461, (1866)
Gazzetta chimica italiano 24, 364, (1894)
Journal American Chemical Society 35, 543-546, (1913)
Svensk Kemisk Tidsckrift 13, 108, (1920)
Journal of the Chemical Society (London) 117, 1103 (1920)
Science 67, 19, (1928)
Monatshefte fur Chemie und verwandte Teile anderer Wissenschaften 93, 49, (1962)
OBJECT OF THE INVENTION
It is therefore a significant object of the present invention to provide a dithiocarbonate that is particularly effective for achieving complete control, complete extermination and removal of undesired pathogens after they have infested an area to be protected without contamination of the environment or damage to the plant to be protected.
Consistent with this object, it is a primary object to provide an improved dithiocarbonate that is free of side reaction products, alkali and metal, although alkalies may be used as reactants.
Another object of the invention is to provide dithiocarbonates when treated with sulphur and chlorine compounds (where sulphur and chlorine are in the same molecule) do not decompose in the reaction.
A still further object of the present invention is to provide an improved accelerator to improve the vulcanization of synthetic and natural rubber compounds, due to the purity of the accelerator.
A further object of the invention is the provision of a simple and efficient method for the preparation of the compounds of this invention.
Still another object of the invention is the provision of the novel compounds and compositions that exhibit a favorable rate of dissappearance from soil after application thereby avoiding residual action by remaining in the soil after the desired period for chemical control has passed.
Another object of the invention is to provide a pathological compound that is useful as a general fungicide on lawns, golf courses, parks, playgrounds, recreational areas, along highways, home gardens, farms, hot houses, potted plants, nurseries and wherever, with effects visible in a few days.
A further object of the invention is the provision of new dithiocarbonate compounds that do not have adverse effects on aquatic life nor on water so treated, when used for irrigation, human or animal purposes.
BRIEF SUMMARY OF THE INVENTION
Briefly, the invention relates to new compounds of the formula: ##STR2## wherein R is selected from the group consisting of S x , (wherein x is a whole number from 1 to 3), SO, SO 2 , S 2 O 3 , S 2 O 4 , S 2 O 5 .
Compounds of this invention are formed by the reaction of two moles of piperidinyl dithiocarbonic acid, two moles of an alkali, e.g., an ammonium or alkali metal hydroxide, and a compound selected from the group consisting of: SCl 2 , S 2 Cl 2 , SOCl 2 , SO 2 Cl 2 , S 2 O 4 Cl 2 , and S 2 O 5 Cl 2 .
The alkali halide is then removed by filtration and suction, and the alcoholic solution taken to dryness by vacuum distillation. There are no side reaction-products or reactions taking place once the main reaction has taken place.
DETAILED DESCRIPTION OF THE INVENTION
Piperidinyldithiocarbonic acid used in this invention is prepared by adding a mole of piperidine to 500 ml. of cold water (5° C., approximately) in a reactor equipped with a stirring device, followed by one mole of CS 2 poured into the aqueous solution of piperidine. The reactor is then closed and the reactants vigorously agitated for a period of time sufficient for the reaction to take place which generally takes place within about 2 hours. Stirring for a longer period is not detrimental. The water-insoluble precipitate is then recovered by filtration and suction. The filter cake is then dissolved in chloroform, dried over sodium sulphate and filter clay. The drying can be accomplished by drawing warm air (about 70° to 75° C.) through the cake until dry or by washing with acetone or alcohol, refiltering and drying. Drying by drying towers, drying ovens and mechanical devices can be used providing the temperature of the crystalline piperidinyldithiocarbonic acid does not exceed 80 degrees centigrade.
This piperidinyldithiocarbonic acid is essentially chemically pure. Ultra-violet absorbency studies showed no particular peaks from 200 millimicrons up to 400 millimicrons, however, from 285 millimicrons into the visible range there is a high absorbency band.
Infra-red studies from 2.5 microns to 16 microns showed a number of absorption peaks, some of the major peaks were 3.4 and a reverse absorption peak at 3.6, a minor peak at 4.7, several minor peaks between 5.0 and 6.5, with major peaks at 7.2, 8.3, 9.0, 10.5, 11.8 and 13.0.
It should be noted that morpholine could replace piperidine but there are disadvantages associated with the use of morpholine, in the preparation of the dithiocarbonic acid as well as in the processing of the morpholinyldithiocarbonic acid.
The compounds of the present invention are formed by reacting two moles of piperidinyldithiocarbonic acid in 500 ml. of chloroform with one mole of a reactant selected from the group consisting of: (a) SCl 2 , (b) S 2 Cl 2 , (c) SOCl 2 , (d) SO 2 Cl 2 , (e) S 2 O 4 Cl 2 , and (f) S 2 O 5 Cl 2 , and two moles of potassium hydroxide. the reactants are vigorous stirred for one hour. The potassium chloride produced in the reaction is removed by filtration and suction and the product is taken to dryness under reduced heat and pressure. The compounds formed from these reactions, the potassium chloride being removed and the alcohol being recovered by vacuum distillation are: (a) Bis piperidinyldithiocarbonylsulphide, (b) Bis piperidinyldithiocarbonyldisulphide, (c) Bis piperidinyldithiocarbonylsulfoxide, (d) Bis piperidinyldithiocarbonylsulphur dioxide, (e) Bis piperidinyldithiocarbonylsulphurtetraoxide, and (f) Bis piperidinyldithiocarbonylsulphurpentaoxide.
The compounds of this invention can also be prepared by reacting 2 moles piperidinyldithiocarbonic acid and one mole of a reactant defined hereinabove, in 1000 ml. of methanol. The mixture is cooled to 5° C. (approximately). Two moles of crystalline potassium hydroxide is added to the mixture. The reactor is closed and the mixture vigorously stirred for a period of time to cause the reaction to go to completion which is about two hours. The same reaction products defined above, are produced.
COMPOSITIONS
In the formation of compositions for application as an anhydrous application, the compounds of this invention can be admixed with any of the well-known, free-flowing, particulate, dry, inert solid carriers which may be organic or inorganic, dry, inert solid carriers which may be organic or inorganic, including, e.g., sawdust, wood-by-products, lignin and lignin-cellulose, ligninsulfonic acid, cork, urea-formaldehyde, resins, silicas, carbonates, calcite, dolomite, silicates, tricalcium phosphate, boric acid, etc. In addition, the compositions may optionally contain a conventional wetting agent, which renders the product wettable and dispersable, thereby facilitating the application thereof in the field. The wetting agent can be anionic, non-anionic or cationic. Particularly useful wetting agents include those disclosed in Bulletin E-607 of the Bureau of Entolology and Plant Quarantine of the United States Department of Agriculture or those disclosed in U.S. Pat. Nos. 2,426,417; 2,655,447; 2,412,510 and 2,139,276. A preferred surfactant is sodium lauryl sulfonate.
In addition, the compositions may optionally contain from about 0.5 to about 1.0 weight percent of a wetting agent, which renders the products wettable and dispersible, thereby facilitating the application thereof to plants in the field.
The ingredients may be simply mixed together thoroughly with agitation, in some cases the mixture may be passed through a high speed grinder to make the product free flowing.
Some of the products prepared with an anhydrous diluent are water soluble and are mixed with the anhydrous diluent only as an extender of the active ingredient. Such anhydrous diluents should also be water-soluble, such as diatomaceous earths.
EXAMPLE
Separate batches of each compound of this invention are formed by placing two moles of piperidinyldithiocarbonic acid dissolved in 500 ml. of chloroform with one moles of each reactant SCl 2 , S 2 Cl 2 , SOCl 2 , SO 2 Cl 2 , S 2 O 4 Cl 2 , and S 2 O 5 Cl 2 . The ingredients are vigorously agitated as two moles of potassium hydroxide are slowly added over a period of fifteen minutes to each batch of reactants. Salt formation is apparent when the potassium hydroxide is first introduced. Stirring is continued for one hour. The potassium chloride formed is removed by filtration and suction and the product taken to dryness under reduced heat and pressure. Since the chloroform is recovered at 61° C., there is not much heat consumed. The compounds formed are:
(a) Bis piperidinyldithiocarbonylsulphide.
(b) Bis piperidinyldithiocarbonyl disulphide.
(c) Bis piperidinyldithiocarbonyl sulfoxide.
(d) Bis piperidinyldithiocarbonylsulphurdioxide.
(e) Bis piperidinyldithiocarbonylsulphurtetraoxide.
(f) Bis piperidinyldithiocarbonylsulphurpentaoxide.
It should be noted that where potassium hydroxide is referred to in this invention, sodium hydroxide, lithium hydroxide and ammonium hydroxide can be used, however, potassium hydroxide is preferred.
Where ammonium sulphate is referred to in this invention, potassium sulphate or a mixture of ammonium sulphate and potassium sulphate may be used.
Where alcohols are used in this invention, they may be chosen from the alcohols disclosed in my U.S. Pat. No. 2,900,293.
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Compounds of the formula: ##STR1## wherein R is selected from the group consisting of S x , (wherein x is a whole number from 1 to 3), SO, SO 2 , S 2 O 3 , S 2 O 4 , S 2 O 5 .
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